BioZone AQUAZONE 200G User manual

DIGITAL INTEGRATED POWER SUPPLY OZONE
AQUAZONE 200G TO 400G OZONE GENERATOR
USER MANUAL
□200G □300G □400G □600G
Note
Equipment should be installed in a clean environment with good ventilation.
To prevent backflow water, gas-liquid mixing connections should be installed strictly according to this guide.
At least allow 5 seconds to turn on and off the ozone generator.
Please keep the equipment clean and dry.
It is prohibited to operate the equipment before connecting with cooling water.
PLEASE READ THROUGH THIS USER MANUAL BEFORE INSTALLING THE EQUIPMENT

CONTENTS
SAFETY NOTES 2
SAFETY PRECAUTIONS 2
IMPORTANT NOTES 2
Installation personnel must be qualified technicians and maintenance personnel must be trained before
maintenance. 2
SAFETY NOTE 3
OPERATION NOTES AND MAINTENANCE 3
PRODUCT DESCRIPTION 4
FEATURES 4
ACCESSORIES 4
SPECIFICATIONS 5
CONTROL PANEL AND INTERFACE 6
4.1 CONTROL PANEL DESCRIPTION 6
300G INTERFACE 8
200G, 400G AND 600G INTERFACE (TWO SETS,MODULAR DESIGN) 9
4~20MA ANALOG SIGNAL RECEIVING PORT 10
INSTALLATION AND MAINTENANCE 11
INSTALLATION PLACE REQUIREMENT 11
PIPING INSTALLATION 11
ELECTRICAL CONNECTION 11
ON / OFF PROCEDURE 11
NOTES 12
MAINTENANCE AND TROUBLESHOOTING 12
WARRANTY TERMS 12
BIOZONE AFTER SALE SERVICE COMMITMENT 12
MAINTENANCE ITEMS 12
MAINTENANCE CYCLE TABLE 13
TROUBLE ANALYSIS AND INSPECTION (TABLE 6-2) 14
PSU ERROR CODE AND SOLUTION 15
CONTACT US 16
1

● The scope of the user manual
○ The user manual is for our Aquazone 200g - 400g series products.
● Purpose of the user manual
○ Served as the instruction for operation personnel
● Knowledge required for understanding the user manual
○ You will have a better understanding of the user manual if you have a mechanical and
electrical background, and will qualify for the equipment maintenance.
SAFETY NOTES
SAFETY PRECAUTIONS
●Qualified special grounding cable, reliable grounding, and safety grounding are required, otherwise
electric shock and other dangers may occur. The grounding cable must be connected to the
dedicated grounding device of the building; otherwise installation personnel should refuse to install
the equipment. If there is no dedicated grounding device, it should be installed by professional
technicians (the grounding cable must not connect to the gas or water pipe, lightning rod/conductor,
or telephone cable)!
●Ozone is a strong oxidising gas, and the ozone system must shut down when there is Ozone
leakage. Then check the leakage point, and repair it before restarting the system. Otherwise, ozone
leakage will lead to equipment oxidised and is harmful to staff around.
●Staff is prohibited to enter the space when the machine is being used for space sterilisation. In other
words, business time and sterilisation time should be staggered. People are allowed to enter after
sterilisation has been finished for two hours
●Loaded power should be configured with an isolator especially in high moisture locations. Otherwise,
it may cause fire.
●The equipment cannot be installed in areas with high moisture or smoke, to avoid potential danger.
●Unauthorised disassembly, movement and reassembly are prohibited.
●The equipment can only be installed by qualified personnel.
●Improper installation may lead to ozone leakage, electricity short circuit and fire.
●The equipment should be installed in a place where it is convenient for maintenance. Please refer to
the relevant chapter for maintenance. Users should supervise the installation personnel to read the
user manual carefully, arrange the installation order, and fully prepare before installation.
●The equipment must not be installed in an area with risk of Ammonia leakage or explosion.
IMPORTANT NOTES
Installation personnel must be qualified technicians and maintenance personnel must be trained before
maintenance.
●The equipment must prevent water from going into the inside.
2

