Absolute Ozone ATLAS User manual

ABSOLUTE OZONE®
ATLAS®/TITAN®/MAGNUM®
OPERATOR’S MANUAL

ABSOLUTE OZONE®
OPERATOR’S MANUAL
Table of Contents
-1-
Section 1 - General Information 3
1A. Description!4
1B. Specifications!4
1C. Accessories!5
1C.i Ozone Generation!5
1C.ii Required Accessories!5
Section 2 - Installation 7
2A. Location!7
2B. Electrical!8
2C. Plumbing!8
2D. Gas Connections!8
2E. Remote Control!8
Section 3 - Operation
10
10
11
11
3A. LCD Control Panel Overview!
3B. System Start-Up!
3C. System Shutdown!
3D. Standard Operation Procedures!12
Section 4 - Maintenance and Service 13
4A. Preventative Maintenance!13
4B. Troubleshooting!14
Section 5 - Ozone Overview and Safety Procedures 17
5A.Ozone Use and Technology Overview!
17
5A. i Relative Strength of Ozone! !
17
5A. ii Micro-Flocculation and Oxidation!
17
5B. General Safety Information! !
17
5B. i Ozone Properties!!
17
5B. ii Ozone Uses!!
18

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ABSOLUTE OZONE®
MANUAL
Table of Contents
5C. Hazards!
18
5C. i Health Hazards - Detection!!
18
5C. ii Health Hazards- Effects On Humans! 19
5C. iii Electrical Hazards!
20
5C. iv Fire Hazards!
20
5C. v Chemical Action!
20
5D. Precautions for Safe Handling and Use 20!
5D. i Ozone Monitors!
20
5D. ii Ventilation!
20
5D. iii Emergency Procedure!
21
5D. iv Respiratory Protection!
21
5D. v Education and Training!
21
5E. System Operations and Maintenance!
22
5E. i Safety Precautions and Equipment!
22
5E. ii Maintenance Requirements!
22
5F. Monitoring!
22
5F. i Location of Monitors! !
22
5F. ii Monitoring Equipment!!
23
5G. First Aid Procedures! !
23
5G. i General Information! !
23
5G. ii Inhalation! !
23
5G. iii Eye Contact! !
23
5G. iv Precautions! !
24
5G. v Emergency Information Form!
!24
Absolute Ozone Limited Warranty 25
Ozone Generator Dimensions 27
Conceptual Ozone Injection Diagram 30

-3-
For more information about this product visit our
website at, http://www.absoluteozone.com
IMPORTANT SAFETY INSTRUCTIONS. !
PLEASE READ AND FOLLOW ALL INSTRUCTIONS."
Read this manual completely before operation of
ATLAS/TITAN MAGNUM Ozone Generator Equipment.
Warning - High Voltage is present inside the enclosure
USE EXTREME CAUTION"
•Operate the ATLAS/TITAN/MAGNUM 30-200 with safe access to
electrical power.
•Connect to a GFCI type receptacle.
•Follow all applicable electrical codes.
•Do not bury cord.
WARNING: To reduce the risk of electrical shock, replace damaged cord
immediately.
ELECTRICAL SHOCK HAZARD: Turn OFF all power switches and
disconnect power cord from power source receptacle before performing
any service work. Failure to do so could result in serious injury or death.
ABSOLUTE OZONE®
General Information
OPERATOR’S MANUAL

1A. Description
The ATLAS/TITAN/MAGNUM 30-200 are Ozone Generators that produce from 1 to 200
grams of ozone per hour respectively, with ozone concentration up to 22% by weight or
as specified in attached test report.
The ATLAS/TITAN/MAGNUM 30-200 are designed to produce ozone for variety of
applications.
1B. Specifications
-4-
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website at, http://www.absoluteozone.com
ABSOLUTE OZONE®
Section 1
Model ATLAS® TITAN® MAGNUM®
Ozone Production
(g/h)
30 g/h - 100g/h 30g/h - 100 g/h 160 g/h - 200 g/h
Nominal Working Pressure
(psig)
20psig 20psig 40psig
Concentration
(% by weight O3)
5%-22% 5%-12% 6-12%
Power Requirements 120 V ~ ±3%, 50/60 Hz,
Single Phase, 5.0-9.0 A
220 V ~ ±3%, 50/60 Hz,
Single Phase, 3.5-7.0 A
Maximum Power
Consumption: 350-650W
120 V ~ ±3%, 50/60 Hz,
Single Phase, 5.0-9.0 A
220 V ~ ±3%, 50/60 Hz,
Single Phase, 3.5-7.0 A
Maximum Power
Consumption: 350-650W
208/210/220/230 VAC ~
±3%, 50/60 Hz, Three Phase,
8.0-10.0 A
Maximum Power
Consumption: 1600-1700 W
OPERATOR’S MANUAL

