RK 4.5 GRAM Manual
Contents
1. The ozone system should be plumbed using either a sidestream or full flow configuration The sidestream loop method takes a portion of the water from the main flow see Figure 4 1 and diverts it into a sidestream downstream of the filter if so equipped Ozone is introduced into the sidestream water and is allowed contact time with the water before it is returned to the main flow at a point downstream of all other equipment heaters solar panels etc if so equipped in the circulation system A booster pump is usually employed to compensate for the flow restriction caused by the sidestream loop and the injector manifold If a halogen type residual sanitizer is utilized its injection point should be as far downstream as possible from the point at which the sidestream water returns to the main flow In a full flow configuration the same system components are usually involved and appear in the same order with respect to the direction of flow However all the water in the main flow is allowed contact time with the ozone see Figure 4 2 A booster pump may be necessary to maintain proper flow requirements If employed the booster pump is located upstream of the point at which the ozone injector manifold is installed NOTES x z Aaaa i d isolati l Ozone is a powerful oxidizer and will degrade certain t oa use 9 a Seca p E E aat bes nee materials Use ozone compatible plumbing materials gt Hu y L ed to facilitate maintenance for se2. Vacuum Break Detail I Figure 6 3 Ozone Generator Ozone Flow _ GU EH Port Cap D frre n Upper Tee L Ozone Outlet 4 Ozone Flow z ie amp ower Tee l Riser Tube _ f i Drain Barb ae Check Valve Assembly E Overflow Tube a H ounting Clamps B Fill a Epp 8 r 4 I i dg man E F Level lg i 7 p i Riser Elbow X lt r 14 Ozone Injection Manifold Fd Flapper Check Valve START UP amp CALIBRATION CHAPTER 7 The previous sections of this manual have involved comparatively static procedures making Be electrical and pneumatic connections fitting pipe etc This section involves the dynamic process of starting up and balancing the components of the ozone system including initiating water flow S PREF making air and water flow adjustments etc Maximum performance and reliability is achieved when the prescribed air flow is maintained at the ozone generator while the system is operating under pressure Air from the air preparation system is flowing through the ozone generator under pressure and from the ozone generator under a slight vacuum created by the ozone injector manifold The change from pressure to vacuum occurs after the stainless steel ozone outlet needle valve on the ozone generator Air Preparation System Ozone Generator amp Ozone Injector Warning
3. 1 2 hole at each of the marks about 3 1 2 deep Insert a concrete anchor into each hole with the threaded end facing outward Slip the L bracket over the threaded ends of the anchors followed by a washer for each anchor Secure the bracket to the wall by threading a nut onto each anchor and tightening Step 3 Cut the unistrut bar to the desired length and attach it to the L bracket using hardware provided Step 4 Slip the two sides of the 6 clamp into the unistrut bar and then around the contact column Tighten the retaining bolt securing the contact column to the unistrut bar Step 5 Slip the protective end cap over the exposed end of the unistrut bar Sidestream Plumbing Installation Diagram Figure 4 1 rts Flow Diversion Mechanism i IS t 1 nit Filter L Isolation lt D Isolation Valve Valve a a Isolation Service Loop Valve pantsa J i Vessel NZ i it Isolation Isolation Valve Ozone Injector Valve Booster Bypass Pump Valve Full Flow Plumbing Installation Diagram Figure 4 2 Contact Vessel Plumbing continued t t e1n814 MalA pepo dx3 uuunioo 12e3u05 Bag S I LISE M p i a 7 SNN e3ue 4 aseg yayseg eBue J eseg eqn ijesn sua 7 28 g s 1SUSEAA eDue J 3 syog eBue 4 _ uuinjo9 uulnjoo eag siousem gt SINU uw SIO0uouy l i9uoo deo pu3 I 9AIl29j0Jgd 7 OIE 1
4. Figure 8 2 Booster Pump s Drive Module High Ou Figure 8 1 Strainer Baskets Check and clean the strainer basket in the booster pump s as required if so equipped Drive Board Transformers XFMR under boards Ozone Output LED Fuse Transformer XFMR LED Drive Board Main Power LED Fault LED 24VDC Output Connector Variable Input Connector DC Power Input Connector Maintenance continued Ozone Generator Cooling Fan Assembly Figure 8 2 lt Fan ALU Ew ae Ozone Generator Bottom Panel lt _ Finger Guard lt Fan Filter Element lt Fan Filter Grill System Shutdown Procedures CAUTION The ozone generator operates at high voltage Follow these steps carefully before performing any semi annual or annual maintenance procedures Step 1 Turn off power to any peripheral system hydraulic components and air prep system Step 2 Turn the Main Power switch on the ozone generator to the OFF position The Ozone Generator Main Power Light at the bottom of the ozone generator and Ozone Output LED s at the front cover should nor be illuminated Step 3 Disconnect the power to the ozone system either at the service disconnect box if so equipped or main circuit breaker Semi Annual Procedures CAUTION Follow system shutdown procedures outlined above before performing any of the following steps Air Preparation System Air Inlet Filter Repla
5. Slide the four end cap retaining screws through the holes in the end cap aligning them with the heat sink screw bosses Thread screws into screw bosses until heads are snug against the end cap Step 9 Re install complete reaction chamber assembly into the ozone generator by following the Removal and Disassembly instructions in reverse order from Step 6 to Step 2 Follow steps outlined in Chapter 7 Start Up and Calibration to re start the ozone system 2 Pressurized Reaction Chamber Exploded View Figure 8 3 Ozone Outlet Fitting 9 Bottom End Cap i Stainless Steel Clamp Heat Sink and Cathode End Cap Retaining Screw and Washer Glass Dielectric High Voltage Anode Contact Brush uil dea Oxygen Inlet Fitting d VitonWasher A L k amp E d Stainless Steel i Washer L MN CAU W Brush Adapter Nut Le s High Voltage End Cap DG High Voltage Maintenance continued Vacuum Break Cleaning Disconnect ozone delivery lines Remove the vacuum break from mounting clamps Disconnect the overflow tube from flapper valve open flapper and clean the seat with a soft cloth Remove riser tube threaded fitting and flush riser tube with water Re assemble and re install vacuum break making sure to add water to correct level see Figure 6 3 Injector Manifold Check Valve Replace the check valve located at the ozone injection manifold Note Because the system is in the
6. 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 charges 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 dam
