ProMinent Bono Zon BONa User manual

Operating Instructions
for Ozone Generating System
Bono Zon®Type BONa
ProMinent
®
Part No. 987951 ProMinent Dosiertechnik GmbH ·69123 Heidelberg ·Germany BA BOZ 011 04/06 GB
Please read through these operating instructions in full before use. Do not discard!
Damage caused by incorrect operation will invalidate the guarantee.
The manufacturer is not liable for any damage caused by failure to follow operating instructions.
Please enter identitycode of the device here.
BONa A 1 T
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ProMinent®
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Legal notice:
Operating Instructions for Ozone Generating System
Bono Zon®Type BONa
© ProMinent Dosiertechnik GmbH, 2003
Address
ProMinent Dosiertechnik GmbH
Im Schuhmachergewann 5-11
69123 Heidelberg
Germany
Phone: [phone]
Fax: [phone]
[email protected]
www.prominent.com
Subject to technical modifications.
Printed in Germany
Legal notice

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Table of Contents
Page
General user guidelines .............................................................................................................. 6
AInstructions for regulation use ......................................................................................... 7
BObligations of the user .................................................................................................... 7
CInstructions for introducing operators to ozone generating system ............................... 7
D Information on general safety .......................................................................................... 8
E Emissions ........................................................................................................................ 10
FTerms and abbreviations used ........................................................................................ 10
1Introduction .................................................................................................................... 11
1.1 Ozone .............................................................................................................................. 11
1.1.1 Properties of ozone ............................................................................................. 11
1.1.2. Generation .......................................................................................................... 11
1.2 Definition of terms ........................................................................................................... 12
1.2.1 Ozone system ..................................................................................................... 12
1.2.2 Ozone generating system ................................................................................... 12
1.2.2.1 Ozone generator ................................................................................................. 12
1.2.2.2 Ozone generating element .................................................................................. 12
1.2.3 Mixing station ...................................................................................................... 12
1.2.4 Reaction tank ...................................................................................................... 12
1.2.5 Removal system for residual ozone .................................................................... 12
1.2.6 Partial-vacuum system ....................................................................................... 12
1.3 Functional description of ozone generation .................................................................... 12
2 Construction of a Bono Zon®ozone generating system ........................................... 13
2.1 General series structure .................................................................................................. 13
2.2 The air drying system ...................................................................................................... 14
2.2.1 Starting regeneration - manual ........................................................................... 14
2.2.2 Pausing regeneration .......................................................................................... 14
2.2.3 Starting regeneration after manual interruption .................................................. 15
2.3 Ozone generation ............................................................................................................ 15
2.3.1 Cooling water ...................................................................................................... 15
2.3.2 Air flow meter ...................................................................................................... 15
2.4 Electrical part of system .................................................................................................. 16
2.4.1 Control ................................................................................................................ 16
2.5 Setting of ozone generation ............................................................................................ 16
2.5.1 Manual setting of ozone generation (for Type BONa xx xSx-...) ......................... 16
2.5.2 Automatic setting (for Type BONa xx xRx-...) ..................................................... 16
2.5.2.1 Manual setting (condition as delivered) .............................................................. 16
2.5.2.2 Ozone metering proportional to the input signal
(e.g. flow-proportional ozone metering) .............................................................. 17
2.5.2.3 Controlled ozone metering.................................................................................. 17
2.5.2.4 Interval function .................................................................................................. 17
2.6 High voltage transformer ................................................................................................. 18
2.7 Indicators during operation ............................................................................................. 18

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2.8 Monitoring systems ......................................................................................................... 18
2.8.1 Interlocking contact for ozone generation .......................................................... 19
2.8.2 Door contact switch ............................................................................................ 19
2.8.3 Emergency switch ............................................................................................... 19
2.9 Stainless steel ozone generator ...................................................................................... 20
2.9.1 Definition ............................................................................................................. 20
2.9.2 Structure and function ........................................................................................ 20
2.9.3 Cooling water ...................................................................................................... 20
3Assembly and installation ............................................................................................. 21
3.1 Operation room requirements ......................................................................................... 21
3.2 Setting up the system ..................................................................................................... 21
3.3 Cooling water connection ............................................................................................... 21
3.4 Waste water connection .................................................................................................. 21
3.5 Ozone line connection ..................................................................................................... 22
3.6 Electrical connections ..................................................................................................... 22
4Commissioning .............................................................................................................. 23
4.1 Inspection before commissioning ................................................................................... 23
4.1.1 Inspection by expert ........................................................................................... 23
4.1.2 Checks to be carried out before commissioning ................................................ 23
4.1.3 Work on open ozone cabinet .............................................................................. 24
4.1.4 Regeneration of the adsorber ............................................................................. 24
4.2 Commissioning ................................................................................................................25
4.2.1 Setting the cooling water .................................................................................... 25
4.2.2 Starting the ozone system .................................................................................. 25
4.2.2.1 Setting air flow .................................................................................................... 25
4.2.2.2 Checks before turning on high-voltage .............................................................. 26
4.2.2.3 Starting ozone generation ................................................................................... 26
4.2.3 Check of circuit and voltage readings ................................................................ 26
4.2.4 Operations clock ................................................................................................. 26
4.2.5 Cabinet thermostat ............................................................................................. 26
5 Operation ........................................................................................................................ 27
5.1 Starting up ozone generation .......................................................................................... 27
5.2 Turning off ozone generation ........................................................................................... 27
5.3 Operational checks ......................................................................................................... 27
5.4 Restarting after standstill ................................................................................................. 27
5.5 Restarting after error message ........................................................................................ 28
5.6 Autoreset after mains power failure (option).................................................................... 28

