Xylem WEDECO EFFIZON SMOevo Series User manual

English translation of the original German manual
Manual
WEDECO EFFIZON®
Ozone Generating System
SMOevo Series
A
tchison_P-1138
Rev. 1.0

Manual Ozone Generating System SMOevo
Table of Contents
Rev. 1.0 Page 2 of 91
Xylem Water Solutions Herford GmbH
Boschstr. 4 - 14
32051 Herford
Germany
Phone: [phone] - 0
Fax: [phone]
E-Mail: [email protected]
Internet: www.wedeco.com
Version: 09.2013
Date: 26.01.2015
File: Manual_SMOevo610_Atchison_P-1138.doc
© Xylem Water Solutions Herford GmbH 2013
The reproduction, distribution and utilization of this document as well as the communication
of its contents to others without explicit authorization is prohibited. Offenders will be held
liable for the payment of damages. All rights reserved in the event of the grant of a patent,
utility model or design.
Subject to technical changes without notice.

Manual Ozone Generating System SMOevo
Table of Contents
Rev. 1.0 Page 3 of 91
1 Table of Contents
1Table of Contents..........................................................................................................3
2About this Manual .........................................................................................................6
2.1Contact Addresses.................................................................................................6
2.2Target Group..........................................................................................................6
2.3Storage of the Manual............................................................................................6
2.4Liability and Warranty.............................................................................................7
2.5For Your Orientation...............................................................................................8
2.5.1Pictographs ...............................................................................................8
2.5.2Manual Structure .......................................................................................8
2.5.3Abbreviations.............................................................................................9
3Safety............................................................................................................................10
3.1Intended Use of the System.................................................................................10
3.2Definition of Pictographs and Signal Words.........................................................11
3.2.1Action-Related Hazard Warnings ............................................................11
3.2.2Signal Words ...........................................................................................11
3.2.3Hazard Signs...........................................................................................12
3.3Safety Devices .....................................................................................................15
3.3.1Emergency Stop......................................................................................15
3.3.2Main Switch .............................................................................................16
3.3.3Gas Detectors (Ambient Air Monitoring)..................................................16
3.3.4Technical Ventilation System ..................................................................16
3.3.5Door Switch .............................................................................................16
3.3.6Protective Covers....................................................................................16
3.3.7Safety and Warning Signs.......................................................................17
3.4Responsibilities of the Owner / Operator .............................................................17
3.4.1Classification of Operating Staff ..............................................................17
3.4.2Safety Measures .....................................................................................18
3.5Requirements for the Operating Personnel..........................................................20
3.5.1Personal Protective Equipment...............................................................20
3.5.2Behavior in Emergency Situations ..........................................................20
3.6Requirements for the Installation Place ...............................................................21
3.7Hazardous Substance Ozone ..............................................................................22
3.7.1Health Risks ............................................................................................23
3.7.2Precautions .............................................................................................24
3.8Hazardous Substance Oxygen ............................................................................25
3.8.1Health Risks ............................................................................................26
3.8.2Precautions .............................................................................................26
3.9Residual Risks .....................................................................................................27
3.9.1Electrical Hazards ...................................................................................28
3.9.2Thermal Hazards.....................................................................................28

