ProMinent OZLa 06 O User manual

Ozone generation system
DULCOZON type OZLa
Operating instructions
A3467
Target group: trained users
EN
Original operating instructions (2006/42/EC)Part no. 990175 Version: BA OF 039 05/22 EN
Please carefully read these operating instructions before use. · Do not discard.
The operator shall be liable for any damage caused by installation or operating errors.
The latest version of the operating instructions are available on our homepage.

In order to make it easier to read, this document uses the male
form in grammatical structures but with an implied neutral sense.
The document is always aimed equally at women, men and
gender-neutral persons. We kindly ask readers for their under‐
standing in this simplification of the text.
Please read the supplementary information in its entirety.
Information
This provides important information relating to the
correct operation of the unit or is intended to make
your work easier.
Warning information
Warning information includes detailed descriptions of the haz‐
ardous situation, see
Ä Chapter 3.3 ‘Labelling of Warning Informa‐
tion’ on page 10 .
The following symbols are used to highlight instructions, links, lists,
results and other elements in this document:
Tab. 1: More symbols
Symbol Description
Action, step by step.
⇨Outcome of an action.
Links to elements or sections of these instructions or other applicable documents.
nList without set order.
[Button] Display element (e.g. indicators).
Operating element (e.g. button, switch).
‘Display/GUI’ Screen elements (e.g. buttons, assignment of function keys).
CODE Presentation of software elements and/or texts.
General non-discriminatory approach
Supplementary information
Supplemental directives
2

Table of contents
1About the product.................................................................. 6
1.1 Function of the system.................................................. 6
1.2 Nameplate.................................................................... 7
2 Identity code.......................................................................... 8
3Safety.................................................................................. 10
3.1 Labelling of safety information.................................... 10
3.2 Warning symbols denoting different types of danger.. 10
3.3 Labelling of Warning Information................................ 10
3.4 User qualification........................................................ 12
3.5 Intended use............................................................... 12
3.6 Safety equipment........................................................ 13
4 Components of the system and their function..................... 14
4.1 Overview of DULCOZON OZLa 01-16 O.................... 14
4.2 Description of the ozone generation system and
accessories................................................................. 18
4.2.1 The ozone gas transfer unit..................................... 18
4.2.2 Mixing unit (accessory)............................................ 18
4.2.3 Cooling water system.............................................. 18
4.3 Safety equipment........................................................ 18
4.3.1 Flow detector (accessory)........................................ 18
4.3.2 Door safety switch................................................... 19
4.3.3 Emergency Stop switch in the plant room for the
ozone generation system (accessory)..................... 19
4.3.4 Ozone gas detector (accessory).............................. 19
4.4 Process gas flow......................................................... 20
5 Scope of delivery, storage and transport............................ 21
5.1 Scope of delivery........................................................ 21
5.2 Storage....................................................................... 21
5.3 Transport.................................................................... 22
6 Assembly and installation................................................... 23
6.1 Safety guidelines and general requirements.............. 23
6.2 Recommendations regarding the suitability of the
system's installation place.......................................... 23
6.3 Requirements relating to system components............ 25
6.3.1 Mixing modules (accessory).................................... 25
6.3.2 Ozone removal from filters and reaction section..... 26
6.4 Assembly.................................................................... 26
6.4.1 Raw water pipes...................................................... 27
6.4.2 Oxygen supply system............................................. 27
6.4.3 Ozone gas system................................................... 27
6.4.4 Cooling water system.............................................. 28
6.4.5 Air conditioning system (air conditioning unit,
optional)................................................................... 28
7 Electrical installation........................................................... 29
7.1 Information regarding electrical connections.............. 29
7.2 Electrical inputs and outputs of the system................ 30
8 Commissioning................................................................... 31
8.1 Initial start: Functional process................................... 31
8.2 Start of commissioning............................................... 31
Table of contents
3

