Teledyne API AC Gen FBVG User manual

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Copyright 2017 610-0191-01D DCN7808
Teledyne API 22 December 2017
AC-Series
Ozone Generators
User Manual
ACSeriesOzoneGeneratorsUserManual
610‐0191‐01RevDDCN7808 Pagei
Contents
1 SAFETY ...................................................................................................... 1
1.1 General Precautions ................................................................................................................................. 1
1.2 Safety Labels ............................................................................................................................................. 3
1.2.1 Ozone Safety .............................................................................................................................................. 3
1.2.2 Hazardous Voltage ..................................................................................................................................... 3
2 AC SERIES DESCRIPTION ........................................................................... 5
2.1 System Overview ...................................................................................................................................... 5
2.2 Principle of Operation .............................................................................................................................. 6
2.3 Specifications ............................................................................................................................................ 7
3 INSTALLATION AND CONNECTIONS ........................................................... 8
3.1 Facility Requirements .............................................................................................................................. 8
3.2 Water Isolation Valve .............................................................................................................................. 9
3.3 Mounting ................................................................................................................................................... 9
3.3.1 Dimensions – Wall-Mount Systems ......................................................................................................... 10
3.3.2 Dimensions – Rack-Mount Systems......................................................................................................... 11
3.4 Recommended Pneumatic Diagrams .................................................................................................... 12
3.4.1 Option A: Using MFCs and BPR ............................................................................................................. 12
3.4.2 Option B: Using Adjustable Rotameter and BPR .................................................................................... 13
3.4.3 Option C: Using a Flowmeter and Needle Valve ..................................................................................... 14
3.5 Wall Mount, Bottom Connection Locations ........................................................................................ 15
3.6 Rack Mount, Rear Connection Locations ............................................................................................ 16
3.7 Power Connections ................................................................................................................................. 17
3.8 Chassis Ground Connection .................................................................................................................. 17
3.8.1 Wall-Mount System Internal Wiring Locations ....................................................................................... 18
3.8.2 Wall-Mount Field Wiring Pictorial .......................................................................................................... 19
3.8.3 Rack Mount Remote Interface Connector (Rear Panel) ........................................................................... 2 0
3.8.4 Wall-Mount Remote Interface Command Connections (Field Wiring) ................................................... 21
3.8.5 Wall-Mount Remote Interface Relay Outputs (Field Wiring) .................................................................. 22
3.9 Gas Connections ..................................................................................................................................... 23
3.9.1 Particulate In-Line Filters. ........................................................................................................................ 24
4 OPERATION ............................................................................................. 25
4.1 Wall Mount Front Panel ........................................................................................................................ 25
4.2 Rack Mount Front Panel ....................................................................................................................... 26
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4.3
Control Panel Controls/Indicators ........................................................................................................ 27
4.4 RESET Switch on the Wall-Mount ....................................................................................................... 28
4.5 Reset Condition ...................................................................................................................................... 28
4.6 Typical System Operation from a PLC ................................................................................................ 28
4.7 How to select a Mode of Operation ....................................................................................................... 29
4.8 Local Mode .............................................................................................................................................. 30
4.8.1 Local Mode Operation .............................................................................................................................. 30
4.8.2 Reading the Cell Temperature .................................................................................................................. 32
4.9 Remote Mode .......................................................................................................................................... 33
5 SYSTEM SHUTDOWN ................................................................................ 34
6 STANDARD OPERATING PROCEDURES ..................................................... 35
7 PERFORMANCE DATA ............................................................................... 36
8 MAINTENANCE ......................................................................................... 37
8.1 Preventative Maintenance Schedule ..................................................................................................... 37
8.2 Wall-Mount Cooling Air Filter Replacement Kit ................................................................................ 3 8
9 TROUBLESHOOTING ................................................................................. 40
9.1 General Troubleshooting ....................................................................................................................... 40
9.2 What to do when the Ozone Generator is not performing as expected ............................................. 40
9.3 Fault Indications and Codes .................................................................................................................. 41
9.4 How the Fault conditions are detected, cleared and displayed .......................................................... 42
9.5 Recovering from RESET ....................................................................................................................... 42
9.6 Dialing ’00.0’ while in STANDBY ........................................................................................................ 43
9.7 Reading the Fault Code Display ............................................................................................................ 43
10 INSTALLATION KIT .................................................................................. 44
10.1 Spare Parts for Installation Kit ............................................................................................................. 45
10.2 Adjustment of Pressure Gauges and Flowmeter ................................................................................. 46
11 OPTIONAL BULKHEAD CONNECTORS ....................................................... 47
11.1.1 Wall Mount AC Power Inlet Connector (Bulkhead Connector Option) .................................................. 48
11.1.2 Wall Mount AC Power Output Connector (Bulkhead Connector Option) .............................................. 49
11.1.3 Wall Mount Relay Output Connector (Bulkhead Connector Option) ...................................................... 50
11.1.4 Wall Mount Control Input Connector (Bulkhead Connector Option) ...................................................... 51
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610‐0191‐01DDCN7808 Page1
1 Safety
1.1 General Precautions
WARNING!