7. asun oe u1Bu 0 no Tam X Insun eeg sieusem nN 9 1lOq YIM 9 sinu syog A quiessy duue o 9 E P enBi4 uieJ6eiq uonejejsu uuinjo5 12ejuo2 INSTALLATION PROCEDURES Electrical CHAPTER 5 The 6024 and 6032 ozone has an assortment of IEC cords for various voltage s generators are equipped with universal requirements and outlet configurations for use around CS regulated power supplies that accept an the world All possible pre wiring has been completed Bs input voltage from 90 250VAC at 47 at the factory Logic schematics have been provided in 4 63Hz single phase 1 RK2 Systems Inc the Appendix Section D All electrical connections should be made by a Make sure all power is off at the main circuit licensed qualified electrician AII local state and breaker before making any electrical connections national codes must be observed Step 1 Conforming to all local state and national electrical codes ground the ozone generator to a true earth ground Use solid copper bonding wire usually 8 AWG from the copper bonding lug located on the bottom of the ozone generator to the grounding point Step 2 Main Power Plug the IEC end of the power cord into the power entry module located at the bottom of the ozone generator The other end can be plugged into any main CD1500P 1 6 0 8 power source with input voltage from 90 to 250 VAC at 47 CD2000P to 63 Hz single phase Step 3 External Loop
8. disconnected according to the System Shutdown Procedures outlined above Step 2 Unplug the electrical connections from the drive module Step 3 Remove the 4 20mA control board with mounting bracket from the reaction chamber of the 6024 Step 4 Disconnect tubing connections from the fittings on both ends of the reaction chamber Step 5 Disconnect the high voltage lead from the drive module Step 6 Remove reaction chamber from ozone generator Step 7 Remove retaining screws from the two end caps 4 each Step 8 Usinga gentle back and forth twisting motion remove the non high voltage end cap the one without the white power lead attached from the heat sink cathode assembly Note The stainless steel clamp must not be removed Step 9 Remove the high voltage end cap and dielectric from the heat sink cathode assembly Note The stainless steel clamp must not be removed Step 10 With contact brush attached remove the brush adapter nut from the high voltage end cap 17 Maintenance continued Step 11 Inspect the dielectric end caps and cathode for breakage corrosion or debris Clean and or replace parts as necessary If cleaning and or parts replacement is not required re assemble the reaction chamber per the instructions below Assembly and Re installation Step 1 Make sure the glass dielectric is clean free of dust dirt grease oils etc Step 2 Prepare the end caps for re assembly by replacing the O rings
9. 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 to 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 failure to do so may void the warranty INSTALLATION PROCEDURES Getting Started CHAPTER 3 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 Inspec
10. 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 Theory of Operation Product Description continued Depending on the application the RK2 Systems Inc ozone generator may be interlocked with an ORP controller PPM controller pressure switch timer or circulation pump Other safety features are also built in including thermal protection 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 Inc 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 Inc contacting system may also be required Some oxidation reactions t
11. up amp Calibration section Warnings Failure to calibrate may lead to premature failure of the air preparation system Vacuum from the venturi must be interrupted if the air prep system is not ON failure to do so will damage the air prep system External Loop Electrical Interface Figure 5 1 L1 120 VAC Signal 240 VAC Signal Power from ORP PPM L1 Power from ORP PPM pump or timer pump or timer Interface Relay Interface Relay External Loop ji D 0 il External Loop This section outlines the steps required to complete the ozone system pneumatic hook ups The system components include the air preparation system ozone generator vacuum break and ozone injector manifold see Figure 6 1 The air preparation system provides the ozone generator with a source of dry oil free oxygen Figure 6 1 INSTALLATION PROCEDURES Pneumatic CHAPTER 6 enriched air 90 3 oxygen purity at 100 F dew point The air is drawn from the ozone generator where ozone is produced from the oxygen in the air stream and through the vacuum break by the suction created at the ozone injector manifold Booster Pump Ozone Injector Water Flow m Ozone Generator Air Prep System gt ea Lx i BER l I a NE nR I l ENG h Vacuum Break I Ly 43 WA mS Air Prep In Ozone Out Hook Up Air preparation system to ozone generator Step 1 Teflon
12. Disconnect the External Loop dry contact from the ozone generator while performing all start up procedures Failure to do so may result in ozone escaping to atmosphere Step 1 Make sure all isolation valves in the ozone water system are open Figures 4 1 or 4 2 show recommended isolation valve locations Step 2 Start up hydraulics Allow the water system to reach hydraulic equilibrium contact vessel full off gas vent operating etc and observe for plumbing leaks Note Water flow must be established through the main water pump and the ozone system booster pump if so equipped Step 3 Close the ball valve on the injector manifold about half way Step 4 Using your thumb check for the presence of vacuum suction at the ozone injection manifold check valve assembly or use a RK2 Systems Inc vacuum test assembly to check vacuum at the injector port If no suction is present continue to close the ball valve on the injector manifold until vacuum is detected If using the vacuum test assembly check the VAC PSI gauge for vacuum If the needle is in the red zone on the pressure PSI side of the gauge gradually close the ball valve on the injector manifold until the needle moves into the green zone If the needle is in the red zone on the vacuum in Hg side of the gauge gradually open the ball valve on the injector manifold until the needle moves into the green zone While vacuum is in the green zone you must be able to achieve proper SCFH Sta
13. EXT LOOP The external loop is a true dry contact interface Note The term dry contact means that this loop does not supply output nor except input voltages Warning Supplying voltage to the external loop will cause damage to the ozone generator and void warranty Under normal operation the external loop will effectively interrupt the ozone output when the loop has lost continuity this will also illuminate the LED located on the 4 20mA control board inside the ozone generator see Appendix Section A for location of board and turn off the Ozone Output LED s on the front cover Note When the external loop has lost continuity main power to the ozone generator will remain ON giving power to the cooling fan s When continuity is present through the external loop ozone output will continue This continuity will effectively turn OFF the LED of the 4 20mA board and will again illuminate the Ozone Output LED s The external loop a removable two position plug with a white ISAWG wire located at the bottom panel of the ozone generator see Appendix Section A can be interfaced to any control device i e pressure switch vacuum switch flow switch float switch ORP controller PPM controller or timer To interface a control device to the external loop cut the white ISAWG wire in half Connect the control device to each leg of the external loop Note External Loop control devices supplied by RK2 Systems Inc may come equipped