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4Technical Data.............................................................................................................30
4.1Type and Identification of the System ..................................................................30
4.2Operating Data.....................................................................................................31
4.2.1Dimensions and Weights.........................................................................31
4.2.2Cooling Water Requirements and Aeration Requirements .....................32
4.2.3Ozone Generator.....................................................................................32
4.2.4Electrical Connection...............................................................................33
4.2.5Signal Transfer (example of electrical wiring diagram) ...........................34
4.3Feed Gas .............................................................................................................37
4.4Coolant.................................................................................................................38
4.5Vibrations .............................................................................................................38
4.6Permanent Pressure Level, Sound Pressure, Acoustic Capacity Level...............39
5System Description.....................................................................................................40
5.1Ozone Generation Principle .................................................................................40
5.2Ozone System Design .........................................................................................41
5.3Process Description of the System ......................................................................43
5.3.1Subassembly 01: Gas Supply .................................................................43
5.3.2Subassembly 02: Ozone Generation ......................................................45
5.3.3Subassembly 03: Process Gas Line .......................................................46
5.3.4Subassembly 07: Cooling System
...........................................................47
5.3.5Subassembly 23: Converter ....................................................................49
Options ..........................................................................................................................51
5.3.6Option CL (Closed Loop) Cooling Water System....................................51
5.3.7Option COD (Catalytic Ozone Destructor) ..............................................54
5.3.8Option M1, M2 and M3 Ozone Monitoring ..............................................55
5.3.9Option Z1 Nitrogen Boost........................................................................55
5.4Process Control....................................................................................................56
5.4.1Process Values .......................................................................................56
5.4.2System Control Modes ............................................................................56
6Transport and Storage................................................................................................59
6.1Safety during Transport and Storage ...................................................................59
6.1.1Safety Instructions...................................................................................59
6.1.2Personal Protective Equipment...............................................................59
6.2Requirements for Transport Staff.........................................................................60
6.3Transportation of the Ozone System ...................................................................60
6.4Packaging ............................................................................................................61
6.4.1Packaging on Delivery.............................................................................61
6.4.2Packaging during Transport and Storage................................................61
6.5Storage.................................................................................................................61
7Installation and Initial Start Up...................................................................................62
7.1Installation ............................................................................................................62
7.1.1Safety Instructions...................................................................................62

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7.1.2Personal Protective Equipment...............................................................63
7.1.3Requirements for the Installation Staff ....................................................63
7.1.4Operating Room......................................................................................63
7.1.5Installation of the Ozone System.............................................................66
7.1.6Connecting the Ozone System................................................................67
7.1.7Purging the System for Drying Out Purposes .........................................68
7.2Initial Start-Up ......................................................................................................69
7.2.1Safety Instructions...................................................................................69
7.2.2Requirements for the Commissioning Staff.............................................69
7.2.3Starting the Ozone System Initially .........................................................69
7.2.4Setting the Operating Parameters...........................................................70
8Cleaning .......................................................................................................................71
8.1Safety ...................................................................................................................71
8.1.1Safety Instructions...................................................................................71
8.1.2Personal Protective Equipment...............................................................72
8.2Requirements for the Cleaning Personnel ...........................................................73
8.3Requirements for Safe Cleaning ..........................................................................73
8.4Cleaning the Ozone System ................................................................................73
8.4.1Cleaning during Operation ......................................................................74
8.4.2Cleaning with the System Disconnected form Power Supply..................
74
9Maintenance.................................................................................................................75
9.1Safety Instructions................................................................................................75
9.2Personal Protective Equipment............................................................................77
9.3Requirements for Maintenance Staff....................................................................77
9.4Requirements for Safe Maintenance....................................................................77
9.5Maintenance Schedule.........................................................................................79
9.6Disposing of Components and Materials .............................................................82
10Shutdown and Disposal..............................................................................................83
10.1Safety Instructions...........................................................................................83
10.2Requirements for the Personnel .....................................................................84
10.3Temporary System Shutdown.........................................................................85
10.4Final System Shutdown ..................................................................................86
10.5Disposal of Materials.......................................................................................86
11Appendix......................................................................................................................87
11.1Confirmation of Briefing...................................................................................87
11.2Operating Directives........................................................................................88
11.3Swagelok – Installing Instructions for External Connections...........................90
11.4Spare Parts .....................................................................................................91
11.4.1Disclaimer...............................................................................................91
11.4.2Spare Parts Orders.................................................................................
91

