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
___ ___ ___ ___ ___ ___ ___ ___ ___ ___

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

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Introduction
1Introduction
The use of ozone has undergone a history of ups and downs since its discovery (by Schönbein
in 1840). In 1857 the ozone tube was invented by W. von Siemens. In 1873 Fox detected the
germ-killing effect of ozone, necessary for the use of this substance in the treatment of water.
At the turn of the century ozone was first introduced in waterworks for disinfection (at waterworks
in Schierstein, Wiesbaden, Paderborn). The ozone process was slowly becoming accepted; the
first large waterworks using ozone were constructed (Nizza in 1906, St. Maur, Paris in 1909,
St. Petersburg in 1910).
In the 1920s, use of ozone was replaced by the more economical and technically simpler indirect
chlorination. Although understood by then, the technological advantages of the ozone process
were slowly forgotten.
It was only in the 1950s that the “old” procedure was rediscovered. It came back into use not
only as a disinfectant, but also as an oxidation agent inside of treatment plants. At first it was
used in drinking water treatment, then it spread to the production of mineral water, and in the
1960s it became part of swimming pool technology.
Today ozone is used in many areas of water treatment, in processing exhaust and sewage and as
an oxidation agent in chemical reactions.
ProMinent recognised the significance of ozone technology very early and has been for years one
of the leading manufacturers of small and mid-sized ozone systems. Above all, new standards
have been set in the area of control technology and in the manufacturing of compact systems.
The systems in the Bono Zon®and OZONFILT®product lines stand for modern ozone technology.
1.1 Ozone
1.1.1 Properties of ozone
Ozone is an energy-rich modification of oxygen. In concentrated form it is a noticeably blue gas
that is about 1.5 times heavier than air. In the event of leakage, it can accumulate for this reason
in rooms located at a lower level.
Characteristic is the smell of ozone (Greek: “ozein” - to smell), which is perceptible even in
concentrations as small as 1 to 500,000. One notices the typical ozone smell often after powerful
flashes of lightening or near frequently used copying machines.
Ozone can be used to oxidise many chemical compounds, and this can be utilised in the treatment
and disinfection of drinking water, water for industrial use, swimming pool water and sewage.
A significant advantage of ozone as a disinfectant and oxidant is that it decomposes into oxygen,
which is already present in water.
Ozone in a gaseous state has a half-life of between 30 to 40 min., depending on the temperature.
When ozone is dissolved in water, its half-life is reduced to a few minutes.
DANGER
Ozone is poisonous! Concentrations of 10 g/m3are life-endangering and lead to difficulties
in breathing, irritation of the throat, unconsciousness within a short period of time.
The maximum concentration at place of work allowed by German regulations is 0.2 mg/m3.
1.1.2. Generation
Ozone is generated by silent electrical discharge. Using the ozonisator technique developed by
Siemens, air is lead between the two poles of a high voltage field. The oxygen in the air is
transformed into ozone in the presence of blue-violet light. Using common air as the input gas
mixture, it is possible to reach concentrations of approx. 20-35 g ozone/m3.
Necessary conditions for the faultless generation of ozone are dry air free of dust and a satisfactory
means of eliminating heat.
See fig. 1a: Principle of ozone generation and fig. 4: Mixing equipment.
The generation of ozone is influenced by the following factors:
•Volume flow of gas used (this also affects the concentration of ozone)
•high-voltage applied
•temperature of cooling water
•dewpoint of gas used

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1.2 Definition of terms
1.2.1 Ozone system
Ozone system designates the entire system, including: ozone generating system
(example: Bono Zon®Type BONa), mixing apparatus, reactor case and removal system for
residual ozone.
1.2.2 Ozone generating system
The ozone generating system is that part of the system which actually serves to generate ozone.
This includes air treatment, ozone generator and electricity control.
1.2.2.1 Ozone generator
That part of the system in which the ozone generating elements are built (in the case of
BONa-systems, 14 or 19 glass tubes with internal high-voltage electrodes). The ozone generator
is kept at operating temperature by the cooling water.
1.2.2.2 Ozone generating element
Glass tube in which air is subjected to silent electrical discharge. Inside the glass tube is the
high-voltage electrode; ozone forms between the side of the tube and the electrode.
