American Airlines OST-20 Ozone Generating System Property ... · Ozone gas is mixed with the water...

American Airlines OST-20

Ozone Generating System

Installation and OperationManual

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AA OST-20 Manual

Cautions, Warnings and Hazards

Refer to the manual of the ozone generating system first, to assure proper location of all ozone equipment.

Ozone is a powerful oxidizing agent. Observe strict operating procedures when using ozone equipment.

Ensure that the ozone generator and air dryer are in a well-ventilated area. Do not allow rain or condensation to contact these components. The Ozone Injection System pump and contact tank skid can be placed in a more rugged environment while the generator and controller are not weather proof. These units must be operated indoors or in an enclosure in a non-condensing environment.

Note: If the operator has asthma, he/she must not enter an ozonated airspace.Ozone can induce an asthma attack.

Carefully review and familiarize yourself with the following important safety information statements concerning the use of ozone with the Ozone Injection System.

WARNING Ozone is an extremely aggressive and powerful oxidizer. TheOccupational Safety and Health Administration (OSHA) 8-hour exposure limit is 0.10-PPM. The OSHA 15-minute exposure limit for ozone is 0.3 PPM. Above 0.3 PPM, there isthe risk of damage to respiratory tissues.

WARNING People who have no sense of smell should not operate this equipment.

WARNING Never attempt to verify ozone production by directly breathing or smelling the ozone outlet or an ozone-tubing outlet.

WARNING The Ozone Injection System uses ozone compatible Stainless Steel pipes to move water under high pressure in some places. These tubes under high pressures pose a possibility of leaks to occur. In the event water does leak from the Ozone Injection System, shut all equipment off andrepair immediately to prevent electric shock.

WARNING Make sure all tubing connections between the ozone generator and the injection point are secure and in good working condition. Failure to do so could result in the discharge of undesired ozone into an occupied space.

Oxidation Technologies, LLCPhone: 515-635-5854 of 37

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Table of ContentsCautions, Warnings and Hazards..............................................................................2Introduction...........................................................................................................4System Components...............................................................................................5System Component Descriptions..............................................................................6Ozone System Piping Schematic...............................................................................9Wiring Diagram....................................................................................................10Installation..........................................................................................................16Ozone System System Initial Startup Procedure.......................................................17Normal Operating Parameters.................................................................................19Normal System Operation......................................................................................19

System Checks.................................................................................................19Normal Startup and Shutdown............................................................................19Emergency Stop Shutdown................................................................................19Long term shut-down........................................................................................20

Alarm Descriptions................................................................................................20Ozone Injection System Troubleshooting Chart.........................................................23Additional Trouble Shooting...................................................................................24System Maintenance.............................................................................................25Specifications.......................................................................................................26Contact Info.........................................................................................................26


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Introduction

The Ozone Injection System is a skid mounted injection system with all Ozone Resistant parts to withstand high concentrations of ozone for the life of the unit. It is designed to inject ozone into water safely for water disinfection.

Ozone is produced from oxygen with integrated oxygen concentrator. Compressed air is supplied to the oxygen concentrator from an internal air compressor. This compressed air is filtered and bulk moisture is removed with air filters located inside the ozone system.

Within the oxygen generator nitrogen is removed from the air supply using azeolite material and pressure swing absorption (PSA) technology. By altering pressures on the zeolite sieve beds nitrogen is purged and oxygen iscaptured to be used for ozone production. The Oxygen Generator provides oxygen at flow rates up to 15 SCFH.

Oxygen flows into the ozone generator to be converted into ozone. Using a corona discharge ozone generator oxygen is converted to ozone. A high voltage, high frequency spark, or corona is created in the air gap within the corona cell. This electrical discharge splits the oxygen molecule to convert into ozone. Up to 5% of the oxygen is converted to ozone for use in oxidation processes.

Ozone gas is mixed with the water using a venturi injector and ozone injection pump that creates a pressure differential across the venturi during operation. This ozone is mixed with the water in an ozone mixing tank, excess ozone gas is removed from the water via an air vent and reverted back to oxygen in an ozone destruct unit. Ozone in water is pumped to the point of use using the ozone circulation pump that will pump water at 8-10 GPM water flow rate to the point of use. In the event of low water flow ratesthe ozone system will turn OFF on alarm.

