Carlsen SGA User Guide
Contents WARRANTY 1 Limits of Liability 3 SAFETY 4 CONTROL PANEL LAYOUT 5 CONTROL PANEL OPERATION 6 INSTALLATION 6 Location Requirements 6 Electrical Requirements 6 Plumbing Requirements 7 Air Requirements 7 START UP 8 INTERNAL SENSORS 9 SHUT DOWN 9 MAINTENANCE 9 Cleaning 9 Servicing 9 TECHNICAL SUPPORT 10 Technical Support and Parts 10 Online Support 10 Field Services 10 SERVICE 11 Upon Delivery 11 Returning a Unit for Service 11 WIRING DIAGRAM 12 INTERNAL LAYOUT 13 PPK002-002_Carlsen SGA_user manual
MOUNTING LAYOUT 14 SPARE PARTS LIST 15 PPK002-002_Carlsen SGA_user manual 3
Warranty All Pacific Ozone Technology products are covered by the following one year limited warranty, which is included in the Seller s Standard conditions of Sale: Warranty and Claims; Exclusions 1.1 Seller warrants to the original user only that its products to be free from defects in material or workmanship for a period of 12 months from shipment, but only when said products are operated at all times under normal operating conditions and procedures, in accordance with Seller's written instructions and the owner/operator manual supplied with each product. This warranty does not apply to replaceable parts or components normally subject to wear and replacement. Any misuse, improper operation or installation of any product, parts or equipment, as determined by Seller will void any and all warranty claims to the primary component as well as all supporting components. Any repair, modifications, or service performed by someone other than Seller or Seller s authorized technician will void any and all warranty claims to the primary component as well as all supporting components. Specific examples of voided warranty action include but are not limited to: Allowing water to enter the ozone generator. Supplying feed gas that is not dry, clean and free from contaminants. Ozone generators with onboard oxygen concentrators must be supplied clean dry air that meets ISO 8573.1 Quality Class 1.4.2, which is equivalent to 0.01 micron particulate filtration, 3º C (38º F) dew point and 0.08 ppm (0.1 mg/m 3 ) hydrocarbon filtration. Ozone generators without onboard oxygen concentrators must be supplied clean dry air or concentrated oxygen that meets ISO 8573.1 Quality Class 1.2.2, which is equivalent to 0.01 micron particulate filtration, -40º C (-40º F) dew point and 0.08 ppm (0.1 mg/m 3 ) hydrocarbon filtration. Supplying feed water above 30 psig without utilizing a pressure reducing valve. Connecting an improper power source to the unit that does not match the incoming power requirements as outlined in the owner operator manual. Locating any product in an environment that is not well ventilated and protected and that does not remain between 32 F (0 C) and 100 F (43 C), or as otherwise outlined in the product documentation. Any other use or condition which is contrary to specifications provided by Seller in product documentation, including the product manual and instructions. 1.2 Unless stated specifically on a formal, official "Performance Warranty Document" signed by an officer or director level employee of the Seller and an employee of the Buyer who is authorized to make such representations, there is no performance warranty on products or warranty on process results. Buyer acknowledges that the production of ozone is a process that is affected by a number of factors and conditions, and that no specific level of ozone production other than in the Performance Warranty Document, if applicable. PPK002-002_Carlsen SGA_user manual 1
1.3 WARRANTY DISCLAIMER THE LIMITED WARRANTY DESCRIBED HEREIN IS MADE EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. BUYER ASSUMES ALL LIABILITIES FOR USE AND MISUSE BY BUYER, ITS AGENTS OR ASSIGNEES. 1.4 Buyer shall give immediate notice in writing to Seller if products or components thereof or performance (where applicable) appear defective, and shall provide Seller with reasonable opportunity to make inspections, tests and repairs using the most efficient and cost effective methods available for such products or components. If Seller is not responsible under the terms of this document and/or any formal performance warranty, Buyer shall pay Seller the costs and expenses of such inspection, tests and repairs. 1.5 SELLER'S OBLIGATION UNDER THIS WARRANTY IS LIMITED TO THE REPAIR OR REPLACEMENT AT SELLER S BENICIA FACTORY FOR THE ORIGINAL USER OF ANY PRODUCT OR COMPONENT PART THEREOF WHICH SHALL PROVE TO HAVE BEEN DEFECTIVE AND DOES NOT INCLUDE SHIPPING OR HANDLING CHARGES INCURRED DURING WARRANTY CLAIM PROCESS. NO ALLOWANCE WILL BE MADE FOR REPAIRS OR ALTERATIONS MADE BY BUYER WITHOUT SELLER'S WRITTEN CONSENT OR APPROVAL. IN LIEU OF REPLACING OR REPAIRING THE PRODUCTS, SELLER MAY, AT ITS SOLE OPTION, RETURN TO BUYER THE PURCHASE PRICE FOR THE PRODUCTS. 