14. Loop Pressure Switch 4 20mA Control Board Variable Output Signal Shown Electrical Schematic 6032 Reaction Reaction Chamber Chamber F wr x xor E ome 3 PETA a lt m A O lt Drive Module Input Voltages 1 C y 1 s fi 4 4 U L b bap v lec Cus y Shown Dual HO Drive Module 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 date 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 Enduser name Complete address including telephone number 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 carr
15. RK2 SYSTEMS INC Ozone System Installation and Owner s Manual Corona Discharge RK 15 amp 27 GRAM Ozone Generator 421A South Andreasen Drive Escondido CA 92029 760 746 7400 Copyright 2008 RK2 Systems Inc e Reproduction of any kind is prohibited lt Rev 1097 THEORY OF OPERATION PRODUCT DESCRIPTION CHAPTER 1 RK2 Systems Inc ozone systems are designed for safe effective use in a variety of water treatment applications The 6024 and 6032 ozone generators have been tested and certified by the Water Quality Association according to NSF ANSI 50 Each complete integrated system may include the following 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 Booster Pump Ozone Injector Water Flow Ib Off Gas Optional Destruct System Valve Unit a m Air Ozone Generator Preparation al Vac um Break Contact Vessel Air Preparation System RK2 Systems Inc pressurized ozone generators require a source of clean dry oil free oxygen enriched air for effective ozone production To meet that need RK2 Systems Inc employs pressure swing adsorption PSA technology with an oil less compressor to increase the concentration of oxygen and reduce the moisture content in the feed gas the air supplied to the ozone generato
16. TORY SYSTEM This RK2 Systems Inc 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 detectable at very low concentrations 0 02 ppm which is far below OSHA s maximum permissible exposure level of 0 1 ppm CAUTION OZONE GAS HIGH VOLTAGE WARNING OZONE GENERATORS OPERATE AT HIGH VOLTAGE DO NOT TAMPER WITH OR DELIBERATELY BYPASS THE COVER OR SAFETY SWITCHES BUILT INTO THE k e OZONE GENERATOR UNLESS INSTRUCTED TO DO SO BY THIS SY MANUAL IF CONTACT IS MADE WITH OPERATING HIGH VOLTAGE E e COMPONENTS ELECTRIC SHOCK WILL OCCUR RK2 Systems Inc 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 performing any maintenance procedures IMPORTANT SAFETY INSTRUCTIONS When installing and using this electrical equipment basic safety precautions should always be followed including the following 1 2 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
17. Thread the hex brush adapter nut with contact brush attached onto the end of the high voltage end cap cap with the white power lead attached center screw Step 3 Using a gentle twisting motion press the non high voltage end cap onto the heat sink cathode assembly until flush with the heat sink cooling fins Note See Figure 8 3 for correct orientation of end cap Step 4 Slide the four end cap retaining screws through the holes in the non high voltage end cap aligning them with the heat sink screw bosses Thread screws into screw bosses until heads are snug against the end cap Step 5 Roll the high voltage anode foil like material lengthwise preserving the onger dimension Insert the rolled anode into the dielectric Center the anode in the dielectric approximately 1 2 from either end of the glass making sure it is rolled squarely Step 6 Slide the dielectric into the heat sink cathode assembly Seat the dielectric into the O rings of the non high voltage end cap by applying pressure with a gentle twisting motion There must not be any dirt debris oils or fingerprints on the dielectric upon re installation Step 7 Slowly insert the high voltage end cap assembly into the dielectric Note Do not bend center wire of the brush during this procedure It is normal for the bristles to bend Using a gentle twisting motion press the high voltage end cap onto the heat sink cathode assembly until flush with the heat sink cooling fins Step 8
18. age 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 421A South Andreasen Drive Escondido CA 92029 760 746 7400 Fax 760 746 7460 RK2 SYSTEMS PRODUCT LIST hei Parts amp Fittings FOR FURTHER TECHNICAL ASSISTANCE CONTACT YOUR RK2 DISTRIBUTOR
19. ake 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 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 Inc 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 Inc off gas vent the ozone destruct system is an effective way to vent the contact vessel s when it is impractical to send the off gas to atmosphere or reintroduce it to the water bo A Short Course in Fine Bubbles LESSON 1 The large bubble 20mm has 2 volume of 4 1 cm and 2 surface area of 126 cm LESSON 2 296 small bubbles 3mm coule be made from the large bubble in lesson 1 They would have a total surface area of 88 6 cm This is 66 limes tne surface area of the large bubble C LESSON 3 Theoreticaily 6 6 times as much water could be czonated with the same amount of ozone SAFETY INFORMATION CHAPTER 2 SAFETY WARNINGS Two aspects of RK2 Systems Incozone 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 RESPIRA
20. ambers to 10 PSI Check the PSI gauge on the front panel of the ozone generator which measures this backpressure If there is insufficient backpressure the needle valve may be closed slightly similarly if there is too much backpressure the valve may be opened slightly Note The lock nut on the needle valve must be loosened prior to adjustment and tightened after adjustment Due to the pressure switch installed the PSI gauge must achieve 9 PSI before ozone will begin production ClearWater Tech VAC PSI Gauge Step 8 Step 9 Step 10 Step 11 Start up and Calibration continued The CFH gauge on the front panel of the ozone generator will monitor the CFH air flow rate By setting the oxygen concentrator SCFH and ozone generator back pressure PSI there will be no adjustments of CFH air flow See Air prep system air flow specifications outlined in Figure 7 1 Perform a final check of all air connections from the air preparation system to the ozone injector manifold Repair leaks as required Check all system water connections including the ozone injector manifold vacuum break and contact vessel Repair leaks as required Note The check valve at the ozone injector manifold may make a humming noise This is normal Reconnect the External Loop connector to the ozone generator Note The Ozone LED s will not illuminate until the External Loop has been replaced Observe all indicating LED s on the front cover of the ozone gene
