OSMONICS® E-SERIES

OZONE GENERATOR

Operation
and Maintenance Manual

5951 Clearwater Drive, Minnetonka, MN 55343-8995 USA

Phone (800) 848-1750 or Fax (952) 988-6063
http://www.osmonics.com
Please take the time to read and understand this Operation and Maintenance Manual,
paying special attention to the sections on INSTALLATION and MAINTENANCE.

 Osmonics Customer Support Center can be reached by calling (800) 848-1750

or faxing (952) 988-6060, Monday through Friday, 7:30 a.m. - 5:30 p.m. CST.

Mail should be sent to:

OSMONICS, INC.
Attn: Customer Support Center
5951 Clearwater Drive
Minnetonka, MN 55343-8995 USA
 OPERATION AND MAINTENANCE MANUAL

OSMONICS E-SERIES
OZONE GENERATOR
TABLE OF CONTENTS

Page

1.0 SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1

1.1 Safety Summary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1
1.1.1 Read This Manual - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1
1.1.2 Use Proper Wire Connections - - - - - - - - - - - - - - - - - - - - - - -1
1.1.3 Device Labeling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2
1.2 Oxygen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2
1.2.1 Oxygen Characteristics - - - - - - - - - - - - - - - - - - - - - - - - - - -2
1.2.2 Oxygen Safety Precautions - - - - - - - - - - - - - - - - - - - - - - - - -2
1.3 Ozone - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3
1.3.1 Ozone Characteristics - - - - - - - - - - - - - - - - - - - - - - - - - - - -3
1.3.2 Ozone Safety Precautions - - - - - - - - - - - - - - - - - - - - - - - - - -3
1.4 Ozone Generator Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5
1.4.1 Ozone Detectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5
1.5 Electricity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6
1.6 Ozone First Aid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -6
1.7 Ambient Monitoring for Ozone - - - - - - - - - - - - - - - - - - - - - - - - - - -7

2.0 INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8
2.1 Principles of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8
2.2 Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10
2.3 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10
2.3.1 Utility Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10
2.3.2 Interfacing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12
2.4 Main Fuses - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12
2.5 Initial Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12
2.6 Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12
2.7 Plumbing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -13
2.8 Electrical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -13
2.8.1 Supply Power - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -14
2.8.2 Output Signals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -14
2.8.2.1 Fault Relay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -14
2.8.2.2 Remote Ready - - - - - - - - - - - - - - - - - - - - - - - - - - - -15

i
 2.8.3 Input Signals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -15
2.8.3.1 Remote Control 4-20 mA - - - - - - - - - - - - - - - - - - -15
2.8.3.2 Remote Enable - - - - - - - - - - - - - - - - - - - - - - - - - -15
2.8.3.3 Room Ozone Monitor - - - - - - - - - - - - - - - - - - - - - -16

3.0 START-UP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -17

3.1 Generator Start-Up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -17
3.2 Generator Idle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -18
3.3 Operation Status Display Screen - - - - - - - - - - - - - - - - - - - - - - - - -19
3.4 Keypad - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -20
3.5 Security Levels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -21

4.0 OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -22

4.1 Local Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -22
4.2 Remote Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -22

5.0 OPERATOR MENU - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -24

5.1 Operator Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -24
5.2 Operation Status Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -25
5.3 Local/Remote Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -25
5.4 Firmware Version Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -26
5.5 Time and Date Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -26
5.5.1 Setting the Day - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -27
5.5.2 Setting the Date - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -27
5.5.3 Setting the Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -27

6.0 TECHNICIAN MENU - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -28

6.1 Operator Security Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -29
6.2 Relays - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -29
6.2.1 Manual Override - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -29
6.2.2 Auto/Manual Select - - - - - - - - - - - - - - - - - - - - - - - - - - - -30
6.3 Alarms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -31
6.3.1 Cell Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -31
6.3.2 Cell Pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -31
6.3.3 Feed Pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -32
6.3.4 Oxygen Flow - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -32
6.3.5 Remote Input - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -32
6.4 Water Meter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -32
6.4.1 Contacting Head - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -33
6.4.2 Paddle Wheel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -33
6.4.3 Autotrol Turb 1-Inch - - - - - - - - - - - - - - - - - - - - - - - - - - -33
6.4.4 Autotrol Turb 2-Inch - - - - - - - - - - - - - - - - - - - - - - - - - - -33
6.4.5 Water Meter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -34
6.5 System Set-Up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -34
6.5.1 Local Remote Set-Up - - - - - - - - - - - - - - - - - - - - - - - - - - -34

ii
 6.5.2 Remote Enable Configuration Set-Up - - - - - - - - - - - - - - - - -35
6.5.2.1 Remote Enable Configuration - - - - - - - - - - - - - - - - -35
6.5.2.2 Room Ozone Alarm Timer Configuration - - - - - - - - -35
6.5.3 Initialization - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -35
6.5.3.1 Restore Defaults - - - - - - - - - - - - - - - - - - - - - - - - -36
6.5.3.2 Calibrate Pressure - - - - - - - - - - - - - - - - - - - - - - - -36
6.5.3.3 Calibrate Gas Flow - - - - - - - - - - - - - - - - - - - - - - - -37
6.5.3.4 Flow Constant - - - - - - - - - - - - - - - - - - - - - - - - - - -38
6.5.4 Security - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -39
6.5.5 Diagnostics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -39
6.5.5.1 Analog I/O - - - - - - - - - - - - - - - - - - - - - - - - - - - - -39
6.5.5.2 Digital I/O - - - - - - - - - - - - - - - - - - - - - - - - - - - - -40
6.5.5.3 Alarms/Control - - - - - - - - - - - - - - - - - - - - - - - - - -40
6.5.5.4 Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - -40
6.5.6 Firmware Version - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -41
6.5.7 Date and Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -41
6.5.8 Drop Security Level to Operator Mode (View Only) - - - - - - -41

7.0 RELAY OUTPUTS (Engineering Use) - - - - - - - - - - - - - - - - - - - - - - - - - - -42

8.0 SHUTDOWN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -43

8.1 General Emergency Shutdown - - - - - - - - - - - - - - - - - - - - - - - - - -43
8.2 General Normal “Manual” Shutdown - Local Mode - - - - - - - - - - - - -43
8.3 General Normal “Manual” Shutdown - Remote Mode - - - - - - - - - - -43
8.4 Generator Fault Shutdown - - - - - - - - - - - - - - - - - - - - - - - - - - - -43
8.5 Shut Down Alarms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -43

9.0 ESTIMATING OZONE OUTPUT - - - - - - - - - - - - - - - - - - - - - - - - - - - - -44

9.1 Cooling Temperature Effect on Ozone Output - - - - - - - - - - - - - - - -44

10.0 MAINTENANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -46

10.1 Daily - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -46
10.2 Monthly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -46
10.3 Quarterly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -47
10.4 Annually - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -47
10.5 Cabinet Entry and Cell Removal - - - - - - - - - - - - - - - - - - - - - - - - -47
10.6 Cell Reinstallation in Cabinet - - - - - - - - - - - - - - - - - - - - - - - - - - -48
10.7 Circuit Board Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - -48

11.0 TROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -52

11.1 Alarms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -52
11.1.1 Shutdown Alarms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -52
11.1.2 Warnings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -52
11.2 Troubleshooting Chart - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -54

iii
12.0 SPARE PARTS LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -59

13.0 DRAWINGS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -60

13.1 Electrical Drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -60
13.2 Installation Drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -60

14.0 RETURN GOODS AUTHORIZATION (RGA) PROCEDURE - - - - - - - - - - -63

15.0 WARRANTY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -64

APPENDIX A

MSDS Data Sheet

Ozone Generator Performance Data Sheet

LIST OF FIGURES

Figure Title

2.1 Front Control Panel and Indicators - - - - - - - - - - - - - - - - - - -9

2.2 Bottom View of Generator with Connections - - - - - - - - - - -11
3.1 Welcome Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -17
3.2 Operation Status Screen - - - - - - - - - - - - - - - - - - - - - - - - -19
5.1 Operator Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -24
5.2 Operation Status Screen - - - - - - - - - - - - - - - - - - - - - - - - -24
5.3 Local/Remote Menu Screen - - - - - - - - - - - - - - - - - - - - - - -25
5.4 Firmware Version Menu Screen - - - - - - - - - - - - - - - - - - - -26
5.5 Day, Date, & Time Menu Screen - - - - - - - - - - - - - - - - - - - -26
6.1 Technician Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -28
9.1 Ozone Output vs Water Temperature - - - - - - - - - - - - - - - -45
13.1 Electrical Hook-Up Drawing - - - - - - - - - - - - - - - - - - - - - -60
13.2 Installation Drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - -61
13.3 Electrical Schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - -62

LIST OF TABLES

Table Title

1.1 Effects of Ozone at Various Concentrations - - - - - - - - - - - - -4

10.1 Suggested Maintenance Intervals - - - - - - - - - - - - - - - - - - - -49
10.2 Maintenance Log - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -50

iv
1.0 SAFETY PRECAUTIONS

1.1 Safety Summary

The safety summary does not contain all of the safety statements in this manual.
Other safety statements are included within the manual text and are enhanced
and defined as follows:

NOTE: Indicates statements that provide further information and clarifi-

cation.

CAUTION: Indicates statements that are used to identify conditions or prac-

tices that could result in equipment or other property damage.

WARNING: Indicates statements that are used to identify conditions

or practices that could result in injury or loss of life.

WARNING: FAILURE TO FOLLOW THE REQUIREMENTS SET

FORTH IN THIS SECTION 1.0 COULD POSE A RISK
OF SERIOUS INJURY OR DEATH TO INDIVIDUALS
WORKING WITH OZONE.

1.1.1 Read This Manual

Prior to operating or servicing this device, this manual must be read and
understood. Keep it and other associated information near the machine
for future reference.

This manual has been prepared to provide the operator with information
on the installation, operation, maintenance, and troubleshooting of the
E-Series Ozone Generator System.

The E-Series Ozone Generator must be installed, operated, and main-

tained by qualified and properly trained operators. It is the responsibility
of the owner to ensure that operators have been properly trained to
operate and maintain the E-Series Ozone Generator.

1.1.2 Use Proper Power Connections

Use proper wiring and connection methods as stated in this manual and
local regulations.

1
 1.1.3 Device Labeling

Do not, under any circumstances, remove any Caution,Warning, or other

descriptive labels from the devices.

The E-Series Ozone Generator is a durable piece of equipment, which

with proper care will last for many years. Whenever possible precaution-
ary measures have been made to reduce the possibility of a dangerous
condition. However, as a result of misuse or improper maintenance, dan-
gerous conditions may present themselves. The areas of potential danger
include:

• Oxygen
• Ozone
• High Voltage Electricity

1.2 Oxygen

Oxygen is used as the parent gas for the production of ozone in the E-Series
Ozone Generator. Certain precautions must be taken to ensure safety. This sec-
tion discusses the basics of oxygen safety, including oxygen characteristics and
oxygen safety precautions. This section is provided as information only. It is the
owner’s responsibility to determine and follow all national and local codes and
regulations.

