Manual - RK2 Systems
Contents
1. gt O Y gt S Contact Vessel optional To maximize the effectiveness of ozone it must be thoroughly mixed and have adequate time to react with the contaminants in the water before being filtered or utilized Contact vessels are designed to achieve this necessary mixing and contact time RK2 Systems supplies several different types of contact vessels for a variety of applications Booster Pump optional If excessive back pressure is created in the water line by filters pressure tanks or other system parameters a booster pump may be necessary to create a sufficient pressure differential across the venturi This booster pump is used in con junction with a side stream ozone injection loop Electrical Interlock Box optional The electrical interlock box is a multi function electrical enclosure It houses the Motor Control Interlock MCI ORP Interlock and the Vacuum Interlock The enclosure also acts as the air preparation monitoring station controlling the amount of intake air and monitoring the vacuum PLUMBING CONNECTIONS Full Flow Plumbing Connections Refer to the Full Flow Installation diagram on the next page and follow the instructions below if the ozone is being injected directly into the full flow of the pool s return line 1 Tap into the return line after the pump filter and heater The ozone injection point should be the last component in line and as far as possible from the residual2. No vacuum System set to MANUAL No 120 VAC power to terminals 5 and 6 ORP level in excess of preset level Light burnt out e Check power connections amp breakers Jumper terminal from 1 to 4 Hook up neutral Adjust injector vacuum or Check tubing for leaks or Check for booster pump operation or Turn to OFF and back to reset e Switch to AUTO Hook up power to these terminals see manual e Check input signal Replace light Flow meter ball does not adjust No vacuum Vacuum leak In and out hoses reversed e Defective solenoid e Defective check valve 36 Adjust injector vacuum Check and tighten fittings e Switch hoses Inspect and repair or replace solenoid Check and replace check valve DRIVE MODULE WIRING FOR RK8g air RK20g oxygen High Voltage Lead Mounting Holes v A Drive or Module Coil Electronic Assembly Board THERMOSTAT 3 Position AMP Connector Fuse to ground should be 30 24 VOC Test fuse for continuity Should be 5 or less If not replace fuse 37 RK2 Systems Inc Limited One Year Warranty Summary of the Warranty RK2 Systems Inc RK2 makes every effort to assure that its products meet high quality and durability standards and warrants the products it manufactures against defects in materials and workmanship for a period of one 1 year commencing on the dat
3. Ozone Flow ad m 4 Lower Tee Sal gt wu Mounting Clamps gt hy Drain Port gt MI Flapper N ES Valve a Mm ap H H 4 Riser Tube Elbow 7 Plumbing Connections continued OPTIONAL CONTACT COLUMN INSTALLATION Location The contact column s should be installed after the injector manifold s within three 3 feet of a wall or solid mounting surface using isolation valves to facilitate cleaning the diffuser if needed There should be as few elbows as possible between the injector s and the contact column s Be sure to note the flow direction of the column s Mounting To a Wall or Other Solid Mounting Surface Using the Hardware Kit Refer to the diagrams on the next pages and follow these instructions 1 Locate the following items from the hardware kit e L bracket e two 1 2 concrete anchors with nuts and washers unistrut and protective end cap 6 clamp assembly with nut and bolt Mark the two holes for the L bracket on the wall The L bracket should be in located above the center of the length of the contact column A foot or so from the top is ideal Drill two 1 2 holes where you marked about 3 to 4 deep Insert one concrete anchor into each hole with the threaded end sticking out Slip the L bracket over these threaded ends and tighten down with the nuts and washers provided This will cause the ends of the concre
4. thermally protected reaction chambers inside the ozone generator some of the oxygen molecules are split while passing through the high voltage electrical field the corona forming single oxygen atoms O These oxygen atoms then recombine with other oxygen molecules in the air stream forming ozone The modular multiple reaction chamber design allows the ozone generator to keep working even if one or more of the chambers requires service Depending on the application the RK2 Systems ozone generator may be interlocked with an ORP controller pressure switch timer or circulation pump The RK56g is equipped with two three way solenoid valves While the valve on the right closest to the cabinet wall is for additional back flow prevention the valve to the left is to depressurize and off gas residual ozone from the ozone reaction chambers An internal off gas destruct mounted inside the ozone generator is used to destroy this residual ozone see Appendix Section B Other safety features are also built in including a pressure switch and thermal protection A Short Course in Fine Bubbles LESSON 1 The large bubble 20mm has a volume of 4 19 cm and a surface area of 12 6 cm gt LESSON 2 296 small bubbles 3mm could be D made from the large bubble in lesson 1 They would have a total surface area of 83 6 cm This is 6 6 times the surface area of the large bubble LESSON 3 Theoretically 6 6 times as much w
5. Terminal A a sim SEE Grounding Bar Qutlets for Air Dryer and optional ORP Controller 9 1047 Air Outlet 10 374 24 240VAC ELECTRICAL CONNECTIONS WITH OPTIONAL ELECTRICAL INTERLOCK BOX Follow the instructions below and the wiring diagram on the previous page to wire your system Note All electrical connections should be made by a qualified electrical contractor All local state and national codes must be observed Inside the electrical interlock box at the bottom toward the center is a terminal strip All the peripheral equipment is wired to this block with the exception of the air dryer which should be wired separately for continuous operation All possible pre wiring to the terminal block has been done A dedicated 20 AMP circuit should be run from the main electrical panel to the electrical interlock box or from the main electrical panel into a service disconnect box before wiring to the interlock box Terminals 1 amp 2 Main Power 240 VAC 60 Hz 2 Amps w o booster pump 11 AMP with 1 HP booster pump Use minimum 12 AWG Connect 240 VAC 20 AMP from the disconnect box or from a dedicated breaker on the main panel to the 240 VAC terminals 1 L1 amp 2 L2 Connect the green ground wire to the grounding bar Terminal 3 System Neutral Use minimum 12 AWG Provide a true neutral lead for this position A true neutral runs from this terminal to the neutral bus bar in the main breaker panel Do not ground
6. e Replace fuse Replace heater cartridge Desiccant indicator cartridge not blue in color Air leak e Desiccant saturated in storage Tighten fittings e Reactivate desiccant as described in manual Air dryer not cycling Timer defective Relay defective e Defective vacuum gauge Loose Kynar compression fittings 35 e Replace timer e Replace relay e Replace vacuum gauge e Tighten all Kynar fittings ELECTRICAL INTERLOCK BOX TROUBLESHOOTING PROBLEM SYMPTOM POSSIBLE CAUSE SOLUTION MAIN POWER light not on No power to electrical interlock box No neutral in 120 VAC supply Light burnt out e Check power connections amp breakers Hook up neutral Replace light MCI light not on 120 VAC signal not connected to terminal 4 Light burnt out No neutral in 120 VAC supply Jumper terminal from 1 to 4 Replace light Hook up neutral VACUUM SYSTEM light not on No power to electrical interlock box e No MCI No neutral in 120 VAC supply No vacuum Light burnt out e Check power connections amp breakers Jumper terminal from 1 to 4 Hook up neutral Adjust injector vacuum or Check tubing for leaks or Check for booster pump operation or Turn to OFF and back to reset Replace light ORP light not on No power to electrical interlock box e No MCI No neutral in 120 VAC supply
