AmeriWater OZONE Handbuch

98-0109 Rev. B

INDUSTRIAL OZONE

DISINFECTION SYSTEM

OPERATION & MAINTENANCE MANUAL

WARNING: NOT FOR USE IN THE DISINFECTION OF HEMODIALYSIS WATER

DISTRIBUTION SYSTEMS OR OTHER DEVICES FOR HEMODIALYSIS

APPLICATIONS!

Manufactured With Pride

In The USA

www.ameriwater.com • 800-535-5585

AmeriWater • 3345 Stop 8 Rd. • Dayton, OH 45414

Table of Contents

SECTION 1, GENERAL INFORMATION ................................................................................ 1

1.1 INDICATIONS FOR USE.......................................................................................... 1

1.2 WHAT IS OZONE?.................................................................................................... 1

1.3 THE TECHNOLOGY................................................................................................. 2

1.4 THE SYSTEM .......................................................................................................... 2

1.5 SPECIFICATIONS.................................................................................................... 2

1.6 HEALTH AND SAFETY............................................................................................ 3

1.7 OZONE COMPATIBLE MATERIALS........................................................................ 4

SECTION 2, COMPONENTS AND FLOW SCHEMATICS...................................................... 5

2.1 OZONE DISINFECTION SYSTEM COMPONENT IDENTIFICATION...................... 5

2.2 FLOW DIAGRAM AND ELECTRICAL DIAGRAM..................................................... 7

SECTION 3, INSTALLATION & OPERATION......................................................................... 8

3.1 GENERAL OVERVIEW............................................................................................. 8

3.2 TANK FITTING INSTALLATION INSTRUCTIONS ................................................. 10

3.3 WATER TREATMENT SYSTEM DISINFECTION PROCEDURE........................... 11

SECTION 4, MAINTENANCE / TROUBLESHOOTING GUIDE ............................................ 14

4.1 MAINTENANCE...................................................................................................... 14

4.2 GENERATOR TROUBLESHOOTING GUIDE........................................................ 14

4.3 BACKPRESSURE................................................................................................... 15

SECTION 5, PRODUCT WARRANTY .................................................................................. 16

SECTION 6, SPARE PARTS LIST........................................................................................ 17

6.1 OZONE DISINFECTION SYSTEM COMPONENTS............................................... 17

SECTION 7, OZONE AMBIENT AIR MONITORS................................................................. 19

SECTION 8, OZONE MSDS.................................................................................................. 21

98-0109 Rev. B

SECTION 1, GENERAL INFORMATION

IMPORTANT SAFETY INSTRUCTIONS:

1. READ AND FOLLOW ALL INSTRUCTIONS.

2. DANGER – Risk of injury.

a. Replace damaged line cord immediately

b. Do not bury cord

c. Connect to a grounded, grounding type receptacle only

3. WARNING – For indoor use only. This unit is not intended for outdoor use.

NOTE: The operation manual should be stored near the system and used as a

reference and troubleshooting guide.

1.1 INDICATIONS FOR USE

The AmeriWater Ozone Disinfection System is intended for use in disinfection of water distribution

systems. The disinfection process is completed during off-hours when the water distribution system is

not being used to supply water to a point of use. The AmeriWater Ozone Disinfection System provides

dissolved aqueous ozone concentrations of at least 0.5 ppm for disinfection of the water distribution

system.

WARNING: This device is not cleared for market by FDA for use on hemodialysis water

distribution systems or other devices used in hemodialysis applications!

The device is NOT intended for disinfection of medical devices and should

not be used for disinfection of medical devices!

1.2 WHAT IS OZONE?

Ozone is a form of naturally occurring oxygen possessing three atoms of oxygen per

molecule instead of the normal two-atom oxygen molecule. Created by either lightning or

ultraviolet radiation, ozone is commonly found in our atmosphere. The “ozone layer” protects

us from the sun’s radiation. The “fresh air” smell after a thunderstorm is due to lightning

generated ozone.

Ozone has a relatively short life span before it reverts back to oxygen. While active, ozone is

52% stronger and 3,125 times faster (in water) than chlorine as a disinfectant. Since it is

much more effective than chlorine in destroying water-borne contaminants, ozone has

become the preferred method of water treatment for over 4,000 large cities worldwide.