Ozone levels in water are measured and verified with an ORP (oxidation reduction potential) meter. In the event of low ORP levels in the water the ozone system will turn OFF on alarm.

Ambient ozone levels are measured via an ambient ozone sensor, in the event of unsafe ozone levels in the ambient air the ozone system will turn OFF on alarm.


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System Components


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System Component Descriptions

1. POWER indicator - Green◦ ON SOLID - Ozone system is turned ON and either in FILL or RECIRC

mode◦ FLASHING – System shut down due to WATER FLOW or ORP-LOW alarm

condition.

2. OZONE indicator - Blue◦ ON SOLID - Ozone system is running with ORP level in water at target

level◦ FLASHING – System shut down due to WATER FLOW or ORP-LOW alarm

condition.

3. WATER DRAIN Button - Yellow◦ Press to activate DRAIN function and release water from injection system.◦ SYSTEM POWER switch must be OFF to activate this function. ◦ When activated, the water drain valve will open and the yellow button will

illuminate. ◦ After a period of 60 seconds, the valve will automatically close and yellow

light turn OFF.

4. SYSTEM POWER Switch◦ FILL – System pulls water from supply (tank or tap), dissolves ozone into

the water, and delivers it to the aircraft.◦ RECIRC – System opens a return valve, whereby water can be returned

from the aircraft for “loop” operation and ozone level can increase with each pass.

5. OZONE GENERATOR Switch – Activates ozone generator whenever systemis running. Normally can be left in ON position at all times, even when system is shut down.

6. EMERGENCY STOP – Immediately cuts power to all mechanical and electrical components on the system. NOT recommended for regular use.

7. Air Inlets for cooling – Ambient air enters the cabinet through these vents to cool the ozone generator cabinet.

8. Ozone gas valve – Electronic ball valve on the ozone gas outlet protects theozone generator from water back-flowing into the ozone generator from the venturi injector. Opens automatically whenever system starts up.

9. Ozone Injection Pump – Water pump provides pressure differential across the venturi injector and water circulation through the ozone mixing tank to mix ozone gas with the water.


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10. Water circulation Pump – Water pump provides water flow to the aircraft. Pump inlet must be flooded for the pump to create flow, water flows of 8-10 GPM will be realized during operation.

11. Ozone Destruct Device – Undissolved ozone off-gas flows through the destruct device which catalyzes ozone safely back to oxygen.

12. Outlet Box – 120 VAC electrical receptacles. ◦ Top left = Ozone Injection Pump◦ Bottom left = Ozone Circulation Pump◦ Top right = Ozone Destruct Device◦ Bottom right = Spare outlet (1 amp maximum load)

13. Water Flow Switch – Measures water flow through the ozone system provided by the circulation pump. At water flows below 5 GPM the water flowswitch sets the low water flow alarm, which is time-delayed.

14. Ozone air vent – Vents undissolved ozone gas and excess oxygen gas from the ozone mixing tank, separating water by means of a mechanical float-controlled valve. This gas is plumbed to the water trap, then the ozone destruct device to catalyze undissolved ozone safely.

15. Ozone off-gas water trap – Water droplets from the off-gas stream are gravity-drained and separated at this device, prior to the ozone destruct device using a J-tube water trap, forcing gas to the ozone destruct device.

16. Injector outlet pressure gauge – Measures water pressure at the outlet ofthe ozone injector, this is the same pressure as the ozone mixing tank.

17. Injector inlet pressure gauge – Measures water pressure at the inlet of the ozone injector. This pressure is created by the ozone injection pump.

18. Water filter – Filters incoming water to 10 micron to prevent plugging of theventuri or pump vanes.

19. Pressure relief valve – Relieves water pressure on the ozone system for maximum 35 PSI system pressure.

20. Ozone mixing tank – Mixes ozone gas with water while stripping excess undissolved ozone gas and oxygen from the water stream.