8.3 Setting the gas priming pressure................................ 33
8.4 Setting the process gas flow....................................... 33
8.5 Setting the cooling water flow..................................... 34
9 Operation............................................................................ 35
9.1 Touch panel................................................................ 35
9.2 Operating keys and control information...................... 36
9.3 Displays on the process screen.................................. 37
9.4 Authorisation scheme................................................. 37
9.5 Log in/Log out. User: EXPERT................................... 38
10 Operating modes and settings............................................ 39
10.1 Operating modes...................................................... 39
10.2 Gas flow mode (optional).......................................... 40
10.2.1
‘On’ ‘Operation Mode’ ‘Flow’ ............................... 40
10.2.2 ‘On’ ‘Operation Mode’ ‘Constant ozone
concentration’ ........................................................ 40
10.3 Key system statuses................................................. 41
10.3.1 Operating status: Start with ozone generation....... 41
10.3.2 "Start without ozone generation" operating
status..................................................................... 41
10.3.3 "Error" operating status.......................................... 42
10.3.4 "Process water flow too low" operating status....... 42
10.3.5 "STOP" operating status........................................ 42
10.3.6 "Pause" operating status....................................... 42
10.4 Behaviour of the system when power is connected.. 43
11 Displays on the touch panel................................................ 44
11.1 Total system displays............................................... 44
11.2 Display values on the touch panel............................ 44
11.2.1 Control variable in "Internal" operating mode........ 44
11.2.2 Control variable in "External" operating mode....... 44
11.2.3 Ozone volume........................................................ 44
11.2.4 Gas flow................................................................. 44
11.2.5 Pressure in the ozone generator........................... 45
11.3 Setting the operating modes..................................... 45
11.3.1 "Internal" / "External" operating mode.................... 45
11.3.2 0/4 ... 20 mA.......................................................... 45
11.3.3 Fieldbus................................................................. 45
11.3.4 Cooling water......................................................... 45
11.3.5 Primary current...................................................... 45
11.3.6 Primary voltage...................................................... 46
11.4 Status page............................................................... 46
12 Maintenance....................................................................... 47
12.1 Safety guidelines for maintenance and repair.......... 47
12.2 Routine inspection.................................................... 47
12.3 Regular maintenance................................................ 48
12.4 Maintenance of the air conditioning unit................... 49
13 Troubleshooting.................................................................. 50
13.1 Monitoring................................................................. 50
13.2 Fault.......................................................................... 51
13.3 Error table................................................................. 52
Table of contents
4

14 Technical data..................................................................... 56
14.1 Complete system...................................................... 56
14.1.1 OZLa 1-3 O (oxygen as the feed gas)................... 56
14.1.2 OZLa 06-16 O (oxygen as the feed gas)............... 58
14.2 Power supply to the system...................................... 59
14.3 Wiring diagram.......................................................... 60
15 Accessories......................................................................... 61
15.1 Classification............................................................. 61
15.2 Equipment................................................................. 61
16 Dimensional drawing........................................................... 63
16.1 DULCOZON OZLa 01+02O...................................... 63
16.2 DULCOZON OZLa 03+04O...................................... 64
16.3 DULCOZON OZLa 06+08O...................................... 65
16.4 DULCOZON OZLa 12+16O...................................... 65
17 Operating report.................................................................. 66
18 EU Declaration of Conformity............................................. 67
19 Information on the legally compliant use of ozone.............. 68
20 Index................................................................................... 69
Table of contents
5

1 About the product
A3468
Fig. 1: DULCOZON OZLa
The DULCOZON OZLa series of ozone generation systems is
designed as a pressurised system. The feed gas, oxygen, is fed to
the ozone generator under pressure in the system.
The electronic power unit provides extensive protection for the
electrical components (high-voltage transformer and power stage)
and also permits the correct digital display of the ozone output in
"grammes/hour". As a result, any required ozone volume between
3 and 100% of the nominal output can be set reproducibly and
largely independently of voltage and pressure fluctuations.
Operation under pressure means that the ozone generated can be
introduced directly into water systems with ≦ 2.5 bar back pressure
The "control valve" option keeps the ozone concentration or the
gas flow constant regardless of the ozone volume required, as far
as this is possible.
The integral data logger writes data to an SD card where it is
stored.
1.1 Function of the system
The system generates ozone from oxygen for water disinfection.
About the product
6