1.2.1 Oxygen Characteristics

• Colorless, orderless, tasteless

• Heavier than air
• Supports and accelerates burning (particularly in concentrations
> 25%)

1.2.2 Oxygen Safety Precautions

Oxygen must not be exposed to the following:

• Open flames
• Oil and grease

Open flames in the presence of oxygen can cause a potentially explosive

situation. Under no circumstances should smoking, welding, or any source
of ignition (sparking) be allowed in the vicinity of the oxygen producing
equipment.

2
 Oil and grease in the presence of oxygen can rapidly combust. Therefore,
the oxygen equipment must be kept free of oil and grease. This includes
operator and maintenance personnel's clothing in order to reduce the
potential for danger.

Use only oxygen-compatible greases in the system.

1.3 Ozone

The E-Series Ozone Generator converts oxygen-enriched air to ozone. Certain

safety precautions must be taken. This section discusses the basics of ozone safe-
ty; including ozone characteristics and ozone safety precautions. This section is
provided as information only. It is the owner’s responsibility to determine and fol-
low all national and local codes and regulations.

1.3.1 Ozone Characteristics

• Toxic
• Corrosive
• Accelerates burning
• Heavier than air and oxygen
• Acrid odor
• Unstable

NOTE: Ozone can be detected by humans (by the sense of smell) at a

level as low as 0.003 ppm (odor threshold).

NOTE: The owner and/or user is responsible for compliance with all
national and local regulations regarding the use of ozone.

1.3.2. Ozone Safety Precautions

• Follow national and local regulations and guidelines for handling

ozone.

Ozone must not be exposed to the following:

• Open flames
• Oil and grease
• Non-compatible grease

Open flames in the presence of ozone can cause a potentially explosive sit-
uation. Under no circumstances should smoking, welding, or any source of
ignition (sparking) be allowed in the vicinity of the ozone producing equip-
ment.

3
 Oil and grease in the presence of ozone can rapidly combust. Therefore,
the ozone equipment must be kept free of oil and grease. This includes
operator and maintenance personnel's clothing in order to reduce the
potential for danger.

Table 1.1
Effects of Ozone at Various Concentrations

10,000

Fatal Region
1000
Ozone Concentrations, ppm/vol

100 Permanent Toxic Region

Irr
ita
nt

10 Sy Temporary Toxic Region

m
pt
om
at
ic
Non-Toxic Region
1.0

Non-Symptomatic Region

0
0 1.0 10 100 1000 10,000
Exposure Time in Minutes

Ozone Regulations:
EPA Discharge Limits: 1.0 ppm to Atmosphere
OSHA Exposure Limits: 0.1 ppm for 8 hours
0.3 ppm for 10 minutes
10+ ppm - Fatal Level

4
1.4 Ozone Generator Safety

The E-Series Ozone Generators are designed to operate safely. The potentially
lethal nature of ozone requires the equipment owner to follow additional safety
precautions.

1.4.1 Ozone Detectors

Ozone generators can produce ozone concentrations up to 15% wt and

higher. This concentration is above the lethal limit. Even small leaks can
produce dangerous concentrations of ozone in a local area. For this rea-
son, ozone-warning devices must be installed in the area near the ozone
generator and ozone process manufacturing areas. For information on
installing ozone detectors see Ambient Ozone Monitoring (Section 1.7).
To ensure safety the following precautions should be taken:

• Access to ozone generator should be limited to authorized and

trained personnel only.

• Evacuation routes must be clearly marked in the event of an ozone

leak.

• Install an electrical disconnect switch on the power feed to the ozone

generator. This electrical disconnect switch disconnects the electrical
supply to the equipment. This switch should be in an accessible loca-
tion and installed per local regulations.

• Install ozone detectors to monitor for the presence of ozone. Wire

the detectors into the discreet ozone generator shut down input
whenever possible.

• Have suitable breathing apparatus available on site. A breathing appa-

ratus must be worn before entering areas with suspected concentra-
tions of ozone.

WARNING: Once the ozone generator has been turned off, the
machine still contains ozone gas. Before opening
the machine or piping, flush the equipment thor-
oughly with dry air or oxygen gas until no ozone
can be detected.

5
1.5 Electricity

WARNING: Never open the electrical equipment when power is sup-

plied. Always remove power (unplug) before opening
electrical equipment.

WARNING: The internal capacitors can hold a dangerous electrical

charge for up to five (5) minutes after turning the
machine off. Wait at least five (5) minutes after machine
is turned off before opening the door. Always disconnect
power from the machine before opening the door.

WARNING: NEVER WORK ON LIVE EQUIPMENT! HIGH VOLT-

AGE CAN CAUSE INJURY AND DEATH.

1.6 Ozone First Aid

IMPORTANT: The owner and/or user must ensure that first aid measures
meet local codes and regulations.

Following exposure to ozone, the following first aid measures must be performed
immediately.

1. Bring the victim into fresh air.

2. Call emergency services, stating ozone exposure.

3. Give medical-oxygen.

4. Lay victim down and keep victim calm until help arrives.

5. Check pulse, breathing, and consciousness.

6. If breathing stops, begin CPR.

6
1.7 Ambient Monitoring for Ozone

Ambient monitoring units must be installed in all areas where ozone can poten-
tially escape. Air currents need to be taken into consideration. Several monitor-
ing units may need to be installed, depending upon the size of the room.

When in an ambient alarm condition:

• Evacuate all personnel from the contaminated area.

• Enter room wearing a suitable breathing apparatus.

• Disconnect electrical supply and ventilate the area.

WARNING: If the ambient monitors give a warning or fail, the

feed gas supply and the electrical supply must be
immediately and automatically disconnected.
Simultaneously, the warning must initiate an optical
and acoustic alarm, so that personnel in the respec-
tive rooms are warned. As long as the area monitors
indicate a high ozone concentration, the rooms are
only to be entered when wearing suitable breathing
apparatus.

• Wiring terminals are provided on the E-Series Ozone Generator for con-
necting a safety monitor alarm output to automatically shut down the ozone
generator.

• Rooms where ozone will be produced or used should be properly ventilated.

7
2.0 INTRODUCTION

Ozone (O3) is a three-atom allotrope of oxygen (O2). It is second only to fluorine in

electronegative oxidation potential. Ozone is a natural ingredient of the earth's upper
atmosphere, generated by solar energy, and exists in a gaseous form at ambient condi-
tions. Unreacted ozone decomposes in a matter of hours to simple molecular oxygen
and therefore it cannot efficiently be stored. It must be produced on site. A wide vari-
ety of ozone equipment configurations and sizes are available for municipal, industrial, and
laboratory applications.

Ozone is emerging as the most efficient and ecologically sound oxidant to treat both
organic and inorganic substances in air and water.

2.1 Principles of Operation

The Osmonics E-Series Ozone Generator is designed to continuously generate

ozone. The generator offers the user the capability to regulate the ozone output
from 0 - 100% of its rated capacity. This adjustment can be made from the local
control panel or remotely via a 4-20 mA current loop.

Ozone generators produce ozone from a very dry form of oxygen. The supplied
oxygen should be dried to -62°C (-80°F) dewpoint, or drier, and should be par-
ticulate free to 1 micron. The oxygen should have a minimum concentration of
90%. The E-Series Ozone Generators rated output is based on an oxygen feed
of 93% purity.

Prior to entering the E-Series Ozone Generator, the clean, dry oxygen should be
pressure-regulated to between 0.62 and 1.03 barg (9 and 15 psig).

Feed gas passes through a passage that is machined between the electrodes and
the dielectric. This passage is known as the "dielectric gap." The dielectric gap is
the point where electrical energy is applied to the feed gas, creating ozone. By
controlling the amount of energy applied to the cell, ozone output can be con-
trolled. Cooling passages are also machined inside the electrodes, allowing cool-
ing water to carry off excess heat from the process. The entire cell is contained
in a housing, which provides mechanical structure for the cell, as well as a meas-
ure of safety for operators and maintenance personnel.

As feed gas passes through the dielectric gap, a portion of the oxygen molecules
are converted to ozone. An ozone output data sheet is included in this manual
to assist you in estimating the ozone output at certain machine settings.

8
 The amount of ozone created is dependent on several factors:

• Oxygen flow rate, temperature, and pressure

• Cooling water temperature and flow rate
• Applied voltage and frequency
• Oxygen purity and dew point
• Cell contamination

The resultant ozone output can be estimated by observing operating conditions

on the front display on the front panel and comparing them to the data sheet in
this manual. The data sheet reflects test results taken at the factory on this spe-
cific generator.

After the parent gas and ozone mixture leaves the dielectric assemblies, it passes
through an adjustable flow control valve prior to exiting the generator cabinet.
The ozone outlet can be connected to the process via PTFE or stainless steel tub-
ing.

Display
Operator
Interface

7 8 9 ENT
4 5 6 CLR
Keypad 1 2 3 Emergency
0 Stop
OFF ON

Power
Off/On
Switch
Gas Flow
Control Valve

Figure 2.1
Front Control Panels and Indicators

9
2.2 Features

Generator Power Switch Main power switch for generator. Switch

illuminates when inverter is enabled.

Emergency Stop Switch Palm press switch that quickly removes

power from the generator and stops flow of
oxygen in emergency conditions.

Multi-Line Digital Display Displays operating parameters, warnings,

faults, and alarms.

16 Key Keypad Allows the user to adjust settings of the

generator and change views on the display.

Gas Flow Valve Located on the bottom of the unit, adjusts

gas flow through the ozone generator cell.

2.3 Installation

2.3.1 Utility Requirements for E-Series Ozone Generator

Electrical

• 200 - 240VAC, single-phase

• 50/60 Hz
• 3.5 amps full load

Cooling Water

• 1.9 to 3.2 Lpm [30 to 50 gph (0.5 to 0.8 gpm)]

• Potable or better quality (softened water is preferred)
• Maximum pressure: 2.4 barg [35 psig] (10 to 15 psig typical)
• 10 - 29°C (50 - 85°F)

WARNING: If the cooling water is too cold, condensation may

form inside the generator cabinet and damage
internal circuitry. The temperature of the cooling
water should be near ambient room tempera-
ture.

To prevent mineral deposits from damaging the cooling system, the cool-
ing water must have a low mineral content. To protect the generator, a
solenoid valve (1/2 inch 220 Vac) and water flow switch (0.5 gpm) should

10
 be installed in the cooling water supply line. Power the solenoid from ter-
minals 35 and 36 to energize the valve when the generator is turned on,
or power the valve and generator from a common disconnect.