Use this product ONLY as detailed in this manual.
This product is not intended or recommended by Teledyne API
(TAPI) for use in (a) medical therapy or physical therapy of any kind
whether as a direct or adjunct part of such therapy, including,
without limitation, life support (i.e., critical medical) applications or
(b) any nuclear facility applications. TAPI will not knowingly sell this
product for use in such applications. Use of the TAPI product in
connection with medical or like treatment cannot be reasonably
expected to produce accurate monitorings of therapy or treatment
and may cause failure of the life support device or significantly
affect its safety or effectiveness. Use by any direct purchaser or
after-market purchaser in such applications whether or not known
to TAPI shall absolve TAPI of any responsibility or liability to such
purchaser (s) or to any person (s) subjected to or affected by such
use knowingly or unknowingly.
WARNING!
Ozone (O
3
) is a toxic gas. High concentrations of Ozone are
dangerous and harmful to humans. Take reasonable steps to avoid
exposure. The current maximum 8-hour exposure limit for Ozone is
0.1 ppm (according to U.S. OSHA).
Install appropriate safety monitoring equipment wherever high
concentrations of Ozone are used. TAPI manufactures several
Ozone monitors for workplace safety applications.
Materials in contact with high concentrations of Ozone should be
suitable for such use. 316L Stainless, Teflon
®
, Chemraz
®
and
Kynar
®
are recommended.
Use only stainless steel gaskets for VCR
®
gas connections
Ozone must be destroyed before it can be released to exhaust. TAPI
manufactures a complete line of Ozone destruction equipment.
Please consult with us for your Ozone destruction requirements.
Never attempt to open Ozone catalyst canisters (if supplied). The
content of the canisters can be hazardous if not handled properly.
Use only TAPI-recommended spare parts. Substitution parts could
result in damage to the equipment, may create hazardous
conditions and will void the warranty.
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610‐0191‐01DDCN7808 Page2
WARNING!
Electrical Hazard. DO NOT OPEN COVERS to access electrical
equipment with the power on, unless you are certified to perform
specific troubleshooting/repair tasks.
When performing any maintenance to the unit, make sure all AC
power is disconnected from the unit.
WARNING!
LOX FIRE HAZARD!
When liquid Oxygen (LOX) is used as a source for gaseous Oxygen,
care must be taken to maintain the evaporating equipment so that
liquid Oxygen does not enter the Ozone Generator. LOX is highly
inflammable when exposed to flammable materials. For further
information, refer to an appropriate MSDS
WARNING!
Certain components may be hot to the touch. Please allow proper
cooling time before working with these components.
CAUTION!
Read the operating manual before operating the unit.
Do not subject the unit to extreme physical or thermal shock.
Use care in handling the unit and any of its components.
DO NOT use this equipment in any manner not specified by the
manufacturer. If the equipment is used in a manner other than as
specified in this document, the safety protections may be impaired.

ACSeriesOzoneGeneratorsUserManual
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1.2 Safety Labels
1.2.1 Ozone Safety
TheOzonesafety‐warninglabelisintendedtowarnusersaboutthetoxicityanddangerof
Ozonegas.Priortooperatingthegenerator,ensurethatyoursystem/facility’sOzone
detectorisattachedtothegeneratorandisfunctional.Ensurethatallothersafety‐
monitoringfeaturesarefunctional.
1.2.2 Hazardous Voltage
Oneormorehazardousvoltagelabelsmaybeaffixedtothedevicetowarnofpossible
electricalshockorburnhazards.Followallsafetydirections.
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GENERAL NOTES
Alltrademarks,registeredtrademarks,brandnamesorproductnamesappearinginthis
documentarethepropertyoftheirrespectiveownersandareusedhereinforidentification
purposesonly.
TeledyneAPI(TAPI)reservestherighttomakechangestotheproductcoveredinthis
manualtoimproveperformance,reliabilityormanufacturability.Makesurethatthis
ManualisusedwiththeoriginalProductwithwhichitwasshipped.
