Del ozone AGW-4015 User manual

AGW-4015 / AGW-4025 / AGW-4045
Skid-Mounted Ozone Sanitation Systems
OWNER'S MANUAL
EPA Estab. No. 071472-CA-001
DEL OZONE · SAN LUIS OBISPO, CA 93401 · USA · 800-676-1335 · Fax: [phone] Rev.F
#129380 / #129381

AGW-4015/4025/4045 Skid-Mounted Ozone Sanitation Systems
TABLE OF CONTENTS
SECTION 1
General Information
1A. Description ...........................................................1
1B. Specifications .......................................................1
SECTION 2
Installation
2A. Location ...............................................................1
2B. Electrical ..............................................................1
2C. Plumbing ..............................................................1
SECTION 3
System Configuration/Installation Diagrams
3A. Tank System.........................................................2
3B. Tank Cleaning ......................................................3
3C. Spray System.......................................................4
SECTION 4
Operation
4A. Control Panel Overview ....................................... 5
System Component/Connection Locations ........ 6
4B. Quick System Start-Up ........................................ 7
4C. Detailed System Start-Up .................................... 7
4D. System Shut-Down / Freeze Protection ............... 7
4E. Standard Operating Procedures .......................... 7
4E1. Clean In Place (CIP) Operation ................... 8
4E2. Facility Washdown ....................................... 8
4E3. Direct Contact ............................................. 8
4E4. General Water Purification .......................... 8
SECTION 5
Maintenance & Service
5A. Preventative Maintenance Schedule..................... 9
5B. Air Compressor Servicing .....................................9
5C. Digital Flow Meter Servicing ................................ 9
5D. Trouble Shooting ..............................................9-10
5E. Wiring Diagram ...................................................11
SECTION 6
Replacement Parts & Order Info
6A. Ordering Information ............................................10
6B. Standard Replacement Parts List.........................10
SECTION 7
General Ozone Use & Safety Procedures
7A. Ozone Use and Technology Overview .............. 13
7B. General Safety Information ...........................13-14
7C. Hazards ............................................................. 14
7D. Precautions for Safe Handling and Use ............. 15
7E. Monitoring .......................................................... 15
7F. First Aid Procedures .......................................... 16
7G. MSDS................................................................. 16
Daily Ozone Data Log ............................................ 17
Emergency Information Form .................................. 18
MSDS ...................................................................... 19
Warranty .................................................................. 22

AGW-4015/4025/4045 Skid-Mounted Ozone Sanitation Systems
IMPORTANT SAFETY INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS.
Read this manual completely before operation of AGW-4015/4025/4045 Ozone Generator Equipment.
The High Voltage Transformers in this unit create 7,000 volts, with the outer jacket of the High Voltage lead reaching
3,000 volts.
- USE EXTREME CAUTION -
Operate the AGW-4015/4025 on a near level surface 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 recep-
tacle before performing any service work. Failure to do so could result in serious injury or death.
SAFETY CLAIMS
Performance safety testing was based on the Hazard Communication Standard as promulgated through the Occupational
Safety and Health Act of 1970 and documented in the Code of Federal Regulations, Title 29, Chapter XVII, Part 1910,
Section 1910.1200. The inherent low hazard due to the AGW-4015/4025/4045’s design and construction, coupled with the
safety features, monitoring data, and the precautionary directions provided in the owner’s manual are sufficient for The Toxicol-
ogy Group, LLC, a division of NSF International (Ann Arbor, MI), to provide a professional opinion that the AGW-4015/4025
/4045Mobile Recirculating Ozone Sanitation System poses no safety concerns when operated under the prescribed condi-
tions as set forth in the owner’s manual.
ANTIMICROBIAL CLAIMS
This device has been determined acceptable for use as an ozone generating device providing sanitization and disinfection
of hard, inanimate, pre-cleaned surfaces, in and around food processing areas (P1). A potable water rinse is not required
following the use of this device on previously cleaned hard surfaces.
NSF International Registration for this device is based, partially, upon documentation indicating that it meets all necessary
requirements including labeling, EPA Establishment Registration, and safety requirements set forth under Federal Insecticide,
Fungicide, and Rodenticide Act (FIFRA) of June 5, 1947, Section 2(q)(1) and Section 7.
Efficacy studies conducted according to AOAC Official Method 961.02; Germicidal Spray Products as Disinfectants Test and
AOAC Official Method 960.09*; Germicidal and Detergent Sanitizing Action of Disinfectants provided the following results:
Organism Applied Dose Actual Dose (at nozzle) Spray Duration Reduction
Trichophyton mentagrophytes 3.0 PPM 1.85-2.25 PPM 30 seconds 6 log (99.9999%)
(ATCC 9533)
Salmonella choleraesuis 3.0 PPM 1.85-2.25 PPM 3 minutes 6 log (99.9999%)
(ATCC 10708)
Staphylococcus aureus 3.0 PPM 1.85-2.25 PPM 10 minutes 6 log (99.9999%)
(ATCC 6538)
Pseudomonas aeruginosa 3.0 PPM 1.85-2.25 PPM 5 minutes 6 log (99.9999%)
(ATCC 15442)
Campylobacter jejuni 3.0 PPM 1.85-2.25 PPM 3 minutes 4 log (99.99%)
(ATCC 15442)
Listeria monocytogenes 3.0 PPM 1.85-2.25 PPM 3 minutes 4 log (99.99%)
(ATCC 7644)
Aspergillus flavus 3.0 PPM 1.85-2.25 PPM 5 minutes 4 log (99.99%)
(ATCC 9296)
Brettanomyces bruxellensis 3.0 PPM 1.85-2.25 PPM 3 minutes 4 log (99.99%)
(ATCC 10560)
Escherichia coli* 3.0 PPM 2.1 PPM 30 seconds 5 log (99.999%)
(ATCC 11229)

