Azco RM900 User manual

O3
AZCO INDUSTRIES LIMITED
OWNER’S MANUAL
RM900 GENERATOR

Unit Type: Interface Board Version:
Unit Serial No.: Over Voltage Version:
Delivery Date: Circuit Breaker:
Installation Date: OPTO Relay:
Voltage: Oxygen Valve:
Mother Board Version: Drain Valve:
PLC Board Version: Vacuum Valve:
Driver Board Version: Internal Pump Type:
In addition to normal safety rules which should be observed with stationary
Ozone Generators and equipment, the following safety directions and pre-
cautions are of special importance.
When operating this unit, the operator must employ safe working practices
and observe all related local work safety requirements and ordinances.
The owner is responsible for maintaining the unit in a safe operating condi-
tion. Parts and accessories shall be replaced if unsuitable for safe operation.
Installation, operation, maintenance and repair shall only be performed by
authorized, trained, and competent personnel.
Normal ratings, pressures, temperatures, time settings, etc., Shall be dili-
gently adhered to.
Any modifi cation to the Ozone Generator, and/or related equipment, shall
only be performed in agreement with Azco Industries Limited and under
supervision of authorized, competent personnel.
If any statement in this book, especially with regard to safety, does not
comply with local legislation, the stricter of the two shall apply.
These precautions are general and cover several machine types and
equipment; hence some statements may not apply to the unit(s) de-
scribed in this book.
INSTALLATION
1. The Ozone equipment should only be lifted with adequate equipment in
conformity with local safety rules. Wear a safety helmet when working in
the area of overhead or lifting equipment.
2. Place the unit where the ambient air is as cool and clean as possible. If
necessary, install a suction duct. Never obstruct the air inlets. Care should
be taken to minimize the entry of moisture into the air inlet.
3. The unit shall be installed in such a way that an adequate fl ow of cooling air
is available.
4. Ensure that the rear exhaust vents are not in contact with or near to fl am-
mable materials.
5. All Azco products are designed to operate under vacuum. DO NOT operate
under pressure.
6. Install the equipment on a solid fl oor suitable for the weight, this applies to
all other equipment as well e.g. SPT’s and Foam Fractionator’s. If ground
is not level or can be subject to variable inclination, consult Azco Industries
Limited.
RM900
OWNERSHIP DATA
SAFETY PRECAUTIONS

OPERATION
1. ATTENTION: Please read the section labeled “First Start-up” prior to
operating the unit.
2. Air hoses shall be of correct size and suitable for the working vacuum/
pressure. Never use frayed, damaged or deteriorated hoses. Use only the
correct type and size of hose end fi ttings and connections.
(Caution: Use extreme care with the ozone gas lines when in operation, the unit must be
turned off before any of the ozone lines are disconnected. Carbon face masks should be
worn if an ozone leak arises.)
3. Never operate the unit when there is a possibility of taking in fl ammable
or toxic fumes.
4. Never operate the unit at pressures below or in excess of its limit ratings
as indicated on the product specifi cations sheet.
5. Keep all body panels closed during operation. Caution (High Voltage
inside)
6. Periodically check that:
• All hoses and/or pipes inside the unit are in good condition, se-
cure, and not rubbing
• There are no leaks
• All electrical leads are secure and in good order
• Air outlet lines are in good repair and free of wear or abuse.
MAINTENANCE
1. Maintenance and repair work shall only be done under supervision of
someone qualifi ed for the job.
2. Use only the correct tools for maintenance and repair work.
3. Use only genuine Azco spare parts
4. All maintenance work, other than routine attention, shall only be under-
taken when the unit is stopped, the main power supply is switched off and
the machine has cooled down. Take precaution to ensure that the unit
cannot be started inadvertently.
(In addition, a warning sign bearing a legend such as “work in progress; do not start” shall
be attached to the starting equipment.)
5. Never use fl ammable solvents or carbon tetrachloride for cleaning parts.
Take safety precautions against toxic vapors of cleaning liquids
6. Make sure that no tools, loose parts or rags are left in or on the unit.
7. Never use caustic solvents which can damage internal components and
materials. All responsibility for any damage or injury resulting from neglecting
these precautions, or by non-observance of ordinary caution and due
care required in handling, operating, maintenance or repair, even if not
expressly mentioned in this book, will be disclaimed by Azco Indus-
tries Limited.
SAFETY PRECAUTIONS (Continued)