●During operation, the equipment generates high voltage. Hence, it is prohibited to open the
equipment control panel and power control cabinet.
●There is a safety breaker in the front enclosure, and when the front enclosure of the equipment is
open. The equipment will stop working automatically. Hence, it is forbidden to open the front
enclosure during operation.
●The equipment should be equipped with a dedicated electrical distribution cabinet, and proper
grounding device.
●The equipment comes with operation instruction, and the operation personnel should be trained
before operation.
SAFETY NOTE
●Make sure input and output pipes are connected correctly. Incorrect connection will lead to leakage
or damage of the equipment.
●Equipment should be installed with enough space for better heat dissipation and maintenance.
●Do not use any damaged parts, otherwise it may lead to accidents or damage to the equipment.
●During installation or operation, make sure no ozone leakage and the wiring cable size meets the
requirement, in order to avoid fire risk.
●To move the equipment, it is required to be guided by professionals.
●The equipment is water-cooling, and the heat will need to be dissipated out of the equipment in time.
Hence, the equipment room has to be in good ventilation and install an exhaust fan if necessary. The
ambient humidity must not be higher than 90%, otherwise, there will be water drops inside the
equipment causing electricity leakage or fire.
●Incorrect wiring will lead to electrical parts damaged or even dangerous.
●Users must not change electrical cables or power connectors unless authorised.
OPERATION NOTES AND MAINTENANCE
●Do not rinse the equipment.
●Do not clean the equipment with hot water higher than 60℃, which may cause deformation or colour
fading.
●Volatile solution or organic solvent must not be used; otherwise it may damage the equipment
surface.
●Clean the ozone module inner chamber and discharge tubes carefully by soft cloth moistened with
alcohol every year (very important)!
●The power source should be disconnected during the non-operation period.
●Make sure the inlet and outlet valves are closed during the non-operation period.
●Make sure the valves are working normally, and filters with regular maintenance.
●Keep the ambient area clean, dry, with a ventilation device installed.
●Do not damage the wiring cable, otherwise it will cause electric shock.
●Do not use flammable spray material to spray on the equipment, which may cause fire.
●Inlet or outlet must not be blocked; otherwise equipment performance will be lowered and out of
order! Do not put sticks or other things to the inlet or outlet! Otherwise, it may touch the electric
components and cause danger!
3

●Do not use heating appliances near the equipment, which may lead to melt of the plastic
components.
●Keep the equipment external clean.
●During a long non-operation period, the power source should be disconnected and the equipment be
covered with plastic sheeting.
●To ensure safety, maintenance can only be conducted with equipment power off.
●Touch screen is an accurate device, and hands should be clean when touching, or touched by soft,
sleek sticks instead of wet, sharp objects.
PRODUCT DESCRIPTION
This product uses heat-resistant HQG non- glass structure dielectric (BNP patent), the structure is extremely
stable, long lifespan, high discharge efficiency, and not easy to damage in the case of back flow water.
FEATURES
●The ozone generator utilised the HQG ozone generation cell patented, and has been proved to be
very reliable, long service life, high ozone concentration, and is not easily damaged by back flow
water.
●The PSU is utilising the digital integrated power supply unit which has comprehensive control and
protection. The modular design has also made it quite simple for maintenance.
●Anti- moisture HV transformer design. The HV transformer is sealed with epoxy resin and enables
the ozone generators working in some harsh environments.
●Standard 4 ~ 20mA signal control. The equipment can be precisely controlled by different types of
ozone measuring devices and has met the requirements of many world leading beverage and bottled
water companies.
ACCESSORIES
●Ozone duct 8m with PVC material, and is only used for commissioning, and PTFE tube or 304
stainless steel pipe is recommended after the commissioning.
●1 piece 304 stainless steel non-returning check valve; non-returning check valve has to be installed
when there is possible back flow water in ozone system and should be installed in the gas-water
mixer suction port; non-returning check valve cannot guarantee to prevent back flow water
completely, and back flow water protection device should be used in water treatment (especially for
swimming pool, pressure mixing tank).
●1 *Manual, 1* ozone output connector, 1 set of the cooling water connector
4

SPECIFICATIONS
Model
Parameter
200G
300G
400G
600G
Capacity (g/hr)
200
300
400
600
Voltage
3*380V
Frequency
50/60Hz
Rating current
3*3.5A
3*5A
3*3.5A each set
Two sets modular design
3*5A each set
Two sets modular
design
Power
2.5
3.5
4.8
7.0
Working pressure
≤0.2bar
Cooling water flow（
25℃）
6LPM
10LPM
12LPM
20LPM
Ambient temperature
＜40℃
Ambient humidity
＜70%
Cooling water
input/output interface
1/2“ inner thread
Oxygen input
interface
Ozone output
interface
Cable size（mm2）
5*1.5
5*2.5
Dimension（mm）
1000*500*1550
100*800*15500
Weight（kg）
85
95
150
170
5

