M43-31366 REV B

Installation, Operation and

Maintenance Manual
AIM 40, AIM 60 & AIM 80
Ozone Generators

Designed and Manufactured Exclusively

by
Ozotech, Inc.
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Table of Contents
1.0 Limited Warranty

2.0 Service Returns

3.0 Caution

4.0 Theory of Operation

4.1 About the Generator

4.2 Gas Flow

5.0 Operating Conditions

5.1 Operating Environment

5.2 Internal Air Flow Specifications

5.3 Preparation of Input Air

5.4 Input Power Requirements

5.5 Fusing

6.0 Installation

7.0 Maintenance

7.1 Corona Discharge Cell Maintenance

7.2 Intake Filter Maintenance

7.3 Chassis Maintenance

7.4 Check Valve Replacement

8.0 Spare/Replacement Parts

9.0 Troubleshooting Guide

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1.0 Limited Warranty

Ozotech, Incorporated warrants the AIM Stainless Steel Series ozone generators to be free from defects
in parts and workmanship to original purchaser, for 12 months from date of invoice, under conditions of
normal use. The Corona Discharge cell(s) and the high voltage transformer(s) are warranted against
catastrophic electrical failure for 2 years from date of invoice, under conditions of normal use. Ozotech,
Incorporateds warranty obligation with regard to equipment not of its own manufacture is limited to the
warranty actually extended to Ozotech, Inc. by its supplier.

Ozotech, Incorporated will refund the purchase price, perform repairs or replace equipment, at the
option of Ozotech, Incorporated.

ANY REPAIR OR REPLACEMENT WILL BE WARRANTED ONLY FOR THE BALANCE OF

THE ORIGINAL WARRANTY PERIOD.

The warranty shall be null, void, and non-binding upon Ozotech, Incorporated if Ozotech, Incorporated
(or authorized service center) determines the cause of malfunction or defect to be a result of 1) Failure
to perform proper maintenance as defined and recommended in this manual, 2) Failure to adhere to and
provide proper operating conditions, as defined in this manual, including operation outside of air flow
specification range, operating in wet or dirty environment, operation outside of manufacturer's
specifications, operation without support of air preparation equipment, 3) Adjustments or changes to as-
designed configuration, made by user other than product output flow rate within ranges specified by
manufacturer, or adjustment of variable output control (rheostat) to vary transformer primary voltage
input.

Ozotech, Incorporated assumes no liability for damages incurred by deliberate or incidental misuse of
this product, or damages incurred in transit.

2.0 Service Returns

If the need arises to return your equipment for service, the following procedure must be followed to
ensure accurate and timely processing of repairs.

Obtain the serial number of unit to be returned.

Obtain model number/name of unit to be returned.

Contact Ozotech, Incorporated and request a Return Material Authorization (RMA)

form. Make sure to give the factory representative an accurate and current shipping
address.

Enclose a description detailing the problem with the unit. Be as specific as possible.

After receipt of RMA form, package unit for shipment. Enclose the RMA form with the
unit. Use the original packaging materials if possible.
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Clearly write the RMA number on the outside of the shipping package.

Verify that the address is correct and current.

Shipments that are not factory authorized will be refused.

It is recommended that you ship with a reputable and reliable shipping company, and that the contents
of the package are insured. Ozotech, Inc. accepts no responsibility for damage or loss of equipment in
transit.

ALL FREIGHT CHARGES INTO THE FACTORY MUST BE PREPAID. If the repair is covered
under warranty, the factory will pay return shipping charges (surface rates only) to the address listed on
the RMA, within the Continental United States. If the repair is not covered under warranty, the
returning party is responsible for payment of return shipping and handling charges, as well as labor and
equipment costs associated with the repair.

3.0 Caution

Read the following safety guidelines thoroughly before attempting to operate or install your
equipment.

< As with all electrical devices, this equipment should never be allowed to come in contact with
water.

< Installation and operation must provide for removal of ozone gas from areas occupied by
humans.

< Only qualified personnel should be allowed to set up, maintain and operate this equipment.

< The equipment must be operated using a properly grounded electrical circuit.

< Ozotech, Inc. assumes no liability for damages or injuries incurred by misuse of this product.

< Do not use an extension cord to supply power to this equipment.

< Never use a fuse of incorrect size or type. Serious damage could result.

< Use a Power Conditioner if line voltage fluctuates outside of specified range.

< Unit must never be run with internal air flow rate below manufacturer's specifications.

< Unit must never be allowed to operate without properly prepared feed gas (air preparation).

