13
START-UP & CALIBRATION
CHAPTER 7
The previous sections of this manual have involved comparatively static procedures – making
electrical and pneumatic connections, fitting pipe, etc. This section involves the dynamic process of
starting up and balancing the components of the ozone system, including initiating water flow, making
air and water flow adjustments, etc.
Maximum performance and reliability is achieved when the prescribed air flow is maintained at the ozone generator while
the system is operating under pressure. Air from the air preparation system is flowing
through
the ozone reaction
chambers under pressure, and
from
the ozone generator under a slight vacuum (created by the ozone injector manifold).
The change from pressure to vacuum occurs after the stainless steel ozone outlet needle valve on the ozone generator.
SC27P Ozone Generation System and Injection Manifold
Warning:
Disconnect the External Loop dry contact from the ozone generator while performing all start-up
procedures.
Failure to do so may result in ozone escaping to atmosphere.
Step 1:
Make sure all isolation valves in the ozone water system are open (Figures 4-1 or 4-2 show recommended
isolation valve locations).
Step 2:
Apply main power to the SC27P. Switch the main power switch to the “ON” position. At this time the SC27P
will be powered up, the air preparation system and cooling fans should be “ON” and power should be present
to the External Contactor output signal. If the External Contactor output signal is interlocked to a booster
pump, the booster pump should be “ON”.
Note: Ozone will
not
be produced until the “External Loop” is
in place and at least 9 PSI present at the PSI gauge located on the control panel.
Step 3:
Start-up hydraulics. Allow the water in the system to reach hydraulic equilibrium (contact vessel full, off-gas
vent operating, etc.) and observe for plumbing leaks.
Note: Water flow
must
be established through the
main water pump and the ozone system booster pump (if so equipped).
Step 4:
Close the ball valve on the injector manifold about half way.
Step 5:
Using your thumb, check for the presence of vacuum (suction) at the
ozone injection manifold check valve assembly or use a ClearWater
Tech vacuum test assembly to check vacuum at the injector port. If no
suction is present, continue to close the ball valve on the injector
manifold until vacuum is detected. If using the vacuum test assembly,
check the VAC/PSI gauge for vacuum. If the needle is in the red zone
on the pressure (PSI) side of the gauge, gradually close the ball valve on
the injector manifold until the needle moves into the green zone. If the
needle is in the red zone on the vacuum (in.Hg) side of the gauge,
gradually open the ball valve on the injector manifold until the needle
moves into the green zone. While vacuum is in the green zone you must
be able to achieve proper SCFH (Standard Cubic Feet per Hour) of air flow (see the “Pneumatic Operating
Parameters” chart for venturi SCFH required, Figure 7-2).
Step 6:
The air preparation system air flow must be set to “atmospheric pressure” prior to final start-up of the SC27P.
Step 1:
Check to make sure the compressor of the air preparation system is operating.
Step 2:
Check the system PSI gauge for pressure, located on the control panel. If pressure is registered on
the PSI gauge open the stainless steel needle valve by turn it counter clockwise so that no pressure is
registered on the gauge. See Appendix-Section A for PSI gauge and stainless steel needle valve locations.
Step 3:
Using the air flow gauge adjustment valve on the control panel, adjust the SCFH air flow according
to the “Air prep system air flow” specifications outlined in Figure 7-2.
Step 7:
Connect the Teflon
ozone delivery line from the vacuum break to the ozone inlet fitting located at the ozone
injection manifold check valve assembly.
Step 8:
Adjust the stainless steel needle valve located at the bottom the ozone generator (see Appendix-Section A)
clock-wise, adjusting the system backpressure to 10 PSI. Check the PSI gauge on the control panel, which
measures this backpressure. If there is insufficient backpressure the needle valve may be closed slightly;
similarly, if there is too much backpressure the valve may be opened slightly
.
Due to the pressure switch
installed, the PSI gauge must achieve 9 PSI before ozone will begin production.
Step 9:
By setting the air preparation SCFH (step 6) and system backpressure PSI (step 8), the air flow gauge on the
control panel will read in CFH rather than SCFH. At this point the air flow meter becomes passive and should