21. Electrical cord/plug – Power cord for the ozone system, plugs into a 220 VAC, 1-phase power source.

22. Air outlet for cooling – Cooling fans blow ambient air through the cabinet for cooling of the ozone system. This air flows out of these vents.


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23. Water inlet – 1” female NPT connection for water inlet to the ozone system

24. Water drain valve – Electric ball valve drains water from the ozone system through this valve.

25. Water outlet – 1” female NPT connection for water outlet from the ozone system

26. Compressed air moisture drain line – Moisture captured in the compressed air filter is drained from this line automatically, opening for 2 seconds every 5 minutes.

27. Oxygen Concentrator – Purges nitrogen from the compressed air to capture oxygen using PSA (pressure swing absorption).

28. Compressed air filter – Filters compressed air supply prior to the oxygen concentrator, also captures moisture from the air to drain from the air to protect the oxygen concentrator

29. Oxygen pressure regulator and gauge – regulates oxygen pressure and indicates regulated pressure on the pressure gauge

30. Compressed air pressure gauge – Indicates air pressure at the inlet of theoxygen concentrator

31. PLC Controller – Programmable Logic Controller (PLC) provides automated control for the ozone system

32. Cabinet air temperature switch – Measures air temp and will turn OFF ozone system in the event of high ambient temperatures inside the ozone system

33. Oxygen flow-meter – Displays oxygen flow through the ozone generator cells

34. Cooling fans – Provide ventilation airflow through the ozone system cabinet for cooling

35. Compressed air inlet filter – Filters inlet air into the air compressor

36. Air Compressor – Provides approximately 4 CFM compressed air for the oxygen concentrator, at pressure of 20-30 PSI

37. Oxygen concentrator outlet – 120 VAC electrical receptacle to power the oxygen concentrator. PLC turns this outlet ON and OFF automatically when system is started.


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38. Air compressor outlet – 120 VAC electrical receptacle to power the air compressor. PLC turns this outlet ON and OFF automatically when system is started.

39. Ambient ozone leak sensor – Measures ozone in the ambient air inside theozone cabinet. In the event ozone levels rise to unsafe ozone levels the ozone generator will turn OFF. The system will stay operational unless the ORP drops due to lack of ozone in the water, at which time an alarm will be annunciated.

40. ORP Monitor– Indicates ORP levels in the water on the LCD display and provides control outputs to the PLC for ozone level controls

41. Ozone leak alarm indicator– Red indicator illuminates when the ambient ozone leak sensor measures unsafe ozone levels in the ozone cabinet

42. Cabinet high temp alarm indicator– Red indicator illuminates when the ambient temperature sensor measures unsafe ambient temperatures in the ozone cabinet

43. No water flow alarm indicator◦ ON SOLID – Water flow is currently low◦ FLASHING – System shut down due to WATER FLOW alarm condition for

more than 30-seconds

44. ORP low alarm indicator◦ ON SOLID – ORP level is currently low◦ FLASHING – System shut down due to ORP LOW alarm condition for more

than 120-seconds

45. Ozone Generator #1– Ozone generator assembly produces ozone via corona discharge in the air cooled corona cell. A high frequency, high voltage spark is generated by the transformer and electric circuit board on the ozone generator.




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Ozone System Piping Schematic


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Wiring Diagram


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Installation

Ensure system is installed in a clean, dry location with no splashing/dripping water.

Location must be well ventilated as the ozone system is air cooled and requires sufficient air flow through the vent fans for proper cooling and operation.

Electrical power (#21) - Connect system to electrical power using supplied electrical plug

• Voltage: 208-230VAC 1-phase w/Neutral• Full Load Amps: 16

Water Inlet (#23)– 1” Female NPT connection. Water inlet must be flooded with water at all times when the system is in operation

Water Outlet (#25)– 1” Female NPT connection. Water outlet connected to point of use.


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Initial Startup ProcedureThis procedure is for startup of any new machine, or any machine which has just undergone maintenance.

NOTE: During any non-routine startup or troubleshooting, it is recommended that the OZONE GENERATOR switch be OFF. Since boththe oxygen and the water flow freely through the system without ozone, almost all required adjustments or corrections can be performed. This usually simplifies troubleshooting and is safer for the operator. Once the system is running steady, the OZONE GEN can be turned ON.

