GM-series operators manual
Contents
1. Even moderate condensation may cause system malfunction To avoid this place the generator in dry or air conditioned environment or connect it to a generator drier adsorption drier Primozone provides generator driers Ask your local representative for a quotation Manual GM Series Ozone Generators RevG 20140319 Primozone Production 2014 22 MANUAL Primozone GM series 4 3 Module controller overview 4 3 1 Module controller screen overview Information PE Vis Escape button n SE Primozone Pii Enter Scroll butt Keyboard EIS A ETT EK PRIMOZONE GM PRESTESOTOR MAIN SORTEN PRESSIZTO START GM Main screen 1 ON OFF screen PRIMOZONE GM 18 22 SP COMO 205 grind AOOU RUNTIME 105 bow 1125 kwh 240C 245C Main screen 2 Primozone Production 2014 Manual GM Series Ozone Generators_RevG_20140319 Primozone GM series MANUAL 23 4 3 2 General information provided in the module controller The two main screen pages on the module controller provide all the necessary information to monitor and control the ozone production Main screen 1 of 2 Capacity This set point can be adjusted to a desired value in percent E g if a generator module produces 900 g O3 h at a capacity of 100 reducing the capacity to 50 leads to the same reduction in the ozone production as well Gasflow This process value is affected by the capacity level and cannot be adjusted When the capacity i2. PRIMOZONE GM 18 2 Switch the automatic fuse F4 in the ozone generator fam zone fuse box to the ON position to start the ozone generator module controller PhtSST2TO START OM on 3 Start the ozone generator by pressing F1 the ON OFF screen in figure 14 will be displayed Then press F2 and the generator will start to return to the main screen press ESC NOTE Since only fuse F4 is in the ON position oxygen gas flows through the ozone generator but the ozone production has not started Figure 14 ON OFF screen 4 Set the capacity to 100 by pressing ENTER arrow on mail screen 1 see figure 15 Use keyboard to enter the value and press ENTER arrow to confirm MERE uw CAPACITY 5 Let the oxygen gas flow through the ozone outlet ev Mem hose to dry the system rowencons 6 After 90 minutes stop the ozone generator by pressing F1 then F2 Figure 15 Main screen 1 NOTE The proportional valve can take up to two minutes to open after transportation which can reduce or prevent the gasflow Primozone Production 2014 Manual GM Series Ozone Generators_RevG_20140319 25 Primozone GM series MANUAL 4 5 Normal operations 4 5 1 Start up NOTE Make sure that all relevant automatic fuses are in the ON position Make sure that the flow the temperature and the pressure of the inlet cooling water are according to specification See section A5 in Appendix A Make sure that the
3. Check your local regulations for any restrictions on ozone generators power connections regulation etc Primozone Primozone Production AB Terminalvagen 2 246 42 L ddek pinge Sweden Tel 46 46 704570 Tel 46 734 433454 Fax 46 46 704580 support primozone com www primozone com Operators Manual GM RevG Primozone Production 2013 Manual GM Series Ozone Generators_RevG_20140319 Primozone Production 2014 MANUAL Primozone GM series TABLE OF CONTENTS L INTRODUCTION icassqiciicsannts scantnoseaianpeectnpsacssepetepireietaniatinenaes 6 LL ThePrnmozone GI 4 ERE 6 1 2 Basic construction of the GM series ozone generators ssss 7 BN OVervieW REESE 8 L4 Warning siens mihe TS HB Liceo xe doped EN d dS o NOD PERRA oae EpL SER HIR d eO Ud Qus etas 10 15 Warning signs on the ozone generator esses 2i 2 SAFETY PRECAUTIONS 55 teuuctiastau utin tU sRadiiaid reteset 12 AME 0 RT HEC PEN 12 22 Emergency StD aere re eta i E a Tn i UA NER IHE S RETENIR 13 ENS C irena a eee eee ee E A A E EA het mee NE 14 Ao OZONE ere EE E E E EES 14 3 INSTALLATION ciron 15 31 eiie NE c Rt TE 15 3 2 Electrical IS Sl POM 2 cuppa Diseno va de proe De edo pana pros ipea rei Doble oes beds etaed deta 19 4 OPERATIONS uecendodasa UU TENA VD OS SS Du Un RE M Gor D OOM IN MERGE 20 1 Before iesu cC Be IB asc aeis deosacsa acce O ice ed eot ado iode Do tp deste rant 20 Hn IU SUE ours edeiedbtediu
4. 94 98 Oxygen dew point 70 C at 1 bar a Hose oxygen gas 1 5 meter stainless steel flexible hose not included in a standard delivery Connector internal 1 2 BSP thread external 1 2 NPT can be provided upon request Micro filter 0 01 micron Primozone Production 2014 Manual GM Series Ozone Generators RevG 20140319 Primozone GM series MANUAL 33 A 4 OZONE GAS Ozone pressure 1 5 2 2 bar g at the ozone generator outlet valve depending on the flow Ozone production 30 to 900 grams ozone per hour at 200 grams ozone Nm3 oxygen depending on model Concentration Std 200 grams ozone Nm3 oxygen Min 150 grams ozone Nm3 oxygen Max 300 grams ozone Nm3 oxygen Power consumption 12 kWh per kg ozone at a water temperature of 10 C and an ozone concentration of 200 g Nm3 oxygen Hose ozone gas 1 5 meter stainless steel flexible hose not included in a standard delivery Hose connector internal 1 2 BSP thread A 5 COOLING WATER B OMR O GM6 Temperature range 3 C to 20 C Target temperature 10 C Water pressure range 0 7 bar g to 6 bar g Water pressure drop 0 4 bar Water quality drinking water 98 83 EG or a closed water loop system Water hardness lt 10 DH to avoid lime scaling Water hose 2 meter steel coated hose Hose connector internal 3 4 BSP thread A 6 MATERIALS Cover and rack Stainless steel glass Hose cooling water Steel coated rubber Hose o
5. F 1 CHANGING SPARE PARTS Normally all maintenance work is done by Primozone Production AB However after going through the Primozone service education the changing of a SEPT can be performed by the owner of the GM ozone generator F 1 1 Removing the steel front cover In order to perform any maintenance operations or to drain the GM18 of cooling water the front cover must be removed Always keep the lockable main power switch locked in the OFF position when you remove the front cover F 1 1 1 Remove the front cover 1 Use the system controller to stop the GM18 2 Turn off the main power supply and lock the switch HIGH VOLTAGE An Do not touch any inner electrical parts of the GM18 Physical contact with electrical parts can cause severe harm or death If an accident occurs immediately call for medical assistance The lockable main power switch must be locked in the OFF position before LOCK THE MAIN POWER SWITCH any work on the electrical components is started Manual GM Series Ozone Generators_RevG_20140319 Primozone Production 2014 42 MANUAL Primozone GM series 3 Remove the two bolts 2 and nuts 3 from the bottom of the front cover Refer to figure 27 4 Loosen the four bolts 5 that hold the front cover to the GM18 There are two bolts on each side of the generator 5 Lift off the cover upwards and outwards F 1 1 2 Install the front cover 1 Position the steel cover 1 on the GM18 Refer to