AGW-4015/4025/4045 Skid-Mounted Ozone Sanitation Systems
1
SECTION 2
Installation
2A. Location
The AGW-4015/4025/4045 skid is designed to be
conveniently forklifted to a location close to your pro-
cess. This can be a level location indoors or covered
outdoors. Allow for access to electrical power and
required water connections.
2B. Electrical
Main Power Supply Circuit:
The AGW-4015/4025/4045 is supplied with a standard
25 Foot power cord. Plug cord into standard 230VAC (20
Amp) grounded receptacle.
2C. Plumbing
Water Inlet Connection: 1.25” FPT
Water Outlet Connection: 2” FPT
SECTION 3
System Configuration/Installation Diagrams
The following 3 pages include diagrams for the following:
• Tank Charging System
• Tank Cleaning System
• Spray System
Figure 1: AGW-4015/4025/4045
Skid-Mounted Ozone Sanitation System
SECTION 1
General Information
1A. Description
The DEL AGW-4015/4025/4045 described in this
manual recirculates ozone-enriched water through
tanks sized from 50 gallons to 2,500 gallons. It is de-
signed to "charge" a given tank of water with ozone for
safe and effective clean in place (CIP) and clean out
of place (COP), direct contact on food products, and
general water sanitation/disinfection.
1B. Specifications
Ozone Output,
g/hr
4015 4025 4045
15 25 45
Ozone Flow (max),
scfh
13 18 30
% Weight 034.2 4.2 4.2
Applied dose (ppm)
@ Flow (gpm)
3.2@20 3.2@35 5.5@35
Power Requirements:
230VAC, 60 Hz, 1Ø, 15.0 A (20 Amp Service)
Water Flow Rate: AGW-4015: 20 GPM factory preset
AGW-4025: 35 GPM factory preset
AGW-4045: 35 GPM factory preset
NOTE: The purpose of the pump in the AGW-
4015/4025/4045 is to provide the proper pressure and
flow rate for the most efficient injector operation. It is
designed to circulate cold water only. The inlet of the
AGW-4015/4025/4045 should never be connected
directly to a pressurized water source and the outlet
should never be throttled or restricted. Please call
DEL if further explanation is required.
Water Requirements:
Temperature:...........40°F - 90°F
Pressure: ..............0 - 10 psi
Water Quality: potable, mineral & chemical free water
NOTE: Water passing through the AGW-4015/4025
cools the ozone generator module. Ozone effective-
ness, generator efficiency and service life will be
improved at water temperatures of 60 - 80°F.
Overall Dimensions: 64”H x 32”W x 28”D
Shipping Weight w/Crate: Approx. 500 pounds
Dry Weight: Approx. 450 pounds
Ambient Temperature:
Operation: Ambient Temperature 40°F - 100°F
WARNING: Not to exceed 100°F or damage to
system may result!
Op

