Ozotech AIM BTU 1000 Manual

AIM BTU 1000 & 2000
Ozone Generators
Installation and Service Manual
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Dear Valued Customer:
Congratulations on your purchase of the AIM Series ozone generator!
This user manual was created to help you get the most out of your new device and to
assist you with the initial set up. Please visit ozotech.com to learn more about this and
other products.
Thank you for choosing Ozotech products!

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Read the following safety guidelines thoroughly before attempting to install or operate your
equipment:
SAFETY FIRST
As with all electrical devices, this equipment should never be allowed to come in contact
with water.
Only qualied personnel should be allowed to set up, operate and maintain this
equipment.
Do not use an extension cord to supply power to this equipment.
Use a power conditioner if line voltage uctuates outside of specied range.
Unit must be disconnected from power prior to performing service or repair.
*Ozotech, Inc., assumes no liability for damages or injuries incurred by misuse of this
product.

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Table of Contents
1.0 Theory of Operation 1
1.1 Cold Plasma Corona Discharge Ozone Generation
2.0 Operating Conditions 1
2.1 Operating Environment 1-2
2.2 Internal Air Flow Specications 2
2.3 Input Air Preparation 2
2.4 Input Power Regulations 3
3.0 Maintenance 4
3.1 Corona Discharge Cell Maintenance 4-7
3.2 Intake Filter Maintenance 8
3.3 Chassis Maintenance 8
3.4 Check Valve Replacement 9
4.0 Fusing Specications 10
5.0 Spare/Replacement Parts 10
6.0 Troubleshooting Guide 11-12
7.0 Illustrations 13-16
8.0 Limited Warranty 17
9.0 Service Returns 18

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1.0 Theory of Operation
Your AIM series ozone generator is a state-of-the-art device designed to produce signicant
concentrations of high-purity ozone by means of our proprietary Advanced Impedance
Management technology, “AIM”. The technology utilized by Ozotech, Inc., to generate ozone is
known as “Cold Plasma Corona Discharge”.
1.1 Cold Plasma Corona Discharge Ozone Generation
Cold Plasma Corona Discharge generators create ozone through the action of extremely high
voltage (HV), low current electrical “arcs”across an air space. When oxygen (O2) is passed through
the air space, some molecules are split, resulting in “free” oxygen atoms which quickly attach
themselves to intact O2 molecules. The result is a very unstable form of oxygen, ozone (O3). It is
the extra atom of oxygen that gives ozone its superior oxidation capabilities.
As opposed to plate-type or open-air dielectric corona discharge generators, Cold Plasma Corona
Discharge utilizes a cell lled with proprietary gases. The cell (or cells) are then surrounded by a
perforated stainless steel grid, connected to earth ground. When high voltage is applied to the
cell, an electrical arc, called“corona” is formed between the cell and the grid.
Each cell/grid combination is separately housed within its own holding chamber (manifold).
All air drawn through the manifold is channeled directly through the corona gap. This design
surpasses plate-type corona discharge designs by constantly exposing a fresh supply of oxygen
molecules to the corona, and by keeping the cell and manifold cool. Recent improvements in the
design have led to a method of producing ozone where the cell: 1) Is capable of withstanding
high voltage inputs without plating; 2) Experiences no relative expansion or contraction of the
parts; 3) Is able to operate at lower temperatures than conventional corona discharge generators,
thus improving reliability and eciency without the need for separate cooling water circuitry; 4)
Provides maximum ozone output with minimum high voltage input.
2.0 Operating Conditions
Your AIM Series Ozone Generator requires special operating conditions in order to maintain
top performance and reliability. Warranty coverage of your equipment is contingent upon strict
compliance with the operating conditions specied in this manual.
2.1 Operating Environment
EXTERNAL
Choose a location for your equipment that is clean, dry, and free of excessive airborne particles.