Manual Ozone Generating System SMOevo
About this Manual
Rev. 1.0 Page 6 of 91
2 About this Manual
In this section you will learn how this manual is organized. For your orientation, this section
specifies all the means and symbols of presentation used in this manual.
Xylem Water Solutions Herford GmbH is the full legal name of the manufacturer of WEDECO
products. For simplicity's sake, the term WEDECO is used in this manual when referring to
Xylem Water Solutions Herford GmbH.
The manual was created with utmost care. However, if you find any incomplete information
and/or errors, please let us know immediately. Refer to section Contact Addresses.
Your improvement suggestions will be appreciated. They will help design our manuals even
more user-friendly.
2.1 Contact Addresses
If you have any queries, please contact your regional
Sales Company for WEDECO products.
You will find a current list of contact persons on
www.wedeco.com.
2.2 Target Group
This manual is intended for
the owner / operator of the ozone system,
the operating personnel of the ozone system,
the qualified personnel in charge of installation, commissioning, maintenance and
repair work with regard to the ozone system.
2.3 Storage of the Manual
The manual is an integral part of the ozone generating system. It must be accessible to the
operating personnel and the maintenance and repair staff for the whole duration of the
service life of the system. Always keep this manual near the ozone system for future
reference.
Further copies of this manual can be ordered from your regional WEDECO Customer
Service. Refer to section Contact Addresses.

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About this Manual
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2.4 Liability and Warranty
All the data and information concerning operation and maintenance of the system are to the
best of our knowledge, based on our previous experience and know-how. We are only liable
within the framework of the warranty obligation agreed upon in the main contract for any
legal entitlements resulting from this contractual agreement.
The original version of this manual was created in German language. The translation into the
relevant language of the contracting country was done by certified translators.
Any warranty becomes void if
the information given in this manual is not or not sufficiently observed
the ozone generating system is used not according to its intended use
spare parts or any parts not approved by WEDECO are used
functions or materials of the system are modified without approval
the system is incorrectly operated or operated by unqualified personnel
protective equipment is removed, manipulated, or not employed
the system is incorrectly or unprofessionally cleaned
maintenance work is done improperly or if maintenance intervals are not observed
wear parts are concerned.
Modifications and/or adjustments on the ozone system are possible in certain cases.
Such cases require written approval by WEDECO.

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About this Manual
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2.5 For Your Orientation
2.5.1 Pictographs
This section gives an outline of the kind of pictographs used in this manual.
Pictograph Description
Warning signs are triangular with a black
pictograph on a yellow background.
Prohibition signs are round with the safety color
red around the edge and a red transverse bar.
Mandatory signs are round with a white
pictograph on a blue background.
Notices contain general important information not
related to personal injury.
2.5.2 Manual Structure
This section gives an outline of the information given in the individual sections of his manual.
Name of the section Contents of the section
About this Manual,
section 2
How is this manual organized, liability and warranty,
pictographs, terms and abbreviations, information on contact
addresses.
Basic Safety Guidelines,
section 3
What does endanger my own safety or the safety of the
system?
What do I have to observe when handling ozone and oxygen?
Technical Data,
section 4
What are the performance, dimensions and weight of the
ozone system?
System Description,
section 5
How does ozone generation work?
What are the process steps and the layout of the ozone
system?
Transport and Storage,
section 6
What do I have to observe regarding transport and storage of
the system?

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About this Manual
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Name of the section Contents of the section
Installation and Initial
Start-Up,
section 7
How is the ozone system installed? What do I have to observe
prior to commissioning?
Cleaning ,
section 8
How do I clean the ozone system? What is to be observed?
Maintenance,
section 9
How do I keep the ozone system in functional condition? What
maintenance work do I have to carry out?
Shutdown and Disposal,
section 10
What do I have to observe when decommissioning and
disposing of the ozone system?
Appendices 11 Form 'Confirmation of Briefing'
Example Operating Directives
Swagelok – Assembly Instructions for External Connections
Where and how do I order spare parts?
Spare Parts Lists
2.5.3 Abbreviations
This section gives an overview of abbreviations used in this manual.
Abbreviation Meaning Description
TLV Threshold Limit Value
Upper limit on the acceptable
concentration of a hazardous substance
in workplace air
P&ID Piping & Instrumentation
Diagram
Identification of measuring and control
points
PLC Programmable Logic Control Programmable control unit with
microprocessor
HMI Human Machine Interface
The HMI is used to visualize information
and to allow the operator to interact with
the ozone system.