6. Primozone Production AB Ozone production Make sure that the ozone production complies with the requested specification Refer to the ozone generator Module Controller manual for instructions on how to read and set the ozone production parameters Manual GM Series Ozone Generators_RevG_20140319 Primozone Production 2014 38 MANUAL Primozone GM series D 3 WEEKLY VISUAL INSPECTION In addition to the daily inspection a weekly check of the ozone generator must be performed Check the following Environment Make sure that the temperature and the air humidity are within specifications in the room where the ozone generator is installed Refer to section 4 for specifications Refer to the ozone generator Module Controller manual for information on how to read and set the system parameters e Oxygen gas Make sure that the gas regulator for the oxygen supply shows the specified value Refer to section A3 in Appendix A e Cooling water Make sure that there are no leaks from the cooling water connectors at the rear of the ozone generator Make sure that the pressure the temperature and the water flow of the cooling water are within specifications Refer to A5 in Appendix A Primozone Production 2014 Manual GM Series Ozone Generators RevG 20140319 Primozone GM series MANUAL 39 APPENDIX E ALARM SIGNALS AND TROUBLE SHOOTING E 4 SEPT ALARMS Alarm signal Probable cause Recommended action E SE
7. figure 27 2 Tighten the four bolts 5 that hold the steel cover in place There are two bolts on each side of the GM18 3 Install the two bolts 2 and the two nuts 3 at the bottom of the steel cover ee Um 5 gt je 1 3 77 1 Steel front cover Se 2 Bolts 2 pcs f ae gt 3 Nuts 2 pcs 4 Rack 2 5 Bolts 4 pcs Figure 27 How to remove the steel front cover of a GM ozone generator Primozone Production 2014 Manual GM Series Ozone Generators_RevG_20140319 Primozone GM series MANUAL 43 F 1 2 Changing a SEPT The GM18 has three electrical power units called SEPTs Self regulating Electronic Power Transformer Indications that one or more SEPTs must be changed are for example e a power drop in the SEPT e decreased ozone outlet e an orange indicator light in the front of the SEPT Before you change a SEPT make sure that a faulty SEPT is the source of the problem F 1 2 3 Removing a SEPT 1 Remove the front cover of the GM18 to get access to the SEPTs WARNING Make sure that the lockable main power switch is locked in the OFF position before you start to remove the SEPT 2 Open the cable lock 2 on the SEPT power supply connector 1 Refer to figure 28 1 2 3 4 5 K oo SEPT power supply c
8. flow the concentration and the pressure of the inlet oxygen gas are according to specification See section A3 in Appendix A Open the shut off valves for oxygen ozone and cooling water if manual 1 Start the ozone generator by pressing F1 the ON OFF screen in figure 14 will be displayed Then press F2 and the generator will start to return to the main screen press ESC 4 5 2 Set ozone capacity 2 Set the capacity to desired value by pressing ENTER arrow on main screen 1 see figure 15 Use keyboard to enter the value and press ENTER arrow to confirm CAUTION fi Make sure that the indicators in the front of the SEPTs show a steady green light within one minute after the ozone generator was started If one of the indicators remains orange for more than one minute refer to Appendix E NOTE When all four automatic fuses are in the ON position and the ozone generator has been started the ozone production starts If a SEPT indicator lamp remains orange for more than one minute after start refer to Appendix E 4 5 3 Shut down 1l Shut down the ozone generator by pressing F1 the ON OFF screen in figure 14 will be displayed Then press F2 and the generator will stop return to main screen press ESC NOTE When the generator is shut off it prior automatically purges for 3 minutes If contact with the module controller is lost use the lockable main power switch to shut down the ozone generator In case of emergenc
9. having both the Generator ON and the SEPT ON lOs high and change the ozone production rate by changing the 4 20 mA input e Monitor if there are any alarms that shuts down the generator High signal means that the system is running and low signal means that the system has shut down itself in order to protect itself Primozone Production 2014 Manual GM Series Ozone Generators_RevG_20140319 Primozone GM series MANUAL 31 SEPT On Generator On 4 20mA T 4 20mA 24vdc Alarm sum M DU PWNPR Manual GM Series Ozone Generators_RevG_20140319 Primozone Production 2014 32 MANUAL Primozone GM series APPENDIX A TECHNICAL SPECIFICATIONS A 1 DIMENSIONS 3MI2 GM6 230 kg 125 kg 1900 mm A 2 ELECTRICAL DATA PE AC 50 60 Hz PE AC 50 60 Hz PE AC 50 60 Hz PE AC 50 60 Hz connector plug Power cable 3 meters 5 x 3 meters 5 x 3 meters 5 x 3 meters 3 x unl 2 5 mm rubber 2 5 mm rubber 2 5 mm rubber 2 5 mm rubber cable cable cable cable Power 10 8 kW 7 2kW 3 6 kW 3 6 kW consumption at 100 capacity Powerfactor 099 o99 099 1099 Control range 10 100 96 10 100 10 100 10 100 96 Saftey fuse Automatic fuse Automatic fuse Automatic fuse Automatic fuse A 3 OXYGEN GAS SUPPLY Gas pressure at inlet 2 2 bar g Gas flow range GM6 10 to 50 liters per minut GM12 10 to 100 liters per minut GM 18 10 to 150 liters per minute Oxygen purity