Gas Flow
Control Valve

Ozone Gas
Outlet

Cooling Water Inlet

Knockout w/plugs

Oxygen Inlet
Cooling Water
Outlet
Figure 2.2
Bottom View of Generator with Connections

Dry Oxygen Supply

• Pressure: 0.62 to 1.03 barg (9 to15 psig)

• Flow: 2 to 12 sLpm (4.2 to 25 scfh)
• Moisture content: -62°C (-80°F) dewpoint max.
• Maximum temperature: 29°C (85°F)
• Purity: greater than 90% oxygen

NOTE: If using an oxygen concentrator, such as SeQual ATF-25, be sure

there is no air pressure into the concentrator except when
power is applied. On systems using plant air, a solenoid valve
(3/4-inch, 220 Vac) must be installed at the concentrator input
and powered with the concentrator. On systems with a com-
pressor, the concentrator and compressor must be powered
from a common switch. Terminals are also provided on the
wiring strip inside the cabinet for connecting a cooling water
flow switch and remote 4-20 mA control signals.

11
 2.3.2 Interfacing

Connect room ozone safety monitor and any remote alarm devices to the
wiring strip inside the cabinet.

2.4 Main Fuses

These fuses are located in the fuse holders on the main terminal strip. All cur-
rent for the ozone generator unit passes through these fuses.

2.5 Initial Inspection

Inspect the shipping carton for obvious external damage. Note on the carrier's
bill-of-lading the extent of the damage, if any, and notify the carrier. Save the ship-
ping carton until your ozone generator is up and running.

 If there was shipping damage, call the Osmonics Customer Support

Center at (800) 848 - 1750 or (952) 933 - 2277 for instructions.

2.6 Location

Place the ozone generator as near as possible to where ozone is to be applied to

the process. There should be a minimum of three (3) feet (0.91 m) clearance
below and in front of the generator.

CAUTION: DO NOT SUBJECT THE OZONE GENERATOR OR AIR

COMPRESSOR TO DIRECT SUNLIGHT, WATER, OR
FREEZING CONDITIONS OR EXCESSIVELY DUSTY,
HUMID AND CORROSIVE ENVIRONMENTS. CHEMI-
CAL FUMES MUST ALSO BE AVOIDED.

Your Osmonics E-Series Ozone Generator must be operated in a clean, dry envi-
ronment that does not contain any corrosive or volatile airborne contaminants.
Excessive moisture, dust and/or vapors from stored chemicals, paints, or solvents
will damage the generator's electronic components. Vapors from chlorine or
chlorine-containing compounds are especially damaging.

CAUTION: THE OPERATION OF YOUR OZONE GENERATOR IN

A DAMAGING ENVIRONMENT MAY VOID ITS
WARRANTY!

12
2.7 Plumbing

Connect the water inlet and outlet on the ozone generator using not less than
1/4-inch (0.635 cm) diameter tubing. The incoming water pressure must be less
than 2.4 barg (35 psig). The use of a pressure regulator and flow switch on the
water source is recommended (refer to Figure 2.2).

Do not hard plumb the water fittings to the generator cabinet. All
plumbing connections must be removed from the cabinet to service
the generator cell.

The ozone plumbing needs to extend at least two (2) feet (60 cm)
above the highest water level in the process being treated.

Connect the oxygen inlet using oxygen safe tubing, such as copper, stainless steel,
PTFE, or other such tubing. Connect the ozone outlet using stainless steel tub-
ing, PTFE tubing or other ozone resistant plumbing (refer to Figure 2.2).

Do not hard plumb the gas fittings to the generator cabinet. All plumb-
ing connections must be removed from the cabinet to service the gen-
erator cell.

WARNING: SEVERE DAMAGE WILL RESULT IF WATER BACKS

UP INTO THE OZONE GENERATOR! IT IS THE CUS-
TOMER'S RESPONSIBILITY TO PROVIDE AN INSTAL-
LATION WHICH WILL PREVENT THE BACKFLOW
OF WATER INTO THE OZONE PIPE LINE.

CAUTION: FAILURE TO FOLLOW THE ABOVE WARNING WILL

VOID WARRANTY.

To avoid water backflow, install a stainless steel checkvalve in the ozone

piping. Turn the generator ON to a 0% setting to provide oxygen flow
before turning on your process water.

2.8 Electrical

A terminal strip is provided inside the enclosure for all electrical connections
(refer to Figure 13.1).

WARNING: NEVER WORK ON LIVE EQUIPMENT! INSTALLA-

TION MUST ADHERE TO NATIONAL AND LOCAL
CODES AND BE PERFORMED BY A QUALIFIED
ELECTRICIAN.

13
2.8.1 Supply Power

The generator needs a clean and consistent source of 200 to 240 VAC,
single phase power in 50 or 60 Hz. Fluctuations in power may affect ozone
output. Power levels outside the 200 to 240 VAC range may result in
ozone generator failure. Failures from an improper power supply are not
covered under warranty.

200 to 240 Vac, single-phase, 50/60 Hz, 3.5 amp full load.

Supply power can be: one leg of 208 V or 240 V 3-phase, opposing 115 V
phases, or grounded neutral 230 V, etc. Grounded neutral is acceptable,
but not required.

Connect power and ground wires to the terminals provided at the right-
hand end of the terminal strip: L1, L2, and Gnd.

Main fuses are located inside the L1 and L2 terminal blocks.

A single wall-mounted disconnect, or power cord, may be used to supply

both the EO3 generator and the Oxygen Prep system, if permitted by
local electrical regulations.

2.8.2 Output Signals

2.8.2.1 FAULT RELAY (alarm output)

This relay switches whenever the EO3 shuts down in an alarm or

fault condition.These contacts are available for customer use to
signal external equipment or alarm.

• Isolated form-C relay contacts

• Rating: 5 A, 250 Vac, 1/3 Hp

Terminal
18 - normally open
19 - common
20 - normally closed

14
 2.8.2.2 REMOTE READY (output relay)

• Terminals 16 and 17
• Rating: 5 A, 250 Vac, 1/3 Hp
• Isolated normally open relay contacts
• Closes when the following conditions are met:
- The Local/Remote menu item is set to REMOTE mode.
- The Remote Enable input signal is closed.
- No shutdown alarms are active.

The Remote Ready output to external process control equip-

ment indicates that the EO3 is producing ozone based on the
remote 4-20 mA signal input.The Remote Ready output follows
the condition of the Remote Enable input for remote control
applications.

2.8.3 Input Signals

2.8.3.1 REMOTE CONTROL 4-20 mA analog input

A 4-20 mA signal from external process control equipment con-

trols the amount of ozone being generated when the EO3 is
operated in the REMOTE mode (refer to Section 5.3).

Terminal 15 (+) 4-20 mA signal input

Terminal 14 (-) (ground in the EO3).

-- Terminal 15 has a load resistance to ground of 200 ohms.The

external source of the 4-20 mA control signal must be capable
of driving a 200 ohm grounded load.
-- Shielded cable must be used for the 4-20 mA signal wiring.The
shield must be grounded at the source end only..

The EO3 power setting, and amount of ozone being generated, is

determined by the value of the 4-20 mA signal, from 0% at 4 mA,
to 100% at 20 mA.

2.8.3.2 REMOTE ENABLE (digital input)

Terminal 12 and 13.

Connect to isolated (“dry”) relay or switch contact in external

equipment to inhibit ozone production when open. Close to run.

15
 Terminal 12 is grounded in the EO3.
Terminal 13 has a 5k-ohm resistor to +5 Vdc (1 mA DC).

In Remote mode (refer to Section 5.3):

Open - forces the power level to 0% and causes the Remote

Ready relay to open.
If the Remote Enable signal remains open for longer
than 10 minutes, the Oxygen Flow will also stop.
Closed - energizes the Remote Ready relay, and the power
setting returns to the value determined by the 4-20
mA control signal.
- The EO3 will do a 30-second purge if Oxygen flow
was stopped, then it will resume normal operation.

In Local mode, the Setup menu item (Secton 6.5.2) can be set
for:
1 Display message only (default).
2 Force power level to 0%
3 Force power level to 0%, and stop oxygen flow.

2.8.3.3 ROOM OZONE MONITOR (shutdown digital input)

Terminal 10 and 11.

Terminal 10 is ground in the EO3.

Terminal 11 has a 5k-ohm resistor to +5 Vdc (1 mA DC).

Connect to an isolated (“dry”) relay or switch contact, such as

from a room ambient ozone monitor and/or coolant water flow
switch to shut down the EO3 when the circuit is opened.

Several normally closed devices may be wired in series between

terminals 10 and 11. Displays the message: “Room Ozone or
Coolant”.

Coolant water flow switch should be wired in series with the

ambient monitor.

The circuit must be closed to run. To re-start the EO3, press the
[ENT] key.

16
3.0 START-UP

3.1 Generator Start-Up

1. Turn on the cooling water supply to the generator cabinet. Water pressure
should not exceed 2.4 barg (35 psig). Pressurize line and check plumbing for
water leaks before starting. Refer to data sheet for minimum water flow
requirements.

On systems with a solenoid valve installed in the cooling water and/or air
supply lines, the air and water flow will start when the generator is turned on
in step 3.

2. Ensure that all ozone supply lines to your process are properly connected.

3. Switch the master ON/OFF switch to ON to illuminate the display screen.

Then press any key on the keypad to start oxygen flow. After 30 seconds, the
green light in the switch should come on, indicating that the generator is
enabled. If the system fails to power up, check to be sure the Emergency Stop
button is released (twist to release).

Turning the Power Switch ON turns on the ozonator and displays the
"Welcome" screen. Press Clear [CLR] to display the Operation Status dis-
play screen.

Osmonics EO3-Series
Ozone Generator
Firmware Ver 1.00

Press Any Key

Figure 3.1
Welcome Screen

4. Adjust cooling water pressure and flow to 0.5 to 0.8 gpm (1.9 to 3.2 Lpm). If
necessary, press the [ENT] key to clear alarms.

5 If using an ATF-25 oxygen concentrator, adjust the air pressure into the con-
centrator to 36 to 40 psi.

6. Press the UP or DOWN ARROW key to change the display to show gas pres-
sure, oxygen flow, etc. (see Section 3.3).

17
 7. Adjust oxygen feed pressure to the generator until it is between 0.62 - 1.03
barg (9 - 15 psig). Refer to the generator data sheet for some suggested gas
flow rates, as well as gas pressure vs. flow curves.

8. Adjust the oxygen flow rate to desired setting (see data sheet) with the T-han-
dle needle valve at the underside of the generator while ozone generator is
not producing ozone (0.0%). 9.0 SLMP is best for most applications.

NOTE: Since pressure affects flow, some balancing of the pressure and flow con-
trols may be required to stabilize flow at desired settings. Achieving
proper gas flow and pressure ensures that the generator operates effi-
ciently.

9. Allow the oxygen to flow through the generator for a minimum of 15 min-
utes if generator has not been operating within six (6) hours. This allows
clean, dry oxygen to flow through the generator dielectrics, purging any mois-
ture that may have accumulated.

CAUTION: If the generator cell contains any moisture, nitric acid will form in
the cell. Nitric acid is a strong acid and can be dangerous.
Formation of nitric acid will decrease the performance of the gen-
erator. If nitric acid has formed inside the cell, contact the
Osmonics Customer Support Center for instructions.