21. amp tape and attach brass barb provided to the PSA oxygen concentrator outlet Step 2 Teflon tape and attach brass barbs to both sides of indicator cartridge ordered separately Step 3 Mount indicator cartridge on a suitable flat surface using the Clic mounting clamps provided Notes The indicator cartridge must be mounted vertically The indicator cartridge does nof have a direction of flow An external moisture indicating cartridge is used as a reference to indicate the quality of the dry air if the air prep system is not operating properly the silica will turn from blue and white in color to all white See Troubleshooting Guide i Step 4 Using a suitable length of 3 8 braided tubing provided attach one end of the tubing to the oxygen concentrator system to one end of the indicator cartridee Secure the tubing to the brass fittings with the hose clamps provided Step 5 Using a suitable length of 3 8 braided tubing attach tubing to the brass barb located at the other end of the indicator cartridge then attach the other end of the tubing to the brass barb located at the bottom of the ozone generator Secure the tubing to the fittings with the hose clamps provided Oxygen Concentrator Detail Compressor Inlet Filter E Figure 6 2 SCFH Air Flow Meter Compressor ATF Module sieve bed Oxygen Outlet r1 Gu Hour Meter m Power Switch if so equipped Main Power Cord Pneumatic continued Hoo
22. 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 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 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 Ambient temperature range 20 F to 95 F continuous If the temperature around the equipment consistently exceeds 95 F additional air cooling must be provided Humidity 0 90 relative humidity non condensing environment 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 INSTALLATION PROCEDURES Plumbing CHAPTER 4
23. ce the air compressor inlet filter on each air preparation system module see Figure 6 2 Note Manufacturers recommended replacement interval is 4 000 hours of operation Operating conditions in the equipment area will dictate the required frequency of this procedure Annual Procedures CAUTION Follow system shutdown procedures before performing any of the following steps Air Preparation System Compressors Following the procedures outlined in the compressor rebuild kit rebuild the two compressor heads on each air preparation system module see Figure 6 2 Note Manufacturers recommended interval is 5 000 to 12 000 hours of operation Compressor performance and or operating conditions in the equipment area will dictate the required frequency of this procedure Ozone Generators Cooling Fan Filters Clean or replace the cooling fan filter elements as required Inline Filter Replace the inline particulate filter Reaction Chambers Remove and disassemble one reaction chamber according to the steps outlined below see Figure 8 3 Check the chamber interior and dielectric tube for oil dirt or moisture Note RK2 pressurized reaction chambers are anodized blue Removal and Disassembly Note Disassembly and service of the reaction chamber is a technical delicate and critical procedure Please consult your RK2 Systems Inc dealer before attempting this procedure Step 1 Make sure all power to the ozone generator has been
24. conditions in the equipment area will dictate the frequency required for this procedure Remove the filter element and clean with soap and water drying them completely before re installing Ozone Generator Drive Module Operation The Drive Module is made up of two components the drive board and the drive transformer With the ozone generator cover removed check for illumination of the drive module Ozone Output LED s for LED locations see Figure 8 1 if not illuminated see Troubleshooting Guide This procedure is to observe the complete operating function of the drive module s Before checking drive module function remove the ozone generator cover and depress the cover safety switch located on the ozone generator chassis see Appendix Section A CAUTION This overrides the cover safety switch The ozone generator will remain energized with the cover removed Do not touch anything inside the ozone generator while this switch is activated Please consult your ClearWater Tech dealer before attempting this procedure Main Power LED When illuminated this Green LED indicates that main power is supplied to the drive module up to the on board fuse of the drive board Transformer Power LED When illuminated this Green LED indicates that 48V Buss power is available to the drive module transformer XFMR from the on board fuse of the to the drive transformer Ozone Output LED The Amber ozone output LED will illuminate
25. ction s of the system that will come in contact wn TERES with ozone dissolved in water The following is a list of 5 materials that are compatible with ozone Use Schedule 80 PVC for all plumbing connections PVC J Stainless Steel 300 series wherever possible Plumbing size requirements e CPVC s Viton are dictated by the water flow characteristics of Kynar e EPDM the system Teflon Concrete Make ee to lan ap ghe practices m Depending on the application other components psi SERUEE A plumbing and system equipmen gauge flow meter etc may be installed to assist in according to local codes monitoring system parameters Step 1 Arrange the ozone system equipment booster pump injector and contact vessel according to mechanical print or as dictated by equipment layout and serviceability considerations Do not secure booster pump and contact vessel to housekeeping pads at this point Dry fit plumbing as appropriate to insure proper fit and location before making permanent connections I Step 2 Install a tee or plumbing saddle into the main water line after the filter if so equipped and before the flow diversion mechanism The purpose of the mechanism is to restrict water flow so water is diverted into the sidestream see Figure 4 1 If such a mechanism is not present in the system such as a heater bypass valve etc it will require installation of a valve butterfly gate or ball or a flow controller Step 3 Plu
26. eak is in a vertical position and the drain holes are below the level of the ozone generators ozone outlet fitting One clamp should be located so it fits around the Riser Tube Elbow and the other so it fits around the bottom of the Lower Tee see Figure 6 3 Step 3 Remove the Fill Port Cap located on top of the Riser Tube and fill the Riser Tube with clean water no particulate matter until Fill Level line indicated in Figure 6 3 Step 4 Re install the Fill Port Cap using pliers or a wrench to tighten Note Do not over tighten as damage to PVC fittings may occur Step 6 Connect one end of a suitable length of Teflon ozone delivery line to the ozone outlet needle valve see Appendix Section A Notes The compression fitting ferrules are zip tied to the ozone outlet needle valve Attach the other end of the Teflon delivery line to the fitting threaded into the Upper Tee As an additional backflow prevention measure loop this length of tubing as high as is practical between the two connection points Step 7 Connect one end of a second length of Teflon delivery line to the fitting threaded into the Lower Tee The other end of the delivery line will be attached to the fitting located on top of the check valve assembly in step 6 of Chapter 7 Start up and Calibration Procedures Step 8 Adjustments to the valve on the ozone injector manifold will be necessary These steps are covered in Chapter 7 Start up and Calibration Procedures