1.2.3 Mixing station
The mixing station is that part of the system in which gas coming out of the ozone generating
system is mixed with water. In standard models, the mixing station consists of mixer housing,
injector, booster pump and necessary accessories.
Note that use of the oxidising power of ozone depends on how much of the ozone goes into
solution. The mixing is accomplished in Bono Zon®Systems by way of an injector utilising the
principle of partial currents (approx. 90 % efficiency). Basis for a correct estimation is, among
other things, the total volume flow of water, the size of the ozone dosage and the pressure at the
point of dosage (mixer housing).
1.2.4 Reaction tank
The reaction with material in the water takes place in the reaction tank. The tank is situated at the
end of the mixing process, provided that the introduction of ozone and its reaction does not take
place in the same part of the system. Furthermore, air enriched with ozone is separated again in
the reaction tank from the flow of water and emitted as exhaust.
1.2.5 Removal system for residual ozone
This is the part of the system where ozone not used in the reaction decomposes.
1.2.6 Partial-vacuum system
In the case of partial-vacuum systems (e.g., Bono Zon®Systems Type BONa), ozone generators
and lines directing the flow of gas with ozone are subjected to a partial vacuum up to the place of
mixing. In this way the discharge of ozone through possible leakage is prevented.
1.3 Functional description of ozone generation
Bono Zon®Ozone Generating Systems, Type BONa, generate ozone in a partial vacuum, using
oxygen taken from the ambient air. The input gas (ambient air) is drawn through the ozone
transfer system, dried and purified in the air treatment system. It then passes through an air
flowmeter and reaches the ozone generator. Here ozone is generated by silent electrical
discharge and passes on to the mixing station.
glass tube
cooling water
inner electrode
cooling water (opposite pole)
glass tube
A 701.01b
high voltage
air
air
Fig. 1a Principle of ozone generation in the BONa XA (X = 1, 2, 3, .... 9) systems with PVC generator
Introduction

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Construction of a Bono Zon®ozone generating system
2Construction of a Bono Zon®ozone generating system
NOTE
All Bono Zon®ozone generating systems are built conforming to current German regula-
tions. We strongly recommend reading the corresponding regulations which govern
operation in your country.
Bono Zon®ozone generating systems consist of three components:
•air treatment system
•ozone generation
•electricity control
In the case of small systems, all components are housed in a standard control cabinet. Larger
systems are distributed into several cabinets. The construction principle is the same for all
systems.
See also fig. 2b: Construction of a Bono Zon®ozone generating system (appendix).
These systems are listed as partial-vacuum systems and conform to the highest safety standards.
By way of electronic control (SPS), all processes can be monitored. This makes early error
detection possible, protecting the user against expensive repairs and lengthening the lifetime of
the system considerably. By way of built-in automatic adjustment of ozone production, certain
models make continuous adaptation to particular needs possible.
2.1 General series structure
The product line BONa begins with 40 g/h ozone output. Maximum level per ozone generator is
80 g/h. This results in the following product line:
BONa 1 B 40 g ozone per hour
BONa 1 A/D 80 g ozone per hour
BONa 2 C/E 120 g ozone per hour
BONa 2 A/D 160 g ozone per hour
BONa 3 A/D 240 g ozone per hour
BONa 4 A/D 320 g ozone per hour
BONa 5 A/D 400 g ozone per hour
BONa 6 A/D 480 g ozone per hour
BONa 7 A/D 560 g ozone per hour
BONa 8 A/D 640 g ozone per hour
BONa 9 A/D 720 g ozone per hour
Apart from ozone output, other system features may vary, depending on the model:
• setting the ozone output is carried out continuously by way of the adjusting knob of the
regulating transformer, or automatically by way of a motor-driven variable-voltage transformer.
The latter is triggered by an ozone online sensor (or redox detector) connected to a controller.
•Power and power protection of booster pump integrated in the control cabinet.
•Supply voltage: 230/400 V
•Power frequency: 50 or 60 Hz
An identcode (identification code) has been introduced to clearly define the system
characteristics.
See identcode for BONa systems, fig. 6 (appendix).