AGW-4015/4025/4045 Skid-Mounted Ozone Sanitation Systems
2
3A. Tank System

AGW-4015/4025/4045 Skid-Mounted Ozone Sanitation Systems
3
3B. Tank Cleaning

AGW-4015/4025/4045 Skid-Mounted Ozone Sanitation Systems
4
3C. Spray System

AGW-4015/4025/4045 Skid-Mounted Ozone Sanitation Systems
5
SECTION 4
Operation
4A. Control Panel Overview
4A-1. Indicator Lights
a. Green Lights
1) Main Power (Ozone Generator): indicates
that power is being supplied to the
Ozone Generator.
2) Ozone Power: indicates that power is
being supplied to the high voltage Corona
Discharge circuits and that ozone is being
produced (see Sections 4B and 4C).
3) Pump On: indicates that the pump is running.
b. Red Lights (Ozone Generator)
1) Vacuum: indicates that vacuum is out of
range. The light will be lit for low vacuum
conditions.
2) High Coolant Temperature: indicates that
water temperature is over 110 °F.
(Refer to TROUBLESHOOTING Section.)
3) Water Back Flow Detected: indicates that
water back flow from the injector into the
generator has been detected.
(Refer to TROUBLESHOOTING Section.)
4A-2. Other External Components
a. Main Power Switch: Activates water pump and
supplies power to ozone generator.
b. Ozone Power Switch: Activates ozone gener-
ating equipment.
c. Injector Vacuum Gauge: Indicates Vacuum of
the ozone in the injector system.
d. Vacuum Adjustment Valve: Controls Vacuum
by adjusting the flow of water to the ozone injec-
tor.
e. Back-Pressure Gauge: Indicates back-pressure
in the main flow loop (after the injector).
f. Flow / Back-Pressue Adjustment Valve: Con-
trols total system water flow and back-pressure.
g. Inlet Pressure Gauge: Indicates inlet pressure
in the main flow loop (before the injector).
h. Dissolved Ozone Monitor/Controller: Displays
dissolved ozone level in water and can be set for
ozone generator to maintain desired ozone level.
(See Section 4E and ATI Dissolved Ozone Moni-
tor/Controller owner’s manual for further informa-
tion.)
Figure 2: AGW-4015/4025/4045 Control Panel
Main Power Switch
Pump On
Inlet Pressure Gauge
Main Power
Ozone Power
Vacuum
High Coolant Temp.
Back Pressure Gauge
Flow Meter
Injector Vacuum Gauge
Ozone Power Switch
Dissolved Ozone
Monitor/Controller
Water Backflow
Detected

AGW-4015/4025/4045 Skid-Mounted Ozone Sanitation Systems
6
AGW-4015/4025/4045 Water Connections
AGW-4015/4025/4045 Components
Water Pump (1.5 HP)
Heated Catalytic Ozone Destruct
Mixing Tank
Degas Valve
Venturi Injector
Flow / Back-Pressure
Adjustment Valve
Vacuum Adjustment Valve
Pump Drain Plug (1/2”)
Water Inlet (1.25” FPT)
Water Outlet (2” FPT)

AGW-4015/4025/4045 Skid-Mounted Ozone Sanitation Systems
4B. Quick System Start-Up
Presumes unit is tuned to its present application. (Follow
detailed start up section 4C).
1. Turn Main Power switch to ON. Pump On green light will
illuminate. Allow one minute for system to stabilize.
2. Turn Ozone Power switch to ON.
3. Check System Vacuum Gauge. Adjust Vacuum Adjust-
ment valve until gauge reads approximately -3 to -7 in.
Hg. vacuum. Ozone Power green light will illuminate
upon reaching approximately -5 in. Hg.
4C. Detailed System Start-Up
Read completely before starting system.
1. Check for proper electrical and water connections.
2. Switch Pump Power ON (Pump On green light will illu-
minate), allow pump to run for one minute as water level
in mixing tower fills and stabilizes.
3. If the mixing tower doesn’t fill with water then the pump
needs priming. Turn off the Pump Power, DO NOT RUN
PUMP DRY (pump seal failure will result). Insure the wa-
ter supply hose is full of water and the water source has
sufficient flow capacity for the pump. Turn on the Pump
Power. Repeat until the mixing tower has filled, stabilized
and water is circulating.
4. Switch Ozone Power ON.
5. Check System Vacuum Gauge. Adjust Vacuum Adjust-
ment valve until gauge reads approximately -5 in.Hg.
vacuum. Ensure that the back pressure gauge is at or
above 18 psi for AGW-4015/4025 and at or above 8 psi
for the AGW-4045.
Ozone On green light will illuminate upon reach-
ing approximately -5 in. Hg. NOTE: Applications with
elevated head pressures will raise bypass and back
pressures. The above values are minimum operating
pressures. If the system is out of specified operating
parameters, see Flow Adjustment Instructions below.
System Flow Adjustment Instructions
To make water flow adjustments to the AGW-4015/4025
while enabling optimum ozone mass-transfer, please follow
these steps:
1. With the unit running, observe the water flow.
2. Adjust flow/back pressure valve (the red gate valve) to
achieve 18 psi for AGW-4015/4025 and 8 psi for the
AGW-4045.
3. Next, adjust the vacuum adjustment valve to read -5
in. Hg.
4. Multiple iterations of adjusting both the flow/back pres-
sure valve & the vacuum adjust valve may be required to
achieve settings as close as possible to those described
in steps 2 & 3.
7
4D. System Shut-Down / Freeze Protection
1. Turn OFF Ozone Power switch.
2. Turn OFF Main Power switch.
3. Remove hoses (if applicable) and allow water to drain
from system (a small amount of water will remain in the
ozone degas chamber).
4. Freeze Protection: It is recommended that the AGW-
4015/4025/4045 be protected from freezing tempera-
tures. If this is not possible, the pump must be drained
by removing the 1/2" drain plug located underneath the
pump (see page 8). WARNING: Pump damage will
occur if pump is not drained before unit is stored
in freezing temperatures or for extended periods of
time. A small heater may be used to prevent remaining
water in the system from freezing.
4E. Standard Operating Procedures
The following chart provides ozonation time estimates
to charge tanks ranging in size from 300 to 2,000 gal-
lons using the AGW-4015/4025. Note: Water temp.
and oxidizer load will affect ozone levels and max
PPM.
Ozone Tank Charging Guidelines
Tank Size Charge Time Ozone Dose
(gallons) (minutes) (PPM)
AGW-4015 AGW-4025
300 15 10 1
300 30 20 2
300 45 30 3
300 60 40 4
400 60 40 3
500 75 50 3
600 90 60 3
700 105 70 3
800 135 90 3
900 150 100 3
1000 180 120 3
1100 210 140 3
1200 240 160 3
1300 270 180 3
1400 300 200 3
1500 330 220 3
1600 360 240 3
1700 390 260 3
1800 420 280 3
1900 450 300 3
2000 480 320 3
There are two ways to measure and/or control the
amount of ozone in the water:
Dissolved Ozone Monitor/Controller
By far the most accurate way to measure and control the
ozone in the water, a dissolved ozone monitor/controller may
be used to ensure that the water is completely charged before
starting the timing of the cycle, as well as providing a continu-
ous monitor for observation. In addition, it can be used to con-
trol the ozone system so that the tank of water can be main-
tained continuously and stays charged at the exact amount
determined by the adjustable set-point; it will cycle the ozone
system on and off as needed to maintain the set-point.