27. essel and before returning to the main water line Step 7 Secure the booster pump and contact vessel to solid mounting surfaces using appropriate hardware and according to local codes If installing a RK2 Systems Inc contact column use a RK2 Systems Inc contact 6 Plumbing continued column mounting kit and install according to the instructions below If installing a contact tank secure to a solid horizontal surface using mounting flange or feet Step 8 Install the contact vessel venting system into the top of the vessel If using the RK2 Systems Inc contact column the vent kit supplied includes fittings a control valve and Teflon tubing The contact tank venting system includes an air relief valve fittings and a length of Teflon tubing Depending on conditions the vented gas may be directed to an ozone destruct system to atmosphere or to the low pressure side of the water system Note Do not direct the tubing to the suction side of any pump in the system Contact Column Installation if so equipped Step 1 Make sure the following hardware items are included in the contact column mounting kit L bracket Unistrut bar 1 2 concrete anchors Protective end cap 6 clamp assembly Mounting hardware Step 2 Referring to Figure 4 3 mark the two holes for mounting the L bracket to the wall The bracket should be located so that the 6 clamp assembly will be approximately 12 from the top of the contact column Drill a
28. inated CHAPTER 9 SOLUTION POSSIBLE CAUSE No power to system Power switch in OFF position Incorrect wiring Flow meter out of adjustment Check main power to system Turn switch to ON position See Installation Procedures Electrical Adjust flow meter See Start Up amp Calibration Step 5 Replace inlet filter Rebuild or replace as required Replace pressure relief valve Check check valve for proper operation replace as required Replace tubing Rebuild or replace as required Repair or replace ATF as required Fouled compressor inlet filter Compressor not functioning ressure relief valve not operating Excessive backpressure in system Pinched tubing Compressor not functioning ATF not operating Check amp tighten fittings Rebuild replace compressor or ATF module as required Replace indicating desiccant Moisture has entered air prep system Place unit on a flat level surface Locate damage and repair replace parts Clear obstructions Unit not properly secured to floor Shipping damage Fan blocked Packaging material not removed Remove packaging material D DIN i P Replace light Check circuit breakers Turn switch to the ON position Replace fuse See Installation Procedures Electrical See Installation Procedures Electrical Replace with correct ci
29. k Ups Ozone generator to vacuum break amp vacuum break to injector manifold The RK2 Systems Inc vacuum break provides a positive atmospheric break between the ozone injector manifold and the ozone generator preventing water from flowing back into the ozone generator should the venturi check valve fail Under normal operating conditions the vacuum break s flapper valve see Figure 6 3 is closed allowing the vacuum created by the venturi to draw the output gas from the ozone generator If the check valve at the venturi begins to leak or fails completely vacuum is interrupted and water will flow toward the ozone generator With the vacuum break properly installed between the venturi and the ozone generator the water will flow down the riser tube away from the ozone generator and out to drain protecting the ozone generator from potential water damage Note All Teflon amp delivery lines that are secured by a stainless steel compression fittings require a tubing insert inserts are located in the Vacuum Break parts bag This insert will prevent crushing of the tubing which may create an ozone leak All stainless steel compression fittings must be tightened no more than 1 1 4 turns past finger tight Step 1 Select a suitable vertical surface that is accessible and in close proximity to both the ozone generator and the ozone injector manifold Step 2 Install the two Clic mounting clamps provided onto the vertical surface so that the vacuum br
30. mb a line from the tee or plumbing saddle to the booster pump For serviceability of the equipment in the sidestream loop be sure to install an isolation valve between the tee or saddle and the booster pump Step 4 Plumb from the booster pump to the injector manifold Make sure to note the correct direction of flow indicated by a blue arrow on the inlet side of the manifold body The check valve assembly is strapped to the manifold using wire ties Remove the assembly using Teflon tape install it onto the top opening of the injector Step 5 Plumb from the injector manifold to the inlet side of the contact vessel To reduce possible backpressure to the injector minimize the number of elbows between the injector manifold and contact vessel The contact vessel is a specified size determined by water flow requirements RK2 Systems Inc contact columns and the 30 40 80 and 120 gallon contact tanks have inlet and outlet fittings on the bottom of the vessel and are designated with arrows showing the direction of flow Note The inlet and outlet arrows on the contact tanks are under the base of the tank The inlet on the 264 463 and 850 gallon tanks is located at the top with the outlet at the bottom Step 6 Using a tee or plumbing saddle plumb from the outlet of the contact vessel back into the main water line For serviceability of the equipment in the side stream loop be sure to install an isolation valve between the outlet fitting on the contact v
31. ndard Cubic Feet per Hour of air flow see the Pneumatic Operating Parameters chart for venturi SCFH required Figure 7 1 Step 5 Make sure electrical power is on to all ozone system electrical components The main power switch of the air preparation system must be in the ON position if so equipped see Figure 6 2 The air preparation system must be set to atmospheric pressure prior to full start up of the system Disconnect the oxygen delivery line from each oxygen concentrator if delivery has already been attached Note This should have been completed in Step 5 of Installation Procedures Electrical Step 1 Check to make sure the compressor of the air preparation system is operating Step 2 Using the air flow gauge adjustment valve on the air preparation system see Figure 6 2 adjust the air flow according to the Air prep system air flow specifications outlined in Figure 7 1 Note When the system is under normal operation the air flow will drop from the initial setting due to the air preparation system being under back pressure DO NOT READJUST THE AIR FLOW GAUGE ADJUSTMENT VALVE Step 6 Connect the Teflon ozone delivery line from the vacuum break to the ozone inlet fitting located at the ozone injection manifold check valve assembly Step 7 Using the stainless steel ozone outlet needle valve located at the bottom the ozone generator see Appendix Section A adjust the backpressure of the ozone reaction ch