1.2 Nameplate
A3540
Fig. 2: Nameplate
About the product
7

2 Identity code
Type of ozone generator:
Oxygen operation - number of blocks
01 1
02 2
03 3
04 4
06 6
08 8
12 12
16 16
Feed gas:
O Oxygen
Design:
P ProMinent
S Non-standard
Cooling:
0 None
1 Control cabinet air conditioning
Mechanical design:
0 Standard control cabinet / with packaging for transport by truck
1 Standard control cabinet / with packaging for sea/air freight
2 Stainless steel control cabinet / with packaging for transport by truck
3 Stainless steel control cabinet / with packaging for sea/air freight
M Modified
Gas treatment:
0 Not integrated
Pre-set language:
DE German
EN English
FR French
IT Italian
ES Spanish
PT Portuguese
PL Polish
CH Chinese
Communication interfaces:
0 None
Identity code
8

2 Modbus TCP
3 Modbus RTU
4 Profibus DP
5 Profinet
Additional options:
0 None
1 Gas control valve
2 Ozone measuring unit
3 Gas control valve + ozone measuring unit
Certification:
0 CE
Tab. 2: Explanation of the identity code:
Mechanical design: With designs 0 and 1, the system is installed in a standard powder-
coated steel control cabinet.
Identity code
9

3 Safety
3.1 Labelling of safety information
The following signal words are used in these operating instructions
to denote different levels of danger:
Signal word Meaning
DANGER! This combination of symbol and
signal word indicates an imme‐
diate dangerous situation that
will result in death or serious
injury if it is not avoided.
WARNING! This combination of symbol and
signal word indicates a possible
dangerous situation that can
result in death or serious injury
if it is not avoided.
CAUTION! This combination of symbol and
signal word indicates a possible
dangerous situation that can
result in minor injury if it is not
avoided.
NOTICE! This combination of symbol and
signal word indicates a possible
dangerous situation that can
result in material and environ‐
mental damage if it is not
avoided.
3.2 Warning symbols denoting different types of danger
The following warning symbols are used in these operating instruc‐
tions to denote different types of danger:
Warning signs Type of danger
Warning – high-voltage.
Warning – toxic substances.
Warning – danger zone.
3.3 Labelling of Warning Information
These operating instructions provide information on the technical
data and functions of the product. These operating instructions pro‐
vide detailed warning information and are provided as clear step-
by-step instructions.
Identification of safety notes
Warning symbols denoting different
types of danger
Introduction
Safety
10

The warning information and notes are categorised according to
the following scheme. A number of different symbols are used to
denote different situations. The symbols shown here serve only as
examples.
DANGER!
Nature and source of the danger
Consequence: Fatal or very serious injuries.
Measure to be taken to avoid this danger.
Description of hazard
–Denotes an immediate threatening danger. If
the situation is disregarded, it will result in fatal
or very serious injuries.
WARNING!
Nature and source of the danger
Possible consequence: Fatal or very serious inju‐
ries.
Measure to be taken to avoid this danger.
– Denotes a possibly hazardous situation. If the
situation is disregarded, it could result in fatal
or very serious injuries.
CAUTION!
Nature and source of the danger
Possible consequence: Slight or minor injuries.
Material damage.
Measure to be taken to avoid this danger.
– Denotes a possibly hazardous situation. If the
situation is disregarded, it could result in slight
or minor injuries. May also be used as a
warning about material damage.
NOTICE!
Nature and source of the danger
Damage to the product or its surroundings.
Measure to be taken to avoid this danger.
– Denotes a possibly damaging situation. If the
situation is disregarded, the product or an
object in its vicinity could be damaged.
Type of information
Hints on use and additional information.
Source of the information. Additional measures.
– Denotes hints on use and other useful informa‐
tion. It does not indicate a hazardous or dam‐
aging situation.
Safety
11