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2.2 The air drying system
The ozone system is designed with a two-stream adsorber drier and hot air regeneration, which
enables continuous ozone generation.
The adsorber drier system is designed for a rel. humidity of 60 % at 30 °C. Short-term overload
of the drier system caused by weather conditions poses no problems. Higher temperatures and /
or higher humidity over a longer term are to be avoided. The air intake must be pre-treated or
taken from another room in this case.
Care should be taken to ensure that the warm, humid exhaust regeneration air does not cause
any change to the specified ambient climatic conditions. Otherwise air must be diverted out of
the installation room via special valves.
The air-drying system is designed as a two-stream adsorber drier system (Fig. 1-3). The process
air is passed through a desiccant. The desiccant adsorbs the moisture from the air and the
resulting dry air can then be used for ozone generation. The heat produced by the adsorption is
driven off by convection. From adsorber size I 250 K) (BONa 2), cooling is fan-assisted. Generally,
one adsorber drier is in operation while the second is regenerated. A light on the adsorber is lit
green when that adsorber is in operation Fig. 3-3.
The operating and regenerating times are fully automated and controlled by the control. The
regeneration time depends on the amount of moisture stored in the adsorber.
After the operating period has finished (maximum 16 hours) the system automatically switches to
the second adsorber while the first is regenerated. Regeneration is achieved by blowing hot air
back through the desiccant. The regeneration fan (Fig. 2 b-22) forces the air into the lower
section of the adsorber where it is heated before reaching the desiccant. The temperature of the
regeneration air is controlled by a thermostat and the heater is switched on and off accordingly.
The LED, Fig. 3-1, is lit green during the heating phase of the regeneration.
Regeneration ends when the temperature reaches the upper thermostat switching limit in the top
section of the desiccant. The duration of the heating phase is limited. If the upper thermostat
switching limit is not reached within the specified time (maximum: 7 hours) the system registers a
fault, LED Fig. 3-1 lights up red.
Once complete, regeneration is followed by the cooling phase. This lasts 9 hours. The LED Fig.
3-1 flashes green throughout this period. Once the cooling phase is over the control switches to
the just-regenerated adsorber.
2.2.1 Starting regeneration - manual
Regeneration can be started manually using the yellow pushbutton in the open door of the
control cabinet. To start the regeneration process, press the yellow button, close the door of the
control cabinet once more and then press the “Reset error” button, Fig. 3-13.
2.2.2 Pausing regeneration
Press the yellow push button to pause regeneration. The LED Fig. 3-1 then lights up red.
In case regeneration is interrupted before reaching the breakthrough temperature, the adsorber
cannot be placed in operation again.
Construction of a Bono Zon®ozone generating system

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2.2.3 Starting regeneration after manual interruption
After regeneration has been interrupted, it can be started again by repeatedly pushing the yellow
button. After push-ing the yellow button, close the door to the control cabinet and push the
“failure re-set” button (fig. 2-13). The regeneration process will continue until the heating phase is
finished.
In case the breakthrough temperature has not been reached, the heating phase can be repeated
by pressing the yellow button.
2.3 Ozone generation
The ozone is produced in the ozone generator (Fig. 2b-1). The ozone generator comprises
individual ozone generating elements with external glass tubes containing high voltage
electrodes. The air required to produce the ozone is fed between the glass tubes and the metal
electrodes (see Fig. 1a). A high voltage alternating current is applied to create a corona, by which
means part of the oxygen in the air is transformed into ozone. The discharge voltage can be
altered by the regulating transformer to adjust the performance of the ozone system.
2.3.1 Cooling water
The cooling water flows through the ozone generator from the bottom to the top (Fig. 2 b-13, 14).
The specified flow is monitored by a float and orifice-type flow monitor with a latching contact. A
thermostat monitors the temperature of the cooling water. Water used as cooling water should be
clean (in accordance with specification) and have a max. temperature of 25 °C . A higher
temperature will lead to a reduction in the ozone generation. In this case, the operator should
contact the manufacturer.
Cooling water should be available at a minimum pressure of 1.5 bar. Special cooling water
pipework is necessary for lower pressures. The flow of cooling water is regulated by way of the
corner valve (fig. 2b-11). If several ozone generators are present in the system, then each
generator has its own corner valve. The same amount of cooling water must flow through each
generator.