7. enclosures are not rain proof so it is important to choose a location that will keep the system away from direct weather and excessive heat Mounting holes are located on the back of all components for convenient wall mounting Mounting hardware is not provided Materials Installation Procedures continued Use Schedule 80 PVC for all plumbing connections whenever possible Also it is recommended that unions and valves are used wherever practical Ozone rapidly deteriorates a variety of compounds the following is a list of materials that may be used with ozone in gaseous phase at high concentrations Viton Teflon Stainless Steel EPDM Silicon Kynar Hepalon with ozone in aqueous phase at low concentrations Viton Teflon Stainless Steel EPDM Silicon Kynar Concrete Hepalon Schedule 40 PVC Schedule 80 PVC NOTE Be sure to use good plumbing practices and install unions and isolation valves wherever the situation dictates i e pump or injector removal etc Secure all plumbing with unistrut or similar hardware Tubing Installation 1 Install braided tubing from the indicating desiccant chamber on the air dryer to the brass AIR INLET fitting on the bottom of the ozone generator or the bottom of the electrical interlock box if so equipped If you are not using an electrical interlock box skip Step 2 and go to Step 3 2 If equipped with the electrical interlock box continue running the braided tubing from the elect
8. ozone generator This substantially improves the output capability of the ozone generator and prevents premature failure of key internal components These air preparation systems deliver 90 3 oxygen purity at 100 F dew point and at very low pneumatic pressures minimizing noise and reducing compressor wear If Plant Air feed gas is to be used in place of the RK2 Systems air preparation system the same air quality standards must be met to achieve the ozone output and longevity of the ozone generator A PSI pounds per square inch regulator must be installed when using plant air feed gas The regulator must be set to a maximum of 10 PSI Theory of Operation Product Description continued Ozone Generator RK2 Systems pressurized ozone generators are designed to supply high concentrations of ozone gas up to 10 at 10 PSI The oxygen feed gas produced by the air preparation system is supplied to the ozone generator which flows through a built in flow meter A stainless steel needle valve preset inside the ozone generator located on the stainless steel delivery line is used to maintain optimum pneumatic parameters inside the reaction chambers After this point the vacuum created at the ozone injector draws the ozone gas into the water line The ozone generator is equipped with a pressure switch which prevents its operation of the system if the pressure within the reaction chambers drops below 9 PSI As the feed gas enters the fused
9. recirculation the pH adjustment chemical injection point must be located downstream of the residual sanitizer injection point if so equipped e Ina Full Flow plumbing configuration see Figure 5 2 without recirculation locate downstream of the pH adjustment chemical injection point e Adequate protection from weather dust and excessive heat e Like any electronic component performance and longevity is enhanced by favorable operating conditions Also since each air preparation system and ozone generator is air cooled a relatively dust free well ventilated area is required No caustic chemicals should be stored in the area surrounding the equipment A minimum clearance of six inches from the vents on either side of the ozone generator is required e The equipment is heavy and requires proper support Therefore a clean dry level surface should be provided for the air preparation system and ozone generator These components should be securely fastened to the surface using the mounting holes and or tabs provided e The air preparation system and ozone generator are not designed to withstand outdoor elements including direct contact with water and or temperature extremes Therefore the equipment must be installed in an environment consistent with the following operating parameters e Ambient temperature range 20 F to 85 F continuous If the temperature around the equipment consistently exceeds 85 F additional air cooling must be provide
10. sanitizer injection point 2 Glue in the proper injector noting the direction of flow indicated by an arrow on the injector 3 Once the injector is installed the vacuum may be adjusted as described in the ozone generator operation section If the system is equipped with the optional electrical interlock box the vacuum can be observed on the VAC PSI gauge located above the SCFH gauge on the electrical interlock box Note The ozone generator will only energize for 15 seconds or until a vacuum is attained Tubing Installation 1 Install braided tubing from the air dryer to the AIR INLET fitting on the bottom of the ozone generator or the bottom of the electrical interlock box if so equipped If you are not using an electrical interlock box skip Step 2 and go to Step 3 2 If equipped with the electrical interlock box continue running the braided tubing from the electrical interlock box to the brass barb fitting on the bottom of the ozone generator 3 Install the check valve assembly into the injector Connect the 1 4 Teflon tubing from the OZONE OUT fitting on the bottom of the ozone generator to the check valve assembly on the injector Secure by tightening the fitting around the 1 4 Teflon tubing after insertion If equipped with the electrical interlock box install the 1 4 Teflon tubing from the OZONE OUT fitting on the bottom of the ozone generator to the stainless steel solenoid valve located on the top of the
11. transportation or storage is required The most powerful oxidizer commercially available very effective for May disinfection and oxidation without handling problems e Ozone creates no potentially harmful by products such as THMs the only by product is oxygen 4 e Ozone leaves no telltale taste or odor References 1 Water Quality Association Ozone for POU POE and Small Water System Water Treatment Applications Lisle IL 1999 THEORY OF OPERATION PRODUCT DESCRIPTION RK2 Systems ozone systems are designed for safe effective use in a variety of water treatment applications Each complete integrated system includes the components required for reliable efficient ozone production and can be divided into four general segments Air preparation system Ozone generator Ozone injection contacting Ozone destruct Ozone Injector Booster Pump Water low gt Ozone Destruct Unit Ball Valve Ozone Generator Air Preparation System Water Trap Contact Vessel Vacuum Break Air Preparation System RK2 Systems commercial cabinet ozone generators require a source of clean dry oxygen enriched air for effective ozone production To meet that need the rack mount air preparation systems built by RK2 Systems employ pressure swing adsorption PSA technology to increase the concentration of oxygen and reduce the moisture content in the feed gas the air supplied to the
12. x S e mr c l l l l Valve Body l l i l l EAS AS A BE re ER G l 32 PARTS LIST FOR RK8g air RK20g oxygen PART CKV20 FA40 FA41 FA42 FA43 FA44 FLT34 RCC6 RCC20 RCC70 RCC80 RCC103 RCC108 ORS30 DRM10 DRM12 DESCRIPTION Check valve CD 1 4 kynar FPT low pressure Fan Cooling CD filter element only 4 Fan Cooling CD 120V 50 60 Hz 4 Fan Cooling CD 240V 50 60 Hz 4 Fan Cooling CD external finger guard 4 Fan Cooling CD internal finger guard 4 Filter inline particulate 1 4 for one to three cell CD systems Complete CD reaction chamber 2 does not include fittings Cathode with heat sink and feet Dielectric only all CD reaction chamber 2 High voltage lead all 2 CD reaction chambers High voltage end cap with O Rings Non high voltage end cap with O Rings O Ring package Drive Module M 1500 or P 2000 complete with HV transformer and mounting bracket Drive Module CD 1500 or CD 2000 HO complete with HV transformer and mounting bracket HVT100 H V coil only for 2 CD reaction chamber HWS2012 Mounting screws for reaction chamber FTK325 FUS20 PS150 PS155 PS300 PS305 DES12 DES16 SV200 SV500 TMI15 ADP20 ASP158 ASP156 Fitting Kynar elbow for reaction chamber Fuse CD 5 Amp slow blow Power supply 150 watt for M 1500 or CD 1500 100V 120V 50 60 Hz Power supply 150 watt for M 1500 or CD 1500 208V 240V 50 60 Hz Power supp