AGW-4015/4025/4045 Skid-Mounted Ozone Sanitation Systems
8
Dissolved Ozone Monitor/Controller
By far the most accurate way to measure and
control the ozone in the water, a dissolved ozone
monitor/controller may be used to ensure that the
water is completely charged before starting the tim-
ing of the cycle, as well as providing a continuous
monitor for observation. In addition, it can be used
to control the ozone system so that the tank of water
can be maintained continuously and stays charged
at the exact amount determined by the adjustable
set-point; it will cycle the ozone system on and off
as needed to maintain the set-point.
Indigo Blue Ampules with Colorimeter (Hach Ac-
cuVac Test Kit)
This method can be used to determine the amount
of ozone at the discharge of the CIP (at the end
of the cycle). It cannot be used to determine the
amount of ozone in the ozone charge tank because
the highest range of detectability is 1.5 PPM. There-
fore, refer to the Ozone Tank Charging Guidelines,
charge the ozone charge tank for the proper amount
of time and then begin the CIP. After 30 minutes,
test the discharge water with the Hach AccuVac
Ampule. If there is 1.0 - 1.5 PPM ozone in this
discharge water, it can be safely determined that the
system is sanitized.
4E-1. CIP (Clean In Place)
4E-1a. Refer to the Ozone Tank Charging Guide-
lines. Determine the amount of water in the ozone
charge tank. Operate the AGW-4015/4025/4045
for the proper amount of time based on the amount
of water in the ozone charge tank, and charge the
water to approximately 3 PPM. The time necessary
to accomplish this is dependent on the volume of
water in the tank. Once the water is charged with 3
PPM ozone, CIP operation can begin. Experience
dictates that 15 - 30 minutes of CIP operation with
an applied dose of 3 PPM is an acceptable amount
of time to attain a zero microbial count. A longer
duration will not cause any harm. Individual prefer-
ences vary, but 30 minutes is the recommended
optimum.
4E-1b. General Tank Sanitation - See page 3,
drawing 3B. Wash debris and rinse the tank with
clean water. Connect the AGW-4015/4025/4045 to
the tank and recirculate the system while spraying
with any standard spray ball. Approximate spray
time is 15-30 minutes.
4E-2. Facility Washdown
Refer to the Ozone Tank Charging Guidelines.
Determine the amount of water in the ozone charge
tank. Operate the AGW-4015/4025/4045 for the
proper amount of time based on the amount of wa-
ter in the ozone charge tank, and charge the water
to approximately 2-3 PPM.
The time necessary to accomplish this is dependent
on the volume of water in a given tank. Once the
water is charged with 2-3 PPM ozone, a spray rig
can draw this ozone charged water from the ozone
charge tank.
CAUTION: Maximum pressure 22 psi - higher
pressure will result in excessive ozone off-gas!
The spray can be directed on floors, drains, walls,
wettable equipment, external or internal tanks, clean
rooms, etc. (If the ozone spray is being applied in a
very small, enclosed, poorly ventilated area, it may
be necessary to wear a standard ventilator to avoid
the inhalation of ozone gas. Breathing exposure to
greater than 0.1 PPM ozone gas can irritate eyes
and sensitive lung tissue. Please see the Safety
Section 7 for further details and a Material Safety
Data Sheet on ozone.)
Based on industry experience, the amount of time
necessary to attain sanitation depends on the
amount of debris found in the area to be cleaned.
Sweep or remove heavy surface dirt first to expedite
the ozone cleaning process. Time estimates for
proper sanitation are difficult to predict due to the
variety of areas, surface materials and contami-
nants. However, experience and studies support
that 30 sec to 2 minutes of spray time is generally
all that is necessary for complete sanitation. DEL
recommends that end-users utilize their own sani-
tation efficacy testing protocol to determine nec-
essary spray time.
4E-3. Direct Contact - Spray Nozzle, Flume, Cas-
cade
Applications vary. Please contact DEL for advice/
consultation at 800-676-1335.
4E-4. General Water Sanitation/Disinfection
Applications vary. Please contact DEL for advice/
consultation at 800-676-1335.