The stop valve and the pressure regulator are to be added upstream from the cooling water
connection. A filter should be fitted upstream if cooling water is contaminated.
A solenoid valve is located upstream from the corner valve (fig 2b-12). As soon as ozone
generation shuts down, this valve closes automatically.
2.3.2 Air flow meter
A temperature-compensated mass flow meter in the bypass serves as an air flow meter. It is
connected to a perforated disk in the main airflow line between the adsorber drying facility and
the ozone generator (fig. 2b-16, 17). The flow of air is measured electronically and shown in m3/h
in the display. Calibration of the sensor and setting of the minimum contact are made in the
factory.
Should the flow of air fall below the minimal setting, then the system switches to the failure-mode
(LED fig. 3-6, red).
Construction of a Bono Zon®ozone generating system

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2.4 Electrical part of system
The electrical components (regulating transformer, high voltage transformer and the power
section with the motor safety switch) are housed in the control cabinet. The power section (see
fig. 2b-2, mounting plate assembled) varies according to the size of the system. This section
contains the main protection, the safety switches for the regulating transformer and the high
voltage transformer and also for the heating, rotary current motor and the control transformer.
2.4.1 Control
On the inside of the door are the following: the control, auxiliary relays and operating panel with
controls and display reading.
2.5 Setting of ozone generation
Before using the start/stop button (fig. 3-14), the interlocking contact (see 2.9.1) must be closed
and the main switch turned on. Press the Start/Stop button (Fig. 3-14) to switch on the booster
pump and the ozone generator after a delay period has elapsed.
2.5.1 Manual setting of ozone generation
(for Type BONa xx xSx-...)
Set the ozone generation using the adjusting knob of the regulating transformer (fig. 2b-5). Ozone
generation begins after the ionising voltage is reached. This can be observed by way of the
varying readings of the current and voltage indicators.
The regulating transformer (Fig. 2 b-5) is used to adjust the high voltage and alter the system’s
ozone output.
2.5.2 Automatic setting (for Type BONa xx xRx-...)
In this model, a controller built into the door operates the variable-voltage transformer.
The variable-voltage transformer is set via a motor actuator.
The electronic circuit is designed so that the system runs down when stroke control motor is
switched off by the controller.
The operation of the controller is described in the operating instructions DULCOMETER®D1C,
part 2, measuring value ozone. However, only some functions are available. A new feature is the
simplified manual operation described in ‘manual settings’.
The defaults were specified such that in condition as delivered the ozone generation may be set
manually without necessitating any modifications. For all other modes, the D1C is to be
programmed correspondingly. This requires, however, that the operating menu of D1C is
switched from “restricted” to “complete”.
Operating functions available:
2.5.2.1 Manual setting (condition as delivered)
Set display at controller to PERMANENT DISPLAY 2 using the button “change display”. Set
desired value pressing buttons (e.g. 60 %) and acknowledge using “ENTER”. The value will
then be accepted as regulated value and the variable transformer adjusts to this value when the
system is switched on. Note that the percentage of the regulated value in the range of approx.
30-100 % refers to the ozone performance and not to the position of the variable-voltage
transformer.
When the system is switched off, the variable-voltage transformer adjusts to zero; when the
system is switched on again, the preset value is again adjusted.
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2.5.2.2 Ozone metering proportional to the input signal
(e.g. flow-proportional ozone metering)
a)Input signal 0...20 mA (condition as delivered):
This function is realised as follows: In manual operation, the input signal is added to the regulated
value set to zero as feed forward control. This requires the following operation steps:
Connect signal to terminal feed forward control nominal signal (on the terminal strip “ozone
control”: x 0.1). Set display at controller to PERMANENT DISPLAY 2 using the button “change
display”. Set the manual setting value “M” to 0 % by pressing the buttons and acknowledge
by pressing “ENTER”. The value will be accepted as regulated value and the variable transformer
adjusts to zero. A base load may also be set. The signal line is applied to the feed forward control
nominal signal (on the terminal strip “ozone control”: x 0.1). An incoming signal will be added
to the manual setting value (=0); the incoming value is equal to the regulated value. An evaluation
of the input signal may be performed in the menu ‘servo motor’ through modifying the parameter
‘control range’ (only possible in the complete operating menu).
b)Input signal 4...20 mA:
Set the operating menu in the menu “general settings” to ‘complete’ and then “4...20 mA” in the
menu ‘feed forward control’. Connect signal cable to terminals “standard signal disturbance
value”. For further steps see a).
c)Input signal frequency 0...10 Hz or 0...500 Hz:
Set the operating menu in the menu “general settings” to “complete” and then to “10 Hz” or
“500 Hz” in the menu “feed forward control”. Connect signal cable to terminals “disturbance
frequency”. (For further steps see a).