13. Any product and or part not performing satisfactorily may be returned to RK2 for evaluation a Return Goods Authorization RGA number must first be obtained by either calling or writing your local authorized dealer distributor or RK2 direct prior to shipping the product The problem experienced with the product and or part must be clearly described The RGA number must appear prominently on the exterior of the shipped box es The product and or part must be packaged either in its original packing material or in comparable and suitable packing material if the original is not available You are responsible for paying shipping charges to RK2 and for any damages to the product and or part that may occur during shipment It is recommended that you insure the shipment for the amount you originally paid for the product and or part If after the product and or part is returned prepaid and evaluated by RK2 it proves to be defective while under warranty RK2 will at its election either repair or replace the defective product and or part and will return ship at lowest cost transportation prepaid to you except for shipments going outside the 50 states of the United States of America If upon inspection it is determined that there is no defect or that the damage to the product and or part resulted from causes not within the scope of this limited warranty then you must bear the cost of repair or replacement of damaged product and or part and all return freight charg
14. C terminals 1 amp 2 to the 240V terminals on the terminal strip in the electric interlock box Connect the white neutral wire to terminal 3 and connect the green wire to the grounding bar in the electric interlock box The system can be controlled by the circulation pump timer by wiring the timer to terminals 1 amp 2 120 VAC systems 120 VAC 60 Hz 6 AMP w o booster pump 22 AMP with 1 HP booster pump Connect 120 VAC 10 AMP service to terminal on the terminal strip Connect the white neutral wire to terminal 2 and connect a 12 AWG jumper wire from terminal 2 to terminal 3 Connect the green wire to the grounding bar Terminal 4 MCI Motor Control Interlock 120 VAC 60 Hz Use 18 AWG This is an interlock from the main circulation pump to the ozone system Run a 120 VAC line from the motor starter to this terminal Should this feature not be used simply install a jumper from L1 to this terminal The unit will not function without a 120 VAC signal to this location Terminals 5 amp 6 Oxidation Reduction Potential ORP Controller 120 VAC 60Hz Use 18 AWG This is control voltage only 120 VAC from the controller to a relay integrated into the ozone system Note 70 override the ORP control signal simply turn the ozone switch on the electrical interlock box to the ON position Electrical Connections Continued Terminals 7 amp 8 Booster Pump 240 VAC 60 Hz 8 AMP 1 HP Use minimum 14 AWG 120 VAC 60 Hz 16 AMP use minimu
15. CAL INTERLOCK BOX The air preparation and ozone generation systems on RK2 Systems RK8g air RK20g oxygen is a vacuum type and will require adjustment of the air flow through the system An SCFH Standard Cubic Feet per Hour gauge is used to accurately measure the amount of air flowing through the ozone delivery line on single speed injectors in other words the amount of ozone being injected into the water Follow the directions and illustration below to optimize flow through the injector 1 With the pump running disconnect the ozone line from the outlet on the ozone generator and connect it to the fitting on the back of the SCFH gauge provided see drawing While holding the gauge vertically read the amount indicated on the gauge The optimum flow is 11 to 15 SCF for the RK8g air RK20g Note Do not obstruct the bottom air hole on the gauge On a single pump system the injector will have a ball valve to adjust the amount of flow To adjust the SCFH simply install the gauge as above and open the gate valve completely With the pump running begin closing the gate valve until the optimum flow is achieved on the SCFH gauge If possible remove the gate valve handle to prevent tampering with the setting Attach Ozone Line Keep Gauge Vertical Injector Manifold with check valve Do not block gt __ gt lower hole 22 21 75 Cooling Far Outets 2 j Feed Air Inlet l IH Check Yale 4 75 Mi Ozone Out Fit
16. OCEDURES Getting Started Unpacking Compare the ozone system equipment received to the packing list provided Before beginning any installation procedures thoroughly inspect all components for damage If damage is noticed promptly notify the freight carrier and request an on site inspection Inspect all packing materials for small parts before discarding Inspect all plumbing fittings and tubing for packing material that may have become lodged in openings Equipment Placement e When placing the ozone system components in the equipment room make sure to consider safety maintenance requirements local building and fire codes etc The components should be easily accessible by the operators including equipment access doors and electrical hook up boxes All meters gauges indicator lights and switches should be visible and accessible Dimensional drawings of each air preparation system and ozone generator are included in Section A of the Appendix e The air preparation system and ozone generator should be located as close as possible to the point of ozone injection Ozone is an unstable gas and will begin reverting back to oxygen very quickly To determine the most favorable ozone injection point the following items should be considered e Located downstream of all other existing water system components e Located upstream of the residual sanitizer injection point if so equipped e Ina Sidestream plumbing configuration see Figure 5 1 with
17. RK2 SYS 7 ENTS Installation and Owner s Manual RK3g Air RK20g Oxygen 421A South Andreasen Drive Escondido CA 92029 760 746 7400 www rk2 com copyright 2013 RK2SYSTEMS INC All Rights Reserved Any reproduction without the written permission of RK2 SYSTEMS is prohibited Introduction This Installation and Operation Manual is written to assist in the installation operation and maintenance of ozone delivery systems manufactured by RK2 Systems Inc The equipment has been designed using the most modern materials and technology available Please read this manual carefully and in its entirety before proceeding with any installation operation or maintenance procedure associated with this equipment Failure to follow these instructions could result in personal injury damage to the equipment or reduced product performance In an ongoing effort to improve reliability and operating efficiency RK2 Systems may find it necessary to make changes to its products Therefore the information contained in this manual may not conform in every respect to earlier versions of RK2 Systems ozone systems found in the field If you have any questions please contact your RK2 Systems dealer or the RK2 Systems service department How Ozone is Generated Ozone is generated by exposing oxygen molecules O in an air stream to a controlled high energy electrical field As the air stream passes through the electrical field produced i
18. arge Reaction Chambers 2 Drive Modules 2 r Feed Gas Chassis Inlet Tubing gt Power k LU LIT E Supply 12 2 Ozone ilies oe Tubing u Fan Fan Assembly Assembly Check Valve Ozone Out Fitting Condulet On Off Switch Indicator Light Control Board Fuse s one for 120V two for 240V Grounding Lug SPECIFICATIONS Energy Required 105 V min 125 V max 120VAC models 50 60 Hz 1 6 Amps Energy Required 208 V min 240 V max 240 VAC models 50 60 Hz 0 8 Amps Shipping Wt 49 Ibs 29 EXPLODED VIEW OF CORONA DISCHARGE REACTION CHAMBER Fitting Kynar Elbow t High Voltage Endcap with O Rings High Voltage Contact Dielectric Cathode with Heat Sinks amp Feet Non High Voltage End Cap with O Rings Fitting Kynar Elbow 1 H L A A Mounting Screws 30 POWER SUPPLY FOR RK8g Air RK20g oxygen Im Power Supply for Multi Cell Units 100 120V Pt PS300 208 240V Pt PS305 31 SOLENOID VALVE ON OPTIONAL ELECTRICAL INTERLOCK BOX Wrench Nut required for l i Complete sleeve removal l Solenoid Valve I Assembled includes all parts except Wrench Nut 120V Pt SV 100 240V Pt SV 100 i i i i 1 Solenoid T Pt SV500 i l i i l Plunger i i l i i l LE K a ms Flange Seal I N I b x m v ee Fe m x v m v x m