1C. Accessories
The ATLAS/TITAN/MAGNUM 30-200 could be used with several accessories and
safety devices to assure long service life of the Generator.
1C.i Ozone Generation
•Air Compressor: air compressor pumps ambient air into the oxygen concentrator
•Oxygen Concentrator separates oxygen from Nitrogen and supplies it to ozone
generating cell.
•Ozone Generating Cell design is based on proprietary Microfluidic Platform
Technology, constructed from ozone resistant materials and offers extremely high
performance and reliability. Ozone Cell is designed to be absolutely maintenance
and service free. Anticipated service life 15-20 years.1C.2 Required Equipment
& Accessories
1C.ii Required Equipment and Accessories
•Oxygen Concentrator: The oxygen concentrator uses a PSA (pressure swing
adsorption) molecular sieve to remove dirt, moisture, nitrogen and other trace
gases, producing oxygen at greater than 90% purity and less than –60°C dew-
point. The air compressor pumps ambient air into the oxygen concentrator.
Concentrated oxygen feed-gas enables ozone concentration up to 14% by
weight. In our experience, Oxygen Concentrators made by AirSep work well with
all Absolute Ozone generators.
•To protect Absolute Ozone Generator from sieve particles in case of oxygen
concentrator failure we recommend installing Oxygen Filter Upstream from the
generator.
•Ozone Flow Control Valve: Downstream from ozone generator to maintain
working pressure across ozone cell as specified 20-120 PSIG for the unit.
•Automatic Ozone Compatible ALD2000 Water Drain system to prevent Ozone
Generator flooding. Please note – Non return valves (check valves) do
not provide 100% protection to ozone generator!
•We do not recommend installing ozone generator, without this device.!
-5-
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ABSOLUTE OZONE®
Section 1
OPERATOR’S MANUAL

•!
ABSOLUTE OZONE®
Section 1
Oxygen Concentrator/
Other Oxygen Source
Filter
Ozone Generator
Ozone Resistant Flow
Meter
Anti-Flood Device
With Check Valve
To Drain
1/4” Teflon Tubing
To
Application
•Ozone Injector for Water Treatment Applications: Inlet water flows through the pump
and through the ozone injector, creating vacuum that pulls ozone gasfrom the
ozone generation module and injects the ozone into the water flow. The injector
should be sized to dissolve a minimum of 90% of the ozone gas into the water flow
continuously.
•Ozone Degas Chamber: Ozone-enriched water from the ozone injector flows into the
degas chamber where the counter-current design forces any undissolved ozone
gas through the float valve-protected top vent to the Ozone Destructor.
•Ozone Destructor: Undissolved ozone gas passes through the heated catalytic
ozone destructor that is made of non-consumable manganese dioxide (heat
protected from moisture fouling). The manganese dioxide and heat offer
redundant ozone destruct capabilities.
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OPERATOR’S MANUAL

¥
2A. Location
The ATLAS/TITAN/MAGNUM 30-200 Ozone Generators are designed to be installed
on the wall, on the rack or stack up system in convenient location mobile cart or skied.
Allow for access to protected electrical power and required gas connections and cooling
air to the Ozone Generator. Do not obstruct cooling air vents of the Generator!
Unit could be installed indoors & outdoors if protected from weather element. Ambient
working temperature from –10°C to +30°C.
Reversible Universal Control Panel
We had to strive for efficiency in every detail, right down to how it connects and
mounts. So we contributed to a new reversible universal control panel. Designed to
efficiently accommodate installing the ATLAS in an upright or downright position
Stackable Without a Rack
Every Absolute Ozone® ozone generator comes equipped with attachment tabs that
can be reversed to provide you with the liberty to install the ATLAS one on top of
another in a rack mount formation but without requiring a rack.
ABSOLUTE OZONE®
Installation
Control Panel In Upright
Position
Tighten Screws
Now the ATLAS/Magnum
can be installed in this
position
Remove 4 screws and
reverse the control panel in
the downright position
Reversible tabs in original
position
Tighten Screws
Now the ATLAS/Magnum
can installed in this
position
Loosen screws and swing
the tab into the upright
position
-7-
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OPERATOR’S MANUAL