32. nerator air flow line of the Pneumatic Operating Parameters see Figure 7 1 Adjust if necessary by following steps outlined in the Start Up amp Calibration section Pressure Check the PSI gauge located on the ozone generator cabinet door Make sure pressure is within the range shown on the PSI Gauge line of the Pneumatic Operating Parameters chart see Figure 7 1 Adjust if necessary by following steps outlined in the Start Up amp Calibration section Vacuum Break I Walter Level Check the water level in the vacuum break Make sure it is above the flapper valve in the overflow tube Fill as required by removing the threaded fitting on top of the riser tube until water is up to the Fill Level in the overflow tube see Figure 6 3 Injection Manifold Check Valve Inspect the Teflon ozone delivery line that runs between the vacuum break and the check valve assembly on the suction port of the ozone injector manifold If water is observed in the delivery line near the check valve assembly the check valve has failed See Troubleshooting Guide Monthly Procedures Air Preparation System Cooling Fan Operation Check to make sure the cooling fan mounted on the side panel of the air preparation System is operating If not refer to the Troubleshooting Guide 15 Maintenance continued Cover Filter Check the cover filter element mounted on the side of the air preparation system and clean as required Operating
33. on in venturi Rebuild or replace as required Fill vacuum break with water See Start Up and Calibration Vacuum Break Check booster pump contact dealer No vacuum Debris on seat of vacuum break flapper valve Water bubbling in vacuum break Low vacuum Hydraulics Pneumatics out of adjustment Defective check valve Hydraulic back pressure Defective solenoid valve No water in vacuum break Booster pump not functioning properly See Start Up amp Calibration Steps 1 4 Hydraulics Pneumatics out of adjustment See Start Up amp Calibration Steps 1 4 Change in hydraulics excessive water flow through ozone injector High Vacuum Ozone smell detected around No vacuum See Start Up amp Calibration Steps 1 4 vacuum break or ozone injector Loose fittings Tighten all fittings Broken fittings Replace fittings bo N APPENDIX Section A CHAPTER 10 Specifications Air Prep System with Cover Air Prep System with out Cover AIR PREP SYSTEM SPECIFICATIONS OXYGEN OUTPUT SCFH 15 5 hx17 wx16 d 45lIbs 90 396 12 scfh 12PSI with cover 23 Appendix continued Section A Specifications Ozone Output LED 5 aa ml o Sex NE T cod i E gt k P R ET p lm e e C 1 rey BG gg UI L i Pressure Gauge TER CFH Gauge Drive Board and Po
34. paration System Power Switch Check the power switch on the air preparation system see Figure 6 1 if so equipped Indicator Cartridge Inspect the air preparation system indicator cartridge A change in the blue crystals to a light pink or white color indicates the presence of moisture in the feed gas coming from the air preparation system If such a change is observed refer to the Troubleshooting Guide Air Flow Check the air flow gauge on the air preparation system see Figure 6 1 Make sure the air flow is within the SCFH range shown on the Air prep System Air Flow line of the Pneumatic Operating Parameters chart Figure 7 1 Adjust if necessary by following the steps outlined in the Start Up amp Calibration section Ozone Generator Indicator Lights Check the Main Power indicator light at the bottom of the ozone generator and Ozone LED s at the cover of the ozone generator see Appendix Section A The Main Power light should be illuminated when main power to the ozone generator is present and the main power switch is On The Ozone Output LED s should be illuminated when the External Loop has continuity the Manual Ozone Output Adjustment Knob is at a desired setting other than 096 or a Remote 4 20mA Control Signal is sensed See Troubleshooting Guide Air Flow Check the air flow gauge at the ozone generator cover Make sure air flow is within the CFH cubic feet per hour range shown on the Ozone ge
35. r 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 Inc air preparation system the same air quality standards must be met to achieve the ozone output and longevity of the ozone generator A pounds per square inch PSI regulator must be installed when using plant air feed gas This regulator must be set to a maximum of 10 PSI Ozone Generator RK2 Systems Inc pressurized ozone generators are designed to supply high concenirations of ozone gas up to 1096 at 10 PSI The oxygen feed gas produced by the air preparation system is supplied to the ozone generator which flows through the built in flow meter A stainless steel needle valve located externally at the ozone outlet is used to maintain optimum pneumatic parameters inside the ozone 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 operation if pressure within the reaction chambers drops below 9 PSI As the feed gas enters the fused thermally protected reaction chambers inside the ozone generator some of the oxygen molecules are split while passing
36. ra Uu Pressure Switch HUT x 2 GL SEE BEEJEI 4 20mA Control Board z2 FL E ts L A L1 Tum GE m T 1 Cover Safety Switch fex Ot T m z Y L External Loop S NS Remote 4 20mA Control Leads Fan and Fan Filter Air Prep Inlet Manual Ozone Output Adjustment Knob Main Power Light External Loop Connector Remote 4 20mA Connector Ozone Outlet Needle Valve Bonding Ground Lug Power Entry Module OFF ON Switch Cord Input Fuse Carrier OZONE GENERATOR SPECIFICATIONS OZONE OUTPUT SCFH 6032 23 h x 20 25 w x 5 5 d 49 Ibs 26 5g h 6 12 scfh 10PSI PSA Oxygen Mounting Hole Measurement 13 50 h x 21 75 w N Un APPENDIX Logic Schematics 6024 Power Entry Module With Fuses Cover Safety Switch Manual Ozone Output Control 24VDC Remote 4 20mA Ozone Output Control Orange Purple External Loop Pressure Switch Drive Board 4 20mA l Control Board f Variable I Output Signal High Voltage I Transformer Reaction Shown Electrical Schematic Chamber 6024 Appendix continued Logic Schematics 6032 G L1 L2 N e D Power Entry Module With Fuses Cover Safety Switch Manual Ozone Output Control Remote 4 20mA Ozone Output Control Orange Purple External