19. ater could be ozonated with the same amount of ozone Ozone Injection Contacting The ozone injector serves two purposes One it creates the vacuum required to safely draw the ozone gas from the ozone generator and two it provides a means by which the ozone gas can become dissolved in water A very dynamic injection process is required to effectively dissolve ozone in water RK2 Systems injection systems use only Mazzei injectors for maximum mass transfer efficiency The injector produces a cavitation effect enabling the ozone gas to join the water stream in the form of extremely tiny bubbles These bubbles must be as small as possible in order to increase the ratio of bubble surface area to the amount of ozone entering the water Depending on the application and the water treatment goals a RK2 Systems contacting system may also be required Some oxidation reactions take place so quickly that they are limited only by the rate at which the ozone is dissolved in the water Other reactions such as disinfection may require that a proper ozone residual be maintained for a specific amount of time A correctly sized contact vessel is used for this purpose Ozone Destruct The RK2 Systems off gas destruct systems consists of two components the ozone destruct unit a heated chamber filled with manganese dioxide and copper oxide and a water trap Used in conjunction with a RK2 Systems off gas vent the ozone destruct system is an effective
20. ation pump or a pre plumbed independent suction fitting if new construction install a tee and an isolation valve 2 Install the booster pump Secure the pump on a housekeeping pad with the appropriate mounting hardware 3 If an auxiliary control relay i e flow switch is being used install it into the line after the ozone booster pump 4 Install the injector manifold after the ozone booster pump making sure to note the correct flow direction of the injector manifold Remove the tie wraps that secure the check valve assembly to the injector manifold and thread the check valve assembly onto the opening of the venturi OPTIONAL VACUUM BREAK INSTALLATION Plumbing Connections continued Location Select a suitable vertical surface that is accessible and in close proximity to the ozone generator and venturi manifold on which to mount the vacuum break Installation Steps 1 10 11 12 13 Install the two mounting Clic clamps provided on the vertical surface so that the vacuum break will be in a vertical position and the height of the fill drain valve fitting will be below the level of the ozone generator bulk head check valve One clamp should be located directly above the vacuum break s bottom end cap and the other just below the fill drain fitting tee Install the two reducer bushings provided into the riser tee one into the side tapping and the other into the top tapping Be sure to use 2 3 wraps of Teflon tape
21. d e Humidity 0 90 relative humidity non condensing environment e Line voltage 10 of rated input Note Equipment installed in extreme environmental conditions will void manufacturer s warranty Allow room for the peripheral equipment booster pump injector manifold contact vessel etc CORONA DISCHARGE CD OZONE SYSTEMS Installation Procedures continued Ozone is manufactured in the CD ozone generator by drawing in air which is composed of 20 oxygen O and exposing it to multiple high voltage electrical discharges This causes a percentage of the oxygen molecules to dissociate and reassemble as ozone O The corona discharge method is the most efficient way to produce large amounts of ozone 3 0 ___________ gt 2 0 Chemical Formula simplified for Corona Discharge Ozone In contrast to ultraviolet ozone generators corona discharge systems produce a much higher concentration of ozone and in much larger quantities In addition the annual expense of replacing lamps and checking ballasts is unnecessary with corona discharge systems Corona discharge ozone generation is the most economical and effective method to use on most water treatment applications RK2 Systems manufactures high output corona discharge systems capable of producing enough ozone to oxidize iron sulfide manganese and act as an efficient sanitizer in a variety of applications Ozone reacts to water borne contaminants significantly faster than o
22. d if necessary Once each year remove one reaction chamber and inspect the dielectric tube for debris If the tube is clean and free of any debris oil or dirt it may be replaced and no further maintenance is required If the tube is dirty or cracked all dielectric tubes must be inspected and cleaned Cracked dielectrics should be replaced Please consult your RK2 Systems distributor as the improper installation of the dielectric may cause safety problems Since the air that is introduced into the reaction chambers is high quality the dielectric tubes should remain clean for at least one year before inspection is required 27 Removal of the Dielectric Tubes Disconnect all the power to the system including panel breakers service disconnect box and main circulation pump interlock Unplug the electrical terminal on the back of the drive module disconnect the polypropylene barbed air fitting and the Kynar ozone fitting Remove the ozone reaction chamber s from the back plate Disconnect the high voltage wire from the coil Remove the stainless steel nut and Kynar center rod from the center of the reaction chamber The Teflon end caps can now be gently removed by slowly pulling straight out The glass dielectric will remain attached to one of the end caps If the dielectric tube is dirty clean the glass with Isopropyl alcohol Do not use a solvent that will leave an oily residue Clean the inside of the stainless steel reaction chambe
23. e of original shipment from RK2 with the following exceptions 1 The warranty period shall begin on the installation date if the installation is performed within 90 days of the original shipment from RK2 2 The warranty period shall begin on the date of the bill of sale to the end user if the installation date is more than 90 days after the original shipment date To validate the warranty a warranty card accompanied by a copy of the bill of sale must be returned to RK2 and must include the following information End user name e Complete address including telephone number e Date installed Complete model and serial number information Name of company from which the unit was purchased Repairs and replacement parts provided under this warranty shall carry only the unexpired portion of this warranty of 90 days whichever is longer Items Excluded from the Warranty This warranty does not extend to any product and or part from which the factory assigned serial number has been removed or which has been damaged or rendered defective as a result of an accident misuse alteration or abuse an act of God such as flood earthquake hurricane lightning or other disaster resulting only from the forces of nature normal wear and tear operation outside the usage parameters stated in the product user s manual e use of parts not sold by RK2 service or unit modification not authorized by RK2 Obtaining Service Under the Warranty
24. el or Kynar check valves not sourced through RK2 Systems must not exceed 0 5 Ib 0 33 Ib is recommended PRODUCT DESCRIPTION Ozone Generator The ozone generator houses the ozone reaction chamber s power supply and all electrical components directly related to the production of ozone Ozone is produced when the feed gas is exposed to a high voltage electrical current inside the reaction chamber Air Preparation The RK2 Systems ozone system may be equipped with a heat regenerative desiccant air dryer Corona discharge ozone generators are much more effective produce more ozone and require far less maintenance if an air preparation unit is included The air preparation system lowers the dew point of the feed gas Moist feed gas air will cause nitric acid to form inside the generator which decreases ozone production and if not removed causes corrosion and eventual failure of the generator s internal components The ability of the ozone generator to produce ozone is drastically reduced as the dew point rises above 60 C Injector Manifold The ozone gas is injected into the filtered water return line by means of the injector manifold This allows the ozone to be injected into the water under a vacuum condition which is the safest technology available BALL VALVE
