Ozone AM5000 Series User manual

AM5000 Doc No. 290-062-00 Rev. A June 2005
INSTALLATION, OPERATING & MAINTENANCE
INSTRUCTIONS FOR MODELS
AM5100, AM5101, AM5200
AM5201
Model Specifications:
AM5100 - 1gm/hr output
AM5101 - 1gm/hr output with countdown timer
AM5200 - 2gm/hr output
AM5201 - 2gm/hr output with countdown timer
For settings see appendix A
AM5000
SERIES
Ozone Generator

AM5000 Doc. No. 290-062-00 rev. A June 2005
INTRODUCTION
This range of Ozone Generator is designed to allow flexibility in the
control and output of Ozone to suit the application. There are many
applications for which the Ozone may be used e.g. the destruction of
malodours in air, the destruction of bacteria and chemicals in water, air
and on surfaces. This manual does not specify applications in which
these units may be used, nor does Ozone Industries Ltd. take any
responsibility for any associated equipment used with these units and
not supplied by Ozone Industries Ltd.
This manual covers the ‘open cell’ range of generators capable of
producing up to 2 grams per hour (g/hr) of Ozone.
NOTE: The ozone generator contains brittle ceramic plates and
must not be knocked, dropped or subjected to vibration.
1.0 HEALTH AND SAFETY
Ozone is an irritant and a powerful oxidising agent. Like most products
Ozone is only dangerous if used irresponsibly, therefore it is important
to follow the guidelines detailed in this manual.
Due to the high levels of Ozone produced by the unit it is strongly
recommended that no person or animal be in the room when the unit is
running.
The UK Health and Safety Executive (HSE) issue two documents
controlling the use of Ozone.
EH38 ‘Ozone: health hazards and precautionary measures’
EH40 ‘Occupational Exposure Limits’
In addition a material Safety Data Sheet, required for COSHH
compliance, has been included (Appendix 1)
As Ozone cannot be stored, transportation legislation (CHIP) does not
apply.

AM5000 Doc. No. 290-062-00 rev. A June 2005
3.0 UNIT DESCRIPTION
The AM5000 series of generator is designed to convert Oxygen found in
the normal air into Ozone. It does this using the Corona Discharge (CD)
principle, where air is blown over a ceramic plate with a stainless steel
electrode, known as an open cell. Each cell has its own power supply,
which delivers high voltage, high frequency electricity to the cell. Each
cell is capable of producing up to 1g/hr of Ozone.
The unit is available in two sizes, the AM5100 and the AM5200.
AM5100 is a single cell design.
AM5200 is a double cell design.
See section 9.0 for more detailed specifications of the units.
4.0 INSTALLATION
These Ozone generators are primarily designed as a portable unit which
is supplied with a UK 3 pin plug, fitted with a 3 Amp fuse and only
requires a 13 Amp 230V 50Hz switched power supply. All electrical
connections should comply with current IEE wiring regulations (BS
7671: 1992 or equivalent).
There are a few guidelines to positioning the unit in order to maximise
its effectiveness:
On a flat, vibration free surface.
Centrally in the area to be treated and if possible at approximately
table height.
The airflow around the unit should not be restricted, a minimum
clearance of 800mm around the unit is recommended.
There should be no risk of the unit being splashed with water, or
other liquids.
The temperature should be between 0ºC to +30ºC.
The relative humidity should not exceed 75% at 20ºC, non-
condensing.
The environment should contain no combustible gases or
aggressive/corrosive chemicals such as bleach, bromine or similar.
Additional fixings are available separately, to allow connection to a 4”
ducting set-up and Heating, Ventilation and Air Conditioning (HVAC)
ducting. Instructions on how to fit these are supplied with the parts.

AM5000 Doc No. 290-062-00 Rev. A June 2005
5.0 OPERATION
5.1 Output Setting.
The output setting of the unit will depend upon the model of generator used,
the volume of the room to be treated and the level of Ozone required.The
Ozone level achieved in a room will depend on the room size, temperature,
humidity, the number of air changes, the length of time the Ozone generator is
run and the output setting.
Any ventilation installed may reduce the effectiveness of your ozone generator.
The output can be set as follows:
a) 100% output, with the countdown timer, for up to 2 hours.
b) 100% output permanently (without countdown timer).
c) 75% output, using mechanical segment timer with three segments
set to switch ON per hour. (one segment equals 15 minutes).
d) 50% output, using mechanical segment timer with two segments
set to switch ON per hour.
e) 25% output, using mechanical segment timer with two segments
set to switch ON per hour.