Your equipment requires a constant ow of clean air for proper internal cooling. A minimum of
six (6) inches clearance is required around the front, bottom, left and right sides of the unit to
eliminate the restriction of airow. A minimum of thirty (30) inches clearance is required above
the unit to permit access to the Corona Discharge Cells. Direct exposure to moisture must be
avoided. The AIM series ozone generator chassis is designed to be drip-proof. It is not watertight.
Mount your AIM series ozone generator vertically oriented on a wall in the best possible
operating environment available at your installation site.
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INTERNAL
The operating environment inside the chassis is also important. Maintaining a clean, dry unit will
increase overall performance and extend service life. A common cause of failure is un-contained
corona (electrical arcs) within the chassis environment. Moisture and dust are facilitators of this
condition. They both help set up a “path” for the corona to develop and follow. Once established,
corona usually does not stop until it has become severe enough to cause catastrophic failure of
the corona discharge cell or manifold, and subsequently blows the fuse. Note: If this condition
develops, contact the manufacturer.
2.2 Internal Air ow Specications
As mentioned in the Theory of Operation section, Cold Plasma Corona Discharge relies upon a
ow of air passing between the corona discharge cell and the perforated grid to produce ozone
and keep the corona cell and manifold cool.
The rate at which air is drawn (or forced) through the ozone generator is user adjustable. You
may ne-tune the ow rate to best suit your specic application. However, in no case should the
airow rate be allowed to drop below the minimum values specied below. Failure to provide
minimum airow rates may allow your ozone generator to develop excessive heat, possibly
leading to equipment failure.
The minimum air ow rate is: 3 SCFH (1.5 LPM).
The maximum air ow rate is: 20 SCFH (9.5 LPM).
2.3 Input Air Preparation
Regardless of the method of ozone generation, properly preparing the input air (feed gas) will
pay huge dividends in performance and reliability. Ozotech, Inc. does not recommend the use
of any AIM series ozone generator without air preparation. Warranty coverage of your ozone
generator is contingent upon operation with air preparation equipment.
The key to air preparation is in the removal of hydrogen (H) and nitrogen (N) found in ambient air.
When atoms of hydrogen and nitrogen are subject to corona discharge (cold spark or otherwise),
by-products such as nitrous acid (HNO2) and nitric acid (HNO3) are formed. The formation of
these compounds inhibits performance and increases the frequency of maintenance.
To understand how performance is aected, we must recall from the Theory of Operation section
that ozone is created by splitting an oxygen molecule (O2), and then joining the liberated oxygen
atoms (O) with intact oxygen molecules.
Imagine that in addition to oxygen molecules, your feed gas also contains hydrogen and nitrogen
atoms. After being subjected to corona, some of the hydrogen and nitrogen atoms will attach
themselves to intact ozone molecules, forming HNO3, or nitric acid. Others will attach themselves
to oxygen molecules, forming HNO2, or Nitrous acid. It is the formation of these compounds
that reduces performance potential. It is simple to understand why. If ozone molecules were not
being “used” by hydrogen and nitrogen in the formation of acids, more would be available to be
used in oxidation. Likewise, if oxygen molecules were not“used” to form acids, they would be
available for the creation of more ozone.
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Increased service life and reduction in maintenance are gained due to the same principle. With
less HNO2 and HNO3 being formed, corona discharge cell maintenance, or cleaning the cell, can
be reduced without the risk of acid buildup. Since both HNO2 and HNO3 are highly conductive,
they can produce a path for corona (electrical arcs) outside of the corona discharge cell and
manifold. As stated previously, once an arc has started, catastrophic failure is the usual result.
Your AIM series ozone generator is capable of operating with either negative or positive pressure
air preparation devices. Negative pressure devices, such as heat-regenerated desiccant air dryers
rely upon the action of the venturi injector to draw air through the generator (and the dryer). This
method is typically not utilized with the AIM series, due to the diculties of meeting minimum
airow requirements through the vacuum action of a venturi injector alone. Positive pressure
devices, such as the Power Prep Series manufactured by Ozotech, Inc., utilize an internal air
compressor to push prepared air through the generator. This method is utilized in the majority of
AIM series ozone generator applications.