10. oxygen inlet 6 3 1 2 Install the hose for ozone gas NOTE Hoses are not supplied with the generator Contact Primozone for a quote l Connect the hose for outlet ozone gas to the ozone system Make sure that the ozone gas hose connector is securely fastened 2 Removethe red plastic seal from the ozone gas outlet 3 at the rear of the ozone generator See figure 9 3 Connect the hose to the ozone gas outlet 3 4 Make sure to use a proper device to prevent water from flowing backwards into the ozone generator Contact Primozone for more information Primozone Production 2014 Manual GM Series Ozone Generators_RevG_20140319 Primozone GM series MANUAL 17 Ethernet Lan RJ45 Water outlet connector Ozone outlet connector Bottom stand Water inlet connector Oxygen inlet connector NOOR WN Power inlet Figure 9 Use four 12 mm bolts not included to secure the GM ozone generator to the floor Manual GM Series Ozone Generators_RevG_20140319 Primozone Production 2014 18 MANUAL Primozone GM series 3 1 3 Install the hose for inlet and outlet cooling water NOTE Hoses are not supplied with the generator Contact Primozone for a quote 1 Connect the hose for inlet cooling water to the water supply and connect the hose for outlet cooling water to the water drain circulation connector 2 Remove the red plastic seal at the water inlet 5 and outlet 2 connectors at the back of the ozone gener
11. ozone generator is installed in the power outlet F1 SEPT No 1 20A F2 SEPT No 2 20A F3 SEPT No 3 20A F4 Module controller 2A Figure 11 Automatic fuses on the GM 3 2 2 Network cable The network cable must have an RJ45 plug to fit the ozone generator network connector To install the network cable insert the network cable plug into the network cable connector 1 at the rear of the ozone generator Refer to figure 9 NOTE The network cable is not supplied with the ozone generator Manual GM Series Ozone Generators_RevG_20140319 Primozone Production 2014 20 MANUAL Primozone GM series 4 OPERATIONS 4 1 Before first start up Checklist Before you start the ozone generator for the first time make sure that the following preparations have been performed LI LI O Od oO O QO O QO 00o 00 da Make sure that all parts of the ozone production system are installed correctly Make sure that the ozone alarm is functional in the room where the ozone generator is installed The ozone sensor must be located within 2 meters from the ozone generator The ozone generator must be in its upright position and securely fastened to the floor The inlet hose for oxygen gas must be securely connected to the oxygen supply system Make sure to install a particle filter between the oxygen source and the ozone generator Make sure to purge the oxygen hose prior to connecting it to the ozone generat
12. remove the covers of the GM series ozone generators if not trained by Primozone personnel and have a written authorization HIGH VOLTAGE An Do not touch any inner electrical parts of the ozone generator Physical contact with electrical parts can cause severe harm or death If an accident occurs immediately call for medical assistance The lockable main power switch must be locked in the OFF position before f LOCK THE MAIN POWER SWITCH any work on the electrical components is started The main power switch is located near the ozone generator Work on electrical equipment must be performed by authorized personnel only Manual GM Series Ozone Generators RevG 20140319 Primozone Production 2014 14 MANUAL Primozone GM series 2 4 Oxygen Oxygen is a colorless odorless and tasteless gas If there is a leakage of oxygen from the ozone generator the oxygen content in the air is increased Pure oxygen can cause oil and grease to spontaneously combust FIRE HAZARD A Do not smoke or light an open flame near the ozone generator Make sure that you do not leave spill from oil or grease near the ozone generator 2 5 Ozone Ozone 03 is a pale blue gas with a characteristic odor It is highly reactive and corrosive and can cause harm if inhaled TOXIC GAS Ozone is a toxic gas Do not inhale ozone Install an ozone alarm near the ozone generator Ensure good ventilation In case of accident evacuate the person into
13. 6 FT TOTO TP m rmTT 6 High voltage connector TETTE 3 oo 8 Indicator lamps 8 8b 8 green light bs b orange light SA Generator block No 3 10 Drainage valve E 11 Drainage valve 9 12 Ozone outlet propotional valve VO3 1 13 Fan No3 14 Rack 15 SEPT No3 16 Fan No2 17 SEPT No2 18 SEPT Nol 19 FanNol 10 20 Water pressure sensor 21 Module controller c 5s Figure 2 Front view of the Primozone GM18 ozone generator after cover has been removed Primozone Production 2014 Manual GM Series Ozone Generators_RevG_20140319 I1 Ke Primozone GM series MANUAL Ethernet Lan RJ45 Water outlet connector Ozone outlet connector Bottom stand Water inlet connector Oxygen inlet connector NOY Ov Qe LR Power inlet Manual GM Series Ozone Generators RevG 20140319 Primozone Production 2014 10 MANUAL Primozone GM series 1 4 Warning signs in the manual This manual contains different messages WARNINGS CAUTIONS RECOMMENDED ACTIONS and NOTES WARNING heading in red It is mandatory to follow the instructions of a warning message Failure to do so can cause severe harm or death to personnel CAUTION heading in black It is mandatory to follow the instructions of a caution message Failure to do so can cause harm to personnel or severe damage to equipment gt gt Warnings and cautions are marked with yellow warning triangles with different meanings WARNING General
14. Installation and Operation Manual Primozone GM series Ozone Generators Primozone Clean water The natural way Primozone GM series MANUAL eoo Co Responsibility and Disclaimer Primozone accepts responsibility for the reliability and performance of this equipment only e f any modifications to the equipment are authorized in writing by Primozone and carried out by an authorized service technician e If the electrical installation for powering the equipment complies with all applicable local electrical codes and requirements including if applicable IEC requirements e If the equipment is used in accordance with its manuals Primozone will provide on request a service manual which contains all necessary circuit diagrams and service information to enable authorized service technicians to repair those parts of this equipment which Primozone considers to be repairable Since Primozone has no control over service work which is not performed by authorized service technicians Primozone will in no way be responsible or liable for any damages resulting from the operation or performance of any device or any injury caused thereby after repair has been performed by any person other than a factory representative of Primozone Under no circumstances will Primozone be liable for any indirect incidental special or consequential damages of any kind its liability being hereby limited solely to repair or replacement Note