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6Troubleshooting ............................................................................................................. 28
6.1 LED in fig. 3-1 lights up red ............................................................................................. 28
6.2 LED in fig. 3-3 blinks green ............................................................................................. 29
6.3 LED in fig. 3-6 lights up red ............................................................................................. 29
6.4 LED in fig. 3-8 lights up red ............................................................................................. 29
6.5 LED in fig. 3-9 blinks red ................................................................................................. 29
6.6 LED in fig. 3-10 lights up red ........................................................................................... 29
6.7 LED in fig. 3-12 blinks yellow .......................................................................................... 29
6.8 LED in fig. 3-12 lights up yellow ...................................................................................... 29
7Maintenance .................................................................................................................. 30
7.1 Testing BONa ozone generating system ......................................................................... 30
7.2 Testing supplementary devices of ozone generating system.......................................... 31
7.2.1 Injector ................................................................................................................ 31
7.2.2 Exhaust valve ...................................................................................................... 31
7.2.3 Residual ozone eliminator ................................................................................... 31
7.2.4 Other checks ....................................................................................................... 31
7.2.5 User obligations .................................................................................................. 31
8Technical specifications for BONa systems ............................................................... 32
8.1 Input gas .......................................................................................................................... 32
8.2 Cooling agent .................................................................................................................. 32
8.3 Rated ozone concentration ............................................................................................. 32
8.4 Operating frequency and connected load ....................................................................... 32
8.5 Setting range for ozone generation ................................................................................. 32
8.6 Conditions for surroundings ............................................................................................ 32
8.7 Phases for adsorber regeneration ................................................................................... 32
9Illustrations .................................................................................................................... 35

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General user guidelines
Please read through the following user guidelines! They will help you to gain the maximum use
from this manual.
The following are highlighted in the text:
•Numbered points
Instructions
Operating instructions:
NOTE
Notes are intended to make your work easier.
and safety instructions:
DANGER
Describes an imminent danger. If not avoided could lead to death or extremely serious
injury.
WARNING
Describes a potentially dangerous situation. If not avoided could lead to death or extremely
serious injury.
CAUTION
Describes a potentially dangerous situation. If not avoided, could result in slight or minor
injury to persons or property.
General user guidelines

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AInstructions for regulation use
A.a Regulation Use
Ozone generating systems are made only for the disinfection of water and may not be used for
any other purpose.
NOTE
Ozone (O3) decomposes during and after use to ordinary oxygen.
As a gas, ozone has a half-life of between 30-40 min., depending on the temperature.
Dissolved in water, ozone’s half-life is reduced to a few minutes.
The maximum allowable concentration at a place of work (according to German regulations)
is 0.2 mg/m3.
A.b Non-regulation use
WARNING
Under no circumstances should ozone generating systems be used for the treatment of
gaseous substances, liquids other than water, or for treating any solid material.
BObligations of the user
This operating manual should be available to all supervisors and operating personnel and kept
readily accessible near the ozone generating system.
The user must ensure that ozone generating systems are only used and operated by specially
trained, expert persons. It is recommended to have operators confirm that they have been
trained and introduced to the system.
The manufacturer should be notified immediately in the event of technical problems that could
effect the health of persons having contact with water treated by the system.
After installation of the system by trained personnel, the system must be tested and approved for
use by an expert authorised by ProMinent.
NOTE
The operator has the duty to create a working directive (including instructions for avoiding
danger, and an alarm plan) taking into account the local conditions on site.
As further sources of information apart from the operating instructions manual, the following
German directives of the main league of the trade associations and of the trade association
of the chemical industry can be taken into consideration too:
a) ZH 1/474 “Directives for the use of Ozone in water processing”
b) ZH 1/262 “Specification leaflet 052 Ozone”
CInstructions for introducing operators to ozone
generating system
It is mandatory that all chapters of this operating manual, especially those describing the ozone
generating system and their commissioning be carefully read.
An expert from ProMinent must give operators a detailed introduction as part of the commissioning
of the system.
This manual will provide enough information to answer almost all questions arising from
malfunctioning. In addition, the user is responsible that extensions of the system, such as ozone
transfer system, reactor tank, exhaust, etc., are properly maintained, and that environmental
conditions are satisfactory for usage of an ozone generating system. Questions necessitating
more detailed information should be addressed to the manufacturer of the system.
General Use