Your AIM series ozone generator is designed for not more than +/- 5 psi of internal pressure.
2.4 Input Power Requirements
The AIM Series Ozone Generators were developed to accommodate a wide range of world
supply voltages and frequencies. Because of this versatility, they are built without a specic
power cord or plug and will require an appropriate connection to be installed at the desired
installation site. If the customer is unfamiliar with installing power connections and this type
of electrical work, it is strongly recommended that a licensed, and certied professional
be used to perform this connection work. Because many power supply voltages uctuate, it is
recommended to monitor your voltage uctuations, before and after installing this equipment, to
assure it is within acceptable variance values listed below.
Voltage (VAC) = 115 / 230 (+/- 10%)
Frequency (Hz) = 50 / 60 (+/- 10%)
Note: lower frequencies will result in slightly less ozone generation performance
Power consumption, AIM series = Nominally 150 watts (50/60Hz)
Note: If your line voltage uctuates beyond acceptable variance, it will be necessary to connect
your equipment to a line conditioner.
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3.0 Maintenance
The AIM Series Ozone Generator is designed and delivered for maximum eciency and long
life. No adjustments, other than ne-tuning the airow rate to match user-specic requirements,
should be made by the end-user. Simple maintenance and appropriate operating conditions are
the only requirements to keep the unit functioning within manufacturer’s specications.
Performing any other modications or adjustments to internal components will cause the unit to
function outside of manufacturer’s specications and will cause damage to the unit not covered
under terms of warranty. Maintenance should only be performed by qualied individuals. Your
ozone generator operates under conditions of high voltage; maintenance personnel should be
trained in electrical safety.
3.1 Corona Discharge Cell Maintenance
Corona discharge cell maintenance is simply a matter of keeping the cells clean and ensuring the
O-Ring seat is in good condition. AIM BTU 2000 units will have two (2) cell chambers to maintain
while AIM BTU 1000 units will have one (1) cell chamber. Ozotech, Inc., has designed a cell-to-
chamber interface that restricts the corona discharge to only the stainless steel manifold, thereby
reducing any possibility of catastrophic failure due to heat or high voltage arcing.
Frequency of Maintenance: Every 4800 hours (6 months)
To maintain the Corona Discharge Cells:
1. Disconnect unit from power source. Allow generator and room to clear of ozone gas.
2. Loosen the four (4) screws securing the chassis lid and remove the lid assembly.
3. Locate the high voltage wires connected to the top of each corona discharge cell. Pay close
attention to the wire routing. It will be necessary to route in the same manner when
maintenance is complete.
Note: In any case, wires must be routed so that a minimum clearance of 1 inch is provided
between HV wire and chassis (or metal parts attached to chassis).
4. Unplug the CD cell cap high voltage wires from the transformer high voltage wire.
(See Figure 1)
5. Carefully loosen and remove each of the six (6) nylon standos that secure the cap(s) onto the
manifold. Pull each CD cell cap straight o the mounting studs. (See Figure 2)
6. Very carefully remove the CD cell(s) straight out of the manifold assembly. (See Figure 3)
Note: Your corona discharge cells are made of glass, so extreme care must be taken to avoid
breakage!
7. Clean the entire cell and cap with glass cleaner, or soap and water.
DRY THOROUGHLY.
Note: Replacing a wet cell will cause damage to the ozone generator.
8. Install the corona discharge cell(s) by reversing the above steps.
a. Route high voltage wires as close to original routing as possible.
b. The object is to separate these wires from sources of ground, such as the chassis, and
low voltage (115 or 230V) components.
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9. Pressure check your unit.
a. With the unit powered down and a source of positive pressure owing into the unit,
open the airow meter until the indicating ball reaches the top of the scale.
b. Remove the ozone delivery tubing from the venturi injector inlet (or equivalent) and
seal to pressurize the generator and ozone delivery tubing.
c. Using a suitable leak check solution (available through your Ozotech, Inc., dealer) check
for leaks at the tube/chamber interface, tubing connections, etc. Immediately correct
any leaks prior to placing your unit back in service.