15. PT Alarm O High voltage too high Check incoming power SEPT Alarm 1 High Voltage too low Check incoming power f SEPT Alarm 2 Main voltage too high or too Check incoming power low SEPT Alarm 3 Heat sink temperature Check cooling water both temperature and flow Check that the SEPT is firmly mounted on the cooling bar SEPT Alarm 4 Transistor temperature Check cooling water both temperature and flow SEPT Alarm 5 Air temperature Check the cooling fan in the SEPT SEPT Alarm 6 Frequency high Check reactors ability to maintain potential SEPT Alarm 7 Frequency low Check reactors ability to maintain potential SEPT Alarm 12 Power read over absolute Check incoming power max limit fuse F1 off Communication error Check cable error on R8485 Communication error Running the generator with Switch on fuse and reset fuse F2 off Communication error Check cable error on RS485 Communication error Running the generator with Switch on fuse and reset fuse F3 off Communication error Check cable error on RS485 f Communication error Running the generator with Switch on fuse and reset Manual GM Series Ozone Generators_RevG_20140319 Primozone Production 2014 40 MANUAL Primozone GM series E 5 OTHER ALARMS a Alarm signal Probable cause Recommended action One of the fuses is Error in the SEPT or a reactor Contact Primozone in the OFF position Production AB Gas pressure is Low gas pressure Make sure that the ox
16. Primozone Production AB Terminalvagen 2 246 42 L ddek pinge Sweden Phone 46 46 70 45 70 Fax 46 46 70 45 80 Mail info primozone se www primozone com Primozone Production AB 2014 Primozone Production reserves the right to change any information in this publication without prior notice Primozone Production does not take any responsibility for errors or omissions in this publication
17. TSEIBEIDS catus tabu pete sac Mta o aM e RE 39 GMEES 0 i ESTNE ten eee eee ae cee 40 APPENDIX F SPARE PARTS LIST AND SEPT REPLACEMENT 41 1 1 Removing the steel front COVEN usadas Es tea gp Le aan xeu pa pnl eund plea boe E Date uade uE Al A Bec g lg ec gt alee encom ern eee add usc etat eee nei iun Cena ur ere eta 43 Manual GM Series Ozone Generators_RevG_20140319 Primozone Production 2014 6 MANUAL Primozone GM series 1 INTRODUCTION This manual describes the installation and operation process for the Primozone GM series ozone generators All personnel should read the whole manual before installing or operating the ozone generator It is especially important that all personnel read and understand the Safety precautions chapter before handling the generator Only trained personnel should be allowed to handle the ozone generator Training is supplied by Primozone For more information please contact Primozone at support primozone com or telephone 46 0 46 70 45 70 1 1 The Primozone GM series This manual covers three of the ozone generator models in the Primozone GM series GM18 GM12 and GM6 The ozone output can be set to between 10 and 100 of the maximum capacity at a given concentration of the ozone generators The maximum capacity at 13 4 ozone concentration is according to the table below Ozone production gyn 900 600 so All images in the manual are images of the GM18 ozone g
18. WARNING Fire hazard WARNING Toxic gas WARNING High voltage gt gt e gt In addition to the warning signs there are RECOMMENDED ACTIONS and NOTES RECOMMENDED ACTIONS Necessary security and preventive actions are marked with a blue mandatory sign x NOTE A note is marked Note and contains extra information that is useful when handling the ozone generator Primozone Production 2014 Manual GM Series Ozone Generators_RevG_20140319 Primozone GM series MANUAL 11 1 5 Warning signs on the ozone generator High Voltage Cut off power before handling this unit Figure 6a Figure 6b Manual GM Series Ozone Generators_RevG_20140319 Figure 6 There are eight warning labels on the GM ozone generator one at the front of each SEPT figure 6a one at the rear of the GM ozone generator next to the main power connector figure 6b two on each side of the GM ozone generator figure 6c Figure 6c Primozone Production 2014 12 MANUAL Primozone GM series 2 SAFETY PRECAUTIONS All personnel must read and understand the safety precautions before installing or operating the ozone generator NOTE In addition to the instructions and guidelines in this manual make sure to follow all local safety regulations 2 1 Perso
19. ake sure that the location has a flat surface and that it is stable 3 Make sure to have a distance of 0 7 meter behind the ozone generator to assure possible service 4 Secure the ozone generator to the floor with four 12 mm bolts See figure 7 The bolts are not supplied with the ozone generator Figure 7 Use four 12 mm bolts not included to secure the GM ozone generator to the floor Manual GM Series Ozone Generators_RevG_20140319 Primozone Production 2014 16 MANUAL Primozone GM series 3 1 1 Install the hose for oxygen gas NOTE Hoses are not supplied with the generator Contact Primozone for a quote NOTE Before installation e To secure oxygen purity make sure to connect a filter to the hose or make sure that the PSA oxygen source is fitted with a filter Filter requirement 0 01 micron e The pressure regulator should be place after the filter and before the ozone generator Oxygen Filter Pressure GM ozone source 0 01 micron regulator generator o Blow oxygen through the hose before connecting it to the ozone generator to make sure the hose is clean and dry 1 Connect the hose for inlet oxygen gas to the oxygen gas sorce Make sure that the gas hose connector is securely fastened to the oxygen source 2 Remove the red plastic seal from the oxygen gas inlet 6 at the rear of the ozone generator See figure 9 3 Connect the hose to the
