OPERATION AND MAINTENANCE

MANUAL FOR

10 GM/HR

OZONATOR

With

OXYGEN CONCENTRATOR
 KANTI INDUSTRIES

CONGRATULATI ONS! You have just purchased

Kanti industries make Ozonation Machine . This
machine is a product of Indigenous research and
development for over 15 years. The accessories
are the products of engineering design based on
the field experience over many years. The design
of this System is proven and state-of-the-art, our
machines are Solid-state systems, and designed
to be maintenance free as maximum as possible.
Experience dictates that performance is directly
related to the quality of installation and the
knowledge of the user in operating and
maintaining the instrument. Therefore, we
suggest that, this manual be read thoroughly
before proceeding with i nstallation and
commissioning.

We assure you that we will continue to provide

you, the most advance products and services
possible. We are sure that the system supplied to
you will give you years of trouble free service,
provided you take necessary precau tions in the
operation Maintenance as per the proposed
schedule.

We reserve the right to make changes in design

details, performance data and in appearance of
the unit due to continuous research and
development.

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 KANTI INDUSTRIES

Content
SNO. SUBJECT PAGE
NO.

1.0 O ZONE AN INTRODUCTION 3

2.0 CONSTRUCTION OF OZONATOR

2.1 Oxygen Concentrator 4

2.2 Ozone Cells 4
2.3 H.F.H.T. Convertor 4
2.4 Control System 4
2.5 Cooling System 5
2.6 Venctury Injector 5
2.7 NRV 5

3.0 OPERATION OF THE OZONATOR

3.1 Star t Up
3.2 Sett ing of Venctur y I nject or 5
3.3 Op er ational Par amet er 5
3.4 Shut D own 6

4.0 PRECAUTIO NS

4.1 Envir onmental 6

4.2 Equ ip ment Safet y 6
4.3 Electr ical 6
4.4 Hu ma n Safet y 6

5.0 PREVENTIVE MAINTENANCE

5.1 Daily Check Up Schedu le 7

5.2 Weekly C heck Up Schedu le 7

6.0 FAULT FINDING AND REMEDIES

6.1 Ozonator is not working 7

6.2 Fuse blown indicator is glowing 8
6.3 Machine is working but no Ozone 8

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1.0 OZONE AN INTRODUCTION

When the oxygen (O2) that is all around us rises to the upper atmosphere, and is
exposed to the sun's ultraviolet rays, that oxygen is naturally turned into ozone
(O3). That is the "OZONE LAYER" that protects us from the sun's harmful UV rays.
Since ozone is heavier than air it naturally falls back to earth. This is the ozone that
naturally purifies our air and water. Without ozone nature could not purify our Earth.
Because it is made up entirely of oxygen, ozone is sometimes called "ACTIVATED
OXYGEN". Ozone is the second most powerful sterlilant in the world and its function
is to destroy bacteria, viruses and odors. Ozone also occurs commonly in nature as a
result of lightning strikes during thunderstorms. The "FRESH, CLEAN, SPRING
RAIN” smell that we notice after a storm results from natures creation of ozone.
Ozone is also created by water falls. If natural ozone ceased to exist, life on this
planet would also cease to exist. Ozone is nature's way of purifying the air we
breathe.
Ozone is O3, three atoms of oxygen linked together, rather than the two atoms of
oxygen, O2. Ozone kills bacteria by rupturing the cell wall of the offending
organism. While ozone is very powerful, it has a very short life cycle. When it is
faced with odors the extra atom of oxygen destroys them completely by oxidation. In
addition to the effectiveness of ozone, we also know that it is safe when used
properly. Note that there has never been an illness claimed to have resulted from
ozone exposure.
The three atom form of oxygen is a naturally occurring compound in the earth's
atmosphere. The life cycle of ozone is: generation, oxidation, and return to oxygen.
Ozone cannot be stored or transported because of its unstable tendency to break down
quickly, so ozone must be generated on site. Because gaseous ozone is highly
reactive, it readily oxidizes (breaks down) organic matter. When the ozone
encounters another compound, one oxygen atom will break away, attach itself to the
compound, and oxidize it. Ozone actually breaks down odor causing compounds,
thereby eliminating the odor and changing the ozone back to oxygen (O2). Ozone acts
3000 times faster than chlorine as a bactericide and it is the strongest oxidant
commercially available for air & water treatment. One of the best features of ozone is
its ability to control odors by attacking the offending organisms. Far stronger than
simple oxidizers, which cannot possibly kill substantial amounts of bacteria, OZONE
has the ability to kill any bacteria or virus known to man.
2.0 CONSTRUCTION OF OZONATOR
This Ozonator is designed on the principal of corona discharge-simulation of the
lightning. For commercial production, Ozone is produce by passing dry Oxygen
between two electrically charged concentric cylindrical electrodes, separated by
dielectric where corona discharge take place in a narrow discharge gap. Under these
condition Oxygen converts in to Ozone.
As the Oxygen passes through the ozone cell, the supplied electric energy splits some
Oxygen molecules into Oxygen atoms. Some of these atoms, then quickly react with
Oxygen molecules to form Ozone (O + O2 = O3). The major components are as
under:-