< Unit should be wall mounted only where structure is capable of supporting weight. Mount with
not less than (4) 1/4" diameter fasteners.
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4.0 Theory of Operation

Your AIM Stainless Steel Series ozone generator is a state-of-the-art device designed to produce
significant concentrations of high-purity ozone. The technology utilized by Ozotech, Inc. to generate
ozone is known as Cold Plasma Corona Discharge.

Cold Plasma Corona Discharge generators create ozone through the action of extremely high voltage/low
current electrical arcs, across an air space. When oxygen (O2) is passed through the air space some
molecules are split, resulting in free oxygen atoms. These free atoms of oxygen quickly attach
themselves to intact O2 molecules. The result is a very unstable form of oxygen, O3 (ozone). It is the
extra atom of oxygen that gives ozone its superior oxidation capabilities.

As opposed to plate-type or open-air dielectric corona discharge generators, Cold Plasma Corona
Discharge utilizes a cell filled with proprietary gases. The cell (or cells) is then surrounded by a
perforated stainless steel grid which is connected to earth ground. When high voltage is applied to the
cell, an electrical arc, called Corona is formed between the cell and the grid, called the corona region.

Each cell/grid combination is separately housed within its own chamber. All air drawn through the
chamber is channeled directly through the corona region. This design surpasses plate-type corona
discharge designs by constantly exposing a fresh supply of oxygen molecules to the corona region, and by
keeping the cell and chamber cool. Recent improvements in the design have led to a method of producing
ozone wherein the cell is: 1) Capable of withstanding high voltage inputs without plating; 2) No relative
expansion and contraction of the parts; 3) Able to operate at lower temperatures than conventional
corona discharge generators, thus improving reliability and efficiency without the need for separate
cooling water circuitry; 4) Maximum ozone output with minimum high voltage input; 5) No
degradation in ozone output over time.

4.1 About the Generator

The A.I.M. series of Corona Discharge ozone generators feature a thoughtful, consistent layout from model
to model which builds confidence for both operator and maintenance personnel. Due to the deliberate
similarity in configuration, familiarity with one model can quickly be applied to others.
Instrument Panel
Attached to the upper left-hand corner of the door, are three lights. Each light is dedicated to one particular
function. The power light shows that the unit has power, the fan light indicates that the cooling fans are
enabled, and the ozone light indicates that the high voltage transformers are firing, and functions as a
visual indication that the unit is making ozone.
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Air Flow Meter

Attached to the right side of the generator chassis is the air flow meter. The flow meter controls the gas
flow through the system. T h e m e t e r s h o u l d b e s e t b e t w e e n 1 0 - 2 0 S C F H
depending on the unit you are using and the available feed gas .

4.2 Gas Flow

The A.I.M. 40, A.I.M. 60, and A.I.M. 80 utilize a series-parallel gas flow path. This design affords the
ability to completely close air flow (and ozone production) to one or more banks. This feature enables
continued operation of the unit, even if a problem has occurred with one bank. Feed gas enters at the
Oxygen Inlet, and splits into either a two, three, or four parallel path. Air flow through each bank is
controlled by a balanced air flow manifold using a first in/last out flow dynamic.

5.0 Operating Conditions

Your ozone generator requires certain operating conditions in order to maintain performance and
reliability. Warranty coverage of your equipment is contingent upon strict compliance with the
operating conditions specified in this manual.

5.1 Operating Environment

Choose a location for your equipment that is clean, dry, and free of excessive airborne particles. Your
equipment requires a constant flow of clean air for proper internal cooling. A minimum of six (6) inches
clearance is required around the bottom, left, and right side of the unit to eliminate restriction of air
flow. Direct exposure to moisture must be avoided. The ozone generator chassis is designed to be drip-
proof. It is not water-tight.

The operating environment inside the chassis is extremely important. Maintaining a clean, dry unit is
essential to overall performance and reliability. A common cause of ozone generator failure can be
attributed to moisture and contaminants within the chassis. This condition facilitates un-contained
corona (electrical arcs) within the chassis environment. Once established, this corona usually does not
stop until it has become severe enough to cause catastrophic failure of the corona discharge cell or
manifold. Note: If this condition develops, remove generator from service immediately, and contact
manufacturer.

5.2 Internal Air Flow Specifications

As stated in the Theory of Operation section, Cold Plasma Corona Discharge relies upon a flow of air
passing between the Corona Discharge cell and the perforated grid to produce ozone and keep the
chamber cool.