ORIENTATION 6
INSTALLATION 8
START-UP 10
START-UP CONT. 12
START-UP CONT. 14
OUTPUT CHART 15
TROUBLESHOOTING 16
Table of Contents

1. System Status LED’s
2. Pressure/Flow Display
3. Pressure/Flow Toggle Switch
4. ORP/Vacuum Display
5. ORP Low/High Toggle
6. ORP/Vacuum Switch
7. PCB Status LED
8. 10-position switch and indicator
9. Control keylock
10. On/Off switch. (Main shut off circuit breaker on rear panel)
6
Front
ORIENTATION
*There are a total of 8 separate blocks internally. Line 1 and line 3 Carry 3 blocks each while
Line to carries the remaining 2, thus the discrepancy

1. Main Circuit Breaker
2. Power plug receptacle (power plug included)
3. 1/2” NPT Female brass connector (For Oxygen in)
4. 5/8” O.D. S.S. Compression fi tting (For Ozone out)
5. ORP BNC connector (Jumper included)
6. 2-Pin Switchcraft quick connect for External Control
7. 2-Pin Switchcraft quick connect for Remote Control
8. Female AMP-37 pin PLC connector (Male adapter included)
Rear

Gas Line Plumbing
Plumbing of this equipment only requires the connection from the water trap (diagram 3) to the S.S. Ball
valve and then to the injection point. The Rear Orientation diagram shows all of the connections on the rear of the
RM900.
All connections to the water trap MUST use Tefl on® lined, Solid Tefl on® tubing, or 316 SS. The connections are as
follows,
1. Vacuum sensor port not present for use with RM900
2. Ozone-In ports. These ports are to be connected to the ozone generators’ ozone-out ports (#6 rear orientation).
3. Ozone-Out port(s). Connected to S.S. ball valve shown on the fl ow diagram on page 12 and then to the injector.
Physical Space
The RM900 is 590mm Wide by 750mm Deep by 1645mm Tall. This equipment is both air and water cooled and
thus requires space to allow the air to enter and escape. At least 30 cm (~12”) should be free from obstructions in
the front and rear of the machine. All controls and fan inlets are located in the front and rear and under NO circum-
stances is this to be obstructed. This equipment should be placed near a drain so that the water trap can be allowed
to expel access water before it reaches the sensitive electrical equipment (via the water trap).
AZCO Industries LTD. is not liable for water release due to a failure of any part or failure to control the external water
supply, The customer shall provide proper drainage of the space below the unit. Going beyond the pressure limits
may cause damage internally to the RM900 causing potential water leaks.
Environmental Conditions
A clean, well ventilated environment is vital to the equipment’s longevity. Major factors that should be consid-
ered when installing are as follows:
• Ambient Temperature must be maintained below 35 degrees Celsius.
• Ambient Relative Humidity must be maintained below 85% non condensing.
• Corrosive and oily vapors as well as dust must be kept to a minimum.
• Proper ventilation is also a must and can greatly help in keeping the above mentioned problems in check.
• The equipment must also be indoors sheltered from rain and other hazardous environments.
• An adequate supply of fresh air is necessary to prevent temperatures from building
1. Physical Space
• The System requires at least
30cm (12 Inches) of clearance on
each side.
• 590mm x 750mm x 1645mm
2. Environmental
• Amb. Temp. <35 degree Celsius
• Amb. R.H. < 85%
• Minimize dust and corrosive
vapors
• Good Ventilation
3. Connections
• Plumbing
a. #6 on rear panel to #2 on
water trap
b. #3 on water trap to Ball Valve
c. Ball Valve to Injector
• Electrical
a. Wire the plug and plug it in
4. Ready to move onto Start-Up
LOCATION
CONNECTIONS
INSTALLATION
8