1. Switch all ON/OFF switches to the OFF position.

2. Ensure that water is connected and available at the WATER INLET fitting.

3. Plug in the cord or supply power to the system.

4. Turn SYSTEM switch the ON position. The system will automaticallystart up in sequence:

▪ The air compressor, and oxygen concentrator should start cycling and producing oxygen at this time. Inside, the air pressure gauge and flowmeter will indicate pressure and flow.• AIR pressure: oscillating 15-30 PSI• O2 pressure: 5-10 PSI• O2 flow: 5-15 CFH

▪ The circulation, and injection pump will start, and water pressuregauges will rise after about 10 seconds.• INJECTOR OUTLET pressure: minimum 10 PSI• INJECTOR INLET pressure: minimum 40 PSI

5. Normally no adjustments will be required as all parameters are pre-set at the factory. If oxygen flow adjustment is required, utilize theoxygen pressure regulator to change the pressure, which will correspond with a change in flow.

6. At this time the ozone generator can be started. Turn the OZONE GENERATOR switch ON. The blue OZONE light will turn on and the ORP will begin to rise.


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Normal Operating Parameters

Air pressure = 20-30 PSI (#30)

Regulated O2 pressure = 10 PSI (#29)

Oxygen flow = 10 SCFH (#33)

Injector inlet pressure = 60 – 80 PSI (#17)

Injector outlet pressure = 30 PSI (#16)

ORP = 950 – 1050 (#40)

Normal System Operation

System ChecksMonthly operational checks should include the following:

Ensure normal operating parameters listed above are present.

Ensure compressed air condensate is draining (no evidence of water in

second filter).

Visually inspect for water leaks while system is running.

Day-to-Day Startup and ShutdownNormal operation start/stop is done with the SYSTEM POWER switch, while the OZONE GENERATOR switch can be left ON at all times. All components will start up and shut down in proper sequence automatically.

Emergency Stop ShutdownEmergency shutdown should be used only when required. If it is necessary to use the emergency stop, then it is advantageous to re-start the system toflush ozone from the cells and piping as soon as possible, for maximum system longevity.

Long term shut-downNo special procedures are required, except that water should be drained from system to prevent freezing. Any open ports should be capped to prevent entry of foreign material.


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Alarm Descriptions

This ozone system is a fully automated system. Therefore all components will be turned ON and OFF as needed by the PLC control system. In the event parameters fall out of range of the automated system the RED status indicators will be illuminated indicating a problem with the system.

Ozone Leak Alarm (#41) – There is an ambient ozone leak sensor (#39) located inside the control cabinet. The purpose of the sensor is to prevent unsafe conditions for the ozone system components, or persons in the area. Since the cabinet is ventilated, this will also detect fugitive ozone from outside the cabinet. Default setting for this alarm is 0.3 PPM (this can be adjusted if necessary, consult factory for details).

• In the event of an ozone leak inside the ozone system or in the area:◦ The ozone cells will be turned OFF (no ozone production)◦ The red “Ozone Leak” alarm light will be illuminated. ◦ The system will remain running without producing ozone.◦ The ventilation fans will remain running, even with the system

switch OFF, in order to ventilate the cabinet until the ozone leak subsides

• If the fugitive ozone level drops to acceptable levels:◦ Ozone generators will automatically restart.◦ Red light will turn OFF.

Cabinet high temp alarm(#42) – There is a temperature switch (#32) located inside the control cabinet. The purpose of the sensor is to prevent damage to system components due to overheating. Since the cabinet is ventilated, this alarm may occur due to high ambient temperatures even though the system does not need maintenance. Default setting for this alarm is 105F (this can be adjusted if necessary, consult factory for details).

• In the event of high temperature inside the ozone system or in the area:◦ The ozone cells will be turned OFF (no ozone production)◦ The red “Cab Temp High” alarm light will be illuminated. ◦ The system will remain running without producing ozone.◦ The ventilation fans will remain running, even with the system

switch OFF, in order to ventilate the cabinet until the temperature drops

• If the temperature drops to acceptable levels:◦ Ozone generators will automatically restart.