The rate at which air is drawn (or forced) through the ozone generator is user adjustable. You may fine
tune the flow rate to best suit your specific application. However, in no case should the air flow rate be
allowed to drop below the minimum values specified below. Failure to provide minimum air flow
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rates may allow your ozone generator to develop too much heat, possibly leading to equipment
failure. Conversely, flowing too much air may exceed manufacturers specifications on your air prep
equipment. Refer to the operation manual supplied with your air preparation equipment for maximum
output specifications.

Minimum Air Flow Rate in

Model Standard Cubic Feet per Hour (SCFH)

A.I.M. 40 10

A.I.M. 60 15

A.I.M. 80 20

5.3 Preparation of Input Air

Air Flow Meter
Regardless of the method of ozone generation, properly preparing the input air (feed gas) will pay
huge dividends in performance and reliability. Ozotech, Inc. does not recommend the use of any
A.I.M. series ozone generator without air preparation. Warranty coverage of your ozone generator is
contingent upon operation with properly functioning air preparation equipment.

The key to air preparation is in the removal of Hydrogen (H) and Nitrogen (N) found in ambient air.
When atoms of Hydrogen and Nitrogen are subject to Corona Discharge (Cold Spark or otherwise), by-
products such as Nitrous acid (HNO2) and Nitric acid (HNO3) are formed. The formation of these
compounds inhibits performance and increases the frequency of maintenance.

To understand how performance is affected, we must recall from the Theory of Operation section that
ozone is created by splitting an oxygen molecule (O2), and then joining the liberated oxygen atoms (O)
with intact oxygen molecules.

Imagine that in addition to oxygen molecules, your feed gas also contains Hydrogen and Nitrogen
atoms. After passing through the corona region, some of the Hydrogen and Nitrogen atoms will attach
themselves to intact oxygen molecules, forming HNO2, or Nitrous acid. Other atoms will attach
themselves to ozone molecules, forming HNO3, or Nitric acid. It is the formation of these compounds
that reduces performance potential. It is simple to understand why. If ozone molecules were not being
used by Hydrogen and Nitrogen in the formation of acids, more would be available to be used in
oxidation. Likewise, if oxygen molecules were not used to form acids, they would be available for
the creation of more ozone.

Increased service life and reduction in maintenance are gained due to the same principle. With less
HNO2 and HNO3 being formed, Corona Discharge cell maintenance, (or cleaning the cell), can be
reduced without the risk of acid buildup. Since both HNO2 and HNO3 are highly conductive, they are
capable of producing a path for corona (electrical arcs) outside of the corona region. As stated
previously, once an arc has started, catastrophic failure is the usual result.
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Your ozone generator is capable of operating with either negative pressure or positive pressure air
preparation devices. Negative pressure devices, such as heat-regenerated desiccant air dryers rely upon
the action of the venturi injector to draw air through the generator (and the dryer). This method is
typically not utilized with the A.I.M. series, due to the difficulties of meeting minimum air flow
requirements through the vacuum action of a venturi injector alone. Positive pressure devices, such as
the Power Prep Series manufactured by Ozotech, Inc., utilize an internal air compressor to push
prepared air through the generator. This method is utilized in the majority of A.I.M. applications.

5.4 Input Power Requirements

Ozotech, Inc., offers the A.I.M.40 - 80 in a variety of configurations to accommodate a wide range of
world supply voltages and frequencies. Refer to the Input Wiring Diagram located inside the
generator cabinet for proper input voltage connections. It is extremely important that your equipment
is connected properly for your specific operating voltage. Most supply voltages fluctuate, so it is
necessary to monitor your voltage and assure it is within acceptable variance values listed below.

Voltage = (Specified) +/- 5%

Frequency = (Specified) +/- 5%

Power Consumption =240 Watts (Nominal), A.I.M. 40

310 Watts (Nominal), A.I.M. 60
360 Watts (Nominal), A.I.M. 80

Note: If your line voltage fluctuates beyond acceptable variance, it will be necessary to
connect your equipment to a Line Conditioner.

5.5 Fusing
Since each model is somewhat unique, a fuse diagram is attached to the inside of each ozone generator.
Refer to this diagram when and if the need arises to replace a fuse. Never substitute a fuse of different
size or type.

Remember, when a fuse blows, it is usually an indication of a problem. Rather than simply replacing the
fuse, consult the Troubleshooting section of this manual.