20. ator 3 Connect the inlet water hose to the inlet water connector 5 and the outlet water hose to the outlet water connector 2 COOLING WATER QUALITY AND TEMPERATURE The cooling water quality and temperature is very important for the performance of the ozone generator 5 Target temperature 10 C Quality drinking water quality i e particle free and demineralized water or closed loop For more cooling water requirements refer to Appendix A 5 Primozone Production 2014 Manual GM Series Ozone Generators RevG 20140319 Primozone GM series MANUAL 19 3 2 Electrical installation All electrical installation must be done by authorized personnel and according to local regulations ELECTRICITY The input voltage to the ozone generator is 400 V 230 V and physical contact with electrical parts can cause severe harm or death If an accident occurs immediately call for medical assistance For more electrical requirements refer to Appendix A 2 3 2 1 Automatic fuses The ozone generator has two to four automatic fuses depending on model which are located in the fuse box at the top of the ozone generator See figure 11 The three fuses on the left F1 F2 F3 are connected to each of the three separate SEPTs These are 20A fuses The fuse to the far right F4 is connected to the module controller of the ozone generator This is a 2A fuse NOTE All fuses must be in the OFF position when the main power cable of the
21. dec teiero ebiscdisubqatissede a o codidutoobeies 21 AS Module controller Overview 52 ui iecadasess cse pnt ects Secs Ene o ROSE ipsia rti Sbx SE Re GG 22 4 4 Start up after installation purge and dry for 90 min sesssss 24 45 PRINS Eo ot RETE mem 25 Z6 Txemal cono SPUN sedens epe bo NN UpUE pa USES Rega pz ER Fix dni EESTEC EER R 30 APPENDIX A TECHNICAL SPECIFICATIONS 32 PN DIMENSIONS NR ETT A 32 Pea Ee meaa DUE A E rm 32 A 3 Oxygen gas Supply eargesiccaeveoensousevesarcsesicsastonesnaaeieandsanehamasvuesesgscanesnweounrenoeanaess 32 AAs OZONO o eama a a e a AO 33 AS ed RR ET 23 ORE U2 ERREUR RR D 33 NEN NN T I RES 33 AS Control Signal RO ERREUR DERE NOOR EnG 34 AS Waranty and Service agreement cisocana A Roa HERE SES pap DAS Dad 34 nap DUM Eee ene ete ts Mud E D ELEM xD S OI EE 34 Primozone Production 2014 Manual GM Series Ozone Generators_RevG_20140319 Primozone GM series MANUAL s 5 Pick A PSOE RUTRUM 34 AAS a ene meen ERR ge er eee NR a eee ar eC NEUE ne ene ROUTERS ema 34 A 13 Electromagnetic compatibility 5 c2veremususysesaeeseeouscsusuansnenadasenestausvouneshsestiununcunts 34 APPENDIX B HANDLING AND TRANSPORT 35 APPENDIX C OZONE MATERIAL SAFETY DATA 36 APPENDIX D INSPECTION isasbskxrutop pss ved RS EVREDEE KFida d EYE d gEE ES aig 37 APPENDIX E ALARM SIGNALS AND TROUBLE SHOOTING 39 EA SE
22. enerator Primozone Production 2014 Manual GM Series Ozone Generators RevG 20140319 Primozone GM series MANUAL 1 2 Basic construction of the GM series ozone generators The reactors are installed in groups called generator blocks with six reactors per block As shown in figure 1 Each generator block has an electrical power unit a Self regulating Electrical Power Transformer SEPT The SEPT is mounted on top of the generator block The ozone generator consist of generator blocks with a corresponding SEPT a control unit the module controller and a set of automatic fuses Left to right e Front cover gray 1 3 SEPTs red depending on model e 1 3 generator blocks turquoise depending on model 1 3 steel plates and 3 ventilating fans yellow depending on model Protective cover and electrical cabinet with the module controller and the fuse box orange Aluminum profiles for gas and cooling water green e Stainless steel rack purple Figure 1 Construction of the GM18 ozone generator Manual GM Series Ozone Generators RevG 20140319 Primozone Production 2014 MANUAL Primozone GM series 1 3 Schematic overview lw ow ow FEES ee 5E B a 1 Fuse box gt 2 Gas pressure sensor LA cl 3 Flow meter MFM 1 FTTPTPETETTTI 6 4 Oxygen valve VO2 1 Po 7 8a 5 Generator block No 1 1
23. fresh air and call for medical assistance The human nose can detect ozone at concentrations above 0 02 ppm The maximum allowable ozone concentration in industrial working areas is O 10 ppm according to EU regulations with a permissible human exposure of 8 hours per day 6 days per week Make sure that there is a functional ozone alarm in the room where the ozone generator is installed The ozone sensor must be located within 2 meters from the ozone generator Make sure that applicable safety equipment is available NOTE Make sure to follow applicable local regulations For more hazard identification on ozone see Appendix C Ozone material safety data Primozone Production 2014 Manual GM Series Ozone Generators_RevG_20140319 Primozone GM series MANUAL 15 3 INSTALLATION Before you remove the transport protection examine the wooden transport box and make sure that it is free from visible damage Any damage must be documented and reported to Primozone 3 1 Mechanical installation Hoses for gas and cooling water are not supplied with the ozone generator Position and install the ozone generator 1 Use a fork lift to move the ozone generator to where it is to be installed Make sure that the fork is placed under the bottom stand of the ozone generator and that it is stabilized with straps while it is moved See Appendix B 2 Place the ozone generator where it is to be installed in its upright and vertical position M
24. hten the four bolts 5 that hold the SEPT to the GM18 3 Install the high voltage cable connector 7 in the SEPT Refer to figure 28 4 Turn the connector on the high voltage cable 7 so that the cable is securely fastened to the SEPT 5 Install the network cable connector 5 in the SEPT and close the lock 4 6 Install the SEPT power supply connector 1 in the SEPT and close the lock 2 NOTE Make sure that all cables are securely fastened to the SEPT before installing the front cover on the GM18 7 Install the steel front cover on the GM18 Manual GM Series Ozone Generators RevG 20140319 Primozone Production 2014 About Primozone At Primozone we are committed to provide our customers with cost efficient and environmentally friendly ways to clean and treat water with ozone Our ozone generators and ozone water treatment systems are based on cutting edge technology and generate far more ozone while using far less energy At Primozone we have found an innovative way to make ozone generation efficient and cost effective Our solution has proven to save up to 70 of the energy consumption compared to traditional ozone generators Furthermore the Primozone Ozone Generator is small and has the capacity to generate ozone with a proven high concentration Ozone is not only a natural product but also one of the most efficient methods to clean and treat water Primozone Clean water The natural way