Althougheveryefforthasbeenmadetoensureaccuracyoftheinformationcontainedinthis
manual,TAPIassumesnoresponsibilityforinadvertenterrors.Contentsofthemanualare
subjecttochangewithoutnotice.
TAPIassumesnoresponsibilityfortheuseofanymeasuringschemesdescribedherein.
Thisproductshouldonlybeusedasspecifiedbythismanual.Anyuseotherthanasspecified
mayimpairthesafetyfeaturesofthesystem.
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2 AC Series Description
2.1 System Overview
TheACseriesOzonegeneratorsaredesignedtoproducehighpurityOzonegasfrom
Oxygensources,includingOxygenconcentrators.TheACgeneratorsareavailablein
standardrack‐mount(ordesktopapplication),aswellaswellasawall‐mountconfiguration.
Figure 1: AC Series Ozone Generators – Front Views
AC Series
Wall-Mount
AC Series
Rack-Mount
ACSeriesOzoneGeneratorsUserManual
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2.2 Principle of Operation
TeledyneAPI’sINUSA‐brandOzoneGeneratoruseshighvoltageelectricityinaproprietary
systemtoefficientlyconvertOxygentohighpurityOzone.Oxygenflowsatacontrolledrate
throughthegeneratorwhereitencountersaprogrammedelectricalenergy.The
percentageofOzoneintheoutletstreamisprimarilydependentontheappliedvoltage.
OtherfactorsaffectingOzoneconcentrationinclude:
Oxygeninletpressure
Oxygenflowrate
Generatorbackpressure
Ambienttemperature
Oxygenconcentration
Oxygenimpurities
Generatorcoolingandcellconditions
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2.3 Specifications
Specification Rack‐MountSystem Wall‐MountSystem
Dimensions(approximate)
(WxHxD):
19”x6.97”x19.63”
(483mmx177mmx499mm)
30.14”x20”x11”
(766mmx508mmx279mm)
Oxygenflow:
0.05to20slm
Ozoneoutletpressure:
20to35psig(Typicallysetto23psig)
Proofpressure:
120psig
Storagetemperature:
5–35C(<40%relativehumidity)
ACpower:
115to240VAC,1/2,50/60HZ,1kVA
HeatLoad
IKWapproximately
Coolingrequirement:
AirCooled18C±3C
Properaircoolingofthecomponentsisessentialtoproperoperation.
Neverblocktheairvents.
Neverplaceanyhigh‐heatoperatingequipmentorexhaustsnearthesystem.
Donotmountinenclosedcabinets.
Thermalshutdowncanresultinthecaseofinadequatecooling.
Twocoolingfans,ontheleftside,
drawairintothehousing,
exhaustingitontherightside.
Provideadequateventingonboth
sidesofthegenerator–thismay
requirehavinglargeholesinboth
sidesofacabinet.
Fourcoolingfansareprovidedinthe
generatorhousing.Twofansonthe
rightside(asfacedfromthefront)
drawairintothehousing,whiletwo
fansontheleftsideexhaustairoutof
thehousing.
Approximateweight:
25Lbs.(11.3kg) 82Lbs.(37kg)
ACSeriesOzoneGeneratorsUserManual
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3 Installation and Connections
3.1 Facility Requirements
Requirement Rack‐MountSystem Wall‐MountSystem
Oxygensupply:
Oxygen,withatleast0.5%contentNitrogen,andlessthan10PPMwater
(DewPointof‐60°Corlower)
or
OutputofOxygenConcentrator(>90%byVol),lessthan10PPMwater
(DewPointof‐60°Corlower)
Gasconnection:
GasInlet:¼”maleVCRorcompression
(stainlesssteel)
GasOutlet:¼”maleVCRor
compression(stainlesssteel)
GasInlet:¼”malecompression
(stainlesssteel)
GasOutlet:¼”malecompression
(stainlesssteel)
Power:
Input:115to240VAC
Phases:1or2
Frequency:50/60Hz
FullLoad:1kVA
InputBreaker:10A
LargestLoadAmpRating:10A
CoolingAir:
18
o
C+3
o
C,unobstructedto,fromandthroughthegenerator
Ozoneleakdetectors:
Installindesiredprotectionareas.
TAPIoffersawiderangeofOzoneLeakdetectors–pleaseconsultwithyourTAPI
representativeforrecommendations.
WARNING!
LOX FIRE HAZARD!