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◦ Red light will turn OFF.

No water flow alarm (#43) – There is a water-flow switch (#13) located in the piping, down-stream of the water filter. The purpose of the sensor is to detect water flow through the system – this ensures that system components are working properly, and that water is available and being delivered. If the system is empty of water, this alarm may occur even though the system does not need maintenance (it is allowable to restart the system 2-3 times before diagnosis is needed). Default setting for this alarmis 5 GPM (this can be adjusted if necessary, consult factory for details).

• In the event of no water flow:◦ The red “No Water Flow” alarm light will be illuminated. ◦ The system operation will remain normal for exactly 30 seconds

without flow detected. After no-flow condition exists for 30 seconds, the alarm will “latch” and the following will occur:▪ System will shut down▪ The BLUE and GREEN lights on the front of the system will flash▪ The red “No Water Flow” light will flash, to indicate the reason

for shutdown.• To reset the alarm, turn the System Power switch to OFF.

ORP low alarm (#44) – There is an ORP sensor located in the piping, near the water-OUT fitting. This is connected to a monitor inside the cabinet (#40) which displays the ORP level. The purpose of the sensor is to detect ORP level in the water as it leaves the system – this ensures that system components are working properly, and that ozone level in the water is sufficient. If the system is utilizing warm or stagnant water, this alarm may occur even though the system does not need maintenance (it is allowable to restart the system 2-3 times before diagnosis is needed). Default setting for this alarm is 800mV (this can be adjusted if necessary, consult factory fordetails).

• In the event of low ORP:◦ The red “ORP Low” alarm light will be illuminated. ◦ The system operation will remain normal for exactly 30 seconds

with low ORP detected. After ORP-low condition exists for 30 seconds, the alarm will “latch” and the following will occur:▪ System will shut down▪ The BLUE and GREEN lights on the front of the system will flash


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▪ The red “ORP Low” light will flash, to indicate the reason for shutdown.

• To reset the alarm, turn the System Power switch to OFF.


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Replacement Parts List


Identifier Part Number Part Description1 CSW-SD2F indicator, lens, green2 CSW-SD4F indicator, lens, blue3 CSW-SD3F indicator, lens, yellow4 CSW-CK2F90F Switch actuator OFF/ON, black, 90deg5 CSW-CK2F90F Switch actuator OFF/ON, black, 90deg6 CSW-BESPF Switch actuator, E-STOP7 Fan grill f Filtered fan grills8 AC2CW Electric Ball valve9 CM5-2 CM5-2 pump10 CM5-2 CM5-2 pump11 CDU-30-H-WB CDU-30 destruct unit13 WFS-16 Water flow switch14 11AV 11AV air vent15 MS- Ozone off-gas water trap16 PG-100-SS-R 0-100 PSI center back, 1/4” NPT pressure gauge17 PG-100-SS-R 0-100 PSI center back, 1/4” NPT pressure gauge18 Filter-W-16 Filter assembly18 Filter-W-16-R-100 Replacement filter element19 PRV-1-30-SS Pressure relief valve20 Tank-SS-AA Tank21 L1430P Electrical plug – 220 VAC, 1-phase22 Fan grill M Fan Grills – steel23 AA-Water inlet fitting Water inlet fitting – 1” SS tee with bushings24 AC2CW Electric Ball valve25 AA-Water outlet fitting Water outlet fitting – 1” sanitary tube with NPT connection26 HPT-3/16x1/4 Compressed air moisture drain line27 OG-15-OEM OG-15 Oxygen Concentrator28 M28-03-CK00 Air filter assembly CK0028 MSP-96-648 Replacement air filter CK0029 PR-50-A Oxygen pressure regulator – 0-50 PSI29 PG-30-2-R Oxygen pressure guage – 0-30 PSI center back, 1/8” FNPT30 PG-60-B-R Air pressure gauge – 0-60 PSI, center back, 1/4” FNPT31 P1-540 PLC32 1146.9 Temp sensor33 VFA-4-SS-WL Oxygen flow-meter – 0-20 SCFH, no valve34 Fan 4.7 – 120 Cooling fan35 Filter-4-R Replacement inlet air filter36 CP-Comp Oil-less air compressor39 OEM-3 OEM-3 ozone monitor39 SM-3 OEM-3 replacement sensor40 ORP Monitor – Pulse ORP monitor41 CSW-SD2F Indicator, lens, red45 VMUS-4 OEM Ozone Generator assembly46 VMUS-4 OEM Ozone Generator assembly47 VMUS-4 OEM Ozone Generator assembly48 P1-16CDR PLC slot #1 & 249 SC-E02 Electric contactor 120 VAC coil50 PTF08AE Ice Cube relay and relay base, DPDT51 Compressed air cooler Compressed air cooler51 KC-10-6-6-KPG Kynar compression fitting, 3/8 comp x 3/8” Male NPT elbow52 KC-40-6-6-KPG Kynar compression fitting, 3/8 comp x 3/8” Male NPT Straigh53 M784 Model 784 venturi53 Clamp-SS-1.5 1-1/2” Sanitary clamp53 Clamp-seal-1.5 1-1/2” seal54 CHK-6SV 3/8” stainless steel check valve55 CSW-BIDLF0E10 indicator, lamp, LED 120V56 BC10F-CSW Switch base/contact N.O.57 BC01F-CSW Switch base/contact N.C.58 SV-2-B Drain valve, 1/8”59 PSB24-060-P Rhino power supply60 CHK-6K Kynar check valve 3/8” NPT61 FEP-1/4x3/8 1/4” x 3/8” FEP tubing62 MTP-96-649 Replacement air filter BK0062 VMUS-4 OEM VMUS-4 OEM 63 CHK-4B 1/4” barbed check valve64 ORP-Sensor ORP sensor