Ozone is recognized by the U.S. Environmental Protection Agency as a viable water

treatment alternative to chlorine, and the FDA has added ozone to its list of disinfectants

approved “Generally Recognized as Safe.” Ozone is the most powerful and rapid acting

oxidizer disinfectant produced, and will oxidize all bacteria, endotoxin and biofilms it comes in

contact with in medical piping and water systems.

98-0109 Rev. B

1.3 THE TECHNOLOGY

The AmeriWater Ozone Disinfection System uses a high technology corona discharge

process for producing ozone. This design provides the most efficient ozone production

available in the small-scale ozone equipment market. Ozone is manufactured by drawing

oxygen (O2) into the ozone generator and exposing it to multiple high voltage electrical

discharges. This causes a percentage of the oxygen molecules to dissociate and

reassemble as ozone (O3).

The ozone is drawn into the water by a venturi injector / mixer. This allows the ozone to be

injected into the water under a vacuum condition, which is the safest and most efficient

technology available. A pressure differential of at least 15 PSI (Pound per Square Inch) must

be maintained across the venturi injector. This pressure causes a vacuum that is measured

on the vacuum gauge. The gauge should read between –3” and –8” Hg when the system is

in normal operation.

1.4 THE SYSTEM

The AmeriWater Ozone Disinfection System is a complete unit with ozone generator, venturi

injector mixer, gas off chamber with excess ozone gas destruct, feed water flow meter,

oxygen flow meter and vacuum gauge that are mounted in a portable cabinet for disinfection

of water distribution systems.

1.5 SPECIFICATIONS

Model 0077-0010

Dimensions 35” High X 15” Wide X 24” Deep

Weight 70 pounds

Electrical Requirements 115 VAC, 60Hz, 3 AMP

Power Consumption 275 Watts

Ozone Output 10 Grams/Hour (Oxygen)

Indicators: RPC K100-0111 Ozone Test Strips, 0.05 - >0.5 ppm (Not provided)

HACH 25180-50, Accuvac Ozone, High Range Test Kit. (Not provided)

Water Feed Flow Meter - GPM (Gallons Per Minute)

Oxygen Flow Meter SCFH (Standard Cubic Feet/Hour) with flow control valve

Injector Vacuum Gauge (inches of mercury)

Safety: Ozone Safety Vacuum Switch prevents the ozone generator from operating

without the proper ozone draw (vacuum).

Ozone Overload Switch shuts the ozone generator off when the system begins

to overheat.

Door switch kills power to the system when door is not in place.

Ozone gas-off destruct device eliminates excess ozone gas.

98-0109 Rev. B

1.6 HEALTH AND SAFETY

Ozone is a toxic gas above certain high concentrations, and an irritant at lower

concentrations. The Occupational Safety and Health Administration (OSHA) regulations

state that an individual must not be exposed to a concentration of ozone gas higher than:

1) 0.10 PPM (Parts Per Million) by volume over an 8-hour period.

2) 0.20 PPM by volume over a 10-minute period.

*See ambient air ozone monitor information in Section 7.

The AMERIWATER OZONE DISINFECTION SYSTEM uses a gas off tank to contain any

ozone gas not dissolved in the water and an ozone gas destruct device to limit the ozone

exposure in the area of use. Ozone has a very short half-life and will decompose to oxygen

in less than 5 hours. The human nose can detect the ozone odor at .02 PPM, which is 5

times lower than the OSHA safe level.

Call 1-800-535-5585 for the ozone MSDS sheet.

WARNING: Oxygen is a fire hazard. It is a highly active oxidizer as it vigorously

accelerates the burning of combustible materials. Do not use oil, grease,

cotton fibers or any other combustible material on or near the Ozone or

Oxygen Generator. Smoking, heat or any open flame should be

kept at a distance of not less than 5 feet from any part of the system. It is

STRONGLY recommended that only individuals experienced in the safe

handling of Oxygen be allowed to operate this equipment.

WARNING: Connect power cord only to a properly grounded wall outlet.

WARNING: High voltage is present in Ozone Generators. Only qualified electricians

should work on this equipment.

98-0109 Rev. B

1.7 OZONE COMPATIBLE MATERIALS

Ozone is one of the strongest oxidizing agents currently available for water treatment, so

great care should be taken to ensure that all piping, valves, gaskets, and other materials

used in the water treatment system that will come in contact with ozone are resistant to the

concentrations of ozone present during disinfection. Just about all the materials except filter

cartridges and membranes used in the typical water system are acceptable.