1.6 LIMITATION OF REMEDIES. IN NO EVENT SHALL SELLER BE LIABLE TO BUYER FOR ANY AMOUNT, INCLUDING COSTS INCURRED OR EXPENDED BY BUYER IN ATTEMPTING TO CORRECT ANY PRODUCT DEFICIENCY, RELATING TO ANY CLAIM BY BUYER AGAINST SELLER IN EXCESS OF THE AGGREGATE TOTAL PURCHASE PRICE UNDER THIS CONTRACT. NO CHARGES OR EXPENSES INCIDENT TO ANY CLAIM WILL BE ALLOWED. THE REMEDIES PROVIDED HEREIN ARE EXCLUSIVE, AND SELLER SHALL INCUR NO LIABILITY OTHER THAN THAT STATED HEREIN. SELLER WILL NOT BE LIABLE FOR BUYER S LOST PROFIT, LOSS OF USE, INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SELLER S ATTEMPT TO REPAIR THE DEFECT FAILS. BUYER HAS ACCEPTED THIS RESTRICTION ON ITS RIGHT TO RECOVER DAMAGES AS PART OF ITS BARGAIN IN THIS TRANSACTION, AND ACKNOWLEDGES THAT THE PRICE OF THE PRODUCT WOULD BE HIGHER BUT FOR THIS LIMITATION ON LIABILITY. 1.7 Goods may not be returned to Seller without Seller's written permission. Seller will provide Buyer with a "Return Material Authorization" number to use for returned goods. All returns shall have freight and related costs prepaid by Buyer from point of origin. 1.8 Seller is not responsible for meeting state and local codes or ordinances, or other special codes not specifically stated in writing on the purchase document or contract. PPK002-002_Carlsen SGA_user manual 2
1.9 TECHNICAL ADVICE -Seller may, at Buyer's request, furnish technical assistance, advice and information with respect to the products supplied under this contract, if and to the extent that such advice, assistance and information is conveniently available, Seller has no obligation to provide such information, which is provided without charge at the Buyer's risk, and which is provided subject to the limited warranty of Paragraphs 1.1 and 1.2 above. 1.10 Warranty of equipment or accessories from outside sources, purchased by Seller and incorporated in the Seller products, is subject to that manufacturers standard warranty, to the exclusion of the limited warranty described herein. A copy of the aforementioned warranty is available on request. Limits of Liability Pacific Ozone Technology shall not be liable for any special, indirect, incidental or consequential damages that result from the use or malfunction of any system, ozone generator and/or any of its components. Pacific Ozone Technology equipment and components are sold for use in industrial and commercial applications only. PPK002-002_Carlsen SGA_user manual 3
Safety Carefully review and familiarize yourself with the following important safety information statements concerning Pacific Ozone Technology generators. WARNING: Oxygen is a fire hazard. It is very dangerous and vigorously accelerates the burning of combustible materials. To avoid fire and/or explosion, never use oil, grease, cotton fibers or any other combustible material on or near the ozone or oxygen generators. Smoking, heat, and open flame should be kept at a distance of no 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: OSHA exposure limit to ozone is 0.1 ppm for a period of 8 hours. (Ref. OSHA Air Contaminants Standard, 29 CFR 1910.1000) (EU Directives - 96/62/EC, 92/72/EC, 99/30/EC) WARNING: Ozone is a highly toxic oxidizer. Ozone has a distinctive odor, which is easily recognized at very low concentrations. If this odor presents itself at any level, disconnect the generator and contact your installer. WARNING: High voltage and high capacitance is present in ozone generators. Only qualified electricians should work on this equipment. PPK002-002_Carlsen SGA_user manual 4
Control Panel Layout High Voltage and Ozone Gas Caution Notice Reactor Pressure Gauge PSIG (kpa) Air Supply Pressure Gauge PSIG (kpa) Ozone output indicator Gas Flow Meter (SCFH) Power on indicator Hour meter On/Off Main Power Switch Ozone output enable Switch PPK002-002_Carlsen SGA_user manual 5
Control Panel Operation Gas Flow Meter (SCFH): Indicates the amount of oxygen that is fed through the ozone production cells. Reactor Pressure Gauge 0-15 PSIG (0-103 kpa): Indicates the level of back pressure being placed on the ozone generator reactor cell. The reactor pressure will adjust with incoming water pressure 4 and 9 PSIG (27-62 kpa) nominal. Maximum continuous pressure not to exceed 12 PSIG (83 kpa). Air supply Pressure Gauge 0-60 PSIG (0-412 kpa): Indicates the level of air pressure being fed into the oxygen concentrator. Ozone Output Indicator Light: Verifies that the ozone modules are working and producing ozone. Ozone Output Enable switch: Turns the ozone production on or off. On/Off Main Power Switch : Controls incoming power to the entire ozone generator. Hour meter: Records the number of hours that the generator has been in use. Installation Location Requirements Clean and dry Well ventilated A minimum 24 inches of free air space on all sides of the ozone