2.5.2.3 Controlled ozone metering
Connect DULCOTEST®ozone measuring cell or other sensors to terminals “measuring value
input”. Set the operating menu in menu “general settings” to “complete”, then set the measuring
range in the menu “measuring value” to the corresponding signal transmitter. If a DULCOTEST®
measuring cell is used, this cell is to be calibrated. Set menu “control” to “control normal” and
modify the control parameters, if necessary. With regard to controlled metering, base load metering
and feed forward control (addition and multiplication) are possible.
2.5.2.4 Interval function
A remote contact is to be connected to the terminals “input pause”. By opening the contact, the
variable transformer can be ramped down remotely. This function is available with all described
operating functions.
Basic settings of the controller built into the ozone generating system in condition as
delivered:
Calibration: not calibrated
Measuring value range 0 mA = 0 ppm
assignment: 20 mA = 2 ppm
Measuring value control time: OFF
Limit 1: lower: 0.1 ppm
Limit 2: upper: 1.0 ppm
Hysteresis limits: 0.04 ppm
Control time limits: OFF
Servo motor: OK
Metering: O3
Range of regulatet value: 0-100 % of operating range
Control: regulatet value positive O3
Control: manual
Manual metering: 0 % of range of regulatet value
Feed forward control: 0...20 mA
Feed forward control nominal value: 20 mA
Feed forward control, disturbance effect: additive
Feed forward control, max. additive d.: 100 %
Standard signal output: measuring value, 0...20 mA
0 mA = 0 ppm
20 mA = 2 ppm
Identcode: D1CAD0Z10111Z020D
Alarm relay: active
Operating menu: language according to customer, limited version
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Page 18
2.6 High voltage transformer
Reactive power compensated, multiple-immersed dry transformers with separate windings are
used to generate high voltage (fig. 2b-7).
NOTE
High voltage transformers for the type of use required by Bono Zon®Systems are sensitive
to moisture condensation. For this reason, a dry room should be set aside for the operation
room. This problem area is less significant as long as the system is in continuous
operation. Re-starting after an interruption is critical.
2.7 Indicators during operation
LEDs used are one-coloured or two-coloured (green/red). They can light up continuously, blink
slowly or rapidly, depending or operational conditions or malfunction. LEDs come in pairs to
prevent possible failure of an indicator.
During normal operation the following LEDs light up:
• LED system in operation (fig. 3-15), green
•Adsorber in operation (fig. 3-3), green
•Adsorber in regeneration (fig. 3-1); if the LED in fig. 3-1 is lit up, then the adsorber whose LED
is not lit up (fig. 3-3) is in regeneration
•Adsorber in cooling-off phase: LED in fig. 3-1 blinks slowly green
• Display reading: can be switched back and forth to show different readings (green LED), air
flow, primary voltage, or current (primary of high voltage transformer)
•Booster pump under voltage, LED in Fig. 3-8, green
•LED (fig. 3-17), green; operation indicator of electric circuits
• LED in fig. 3-16, green; indicates from which electric circuit the current and voltage values are
shown; for BONa 1-3 always LED 1.
•LED in fig. 3-18 off
2.8 Monitoring systems
The following functions are monitored by the control:
•switch cabinet doors closed
•operational condition of regeneration blower, booster pump and high-voltage transformer
•operational air flow
•adsorber switching (after expiry of cooling phase)
•cooling water temperature, max.
•cooling water flow, min.
•mains power failure
•interlocking contact open
•current consumption of ozone generating system
•temperature of high-voltage transformer
In the case of error recognition by the control, the system shifts automatically into the failure mode,
and the LED (fig. 3-12) lights up yellow. The cooling water is shut off, the power supply to the
regulating transformer and the high voltage for the ozone generator are shut down.