AM5000 Doc No. 290-062-00 Rev. A June 2005
5.2 Control Options.
The operation of the unit will vary depending upon the type of control panel fitted.
These instructions describe how to operate the unit with the various options.
The following information is common to all control panels:
Ensure doors and windows of the room to be treated are closed and place
warning notices stating “CAUTION THIS ROOM IS BEING OZONISED DO
NOT ENTER BETWEEN XX O’CLOCK AND XX O’CLOCK” at the entrances.
If you need to enter an Ozonised room with a high Ozone concentration, use a
mask. A suitable Ozone mask is 3M Respirator type 9925.
NOTE: the time spent in the room must be kept to a minimum.
The Ozone will change back to Oxygen within 3 hours when the recommended
settings are used. After this time it is safe to enter the room without a mask.
This decay period must be allowed for when calculating the time it is safe to
return to the room.
If the desired result is not achieved completely in the first instance, the process
can be repeated as many times as is required until the desired results are
achieved.
5.2.1 Two Hour Countdown Control Panel.
Set the timer to the desired duration, up to a maximum of two hours.
Connect the unit to the electrical supply and start treatment.
Once the timer duration has completed the unit will turn itself off.

AM5000 Doc. No. 290-062-00 rev. A June 2005
5.2.2 ON/OFF Control Panel.
Connect the unit to the electrical supply and start treatment. The red mains
switch on the control panel will illuminate to indicate that the unit is running.
It is recommended that this panel is used in conjunction with an external power
switch or plug in timer to turn the unit off remotely. If this is not possible use a
protective mask to enter the room and switch off the unit.
5.2.3 Mechanical Segment Daily Timer (Mains socket plug in type).
The timer is for indoor use only.
Unplug the timer before setting times.
The timer will turn the unit ‘on’ and ‘off’ up to 48 times per day.
a) Setting switch OFF times:
With your finger, pen or small screwdriver, pull up segments corresponding
to the required OFF period.
Check that you cannot see ‘red’ against the rim of dial.
Note: each segment represents 15 minutes; 4 segments equal 1 hour.
b) Setting switch ON times:
With your finger, pen or small screwdriver, push down all segments
corresponding to the required ON period. Check that you can see ‘red’
against the rim of dial.
c) Setting current time:
Turn the dial clockwise (as per indicating arrows) until the current time of day
is set against the arrowhead (24 hour clock). Check that segments have not
been accidentally pushed when rotating the dial.

AM5000 Doc. No. 290-062-00 rev. A June 2005
d) Connecting the generator:
Plug the generator into the socket of the timer and insert the timer into a
socket outlet. Ensure the outlet socket is switched on.
e) Timed switching:
Ensure the red slide switch on the side of the timer is set to the centre (AUTO)
position, with the clock face symbol.
f) Manual override:
To switch the plugged in generator permanently on, set the red slide switch on
the side of the timer to the ‘1’ ON position.
To switch the plugged in generator permanently off, set the red slide switch on
the side of the timer to the ‘0’ ON position.
Usage –Important
The timer is rated at 13 Amps (resistive load) and 4 Amps (inductive load).
If you have any queries regarding the operation of the various control panels
please contact your supplier.
6.0 MAINTENANCE AND SERVICING.
The exterior of the unit requires an occasional wipe with a damp cloth to maintain
its appearance, do not use abrasives.
Servicing of the unit must be carried out by a competent person who has read and
understood the instructions.
The service frequency will vary depending upon the output setting and the
environments in which the unit has been used in.
A guide to maintenance and service of the unit is:
6.1 Weekly: Check the operation of the fan.
Switch on the power supply to the unit.
Check that the fan is rotating freely. If the fan is faulty please refer to the
Annual service section for details on how to replace it.
6.2 Three Monthly: Check and clean the inside of the unit.
Isolate the mains supply to the unit.
Remove the lid of the unit by undoing (anti-clockwise) the 8 quarter turn
fasteners.