25. ication error SEPT 1 2 Communication error SEPT 2 3 Communication error SEPT 3 Figure 18 4 Communication errors Modbus Master 4 5 5 1 Alarm menu To open the alarm menu press keyboard button 8 main screen 1 fig 18 The alarms are arranged in groups where group O E TI dA ng Ales n General Collection is the default group refer to figure 01 1 General Collect 19 This display shows all groups that contain one or more pending alarms If the alarms in a group are no longer pending the group is not displayed e ID Displays the group ID number e Count The number of alarms in the group Figure 19 e Group Name The name assigned to the group To see the whole text of the group name use the left and right scroll buttons to roll the text o Alarms in Group Group O asc A ID Tine Un AcAlam Na Press Enter for more details of the alarms in a specific 2 164040 Gas pressu group 3 164040 Gas pressu Figure 20 shows the all the details of the alarms such as the alarms ID the time when it occurred if it s acknowledged and the name of the alarm To see the whole text of the alarm name use the left and right scroll buttons to roll the text Figure 20 Manual GM Series Ozone Generators RevG 20140319 Primozone Production 2014 28 MANUAL Primozone GM series To acknowledge an alarm use the up and down arrows to scroll to the desired alarm and press ENTER refer to figure 20 To ackn
26. nnel All personnel working with the ozone generator must use appropriate safety clothing and equipment in accordance with company policy and relevant local regulations NOTE All personnel operating the ozone generator must be trained by authorized Primozone personnel 2 2 Emergency stop It is highly recommended that the ozone generator is equipped with an emergency stop NOTE The emergency stop must be installed according to local regulation Please check before installing Before you reset the emergency stop make sure that the reason for the stop has been eliminated or damage to the equipment DO NOT USE THE EMERGENCY STOP FOR Q The emergency stop should only be used if there is risk for harm to personnel NORMAL SHUT DOWN OF THE OZONE GENERATOR For a normal shut down e Use the module controller for normal stops See chapter 5 3x400V N PE Lockable main power switch Emergency stop circuit 3 phase power connector GM Power supply Power outlet Figure 4 Recommended installation of the emergency stop and power switch FOLLOW LOCAL REGULATIONS Primozone Production 2014 Manual GM Series Ozone Generators RevG 20140319 Primozone GM series MANUAL 13 2 3 High voltage The ozone generator has an input voltage of 400V which is lethal if not properly installed Do not remove the covers from a ozone generator unless the main power has been switched off Do not
27. onnector Lock on the SEPT power supply connector SEPT Lock on the network cable connector Network cable connector Bolts 4 pcs High voltage cable connector SO 0 o pom or Figure 28 How to remove the cables from the SEPT Manual GM Series Ozone Generators RevG 20140319 Primozone Production 2014 44 MANUAL Primozone GM series 3 Pull the SEPT power supply connector 1 straight out from the GM18 CAUTION Do not pull at the cable to remove it pull at the cable plug 4 Open the cable lock 4 on the network cable connector 5 eo Disconnect the network cable connector 5 from the GM18 6 Unscrew the high voltage cable connector 7 and pull it straight down to remove it from the GM18 7 Loosen the four bolts 5 from the front of the SEPT Refer to figure 29 Note The SEPT is now free to be removed from the GM18 8 Lift the front of the SEPT slightly so that it does not touch the aluminum plate 6 9 With the front slightly lifted carefully push the SEPT toward the rear of the GM18 so that the steel list 7 under the SEPT is pushed out from the groove at the back of the aluminum plate 6 10 Lift the SEPT up and then out from the GM18 1 2 3 4 1 SEPT 2 Power cable socket 7 6 5 3 Ventilation holes 4 Allen key Figure 29 How to remove the SEPT side view 5 Bolts 4 pcs 6 Aluminum plate Y Steel list 8 Contact areas Primozone Production 2014 Manual GM Serie
28. or to make sure it is clean and dry The outlet hose for ozone gas must be securely connected to the ozone system The hoses for inlet and outlet cooling water must be securely connected to the cooling water system Make sure that the four automatic fuses in the ozone generator fuse box are in the OFF position Make sure that the electrical wall plug of the ozone generator is securely installed in the power outlet Make sure that the lockable main power switch is in the ON position Make sure that the pressure the temperature and the water flow of the cooling water is correct See section A5 in Appendix A Open the shut off valves for inlet and outlet cooling water Make sure that the oxygen gas pressure is correct See section A3 in Appendix A Open the shut off valves for the oxygen gas supply and for the ozone gas outlet The inlet for oxygen gas must have a pressure regulator 0 4 bar g and a visible gauge Make sure to prevent water from flowing backwards into the ozone generator Primozone Production 2014 Manual GM Series Ozone Generators_RevG_20140319 Primozone GM series MANUAL 21 4 1 1 Environmental requirements 2d in an environment that m Make sure that these criteria are not disregarded after the ozone generator has been installed and taken into use 4 2 Condensation High ambient temperature in combination with low cooling water temperature may cause condensation inside the ozone generator