10. Check that the process to be treated is filled and operating properly, and that
all ozone destruct, safety, and ventilation devices are operating.

11. Use the LEFT and RIGHT ARROW keys to adjust the generator power level
and therefore the amount of ozone produced.

12. If any faults or alarms occur during the start-up period, they will show on a
flashing banner on the display. Refer to Troubleshooting (Section 11.0).

3.2 Generator Idle

3.2.1 The generator will not produce ozone under the following conditions:

• During the first thirty (30) seconds after start-up.

• In Manual Mode, if the generator output is set to 0%.
• In Remote Mode, if the input signal drops to 4 mA.
• In Remote Mode, if the remote enable signal input is open.

18
 3.2.2 In idle conditions, gas will flow through the system unless the solenoid
valve is programmed to shut off under certain conditions. The solenoid
valve may be shut off for the following conditions:
• In Remote Mode, if the remote enable signal input is open longer than
10 minutes.
• Alarm conditions (refer to Sections 8.5 and 11.1)
• Failure conditions

3.2.3 The generator is preprogrammed to stop gas flow under the following
conditions:
• Door open
• High Feed pressure (oxygen)
• Inverter fault
• Room Ozone or Coolant fail
• High Temperature

3.3 Operation Status Display Screen

Top Section: Displays the Power Setting of the generator as a

percentage of full power. Performance Charts are
provided for the Concentration and Lbs/day
(gms/hr) of Ozone output, based on the Power set-
ting (%) and gas flow (slpm).

Alarm Display Line: Displays any active alarms (refer to Section 11). In
Remote mode, displays “Remote Control Mode”
message.

Lower Section: Displays various operating parameters, as selected

by the Up and DOWN Arrow Keys.

Bottom Line: Displays system status messages.

0.00% Power Setting

Alarm Messages

OXYGEN FLOW =
6.36 SLPM Operating Parameters
OXYGEN FLOWING
System Status
Messages
Figure 3.2
Operation Status Screen

19
 The operating parameters displayed in the lower portion of the screen can be
selected using the UP and DOWN ARROW Keys:

• OXYGEN FLOW (0 - 16.0 SLPM)

• CELL PRESSURE (0 - 2.00 BARG)
• FEED PRESSURE (0 - 2.00 BARG)
• CELL TEMPERATURE (0 - 99.9 °C)
• REMOTE INPUT (4 - 20 mA)
• PROCESS WATER FLOW (not currently implemented)
• TIME AND DATE.
• RELAYS AND TIMERS (engineering use).

3.4 Keypad

Enter (ENT) Use in the menus to select items and enter data.

Clear (CLR) Brings up either the Operator Mode or the

Technician Mode, depending on which Security
Level is active.

When in the Menus, the [CLR] Key will exit back

to the previous menu.

Scroll Keys UP and DOWN Arrow Keys select which of the

operating parameters is displayed in Operation
Mode (refer to Section 3.3) or select items in the
menus.

Power Control Keys LEFT and RIGHT Arrow Keys increase and
decrease the power applied to the cell from 0 to
100%, in steps of 6.25%.

20
3.5 Security Levels

Pressing the [CLR] Key from the main Operation status display will bring up
either the Operator Menu, or the Technician Menu, depending upon which secu-
rity level is active.

Technician Mode View and adjust alarm settings, and perform diag-
nostics and calibrations. To enter the Technician
Mode from the Main Operation Status screen, enter
the 4-digit security code (“5951”) using the number
keys.

Operator Mode The Operator Mode is read-only. To enter from the

Technician Menu press the [0] key. The Operator
Mode allows adjustment of the time, date, power
level, and local/remote.

21
4.0 OPERATION

To select Local or Remote mode, refer to Section 5.3.

4.1 Local Mode

1. Before applying power to the ozonator, be sure that the cooling water supply
is turned on and the oxygen supply to the generator is between 0.62 to1.03
barg (9 to 15 psig).

On some systems the cooling water and oxygen will come on with the main
power.

2. After power is applied and any Key on the keyboard is depressed, the gas sole-
noid valve is energized. The message "OXYGEN FLOWING" will appear on
the bottom line. The oxygen flows for 30 seconds to purge the system of
moisture and any residual ozone before the ozonator power level can be
brought up.

3. No alarm messages should appear in the Alarm Display Line.

If any alarm messages appear in the Alarm Display Line, clear the message by
correcting the fault condition before proceeding. Refer to Troubleshooting
(Section 11.0) for assistance.

4. Use the Flow Control Valve on the underside of the cabinet to adjust the gas
flow to the desired flow rate between 2.0 slpm (4.2 scfh) and 12.0 slpm
(25 scfh).

5. Thirty (30) seconds after the "OXYGEN FLOWING" message, the Inverter
Enable relay should energize. The bottom line of the display should display:
"MAKING OZONE," indicating that the generator is ready to make ozone.

6. Check for proper cooling water flow, ozone destruct and safety equipment
are operating, the process being treated is operating properly, and there are
no ozone leaks.

7. After the "MAKING OZONE" message appears, Press the RIGHT Arrow Key
to increase the Power Setting display to the desired output level. The reading
will increase by 6.25% for each press of the RIGHT Arrow Key. Press the
LEFT Arrow Key to decrease the power setting of the inverter to the desired
level. The reading will decrease by 6.25% for each press of the LEFT Arrow
Key.

22
 When operating with oxygen flow of less than 4.0 slpm, do not raise the
power level above 75%.

4.2 Remote Mode

Remote Mode is exactly the same as Local mode, except at step 6, check that the
dissolved ozone monitor and 4-20 mA controller are powered on and operating.

After the “Making Ozone” message appears, the power setting will automatically
increase to the value determined by the 4-20 mA control signal.

The message “Remote Control Mode” will be flashing on the display.

23
5.0 OPERATOR MENU

5.1 Operator Mode

Press Clear [CLR] from the main Operation status display. This brings up the
Operator Menu.*

OPERATOR MENU

1 OPERATION
2 LOCAL/REMOTE
3 FIRMWARE VERSION
4 CLOCK

Figure 5.1
Operator Menu

Menu Selection

Select the desired menu item by either:

• Pressing the number key corresponding to the desired item,

or,

• Using the UP and DOWN ARROW Keys to select the desired item, then
press [ENT] to select.

* If the “Technician Menu” comes up instead, press the [0] key (while the
Technician Menu is displayed), then select “Yes” to drop the security level.

24
5.2 Operation Screen [1]

Press [1] or [ENT] to exit the Operator Menu and return to the main Operation
Status Screen (refer to Section 3.3).

0.00% Power Setting

Alarm Messages

OXYGEN FLOW =
6.36 SLPM Operating Parameters
OXYGEN FLOWING System Status
Messages
Figure 5.2
Operation Status Screen

5.3 Local/Remote Menu [2] (from Operator Menu)

Press [2] to display the “CONTROL MODE” screen. Select "LOCAL" or

"REMOTE" control of the Power setting;

In LOCAL Mode the % Power is controlled by the LEFT and RIGHT Arrow keys.

In REMOTE Mode, the generator % Power is controlled by the 4 - 20mA input

signal.

Press [CLR] to exit back to the Operator Menu.

CONTROL MODE

1* LOCAL
2 REMOTE

Figure 5.3
Local/Remote Status Screen

* Indicates the current operating mode.

25
5.4 Firmware Version Menu [3]

This screen indicates the version of firmware used with your generator. This
information may be useful in future maintenance or troubleshooting situations.

OSMONICS E-SERIES
OZONE GENERATOR
FIRMWARE P/N 1223876

VERSION: x.xx

Figure 5.4
Firmware Version Menu Screen

Press [CLR] to exit back to the Operator Menu.

5.5 Clock Menu [4]

MON
23 JUL 01

09:43:56
>=CHANGE CLR=EXIT

Figure 5.5
Day, Date, and Time Menu Screen

Press [4] from Operator menu to bring up the Clock Menu Screen.

Press the [CLR] key at any time to exit back to the Operator Menu, leaving the
clock unchanged.

26
5.5.1 Setting the Day

1. Pressing the RIGHT ARROW Key highlights the weekday.

2. Use the UP and DOWN ARROW Keys until the correct weekday is
displayed.

3. Press [ENT] to save the weekday and highlight the Day of the Month.

5.5.2 Setting the Date

1. Press the Number Keys to set the numerical day of the month.

2. Press [ENT] to save the Day (highlights the month).

3. Press the UP and DOWN ARROW Keys to set the Month.

4. Press [ENT] to save the month (highlights Year).

5. Press the Number Keys to set the year.

6. Press [ENT] to save the year (highlights the Time).

5.5.3 Setting the Time

1. Use the number keys and [ENT] to set the Time.

2. Press [ENT] to save the new Date, Day,Time settings.

NOTE: Pressing Clear [CLR] at any time returns you to the previous
Menu and does not save any changes.

27
 6.0 TECHNICIAN MENU

From the main Operation Status screen, enter the Password to get to the Technician
Menu, refer to Section 3.5.

As an introduction, here is a graphic overview of the first level of each option in the
Technician Menu to see how it operates. Complete detail of each option is provided on
the following pages.

To select a menu item, use the UP and DOWN ARROW keys to scroll to the desired
item, then press [ENT], or simply press the number key.

TECHNICIAN MENU
1. OPERATION
2 RELAYS
3 ALARMS
4 WATER METER
5 SYSTEM SETUP
6 CLOCK

1 2 3 4* 5 6
CONFIGURE RELAYS ALARM SETPOINTS WATER METER TYPE SYSTEM SETUP TUE
0.00 14 JUN 00
1 MANUAL OVERRIDE 1 CELL TEMPERATURE 1 CONTACTING HEAD 1LOCAL /REMOTE
2 AUTO/MAN SELECT 2 CELL PRESSURE 2 PADDLE WHEEL 2 REMOTE ALM CONF. 14:32:400
OXYGEN FLOW= 3 FEED PRESSURE 3 AUTOTROL TURB 1 IN. 3 INITIALIZATION
6.36 SLPM 4 OXYGEN FLOW 4 AUTOTROL TURB 2 IN. 4 SECURITY
5 REMOTE 4-20 INPUT 5 DIAGNOSTICS
>=CHANGE:
OXYGEN FLOWING 6 FIRMWARE VERSION CLR=EXIT

* The water meter option is not currently programmed for operation.

Figure 6.1
Technician Menu

Press [CLR] to return to a previous screen. Repeated use of [CLR] allows you to return
all the way back to the Technician Menu from anywhere in the program.

NOTE: Some menus return to the Operation Status screen. If desired, press the [CLR]
key to bring up the Technician Menu.

28
6.1 Technician Menu

Press [0] to change to the Operator Security Mode (read-only).

Press [1] or [ENT] to return to the Operation Status Display (Section 3.3).