AGW-4015/4025/4045 Skid-Mounted Ozone Sanitation Systems
9
SECTION 5
Maintenance and Service
5A. Preventative Maintenance Schedule
(also refer to Ozone Generator manual)
DAILY:
1. Check ozone generator for proper operation.
- Make sure no red indicator lights are lit.
MONTHLY:
1. Remove & clean ozone generator cabinet air fil-
ter.
2. Perform general cleaning of cabinet exterior.
3. Using clean/dry compressed air, blow out the
interior of the ozone generator cabinet taking
special care around small components and
wiring.
4. Inspect and replace compressor or air filters
as required. (Replace no less than Quarterly)
EVERY 8,700 HOURS:
1. Inspect and replace compressor air filter car-
tridge as required using DEL P/N 8-0061.
2. Rebuild compressor. See COMPRESSOR
SERVICING section 5B.
3. Replace circulation pump seal using DEL
P/N 5-0987.
EVERY 18,000 HOURS:
(refer to Ozone Generator Manual):
1. Replace the CD ozone cells using DEL P/N 9-0927
(two required for AGW-4015, four required for
AGW-4025, six required for the AGW-4045).
5B. Air Compressor Servicing
Air compressor requires a rebuild after one (1) year or
after every 8760 hours, which ever is reached first.
a. Purchase Compressor Rebuild Kit using DEL
P/N 2-1025. See Section 6B for ordering infor-
mation.
b. Follow instructions in Compressor Rebuild Kit to
rebuild compressor.
5C. Digital Flow Meter Servicing (if applicable)
The digital flow meter batteries should be replaced
every 12 months. Two AAA batteries are required.
a. Remove the flow meter by loosening the union
nut.
b. To replace the batteries, open the rear panel by
removing the two Phillips screws. Be sure the
foam insert is in place before closing the rear
panel.
c. Replace the flow meter and tighten the union
nut.
5D. Trouble Shooting (also refer to Ozone Gen-
erator manual)
Knowledge of electrical applications is required for
trouble shooting. Contact a certified electrician if you are
unsure of your ability to service the equipment.
If any condition persists, call 800-676-1335 or for inter-
national call 805-541-1601 for technical assistance.
I. Symptom:“PUMP ON” green indicator light out when
MAIN POWER switch is in the “ON” position.
1. No power to the AGW-4015/4025/4045 from the power
supply.
a. Check the circuit breaker at the facility power distri-
bution box.
b. Check for loose connections or wiring breaks
from the power distribution box to the AGW-
4015/4025/4045.
II. Symptom:“OZONE POWER” green indicator light out
when OZONE POWER switch is in the “ON” position.
1. a. Check cable & connectors. Reconnect if in good
condition.
2. Dissolved Ozone Monitor/Controller may have shut-
down the ozone generator when the dissolved ozone
level reached set point.
a. Wait for dissolved ozone to come down below set
point. Generator will restart when dissolved ozone
is below set point.
3. Abnormal operating conditions exist.
a. Check red fault lights. Refer to corresponding
symptom and corrective action.
4. Cabinet door ajar.
a. Close and latch door.
III. Symptom: “VACUUM” red indicator light is on indicating
out of range vacuum is being supplied.
1. Injector not supplying adequate vacuum.
a. Check pump and ensure water is flowing through
injector.
b. Check vacuum gauge & adjustment valve. Adjust
if necessary to obtain proper reading on vacuum
gauge (-5 in. Hg).
2. Injector supplying too much vacuum.
a. Check vacuum gauge & adjustment valve. Adjust
to proper pressure to obtain correct vacuum (ap-
prox.-5 in. Hg).
b. Check system back pressure gauge to insure
back pressure is approximately 18 psi for AGW-
4015/4025 and 8 psi for AGW-4045.