3.4 User qualification
WARNING!
Danger of injury with inadequately qualified per‐
sonnel
The operator of the system / equipment is respon‐
sible for ensuring that the qualifications are ful‐
filled.
If inadequately qualified personnel work on the unit
or loiter in the hazard zone of the unit, this could
result in dangers that could cause serious injuries
and material damage.
– All work on the unit should therefore only be
conducted by qualified personnel.
–Unqualified personnel should be kept away
from the hazard zone.
The pertinent accident prevention regulations, as
well as all other generally acknowledged safety
regulations, must be adhered to.
Training Definition
Instructed personnel An instructed person is deemed to be a person who has been instructed and,
if required, trained in the tasks assigned to him and possible dangers that
could result from improper behaviour, as well as having been instructed in the
required protective equipment and protective measures.
Trained user A trained user is a person who fulfils the requirements made of an instructed
person and who has also received additional training specific to the system
from the manufacturer or another authorised distribution partner.
Trained, qualified per‐
sonnel
A trained, qualified employee is deemed to be a person who is able to assess
the tasks assigned to him and recognize possible hazards based on his
training, knowledge and experience, as well as knowledge of pertinent regula‐
tions. A trained, qualified employee must be able to perform the tasks
assigned to him independently with the assistance of drawing documentation
and parts lists. The assessment of a person's technical training can also be
based on several years of work in the relevant field.
Electrical technician An electrical technician is able to complete work on electrical systems and rec‐
ognise and avoid possible dangers independently based on his technical
training and experience as well as knowledge of pertinent standards and regu‐
lations. An electrical technician must be able to perform the tasks assigned to
him independently with the assistance of drawing documentation, parts lists,
terminal and circuit diagrams. The electrical technician must be specifically
trained for the working environment in which the electrical technician is
employed and be conversant with the relevant standards and regulations.
Service The Service department refers to service technicians, who have received
proven training and have been authorised by the manufacturer to work on the
system.
3.5 Intended use
nThe system is intended solely for generating and metering an
ozoniferous gas mixture from oxygen.
nAll other uses or a modification of the system are only per‐
mitted with the written authorisation of ProMinent GmbH, Hei‐
delberg.
Safety
12

nDo not operate the system in conditions other than those
described in this document.
nThe system is not intended for operation outdoors.
nThe system is not intended for portable operation.
nThe correct and proper operation of the system cannot be
guaranteed if non-genuine parts or third-party accessories are
used.
nOnly permit adequately qualified personnel to operate the
system.
nYou have a duty to observe the information contained in the
operating instructions during the different phases of the unit's
service life.
3.6 Safety equipment
The safety equipment is described in the "Assembly and installa‐
tion” chapter.
Further safety equipment is described in the "Components of the
system and their function" - "Safety equipment” chapter.
Safety
13

4 Components of the system and their function
4.1 Overview of DULCOZON OZLa 01-16 O
10 7 13
12
11
2
1
27
25
19
18
29
28
175
55
58
24, 40
3
A3469
Fig. 3: Ozone generation system illustrated by the OZLa 04O with air conditioning and without door
No. Component Function
1 Pressure regulating valve Unit for adjusting the priming pressure of the system
2 Ozone generation module A portion of the oxygen, the feed gas, is converted into
ozone in the water-cooled ozone generator.
5 Ozone outlet diaphragm valve The diaphragm valve protects the ozone generator against
the backflow of process water.
7 Ozone outlet -
10 Cooling water outlet -
12 Control (PLC) The control (PLC) is used to control and monitor the entire
system.
13 Door switch The door switch stops ozone generation as soon as the con‐
trol cabinet door is opened.
17 Fan control The fan control is used to regulate the control cabinet fan
according to the temperature.
18 Control cabinet temperature monitor The temperature monitor is used to monitor the temperature
in the control cabinet.
Components of the system and their function
14