Manual Ozone Generating System SMOevo
Safety
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3 Safety
This section describes the safety equipment and safety measures relating to the use of the
ozone generating system. Read this section carefully prior to operating the system.
Ensure that the manual for the system is accessible to the user and the maintenance and
repair personnel for the duration of the system service life.
Keep a copy of this manual in close vicinity to the system!
3.1 Intended Use of the System
Herewith the manufacturer declares that the ozone generating
system including, where required, provided optional parts is
exclusively designed to be used for the generation of ozone as per
its specification. The ozone may only be introduced in closed
systems.
The intended use of the ozone generating system for different
applications is laid down in the agreement made by and between
the owner / operator and WEDECO.
Any use exceeding this purpose is inadmissible and bears
unforeseeable risks for the safety of the operating personnel.
Disclaimer of
warranty
The manufacturer is not liable for any damage or consequential
damage in terms of the Product Liability Act resulting from
inadmissible use of the ozone system.
Safety
requirements
The ozone system was built in accordance with the basic safety
and health requirements of the European Union. However,
dangerous situations may occur.
The ozone system was built in accordance with the current state-
of-the-art technology, and is operationally safe if all the instructions
given in this manual as well as the system and operation related
specifications and the accident prevention regulations are
observed.
Residual hazards When using the ozone generating system, residual hazards may
occur. By observing corresponding safety measures as described
in this manual, such residual risks can be minimized.
Installation
location
The ozone generating system is only permitted to be used in
closed, dry and frost-protected rooms.
Intended use also includes observance of
the safety notes
professional and regular maintenance work
professional and regular cleaning work.

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Safety
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The personnel assigned to the installation, commissioning, operation and maintenance of the
ozone system and its equipment must read and understand this manual including the safety
section. Depending on the qualification of the personnel, additional training might be
necessary.
If any unpredictable incidents or dangerous situations occur despite observance of all the
safety precautions, please inform us immediately.
3.2 Definition of Pictographs and Signal Words
In this section, pictographs and signal words used in this manual are explained.
3.2.1 Action-Related Hazard Warnings
When operating the ozone generating system, hazards may occur in certain situations or due
to certain behavior. Relevant procedures are preceded with hazard warnings as follows:
SIGNAL WORD!
Kind and source of hazard
Possible consequences if not avoided
Instructions on how to avert the hazard
3.2.2 Signal Words
DANGER!
Indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING!
Indicates a hazardous situation which, if not avoided, could result in
serious injury or death.
CAUTION!
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE!
Indicates a hazardous situation which, if not avoided, could result in
property or environmental damage.

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Safety
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3.2.3 Hazard Signs
Warning Signs
Pictograph Description
Danger! Hazardous voltage!
Warning of ozone
Warning of suspended loads when loading and unloading
Warning of poisonous / toxic substances
Warning of explosion hazard
Warning of hot surfaces
Warning of hazard
Warning of electromagnetic field

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Safety
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Prohibiton Signs
Pictograph Description
Smoking and open flames forbidden
Do not spray water
Do not touch, live parts
Mandatory Signs
Pictograph Description
Wear ear protection
Wear safety gloves
Wear safety shoes
Wear safety helmet
Isolate before working on the system

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Safety
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Safety Signs at the Place of Installation
Rooms housing ozone generating systems must be provided with the following warning and
prohibition signs:
Warning of poisonous substances!
Ozone plant! Access for authorized personnel only
No persons with pacemaker
Smoking and open flames forbidden
Safety Signs on the Ozone System
Symbol Description
Warning of ozone
Warning of poisonous substances!
Ozone plant! Access for authorized personnel only
Danger! Hazardous voltage! Contact may cause electric
shock or burn
Warning of hot surfaces
Warning of hazard
No access for unauthorized persons