6.0 Choosing a Location

Choosing a location for your Ozone Generator is the first step to insure trouble-free service and
minimize costly and inconvenient downtime. Judge your proposed installation site against the
Operating Conditions section of the Operation/Maintenance Manuals provided with your equipment prior
to performing any physical modifications to existing water treatment equipment or plumbing.

Location should be clean, dry and away from sources of moisture and humidity. Your ozone
generators chassis is designed to be drip-proof, not watertight.
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Your ozone generator is a sophisticated electrical device. When choosing an installation site,
evaluate whether you would place a television set in a similar location. If not, search for a
more suitable location.

Many problems experienced by end-users of ozone generation (and air preparation)

equipment, especially bottled water applications, are due to placement of equipment in close
proximity to bottle washers, air conditioners, etc. Moisture-laden air must be avoided.

The location must provide for a minimum of six (6) inches clearance around the top, bottom, left
and right sides of the ozone generator, to avoid restriction of cooling air flow and three (3) feet
of clearance around the front to provide sufficient access for scheduled maintenance.

The Ozone Generator should be placed as close as possible to the venturi injector. This will
minimize loss of ozone along the ozone delivery line.
The Ozone Generator should be placed in close proximity to a grounded power supply.

Mounting
Once a suitable location has been found, you are ready to mount the unit.

Provide at least six (6) inches of clearance around the bottom, left and right sides of the
chassis, and approximately three (3) feet around the front of the chassis. This will avoid
restriction of cooling airflow through the unit, and will provide adequate access to facilitate
scheduled maintenance.

Attach the unit securely to the wall, using four (4) fasteners, 1/4" Dia., minimum.

Installation of Corona Discharge Cell

Corona Discharge cells are constructed of glass, and are therefore shipped in a separate container. Your
ozone generator may require up to (8) cells. Always perform the following procedure with the ozone
system powered down.

1. Carefully remove the Corona Discharge cells from the packing material. Use extreme care not to
damage the point on the end of each cell. Remove any packing debris that may be clinging to the
cell.

2. Turn door latches with a large, standard screw-driver. Swing door open.

3. Carefully swing Cell/Manifold Assembly toward you, by disconnecting Cradle Retainer, grasping
manifold, and allowing the assembly to rotate on its hinge.

4. Carefully insert each ozone cell in the ozone chambers and secure the ozone cells 3/4" metal
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standoffs.

5. Connect the high voltage leads from Transformer #1 to the corona discharge cells in Bank
#1, as shown below.
CAUTION: It is necessary to keep the High Voltage leads clear of the chassis, metallic
components within the chassis, and standard voltage wires (115 or 230V) by a minimum of
one (1) inch. Failure to do so may cause electrical arcing. If you cannot maintain the proper
clearance, it is likely that the leads are connected improperly.

Disconnect power, pull hinged Gently, Insert glass CD tube and be Replace cap and tighten the Cap
manifold assembly toward you. sure to center on the spring platform Retaining Nuts to 3 in/lbs using a
Remove the Cap retaining nuts & Cap at the bottom of the chamber torque sequence of Bk, Frt, L Bk, R
Frt, R Bk, L Frt.

Pressure Test
It is vital to establish an air tight seal between each Corona Discharge cell and Chamber. It will
prevent ozone from escaping into the chassis, and ultimately into the equipment room, possibly
causing damage to the ozone generator and air preparation equipment. Perform the following steps with
the ozone generator disconnected from power.

It is helpful to have an assistant when performing the pressure test procedure.

1. Set the air flow meter to open position (full clockwise is closed).
2. Remove nut, and ferrules from the ozone output fitting. In a later step, you will be using your
finger to block this opening.
3. Connect a positive pressure air preparation device such as the Power Prep Titan to the Air
In fitting.
4. Turn the air preparation unit on and observe the air flow meter reading. The indicating ball should
rise, indicating air flow through the meter.
5. Have your assistant place their finger over the ozone output opening to trap air in the
manifold assembly.
6. Once again, observe the air flow meter. You should see the ball begin to travel toward the
bottom of the meter, indicating a reduction in air flow. Within a minute or two, the ball should
be at rest at the bottom of the meter, indicating zero air flow.
7. With the generator now pressurized, use an approved leak check solution to check for leaks
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at the tube/chamber interface and all tubing fittings.

8. If pressure test fails, it will be necessary to fix the leak. Typically, readjusting and slightly
tightening the stainless steel clamps will correct the leak.
Caution: This procedure must be repeated until pressure test is passed.