AGW-4015/4025/4045 Skid-Mounted Ozone Sanitation Systems
10
3. Another abnormal condition exists causing the ozone
output solenoid to be closed.
a. Check red fault lights. Refer to corresponding
symptom and corrective action.
b. Check hose connections.
c. Solenoid valve may be stuck in closed posi-
tion. Free plunger and return system to normal
operation.
IV. Symptom: “HIGH COOLANT TEMP” red indicator
light is on indicating ozone generator temperature is
over 110°F.
1. Coolant water flow has been interrupted.
a. Check all tubing connections insuring tight leak-
free connections
b. Trace tubing and look for flow blockage.
c. Re- establish proper coolant water flow.
2. System is left in self-recirculation mode too long.
V. Symptom: “WATER BACKFLOW DET.” Red indicator
light is on indicating possible water in ozone line.
1. Water has flowed back from injector to the ozone
generator module.
a. Re-establish proper water flow through injector
and correct vacuum.
b. Drain Back Flow Preventer by first routing drain
tubing out of the cabinet and opening ¼" stain-
less steel ball valve.
c. After water has completely drained, close valve,
secure cabinet door and restart system.
VI. Symptom: CD Module is not operating. Ozone output
has dropped.
1. No power to the generator module from the power
supply.
a. Check high voltage (HV) cables for breaks or
loose connections, replace if required.
b. Check for power at input terminals of the HV
power supplies.*
c. Check ozone power relay for loose connections
or faulty operation.
*CAUTION: HIGH VOLTAGE (7,000 V)
VII. Symptom: No oxygen flow through the ozone
generator.
1. Air compressor is not operating properly.
a. Listen for air compressor operation.
b. Check all tubing connections from the air com-
pressor through the system for leaks. Repair as
required.
VIII. Symptom: Low dissolved O3 level. System is op-
erational but measured O3level in water is lower than it
should be.
1. See VII.
2. Ozone is not dissolving efficiently into water.
a. Check back pressure gauge - gauge should read
approximately 18 psi for AGW-4015/4025 and 8
psi for AGW-4045.
b. If using optional flow meter, check water flow
rate through it. Adjust flow according to direc-
tions in section 5C.
SECTION 6
Replacement Parts and Order Information
6A. Ordering information:
For replacement parts call DEL at 1-800-676-1335 or for
international call 805-541-1601.
Be prepared with the following information:
· Customer Name · Customer Address
· DEL Model Number · DEL Serial Number
· Date Purchased · Proof of Purchase
6B. Standard replacement parts list:
1. CD Ozone Cell .........................................9-0927
a. AGW-4015 - two cells required
b. AGW-4025 - four cells required
c. AGW-4045 - six cells required
2. Compressor rebuild kit, ............................2-1025
a. AGW-4015/4025 - one kit required
b. AGW-4045- two kits required
3. Cabinet Air Filter Cartridge .......................7-0615
4. Compressor Air Filter Cartridge................8-0061
5. Ozone Tubing, Teflon.................................7-0126
6. Power Cable, 25 Ft (230V only) ................5-0898
7. Pump Seal ................................................5-0987
8. Check Valve .............................................8-0330

AGW-4015/4025/4045 Skid-Mounted Ozone Sanitation Systems
11

AGW-4015/4025/4045 Skid-Mounted Ozone Sanitation Systems
12

AGW-4015/4025/4045 Skid-Mounted Ozone Sanitation Systems
13
SECTION 7
Ozone Overview & Safety Procedures
7A. Ozone Use and Technology Overview
7A-1. Relative Strength of Ozone
The following compares the strengths (electron
oxidation potential) of several common oxidizing
reagents:
Oxidizing Reagent 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
The following compares the CT values for water of
ozone versus forms of chlorine:
7A-2. Materials Selection
7A-3. Micro-Flocculation and Oxidation
Ozone oxidizes the following metals (know as mi-
cro-flocculation), enabling their removal via filtration:
• Iron
• Copper
• Manganese
• Zinc
• Arsenic
Ozone neutralizes "nuisance" compounds - most
commonly, hydrogen sulfide.
7A-4. Factors Affecting Sanitation
The following factors will affect the ability of ozone
to effectively act as a sanitizer:
• Type and level of contaminant
• Physical/chemical parameters of the environs
• Exposure time
• Temperature
• Concentration
• Water chemistry and pH
• Cleanliness
• Microbial attachment
7B. General Safety Information
7B-1. Ozone Properties
• Colorless to blue gas (greater than -169°F)
• Characteristic odor often associated with electrical
sparks or lightning in concentrations of less than
2 ppm
• Severe irritant above 1-2 ppm
• Generally exists as a gas
• Highly chemically reactive
• Non-flammable, non-carcinogenic
• Hazardous polymerization can occur
• Spontaneously decomposes to oxygen gas
7B-2. Ozone Uses
• Air and water disinfection
• Surface sanitation
• Water treatment plants
• Bottled water, irrigation, community water supplies,
swimming pools/spas, etc.
• Aquariums/life support
• Agricultural wash water
• Wastewater treatment
• Mold and bacteria control in cold storage