No. Component Function
19 Master switch The master switch connects or disconnects the system from
the supply voltage or from the mains/power supply.
24 Cooling water inlet angle valve The cooling water flow through the ozone generator can be
adjusted using the angle valve.
25 Cooling water inlet -
27 Manometer The operating priming pressure is displayed on the manom‐
eter
28 Feed gas inlet -
29 Touch panel (display and operating
unit)
The touch panel (display and operating unit) acts as an
interface between the system and the operating personnel.
30 Water mixed with ozone -
31 Mixing section (accessory) Mixes the ozoniferous gas with the process water
32 Check valve at the point of injection Must be fitted vertically pointing downwards.
33 Check valve at the point of injection The check valve prevents the backflow of process water into
the pipework at the ozone outlet of the system.
34 Ozone feed -
35 Raw water -
40 Cooling water inlet solenoid valve The solenoid valve at the cooling water inlet stops the flow
of cooling water when the system is idle.
55 Oxygen feed solenoid valve The solenoid valve at the oxygen inlet stops the flow of
oxygen when the system is idle.
58 Gas control valve (optional) Regulates the mass volumetric flow of the oxygen
Components of the system and their function
15

35 34
33
32
31 30
28
29
10
7
25
A3470
Fig. 4: Ozone generation system OZLa with mixing unit and without air conditioning
7 Ozone outlet
10 Cooling water outlet
25 Cooling water inlet
28 Feed gas inlet
29 Display and operating unit
30 Water mixed with ozone
31 Mixing section (accessory)
32 Must be fitted vertically pointing downwards.
34 Ozone feed
35 Raw water
Components of the system and their function
16

T
PI
PI
PI
O
3
5
29
42
40
11
4
6
8
7
25 10
35 30
31
52
3
27
55
5656
5656
1
33
63
62
58
24
59
56
A3481
I.
II.
Fig. 5: Schematic pneumatic and hydraulic flow in the ozone generation systems OZLa 01-16 O for use with
oxygen as feed gas
1 Ozone generator block
2 Ozone generator
3 Pressure regulating valve with manometer
4 Adjustable feed gas throttle valve
5 Ozone outlet diaphragm valve
6 Ozone generator operating pressure sensor
7 Ozone outlet
8 Ozone generator pressure relief valve
9 Impeller counter
10 Cooling water outlet
11 Gas flow meter
24 Filter pressure reducer
25 Cooling water inlet
27 Pressure reducer with manometer
30 Raw water outlet
31 Mixing section (accessory)
33 Check valve at the point of injection
35 Raw water inlet
40 Cooling water inlet solenoid valve
42 Cooling water outlet temperature sensor
52 Raw water manometer (accessory)
55 Solenoid valve, oxygen inlet
56 Shut-off device
58 Gas control valve (optional)
59 Built-in ozone measuring unit (optional)
62 Back pressure valve
Components of the system and their function
17

63 Water trap with liquid level sensor (accessory)
I. Extendible to up to 16 modules
II. Oxygen supply, external
4.2 Description of the ozone generation system and accessories
Type OZLa ozone generation systems are designed for operation
with pure or enriched oxygen as the feed gas.
4.2.1 The ozone gas transfer unit
From the outlet of the ozone generator, the ozone gas mixture
passes via the diaphragm valve to the ozone outlet of the system.
The diaphragm valve prevents the backflow of process water from
the mixing unit into the ozone generator. Stainless steel or PTFE
pipes (accessory) transport the ozone-carrying gas from the ozone
outlet of the system to the mixing unit (31).
4.2.2 Mixing unit (accessory)
The ozone gas mixture is fed to the process water flow via the
check valve (33) fitted directly at the inlet of the mixing unit (31).
The check valve (33) prevents the backflow of the water in the line
between the ozone outlet of the system and the inlet of the check
valve (33).
The mixing unit (31) houses individual mixing elements for mixing
the ozone into the process water. The mixing unit needs to be
appropriately configured to the process water throughput for
optimum incorporation of the ozone into the process water.
Optimum mixing is not possible if the throughput is too low.
4.2.3 Cooling water system
The cooling water has the task of absorbing and dissipating the
heat produced during ozone generation in the chamber of the
ozone generator (2).
The cooling water travels from the filter pressure reducer to the
impeller counter (24), at which the flow can be regulated, to the
ozone generator (2).
An impeller counter for each ozone generation block (9) down‐
stream of the cooling water outlet of the ozone generator switches
off the system if the flow falls below the requisite minimum coolant
throughput. The cooling water temperature is also measured by a
temperature sensor (42) and the system is switched off with a cor‐
responding fault alert, should the maximum temperature be
exceeded. Detailed information on water quality, temperature and
flow volumes can be found in the "Technical data” chapter.
4.3 Safety equipment
4.3.1 Flow detector (accessory)
Ozone may only be introduced into the mixing unit if the requisite
minimum flow of raw water is guaranteed.
Components of the system and their function
18