CONTROL PANEL AND INTERFACE
4.1 CONTROL PANEL DESCRIPTION
●Ozone regulating knob
○ Amount of ozone can be adjusted by adjusting the working current and the adjustable range
is from 0% to 100%
●Power indicator
○ Light up when equipment work normally
●Operation indicator
○ Light up when equipment work normally and extinguished when equipment is abnormal
●Fault indicator
○ Extinguished when equipment is normal and light up when a fault is detected;
●Power switch
○ Ozone generator on/off control. 30 second delay and then start making ozone.
●Ammeter
○ Ozone generation working current. The working current cannot exceed the current in the
specification.
●Equipment overcurrent protection
○ This feature is reserved
●IGBT overcurrent protection
○ This feature is reserved
●High voltage transformer overheat protection
○ When the indicator lights up, check whether high voltage transformer cooling fan is working,
the ambient temperature is too high and the equipment cooling fan dust filter is blocked
●Back flow water protection:
○ The indicator lights up when back flow water is detected. Checking non-returning valve and
backflow water prevention devices (if applicable) is normal.
●Cooling water overheat protection
○ The indicator lights up when the discharge tube temperature is too high. Check whether the
cooling water valve is open and the flow rate is too low ;
●High pressure protection
○ This feature is reserved
●Low pressure protection
○ This feature is reserved
6

7

●Equipment side interface description
○ Flow meter
○ Ozone generator input gas flow display
●Gas source input
○ Either oxygen input or air input
●Cooling water inlet
○ It is advised to use tap water for cooling water. If use other water or circulating water,
Polypropylene (PP) cotton water filter should be installed before cooling water inlet,
otherwise impurities in the water or metal oxides will lead to insufficient heat dissipation.
●Cooling water outlet
○ Outlet water temperature should be lower than body temperature (feeling cool), otherwise, a
higher flow is required.
●Ozone outlet
○ A non-returning check valve and backflow water prevention device have to be installed
between the ozone outlet and the venturi injection device in the water treatment application,
preventing back flow water from going into the equipment!
●4 ~ 20mA signal receiving port
○ Automatically adjust the amount of ozone when received 4-20mA analog signal
●Power cable
○ 220V 50Hz and the power must come with the ground cable, otherwise may lead to electric
leakage when the equipment gets wet!
300G INTERFACE
8

200G, 400G AND 600G INTERFACE (TWO SETS,MODULAR DESIGN)
9

4~20MA ANALOG SIGNAL RECEIVING PORT
10

INSTALLATION AND MAINTENANCE
INSTALLATION PLACE REQUIREMENT
Equipment should be installed indoors, with clean, adequate light and a good air circulation environment. It is
prohibited to be installed in the environment of exposure to sunlight, rain, water vapour, moisture, corrosive
gas, explosive gas and dust.
Environment temperature should be lower than 40℃，humidity lower than 70℃(preferably, install air
conditioner for cooling and drying). Environment temperature too high may lead to equipment cease and
lower ozone generator production. High humidity may lead to controlling circuit malfunction or damage.
The distance between equipment and wall, ceiling should be more than 600mm, which is convenient for
future maintenance.
Equipment should be installed on solid, horizontal ground. Installing on uneven ground may lead to a high
level of equipment noise and vibration.
PIPING INSTALLATION
●Gas input pipe
○ DN20 PVC or 12*8 PU pipe is suggested. The inner diameter needs to be over 15mm if the
gas source is air and over 8mm if it is oxygen.
●Cooling water pipe
○ DN20 PVC is suggested. The inner diameter needs to be over 10mm.
●Ozone output pipe
○ 304/316 stainless steel pipe or PTFE pipe is suggested. The inner diameter needs to be
over 15mm if the gas source is air and over 8mm if the gas source is oxygen. Otherwise, the
inner pressure is too high which will lead to arcing, and main circuit board damage.
ELECTRICAL CONNECTION
●The connection cable size should not be less than specified in the specification, and when cable
length is more than 10 meters, a bigger size should be used.
●The power source should meet the voltage and frequency requirement.
●The voltage fluctuation cannot be too high, and it should be within the range of -10%~+10% of the
nominal voltage. It cannot be used if voltage is out of range, otherwise it will cause equipment
damage, and voltage stabiliser or regulator should be used to meet the voltage range.
●Voltage unbalance of the three phases cannot be too high, and should be within 5%. Stabiliser
should be used if there is high fluctuation.
ON / OFF PROCEDURE
●Check before operation: check whether equipment input piping, cooling water piping, ozone output
piping are in good connection, whether power sources meet the equipment voltage requirement.
11