Figure 1. CD Cell Interface

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Figure 2. CD Cell Cap Removal and Installation

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Figure 3. CD Cell & Manifold Assembly

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3.2 Intake Filter Maintenance
The intake lter is located on the side of the chassis (See gure 5). This lter removes dust
particles from the air drawn into the chassis. Proper cooling of internal components requires
lters to be clean, dry, and intact.
Frequency of Maintenance: Every 2400 hours (3 months)
To Clean Intake Filter
1. The lter retaining ring snaps into grooves in the fan guard. Remove lter retaining ring by
gently pulling on one side.
2. Remove lter media. Wash gently in soap and water. Dry thoroughly. Inspect for tears, holes,
etc. If lter is intact, replace by reversing Step 1.
Note: Depending on the severity of your specic environment, it may be necessary to increase
frequency of maintenance.
Frequency of Replacement: Every 4800 hours (6 months)
To Replace Intake Filter
Replacement procedure is identical to maintenance procedure.
Note: Depending on the severity of your specic environment, it may be necessary to increase
frequency of replacement.
3.3 Chassis Maintenance
Proper maintenance of your generator chassis will provide more than aesthetic advantages.
Dust and moisture can contribute to a path for electrical arcs. A clean internal environment will
reduce the likelihood of corona outside of the corona cell and manifold.
Frequency of Maintenance: Every 2400 hours (3 months)
To Maintain Chassis
1. Disconnect unit from power source.
2. Remove chassis lid and access cover.
3. Using a clean, dry cloth, carefully wipe o inside of chassis and all internal components.
Make certain that the tops of the corona discharge cell(s), the “face”of the transformer, and
the high voltage wire(s) are thoroughly cleaned.
4. Using a damp cloth, clean the outside of the unit. A mild detergent may be used.
5. Thoroughly dry chassis, inside and out.
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3.4 Check Valve Replacement
Protecting your ozone generator from water inltration is vital. Ozone generators will fail
if water is allowed to enter the corona region. Water inltration can be avoided by proper
installation and maintenance of a Backow Prevention Device between the ozone generator
ozone outlet and the venturi injector (or diuser).
We strongly suggest that the check valve is closely inspected as often as possible, such as each
time maintenance of any type is performed. If water is visible between the check valve and the
ozone generator, cracks are visible in the check valve body, or foreign matter has built up on
the internal O-ring, replacement should be performed immediately regardless of elapsed time
since last replacement. Reference gure 4 for check valve detail.
The required replacement schedule is listed below and must be performed on schedule, even if
the check valve appears sound.
Frequency of Replacement: Every 3 months
To Replace Check Valve
1. Disconnect unit from power source. Allow the ozone generator to clear of ozone gas.
2. Remove tubing from barbed end of the check valve.
3. Trim approximately one inch from the end of each tube, to remove distortion caused by the
hose adapter.
4. Place new check valve assembly in-line, between ozone generator and venturi injector.
Note: Check valve ow direction must point toward venturi.
5. Secure the tubing onto barbs by installing snapper clamps
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Figure 4. 47018-304 Check Valve

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There are two (2) fuses connected to the live source conductor and accessible from the outside
of the chassis. Refer to section 7.0, gure 6 for the locations of the fuse holders. In 115 VAC
applications, only the forward fuse is used. In 230 VAC applications, both fuses are used.