25. electrical interlock box Continue running the Teflon line from the solenoid valve to the check valve assembly on the injector Independent Ozone Loop Plumbing Connections Refer to diagrams pgs 7 8 and follow the instructions below if the ozone is being injected into an independent ozone loop Tf circumstances allow new construction pre plumbed for an ozone loop the ideal configuration is for the ozone loop to be com pletely independent from the pool s circulation system Otherwise the feed water for the side stream is pulled from the main return before the circulation pump and returned at a point after the filter and heater This is done so the booster pump is not attempting to draw water through the filter and from the circulation pump when the circulation pump is not operating The pH adjustment point will always be the last item in this sequence Use Schedule 80 PVC for plumbing connections when possible It is recommended that unions and valves are used where practical Ozone rapidly deteriorates many compounds the following is a list of materials that may be used with ozone in an aqueous solution Viton Teflon Sch 40 PVC Stainless Steel EPDM Silicon Kynar Sch 80 PVC Concrete Hepalon NOTE Be sure to use good plumbing practices and install unions and isolation valves wherever the situation dictates i e pump removal etc Secure all plumbing with unistrut or similar hardware 1 Inthe main water return line before the circul
26. enerator cabinet air filters These filters must be cleaned regularly Depending on the location of the unit it may be necessary to clean the air filters monthly On the bottom of the cabinet are filter elements see illustration below These are air intake elements for the cooling fans and may therefore require the most frequent cleaning All elements may be cleaned with soap and water and should be dried completely before reinstalling Note In a clean environment these procedures may only need to be performed every three months IMPORTANT CLEAN THESE FILTERS REGULARLY FAILURE TO DO SO WILL PROMOTE OVERHEATING AND WILL VOID THE WARRANTY e Check valves The system is equipped with two check valves one at the ozone generator ozone outlet and one on the venturi injector The purpose of these check valves is to prevent water from backing up into the ozone generator The Teflon ozone delivery line s should be inspected daily to insure water is not flowing back into the ozone generator Check valves should be replaced yearly Note The only time it is possible for water to flow back toward the ozone generator is during a system shutdown Always inspect for water seepage during this time Fan a gt I Cabinet Bottom Plate Fingerguard Fan Filter Element snaps on and off e Dielectric tubes Dielectric tubes are located in the reaction chambers of the ozone generator These tubes should be inspected periodical ly and cleane
27. es Any unauthorized attempt by the end user to repair RK2 manufactured products without prior permission shall void any and all warranties For service contact your authorized dealer or distributor or RK2 direct at 760 746 7400 Exclusive Warranty There is not other expressed warranty on RK2 products and or parts Neither this warranty or any other warranty expressed or implied including any implied warranties or merchantability of fitness shall extend beyond the warranty period Some states do not allow limitations on how long an implied warranty lasts so that the above limitation or exclusion may not apply to you Disclaimer of Incidental and Consequential Damages No responsibility is assumed for any incidental or consequential damages this includes any damage to another product or products resulting from such a defect Some states do not allow the exclusion or limitation of incidental or consequential damages so that above limitation or exclusion may not apply to you Legal Remedies of Purchaser This warranty gives you specific legal rights and you may also have other rights which vary from state to state THIS STATEMENT OF WARRANTY SUPERSEDES ALL OTHERS PROVIDED TO YOU AT ANY PRIOR TIME RK2 Systems Inc 421 A South Andreasen Drive Escondido CA 92029 760 746 7400 Fax 760 746 7460
28. gas into the water After all the previous electrical and plumbing connections have been completed the system is ready for startup and calibration Starting Position 1 Water flowing in the main line 2 Open the valves to the ozone loop if so equipped 3 Switch the main service disconnect box to the ON position 4 Turn the ozone generator ON at the switch located on the front of the electrical interlock box Note The dryer should already be ON as it is wired for continuous operation The booster pump and ozone generator should now be operating 5 The injector can now be adjusted for suction Observe the SCFH gauge and adjust the air flow using the needle valve on the SCFH gauge Closing this valve will lower the air flow and raise the vacuum If proper flow and vacuum cannot be achieved readjust the bypass valve on the injector manifold until you achieve the SCFH specified for the ozone generator being installed see chart below Note The system will only operate for 15 seconds without vacuum To reset the time sequence turn the ON OFF AUTO switch OFF and back to ON Model OperatingscrH VAC PSI Gauge This gauge measures the relationship between the suction at the injector and the resistance to drawing the dry air and ozone through the system Under ideal conditions this gauge should show a very slight vacuum Safe SCFH Operating Gauge Range Needle PSI Valve 21 INITIAL START UP WITHOUT OPTIONAL ELECTRI
29. ing any maintenance procedures Safety Information continued IMPORTANT SAFETY INSTRUCTIONS When installing and using this electrical equipment basic safety precautions should always be followed including the following a oP A READ AND FOLLOW ALL INSTRUCTIONS SAVE THESE INSTRUCTIONS All electrical connections should be made by a licensed qualified electrician Before attempting any electrical connections be sure all power is off at the main circuit breaker Install all electrical equipment at least five feet from any open body of water using non metallic plumbing Install check valves and a vacuum break to prevent water from contacting the electrical equipment The electrical supply for this product must include a suitably rated switch or circuit breaker to open all ungrounded supply conductors to comply with Section 422 20 of the National Electrical Code ANSI NFPA 70 1987 The disconnecting means must be readily accessible to the operator s but installed at least five feet from any open body of water Be sure to bond ground the system using the copper bonding lug on the bottom of the ozone generator The system should be bonded with solid copper wire conforming with all local state and national electrical codes The system should be sized appropriately for its intended use by a qualified professional familiar with the application This equipment must be validated by the manufacturer for its intended use INSTALLATION PR