●Operation procedure: turn on the cooling water valve, and turn the knob on the control panel to the
minimum. Press the power switch on the control panel, and the equipment starts operation, with
working current to be 0, fault indicator lights up; slowly turn the knob clockwise, and the working
current increases. When the knob is turned to 100%, namely the equipment reaches its rated
current, the fault indicator extinguishes, and the working indicator lights up.
●Shut down operation: turn the knob on the control panel to the minimum, and then turn off the power
switch on the control panel and the equipment stops operation.
NOTES
●For the dual set ozone generator (200G / 400G / 600G), when only one set is operating, the flow
meter of the other set which is not operating should be turned off. Otherwise, the gas source will also
go to the non-operation ozone module, and lead to lower concentration of ozone output!
●For the dual set ozone generator (200G/400G/600G), a stainless steel ball valve should be installed
at each of the ozone outlets. When only one set is operating, the ball valve for the other set should
be turned off!
MAINTENANCE AND TROUBLESHOOTING
WARRANTY TERMS
BIOZONE AFTER SALE SERVICE COMMITMENT
●All products (not including consumable material, accessories and the L series products) from
Biozone are warranted for one year from the date of purchasing.
●The following occasions are excluded from the warranty, and Biozone may charge for the repairing
materials.
●Product damages due to high humidity working environment or oxygen concentrator flooded by
water.
●Product damages due to unauthorised operation unless instructed by Biozone or Biozone authorised
distributor.
●Product damages due to natural disaster, or any other force majeure.
●The warranty is valid for factory defects and not for misuse or not following the instructions or not
keeping the unit clean and serviced and maintained.
●Fail to provide proof of purchase or serial numbers are not attached to the units.
●If on-site service is required, customers will be required to pay for the cost of travelling, and Biozone
or distributor can decide to come or not according to the distance.
●In the case that the sterilisation standard is not met due to improper operation or malfunction
of the product, Biozone does not take any responsibility.
MAINTENANCE ITEMS
●Fan filtering net cleaning/replacement: the dust net needs regular cleaning due to accumulated dust
from the air (refer to the maintenance cycle table below). Turn off the power before cleaning, and
take off the cover of the fan. Then take out the stainless steel fan filtering net, clean it with clean
water, and do not re-assemble it until it is dry.
12

●High voltage parts water removal: during the humid season, there is moisture on the connecting
cable of the transformer (the high voltage unit), transformer, and the connecting cables of the ozone
module. Dry it with cloth and hair dryer. Otherwise, it may lead to damage to the equipment.
●Ozone module inner chamber, discharge tube cleaning/ replacement: accumulate small partial on
the inner chamber and electrode from the gas source will lower the ozone production and
concentration. Hence, they need to be cleaned regularly.
MAINTENANCE CYCLE TABLE
Item
Content
Circle
Remark
day
week
month
Three
month
Half year
One
year
Two
year
Three
year
Fan filter net
Clean,
replace
○
●
Cycling clean
Dry moisture on
high voltage
parts
Clean
○
Maintain during
humid season
Inner side of
internal and
external
electrode
Clean
○
Regular clean
when used in
beverage and
food industry
Internal
electrode
Replace
●
Replace if high
demanded
External
electrode
Replace
●
Replace if high
demanded
Fault detection
circuit board
Replace
●
Replace if high
demanded
Transformer
(high voltage
unit)
Replace
●
Replace if high
demanded
Note
●○：means inspection, adjust or clean;●：means replacement
●The above table is the suggested maintenance/ replacement cycle from manufacturer and customer
can also conduct the maintenance/replacement according the actual operation environment and
intensity of work
●All maintenance/replacement can only be conducted when the power is off and pressure release,
ensuring the safety of the operation personnel.
13