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Ozone Injection System Troubleshooting Chart


O3 leak light lit O 3 is leaking inside ozone generator Turn off O 3, leave O 2 running, check for leak inside unitO 3 is leaking from tubing or point of u Turn off O 3, leave O 2 running, check for leak outs ide unitO 3 sensor has failed Check, replace SM-5 O zone sensor

Low O2 Pressure Pressure regulator adjustment A djust pressure regulator as neededO xygen flow too high A djust oxygen flow us ing flow meter valveA ir filters are restricted replace inlet air filtersO xygen concentrator failure Rebuild/replace oxygen concentrator

High O2 Pressure Pressure regulator adjustment A djust pressure regulator as neededExternal restric tion find and correct external flow restric tionO xygen concentrator failure repair/replace oxygen concentratorLow venturi suction See below

Low O2 Flow Flowmeter requires adjustment A djust oxygen flow us ing flow meter valveO xygen pressure low A djust oxygen pressure regulator as necessary

External restric tion

Low venturi suction See below

High O2 Flow Flowmeter requires regulation A djust oxygen flow us ing flow meter valveO xygen pressure high A djust oxygen pressure regulator as necessary

Low venturi suction High incoming water pressure A djust incoming water pressure to 30 PSIP lugged/dirty injector Remove and c lean injectorLow injector inlet pressure See below

Water pump failure Check pump operation and vanes for dirt

P iping failure Ensure water inlet into pump is c lear of obstruction

Low dissolved O3 Low oxygen flow/pressure See aboveLow oxygen purity Check oxygen purity, repair as necessaryLow/high inlet water pressure A djust incoming water pressure to 30 PSIPoor injector performance Check injector pressure differential and suctionPoor ozone generator performance Call factory for ass istance

No O3 output O zone generator power not on Ensure O 3 generator is O N and ozone leak is not presentO zone generator fault Check for red LED on ozone generatorO zone Generator failure Call factory for ass istance

Low ORP Levels Low dissolved ozone levesl See aboveA ir pocket in O RP probe TEE A djust O RP teeO RP out of calibration calibrate O RP probeO RP Probe failure replace O RP probe

Check for restric tion after ozone generator by disconnecting ozone outlet line

Low injector inlet pressure

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Additional Trouble Shooting

If the water pump is not operating Unplug the pump from the outlet on the rear of cabinet. Substitute a

small load that you can plug in, such as a light or battery charger. Start the system to determine if power is present at the outlet.