Piping and Electrical Connection

After mounting all components of your installation package, you are ready to proceed in piping your ozone
generator gas outlet to the ozone injection device (i.e., venturi injector), and in piping the feed gas from
your air preparation unit to the ozone generator gas inlet. Read the following general guidelines prior
to beginning step by step hookup instructions. There are two ways to connect your ozone generator
piping to the ozone injection device. The ways are specified by the type of air preparation device that
will be used to feed the ozone generator. The first type would be a 'negative pressure' installation, utilized
by devices such as heat regenerative air dryers, which do not contain an internal compressor to move air
on their own. The second would be a 'positive pressure' installation, utilized by devices such as oxygen
concentrators, which do contain an internal compressor in which they can move air on their own.

You will also be performing the connections to supply power to the ozone generator. It is important that
you verify that the equipment is compatible with the available power source, and that all connections
are performed in compliance with electrical code. It is recommended that only a qualified electrician
perform this type of work.

General Considerations

At minimum, the ozone generator must be protected by a one-way check valve. This device
prevents water from backing up (through the ozone delivery tubing) into the unit.

Placement of the check valve should be in an area that is easily accessible, due to the
importance of regular inspection and replacement. Remember, depending on the nature of
your installation, this device may be the only protection against water entering your Ozone
Generator. Consult the Operation/Maintenance manual for the check valve
inspection/replacement schedule.

Connection of components to power source must be performed in accordance with all local, state
and federal electrical and fire safety codes. Only a qualified electrician should attempt electrical
connection.

Hookup of Negative Pressure Systems

1. Attach tubing from the output of the air drier to the Air In fitting of the ozone generator.

2. Install desiccant indicator in-line between the air drier and the ozone generator. Placement
should allow for ease of inspection. Do not worry about flow direction.
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3. Attach tubing to the ozone generator O3 Out fitting. At the end of this tube, you will install
the Check Valve, so make sure to trim the tubing to a length that will place the check valve within
easy access. (Refer to the Figure below.)

4. Locate the Check Valve and two (2) hose adapters from the shipping accessory packet. Apply
Teflon tape, or equivalent, to male threads on hose adapters, and install in ends of Check
Valve. Note: Typical installations use a 1/4" Barb fitting on the input end of check valve, and a
3/8" Barb fitting on the output.

5. Install Check Valve assembly into end of output tubing, with direction of flow away from ozone
generator.

6. Attach tubing from output of check valve to input of BF1.

7. Mount the BF1 to a vertical surface, if you have not yet done so. The input end must point
straight up. Caution: The BF1 is designed to drain water out of the ozone delivery line in
case of water backup. For this reason, install the BF1 in an area that is not susceptible to
water damage.
8. Attach tubing from the BF1 output to the venturi injector suction port.

9. Note: If system is hydraulically non-pressurized, it is suggested that a Hartford Loop be

formed between the check valve and the ozone injection device. This requires looping the tubing
above the highest water line in the system, and affords additional water backflow protection.

10. Pressure check the piping just assembled by using the ozone generator pressure test
procedure, only block the airflow at the connection point on the generator side of the BF-1.

11. Proceed with system startup.

Startup
Two startup procedures are provided, to accommodate both negative and positive pressure systems.
Choose the appropriate procedure for your system.
Negative Pressure Startup
1. Check all components, electrical connections, tubing, etc.

2. Apply power to the system.

3. Verify that ozone generator functions. This is indicated by the red lights on the chassis turning
on.

4. Verify that the air dryer functions. This is also indicated by the light on the chassis turning on.
Note: Your desiccant indicator beads may turn clear initially, indicating moisture-laden air. This is
not a cause for alarm. The air dryer may take up to two hours of continuous operation prior to
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effectively drying the air. Note: Constant power needs to be provided to the regenerative air dryer.

5. Adjust air flow meter to desired setting, within the minimum air flow rates defined in the
Operation/Maintenance manual provided with your ozone generator. Note: The Venturi Injector
Installation/Calibration Guideline will provide you with optimum flow rates for your particular model
of generator.
6. Verify system integrity by checking the desiccant indicator and the air flow meter after several
hours. The desiccant indicator beads should be dark blue. The air flow rate, as shown on the
flow meter should be approximately equal to the initial setting.

We strongly suggest that the final step in your installation process be placement of the
Operation/Maintenance Manuals in a convenient location, near the ozone generator and air prep
equipment. If you are not the end-user of this product, you must provide your customer with the
Operation/Maintenance Manuals. The information contained therein is vital to equipment
performance, reliability and warranty eligibility.