30. inually bleed ozone gas buildup on top of the column to be mixed back into the main water line Do not install this vent line on the suction side of the pump 2 Install the Teflon vent line from the Kynar fitting on the top of the contact column to the location drilled into the main water line Vent Line Installation Detail Compression Elbow Fitting F Needle Valve may be installed anywhere along vent line Vent Line Contact Column Compression Fitting i Water Return Line Vent Line Location Diffuser Section Internal Upright ELECTRICAL CONNECTIONS GENERAL INFORMATION Please read the following important information before making any electrical connections 1 All electrical work should be done by a licensed electrician All local codes must be observed 3 The ozone generators are available in 120 VAC and 240 VAC models Be sure to install the proper model for each application 4 Before attempting any electrical hook up be sure the power is OFF at the main circuit box 5 Ground the ozone generator using the copper grounding lug on the bottom of the unit Solid copper wire conforming with all local state and national electrical codes should be used The ozone generator should be wired so that the ozone comes ON when the main circulation pump comes on for filtration This can be accomplished by utilizing the optional elctrical interlock box to i
31. ly 300 watt for P 2000 or CD 2000 100V 120V 50 60 Hz Power supply 300 watt for P 2000 or CD 2000 208 V 240V 50 60 Hz Desiccant AD 40 heating chamber recharge nonindicating Desiccant indicating chamber recharge 11b Solenoid 3 Way valve for air dryer w o fittings 120V 50 60 Hz Solenoid valve rebuild kit for Electrical Interlock Box Timer solid state for the dryer 2 cube AD 40 part heating element Maintenance Kit for M 1500 amp CD 1500 Maintenance Kit for P 2000 amp CD 2000 33 OZONE GENERATOR TROUBLESHOOTING PROBLEM SYMPTOM POSSIBLE CAUSE SOLUTION Unit does not turn on No power to unit e Switch not turned on Blown fuse e Cover door interlock not active Incorrect wiring connections e Check breakers e Check switch e Replace fuse on bottom panel e Check door interlock switch replace cover e Check wiring see manual Unit does not stay on Unit overheating Insufficient vacuum should be 5 to 15 on SCFH gauge Defective solenoid Defective check valve e Clean fan filter check fan Adjust injector vacuum be sure check valves are properly installed Inspect and repair replace if necessary Inspect and replace if necessary Unit cycles on and off e Overheating e Defective power Defective solenoid e Clean fan filter check fan e Check for constant power if not timer controlled Inspect and repair replace if necessary I
32. m 12 AWG Wire from the terminal strip to the booster pump as indicated The booster pump will be controlled by the interlock box In many cases this feature is not be used the operation of the remaining equipment will not be affected Terminals 9 amp 10 Ozone Generator 240 VAC 60 Hz 2 AMP or 120 VAC 60 Hz 4 AMP Hard wire the electrical cord on the ozone generator to the terminal strip as indicated The ozone generator will be controlled by the electrical interlock box Air Dryer 120 VAC 60 Hz 1 AMP Plug the air dryer into a standard wall outlet 120 VAC 60 Hz The air dryer should remain energized at all times with the exception of long term shutdown for service The air dryer can be hard wired to the electrical interlock box utilizing terminals 1 120V and 3 neutral Using a bonding wire conforming with all local state and national electrical codes normally a 8 AWG ground the components to the grounding bar on the electrical interlock box and bond the electrical interlock box to a true earth ground a NEON TA TASS LOAD TI LAD TEEN TET AD EAT LATA SS R E R ee ee D PER ee ed ES 129345678 9 10 120 VAC MODELS 240 VAC MODELS 1 Line in 120V 1 Line in 240V 2 Neutral in 2 Line in 240V 3 Neutral in 3 Neutral In 4 MCl in 4 MClin 5 ORP Line in 5 ORP Line in 6 ORP Neutral 6 ORP Neutral 7 Booster Pump Out 120V 7 Booster Pump Line Out 240V 8 Booster Pump Neutral 8 Booster Pump Line OUt 240V 9 Ozone Generat
33. ndividual drive indicator lights not on No power to drive module Blown fuse Drive module burnt out e Check drive module see illustration e Replace fuse e Replace drive module Unit trips circuit breaker Incorrect wiring Incorrect circuit breaker e Check wiring see manual e Check and if necessary replace with correct circuit breaker You receive an electrical shock upon touching the unit Incorrect wiring Unit not grounded e Unit has been flooded e Check wiring see manual Ground unit in accordance with local codes Return unit for major service or completely disassemble and clean Water in unit or ozone delivery tubing Insufficient vacuum e Defective check valve s Excessive back pressure on check valve Adjust injector vacuum e Replace check valve s e Back pressure not to exceed 40 psi if over 40 psi consult CWT distributor Ozone smell present Insufficient vacuum Loose internal fittings Defective O ring seals in reaction chamber e Defective dielectrics Defective reaction chamber Adjust injector vacuum Inspect and tighten fittings e Check and replace if necessary e Check and replace if necessary e Check and replace if necessary You suspect that no ozone is being produced e Drive module failure e Dielectric failure 34 Touch the bottom of the coil replace if it is not warm Inspect and re
34. nside the ozone generator some oxygen molecules are split forming single oxygen atoms O These oxygen atoms then recombine with other O molecules in the air stream forming ozone O Properties of Ozone Oxygen O Electrical Field gt Ozone is the most powerful oxidizer available that can be safely used in water treatment It is used to treat drinking water bottled water swimming pool water wastewater food and beverage processing water and in many other applications Ozone is effective in performing the following water treatment functions Disinfection Bacterial disinfection inactivation of viruses and cysts e Oxidation of Inorganics Precipitates iron manganese sulfides nitrites and organically bound heavy metals e Oxidation of Organics Including organics causing color taste and odor problems some detergents and pesticides phenols VOCs turbidity control and microflocculation of soluble organics Benefits of Ozone Use Molecular weight Odor Readily detectable at concentrations above 0 02 ppm in air Color Bluish in ozone generator cell but ozone air mixture exiting generator is invisible even at high ozone concentrations Gas Density 2 144 grams liter at 32 F approx 150 that of oxygen Solubility Only partially soluble in water but about 10 20 times more soluble than oxygen at 68 F ofi e Ozone is generated on site no
35. nterface with a flow switch ORP monitor timer or motor control interlock MCI to the main circulation pump If the optional electrical interlock box is not used the ozone generator should be wired to the main circulation pump s power source or timer if a timer is used If a side stream booster pump is used the ozone generator and the booster pump should be interlocked to the main circulation pump The ozone generators come standard ready to be hard wired using 1 2 liquid tight conduit ELECTRICAL CONNECTIONS WITH OPTIONAL ELECTRICAL INTERLOCK BOX Note All electrical connections should be made by a qualified electrical contractor All local state and national Ocodes must be observed Inside the electrical interlock box at the bottom toward the center is a terminal strip All the peripheral equipment is wired to this block with the exception of the air dryer All possible pre wiring to the terminal block has been done Refer to the diagram on the following page for details A dedicated 20 AMP circuit should be run from the main electrical panel to the electrical interlock box or from the main electrical panel into a service disconnect box before wiring to the interlock box Terminals 1 2 and 3 Main Power 240 VAC systems 240 VAC 60 Hz 3 AMP w o booster pump 11 AMP with 1 HP booster pump Use minimum 12 AWG Connect 240 VAC 20 AMP service from the disconnect box or from a dedicated breaker on the main panel to the 240 VA