6.2 Relays [2] (For Engineering Use Only)

CONFIGURE RELAYS

1 MANUAL OVERRIDE
2 AUTO/MAN SELECT

Press the [CLR] key tp return to the Technician menu.

6.2.1 Manual Override [1]

RELAY MANUAL CONTROL

(1) OXY AUTO

(2) INV AUTO
(3) RDY AUTO
(4) ALM AUTO

PRESS 1 - 4; CLR = EXIT

This menu is used to manually turn the relays On and Off.

The rectangle in the center column displays the status of the relay (Filled
= On, Clear = Off). The mode of each relay is shown on the right.

CAUTION: This is only to be for troubleshooting external connections.

NEVER set the OXY or INV relays to MANUAL.

When a relay is in MAN mode, press the respective number key to switch
the relay On and Off. When the relay is in AUTO mode, pressing the num-
ber key has no effect.

29
6.2.2 Auto/Manual Select [2]

1. Press [CLR] to go back to the “Configure Relays” menu.

2. Press [2] (Auto/MAN Select).

This menu is used to bring up the “Select Relay” menu.

SELECT RELAY

1 OXYGEN
2 INVERTER
3 READY
4 ALARM

Select the desired relay using the number keys. Press [CLR] to go back
to the “Configure Relays” menu.

CAUTION: This is only to be for troubleshooting external connections.

NEVER set the OXY or INV relays to MANUAL.

All the relays default to AUTO when the system power is removed. To set
a relay to MAN mode:

1. Press the number key for the desired relay.

2. Press [1] (Auto) or [2] (Manual).

SELECT AUTO/MANUAL

1 AUTO
2 MANUAL

3. Press [CLR] to go back to the “Configure Relays” menu, then select

[1] to go to the “Relay Manual Control” menu.

30
6.3 Alarms [3]

To view or adjust the alarm setpoints, press the desired number key.

ALARM SETPOINT

1 CELL TEMPERATURE
2 CELL PRESSURE
3 FEED PRESSURE
4 OXYGEN FLOW
5 REMOTE INPUT

6.3.1 Cell Temperature [1]

NOTE: The values shown are defaults. Actual values are adjusted during
final test and calibration.

To adjust the settings, enter new value using the number keys, then
press [ENT]. Press [CLR] to leave the values unchanged.

HIGH ALARM
30.0°C
LOW ALARM
8.00°C
ENT = ACCEPT CLR = EXIT

6.3.2 Cell Pressure [2]

HIGH ALARM
1.15 BARG
LOW ALARM
0.69 BARG
ENT = ACCEPT CLR = EXIT

31
(6.3 Alarms continued) under the Technician Menu

6.3.3 Feed Pressure [3]

HIGH ALARM
2.00 BARG
LOW ALARM
0.69 BARG
ENT = ACCEPT CLR = EXIT

6.3.4 Oxygen Flow [4]

HIGH ALARM
11.50 SLPM
LOW ALARM
2.00 SLPM
ENT = ACCEPT CLR = EXIT

6.3.5 Remote Input [5]

HIGH ALARM
20.0 MA
LOW ALARM
4.0 MA
ENT = ACCEPT CLR = EXIT

6.4 Water Meter [4]

NOTE: Water Meter [4] (not currently implemented).

WATER METER TYPE

1 CONTACTING HEAD
2 PADDLE WHEEL
3 AUTOTROL TURB 1 IN.
4 AUTOTROL TURB 2 IN.

32
6.4.1 Contacting Head [1]

MTR1
GALLONS OR LITERS
PER CONTACT =

0100.00

To adjust the setting, enter another value.

6.4.2 Paddle Wheel [2]

MTR1

K-FACTOR =

100.00

6.4.3 Autotrol Turb 1-Inch [3]

MTR1
AUTOTROL TURB. 1 IN.
GALLONS OR LITERS

1* GALLONS
2 LITERS

6.4.4 Autotrol Turb 2-Inch [4]

MTR1
AUTOTROL TURB. 2 IN.
GALLONS OR LITERS

1* GALLONS
2 LITERS

33
 6.4.5 Water Meter [4] [1 - 4] (type) - [1 - 2] (parameter)

RESET TOTAL COUNT?

1* YES
2 NO

6.5 System Setup [5]

From the “Technician Menu” press [5] to bring up the “System Setup” menu.

SYSTEM SETUP

1 LOCAL/REMOTE
2 REMOTE ALM CONFIG.
3 INITIALIZATION
4 SECURITY
5 DIAGNOSTICES
6 FIRMWARE VERSION

Press [CLR] to return to the “Technician Menu”.

6.5.1 Local/Remote Set-Up [1]

CONTROL MODE

1* LOCAL
2 REMOTE

* Indicates the current operating mode of the E-Series ozone generator.

In Local mode, the % ozone power is controlled by the LEFT and RIGHT
ARROW Keys. In Remote mode the % ozone power is controlled by the
remote 4-20 mA signal. (This is the same as in the Operator Menu,
Section 5.3.)

34
6.5.2 Remote Alarm Configuration Set-Up [2] (from Technician Menu - Setup)

REMOTE CONFIGURATION

1 REMOTE ENABLE INPUT

2 03 ALARM TIMER

6.5.2.1 Remote Enable Configuration [1]

REMOTE ENABLE INPUT

1* DISPLAY MSG ONLY

2 INVERTER OFF
3 INVERTER + GAS OFF

* Indicates the current active setting.

NOTE: These settings determine the action performed by the
Remote Enable input signal when the system is in
LOCAL operating mode. Refer to Section 5.3.

6.5.2.2 Room Ozone Alarm Timer Configuration [2]

TIMER VALUE =

002 SEC

ENT = ACCEPT CLR=QUIT

6.5.3 Initialization [3] (from Technician Menu - Setup)

INITIALIZATION

1 RESTORE DEFAULTS
2 CALIBRATE PRESSURE
3 CALIBRATE GAS FLOW
4 FLOW CONSTANTS

35
6.5.3.1 Restore Defaults [1]

WARNING
THIS OPTION MAY
REQUIRE YOU TO
RE-CALIBRATE THE
CONTROLLER
ARE YOU SURE?
1 YES
2* NO

This will reset all the Alarms, Pressure, and Flow calibrations to
their default values.

NOTE: Pressure, Flows, and Alarms are calibrated at the factory.

This will cause the factory calibrations to be lost!

6.5.3.2 Calibrate Pressure [2]

(from Technician Menu - Setup - Installation).

CLOSE THE OUT-FLOW

GAS VALVE,THEN
SET FEED PRESSURE
TO 1.0 BARG (14.5 PSI)

ENTER TO CALIBRATE

Pressure is calibrated at the factory. Pressure only needs to be

calibrated after replacing the Display circuit board, transducer cir-
cuit board, or cell module.

To calibrate the Pressure and Flow display, you will need a pres-
sure gauge (to read 14.5 psi), and a gas flowmeter (1-10 Lpm)
(rotameter) is needed.

Pressure is the most important and must be calibrated first with

power setting at 0%.

Flow will be within about 10% without calibration, but only after
the Pressure has been calibrated.

Pressure may appear accurate but needs to be calibrated for

Oxygen Flow to work, because Flow uses the 3rd and 4th digits
after the decimal in Pressure, which are not displayed.

36
 1. Close the T-handle needle valve (bottom of EO3), and adjust
the Pressure Regulator at the oxygen supply output to set
the Feed Pressure to 14.5 psi (1.0 bar).The needle valve may
need to be opened slightly when making small corrections of
the Regulator.

If no pressure guage is available, adjust the oxygen supply so

the Feed Pressure display reads “1.00 barg”.

2. Allow a minute for the pressure to stabilize at 14.5 psi.

3. In the Technician menu (see Section 3.5) select: 5-Setup, 3-

Initialization, 2-Pressure.Then press the [ENT] key to cali-
brate.

Press [CLR] several times to go to the Main Operation Status

screen and check the Flow readings.

6.5.3.3 Calibrate Gas Flow [3]

(from Technician Menu - Setup - Initialization)

SET CELL PRESSURE

TO 1.0 BARG
ENTER OXYGEN FLOW
FROM 10 - 12

ENT TO CALIBRATE

Flow is calibrated at the Factory!

Oxygen flow should not need to be calibrated in the field.
Accuracy is within 10% without calibration.

This procedure should only be done if higher accuracy is

required.

It is normal for the flow display to show an error at power set-

tings above 0%.

To calibrate the Flow (power must be at 0%):

1. First perform the pressure calibration.

2. Adjust the needle valve to get a flow of about 8.0 Lpm. Allow
it to stabilize for a minute.

37
 3. Multiply the rotameter Lpm reading by 1.25 to get SLPM (at
14.5 psi).

4. In the Technician menu select: 5-Setup, 3-Initialization, 3-Flow.

Then enter the SLPM value calculated in step 3
(i.e. 8.0 x 1.25 = 10.00).

5. Due to pulsations from the oxygen supply, the flow calibra-

tion process may have to be repeated several times to get
good results.

Press [CLR] several times to go to the Operation screen and

check the Flow readings.

Adjust the Flow Alarm high or low setpoint to avoid getting the
alarm at higher % power settings when the Flow reading drifts.

In the Technician menu, press the “0” key, then the “1” (yes) to
return to the Operator menu (read-only).

When operating with Flow less than approximately 4.0 SLPM, the
power level must not be set higher than 75%.

NOTE: Pressure Calibration (Section 6.5.3.2).

6.5.3.4 Flow Constant [4]

EDIT FLOW CONSTANTS

(1) +1.687
(2) -2.870
(3) +5.227
(4) +7.966

ENT=ACCEPT CLR=EXIT

NOTE: The flow constants are factory settings and should

never be changed.

38
6.5.4 Security [4] (from Technician Menu - System Setup)

The Security Code is used at the Main Operation Status Screen to

return to the Technician Mode from the Operator Mode (refer to
Section 3.5).

PASSWORDS ARE 4 KEYS

ENTER A NEW PASSWORD

OLD PASSWORD =
NEW PASSWORD =

This screen is used to change the security code.

(Press [CLR] to return to the Setup menu.)

6.5.5 Diagnostics [5] (from Technician Menu - System Setup)

DIAGNOSTICS

1 ANALOG I/O
2 DIGITAL I/O
3 ALARMS/CONTROL
4 CALIBRATION

6.5.5.1 Analog I/O [1]

(from the Technician Menu - System Setup - Diagnostics)

AD08: 0 RA20: 00.0

AD09: 71 TMP 26.74
AD10: 1886 CELL 0.879
AD11: 7072 FEED: 0.938
DA01: 0 03%: 0.00
WATER; 0 31

SCAN COUNT: 255

Displays the values of the analog input signals. Values shown are
typical, not actual.

39
6.5.5.2 Digital I/O [2]
(from the Technician Menu - System Setup - Diagnostics)

RC4 (DOOR OPEN): ON

RC5 (REM ENABLE): ON
RC6 (REM OZONE): OFF
RA1 (INV FAULT): OFF
RG7 (INV 2 FLT): OFF

SCAN COUNT

Displays the status of the digital input signals.