Disconnect power, remove rear cover of pump and try to turn the pump by hand – it should spin freely both directions with little resistance.

If neither of these procedures correct the issue call the factory for technical assistance

If there is no suction from the injector Are there air bubbles in the clear PVC sight tube? If there are suction

is occurring. If no air bubbles are present pull the Teflon line off the injector, this

will check for obstruction from the ozone generation side. Is the vent line plugged? Disconnect the vent line from the off gas

vent to release air. If this does not resolve the problem, un-thread the cap off the injector

and check for obstruction, if possible blow compressed air into this portto free any obstruction

If this does not resolve the problem remove the entire injector assembly and blow compressed air into the system backward to free obstructions or clean out slime.

If none of these procedures correct the issue call factory for technical assistance.

Oxygen Concentrator Service Verify oxygen purity

1. Use hand-held oxygen meter2. Ensure ozone generator is OFF, but system is operating normally3. Disconnect ozone line at the venturi4. Connect ozone outlet tubing into oxygen meter5. Oxygen purity should be greater than 85%

If oxygen purity is low:1. Ensure air filters are clean and dry2. Ensure incoming air pressure and flow are adequate3. Ensure oxygen flow and pressure is proper4. Allow at least 1 hour for purity recovery, while running at correct

pressure & flow.5. If purity is still low, then oxygen concentrator may need service.

See specific Oxygen Concentrator manual for details.


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System Maintenance Schedule

Maintenance Instructions

Inlet Air Filter replacement (#35) Remove filter housing top from filter housing bottom by pressing down

and rotating counter-clockwise Inspect/replace filter element inside the housing Replace filter housing top. Align the slots properly, press down and

rotate top clock-wise to the base until the slots are completely seated


Component Maintenance Schedule Part Number

FiltersInlet air filter (#35) Check Monthly – replace or clean as needed Filter-4-R

Replace QuarterlyInlet Air Filter 0.1 micron (#62) Check Monthly – replace or clean as needed MSP-96-649

Replace QuarterlyInlet Air Filter 0.01 micron (#28) Check Monthly – replace or clean as needed MTP-96-648

Replace QuarterlyWater Filter (#18) Replace Monthly – replace or clean as needed Filter-W-16-R-100

Check ValvesKynar check valve (#60) Replace Every 1-year CHK-6KBarb check valve (#63) Replace Every 1-year CHK-4BSS Check valve (#54) Replace Every 1-year CHK-6SV

SensorsOEM-3 ozone leak sensor (#39) Replace Every 1-year SM-3ORP Sensor (#64) Replace Every 1-year ORP Sensor

Main componentsDestruct unit (#11) Rebuild Every 1-year CDU-30-rebuild kitAir Compressor (#36) Replace Every 3-years CP-CompOxygen Concentrator (#27) Rebuild Every 2-3 years (as needed) OG-15-OEM-RebuiltWater pump seal kits (#9&10) Rebuild Every 3 years CM5 Rebuild kit

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Air filter replacement (#62 & #28) This unit may be serviced without removing the unit from the

compressed air line Depressurize the unit Remote the bowl/bowl guard assembly by pushing up on the bowl

assembly and turning counter clockwise. Clean inside of the bowl using a clean cloth. Inspect spastic bowl for damage and replace if necessary

Remove filter element by turning element clockwise Install a new filter element/)-ring seal and reassemble in reverse order


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Kynar Check Valve (#60) Check valve is threaded between the motorized ball valve (#8) and the

ozone outlet fitting. Remove tubing from the Kynar compression fitting (#51) by loosening and removing the nut from the fitting.