2B. Electrical
Main Power Supply Circuit: The ATLAS/TITAN/MAGNUM 30-200 are supplied with
3-5 feet power cord. Connect the power cord to a standard grounded 15 Amp (10 Amp
International) power source, according to a local electrical code only.
2C. Plumbing
When injecting Ozone in to water all measures should be taking to protect the Generator
Cell from water exposure, which may cause internal cell damage. A small tank with/or an
automatic water drain system is recommended.
2D. Gas Connections
The Ozone Generator should be connected by tubing made from material appropriate for
ozone and oxygen applications. Connect the Ozone Generator according to indications on
input and output bulkheads. All efforts should be made to protect the generator from
exposure to excessive pressure fluctuations, which may lead to the damage of electronic
circuitry and Ozone Cell. For applications where pressure fluctuations are possible we
strongly recommend installation of a buffer tank with an appropriate hi-low pressure
switch. It is VERY IMPORTANT to protect the Generator from any possible contamination
from the Oxygen Concentrator or from water injection device, by installing oxygen monitor
and filter upstream from the Generator and automatic water drain device in combination
with check valve. Concentration of feed oxygen should not be below 90%.
2E. Remote Control
All Absolute Ozone Generators are equipped with standard “On/Off” remote control
terminals to enabling operator, ambient ozone monitor or PLC to remotely switch the
Ozone Generator On or Off.
This contacts have to be connected to dry contact only (not connected to the ground
on any kind or to any voltage source AC or DC)
ABSOLUTE OZONE®
Section 2
-8-
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OPERATOR’S MANUAL

2E. 4-20mA On/Off Power Remote Control
Description and Schematic of remote control features:
• Remote control of ozone production level by 4-20mA at 10 V signal, no special switching for
both of these signals required
• Remote On/Off. Remote Switch must be normally open for the generator to be “On” and
closed to stop the Ozone production.
• That switch has to be connected to dry contacts only (not connected to the ground on any
kind or to any voltage source AC or DC)
• Remote Ozone Generator status indicator.
a. During Normal Ozone generator operation pin 5 –normally open, pin 6– common, pin 7
–normally closed.
b. If Remote Control Switch is offor safety shutoffis activated the circuit will be closed
between pins 5 & 6.
ABSOLUTE OZONE®
Section 2
1
2
3
1
2
3
Standard Remote Control Schematic
4
5
4
5
6
6
7
7
RED
BLACK
WHITE
GREEN
ORANGE
BLUE
BROWN
Remote
On/Off
Switch
COM
4-20mA at10V
Input Connection
Remote Status
Indicator Dry
Relay Contact
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website at, http://www.absoluteozone.com
-9-
Status
Indicator Relay
1A,
120-240VAC/
24VDC
Remote Control Cables of
required length are available as
a special order option
Use Shielded
Cable Only!
Ground Shield
Only on One Side!
OPERATOR’S MANUAL
NC
NO

3A. LCD Control Panel Overview
Here is a general description of the controller and features it offers:
All Atlas Absolute Ozone® come with 4-20mA remote power control as a standard feature that allows to
select power going to the ozone cell that is later automatically monitored and maintained by a control system,
regardless of minor voltage or pressure deviations. It is standard for all Atlas & Magnum ozone generators.
On top of it new generation controller protects the generator from damage caused by:
· connecting to incorrect power source,
· incorrect wiring or voltage applied to the remote control terminals,
· incorrect operating pressure,
· ozone cell contamination by water or similar,
· overheating or failure of the cooling system, etc.
In addition all Atlas ozone generators have:
· Status indicator that has No/Nc contacts that will change the status every time the generator is not
producing any ozone regardless of the reason.
· On/Off contacts that are “ NO” normally open. If the contacts are closed by external dry contact relay,
the generator will move in to a standby mode. Once the contacts are open, the generator will start producing
ozone again.
Photos of typical LCD 5” control touch screen:
The LCD screen shows the following parameters:
•Selected or Expected power setting %, so you will be able to see on the screen power selected by the
remote control or slider.
•Actual power % & Watt going to an ozone cell.
•The cell voltage V
•Current Amp going to the ozone cell,
•Gas pressure inside the ozone cell
•Temperature inside the ozone cell.
•The LCD screen will allow by touch to switch the generator on and off and to adjust desire power by
moving slider on the screen with your finger.
ABSOLUTE OZONE®
Control Panel
-10-
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website at, http://www.absoluteozone.com
OPERATOR’S MANUAL