A flow detector with minimum contact can be connected to an
input. The flow detector sends a signal to the control to switch off
the system when the flow of raw water becomes too low.
The system must also be locked by the water treatment system cir‐
culating pump via the pause input on the control (12).
The system starts up automatically with the pre-set "Ozone volume
control variable" if:
nThe pause signal is inactive. The contact at the pause input of
the system is closed,
nThere is no other fault.
4.3.2 Door safety switch
DANGER!
Potentially fatal high voltage
– If the door safety switch (13) is bypassed, parts
of the system can become live with potentially
fatal high voltage. Even if the door safety
switch is unlocked or the master switch (19) is
switched off, parts of the system's electrical
system can still carry mains voltage.
–Bypassing the door safety switch is prohibited.
– Disconnect the system from the mains/power
supply before accessing the system cabinet
and ensure that it cannot be reconnected, e.g.
by fitting a padlock to the master switch.
– Only open the system cabinet 5 minutes after
the system has been disconnected from the
mains/power supply.
The system is provided with a door safety switch (22) to ensure
that no live parts can be touched.
4.3.3 Emergency Stop switch in the plant room for the ozone generation system (acces‐
sory)
Install the Emergency Stop switch in an easily accessible, invulner‐
able position in the vicinity of the door of the plant room of the
ozone generation system. The Emergency Stop switch must
appropriately disconnect the electrical supply equipment connected
to the system from the mains/power supply.
4.3.4 Ozone gas detector (accessory)
INFORMATION! It is imperative that you read the operating
instructions for your gas detector.
Install the gas detector at positions where the highest concentra‐
tions of ozone are likely in the event of a fault/malfunction. With
positive pressure systems, install the gas detector in the vicinity of
the ozone generation system. The OZLa is a positive pressure
system.
The gas detector requires a potential-free alarm contact with the
OZLa. The alarm contact is appropriately connected to the input of
the control (12) as per the enclosed terminal wiring diagram
(Appendix).
Components of the system and their function
19

4.4 Process gas flow
The pressure regulating valve (27) at the gas inlet of the system is
supplied with compressed, dry oxygen. The system priming pres‐
sure can be adjusted at the pressure regulating valve (27) and
read off on the manometer. The compressed oxygen then passes
the solenoid valve (55), then through the needle valve (4) or the
control valve (58) to reach the gas flow meter (11).
The pressure sensor (6) measures the operating pressure of the
ozone generator. The value of the gas flow and the pressure is dis‐
played on the touch panel.
The gas then enters the ozone generator (2). Ozone is generated
from some of the oxygen in the ozone generator. The ozoniferous
gas is fed through the solenoid valve (46), the check valve (3), the
solenoid valve (5) via the check valve (33) of the mixing unit (49)
(solenoid valve at the gas inlet, pneumatic valve at the gas outlet).
The ozoniferous gas is mixed with the raw water in the mixing unit.
If the system is idle and a fault occurs, all the solenoid valves at
the system inlet and outlet will close.
Mixing unit with shut-off valve (56), check valve (33) and optional
water trap (63).
OZLa 01-16 O
Components of the system and their function
20