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7B-3. AGW-4015/4025/4045 Safety Features
The AGW-4015/4025/4045 produce ozone which is
automatically and immediately injected into the water
flow. Any ozone which does not dissolve into the water
is separated off in the degas chamber and eliminated
in the heated catalytic ozone destruct. The design of
this self-contained system eliminates the release of
gaseous ozone from the unit. In addition to ozone safety,
the following general safety features are built-in to the
AGW-4015/4025/4045:
• Ozone Generator door safety interlock switch -
disables high voltage power supply when open or
improperly latched
• Circuit Breaker, Fuse
• Vacuum Switch - stops operation in the event of low
water flow
• Ozone cell high temperature indicator
• Interlocked sensors and regulating devices
• Startup/shutdown sequences and fault protection
• Multistage water pump to control flow rate
• Ozone is supplied under negative pressure (induction
- i.e. a leak will draw air into the system).
Slight off-gassing of ozone can occur from the water that
is produced by the AGW-4015/4025/4045 (the physical
properties of ozone make this unavoidable). Laboratory
and field testing in varying environments indicate that
ozone off-gas levels from the water produced by the
AGW-4015/4025/4045 do not exceed 0.1 PPM (the
permissible exposure level (PEL) or time weighted
concentration for gaseous ozone to which workers
may be exposed averaged over 8 hours, 5 days a week
(OSHA)). Gaseous ozone concentrations above 0.02
PPM are detectable by humans.
Inasmuch, sections 7C through 7H of this manual dis-
cuss relative issues regarding safety and monitoring of
gaseous ozone.
7C. Hazards
7C-1. 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. Ini-
tial small exposure may reduce cell sensitivity and/or
increase mucous thickness producing a resistance to
low gaseous ozone levels. As a result, DO NOT RELY
ON ODOR AS A WARNING OF HIGH OZONE CON-
CENTRATIONS.
The permissible exposure level (PEL) or time weight-
ed 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 concen-
tration of 5 ppm ozone in air is generally accepted as
Immediately Dangerous to Life or Health (IDLH).
7C-2. Health Hazards - Effects on Humans
Gaseous ozone acts as a primary irritant, affect-
ing mainly the eyes, upper respiratory tract and the
lungs. Inhalation produces various degrees of re-
spiratory effects from irritation to pulmonary edema
(fluid in lungs). Short exposure to 1-2 ppm con-
centrations 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 thresh-
old limit and so no exposure (regardless of how
small) is theoretically without effect from ozone’s
strong oxidative ability.
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 (15 min.)*
0.01 - 1.0 ..............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 1/2 hour
*Regulatory Levels
7C-3. Hazards - Electrical
Turn OFF all power switches and disconnect power
cord from power source receptacle before performing
service work. Failure to do so could result in serious
injury or death. Operate the AGW-4015/4025/4045
on a near level surface with safe access to electri-
cal power. Connect the AGW-4015/4025/4045 to a
GFCI type receptacle. Do not bury the electrical cord.
To reduce risk of electrical shock, replace damaged
cord immediately.
7C-4. Hazards - Fire
Ozone is nonflammable. Decomposition of ozone into
oxygen gas, O2, can increase strength of fire. Ozone
is unstable at room temperature and spontaneously
decomposes to oxygen gas. Avoid ignition sources
such as heat, sparks, and open flame. Keep away
from strong reducing agents and combustible materi-
als such as grease, oils, and fats.
7C-5. Hazards - Chemical Action
Ozone is chemically incompatible with all oxidizable
materials, both organic and inorganic.

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7D. Precautions for Safe Handling & Use
7D-1. Ozone Monitors
Ambient ozone monitoring equipment should be in-
stalled in the areas where ozone is being generated
or applied. See Monitoring section 7G.
Self-adhesive ozone monitor badges, such as the
Chromair®System by K&M Environmental (Virginia
Beach, VA, www.kandmenvironmental.com), may be
used for personal or area monitoring for exposure
times ranging from 5 minutes to 10 hours.
7D-2. Ventilation
It is mandatory that general and local exhaust
ventilation be provided to dilute and disperse small
amounts of ozone into the outside atmosphere. Fed-
eral, state, and local regulations must be followed.
7D-3. Emergency Procedure
Due to the short life of ozone, evacuation and venti-
lation is all that is generally required in the event of
a high ambient ozone alarm. All ozone generating
and delivery equipment should be shut down (manu-
ally or automatically by alarm) and a high speed fan
activated to dilute and disperse ozone to the atmo-
sphere. Personnel should evacuate the affected
area until levels are returned to below 0.1ppm.
7D-4. Respiratory Protection
A disposable respirator (3M #N95 8214/8514 - Min-
neapolis, MN, www.3m.com) is recommended for
relief against ozone levels up to 10 times the OSHA
PEL or applicable government occupational expo-
sure limits, whichever is lower.
7D-5. Education & Training
The education and training of workers is the respon-
sibility of the employer. An effective training program
must be practical, based on written work procedures
and be specific to both the job-site and the tasks to
be performed. Training shall also include the respon-
sibilities and responses of workers in an emergency.
The employer shall ensure, through the education
and training program, that all workers are able to
work without risk to themselves or others around
them. All workers must clearly understand their
responsibilities with regard to not only specific work
procedures, but also the need to report all hazards,
accidents or incidents and injuries.
All routine work and emergency procedures shall be
reviewed jointly by management and employees at
least annually.
7E. Monitoring
7E-1. Location of Monitors
Ambient ozone detection monitors shall be located
to monitor ozone room air and production/plant room
air for indoor applications.
7E-2. Monitoring Equipment
OZONE IN AIR
Electronic Ambient Ozone Monitor
a. Shall measure the level of ozone present in
the room where ozone equipment is located.
b. The monitor shall include both visible and
audible alarms. The EcoZone™ Model EZ-1
portable ambient ozone analyzer by EcoSen-
sors, Inc. is recommended for use with the
AGW-4015/4025/4045.
b-1. EcoZone™ Model EZ-1 features:
• Constantly monitors work environment
• O3concentration shown by a multi-color
display from green (safe) to yellow (cau-
tion) to red (danger)
• No installation required
• Easily understood by non-technical per-
sonnel
• Field work and "walk around" analyses
possible via power from internal re-
chargeable batteries
• Compatible with EcoSensor VOC and O3
sensing, monitoring, and control products
b-2. EcoZone™ Model EZ-1 specifications:
• Range: 0.02-0.14 ppm O3
• Bar graph display: normally green, yellow
at 0.05 ppm (caution), red at 0.1 ppm
(danger)
• Response time: with a few seconds of O3
reaching the sensor
• Accuracy: within 20% in the 0.05-0.1 ppm
range
• Recommended calibration check annually
• Temperature Range: 18-37°C (65-100°F)
• Measurement principle: HMOS (Heated
Metal Oxide Semiconductor) sensor
• Size: 85 x 35 x 60 mm (3 1/4" x 1 3/8" x 2
3/8")
• Weight: 154 grams (6 oz.)
• Power Requirements: 12-24 volts DC
at 300-500 mA. AC adapters available
worldwide.
• Batteries: self-contained NiMH. Approxi-
mately 2 hour capacity. Recharged by AC
adapter overnight.
Badge-Type Ambient Ozone Monitor
a. Shall measure the level of ozone present in
the room where ozone equipment is located.