3B. System Startup
1. Make sure the Ozone Generator enclosure is securely attached
to an
appropriate frame or wall Ozone Generators Stack.
2. Make sure all connections to the generator, power and gas are
made
according to local codes and regulations.
3. Purge the generator with 90% or higher concentration oxygen
and assure free flow of oxygen through the system and removal
of contaminants. Conduct system leak test applying working
pressure +/-10% using oxygen only. Adjust gas pressure
across the cell according to specifications using downstream
Control Valve (on flow meter) and pressure gage (supplied by
the installer).
4. Plug the system into a specified receptacle.
5. Flip the Power Switch in to “ON” position.
6. Slide red dot on the power control slider upwards to adjust to desired
power from 0-100%according to supplied “Ozone Generator
Performance Test” chart. Now the generator is in optimum
production mode, and ozone should be flowing though the
system.
3C. System Shutdown
-11-
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1. Slide red dot on the power control slider downwards to adjust
power from to 0%. (No ozone is produced at this time.)
2. Switch the power switch (located on the side panel) to OFF
position.
3. Unplug the system from the power source if required.
4. Close down the downstream Control Valve (located on the flow
meter -supplied by installer) to protect unit from accidental flooding.
5. Turn the oxygen source off.
•In a case when incorrect operating parameters are applied to an ozone generator the unit is switched off
by the control system and LCD screen will indicate which of parameters caused the generator shutdown.
•In a safety shutdown mode the generator will be constantly monitoring operating parameters and the
moment they are corrected the generator will restart automatically, without any assistance.
•I.e. if there is a power spike or if there is a pressure drop caused by temporary power failure and interruption
of oxygen supply, the moment the pressure is normal again or voltage supplied is within the operating
range, the generator will restart and will produce ozone again.

3D. Standard Operating Procedures
NOTE: To assure a long trouble-free service life of the ATLAS/TITAN/MAGNUM 30-200
Ozone Generators, provide following operating conditions:
•Make sure that the oxygen concentrator is maintained properly and is producing
oxygen at greater than 90% purity and less than -60°C dew point. Check sieve
conditions and replace it as often as recommendedby manufacturer
•Install oxygen filter and oxygen dryer between oxygen concentrator and the Ozone
Generator, check condition and replace a cartridge as to protect Ozone
Generator from sieve particles in case of oxygengenerator failure and moisture.
• Make sure to maintain working pressure across ozone cell as specified for the
generator protection and most efficient ozone production.
• When injecting ozone in to water make sure to protect the generator from
flooding by installing ALD 2000 Flood Prevention device (can be supplied)
capable of preventing water backup Check valves usually start leaking after few
days of operation in ozone and cause serious damage to the ozone cell. We
recommend using devices, which could automatically drain water out of ozone
line and stop it from entering the ozone cell.
• Protect internal components of the Ozone Generator from water, snow, excessive
dust, dirt, humidity, vibration, and/or mechanical shock; make sure that there is a
sufficient amount of clean air available for the unit cooling air and inlet and
outlet are not obstructed by other equipment or elements.
•Check that electrical power fluctuations are within +/- 10% of the specified AC
Voltage and install power-conditioning devices if necessary.
ABSOLUTE OZONE®
Section 3
-12-
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website at, http://www.absoluteozone.com
OPERATOR’S MANUAL

4A. Preventative Maintenance
Generally the ATLAS/TITAN/MAGNUM 30-200 are maintenance-free although it is useful
to check the Ozone Generator for proper operation:
a. Verify on the LCD display panel that parameters
indicated are consistent with your
On a monthly basis:
1. Make sure that all system equipment (oxygen concentrator, air
compressor, etc.) is maintained according to the manufacturer
recommendations.
2. Remove and replace or clean filter cartridges and other devices if installed and
required.
3. Perform general cleaning of cabinet exterior after disconnecting the
equipment from electrical source.
4. Using clean/dry compressed air, blow out the interior of cabinet,taking special
care around electronic components and wiring.
ABSOLUTE OZONE®
Maintenance
and Service
-13-
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website at, http://www.absoluteozone.com
OPERATOR’S MANUAL