29. owledge a specific alarm press the F2 button When the alarm is acknowledged the Active and the Ack text marked in figure 24 disappears indicating that the alarm has been acknowledged and not active anymore Figure 21 To go backwards to the alarms menu after an alarm has been acknowledged press the ESC button and choose another alarm to acknowledge Another way to browse between the alarms in a specific group is to use the up and down arrows Figure 22 4 5 5 1 Alarm history An alarm is added to the history buffer after it has become inactive when the cause of the alarm has been fixed and not only when the alarm had been acknowledged The history displays records the time the alarm became active the time it became inactive and when acknowledge was performed To access the alarm history press keyboard button 9 from the main menu screen Figure 23 Primozone Production 2014 Manual GM Series Ozone Generators_RevG_20140319 Primozone GM series MANUAL 29 Every alarm has its rise active and fall inactive date and time which can be seen in the alarm history menu refer to figure 24 To see the whole text of the alarm F se 16 06 10 16 10 Duration name use the left and right scroll buttons to roll the text Fall 16 06 10 16 10 00 00 00 Ack 16 06 10 16 10 00 00 17 Res 01 01 00 00 00 Figure 24 To browse between different alarms in the alarm history use the up and down arr
30. ows Fase 16 06 10 16 10 Duration Fall 16 06 10 16 10 00 00 00 Ack 16 06 10 16 11 000101 Res 01 01 00 00 00 Figure 25 Manual GM Series Ozone Generators RevG 20140319 Primozone Production 2014 30 MANUAL Primozone GM series 4 6 External control optional External control is a Hardware and Software add on that can be purchased to the generators in the GM series 4 6 1 Module controller By pressing F2 the operator can turn on off the external control By turning off the external control the operator is able to control the system via the module controller according to previous description By turning on the external control the operator can control the system via the IO interface described below PRIMOZONE GMI 100 0 limi CAPACITY EXT OFF OZONE AMOUNT D gth POWER CONS ow 4 6 2 Hardware IO interface The external control comes with a 2 m long cable that is stripped at the end with 7 cables coming out each having a ferrule The user is able to do the following with this function e Turn ON the generator by giving a high signal to the Generator ON IO green cable and the number 2 on it e Turn OFF the generator by giving a low signal to the Generator ON IO e Purge the system by having the Generator ON high and the SEPT ON low The purging rate is now depended of the 4 20 mA input The system shall be purged for 90 minutes with full capacity 20 mA e Turn on the system by
31. rs_RevG_20140319 Primozone GM series MANUAL 35 APPENDIX B HANDLING AND TRANSPORT When in transport the ozone generator must be handled with care Keep it vertical and make sure that it is kept dry and well protected from physical impact Use a fork lift to move the ozone generator Make sure that the fork is placed under the bottom stand and that the ozone generator is stabilized by straps See figure 26 Do not move the ozone generator by lifting it by any of its parts Make sure that the following precautions are taken into consideration when you move handle or transport the ozone generator e The electrical components of the ozone generator must not be exposed to water oil or chemicals e The ozone generator must not be exposed to temperatures higher than 55 C during handling or transportation e Avoid rapid changes of the surrounding temperature as this can cause condensation inside the ozone generator which can damage the electrical parts e Drain all cooling water from the ozone generator before it is transported Refer to Appendix C Figure 26 When you use a fork lift to move the ozone generator make sure that the fork is placed under the bottom stand Do not lift the ozone generator by any of its parts Manual GM Series Ozone Generators RevG 20140319 Primozone Production 2014 36 MANUAL Primozone GM series APPENDIX C OZONE MATERIAL SAFETY DATA An updated Ozone Ma
32. s increased the gas flow will increase and when the capacity is decreased the gas flow will decrease Ozone Amount This value displays how many grams Figure 12 ozone is produced per hour Main screen 1 Power Cons This value displays the power consumption in watts Main screen page 2 of 2 To display the main screen press the down arrow on the controller Press the up arrow to browse back to the first page SP Conc Displays the ozone concentration in grams per cubic meters oxygen gas Accu Runtime Displays The number of hours the anomie ta ah generator module has been in operation P eiiis pd dines ACOU RUNTIME 105 bow ACOU P 0085 1125 kwh TEMP IN OUT 240C 2450 AOOUODINE 29 Accu P Cons Displays the accumulated power consumption over a specific time period Temp in out Displays the temperature of the cooling water at the inlet and outlet Accu Ozone Displays the accumulated ozone Figure 13 produced over a specific time period Main screen 2 Manual GM Series Ozone Generators_RevG_20140319 Primozone Production 2014 24 MANUAL Primozone GM series 4 4 Start up after installation purge and dry for 90 min When the ozone generator is started after installation or has been shut down for more than one week it needs to be purged and dried before use fx Vision To purge and dry the ozone generator do the following 1 Switch OFF the automatic fuses F1 F2 F3 if applicable
33. s Ozone Generators_RevG_20140319 Primozone GM series MANUAL 45 F 1 2 4 Installing a SEPT Before you start to install the SEPT make sure that the lockable main power switch is locked in the OFF position HIGH VOLTAGE A Do not touch any inner electrical parts of the GM18 Physical contact with electrical parts can cause severe harm or death If an accident occurs immediately call for medical assistance LOCK THE MAIN POWER SWITCH The main power must be switched off and the main power switch must be locked in the OFF position before any work on the electrical components is started gt CAUTION The aluminum plate and the bottom of the SEPT must be clean from dirt dust and other particles 1 Place the SEPT in the GM18 a Hold the SEPT as high up as possible in the space where it is to be installed and lift it into and toward the rear of the GM18 Avoid touching the aluminum plate 6 and make sure that no dirt falls into the greasing oil b Tiltthe SEPT slightly and lower it carefully so that the steel list 7 under the SEPT goes behind the aluminum plate c With the SEPT still slightly tilted pull it toward you so that the steel list 7 under the SEPT goes into the groove at the back of the aluminum plate d Carefully put the SEPT down on the aluminum plate while pulling it toward you e Make sure that the SEPT is firmly set and that there is no gap between the SEPT and the aluminum plate 2 Tig