Below is a list of materials that are compatible for ozone concentrations up to 6 PPM in water.

Piping: Gaskets & Seals:

304L Stainless Steel Kel-F 2800

316L Stainless Steel Kal-Rez

PTFE (Teflon) Chem-Rez

ETFE (Teflon) Gortex

ECTFE (Halar) Teflon tape

PVDF (Kynar) Hypalon

CPVC Schedule 80 Viton

PVC Schedule 80 Silicon

HDPE (Polyethylene) EPDM

PP (Polypropylene)

NOTE: Natural rubber and many plastic and synthetic rubbers cannot be used as

gaskets, seals, or o-rings in combination with ozone. Exposure to ozone will

cause these components to become brittle and crack.

98-0109 Rev. B

SECTION 2, COMPONENTS AND FLOW SCHEMATICS

2.1 OZONE DISINFECTION SYSTEM COMPONENT IDENTIFICATION

FIGURE 1

98-0109 Rev. B

IDENTIFICATION OF COMPONENTS (FIGURE 1)

1. Inlet Hose Connection – (Female connector) Carries water to be disinfected to the

ozone machine.

2. Outlet Hose Connection – (Male connector) Carries ozone rich water to the loop or

tank to be disinfected.

3. Door Switch – Shuts off power to the unit when the cabinet door is removed.

4. Gas Off Chamber – Ozone rich water enters the gas off chamber to remove any

excess, un-dissolved ozone before being directed into the water system.

5. Ozone Gas Destruct Chamber – Converts ozone gas back to oxygen.

6. Ozone Generator – Produces ozone by passing oxygen through a corona discharge.

7. Strainer – 40 mesh screen ensures small particles do not block injector.

8. Injector Vacuum Switch – Turns off the ozone generator when there is not enough flow

of water to create an adequate vacuum.

9. Check Valve – Controls the direction of flow of ozone into the water stream.

10. Injector – Injects ozone gas into the water flow.

11. Ozone Generator ON / OFF Switch – Turns power to ozone generator ON and OFF

and will illuminate when the ozone generator is producing ozone.

12. Water Flow Meter and Valve – Measures the flow rate in gallons per minute (GPM) of

the water.

13. Feed Sample Port – Test port used to sample the water feeding the device.

14. Ozone Sample Port – Test port used to sample product water rich in ozone.

15. Oxygen Flow Meter and Valve – Controls and measures the flow rate in standard cubic

feet per hour (SCFH) of oxygen to the ozone generator.

16. Oxygen Connection – Quick connect fitting for connecting oxygen supply to the

system.

17. Vacuum Gauge – Displays the vacuum draw at the injector vacuum switch.

98-0109 Rev. B

2.2 FLOW DIAGRAM AND ELECTRICAL DIAGRAM

98-0109 Rev. B

SECTION 3, INSTALLATION & OPERATION

3.1 GENERAL OVERVIEW

WARNING: Do not turn the ozone generator on until the water flow has been

established.

The flow path in the AmeriWater Ozone Disinfection System is illustrated in Section 2.2. The

water to be disinfected is pumped into the AmeriWater Ozone Disinfection System by the

water distribution pump(s). The water flows through the feed flow meter and into the venturi

injector, which draws the oxygen from the oxygen valve through the flow meter into the

generator creating ozone. The ozone is then mixed in the water flow. The ozone rich water

enters the gas off tank to remove any excess, un-dissolved ozone gas and then is directed

into the water system to be disinfected. The ozone gas collected in the gas off tank is vented

automatically to the ozone gas destruct chamber and destroyed.

The driving force of the AmeriWater Ozone Disinfection System is the distribution pump(s) on

the water loop. A valve arrangement has to be installed after the water distribution system

distribution pump(s) to divert the flow into the AmeriWater Ozone Disinfection System and

back to the storage tank.

Figure 4a

In the illustration Figure 4a, Valve A is throttled and Valves B and C are open. (Note: Valve

A is only closed enough to divert the loop water through the ozone system.) Once the flow

through the AmeriWater Ozone Disinfection System is established, the “Feed Flowmeter” on

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