4B. Troubleshooting
Knowledge of electrical applications is required for troubleshooting. Contact a certified
electrician if you are unsure of your ability to service the equipment. If
any problem persists, please call 780-486-3761. We will have one of our system engineers
discuss your situation with you over the phone.
Symptom (Warning Message): INCORRECT REMOTE CONTROL VOLTAGE
PLEASE MAKE SURE THE VOLTAGE YOU HAVE SUPPLIED TO THE REMOTE CONTROL
(4-20MA SIGNAL) IS NOT HIGHER THAN 10V.
ABSOLUTE OZONE®
Section 4
-14-
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website at, http://www.absoluteozone.com
OPERATOR’S MANUAL
Symptom (Warning Message): OZONE CELL CONTAMINATION
THE OZONE SENSOR DETECTED OZONE CELL CONTAMINATION BY WATER OR
POSSIBLY SOME OTHER CONDUCTIVE LIQUIDS. PLEASE SWITCH THE OZONE
GENERATOR OFF, LOCATE AND ELIMINATE THE SOURCE OF THE CONTAMINATION.
WHILE HAVING POWER OFF. RUN OXYGEN THROUGH THE OZONE CELL FOR
SEVERAL DAYS TO DRY THE LIQUID AND/OR OTHER CONTAMINANTS OUT AND THEN
TRY TO RESTART THE OZONE GENERATOR.
IF THE PROBLEM PERSISTS PLEASE CONTACT ABSOLUTE OZONE TECHNICAL
SUPPORT.

ABSOLUTE OZONE®
Section 4
OPERATOR’S MANUAL
Symptom (Warning Message): SYSTEM COMMUNICATION PROBLEM
IF AFTER SEVERAL ATTEMPTS DOES NOT RESTART, PLEASE CONTACT US TECHNICAL SUPPORT
Symptom (Warning Message): OZONE SENSOR PROBLEM
AFTER SEVERAL ATTEMPTS DOES NOT RESTART, PLEASE CONTACT US TECHNICAL SUPPORT
Symptom (Warning Message): OZONE CELL PRESSURE TOO LOW
PLEASE MAKE SURE THERE ARE NO RESTRICTIONS ON THE OXYGEN LINE COMING TO THE
OZONE GENERATOR AND THAT THE FLOW IS ONLY ADJUSTED ON THE OZONE LINE AFTER THE
OZONE GENERATOR TO MAINTAIN CORRECT WORKING PRESSURE, IF THE PRESSURE IS TOO
LOW DUE TO INCORRECTLY SET PRESSURE REGULATOR OR FAILURE OF OXYGEN GENERATORS,
PLEASE RECTIFY THE PROBLEM AND THE OZONE GENERATOR WILL CONTINUE OPERATION.
-15-