generator Stable concrete or similar placement surface Ambient temperature of 32º F (0º C) to 100 ºF (43º C) A degree of protection from airborne water and dirt Electrical Requirements Dedicated 115/240 VAC - 15-amp outlet on a circuit with disconnect a maximum 50 feet away and within sight of the ozone generator s operator panel. Warning: Incoming power must be free of any power surges or spikes* greater than 15% of rated voltage i.e. 135 vac max. for 115 vac power and 282 vac max. for 240vac power. (* spikes < 0.5 seconds in duration.) Do not add or remove length to the incoming power cord. The generator must be grounded to an external ground source supplied with the incoming power wiring. PPK002-002_Carlsen SGA_user manual 8
Ozone out is connected from a stainless steel ¼ compression fitting on the bottom left side of the generator. It is recommended that an anti-siphon loop or other back flow protection be used to prevent water from backing up into the ozone production cells. Damage caused by water is not covered under the manufacturer s warranty. Plumbing Requirements Required air supply: SGA21 - minimum 3 SCFM @ 20 PSIG SGA22 - minimum 3 SCFM @ 20 PSIG Warning: Warning: No liquid water should be allowed to enter the ozone generator. The compressed air inlet water load saturated at 120ºF at 30 PSIG is acceptable (.0216 lb water/lb dry air). No oil in either vapor or aerosol form greater than 0.008 ppm should be allowed to enter the ozone generator. Air quality should be equivalent to the output of an oil-less compressor (no hydrocarbons) The compressed air connection is to the filter with a ¼ npt connection port on the bottom right side of the generator. Ozone out is connected from a stainless steel ¼ compression fitting on the bottom left side of the generator. An anti-siphon loop or other back flow protection should be used to prevent water from backing up into the ozone production cells. Damage caused by water is not covered by the manufacturer s warranty. Air Requirements Moisture: No liquid water should be allowed to enter the generator. Maximum Dew Point of 38 F Hydrocarbons: Particulate: Less than.08ppm Filtered to less than.01 micron Reference ISO 8573-1, Quality Class 1.4.2 PPK002-002_Carlsen SGA_user manual
Start Up 1. Make sure the Power on/off switch is in the OFF position. 2. Connect incoming compressed air source to the filter on the air inlet filter assembly. Warning: Warning: No liquid water should be allowed to enter the ozone generator. The max compressed air inlet water load saturated at 120ºF at 30 PSIG is acceptable (.0216 lb water/lb dry air). No oil in vapor or aerosol form greater then 0.008 ppm should be allowed to enter the ozone generator. See Air Requirements (pg.8). 3. Connect ozone output through an anti-siphon loop, check valve, or auto drain valve to application/injection connection. 4. Turn the Power on/off switch to the ON position. 5. The Gas Flow meter will vary between 5 and 15 SCFH for the SGA21 and 10 and 30 SCFH for the SGA22. This gas flow will vary as the amount of injector suction varies. Injector suction will vary as the water pressure varies. 6. The MAXIMUM continuous operating pressure is 12 PSIG. The MAXIMUM reactor cell pressure is 15 PSIG. Higher pressures can damage the ozone generator and void the manufacturers warranty. 7. To start ozone production, turn the Ozone Output enable switch to the on position. Warning! Do not leave the generator connected to an operating injector while the generator while it is turned off Do not pump compressed air into the ozone generator while the generator is turned off PPK002-002_Carlsen SGA_user manual 9
Internal Sensors High temperature sensor If the temperature of the ozone generator cell exceeds 160F, the cell will shut down to protect the electronic components from excessive heat. After the temperature of the cell drops below the set point, the unit will re-engage. The ambient environment must be below 110F to ensure that this over-temperature cycle does not occur. Shut Down 1. Turn the Ozone Output enable switch to the off position. 2. Allow two minutes to purge ozone out of system. 3. Turn the Power on/off switch to the OFF position. Note: In a shut down mode, air or oxygen in a receiver tank may expand and contract in the tank. This will cause water to be pulled over the anti-siphon loop entering the ozone generator. During shut down, open the receiver tank to atmosphere pressure or disconnect the ozone generator from the air or oxygen line. Maintenance Cleaning DO NOT clean generator while in operation. Keep the air intake and exhaust louvers clear, clean and free from obstructions. Keep cooling fan intake openings and screens clear, clean and free from obstructions. Clean external surfaces and components with water and a mild detergent. Inspect the incoming compressed air filter and auto drain valve; check for dirty filters and proper liquid drain operation. Replace filter and auto-drain when necessary. Inspect the compressor filter element. Replace when necessary. Servicing The SGA series standard serviceable parts are listed in the Spare Parts List. Any external filters for incoming air preparation, (including compressed air, water, and oil filters) must be serviced regularly according to the manufacturers instructions. PPK002-002_Carlsen SGA_user manual 11