6.5.5.3 Alarms/Control [3]

(from the Technician Menu - System Setup - Diagnostics)

CELL TEMP: NORMAL

CELL PRESSURE: LOW
FEED PRESSURE: LOW
OXYGEN FLOW: LOW
REMOTE ANALOG: NORMAL
CONTROL MODE LOCAL
ALARM LATCH: 0
SCAN COUNT: 125

Displays the condition of alarms. Values shown are typical, not

actual.

6.5.5.4 Calibration [4]

(from the Technician Menu - System Setup - Diagnostics)

== FLOW CONSTANTS ==
TX OFFSET: 0000
PRESSURE 77
TEMPERATURE 25.0
FLOW: 10.0
CONSTANT: 1.0

SCAN COUNT 255

Displays the constants used in the gas flow calculations. These val-
ues are subject to change when the Flow Calibration is executed.
They are not adjustable from the keypad.

40
6.5.6 Firmware Version [6]
OSMONICS E-SERIES
OZONE GENERATOR
FIRMWARE P/N 1223876

VERSION: x.xx

6.5.7 Date and Time [6]

SUN
23 JUN 00

09:43:56
>=CHANGE CLR=EXIT

Refer to Section 5.5 for detailed instructions on adjusting the date and
time.

6.5.8 Drop Security Level to Operator Mode (View Only)

(from the Technician Menu press the “0” key)
DROP SECURITY LEVEL
TO OPERATOR ACCESS?
WARNING: PASSWORD IS
REQUIRED TO RETURN
TO TECHNICIAN MODE

1 = YES
2 = NO

Select yes or no by pressing the “1” or “2” key.

41
7.0 RELAY OUTPUTS (Engineering use)

Additional diagnostics are available in the Technician Menu, under System Setup (see
Section 6.5.5)

7.1 'RELAY STATES' in the Operation status Display. Use the UP and DOWN
ARROW Keys to view.

Alarm
0.00% First Line
Messages DOOR OPEN
OXY INV RDY ALM Second Line
Alarm Latch
Register 0 0 0 0
OXYGEN FLOWING Third Line

Three lines are shown in the lower half of the display:

• The First Line identifies the four relays:

- OXY (Oxygen) - RDY (Ready)
- INV (Inverter) - ALM (Alarm)

• The Second Line shows a graphic representation of the state (On or Off) of
each relay. A filled in box indicates On.

• The Third Line reads independently of the other lines. It shows the contents
of the Alarm Latch Register (Hexadecimal value) in the left most position
(under the OXY relay symbol) (for use only by Osmonics engineering).

To the right of the Alarm Latch value are the: Room Ozone timer, Inverter
Fault timer, and the High Temperature timer.

7.2 The alarm code that is displayed in the Alarm Latch Register is in the form of a
binary number. All alarms are displayed in plain text in the center of the screen.
Refer to Section 11 and Section 6.5.5.3 for more information on alarms.

Example: Alarm code 25 means that the Inverter is disabled, the Oxygen
solenoid is disabled, and the Room Ozone input signal is On (probably
causing the disables).

7.2.1 Alarm Codes (Engineering use, also screen messages)

0 Room Ozone 4 Inverter Disabled
1 High Temperature 5 Door Open
2 High Cell Pressure 6 & 7 (Unused)
3 Oxygen Disabled

42
8.0 SHUTDOWN

8.1 Generator Emergency Shutdown

• Initiate Emergency Stop Switch. If required, evacuate the area.

• If you are able, turn generator switch to the OFF position.
• Turn the cooling water off.
• Turn the process water off if necessary.

8.2 Generator Normal “Manual” Shutdown - Local Mode

• Push the LEFT Arrow Key until the generator is at minimum power.
• Turn the process water off, if necessary.
• Allow the gas to purge at least two minutes.
• Turn the generator switch to the OFF position.
• Turn the cooling water off.

8.3 Generator Normal “Manual” Shutdown - Remote Mode

• Remote command generator to “Disable.”

• Turn the process water off, if necessary.
• Allow the gas to purge at least two minutes.
• Turn the generator switch to the OFF position.
• Turn the cooling water off.

8.4 Generator Fault Shutdown

Should the ozone generator shut down with a fault, the display will indicate
which alarms are active. Alarms will be displayed on the alarm banner in the
middle of the display screen.The generator will flash each alarm in a cycle. Be
sure to observe all alarm conditions before continuing.

• Observe all alarm conditions.

• Turn the master switch to OFF.
• Consult Troubleshooting (Section 11.0).

8.5 Shut Down Alarms

• Room Ozone 1 second

• High Temperature 30 seconds
• High Feed Pressure (Oxygen) immediate
• Door Open immediate
• Inverter Fault 60 seconds
• Remote Idle relay 10 minutes

43
9.0 ESTIMATING OZONE OUTPUT

Your ozone generator has been factory tested to ensure it meets performance specifi-
cations and output. As part of the factory test procedure, your generator's ozone out-
put has been measured using the ultraviolet absorption method of measurement at var-
ious machine settings. This information is recorded on the Ozone Generator Test Data
Sheet in the Appendix of this manual. From time to time, you may have the need to esti-
mate approximately how much ozone your generator is producing. The most accurate
method would be to purchase or rent an ozone monitor capable of measuring high con-
centration ozone and re-measuring the actual output at your site.

If access to a monitor is not practical, it is possible to closely estimate your ozone out-
put by adjusting the machine settings to match the settings shown on the data sheet. At
these settings (and assuming that your generator has been well maintained) your ozone
output should be similar to the output indicated in the data sheet. The most critical set-
tings to duplicate are:

• Gas flow rate (taken from display screen).

• Generator operating pressure (taken display screen).
• Observed power level (0 - 100%)
• Cooling water temperature and flow rate.

To select a specific ozone output, first duplicate a gas flow and generator pressure set-
ting suggested on the data sheet. While referencing the ozone data sheet or output
curve, apply power by pushing the RIGHT ARROW Key until the power level is in the
range that matches your desired ozone output shown on the graph.

Tip: Your ozone system will operate most efficiently at a low gas flow. Unfortunately,
decreasing the gas flow rate limits how much ozone is created. Select the lowest gas
flow rate that still allows the generator to create the necessary amount of ozone.

9.1 Cooling Temperature Effect on Ozone Output

Cooling water temperature has an effect on ozone output. Refer to the graph
which can be used to more accurately determine ozone output at your actual
cooling water temperature.

WARNING: If the cooling water temp is too low, condensation may

form inside the generator cabinet and damage internal
circuitry.

44
 OZONE OUTPUT vs WATER TEMPERATURE

1.10
Ozone Output Factor
1.05
1.00
0.95
0.90
0.85
0.80
40 50 60 70 80 90 100
Cooling WaterTemperature oF

Note: Cooling water temperature must be higher than ambient dewpoint to prevent
condensation.
Figure 9.1
Ozone Output vs Water Temperature

45
10.0 MAINTENANCE

It is highly recommended that service and maintenance be performed as set forth below.
There are tables available (at the end of this section) that allow the logging of mainte-
nance work and daily checks as they are performed. You may want to copy these tables
from the manual and keep the copies with the ozone generator. All service should be
performed and logged to ensure warranty compliance.

WARNING: Shut power off to the generator at the feed disconnect before
performing any service or maintenance inside the cabinet.

10.1 Daily

Generator

1. Be sure that all gas parameters (gas pressure, flow and temperature) are with-
in the specified operating limits.

2. Check cooling water flow to ensure it is in pressure and temperature ranges.

See Utility Requirements (Section 2.3.1) for ranges.

3. Check overall system for water or gas leaks and repair as necessary.

4. Verify that the process water stream has not backed into generator.

10.2 Monthly

1. Perform a daily inspection (as above).

2. Inspect oxygen supply system.

3. Check the filters in the oxygen supply system and replace as necessary (if
installed).

4. Optional: check ozone output with a high concentration ozone monitor. If

out of desired range (% wt.), adjust the Power Level on generator display to
correct. Some gas flow rate balancing may be required.

5. Check cooling water connections for possible scale formation and clean with
citric acid solution as required.

6. For air compressor, refer to manufacturer’s instructions.

46
10.3 Quarterly

1. Perform a monthly inspection (as above).

2. Use low pressure compressed air to remove any obvious dust or lint from the
generator.

3. Check the oxygen feed filter (if installed).

4. Inspect gas outlet check valve (if installed).

5. Replace compressor piston rings, gaskets and seals as directed by manufac-

turer (if installed).

6. Replace air filters every 6 months.

10.4 Annually

1. Perform a quarterly inspection (as above).

2. With power disconnected and locked out, check the tightness of all nuts and
screws including the electrical terminals and ground wires.

3. Inspect the interior for gas or water leaks.

10.5 Cabinet Entry and Cell Removal

WARNING: Use care to prevent damage to the plastic tubing and

fittings above the transformers. Damage will cause
ozone gas to escape into work area.

1. Disconnect all electrical feed to unit.

2. Open the cabinet door.

3. Remove all plumbing connections from the bottom of the unit. (Ensure that
the gas and water supplies are off before disconnecting lines).

4. Disconnect the plugs and wires from the control board and the inverter.

5. Disconnect the harness to the pressure transducer board.

6. Remove the two screws from the right hand front and rear corners of the
inverter.

47
 7. Remove the eight (8) screws underneath that attach the cell assembly to the
cabinet.

8. The manifold and cell assembly will tilt out of the cabinet. You may need to
adjust the position of the flow control knob to allow the manifold to slide
through the hole in the bottom of the cabinet.

9. Drain as much water as possible from the assembly, then blow the rest out
carefully, using compressed air regulated to 20 psi maximum.

10.6 Cell Reinstallation in Cabinet

WARNING: Use care to prevent damage to the plastic tubing and

fittings above the transformers. Damage will cause
ozone gas to escape into work area.

1. Re-install the cell in reverse order of removal, paying particular attention to

not damage the connectors, circuit board, and tubing.

2. Make sure all wiring is reconnected correctly, and securely.

3. Connect the plumbing to the same places it was removed from.

4. Do the System Startup as shown in Section 3.0.

5. Do the Pressure Calibration (Section 6.5.3.2) if the transducer board was

replaced.

10.7 Circuit Board Replacement

The inverter power board requires special care in mounting the power semicon-
ductors. Repairs should only be done by the Osmonics’ service center (see
Section 14.0).

When replacing the display control board, first record the alarm settings.

After replacing the display control board or transducer board, you must do the
Pressure Calibration (Section 6.5.3.2) even if the display appears good. Otherwise
the Oxygen Flow will not be correct. Pressure Calibration must be done first,
then Flow Calibration is usually not required.