36. on the male threads Install the PVC ball valve provided into the reducer bushing in the side tapping on the riser tee Be sure to use 2 3 wraps of Teflon tape on the male threads This valve controls the amount of water that is drawn up into the riser tube by the suction of the venturi It can also be used to isolate the venturi should a check valve fail Install the 90 Kynar fitting provided into the reducer bushing on the top tapping on the riser tee Be sure to use 2 3 wraps of Teflon tape on the male threads Place the two inch diameter water reservoir into the mounting Clic clamps and secure Check to make sure the height of the fill drain fitting is below the level of the ozone generator bulkhead check valve Slide the riser tube into the water reservoir Attach one end of a suitable length of 1 4 Teflon tubing provided to the 90 Kynar compression fitting on the top of the riser tee Attach the other end of the tubing to the bulkhead check valve on the bottom of the ozone generator The length of the tubing will depend on the distance between the vacuum break and the ozone generator Initiate water flow through the system e g start the circulation pump or booster pump so water is flowing through the venturi injector Adjust the suction at the venturi with a hand held SCFH gauge matching the air flow to the correct specification as outlined on pages 17 and 18 Close the PVC ball valve on the riser tee Using the straigh
37. or Out 120V 9 Ozone Generator Out 240V 10 Ozone Generator Neutral 10 Ozone Generator Out 240V Grounding Bar Electrical Connections Continued ELECTRICAL SCHEMATIC WITH OPTIONAL ELECTRICAL INTERLOCK BOX 240 VAC 60 Hz Single Phase RK8g w air RK20g W oxygen 10 Amps with 3 4 HP Booster Pump Service disconnect Connections l u or from a dedicated Electrical Wiring breaker in the Bu main panel Braided Air Line Teflon Ozone Line Electrical Ozone Vacuum Interlock 4 Outlet L1 Gauge 1 L2 Neutral SCFH Gauge Covered Duplex Convenience Outlets l 120 VAC signal to the 120 VAC signal from the l ozone generator l motor starter of the l form the ORP controller l main circulation pump 20 INITIAL STARTUP AND CALIBRATION WITH OPTIONAL ELECTRICAL INTERLOCK BOX RK2 Systems air preparation and ozone generation system RK8g air RK20g oxygen is a vacuum type and will require adjustment of the air flow through the system On the front of the electrical interlock box is a VAC PSI gauge and an SCFH Standard Cubic Feet per Hour gauge These two instruments are all that are required to keep the system operating within the correct parameters The ozone system will not function without a minimum of 3 vacuum from the venturi injector due to an electrical vacuum interlock relay This is a safety feature designed to prevent the ozone generator from operating without the injector drawing the
38. place if necessary OZONE GENERATOR TROUBLESHOOTING continued PROBLEM SYMPTOM POSSIBLE CAUSE SOLUTION Unit seems noisy e Not properly secured to wall floor e Shipping damage Fan blocked Bolt it firmly into place Locate and repair Check and clear obstructions Flow meter will not adjust Air preparation not operating e Defective solenoid e Defective check valve Internal regulator out of adjustment Make sure air prep package is set properly Check and repair use solenoid bypass kit described in manual e Check and replace Check and adjust regulator Vacuum gauge reads on pressure side Insufficient vacuum e Output solenoid defective e Defective vacuum gauge Loose Kynar compression fittings AIR DRYER TROUBLESHOOTING PROBLEM SYMPTOM POSSIBLE CAUSE Adjust injector vacuum e Check and replace or rebuild e Replace vacuum gauge e Tighten all Kynar fittings SOLUTION Air dryer not operating No power to air dryer e Switch not on Fuse blown e Insufficient vacuum Check power connections e Turn switch on e Replace fuse Adjust injector vacuum Air dryer not producing dry air flow Solenoid valve defective e Replace solenoid valve Air dryer cold when operating No power to air dryer e Switch not on e Fuse blown Defective heater cartridge e Check power connections amp breakers e Turn switch on
39. r with a wire brush as necessary then wipe with Isopropyl alcohol Be sure all solvents have evaporated prior to reassembly Re Installation of the Dielectric Tubes A PS Inspect the O rings and replace as necessary Tighten the end caps so that they are approximately 1 8 from the aluminum extrusion Replace the reaction chambers and connect the air and ozone lines Connect the high voltage wire to the coil Readjust the system as necessary see operating instructions Maintenance Schedule Yearly Service SH TDI Replace the cooling fan filter s on the ozone generator Replace the air inlet particulate filter on the ozone generator Replace the check valves Remove and clean the glass dielectric in reaction chamber Rebuild the solenoid valve on the electrical interlock box Replace the flange gasket and clean the diffuser in the contact column Regenerate the desiccant in the external indicating chamber on the AD 40 air dryer Every Three Years 1 2 Replace the cooling fan s in the ozone generator Disassemble and hone corona discharge reaction chamber s clean glass dielectric s and replace O rings Every Five Years l 2 3 Replace the glass dielectric s in the reaction chamber s and replace O rings Replace the desiccant in the AD 40 air dryer Replace the desiccant in the external indicating chamber on the AD 40 air dryer 28 CD 2000 OZONE GENERATOR COMPONENTS High Voltage Leads 2 Corona Disch
40. rical interlock box brass AIR OUTLET fitting to the brass barb AIR INLET fitting on the bottom of the ozone generator 3 Install the ozone check valve assembly onto the injector Connect the 1 4 Teflon tubing from the Teflon OZONE OUT compression fitting on the bottom of the ozone generator to the Teflon compression fit ting on the check valve assembly on the injector Secure by tightening the fitting around the 1 4 Teflon tubing after insertion If equipped with the electrical interlock box install the 1 4 Teflon tubing from the OZONE OUT fitting on the bottom of the ozone generator to the stainless steel solenoid valve located on the top of the electrical interlock box Continue running the Teflon line from the solenoid valve to the check valve assembly on the injector Check Valve Selection The ozone check valve is an important component in preventing damage to the ozone generator All RK2 Systems RK8g Air RK20g Oxygen ozone generator is equipped with a Kynar low pressure check valve on the ozone outlet A second check valve should be installed on the venturi injector ozone inlet This check valve should be matched to to the application A low pressure Kynar check valve is appropriate for applications where the system pressure will not exceed 40 psi Higher line or system pressure installations require a stainless steel check valve Note The cracking pressure the pressure at which the valve opens of any stainless ste
41. rminal strip as indicated The ozone generator will be controlled by the electrical interlock box Air Dryer 120 VAC 60 Hz 1 AMP Plug the air dryer into a standard wall outlet 120 VAC 60 Hz The air dryer should remain energized at all times with the exception of long term shutdown for service The air dryer can be hard wired to the electrical interlock box utilizing terminals 1 120V and 3 neutral or can be plugged directly into the convenience outlet on the bottom of the electrical interlock box if terminals 1 8 2 are NOT timer controlled If possible the air dryer should be plugged in 24 hours prior to system startup in order to pre dry the desiccant beds Using a bonding wire conforming with all local state and national electrical codes normally a 8 AWG ground the compo nents to the grounding bar on the electrical interlock box and bond the electrical interlock box to a true earth ground 25 Ozone Systems Maintenance Trouble Shooting Manual Parts amp Warranty RK g RK20g Corona Discharge Ozone Generators MAINTENANCE Ozone Generator Care A word of caution There is extremely high voltage inside the ozone generator If you suspect a problem disconnect the power to the unit at the service disconnect box or main electrical panel and immediately contact your RK2 Systems distributor Inspect the ozone delivery line check valves daily for water seepage and replace the injector check valve yearly e Clean the ozone g