ABSOLUTE OZONE®
Section 4
OPERATOR’S MANUAL
Symptom (Warning Message): OZONE
CELL PRESSURE TOO HIGH
PLEASE ADJUST OXYGEN PRESSURE
REGULATOR TO SPECIFIED PRESSURE
AND THAT WILL RECTIFY THIS PROBLEM
AND WARNING MESSAGE.
Symptom (Warning Message):
OZONE CELL TEMPERATURE TOO
HIGH
MAKE SURE THAT THE AMBIENT
TEMPERATURE IN THE INSTALLATION
ROOM IS BELOW 25 C, CHECK THAT
THERE IS GOOD UNRESTRICTED
COOLING AIRFLOW THROUGH THE
OZONE GENERATOR (NOT
OBSTRUCTED ON EITHER SIDE OF
COOLING GRILLS). PLEASE MAKE SURE
THAT THE COLOLING FAN IS WORKING
PROPERLY. IN CASE OF THE COOOLING
FAN FAILURE, PLEASE CONTACT
TECHNICAL SUPPORT FOR FURTHER
INSTRUCTIONS
Symptom (Warning Message): SUPPLY VOLTAGE TOO HIGH OR TOO LOW
PLEASE MAKE SURE THAT THE VOLTAGE SUPPLIED TO THE OZONE GENERATOR AS
SPECIFIED +/- 5% IN ORDER TO CORRECT THE PROBLEM. IF VOLTAGE SUPPLIED IS AS
SPECIFIED AND THE PROBLEM PERSISTS, PLEASE CONTACT OUR SERVICE
DEPARTMENT
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5A. Ozone Use and Technology Overview
5A.i Relative Strength of Ozone
The following compares the strengths of several common oxidizing reagents (EOP vs. Cl2)
•Elemental Fluorine (2.25)
•Hydroxyl Radical (2.05)
•Ozone (1.52)
•Hydrogen Peroxide (1.30)
•Hypochlorite (1.10)
•Chlorine (1.00)
•Chlorine Dioxide (0.93)
•Bromine (0.57)
5A.ii Micro-Flocculation and Oxidation
Ozone oxidizes the following metals (known as micro-flocculation), enabling their removal
via filtration:
•Iron
•Copper
•Manganese
•Zinc
•Arsenic
Ozone neutralizes "nuisance" compounds - most commonly, hydrogen sulfide.
5B. General Safety Information
5B.i Ozone Properties
•Colorless to blue gas (greater than -169°F)
•Characteristic odor often associated with electrical sparks or lightningin
concentrations of less than 0.02 ppm
•Highly chemically reactive
•Non-flammable, non-carcinogenic
•Hazardous polymerization can occur in some rear materials
•Spontaneously decomposes to oxygen gas
ABSOLUTE OZONE®
Safety Procedures"
and Ozone Overview
OPERATOR’S MANUAL
-17-
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5B.ii Ozone Uses
•Chemical Oxidation
•Organic Oxidation
5C. Hazards
5C.i Health Hazards – Detection Levels
Gaseous ozone can be detected in air by its distinctive odor at concentrations of about 0.02
ppm. Although each nose varies, olfactory fatigue occurs quickly.
Initial small exposure may reduce cell sensitivity and/or increase mucous thickness producing
a resistance to low gaseous ozone levels.
DO NOT RELY ON ODOR AS A WARNING OF HIGH OZONE
CONCENTRATIONS. The Permissible Exposure Level (PEL) or time-weighted concentration
for gaseous ozone to which workers may be exposed is 0.1 ppm averaged over 8 hours, 5
days a week (OSHA). The short-term exposure limit is 0.3 ppm averaged over 15 minutes.
The concentration of 5.0 ppm ozone in air is generally accepted as Immediately Dangerous
to Life or Health (IDLH).
ABSOLUTE OZONE®
Section 5
OPERATOR’S MANUAL
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-18-

5C.ii Health Hazards – Effects on Humans
Gaseous ozone acts as a primary irritant, affecting mainly the eyes, upper respiratory tract
and the lungs. Inhalation produces various degrees of respiratory effects from irritation to
pulmonary edema (fluid in lungs). Short exposure to 1-2 ppm concentrations causes
headache as well as irritation to the respiratory system but symptoms subside when
exposure ends. High concentrations of ozone produce severe irritation to the eyes and
respiratory system. Exposure above the ACGIH/OSHA limits may produce nausea, chest
pain, coughing, fatigue, reduced visual acuity and pulmonary edema. Symptoms of
edema from excessive exposure can be delayed one or more hours. There is no threshold
limit and so no exposure (regardless of how small) is theoretically without effect from
ozone’s strong oxidative ability.
ABSOLUTE OZONE®
Section 5
TOXIC EFFECTS OF GASEOUS OZONE
OZONE CONCENTRATION (PPM)
EFFECT
0.01 - 0.10
Range of Odor Threshold
0.1
Permissible concentration (8 hour work
day)*
0.3
Permitted short-term exposure (15min.)*
0.01 - 0.1
Headaches, irritation to respiratory tract,
severe irritation to eyes
1.0 - 10.0
Nausea, chest pain, coughing, fatigue,
reduced visual acuity, pulmonary edema
5.0
Immediately Dangerous to Life or Health
(I.D.L.H)*
>20.0
Can be fatal after 1 hour
>50.0
Can be fatal after 30 minutes
*Regulatory Levels
OPERATOR’S MANUAL
-19-
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