48
 Table 10.1
Osmonics E-Series Ozone Generator
Suggested Maintenance Intervals
SEMI-
DAILY MONTHLY QUARTERLY ANNUALLY ANNUALLY

OXYGEN PREPARATION

Compressed Air Inspect

Pressure

Gas Flow Inspect

Pressure Relief Valves Check

Air Filters Inspect Clean Replace

Oil Vapor Filter Inspect Clean Replace

Compressor Air Intake Inspect & Inspect & Replace

Filters Clean Clean

Oxygen Concentrator Inspect

OZONE GENERATOR
Cooling Water Flow Inspect

Electrical Supply Amps Inspect

General Cleaning Clean

(w/compressed air)

Ozone Check Valve & Inspect Replace

Backflow Preventer

Ozone Safety Monitor Inspect Test Calibration

Ozone Detector Inspect Clean

49
 Table 10.2
Osmonics E-Series Ozone Generator
Maintenance Log
Ozone Generator Serial Number: ______________________________Feed Gas: Oxygen
DATE

Compressed Air
Pressure (psig)

Oxygen Pressures
(psig)

Generator Pressure
(psig)

Gas Flow (Lpm)

Dewpoint Reading
(optional)

Compressed Air
Filter(s) (replace
annually)

Compressor Air
Intake Filters
(clean/replace monthly)

Cooling Water Flow

(gpm/Lpm)

Supply Amps

General Cleaning
(w/compressed air)

Gas Outlet Check

Valve

Ozone Safety
Monitor (test weekly)

Ozone Destructor
Make copies of these sheets for your maintenance log book!
50
 Table 10.3
Osmonics E-Series Ozone Generator
Maintenance Log
Name of Customer:_____________________Service Contact:_____________________
Model: _____________Serial Number: _________________Date Installed: ___________

Date Maintenance Performed Operators Initials

51
11.0 TROUBLESHOOTING

This troubleshooting guide will assist you in identifying the most common operating
problems you may experience with your machine. Many of these problems are easily cor-
rected by the operator, but with other problems or those not understood, you should
contact the Osmonics Technical Service Department. Have the problem and symptoms
clearly defined and operating data available. Have the following information available when
calling your equipment supplier:

1. Serial number (found on the right-hand side of front panel)

2. Daily Log Sheets
3. Description of problem

11.1 Alarms

11.1.1 Shutdown Alarms

These alarms must be cleared by pressing [ENT], except for Inverter

Fault which can only be cleared by shutting the power off.

HIGH FEED PRESSURE - oxygen pressure to the EO3 is too high.

HIGH TEMPERATURE (30 second delay) - cooling water is too warm or
not enough cooling water flow, cell overheating.
INVERTER FAULT (60 second purge) - indicates a malfunction in the
high voltage circuitry.
DOOR OPEN - the cabinet door is open, or interlock switch
malfunction.
ROOM OZONE OR COOLANT - not enough cooling water flow, or
ambient ozone safety monitor has detected a leak.

NOTE: If the system shuts down (green light off) but no alarm message
is displayed, check for fluctuations in cooling water pressure, or
door interlock switch needs adjustment.

11.1.2 Warnings

These alarms display a warning message but do not cause shutdown.The

values for high and low limits are set in the Alarms section under the
Technician Menu.

LOW FEED PRESSURE - oxygen pressure into the EO3 is too low
or zero.
HIGH CELL PRESSURE - gas pressure inside the cell chamber is
too high.
LOW CELL PRESSURE - gas pressure inside the cell chamber is too low.

52
 HIGH OXYGEN FLOW - Flow Control needle valve is open too much.
LOW OXYGEN FLOW - Flow Control needle valve is closed, or piping
is blocked.
LOW TEMPERATURE - cooling water is too cold, or possible sensor
failure.
HIGH REMOTE INPUT - 4-20 mA input current is too high.
LOW REMOTE INPUT - 4-20 mA input current is too low, or
wiring is bad.
REMOTE CONTROL MODE (not an alarm) - indicates that the EO3 is
being controlled by the 4-20 mA input signal, the left and right
arrow keys are disabled.
REMOTE ENABLE INPUT (10 minute delay) - the Remote Enable input
circuit is opened [ input terminals #12 and #13].

• In LOCAL mode a menu can be set to cause: message

only, ozone off, or ozone and gas off.
• In Remote mode: ozone power goes to 0%. Gas flow will
stop after 10 minutes.
• To resume operation, close #12 and #13.

If the suggested remedy fails to correct the problem, and no other malfunction can be
found, it is possible that the alarm menu setting may be incorrect, or a sensor needs to
be re-calibrated, or has failed and may need to be replaced.

53
 11.2 Troubleshooting Chart

PROBLEM WHAT THIS MEANS CORRECTIVE ACTION

Ozone generator Emergency Stop button Turn the knob on the Emergency
does not turn on. pressed. Stop to release.

Check continuity of the fuse with

a multimeter. Find cause of blow-
One or both of the ing fuse; shorted component, etc.
fuses might be blown. (Should be accomplished by a
qualified electrician.).
Spare fuses are located inside the
fuse holders.

The unit may be Plug in unit, or reset circuit break-

unplugged, or a remote cir- er. Check electrical supply voltage
cuit breaker might at L1 and L2.
be off.

High Temperature Alarm The cooling water flow Refer to data sheet for minimum
or abnormally high tem- may be too low or off. cooling water flow at 29°C (85°F)
perature display. water inlet temperature.

NOTE: ALLOW 10 MINUTES

FOR THE OZONE GENERATOR
TO COOL BEFORE RESTART.

The oxygen flow may Refer to data sheet for specific

be too low. oxygen flow rate.

4-20 mA signal wired Reverse 4-20 mA wires

incorrectly. (+ on 15). Shield on 4-20 mA
should be grounded at only one
end.

54
PROBLEM WHAT THIS MEANS CORRECTIVE ACTION

Generator temperature The inlet water tempera- May have to find other source for
high (cont.) ture may be too high. cooling water or add chiller
(maybe go to closed-loop system).
Refer to data sheet for specific
water temperature.Too cold will
cause condensation damage.

Clogged plumbing fit- Check for water flow at flow

ting in the water cool- meter. Filter this water prior to
ing system. entry of cooling system.

Alarms settings in- Verify correct settings in Alarm

correct Menu.

Failed temperature sensor. Transducer board may need to be

replaced.

“Room Ozone or Not enough cooling water. Check the supply of cooling water.
Coolant” Alarm shut-
down Ozone leak. Evacuate the area until safe,
then repair the leak.

The set point of remote Locate the source of the ozone:

ambient ozone monitor leak in plumbing fitting, too much
has been exceeded by ozone to process, etc., and take
a source of ozone. corrective measures.

The set point on the Refer to the monitor's manual.

monitor has been set
too low, or a problem
exists with the moni-
tor's operation.

There may be interfere- Smoke from cigarettes, etc., can

ence from other gases cause false alarm situations. Many
or smoke near the moni- chemicals and gases can cause
tor gas sample inlet. alarm conditions. The monitor's
environment must be free of
gases, chemicals or smoke. Refer
to the monitor’s manual.

55
PROBLEM WHAT THIS MEANS CORRECTIVE ACTION
“Door Open” alarm shut- Door switch may be Ensure door is completely closed
down open or intermittent and locked. Door switch may
need adjustment.

“Inverter Fault” alarm Faulty cable or connector Check cable connectors at

to fixed Frequency Board. Display Board and Fixed
Frequency Board.

Inverter Power Board Return to factory for repair.

failed.

Generator turns on, does O2 supply not working. Check and correct oxygen sup-
not produce ozone, or ply. If using an oxygen concentra-
produces only small tor, ensure that the exhaust air
amounts of ozone. pulse occurs about once each
second.
Oxygen flow may be too high.

Ceramic plate cracked Check for leaking process water

(not repairable). back into generator. Ozone cell
will require replacement.

Pressure and/or flow dis- Faulty ground connection. Check and repair ground con-
plays fluctuate widely or nections and terminals.
stuck at zero.

Faulty cable connection. Check wire connections at trans-

ducer board and display board.

Failed pressure transducer. May need pressure calibration.

Replace pressure transducer.

Flow display changes Interference from high This characteristic is normal -

when power setting is voltage supply. adjust alarm settings as needed.
raised above 0%. Set power to 0% for accurate
readings.

56
PROBLEM WHAT THIS MEANS CORRECTIVE ACTION

4-20 mA display fluctu- Faulty connection. Check wire connections at ter-

ates. minal strip and Display board.

“High Feed Pressure” Oxygen pressure into the Check the oxygen supply, lower
alarm. generator is too high. the pressure into the EO3, 1.2
barg (18 psi) maximum. Note:
maximum from ATF-25 is 15 psi.

“Low Feed Pressure” Not enough oxygen pres- Check for problem in oxygen
alarm. sure. supply. Increase oxygen pres-
sure. Adjust the alarm setpoint.

“High Cell Pressure” Ozone output pressure is Check for blockage or back-
alarm. too high. pressure in the ozone piping.

“Low Cell Pressure” Gas pressure in cell is too Check for excessive vacuum
alarm. low. Oxygen valve failed. from injector, or failed oxygen
valve (located behind fan).

“Low Temperature” alarm. Cooling water too cold. Use warmer water, adjust alarm
Alarm setpoint incorrect. setpoint, transducer board may
Failed temperature sensor. need to be replaced.

“Low Remote Input” 4-20 mA signal is too low. Check 4-20 mA wiring. Check
alarm. Faulty wiring connection. connections at terminal strip.

Oxygen flow display This is normal. Set power to 0% to read flow.

incorrect.
Needs pressure calibra- Calibrate pressure (Technician
tion. Menu).

Failed Transducer. Transducer Board may need to

be replaced.

57
PROBLEM WHAT THIS MEANS CORRECTIVE ACTION

(All alarms) Alarm setpoint may be Check to be sure the actual

incorrect. pressures and flows are within
specifications, and adjust the
alarm setpoints (in Technician
menu).

Oxygen Flow or Pressure This characteristic is normal,

display readings change adjust alarm setpoints to avoid
when power setting is nuisance alarms.
raised.

Failed transducer. Transducer board may need to

be replaced - requires pressure
calibration.

Generator on, but stops There was a momentary Increase the cooling water flow.
producing ozone, “Press loss of cooling water, or Ensure that the supply of cool-
any Key” message is dis- fluctuating pressure. (wire ing water is reliable.
played. terminals 10 and 11).

There was a momentary Repair any ozone leaks. Adjust

alarm from room ozone the monitor for latching alarm
monitor. output, or increase the delay.

There was a momentary Door switch may need adjust-

“Door Open” condition. ment.