When liquid Oxygen (LOX) is used as a source for gaseous Oxygen,
care must be taken to maintain the evaporating equipment so that
liquid Oxygen does not enter the Ozone Generator. LOX is highly
inflammable when exposed to flammable materials. For further
information, refer to an appropriate SDS
ACSeriesOzoneGeneratorsUserManual
610‐0191‐01DDCN7808 Page9
3.2 Water Isolation Valve
IftheOzonegasdownstream(“TOPROCESS”)isdissolvedintowater,amanual2‐way
valve,MV1,shouldbesplicedin‐linewiththeOzonegaspipetoprovideisolationand
protectthegeneratorfromaccidentalflooding.Thisvalveshouldbeclosedwhenthe
generatorisnotinuse.
Anadditionalmethodofprotectionistheuseofawatertrapwhichautomaticallydumps
waterintoadrain.SuchdrainmustbecapableofhandlingOzonatedwater.
3.3 Mounting
RefertotheSystemDimensionssectionofthismanualformountingrequirements.The
systemshouldbeinstalledascloseaspossibletothepointofuse.
Donotsubjectthegeneratortodirectadverseconditions,includingwater,dust,humidity,
chemicalenvironments,staticand/orelectromagneticgeneration,transformers,blowers,
orotherequipmentorhazards.Thesystemmustbeinstalledinacoollocation.See
specifications.
TheRack‐MountdesigncanalsobeBenchMountedonintegralfeet.
RequiredClearance Rack‐MountSystem Wall‐MountSystem
Frontofsystem:
minimumof24”(60cm)
minimumof40”(100cm)
dooropensto16”(40cm)
Rearofsystem:
minimumof24”(60cm) Mountedonawall
Bottomofsystem:
Leavestandardrackclearanceasa
minimum.
Donotmountheatgenerating
equipmentbelowtheACSeriesOzone
Generator.
minimumof12”(30cm)
typicaldepthrequiredforInstallationKit
Allowaboutthreefeetofunobstructed
airflowbelowthegenerator
Donotmountheatgenerating
equipmentbelowtheACSeriesOzone
Generator.
SidesofSystem:
Dependingonapplication;
Mustprovidecoolingairthroughthe
generator.
Notexpectedtobeanissue
IMPORTANT!
Allow the minimum clearance specified around the enclosure to
ensure unobstructed flow of cooling air. Refer to the system
specifications and dimensional drawings. Clearance space can be
shared with other equipment.
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610‐0191‐01DDCN7808 Page10
3.3.1 Dimensions – Wall-Mount Systems
EMERGENCY STOP
FRONT VIEW SIDE VIEW
BOTTOM VIEW
10.00
19.20
30.00
3.27
8.00
EXHAUST
INTAKE
0.44
MOUNTING
HOLES
(4X)
9.75
16.00
7.00 TYP
1.50
2.00
12.32
0.00
2.00
3.50
5.25
7.00
OXYGEN IN, 1/4" SWAGE
OZONE OUT, 1/4" SWAGE
FIELD WIRING (4X)
18.00
10.95
10.82
20.20
Figure 2: Wall-Mount Dimensions (in inches)
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3.3.2 Dimensions – Rack-Mount Systems
19.00
1.49
4.00
18.12
6.97
.28 WIDE SLOT
4X
15.93
19.61
.94
7.26
Figure 3: Rack-Mount Front, Side and Top Dimensions
4.23
1.22
1.11
FIELD WIRING
POWER IN
GAS INLET
1
4
" COMP.
GAS OUTLET
1
4
" COMP.
Figure 4: Rack-Mount Rear Dimensions
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3.4 Recommended Pneumatic Diagrams
UsethefollowingrecommendedpneumaticdiagramstoconfigureanOzonegeneration
system.Eachoptionisprovidedwithcommentstohelpyouevaluateandweighthe
performance,repeatability,andcostbenefitsandconsiderationsforyourapplication.
ConsultINUSAwithanyquestions.
3.4.1 Option A: Using MFCs and BPR
TheuseofMFCsforflowcontrolprovidesthebestperformanceandhighestrepeatability.
1. SetN2inletpressure5psihigherthanO2inletpressure.
2. SetO2flowtodesiredrate(slm:standardlitersperminute).
3. SetN2flowto0.5%byvolumeofO2flow(byselectingMFCswithratioof200,they
canbecontrolledtogether).
4. SetBPR(backpressureregulator)sothatPreadsbetween22and28psig.
5. IfPROCESSisatnegativepressure(vacuumrelativetoatmosphere),adjustneedle
valvesoBPRisregulating.