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Safety
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Symbol Description
No persons with pacemaker
Smoking and open flames forbidden
Wear ear protection
Ozone labeling on pipework
Oxygen labeling on pipework
3.3 Safety Devices
This section describes all the available safety equipment and that what is to be provided by
the owner / operator. Always make sure that the safety equipment is in perfect condition.
3.3.1 Emergency Stop
The electrical equipment of the ozone system is equipped with a red Emergency push
button.
The operator can connect an additional Emergency Stop device by which the ozone
production will be stopped. The control is provided with an appropriate connection option.
Ensure that the Emergency push button / device is located and identified at an easily and
safely accessible place.
Only use the Emergency push button in the event of a potential danger to life and limb or of
potential damage to the system.
Once the Emergency push button is activated, the electrical energy supply and the feed gas
flow will stop immediately.
Prior to re-starting the system, the Emergency Stop circuit must be reset.

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Safety
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3.3.2 Main Switch
The main switch of the ozone system is located on the front of the control cabinet.
By means of the main switch the complete voltage supply of the ozone generating system is
turned on or off.
Always turn off the ozone system and check for absence of voltage prior to carrying out
maintenance or repair work on the system!
3.3.3 Gas Detectors (Ambient Air Monitoring)
Ensure that rooms in which ozone leaks may occur are effectively monitored by means of
gas detectors with visual and acoustic indicators.
Such rooms are, for example: rooms containing ozone systems, rooms crossed with
removable ozone supplying pipelines.
Ensure that the monitoring device (measuring sensor) is positioned at a place where the
highest ozone concentration is to be expected in the event of a hazardous incident (at
ground level).
3.3.4 Technical Ventilation System
Ensure that rooms housing ozone systems are equipped with a technical ventilation system
guaranteeing an air exchange of at least three times per hour. An extraction-type ventilation
with the intake opening located directly above the floor must be installed. The ventilation
system must turn on automatically when a gas detector responds to the potential danger.
3.3.5 Door Switch
The ozone generating system is equipped with a door switches located in the electrical
cabinets. Once a cabinet door is opened during operation, the ozone system will turn off
immediately.
Do not remove or bridge the door switch at any time!
3.3.6 Protective Covers
All system components like the complete electronics, ozone generator, etc. are permanently
installed in a metal cabinet secured by a lockable door to prevent contact with the
components which could lead to severe injuries.
Do not remove or bridge protective devices during operation of the system!
If removal of any protective devices is required during maintenance or repair work, ensure
that these devices are refitted and checked immediately upon completion of the maintenance
and repair work. Only use the original mounting material of the protective devices!

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Safety
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3.3.7 Safety and Warning Signs
All safety and warning signs placed on the ozone system must be clearly legible.
Ensure that damaged name plates and warning signs are replaced immediately.
3.4 Responsibilities of the Owner / Operator
This section describes the responsibilities of the owner of the ozone generating system and
the resulting measures.
3.4.1 Classification of Operating Staff
Owner / Operator The owner / operator, as a higher-ranking legal person, is
responsible for the intended use of the ozone generating system
and for training and employment of the authorized persons.
The owner / operator determines the binding competencies and
respective authorities of the authorized personnel of his company.
Qualified person A qualified person is a person who, due to his or her technical
training, knowledge and experience, as well as his or her
knowledge of the relevant regulations, can correctly judge the work
appointed to them, and who can recognize possible danger.
Trained staff or personnel who have been selected and deemed to
be capable by the owner / operator are qualified persons.
Instructed person An instructed person is a person who has been informed and, if
necessary, trained with regard to the tasks appointed to him or her
and possible danger in the event of improper behavior. The person
has also been instructed with regard to the required protection
devices and protective measures.
Lay person A lay person is a person who is neither qualified nor instructed.
Trainee personnel Trainee personnel may only work on the ozone system under the
supervision of a qualified person.