58
12.0 SPARE PARTS

IFO P/N Description

1100946 Door Switch

1103142 Kynar Bottom Fitting 0.25” T x 0.13” PM
1103144 Kynar 90 degree Elbow 0.25”T x 0.13”PM
1225049 Generator Module Assembly
1225077 Cooling Fan, 24 V DC, 100 CFM
1225074 Fuse, 10 A, 250 V, DELAY, 3AG, CERAMIC
1229915 ON/OFF Switch Assmbly
1229916 Emergency Stop Switch Assembly
1225091 Control PCA and Liquid Crystal Display Panel
1225083 PCA,Transducer, EO3 gen
1229917 PCA, Inverter Power Board Kit, EO3 gen
1225095 VALVE-SOL, 2 way, 24 VDC, Manifold mt
1222960 Power Supply, 24 VDC, 20W
1225116 Adapter, kynar, 0.16 HBX 10-32 (min. qty 2)
1225114 Bushing, ceramic, High Voltage

59
 13.0

13.1

Control
DRAWINGS

Remote
+5 V +5 V Mode Fault
Ready Relay To ON/OFF Switch
Electrical Drawing

F2 F1

4 3 10 11 12 13 14 15 16 17 18 19 20 G L2 L1 Terminal Strip
+

60
Figure 13.1
Coolant

Electrical Hook-Up Drawing

Flow Switch Customer
Connections

N.O. C N.O. C N.C.

Remote Remote Power Feed
Ready Alarm 208 - 230 Vac
Room Enable Control Out Out 1-phase
Ozone (Close to Run) 4-20 mA 3.5-3.1 Amp
Monitor 50/60 Hz
(open to stop) (720 Watts)
(close to run)
13.2 Installation Drawing

.44
10.0 [11]
4.0 [253]
[102]
Operator Interface

Emergency Stop
7 8 9 ENT
4 5 6 CLR
1 2 3
20.4
0
[518]
19.2 OFF ON 18.0
[487] [457]

Power On Switch

.44
[11]
Gas Flow Control Valve

18.0
[457]

Gas Flow Control Valve

Oxone Gas Outlet

Cooling Water Inlet

14.1
[357]

13.0
[330]

8.0
[204]
6.2
[157]

5.7 2.5 .90 Knockout

2.1 [146] [64]
[52] w/Plugs (3PL)
6.3
[161]
Oxygen Inlet
6.8
[174] Cooling Water Outlet NOTE: Water and gas
14.1
[359]
connectors are for 1/4"
PTFE Tubing

Figure 13.2
Installation Drawing

61
13.3 Electrical Schematic

62
14.0 RETURN GOODS AUTHORIZATION (RGA) PROCEDURE

If you wish to return goods for repair, warranty evaluation and/or credit, please have your
original sales order or invoice available when you call Osmonics. Call (800) 848-1750 and
ask to speak with Technical Service. An Osmonics Technical Service representative will
provide instructions and a return authorization number which needs to be clearly writ-
ten on the outside of the box used to ship your materials.A customer supplied purchase
order is required by Osmonics policy to issue an RGA. Nothing will be charged against
this P.O. in the event the claim is verified to be under warranty. All equipment must be
shipped to Osmonics with the freight prepaid by the customer. Call our Customer
Service Center with any questions or issues concerning freight claims and a representa-
tive will discuss your situation.

All materials to be returned must be rendered into a non-hazardous condition prior to

shipping.

63
15.0 WARRANTY

Osmonics, Inc. warrants its products to be free from defects in design, material or work-
manship for a period of 15 months from receipt or 12 months from installation of the
product, whichever occurs first, when said products are operated in accordance with
written instructions and are installed properly. If products are altered or repaired with-
out prior approval of Osmonics, all warranties are void. If any defects or malperformance
occur during the warranty period, Osmonics’ sole obligation shall be limited to alteration,
repair or replacement at Osmonics’ expense, Ex-works, of parts or equipment, which
upon return to Osmonics and upon Osmonics’ examination prove to be defective.
Equipment and accessories not manufactured by Osmonics are warranted only to the
extent of and by the original manufacturer’s warranty. Osmonics shall not be liable for
damage or wear to equipment caused by abnormal conditions, excessive temperatures,
vibration, failure to properly prime, or to operate equipment without flow, or caused by
abrasives or foreign objects or corrosives.The foregoing warranty is exclusive and in lieu
of all other warranties, whether expressed or implied, including any warranty of mer-
chantability or fitness for any particular purpose. In no event shall Osmonics, Inc. be liable
for consequential or incidental damages.

64
 5951 Clearwater Drive, Minnetonka, MN 55343-8995 USA Phone (952) 933-2277 or Fax (952) 933-0141

MATERIAL SAFETY DATA SHEET

Product Name: Ozone (Ambient Air or Oxygen Feed Gas) Date Prepared: 16 Jan 01

PRODUCT AND COMPANY IDENTIFICATION

Manufacturer/Supplier: NFPA Codes:

Osmonics
3
5951 Clearwater Drive
3 2
Minnetonka, MN 55343-8995
Emergency Telephone: ox
(952) 933-2277 Health: 3
(800) 424-9300 CHEMTREC Fire: 3
Common Name: Ozone Reactivity: 2
Chemical Name: Triatomic Oxygen Special: Oxidizer

MATERIAL COMPOSITION
Hazardous Components CAS# % OSHA ACGIH Other Limits
(1% or greater for hazardous components, PEL TLV Recommended
0.1% or greater for carcinogens)

Ozone (O3) 10028-15-16 100* 0.1 ppm 0.1 ppm (c) 0.3 ppm STEL,
(0.2 mg/m3) (0.2 mg/m3) 5 ppm IDLH
*Equipment emits ozone at 1-11% concentration by weight for oxygen feed gas.

PHYSICAL/CHEMICAL CHARACTERISTICS

Boiling point: -170oF (-112oC) Specific gravity: 1.614

Vapor pressure: >1atm Melting point: -313oF (-192oC)

[1 mm Hg & -292.7oF (-180.4oC]

Vapor density: 1.65 Evaporation rate: Not applicable

(Air = 1)` (H2O = 1)

Solubility in water: Almost insoluble Water reactive: Not applicable

[0.0003 g/100 mL at 68oF (20oC)

Appearance and odor: Colorless/blueish gas with pH: Not applicable

pungent odor detectable at 0.01 to 0.04 ppm,
sharp disagreeable odor at 1 ppm
 FIRE AND EXPLOSION HAZARD DATA

Flash point: Not applicable Auto-ignition temp: Not applicable

Flammability limits in air % by volume:

Lower explosive limit (LEL): Not applicable
Upper explosive limit (UEL): Not applicable

Special fire fighting procedures: Ozone is an oxidizer and will accelerate combustion; use media appropriate
for extinguishing surrounding materials.

Unusual fire and explosion hazards: Can react explosively with readily oxidizable substances and reducing
agents. It may present dangerous fire hazards when exposed to aniline, diethyl ether, hydrogen iodide, nitrogen
oxides, organic liquids, lithium aluminum hydride, metal hydrides, nitroglycerin, hydrazine, stilbene, ammonia, arsine,
nitrogen, and phosphine. Ozone is also incompatible with acetylene, alkyl metals, citronellic acid, fluoroethylene,
hydrogen, and tetramethyl ammonium chloride. Ozone reacts with alkenes to form peroxides that are often
explosive. Gelatinous explosive ozonides are formed with benzene and other aromatic compounds. Ozone may
also react with bromine and hydrogen bromide. Combustion is also possible if high concentrations of ozone off-
gas are exposed to carbon-containing ozone destruct devices.

STABILITY AND REACTIVITY DATA

Stability: Unstable. Ozone gas rapidly decomposes to oxygen (O2).

Reactivity: Reacts with any oxidizable organic or inorganic material. Ozone reacts with alkenes and other unsat-
urated organic compounds to form ozonides, many of which are highly unstable and explosive.

Conditions to avoid: Avoid contact with oxidizable materials, powerful reducing agents, and heat or flame.

Hazardous decomposition: None.

HEALTH HAZARD DATA

Emergency overview: Ensure adequate ventilation has been engineered in the area where the ozone genera-
tion equipment is located. Exposure to ozone may cause headaches, irritation of the eyes, throat and mucous
membranes, coughing, dizziness and tightness in the chest.

Potential health effects:

Eyes: Irritating to eyes

Skin: Not an expected route of entry

Ingestion: Not an expected route of entry

Inhalation: Irritating to respiratory system. May cause respiratory complications, coughing, difficulty breathing,
chest pain, headache, pulmonary edema, and bronchial pneumonia.

Chronic/carcinogenicity:
NTP: Not listed
OSHA: Not listed
IARC: Not listed

Medical Restrictions: Persons with asthma, allergies, respiratory disorders, or emphysema may be further
aggravated by exposure to ozone.
 FIRST AID MEASURES

Eyes: In the event of irritating eye contact, promptly wash eyes with copious amounts of water for 15 minutes
(lifting upper and lower lids occasionally) and obtain medical attention.

Skin: Not applicable

Ingestion: Not applicable

Inhalation: Respiratory protection may be necessary in the event of an accidental release of ozone. An ozone
leak can easily be detected by its characteristic pungent odor. If a large amount of ozone is inhaled, move the per-
son to fresh air and seek medical attention immediately.

EXPOSURE CONTROL/PERSONAL PROTECTION

Engineering controls: Ozone generation equipment should never be operated without the parallel use of an
efficient destruct unit to destroy any off-gassing ozone. Provide general or local exhaust ventilation systems to
maintain airborne concentrations as low as possible.

Personal protection:
Eyes/face: None required

Skin: None required

Respiratory: For concentrations greater than 0.1 ppm, use a NIOSH-approved supplied air respirator
or self-contained breathing apparatus.

Handling: Not applicable.

Storage: Ozone cannot be stored. Use ambient room ozone monitor for detection.

DISPOSAL INFORMATION

RCRA hazardous waste: Not applicable (gas)

Waste disposal: Ozone rapidly decomposes to form oxygen (O2). Small to moderate amounts of excess ozone
can be vented to a fume hood or other exhaust system. A 1% off gas at 10 cfm or more is considered to be a
large amount of ozone.When large amounts of excess ozone are anticipated, the excess gas should be passed
through a series of traps containing a 1 to 2% solution of potassium iodide (or other reducing agent), or a catalyt-
ic destruct module before venting to atmosphere.

OTHER

Prepared by: Osmonics Regulatory Affairs Department (952) 933-2277

The above information and recommendations are believed accurate and reliable. Because it is not
possible to anticipate all conditions of use, additional safety precautions may be required.

User responsibility: Each user should read and understand this information and incorporate it into
individual site safety programs in accordance with applicable hazard communication standards and
regulations.
For More Information:
Call Osmonics Process Water Group at (952) 933-2277 or (800) 848-1750, or visit www.osmonics.com

North American Sales Euro/Africa Sales Asia/Pacifics Sales

5951 Clearwater Drive 230 rue Robert Schurman 1044/8 SOI 44/2
Minnetonka, MN ZA des Uselles Sukhumvit Road Parkanog
55343-8995 77350 Le Mée sur Seine. Bangkok 10110
USA FRANCE THAILAND
(952) 933-2277 Phone +33 1 64 10 2000 Phone + 66 2 38 14213 Phone
(952) 988-6060 Fax +33 1 64 10 3747 Fax + 66 2 39 18183 Fax
© Copyright 2002 Osmonics, Inc.
Printed in USA, P/N 1226966 Rev. C