6. UsedraintraptopreventbackflowofliquidintoOzonegenerator
7. 10slmand50sccm(standardcubiccentimetersperminute)areusedasexamplesof
MFCs
Comments:
ThegenerationofOzoneisenhancedbytheadditionofN
2
tothestreamofO
2
.
Checkvalvespreventcross‐contaminationoftheinletgases.
TheBackPressureRegulator(BPR)providestheoptimumpressureattheoutletofthe
Ozonegeneratingcell.
TheBPRoperatesbestwhentheoutletpressureisclosetooneatmosphere.
TheneedlevalveisusedtoprovideapressuredropbetweentheoutletoftheBPRand
processoutlet–assumedtobelessthanatmosphericpressurebecauseofventuriaction
oftheliquidasitpassesbytheprocessoutlet.
TheproperoutletpressureoftheBPRisinferredbytheproperoperationoftheBPR–if
itisregulating,thepressurerequirementsarebeingmet.
Thewatertrappreventsliquidsfromback‐flowingintothegenerator.
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3.4.2 Option B: Using Adjustable Rotameter and BPR
1. AdjustRotametertodesiredflow
2. SetBPR(BackPressureRegulator)sothatPisbetween22and28psig
3. Ifprocessisatnegativepressure(vacuumrelativetoatmosphere),adjustneedlevalve
soBPRisregulating.
4. UsedraintraptopreventbackflowofliquidintoO3generator
Comments:
AnOxygenconcentratorisaneconomicmethodofderivinganacceptablesourceof
Oxygenwithabout4%ofNitrogenandothergases.Theyarecommerciallyavailable
fromavarietyofsourcesandtypicallyincludethepressurecontrolsandfiltersshownin
thediagram.
Forbestperformancefromthistypeofsetup,inputpressurecontrolishighlydesired.
TheadjustablerotameterisaninexpensivealternatetotheMFC(showninprevious
section),butthereadoutofthegaugeintherotameterissubjecttopressurevariations.
TheBackPressureRegulator(BPR)providestheoptimumpressureattheoutletofthe
Ozonegeneratingcell.
TheBPRoperatesbestwhenitsoutletpressureisclosetooneatmosphere.
TheneedlevalveisusedtoprovideapressuredropbetweentheoutletoftheBPRand
processoutlet–assumedtobelessthanatmosphericpressurebecauseofventuriaction
oftheliquidasitpassesbytheprocessoutlet.
TheproperoutletpressureoftheBPRisinferredbytheproperoperationoftheBPR–if
itisregulating,thepressurerequirementsarebeingmet.
Thewatertrappreventsliquidsfromback‐flowingintothegenerator.
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3.4.3 Option C: Using a Flowmeter and Needle Valve
1. Adjustpressureatinputtoflowmeterto25–30psig.
2. Adjustneedlevalvefordesiredflow.
3. UsedraintraptopreventbackflowofliquidintoO3generator
Comments:
AnOxygenConcentratorisaneconomicmethodofderivinganacceptablesourceof
Oxygenwithabout4%ofNitrogenandothergases.Theyarecommerciallyavailable
fromavarietyofsources.Theytypicallyincludethepressurecontrolsandfiltersshown
inthediagram.
Thisisthesimplestsetup,usingonlyinletpressureandoutletconstriction(needle
valve),tooptimizethegenerationofOzone.Thissetuprequiresiterativeadjustments
(fiddling)ofinletpressureandoutletconstriction.
Theflowmeterreadoutaccuracyissubjecttopressurevariations,makingiterative
adjustmentsmoreproblematical.
TherequirementsoftheOzonegeneratingcellaresameasintheprevioussetups,but
themethodofachievingthemisdifferent.
Theneedlevalveandpressurecontrolareusedsimultaneouslytoestablishtheflowof
gasesthroughthegeneratorandtoestablishthepressureattheoutletofthegenerator.
Thewatertrappreventsliquidsfromback‐flowingintothegenerator.
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3.5 Wall Mount, Bottom Connection Locations
Figure 5: Wall-Mount shown with standard conduit entry ways – Bottom View
See section on optional bulkhead connectors for details
Figure 6: Wall-Mount shown with optional bulkhead connectors – Bottom View
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3.6 Rack Mount, Rear Connection Locations
Figure 7: Rack Mount – Rear View
Gas Outlet Port (Ozone) (1/4” male VCR or compression)
Gas Inlet Port (Oxygen) (1/4” male VCR or compression)
Remote Field Wiring Connector
Ground Connection (#10-32 stud)
Main Power Input
1/55