37. rator POSSIBLE CAUSE SOLUTION If the Transformer XFMR Power LED Check all wires and connectors is not illuminated the Ozone Output LED will not illuminate The Manual Ozone Output is turned down to 0 Turning the Manual Ozone Output knob clockwise will increase ozone output percentage and the Ozone Output LED will begin to illuminate see Installation Procedures Electrical Optional Equipment See Troubleshooting Fault LED Check for loose wires or connections Drive board is in Fault mode The remote 4 20mA control signal is not sensed by the 4 20mA control board See Installation Procedures Electrical Wait for the start up to finish Upon start up the Fault LED will be ON for 30 seconds this is normal Loose wire harness connection from the drive board to the drive transformer Failed drive board Failed drive transformer Broken dielectric Water in ozone reaction chamber Check all wires and connectors Replace drive board Replace drive transformer Replace dielectric Clean dielectric and replace O rings reaction chamber Clean dielectric and replace O rings Excessive dirt or debris in the ozone reaction chamber Loose or disconnected High Voltage Lead to transformer High temp Limit Attach High Voltage lead to transformer See High Temp Limit section below Check fan for p
38. rator Adjust the manual ozone output knob to desired level setting Vacuum Break Check the water level in the vacuum break making sure it is above the flapper valve see Figure 6 3 If water is not pressing downward on the flapper valve it will open causing a loss of vacuum A loss of vacuum means ozone cannot flow from the vacuum break which in turn can cause an ozone leak Note If the vacuum break must be refilled with water disconnect the External Loop from the ozone generator and disconnect the Teflon ozone delivery line from the ozone inlet fitting of the vacuum break This will keep the pressure from the oxygen concentrator from pushing out the water and shutting down ozone production Ozone Destruct System Adjust the small ball valve at the tee of the water trap see Figure 6 4 so that only a small amount of water is spitting into the trap This will indicate that the contact vessel is full and only a very small amount of water is allowed to escape Pneumatic Operating Parameters Air prep system air flow Ozone generator total air flow gauge front cover PSI gauge gauge front cover Injector manifold air flow Injector manifold injector Figure 7 1 Operating Range 5 to 6 scfh 2 to 6 cfh 9 to 12 psi 4 to 6 scfh 3 to 8 in hg 6 scfh 3 cfh 10 psi 6 scfh 5 inches Operating Range Optimum Air prep System air flow 10 to 12 scfh 12 scfh Ozone genera
39. rcuit breaker Lamp burned out No power to unit Switch is in the OFF position Blown fuse Incorrect wiring Incorrect wiring L breaker amperage does not match raw Unit flooded with water Assess damage correct cause and rebuild as required See Installation Procedures Electrical Ground unit according to local codes Assess damage correct cause and rebuild as required Check main power to unit Test voltage from power supply to drive module see Appendix Drive Module Input Voltages Check for loose wires or connectors Test voltage from power supply to drive Incorrect wiring Unit not grounded Unit flooded with water No power to drive module from power supply If drive module Main Power LED s not illuminated the XFMR Power LED will not illuminate Blown drive module on board fuse Drive board is in Fault mode module see Appendix Drive Module Input Voltages Replace on board fuse See Troubleshooting Fault LED 20 Troubleshooting continued OZONE GENERATOR continued PROBLEM SYNIPTOM Ozone Output Amber LED not illuminated The Ozone Output LED s not responding to the remote 4 20mA control signal Fault Red LED illuminated High Temp Limit Fan not operating Low air flow or no air flow Unit flooded with water Ozone smell detected in or ozone gene
40. roper operation and clean fan filter Check operating temperature See Installation Procedures Getting Started Equipment Placement Remove obstruction Check main power check fuses Repair or Replace as required Replace fan Unit is over heating Fan obstructed Power supplies not operating Fan inoperable See Start Up amp Calibration Step 5 Change inline filter Air prep system not operating properly Fouled inline filter Air leak Check all fittings tighten as needed Incorrect wiring to air prep system See Installation Procedures Electrical a Defective check valve Replace check valve s I Assess damage repair as required near Insufficient vacuum at venturi Adjust injector See Start Up amp Calibration Steps 1 4 Loose internal fittings Check all fittings tighten as needed Defective O ring seals in reaction chamber s Check amp replace as required Defective dielectrics Check amp replace as required Troubleshooting continued OZONE INJECTION CONTACTING PROBLEM SYMPTOM POSSIBLE CAUSE SOLUTION Defective check valve Replace check valve Water backflow past injector check valve See Start Up amp Calibration Clean seat of flapper See Maintenance Procedures Annual See Start Up amp Calibration Steps 1 47 Replace check valve Back wash filter if so equipped Check for obstructi
41. shutdown mode no vacuum is present at the injector Therefore it is normal for some water to be flowing from the injector during this procedure Contact Vessel Cleaning Contact Column only Inspect the diffuser slots at the top of the contact column riser tube If they are clear no further maintenance is required If the slots are fouled disassemble the column and clean as required following the steps outlined below see Figure 4 4 Step 1 Make sure the isolation valves before and after the contact column are closed Step 2 Disconnect the vent line from the top of the contact column Step 3 Remove the bolts in the 6 base flange Step 4 Remove the column lifting it over the interior riser tube Step 5 Remove and clean the diffuser Step 6 Inspect the flange gasket and replace if necessary Step 7 Reassemble the contact column and attach vent lines TROUBLE SHOOTING AIR PREPARATION PROBLEM SYMPTOM Unit not operating Low air flow or no air flow Compressor pressure relief valve making noise Indicator cartridge desiccant has changed from blue amp white to all pink or white Unit is making excessive noise OZONE GENERATOR ROE IV MIF T QON Main Power light is not illuminated or System is not ON Circuit breaker trips Receive an electrical shock upon touching the unit Drive Module Main Power Green LED s not illuminated Transformer XFMR Power Green LED not illum
42. t all plumbing fittings and tubing for packing material that may have become lodged in openings Equipment Placement 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 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 Located downstream of all other existing water system components Located upstream of the residual sanitizer injection point if so equipped In a Sidestream plumbing configuration see Figure 4 1 with recirculation the pH adjustment chemical injection point must be located downstream of the residual sanitizer injection point if so equipped Ina Full Flow plumbing configuration see Figure 4 2 without recirculation locate downstream of the pH adjustment chemical injection point Adequate protection from weather dust and excessive heat Like
