Teledyne API AC Gen FBVG User manual

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

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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

ACSeriesOzoneGeneratorsUserManual

610‐0191‐01RevDDCN7808  Pageii

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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

ACSeriesOzoneGeneratorsUserManual

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.

ACSeriesOzoneGeneratorsUserManual

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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.

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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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ACSeriesOzoneGeneratorsUserManual

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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.

ACSeriesOzoneGeneratorsUserManual

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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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ACSeriesOzoneGeneratorsUserManual

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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)

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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

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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.



ACSeriesOzoneGeneratorsUserManual

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)

ACSeriesOzoneGeneratorsUserManual

610‐0191‐01DDCN7808  Page11

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

ACSeriesOzoneGeneratorsUserManual

610‐0191‐01DDCN7808  Page12

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.

ACSeriesOzoneGeneratorsUserManual

610‐0191‐01DDCN7808  Page13

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.



ACSeriesOzoneGeneratorsUserManual

610‐0191‐01DDCN7808  Page14

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.



ACSeriesOzoneGeneratorsUserManual

610‐0191‐01DDCN7808  Page15

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

ACSeriesOzoneGeneratorsUserManual

610‐0191‐01DDCN7808  Page16

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

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Teledyne API AC Gen FBVG User manual

Teledyne API AC Gen FBVG User manual

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