AM5000 Doc. No. 290-062-00 rev. A June 2005
NOTE: the lid has an earth lead attaching it to the base, take care when
removing the lid not to stress the lead.
Check the overall condition inside the unit and remove any debris.
Check that all the electrical connections are in good condition.
Clean the surface of the generator cell plkate, highlighted in the diagram below,
using a cleaning wipe*, ensuring that the surfaces are free of all deposits, some
of these deposits may be difficult to see.
* Please see the spares list for details of the cleaning wipe.
6.3 Annually: Replace the generator cell plate and fan assembly.
Isolate the mains supply to the unit.
Remove the lid of the unit by undoing (anti-clockwise) the 8 quarter turn
fasteners.
NOTE: the lid has an earth lead attaching it to the base, take care when
removing the lid not to stress the lead.
Check the overall condition inside the unit and remove any debris.
Check that all the electrical connections are in good condition.
Unplug the red and black generator cell connectors from the bulkhead.
Unplug the Live and Neutral connectors and undo the earth connection from
the fan, do not lose the shakeproof washer and screw as you will need these to
re-connect the earth to the new fan.
Undo the four nuts that secure the fan to the base and lift out the assembly.
Replacement of the new assembly is the reverse of the removal.
6.4 To replace a damaged/faulty generator cell plate assembly.
Remove the lid as described above to gain access to the cell.
Pull the black and red connectors free from the sockets.
Using a suitable 7mm across flats spanner or socket spanner
remove the two nuts and washers securing the plate support
bracket.
Retain the nuts and washers.
Replacement of the new assembly is the reverse of the removal.

AM5000 Doc. No. 290-062-00 rev. A June 2005
GENERATOR FAN PLATE ASSEMBLY
PLATE SUPPORT BRACKET
CLEAN THIS SURFACE ENSURING
ALL DEPOSITS ARE REMOVED.

AM5000 Doc. No. 290-062-00 rev. A June 2005
7.0 TROUBLESHOOTING
Fault
Possible Cause
Suggested Action
No power to unit
Power not switched on
Fuse in plug blown
Switch on power
Replace fuse (3A)
No Ozone smell
Generator cell(s) not
connected.
Generator cells damaged
Generator cell(s) dirty
Check and correct
Replace damaged cell(s)
Clean cell(s)
No airflow through
unit
Fan not connected
Fan faulty
Filter blocked (if fitted)
Check and correct
Replace fan
Clean or replace filter.
8.0 SPARE PARTS
Description
Model
Stock No:
Generator Cell Assembly
5100/5200
400-201-00
Fan
5100/5200
060-010-00
Cleaning Wipe
N/A
010-069-00
9.0 UNIT SPECIFICATIONS
5100/5200
Length
430mm
Width
340mm
Height
205mm
Weight
5.5Kg/6Kg
Electrical Supply
230Vac, 50-60Hz
Power Rating
5100 - 50W / 5200 -
100W
Enclosure material
White Powder Coated
Aluminium
Ozone Output
5100 = 0-1g/hr ±20%
5200 = 0-2g/hr ±20%

AM5000 Doc. No. 290-062-00 rev. A June 2005
Appendix A
SETTING GUIDE
1) Calculate the room volume (length x width x height)
2) Set the output of the machine to suit the room size and odour by altering the timer.
3) Each segment on the timer is equivalent to 15 minutes.
For example, to run the generator for 30 minutes per hour for 2 hours: (a) push down two segements at the
time setting you want the generator to start; (b) leave the next two segments "up"; c) push down the next
two segments.
4) Do not enter the treated room until at least two hours after the ozone generator has stopped.
Example
A room measures 20m x 5m x 3m. So its volume is 300m3
From the chart, the unit can be set at any level to be effective at removing odours. The stronger the odour
the higher the setting.
If the room to be treated is clear of people at 18.00hrs and access is not needed until 07:00hrs the following
morning, the timer should be programmed to turn on at 19:00hrs, run for 9 hours and turn off at 04:00hrs the
following morning.
This will allow 3 hours for the room to be safe to enter.
The warning signs on the entrances should state that the room should not be entered between 18:00hrs and
07:00hrs.
ROOM
VOLUME
timer setting (mins per hour)
m3
15
30
60
100


X
150


X
200



300



400



500



600



700



800



900



1000



1500



2000



Note
:
15 minutes = 1 segment in 4
30 minutes = 2 timer segments in 4
60 minutes = 4 timer segments in 4



X
NOT RECOMMENDED

RECOMMENDED


OZONE LEVEL TOO LOW TO BE EFFECTIVE