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2.1 Oxygen Concentrator

This Oxygen concentrator is provide 93% pure Oxygen to feed to Ozone
cells. This is supplied at 5 LPM flow rate. This concentrator has in built oil free air
compressor and Oxygen enrichment units.
The compressor sends filtered ambient air to a group of valves, which allows
compressed air to pass to the column in production. The column contains a molecular
sieve, whose function is to adsorb the Nitrogen and thus allow Oxygen to pass. The
oxygen enriched air is the directed to a pressure reducing valve through the flow
control valve to the oxygen outlet fitting.
During this time the column which is being “regenerated” is connected to the
ambient air and a current of Oxygen enriched air is passed through it (from the
column in “Production”). In this way, when one column is in production, the other is
in a nitrogen desorption or “regeneration” phase. The Oxygen enriched air is finally
passes through a product filter situated prior to the Oxygen outlet.
2.2 Ozone Cells
Ozone cells are constructed in cylindrical form. In ozone cells there are two
electrode of SS 316L which are separated by a dielectric. Between dielectric and inner
electrode a micro gap is provide. In the micro gap corona discharge take place. When
Oxygen passes through this corona discharge it converts in to Ozone.
In this Ozonation machine there are twenty number of Ozone cells. These
cells are under very high voltage i.e. 6,000 Volts.
2.3 H.F.H.T. Convertor
There is a H.F.H.T. convertor which produces very high voltage at high
frequencies. This convertor is used to supply high voltage to Ozone cells to generate
corona discharge. This is IGBT based high performance convertor technology.
2.4 Control System
This unit consist all control and display instruments. The main part of this unit
is Ozone output display.
In display system there are two type of display, one is digital ozone output
indicator and second are LED indicators.
Digital display of Ozone output is on front panel. It displays Ozone output in
gm/hr.
There are Two LED indicators. First one is Power On; it glows when machine
is turn on. This indicates that your machine is now working.
Second one is Blown Fuse. It glows when mains fuse is blown. It indicates
that mains fuse has to replace from same value fuse.
In control system there is a mains switch and fuse. There is also a power
supply sensing system to check the power supply.
2.5 Cooling System
There is One cooling fan is mounted inside the main cabinet. This fan is
providing forced air cooling to H.F.H.T. Converters and Ozone Cells
2.6 Vecturi Injector
A vencturi injector is supply with this Ozonator. This vencturi injector is
installing in Ozone recirculation line. This vencturi injector will work on 2.0 kg/cm2
pressure difference.