34. terial Data Sheet is to be found at www primozone com datasheets Primozone Production 2014 Manual GM Series Ozone Generators RevG 20140319 Primozone GM series MANUAL 37 APPENDIX D INSPECTION D 1 VISUAL INSPECTION In addition to the system control monitoring of the ozone generator regular visual inspections must be performed to ensure that the ozone generator is running smoothly This manual lists inspections for daily or weekly checks For inspections that are performed less frequently please refer to the ozone generator Maintenance manual D 2 DAILY VISUAL INSPECTION Do a visual inspection of the ozone generator every day when it is in use Check the following e SEPT indicators Make sure that the indicator lamp in the front of each SEPT shows a steady green light If one of the SEPTs has an orange indicator light refer to Appendix B e Automatic fuses Make sure that all four automatic fuses in the fuse box are in the ON position If any of the fuses is in the OFF position refer to Appendix B Condensation Examine the ozone generator for condensed water especially around the connector for inlet cooling water If there is excess condensation make sure that the environment complies with the required conditions Refer to the ozone generator Installation manual e Sound Listen for noises from the ozone generator If any unusual noises are heard examine the ozone generator for leakage or contact
35. xygen gas Flexible stainless steel Hose ozone gas Flexible stainless steel A 7 NOISE Noise level lt 55 dB Manual GM Series Ozone Generators_RevG_20140319 Primozone Production 2014 34 MANUAL Primozone GM series A 8 CONTROL SIGNAL Communication Network Controller PLC based control system A 9 WARRANTY AND SERVICE AGREEMENT Refer to separate agreements for warranty and service A 10 APPROVAL The Primozone ozone generators are CE approved according to the Low Voltage Directive 2006 95 EU EN60204 1 2006 and it is EMC certified according to EN610000 6 4 2007 A 11 DISPOSAL When the ozone generator is to be disposed of all the electrical components and other materials must be taken care of in accordance to local regulations for electronic and industrial waste The ozone generator does not contain any radiating or otherwise hazardous materials that require special destruction Please make sure to follow local regulations when disposing the ozone generator and use a possibilities to recycle materials that are recyclable A 12 AIR e Minimum air temperature 5 C e Maximum air temperature 40 C e Maximum air humidity 60 e The air must be free of dust salt particles and conductive materials like iron powder A 13 ELECTROMAGNETIC COMPATIBILITY The ozone generators are EMC approved according to international standard EN 61000 6 4 2007 Primozone Production 2014 Manual GM Series Ozone Generato
36. y or if there is risk for harm to personnel or to the equipment use the emergency stop to shut down the ozone generator The emergency stop is located on the main power supply cable Do not use the emergency stop for a normal stop of the ozone generator Manual GM Series Ozone Generators RevG 20140319 Primozone Production 2014 26 MANUAL Primozone GM series 4 5 4 Local or Remote control When the module controller is connected to a system controller the control status will be displayed on main screen 1 see figure 16 To change between local and remote simply press the F2 button Figure 16 Main screen 1 4 5 5 Alarms overview The controller indicates that an active alarm has occurred when the Primozone caption on the main screen flashes see figure 17 4 5 5 1 Alarm state There are three different types of alarms 1 Acknowledged active alarms 2 Unacknowledged active alarms 3 Unacknowledged non active alarms Note Depending on system lay out the alarm set up could have a different content and appearance compared to below information Figure 17 Primozone Production 2014 Manual GM Series Ozone Generators_RevG_20140319 Primozone GM series MANUAL 27 4 5 5 1 Shut down alarms l Gas Pressure is above 2 2 bar g 2 Cooling water temperature is above 40 C 3 Cooling water pressure is below 0 2 bar g 4 Gas Pressure is below 0 5 bar g 4 5 5 1 Communication error alarms l Commun
37. ygen below 0 5 bar gas supply system works according to specification Gas pressure is High gas pressure Make sure that the oxygen above 2 2 bar gas supply system works according to specification Cooling water temp No cooling of the generator Make sure the cooling above 40 C system is ON Check valves Cooling water low Cooling water pressure or Make sure the cooling flow or pressure flow to low system is ON Check valves Low flow OM Gas flow below 30 of Make sure that the oxygen capacity gas supply system works according to specification Gas flow alarm To large difference between Check the oxygen flow and the setpoint and the pressure measured value Low gas flow This is a warning Check ozone valves and backpressure LOX deviation To large difference between Check compressed air the setpoint and the pressure measured value LOX low pressure Dry air pressure below 2 5 bar Check compressed air pressure Contact Primozone Production AB Primozone Production 2014 Manual GM Series Ozone Generators_RevG_20140319 Primozone GM series MANUAL 41 APPENDIX F SPARE PARTS LIST AND SEPT REPLACEMENT Spare parts that are available for the ozone generator are listed in the table below Please contact Primozone Production for more information on the spare parts and instructions on how to install them on the ozone generator N ce AtileNo O gr o o o o o rr UT 4 5 MEE p C a ee a C a een gu
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