42. t compression fitting provided attach another suitable length of 1 4 Teflon tubing to the outlet of the PVC ball valve Attach the other end of the tubing to the compression fitting on the venturi check valve assembly Turn the fill drain fitting so the opening faces upward and add water to the water reservoir until it begins to overflow out of the fill drain fitting Now turn the fitting so the opening faces downward Slowly open the PVC ball valve on the riser tee allowing the water level in the riser tube to rise to a level no closer than two inches from the bottom of the riser tee Connect a suitable length of the 3 4 braided tubing provided to the barbed fitting on the fill drain fitting Make sure the open end of the tubing goes to safe proper drainage and that the tube has no flow restrictions Run the system to ensure the water level in the riser tube is stabilized Note The proper water level must be maintained in the water reservoir When full the reservoir contains about twice the amount of water required to fill the riser tube so 1t must always be kept at least half full An insufficient water level will result in a loss of vacuum preventing air flow through the ozone generator Vacuum Break Detail f Ozone Generator Check Valve Assembly lu Ozone Injector Manifold Plumbing Connections continued Ozone Flow gt 3 Fill Port Cap 8 I gt Upper Tee
43. te anchors in the wall to expand and thus secure the L bracket to the wall Bolt the unistrut to the L bracket with two bolts nuts and washers NOTE The unistrut may be cut to length if desired Slip the two 6 clamp pieces into the unistrut around the contact column Tighten bolt Attach the protective end cap to the exposed end of the unistrut MOUNTING CONTACT COLUMN TO WALL USING UNISTRUT MOUNTING SYSTEM 1 2 Holes Drilled Into Wall 3 5 to 4 deep 6 Clamp Assembly with Bolt amp Nut Bolts Nuts amp Washers 2 each Unistrut may get cut to length desired LED e O SO SO O E e L Bracket Unistrut Protective End Cap Concrete Anchors with Nuts amp Washers 2 each Wall Contact Column MOUNTING TWO CONTACT COLUMNS TO WALL USING UNISTRUT MOUNTING SYSTEM 1 2 Holes Drilled Into Wall 3 5 to 4 deep 6 Clamp Assemblies with Bolt 8 Nut Bolts Nuts amp Washers ME 2 each Ll EOS SO Y 3232030 e O 3203000 ee 2 Unistrut may get cut to length desired L Bracket Unistrut Protective End Cap Concrete Anchors with Nuts 8 Washers 2 each Contact Columns Wall Installation of Contact Column Vent Line l Drill and tap a 1 4 MPT hole into the main water return line after the heater This hole should be drilled into a location with less pressure than the ozone loop so that the contact column will cont
44. ther disinfectants and the primary by product is pure oxygen RK2 Systems ozone systems are built with the finest components available All are air cooled and are most efficient when used with a venturi injection system to create the best possible contact and mixing of ozone while maintaining a high level of safety UNCRATING and INSPECTION Shipping Terms Unless special arrangements have been made the ozone equipment will be shipped FOB RK2 Systems factory in Escondido CA The freight charges will be prepaid and billed or shipped freight collect Transfer of liability to the freight company and the customer occurs as the equipment leaves the factory loading dock and is accepted by the freight line Freight Inspection All equipment should be thoroughly inspected immediately upon delivery If any damage is noticed promptly notify the freight line and request an on site inspection Unpacking Typically the equipment will arrive on a pallet Compare the components with the packing list Thoroughly inspect all packing materials prior to discarding Inspect all plumbing fittings and tubing for packing mate rial inadvertently lodged in any openings Placement of Equipment Select a location for the ozone equipment that is as close as possible to the ozone injection point Arrange the components ozone generator air dryer and electrical interlock box if so equipped in a manner suitable for convenient electrical access The system component
45. this terminal or jumper to the ground Note The unit will not function without true neutral to this location Terminal 4 MCI Motor Control Interlock 120 VAC 60 Hz Use 18 AWG This is an interlock from the main pump to the ozone system Run a 120 VAC line from the motor starter relay to this terminal Should this feature not be used simply install a jumper from L1 to this terminal Note The unit will not function without a 120 VAC signal to this location Terminals 5 8 6 Oxidation Reduction Potential ORP Controller 120 VAC 60Hz Use 18 AWG This is control voltage only 120 VAC from the controller to a relay integrated into the ozone system These terminals may also be used to operate the system using a 120V signal from a flow switch or timer Note To override the ORP control signal simply turn the ozone switch on the electrical interlock box to the ON position Terminals 7 amp 8 Booster Pump 240 VAC 60 Hz 8 AMP 1 HP Use minimum 14 AWG Wire from the terminal strip to the booster pump as indicated The booster pump will be controlled by the interlock box If you are using a pump of over 1 HP you will need to use a magnetic starter relay with these terminals providing the control voltage to the magnetic starter relay In many cases this feature is not be used the operation of the remaining equipment will not be affected Terminals 9 amp 10 Ozone Generator 240 VAC 60 Hz 2 AMP Hard wire the ozone generator to the te
46. ting Condulet Fuseis one for 120 Pero for 2405 Grounding Lug Check Valve Crone Out Fitting variable Ext Dry Contact PlugLoop oltage Selection Svwitcr Condulet Cooling Fan inlets ELECTRICAL CONNECTIONS The installation should be done by a licensed electrician All local codes must be observed The units come standard ready to be hard wired using 1 2 liquid tight conduit The ozone generator should be wired so that the ozone generator is on when the pump is on or when water is flowing through the venturi This can be done by using the electrical interlock box to interface with a flow switch ORP monitor or timer or by using the motor control interlock MCI to work with a main pump IMPORTANT The RK2 Systems ozones are available in 120 volt and 240 volt models Be sure you have the proper sys tem for your application Before attempting any electrical hookup be sure the power is OFF at the main circuit box To hard wire a 120V system connect the black hot wire to terminal L1 Connect the white neutral wire to the L2 ter minal Connect a 12 AWG jumper wire from terminals L2 to L3 Then run the green ground wire to the grounding bar To hard wire a 240 VAC system connect the black wire to terminal L1 and connect the red wire to terminal L2 Con nect the white neutral to terminal L3 Connect the green wire to ground ELECTRICAL INTERLOCK BOX OPTIONAL DIMENSIONS AND LAYOUT Ozone Inlet
47. way to vent the contact vessel s when it is impractical to send the off gas to atmosphere or reintroduce it to the water 5 SAFETY INFORMATION SAFETY WARNINGS Two aspects of RK2 Systems ozone generators represent potential dangers ozone gas and high voltage electricity OZONE GAS WARNING HIGH CONCENTRATIONS OF OZONE GAS ARE DANGEROUS TO HUMANS LOW CONCENTRATIONS CAN CAUSE IRRITATION TO THE EYES THROAT AND RESPIRATORY SYSTEM This RK2 Systems corona discharge ozone generator is designed to operate under a pressure condition While safety precautions have been taken entering the equipment area should be avoided if ozone gas is detected Ozone has a very distinctive odor and is de tectable at very low concentrations 0 02 ppm which is far below OSHA s maximum permissible exposure level of 0 1 ppm HIGH VOLTAGE WARNING RK2 SYSTEMS OZONE GENERATORS OPERATE AT HIGH VOLTAGES DO NOT TAMPER WITH OR DELIBERATELY BYPASS THE DOOR OR SAFETY SWITCHES BUILT INTO THE Lal OZONE GENERATOR UNLESS INSTRUCTED TO DO SO BY THIS cu MANUAL IF CONTACT IS MADE WITH OPERATING HIGH v j VOLTAGE COMPONENTS ELECTRIC SHOCK WILL OCCUR RK2 Systems corona discharge ozone generators take line voltage and convert it to 48 VDC A high voltage transformer then boosts the voltage While each ozone generator has a door switch and other safety interlocks proper care must be used by a qualified electrician when making any internal adjustments or perform
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