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Safety
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3.4.2 Safety Measures
Personnel The owner / operator of the system is obligated to instruct each person
who works with or on this system on the mode of operation, use and the
preventive measures which are to be adhered to.
The instructed persons have to confirm by signature that they have read
and understand all the points in the manual.
Refer to the form Confirmation of Briefing in the Appendix.
The owner / operator is liable for damage that is caused by personnel
who have not been instructed.
Local
Conditions
Always observe the local employment and safety regulations and laws.
The same applies to environmental regulations.
The owner / operator of the ozone system must ensure that appropriate
escape routes have been provided for the personnel in case of
emergency. The owner must ensure that the escape routes are neither
obstructed nor that their function is impaired (e.g. doors opening in the
escape route direction).
The owner / operator must make sure that sufficient illumination is
available at the ozone system.
The owner / operator is obliged to install fully functional gas detectors in
rooms in which ozone may escape in case of a hazardous incident.
The owner / operator is obliged to install fully functional gas detectors in
rooms in which oxygen may escape in case of a hazardous incident or
to ensure that the permissible oxygen concentration will not be
exceeded within the work area.
The owner / operator is obliged to install gas pipes which are used to
discharge oxygen (oxygen concentration >50%) as far as to the open
air.
Personal
Protective
Equipment
The owner / operator must ensure that an ozone proof breathing
protective device in form of a full mask with effective filter is available for
and identified with the name of each respective person working on/with
the ozone system.
The owner / operator must make sure that the breathing protective
devices are always ready for use, easily accessible, free from dust, and
stored in a moisture-proof place.
The owner / operator must ensure that the employees are familiar with
the use of the breathing protection apparatus by having at least one
exercise/practice per year, and that they are properly used.
Suitable ear protection must be provided.
The owner / operator of the system is responsible for posting an
Operating Directive "Handling of Ozone" in the operating room. The
Directive must be clearly legible and accessible for all employees.
Refer to the sample Operating Directives in the Appendix.

Manual Ozone Generating System SMOevo
Safety
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Detection of
Ozone
The owner / operator must provide appropriate aids and appliances for
measuring the ozone concentration in the ambient air and for detecting
leakages.
Ozone System
Check
The owner / operator is obliged to have the ozone system checked for
proper condition by a qualified person at least once a year or after
modification or repair of the system prior to re-starting. The check is to
be proven in writing by the owner / operator.

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Safety
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3.5 Requirements for the Operating Personnel
The operating personnel must read and understand this manual and know the applicable
regulations regarding operational safety and accident prevention.
The operating personnel must accordingly be instructed and trained by the owner / operator
of the system.
Maintenance and repair work may be carried out by qualified personnel only. Only original
spare parts or spare parts approved by the manufacturer may be used
Work on technical equipment may only be carried out by qualified personnel.
Any faults or risks concerning the ozone system immediately must be notified to the owner /
operator of the system or his or her authorized representative.
In addition, observe the following instructions:
Only operate the system in technically perfect condition as well as according to its
intended use, safely and aware of potential hazards.
Rectify any faults immediately which could impair your safety or the safety of the
ozone system.
3.5.1 Personal Protective Equipment
Some work on the system requires protective equipment. The protective equipment must be
provided by the owner / operator of the system.
Observe the following instructions in order to protect your health:
The ozone system produces noise during operation. Using ear plugs or ear muffs is
absolutely necessary.
For some work the use of safety gloves is absolutely necessary.
For some work the use of safety shoes is absolutely necessary.
For some work the use of safety helmets is absolutely necessary.
In addition to this, observe the locally applicable operational safety requirements.
3.5.2 Behavior in Emergency Situations
In case of emergency, follow the following instructions:
Press the Emergency push button immediately.
Exit the operating room immediately in the event of ozone alarm.
In the event of ozone alarm, use the breathing mask only for rescuing injured persons
or for averting other hazards.