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2.7 NRV
There is a NRV supplied with Ozonator is install on vencturi injector. This
NRV is to protect reverse water flow towards Ozonator. This NRV is made of Ozone
resistant PVDF and other parts are of Viton and Stainless Steel.
3.0 OPERATION OF THE OZONATOR
3.1 Start-up
Switch ON Main switch board Green LED indicator will glow on front panel of
Ozonator.
Now switch on main switch provided on front panel of Ozonator. Now system on
LED indicator will glow and machine will start working.
Wait for a minute so that Oxygen concentrator’s flow reaches up to 5 LPM.
3.2 Setting of vencturi injector
Run the recirculation pump and adjust the pressure across vencturi by closing by
pass valve. When vencturi start suctioning air and pressure difference is maintain
around 2.0 Kg/cm2, stop closing the by pass valve. Now your vencturi is set to
suck Ozone.
3.3 Operational Parameters
The Ozonator will be operating with following parameters:
Supply Voltage : 220 Volts AC
Supply Frequency : 50 Hz
Oxygen Flow : 4 LPM (Max)
Ozone output : Not more than 10.0 gm/hr
Ambient Temperature : 10’C to 35’C maximum
3.4 Shut Down
Allow Ozone to pass on for about a minute.
Shut Off switch provided on front panel of Ozonator.
Turn Off mains switch.
PRECAUTIONS
The warranty of the equipment voids if any form of tampering or
mishandling is carried out on the system.
Warranty of equipment also voids if proper Earthing and Proper Voltage
Supply not used.
4.1 Environmental
The equipment should be kept in a clean, dry and in dust free environment.
There should not be any direct sun light or water sledges on and around the parts
of machine.
The machine as well as the accessories of the system should be kept under the
range of temperature prescribed in operating parameters.

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4.2 Equipment Safety

There is no user serviceable part in the system and thus any unauthorized person
or electrician is not permitted to open the equipment for carrying out any repairs
in the equipment.
Do not place any cover on the equipment when they are being operated and a free
passage of air inflow and outflow should be ensured.
4.3 Electrical
Electrical Supply Voltage to Ozonator should be between 220 to 230 Volts, thus a
stabilized power supply is recommended for smooth operation and long life
of the equipment.
There should not be any loose connections or appearance of spark in the
equipment and in the supply points.
The machine should be opened for repairing by authorized service engineer or a
qualified / trained engineer.
A proper Earth is most important and in absence of the same, serious damages
may result to equipment and operator. Machine should not be operated without a
proper Earth Point.
4.4 Human Safety
Ozonator produces very high voltage and thus no one should open the main door
when it is switched on.
5.0 PREVENTIVE MAINTENACE
5.1 Daily Check Up Schedule
Clean the machine from all the sides, front panel, and the surrounding areas.
Check the air filter of the Oxygen concentrator and clean it if required.
Before switching the machine checks the status of the input supply and if normal,
run the system.
After start of the Plant check for the following points;
Any abnormal sound or typical observation, find the reason and rectify it.
Ozone output as per the required level.
5.2 Weekly Check up Schedule
Following points are required to be checked up on weekly basis in addition to the
daily check up mentioned above
The machine is to be cleaned from in side by switching it off with the help of a
soft cloth or a brush.
Check for any sparks in the electrical panel, incase of sparks clean the place to
rectify the problem.

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FAULT FINDING AND REMEDIES

6.1 Ozonator is not working
SYMPTOMS: - No indicator glowing after switching on the Main Switch
CONCLUSION: - Power supply is not reaching the Machine

CHECK-UP ACTIONS TO BE TAKEN

No supply in the mains point Rectify power supply

Mains wire no continuity Replace mains connecting wire
Any loose connections Connect properly
If all the above points are OK Contact factory

6.2 Fuse blown indicator is glowing.

CHECK-UP ACTIONS TO BE TAKEN

Fuse blown up Replace fuse with same rating

Any loose connections Connect properly
If all the above points are OK Contact factory

6.3 Machine is working but No Ozone

CHECK-UP ACTIONS TO BE TAKEN

Ozone regulator is on zero Increase the Ozone output up to desire

level
Any loose connections Connect properly
If all the above points are OK Contact factory