Unthread the check valve from the ball valve and adapter Replace with new check valve, ensure Teflon tape is wrapped around

the threads fully 3 times around the threads, and place a light layer of Teflon paste on the fitting prior to reinstalling

Reconnect fittings and tubing in reverse order


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Barb check valve (#63) Cut tubing on either side of check valve and discard Push new check valve into tubing. Using a heat-gun to heat tubing

slightly will make this easier. If additional tubing is required order “FEP-250x375”

SS Check valve (#54) Check valve is threaded between the Venturi Injector (#53) and the

ozone inlet fitting. Remove tubing from Kynar compression fitting by loosening and removing the nut from the fitting.

Unthread the check valve from the venturi injector Replace with new check valve, ensure Teflon tape is wrapped around

the threads fully 3 times around the threads, and place a light layer of Teflon paste on the fitting prior to reinstalling

Reconnect fittings and tubing in reverse order

OEM-3 ozone leak sensor (#39) Replacement sensor is a small square board that pulls off the main

sensor board. Remote sensor and replace, see image below for example of sensor and location.

ORP Sensor (#64) ORP sensor threads into the stainless piping at the bottom of the

ozone system. It is wired to the ORP monitor inside the system Disconnect wiring from ORP monitor via the BNC connector and

remove wiring completely from the ozone system Unthread the ORP sensor from the stainless fitting


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Replace with ORP sensor, ensure Teflon tape is wrapped around the threads fully 3 times around the threads, and place a light layer of Teflon paste on the threads prior to reinstalling

Reconnect wiring in revers order

Destruct Unit (#11) Remove destruct unit from the system by unplugging the 120 VAC

cord and removing bolts from the wall bracket Un-thread the top cap from the destruct unit and pour contents into a

proper trash bin Replace screens with new screens from rebuild kit, smaller hole screen

is placed in the destruct unit first, larger hole screen is placed second Fill with new catalyst material, tap the side of the unit while filling to

pack material tight Replace the cap, ensure Teflon tape is wrapped around the threads

fully 3 times around the threads, and place a light layer of Teflon pasteon the threads prior to reinstalling

Reconnect to skid and reconnect wiring in reverse order

Air Compressor (#36) Unplug compressor via the 120 VAC cord plugged into the bottom

receptacle on the outlet inside the ozone system Remove nuts from the compressor legs on the bottom of the cabinet Remove compressor from the cabinet Remove the air filter housing and fittings and install on the new

compressor. Remove the compressed air outlet fitting and install on the new

compressor. Ensure all plugs and fittings on old compressor and new compressor

match Install compressor in reverse order

Oxygen Concentrator (#27) Remove oxygen concentrator from system by unplugging 120 VAC

cord from the outlet and unbolting the unit from the wall of the cabinet, there are 4 bolt/nuts that hold the unit to the side of the cabinet that must be removed

Remove oxygen outlet tubing Remove air inlet tubing Remove oxygen concentrator from the cabinet


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Remove oxygen pressure regulator from the old concentrator and install on the new/rebuilt unit

Remove air inlet fittings/gauge from the old concentrator and install onthe new/rebuild unit

Install in reverse order

Ozone Generator (#45, 46, 47) Generators are stacked via stand-offs. Multiple ozone generators may

require removal to access the proper unit for replacement Cut tubing from barbed fittings on ozone generator remove power plug from ozone generator by gently pulling connector

from base Unbolt ozone generator base, 4 bolts Install in reverse order Use a heat-gun to soften tubing to reinstall on barbed fittings of ozone

generator, if required order replacement tubing

Water Pump Seal Kit (#9 &10) Remove pump from skid by unplugging 120 VAC cord from the outlet

and unbolting the pump base from the skid Remove fittings at closest point by removing the 1-1/2” sanitary

clamps Remove excess fittings and components from the pump as required See pictorial diagram from Grundfos below on the seal kit replacement


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Specifications

Environment:Operating Temperature: 32°F to 100°FStorage Temperature: 32°F to 150°F

Mechanical:Ozone Injection System Maximum Dimensions: 55”W x 55”D x 75” HOzone Injection System Dry Weight: 2,300 lbs

Contact Info

By mail: Oxidation Technologies, LLC214 West Highway 18Inwood, IA 51240

By telephone: (515) 635-5854

By e-mail: [email protected]


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American Airlines OST-20 Ozone Generating System Property ... · Ozone gas is mixed with the water...

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