Cooling Water Plumbing
Both inlet and outlet ports are located on the Back side of the ma-
chine Diagram 4. The inlet port (#2) is a 1/2 NPT female connection. The
outlet port (#1) is a 3/4” NPT female connection. It is critical to maintain
the fl ow in the correct direction for the safety of the equipment as well as
the potential output of the machine.
Electrical
3.
G= Ground
W= Neutral
X= Phase 1
Z= Phase 2
Y= Phase 3
3.
1. 2.
Diagram 3: Top of the
water trap showing all con-
nection ports.*
*Ports will be labeled and may vary in orientation and quantity.
Diagram 4: RM900’s Back Lower side
shows the Coolant Outlet #1 and inlet
#2 for the cooling water connections

After verifying that all gas, water plumbing and electri-
cal connections are correct, you will be ready to turn on the
system for the fi rst time. The following steps and diagrams
are designed to make this initial start-up as quick and easy
as possible. Diagrams are numbered to correspond with the
steps below. Remember to use the ORIENTATION diagrams
for reference.
Step 1:
Turn on the main power to the RM900 by lifting the Cir-
cuit breaker (#1) on the back panel of the RM900.
Step 2:
Now that the main power has been turned on, you can
proceed to use the ON/OFF switch on the front panel (#10)
At this point the RM900 should have the status lights lit and
the main display turned on. The next series of steps will
involve preparing and/or clearing the status LED’s one by one
until we have all the conditions green and producing ozone.
Step 3 deals with the ORP settings.
Step 1:
Turn on the main power
Step 2:
Turn on the RM900
Step 3:
Adjust ORP Levels
• Hold “high” and press + or -
• Hold “Low” and Press + or -
Step 4:
• Plug in ORP Probe
• Override with jumper
10
Initial start-up and settings
START-UP
Step 1
Step 2

Step 3:
Before any adjustments are made make sure that the control lock
(#1 on front panel) is disabled. If the ORP is not going to be used then you
must install the ORP jumper(note:). Using the Jumper will zero display #4
and override the ORP settings. Setting the ORP cutoff levels (default levels
are; low: 700mV, high: 800mV, ). Make sure the display (#4) is displaying
the “mV” level (Ambler light at the top of #6) not PPM(ug/l).
1. To adjust the high level Press and Hold “HIGH” on #6, the display will
show the high cutoff point. To adjust this continue to hold the “HIGH”
and press “UP” or “DOWN” on #6 (below the 3 LED’s).
2. To adjust the low level repeat the above except press and hold “LOW”
on #6 instead of “high”.
Step 4:
Plug in the ORP probe into port #5 on the rear panel. The reading on
display #4 will not function properly without the probe or the jumper being
installed. When done correctly the mV or ug/L will be displayed depending
on what you chose to have displayed. Now that the ORP high low levels
have been set, the ozone generator will automatically turn on and off based
on the high and low respectfully.
Step 3:
Note: ORP Jumper