TROUBLE ANALYSIS AND INSPECTION (TABLE 6-2)
Number
Problem
analysis
inspection
1
No power
Power plug/ power cabinet no power
Internal fuse broken
Check the power source.
Replace the fuse and check if the voltage is
normal.
2
No flow from
ozone outlet
Gas source is not connected.
Flow meter has not been turned on
Internal piping leakage
Internal piping folded
Reconnect gas source
Turn on flow meter
Check if there is leakage in the connectors, and
tighten it if any is found.
Straighten out the connection.
3
Alarm is on and
no working
current
⑴ Ozone adjustment knob has not been
turned on.
(2) Transformer (HV transformer) over
temperature protection—4# indicator on
(3) Backflow water protection—5#
indicator on
(4) Cooling water over temperature
protection—6# indicator on
(5) Issue with 4-20mA signal.
⑹ Ozone adjustment knob short circuit
(7) Digital power supply unit issue.
⑴ Turn up the knob to increase output
Clean fan filter net；Transformer (high voltage
unit) cooling fan damaged; transformer
temperature control damaged or in poor contact.
(3) Completely dry water in ozone module;
check backflow water reason.
(4) Open the input water valve or increase
cooling water flow.
(5) Disconnect the 4-20mA signal and check.
(6) Replace potentiometer.
(7) Replace the digital power supply unit.
4
Low ozone
output, low
current（over
0.5A but lower
than rating
current）
⑴ Adjustment knob turned to be small
percentage.
⑵ Abnormal feedback signal from ozone
monitoring device
⑶ Excessive gas pressure inside ozone
module, causing high pressure inside the
ozone generator. Working pressure
should be less than 0.2 bar.
⑴ Turn the knob to higher percentage.
⑵ Disconnect the 4-20mA feedback signal
connector.
⑶ Decrease gas input flow or increase negative
pressure for the injection.
5
Low working
current（lower
than 0.5A）, no
ozone output
⑴ Back flow water in the ozone module.
⑵Excessive gas pressure inside ozone
module
⑶Abnormal feedback signal from ozone
monitoring device
⑷ Transformer connecting cable/
grounding cable is open circuit.
⑸ Quartz electrode damaged
⑹ Transformer damaged
⑴ Completely dry water in ozone module; check
backflow water reason.
⑵Decrease gas input flow or increase negative
pressure for the injection.
⑶Disconnect the 4-20mA feedback signal
connector.
⑷ Re-connect transformer and grounding cable.
⑸ Replace quartz electrode. If no new quartz
electrode is available, only remove the steel wire
on the damaged electrode（Do not remove the
quartz electrode or the concentration will be
decreased ）.
⑹ Replace transformer
14

PSU ERROR CODE AND SOLUTION
Error
code
Description
Possible cause
Solution
E001
PSU Over
current
Input voltage too low
Check the mains voltage, and make sure
correct and firm connection
E002
Working current changes too fast
Slower regulation control
E003
Rapid changes on the load or problem with
the loads
Check ozone cell and HV transformer
E004
PSU over
voltage
Input voltage abnormal
Check the mains voltage, and make sure
correct and firm connection
E005
Working current changes too fast
Slower regulation control
E006
PSU output voltage increase too fast
Change settings on the parameters
E007
Rapid changes or problem with the loads
Check ozone cell and HV transformer
E008
Phase loss
PSU input R, S, T phase loss
Check the mains voltage, and make sure
correct and firm connection
E10
IGBT
protection
PSU Output short circuit
Load short circuit or abnormal
Cooling fan channel blocked or cooling fan
issue
Ambient temperature too high
Check PSU output cables
Check HV transformer and the connections
Clean the cooling channels, replace cooling
fan
Lower ambient temperature
E11
PSU IGBT
over heated
Cooling fan channel blocked or cooling fan
issue
Ambient temperature too high
Clean the cooling channels, replace cooling
fan
Lower ambient temperature
E12
rectifier
modules over
heated
Cooling fan channel blocked or cooling fan
issue
Ambient temperature too high
Clean the cooling channels, replace cooling
fan
Lower ambient temperature
E13
PSU overload
PSU input voltage too low
PSU Over current
Check the mains voltage, and make sure
correct and firm connection
Decrease the current by setting to lower
ozone
Note
●If the problem still exists after the above inspection, please contact our company or local distributor.
●All maintenance/replacement can only be conducted when the power is off and pressure released,
ensuring the safety of the operation personnel.
●When servicing a SOZ series ozone generator with multi-set individual control, make it clear of the
component in each set (AB set: breaker, contactor, relay, digital power supply unit, transformer,
ozone cell, cooling pipe, control panel).
15

CONTACT US
16