Fuse size and value is listed below:
3.15 Amp, Slow Blow, IEC127
5.0 Spare/Replacement Parts
Part # Description
40155 Cool Tube Replacement
47018-304 Ozone Resistant In-line Check Valve
38097 Cabinet Inlet Filter Media (Qty. 5)
43230 Fuse, 3.15A, Slow Blow, IEC 127
45264-03 AIM/BTU Hybrid PVC Cap
44244 Ozone Resistant Tubing, 1/4” ID x 7/16” OD
44141 Ozone Resistant Tubing, 3/8” ID x 5/8” OD
40147-AB1 Replacement HV Transformer – (Prepped for AIM BTU 1000)
40147-AB2 Replacement HV Transformer – (Prepped for AIM BTU 2000)
Note: The spare parts listed above are only the most commonly purchased items. For items not
included in this list, please consult Ozotech, Inc.
4.0 Fusing Specications
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System Possible Cause Solution
Indicator light does not turn on. Unit is not connected to power source or is
connected to improper power source.
Refer to Input Power Requirements,
section 2.4, or power rating label on
side of chassis for proper electrical
requirements.
Connect unit to proper power
source.
Safety Interlock Switch is not engaged by
chassis lid or access door.
Remove lid and/or open access
door; ensure interlock arm fully
contacts lid/door.
Fuse is blown. Visually inspect unit and compare
wiring to diagram. Inspect Corona
Discharge Cell for damage or
corrosion. Inspect High voltage
wires for disconnection or signs or
arcing.
Repair any and all wiring issues pri-
or to placing unit back into service,
or contact Ozotech, Inc. for techni-
cal support.
Light is not receiving power. Connect light power leads to
correct power source per wiring
diagram.
Light has failed. Contact Ozotech, Inc. for
replacement part information.
Unit keeps blowing fuses Electrical short circuit. Visually inspect unit and compare
wiring to diagram. Inspect corona
discharge cell for damage or
corrosion. Inspect high voltage
wires for disconnection or signs or
arcing.
Repair any and all wiring issues
prior to placing unit back into
service, or contact Ozotech, Inc. for
technical support.
Incorrect fuse value or type. Refer to section 4.0 for correct fuse
information. Refer to section 5.0 for
replacement fuse part number from
Ozotech, Inc.
Replace fuse(s) with correct value/
type before placing unit back into
service.
6.0 Troubleshooting Guide
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System Possible Cause Solution
Corona Discharge Cell(s) were not installed. Install cell(s) per Quick Start Guide.
corona discharge cells are shipping
in separate boxes to avoid shipping
damage.
Corona outside of the manifold has estab-
lished due to dirt, moisture, or improper
wire routing.
Corona Discharge Cell may be in need of
maintenance.
Perform corona discharge cell
maintenance procedure found in
section 3.1.
Replace any defective
components before placing unit
back into service.
Unit does not produce adequate
concentration of ozone.
Air ow rate is too high. Adjust air ow meter to lower
setting, within range of specied
Air Flow Specications, found in
section 2.2.
Unit is running to hot due to insucient
cooling air ow
Refer to the Air Flow Specications,
section 2.2.
Ensure intake air lter is clean, dry
and undamaged. Perform any
necessary maintenance before plac-
ing unit back into service.
Unit is connected to improper power
source.
Refer to Input Power Requirements,
section 2.4, or power rating label on
side of chassis for proper electrical
requirements.
Connect unit to proper power
source.
Unit does not produce adequate
concentration of ozone, even with
an air ow rate that previously
produced adequate ozone con-
centration.
Corona Discharge Cells require mainte-
nance.
Refer to section 3.1 for corona
discharge cell maintenance.
Air preparation device is not functioning at
prior level or performance.
Inspect and/or maintain air
preparation equipment in accor-
dance with manufacturer
Water has backed up into the
ozone unit
Failed or missing in-line check valve or BF-1
on ozone output tubing.
Thoroughly dry manifold and
tubing.
Clean or replace CD cell.
Replace or install a new in-line
check valve and/or BF-1, as appli-
cable.
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7.0 Illustrations
Figure 5. Front Exterior View Figure 6. Left Side Exterior View
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Figure 8. Left Side Interior View
Figure 7. Front Interior View
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Figure 9. Right Side Interior View
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Figure 10. AIM BTU 1000/2000 Wiring Diagram
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