Technical Support Technical Support and Parts Technical support is available by telephone directly from Pacific Ozone Technology at (707) 747-9600. When calling, please have the following information available: Model number Serial number Brief description of installation Confirm line voltage Confirm inlet air quality and flow Confirm location ventilation Requests for parts or service may also be faxed to (707) 747-9209 or sent by e-mail to service@pacificozone.com. Online Support Technical Online Support is available through the Pacific Ozone Technology web site at www.pacificozone.com and includes topics such as: Basic start up procedures Troubleshooting guides Product specifications Field Services Complete field services are also available. Please contact Pacific Ozone Technology Services for prices and scheduling. Pacific Ozone Technology will confirm all field service requests in writing prior to scheduling. PPK002-002_Carlsen SGA_user manual 12
Service Upon Delivery If the exterior of a unit s carton is damaged, have the driver make a signed notation on the freight bill. Unpack the unit at once. Inspect the cabinet exterior thoroughly for damage. Open unit and inspect the interior for loose or damaged parts. Inspect the wire harness to be sure that none of the push-on connectors have become disconnected. If a wire has come loose, check first for any clearly identifiable reconnections. NOTE: If concealed damage is found, do not discard the damaged shipping carton. Call the freight company that made the delivery and file a concealed damage claim within 24 hours of delivery. Only the consignee can file a damage claim. Returning a Unit for Service If a unit needs repair, prior approval must be obtained. Pacific Ozone Technology will not accept returned equipment unless a Return Materials Authorization (RMA) number has been issued. No RMA will be issued without the unit s serial number. Return Procedure: Carefully repack the unit with original packaging material. If the box or packaging is severely damaged, then it should be replaced with adequate sturdy cushioning material. The customer is responsible for any damage that occurs in transit. Clearly write the RMA number on the outside of the shipping carton. Prepay the shipping charges and insure the item for its full value. NOTE: Pacific Ozone Technology will not accept returns without an RMA number, or returns that are sent COD or freight collect. Pacific Ozone Technology will not advance customs clearance fees. All international shipments must be shipped door-to-door. PPK002-002_Carlsen SGA_user manual 13
Wiring Diagram PPK002-002_Carlsen SGA_user manual 12
Internal Layout Power Supply (with 8A fuses) Oxygen Concentrator Oxygen Concentrator Motor Controller Door Safety Switch Ozone Outlet Reactor Cell Cooling Fan Filter & auto drain assembly Compressed Air Inlet 16 PPK002-002_Carlsen SGA_user manual
Mounting Layout PPK002-002_Carlsen SGA_user manual 14
Spare Parts List Part number Description Model PPC444 Filter element all IFC451 fan 6", 115 volts all IFC452 fan 6", 230 volts all M01001 reactor cell 21 M02001 reactor cell 22 T06016 power supply (enclosed, HO, 115 volts) All T06017 power supply (enclosed, HO, 230 volts) All EEC864 Crydom 20 volt AC power supply (230 volts) All 230 volts EEC863 Crydom 20 volt AC power supply (115 volts) All 115 volts EEC407 Crydom linear Proportional Controller All Y02005 oxygen concentrator all EEC408 power switch and ozone enable switch all EEC811 Contact block, switch kit, 1-NO, screw type (used on ozone enable switch) all EEC349 Contact block, switch kit, 2-NO, screw type (used on power switch) all EEC166 fuse, 8 amp all FBM026 ¼" Teflon tubing all FBM028 ⅜" nylon tubing all IFC705 door safety switch all PPC353 filter assembly & housing all PPC042 3-30 SCFH flow meter all PPC023 0-15 psi pressure gauge all PPC034 0-60 psi pressure gauge all PPC156 nut & ferrule set, ¼ - stainless (o3) all PPC825 nut & ferrule set, ¼ - brass (o2) all PPC826 nut & ferrule set,⅜ brass (o2) all Preventative Maintenanc e part Suggested Emergency Spare part General Replacemen t part PPK002-002_Carlsen SGA_user manual 15
6160 Egret Court Benicia California 94510 t: (707) 747-9600 f: (707) 747-9209 www.pacificozone.com e-mail Sales: sales@pacificozone.com, Technical Support: support@pacificozone.com