If the function “Autoreset after mains power failure” is activated, the control will only register the
mains power failure as a fault (LED in Figure 3-18, flashing yellow); it will not shut down the plant.
Activation of the fault indicating relay will not take place.
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A corresponding red signal lamp in the operational panel indicates the source of the error. At the
same time the contact at the collective error message unit opens, so that the failure can be
reported further.
After the error indicated is found and corrected, the system can be set back in operation by
pressing the button (fig. 3-13).
2.8.1 Interlocking contact for ozone generation
The ozone system has an external interlocking contact. This contact interlocks the system with
the current of water. If, for example, there is no flow of water to be treated with ozone, then the
ozone system must be shut down by way of the interlocking contact.
Ozone generation shuts off when the interlocking contact is opened; the power supply to the
booster pump stops and the solenoid valve in the cooling water line closes.
A regeneration cycle which has just finished is not interrupted.
This contact can also be used in connection with a gas detector or an emergency cut-off switch.
2.8.2 Door contact switch
If cabinet doors are opened while the main switch is on, then the system turns off automatically
and goes into the failure mode; the LED (fig. 3-12) blinks rapidly (main protection open). After
closing the door, the system can be placed back into operation by pressing the button “reset
after failure” (fig. 3-13).
2.8.3 Emergency switch
In accordance with German safety regulations, it must be able to shut down ozone generation
using an emergency command device (emergency cut-off switch). The emergency command
device must be located in an easily accessible place near the door to the ozone system room
and clearly designated.
Connection of an external emergency cut-off switch is already provided for all Bono Zon®
Systems (see flow diagram for connection; remove jumper in the terminal strip).
The main protection opens when the emergency cut-off switch is used; at the same time the
ozone system is closed down:
•cooling water solenoid valve closes
•solenoid valve air treatment closes
•LED fig. 3-12 (yellow) blinks rapidly.
CAUTION
Opening the door while the system is running, or turning off the main switch or the
emergency cut-off switch can lead to excessively low pressure since the injector water
flow does not break off immediately. None of these steps should be taken (except in
emergency) before the system has been stopped using the start/stop button.
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Cooling water
Air
Glass
cylinder
Ozone
Steel cylinder, high voltage Steel cylinder
2.9 Stainless steel ozone generator
2.9.1 Definition
Systems with PVC generators are identified as type de-scription BONa xA(x=1-9, 80 g/h
generator), BONa xB(x=1, 40 g/h system) or BONa xC(x=2, 120 g/h system).
Systems with stainless steel generators are identified as type description BONa xD(x=1-9) or
BONa 2E(120 g/h system).
Versions A and C of the ozone generator are identical, as are types D and E. In the 120 g/h
systems these generators operate at reduced high voltage.
2.9.2 Structure and function
The stainless steel generators (type D and E) have a nominal capacity of 80 g/h. The mounting
and connections are designed to allow retrofitting into a BONa xA type system.
Stainless steel generators (types D and E) are made up of 19 ozone generating elements. The
cooling water flows into a closed, pressure-tight stainless steel sleeve and has no direct contact
with the dielectric. The air is fed into the dual sleeve system from above. The ozone outlets from
the bottom.
2.9.3 Cooling water
Water used as cooling water must be clean and free from suspended solids (in accordance with
specification). To minimise the risk of corrosion the chloride content must not exceed 250 mg/l.
The ideal temperature is between 10 and 15 °C. A cooling water flow of approx. 100 l/h is
required per stainless steel generator. If the cooling water temperature increases it may be
necessary to increase the flow up to 300 l/h.
If temperatures exceed 20 °C the generator’s current consumption can also increase.
If cooling water temperatures are very high it is necessary to limit the max. current consumption
of the ozone generator at the control transformer (automatic BONas, RS types, by reducing the
setting range at the controller).
To adjust the cooling water for several generators, open all corner valves and set the flow by
adjusting the priming pressure at the pressure release valve.
Construction of a Bono Zon®ozone generating system
Fig. 1b Stainless steel ozone generator: Principle of ozone generation