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b. The ChromAir®System ozone badge (K&M
Environmental P/N 380010-10; www.kandmenvi-
ronmental.com; 1-800-808-2234) may be used
for personnel or area monitoring for exposure
times ranging from 5 minutes to 10 hours. For
higher resolution, the ChromAir ozone badge
may be used in conjunction with the ChromAir
ozone color comparator.
b-1. ChromAir System features:
• Constantly monitors work environment
• Accurate measurements
• Ease of use - requires minimal training
• Cost effective - offers the most inex-
pensive air sampling solution available
b-2. ChromAir System specifications:
• Color change: blue to white
• Exposure range: 0.08–1.6 ppm•hr
• Max. sampling time: 10 hours
• Min. sampling time: 5 minutes
• Relative humidity range: 20% - 90%
• Face velocity range: 10-165 cm/sec
• Temp. range: 16°C - 30°C (61°F - 86°F)
• Light effect - sunlight: not recommended
• Light effect - visible: no effect
• Dimensions: 10.5 cm x 5.5 cm x 0.25 cm
• Weight: 11 g
• Refrigerated shelf life: 1 year
Other ambient ozone monitors are also available.
Contact DEL for further information.
OZONE IN WATER
The ozone concentration in water can be measured
in different ways.
1. Oxidation Reduction Potential (ORP) moni-
tor measures the effective biocidal activity of
dissolved ozone in water in millivolts and can be
converted to mg/l (ppm). NOTE: ORP is an in-
effective measurement of ozone concentrations
greater than about 0.5 ppm.
2. Dissolved Ozone monitors measure levels
of dissolved ozone in water (mg/l or ppm). The
HACH Indigo Blue AccuVac high range dis-
solved ozone test kit (DEL P/N 6-0116) is an
inexpensive colorimetric test. Electronic, in-line
dissolved ozone monitors are also available.
Contact DEL for further information.
7E-3. Ozone Detection Data Log
In addition to automatic chart recorders, operators
should log ozone monitor output. Record ozone output
data twice per shift (maximum 12 hour shift). If system
does not have an automatic chart recorder, record data
every 4 hours, regardless of shift changes. (See Daily
Data Log - Appendix A).
7F. First Aid Procedures
7F-1. General
First Action:
1. DO NOT PANIC.
2. If exposure to gaseous ozone causes headaches
or shortness of breath, immediately remove the
patient to a fresh air environment.
Second Action:
1. Ensure there is no more danger to yourself or the
victim.
2. Workers who have been exposed to low con-
centrations of ozone should be given oxygen to
breathe while under the observation of trained
personnel.
3. If exposure is severe, send for medical assistance
immediately.
7F-2. Inhalation
First Action:
1. Assess patient's breathing.
2. All unconscious patients must be placed in the
drainage position (on their sides), so that fluids
can drain from the airways once breathing has
been restored.
3. Check pulse.
Second Action:
1. If breathing has ceased, start artificial respiration
(rescue breathing is the most effective) method
until breathing has been restored.
2. Send for medical assistance immediately.
3. If breathing and/or pulse is not detected, begin
cardiopulmonary resuscitation (CPR).
7F-3. Eye Contact
First Action:
1. Effective irrigation should start immediately. Eyes
should be irritated for 30 minutes by the clock with
running tap water or preferably normal saline.
Second Action:
1. Effective irrigation must be continued while en-
route to hospital.
7F-4. Precautions
Workers with a previous cardiopulmonary (heart and
lung) condition must consult their physician prior to
working in an area in which they may be exposed
to ozone. Significant alterations in cardiopulmonary
functions have been documented when such workers
have been exposed to low concentrations of ozone.
7F-5. Emergency Information Form
An emergency information form (see Appendix B)
should be filled out prior to operation of ozone gen-
erator.
7G. MSDS
See Appendix C (Page 19 et al.) for full MSDS

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