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DInformation on general safety
CAUTION
This operating manual is to be made available to all operating personnel and kept readily
accessible near the ozone generating system (see section B).
D.a Relevant guidelines and regulations
Bono Zon®Systems are manufactured in compliance with the following regulations effective in
Germany: "Ozon in der Wasseraufbereitung" (ozone in treatment of water) and the "Unfallverhü-
tungsvorschriften" (accident prevention regulations) BGZ; ZH/471, 1994 edition.
CAUTION
When installing and using ozone generating systems, the following German regulations and
ordinances or similar national regulations must be observed and the systems operated in
accordance there of:
a) the "Unfallverhütungsvorschriften" (accident prevention regulations) – GUV 18.13 in the
version of Oct. 1986.
CAUTION
§12 (1-5) prescribes personal protective gear that the user must provide.
b) the "Verordnung über gefährliche Arbeitsstoffe" (ordinance on dangerous working materials)
(Arb-StoffV), in the version of 11 Feb. 1982 BGBI/p. 145.
D.b Requirements for starting components in the production of ozone gas in
Bono Zon®BONa Systems
For process safety reasons, the dewpoint of the initial gas, the cooling water temperature and
pressure must remain within the prescribed limits (see sections 8.1 and 8.2).
CAUTION
After finishing treatment of water for drinking purposes there may not be any impurities left
in concentrations dangerous to human health. In this respect see “Gesetz über den Verkehr
mit Lebensmitteln und Bedarfsständen” (act governing contact with food and public sale
thereof) (Lebensmittelgesetz/Food Act).
Production within specifications other than those in Ch. 8 is permissible only with the
expressed consent of the manufacturer.
D.c Additional information on safety
CAUTION
Any rooms in which the ozone generating system and the mixing station are placed must
be locked when not in use. No persons may be allowed to remain in these rooms over
longer periods of time. It must be adequately ventilated and protected against frost.
Rooms containing ozone generating systems must be separated by fire walls from all other
rooms.
In case of accident:
Should ozone be emitted from the system, observe relevant safety regulations
(see ZH1/474) when taking necessary action.
General Use

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DANGER
The system must be installed in such a manner that ozone cannot be emitted into any rooms
under any circumstances.
WARNING
In the event that water to be treated should fail to flow, it must be ensured that the feeding
of ozone will be automatically stop.
The maximum allowable pressure for the system (see section 8.2) may not be exceeded
under any operational conditions.
Disconnect all electric power when mounting system.
CAUTION
The complete system, including pipes, must be free of leaks at maximum operating
pressure (see section 8.2).
Mount signs informing of danger according to GUV 8.15 Annex 2 and 3 (see also section
D.d "Warning signs").
NOTE
The system may be operated only within environmental conditions specified herein
(see Ch. 8).
The ozone system’s reaction tank is covered by the pressure vessel directive. The operator
is responsible for upholding the relevant directives.
D.d Warning signs
CAUTION
The following warning signs must be hung up during installation (see Ch. 3).
Warning signs
The following two signs must be placed together at the place of entrance to rooms used for
Bono Zon®ozone generating systems..
Warning sign "Toxic Substances" Part no.: 607324
Warning sign "Ozone System. Access for Authorized Persons Only" Part no.: 740921
Warning sign "No Fire, Flame or Smoking" Part no.: 607323
General Use
Ozone System
Access for Authorized Persons Only

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EEmissions
During normal usage there are no emissions from ozone generating systems Bono Zon®
Type BONa. For further information on possible emission dangers, see section D “Information
on general safety” and Ch. 8 “Technical speci-fications”.
FTerms and abbreviations used
acc according
approx. approximately
BONa ozone generating system
Ch chapter
ºC degree celsius
fig figure
g/m3grams per cubic metre
hhour
Hz Hertz (cycles per second)
kg kilogram
llitre
LED light emitting diode
mA milliampere
max maximum
mg milligram
mg/m3milligrams per cubic metre
min minute
ml millilitre
PLC program logic control
PN part number
PN 16 nominal pressure (DIN 8062, PVC pipes)
sec second
tab table
Vvolt
General Use