Step 5: Water Chiller
The connections have already been made and it is time
to establish the fl ow. The “cooling fl ow” status LED shows
the status of the internal water fl ow detection sensor. Start
the fl ow on the water chiller until the status LED turns
green (~10 l/min) The inlet pressure to the ozone genera-
tor must not exceed 10PSI. The lower the pressure the
better. If pressure builds up, check to make sure there are
no restriction between the outlet of the RM900 and the
inlet of the Water chiller. The system should be as free
fl owing as possible. If no restrictions are found try to lower
the fl ow rate.
Step 6: Begin Feedgas Flow
1. Install a pressure regulator and set it to MAXIMUM
7 PSI, 5 PSI is optimal. The use of a pressure
regulator is required!
2. Ensure that valves #1 and #2 are both closed be-
fore proceeding.
3. Start the oxygen. In case of oxygen concentrator,
follow manufacturer’s start up procedure. (Note:
The pressure gauge will not function at this time)
4. Proceed to Step 7 before turning on the pumps to
create suction.
Step 5: Water Chiller
• Max 10 PSI inlet
• No back pressure
• 12 degrees Celsius optimal
Step 6: Gas Flow
• Use Pressure regulator, use a
setting of 5 PSI
• Maximum 7 PSI
• Balancing
Step 7: Status LED’s
Check that all the status LED’s are
green excluding the vacuum LED’s.
Adjusting the vacuum will be ex-
plained in step 6
12
START-UP CONT.
Flow Diagram

Step 7: Clearing Status LED’s
Check the status lights on the Left of the control panel. At this
point one of the vacuum LED’s is the only one that should be red, as
the vacuum still has to be adjusted. If any LED other than vacuum is
red something is wrong. The problems MUST be corrected from top to
bottom. Some of the LED’s can aff ect LED’s below them so going from
top to bottom, excluding OZONE READY, is Vital. Correcting possible
problems with each red LED are listed below.
• ORP CONT: This LED shows the status of ORP level. If the ORP
has turned off the ozone generator the LED will be red.
• REMOTE CONT: This requires a voltage signal of 80-240VAC/VDC
in order to enable the feature. In most cases, this feature is disabled
unless otherwise ordered by the customer.
• EXT. Cont: Identical to remote control, this acts as a secondary port
• FEED GAS R.H.: Feed gas relative humidity measures the dew
point of the incoming Feed Gas. It will turn red if there is a problem
with the oxygen. While the LED is red the oxygen will continue to
run trying to clear any incidental moisture that may have entered the
system.
• INTERNAL TEMP: This status LED is used for both Ambient room
temperature. If the ambient room temperature reaches above 35
degrees Celsius the LED will turn red.
• VACUUM LOSS/HIGH Indicates that the Vacuum is either too high
or too low. To Correct the issue cycle display #4 with #5 until VAC-
UUM is selected. the reading will indicate if you are too high or too
low. Adjust accordingly
• COOLING FLOW: Indicates a lack of water fl ow in the system. It
displays the status of an internal water fl ow indicator sensor.
Note: Any LED that is red will turn offthe ozone generators and place the system into
standby mode until the situation is resolved.
Note: Ozone in air Jumper
Step 5:

Step 8:
Balancing the vacuum and pressure to achieve the
fl ow required can be quite tricky, but with patience and the
following steps the process should be easy.
1. Switch display #4 to vacuum.
2. Turn on the pump(s) to create water fl ow, thus suction,
at the injector.
3. Slowly begin opening valve #2. Continue opening this
valve until the vacuum low LED turns green. When
the condition is green begin to open Valve #1 to allow
oxygen to fl ow. This of course throws the vacuum low
again.
4. Continue opening valves #1 and #2 until you have
reached the desired Flow rate on display #2. When
you have reached the correct fl ow rate, make fi nal
adjustments to the vacuum to achieve a reading of 60-
100 on display #4. At this point switching display #2
to pressure on the front panel will aid you by showing
you if the pressure is stabilizing.
5. Adjusting the fl ow is a matter of fi ne tuning* between
valves #1 and #2 as one is opened more the other
must also be opened more to compensate and vice
versa.
6. Now your system is ready to operate and within a few
minutes the Feed gas status light should switch to
green and the unit will start producing ozone.
Step 8:
1. Switch Main display to vacuum
2. Turn on pump(s) to create suction
3. Balance the fl ow with Valves 1&2
4. Reach proper fl ow and vacuum
5. Fine Tuning
6. Wait for Feed gas to turn green
14
START-UP CONT.
*Note: Fine tuning may be required after first start-up due to changes in flows and pressures

Output Chart

16
Troubleshooting