43. the setting of the manual ozone output control Based on the 4 20mA signal ozone output will increase or decrease 4mA 0 ozone output 20mA 100 ozone output The ozone output level is indicated by the Ozone Output LED s on the front cover of the ozone generator see Appendix Section A Note If the remote 4 20mA signal fails or is missing the system will default to the manual ozone output setting Check and adjust the manual ozone output control knob to avoid over ozonation Electrical continued Step 1 Mount the 4 20mA controller to a suitable vertical surface according to the installation manual supplied with the controller Step 2 Wire the 22 AWG orange positive lead from the ozone generator to the 4 20mA controller according to the manual supplied with the controller Step 3 Wire the 22 AWG purple negative lead from the ozone generator to the 4 20mA controller according to the manual supplied with the controller Step 4 Complete the required programming and calibration steps as outlined in the installation manual supplied with the 4 20mA controller Step 5 Air Preparation System Power 120VAC systems only plug the power cord into main power 240VAC systems only the power cord must be hard wired to the main power source Black L1 White L2 N and Green Ground Notes The prescribed air flow of the air prep system must be set to atmospheric pressure prior to use follow Step 5 of the Start
44. tor total air flow gauge front cover 4 to 6 cfh 6 cfh PSI gauge gauge front cover 9 to 12 psi 10 psi Injector manifold air flow 10 to 12 scfh 12 scfh Injector manifold injector 3 to 8 in hg 5 inches MAINTENANCE CHAPTER 8 Maintenance of the ozone system is critical to its longevity and operating efficiency While all system components are built to provide years of reliable service with minimum maintenance following the SS 2n procedures outlined below is strongly recommended All maintenance procedures have been segmented by interval daily monthly semi annual and annual Daily procedures involve quick visual checks for changes in normal operating conditions Monthly semi annual and annual procedures include cleaning and or replacement of certain critical parts NOTES The ozone generator warranty states that it does CAUTION Observe all common safety practices not extend to any product or part which has been and review the Safety Warnings and Instructions damaged or rendered defective as a result of use in Chapter 2 before attempting any maintenance of parts not sold by RK2 Systems Inc or service procedure that requires the use of tools and or or unit modification not authorized by shutting down the ozone system RK2 Systems Inc Please contact your RK2 Systems Inc dealer if you have any questions about any maintenance procedure before you begin that procedure Daily Procedures Air Pre
45. wer Supply under board Bel B Reaction Chamber lol J Drive Transformer XFMR Inline Particulate Filter 4 20mA Control Board Pressure Switch Cover Safety Switch External Loop Remote 4 20mA Control Leads e e External Loop Connector Air Prep Inlet Remote 4 20mA Connector JXYEYYYIT ELYYTYTEYXy N LLI eee LA YYTILT L ZZ TT CT LLL LLL ELLIE OPAC COCO SLES EO ewe ae fs wel LI n LL LRT KAN KK KN KI ond AA att jt lli Pha aapa KANG AA NA KARA AN 1 A LSN 11 L 4 COONS CTI PACTON O ra Yri i CMY EVEL VILE TATE Ula HO LULA x lI T i Ozone Outlet Needle Valve Main Power Light I XE SIIL r DAMM di 0000000400 Power Entry Module OFF ON Switch Cord Input Fuse Carrier j 1 ITLI YENY MANGAN la LIA ELIO L1 WC 1 II DI kah aki akh Bonding Ground Lug Fan and Fan Filter OZONE GENERATOR SPECIFICATIONS OZONE OUTPUT SCFH 2 h 9 25 5 5 d 2 Ib 15g h 696 6 scfh 10PSI Appendix continued Section A Specifications D Rr Ozone Output LED s Pressure Gauge EES es CFH Gauge 2 C qu f 1 r i 5 W Reaction Chambers i Drive Board and Drive Transformer XFMR under boards Inline Particulate Filter 2 K h EE 7 te j d Power Supply dez pe
46. when ozone drive is being generated The LED will also pulse as the output increases or decreases with either the Manual Ozone Output Control located on the bottom of the ozone generator see Appendix Section A or from a Remote 4 20mA signal see Installation Procedures Electrical Fault LED When illuminated this Red LED indicates that there is a fault with the drive module or the Ozone Reaction Chamber If this LED is illuminated refer to the Troubleshooting Guide Notes Upon startup the fault LED will remain illuminated for 30 seconds before ozone is produced If the drive module goes to a fault condition the drive board will restart every 30 seconds If the fault is not remedied the drive module will continue to go into a fault mode When the drive module is in fault mode ozone will not be generated Before proceeding further release the cover safety switch and replace the ozone generator cover Cooling Fan Operation Check to make sure the two cooling fans mounted on the bottom panel of the ozone generator cabinet are operating If not refer to the Troubleshooting Guide Cooling Fan Filters Check the cooling fan filter elements mounted on the bottom of the ozone generator see Appendix Section A and clean as required Operating conditions in the equipment area will dictate the frequency required for this procedure Remove the filter element and clean with soap and water drying them completely before re installing see
47. with a two position male connector ready to be plugged into the female two position connector mounted to the chassis of the ozone generator If the control device used supplies an output voltage a single pole single throw SPST normally open relay may be used to create a dry contact interface see Figure 5 1 External Loop Electrical Interface Note Attached to the white 18 AWG external loop is a warning THIS CONNECTION IS A DRY CONTACT ONLY DO NOT APPLY VOLTAGE Step 4 Ozone Output Control The 6024 and 6032 ozone generators are equipped with two options for controlling the ozone output The first option is a manual 0 100 ozone output control and the second is a remote 4 20mA control signal The manual ozone output control knob and remote 4 20mA control leads orange and purple are located at the bottom of the ozone generator see Appendix Section A Power Consumption 90 250V AC 47 63Hz 1 Manu l Ozone Output Control Turning the control knob counterclockwise will decrease the ozone output down to 0 while turning the knob clockwise will increase the ozone output up to 100 The ozone output level is indicated by the Ozone Output LED s on the front cover of the ozone generator see Appendix Section A 2 Remote 4 20mA Control A 4 20mA control signal to the ozone generator may be used to control the ozone generator output The ozone generator will automatically sense the 4 20mA input signal and override
48. y 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 use of parts not sold by RK2 Service or unit modification not authorized by RK2 Obtaining Service Under the Warranty 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
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