If you did not purchase maintenance parts with your Ozotech, Inc., equipment, we
strongly suggest that you do so, warranty coverage depends on it. Ozotech has
developed a series of maintenance kits, designed to assist you in following the
maintenance program. We have removed the guesswork by providing our customers
with a simple, reliable and economical means of purchasing only the parts that they
need, all in one package!

Excessive Vacuum (Venturi injector systems only)

In some cases an excessive vacuum can be created, inside the stainless steel manifold assembly, by a
venturi injectors draw, (or suction). If this is allowed to occur the high voltage, inside the
stainless steel manifold assembly, will arc or (short) directly to the closest ground potential possible,
causing a tube and/or cap failure. (You should always check with a representative to ensure that your
venturi injector is the correct size for your application!)
To prevent this from occurring Ozotech, Inc. has placed a one way valve on the ozone out line. If
excessive vacuum is present the one way valve will open, allowing atmospheric air to enter the line and
keep it decompressed.

The following steps should be taken to eliminate the need for the one way valve to be opened.
(Note: The following steps only apply to systems that use a venturi injector)

1. If your injector does not have a bypass assembly with a ball valve installed, install a ball valve
either before and/or after the injector.
2. Install and set up your ozone system as detailed, but do not attach your air dryer or oxygen
concentrator to the ozone generators air inlet port or apply power to the system until the steps in
this section are completed.
3. Fully open your air flow meter. If your ozone generator did not come equipped with an air flow
meter, install one prior to the air inlet port.
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4. Run your water source through your venturi injector as in normal operation.
5. Close your ball valve(s) until the ozone generators air flow meter ball just begins to drop...
6. Attach your air dryer or oxygen concentrator to the ozone generators air inlet port, adjust your air
flow meter to no more than your oxygen concentrator can supply, and apply power!

You are ready to start up your system!

7.0 Maintenance
The A.I.M. 40, A.I.M. 60 and A.I.M. 80 are designed and delivered for maximum efficiency and long
life. No adjustments, other than fine-tuning the air flow rate to match user-specific requirements,
tuning the A.I.M. driver, (only when using 0-5vdc or 4-20mA control), or adjustment of rheostat to vary
transformer input voltage, should be made by the end user. Simple maintenance and appropriate
operating conditions are the only requirements to keep the unit functioning within manufacturer's
specifications.

Performing any other modifications or adjustments to internal components will cause the unit to
function outside of manufacturer's specifications, and will cause damage to the unit not covered under
terms of warranty. Maintenance should only be performed by qualified individuals.

By drawing upon years of practical experience, Ozotech, Inc., has developed a series of Maintenance Kits to
support our complete product line. Each kit contains the correct quantity and type of maintenance parts
for your specific model of ozone generator. Verify that you are using the correct Ozotech, Inc.,
maintenance kit for your particular application.

7.1 Corona Discharge Cell Maintenance

Corona Discharge Cell maintenance is simply a matter of keeping the cells clean. Depending on your
model, you will have either (4), (6) or (8) cells to maintain. Ozotech, Inc., has designed a cell- to-chamber
interface that greatly simplifies cell maintenance.
Frequency of Maintenance
Every 4800 hours (6 months)

To maintain the Corona Discharge Cells:

1. Disconnect unit from power source. Allow generator and room to clear of ozone gas.
2. Turn the (2) screws on the chassis door counter-clockwise and open door.
3. Locate the High Voltage Wires connected to the top of each Corona Discharge Cell. Pay close
attention to the wire routing. It will be necessary to route in the same manner when maintenance is
complete.

Note: In any case, wires must be routed so that a minimum clearance of 1 inch is provided between wire
and chassis (or metal parts attached to chassis). Carefully loosen and remove each of the Nylon stand-
offs that secure the ozone cells into the manifold.
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4. Very carefully pull each CD Cell Cap, then the CD Cell itself, straight out of the manifold
assembly. Your Corona Discharge Cells are made of glass, so extreme care must be taken to
avoid breakage!

5. Clean the entire Cell (glass as well as cap) with glass cleaner, or soap and water. DRY
THOROUGHLY.
Note: Replacing a wet Cell will cause damage to the unit.

6. Install Corona Discharge Cells by reversing steps through . Route High Voltage wires as close to
original routing as possible. The object is to separate these wires from sources of ground, such as
the chassis, and low voltage (115 or 230V) components.

7. Pressure check your unit. With the unit powered down and supplying a source of positive
pressure, open the airflow meters until the indicating ball reaches the top of the scale. Remove the
ozone delivery tubing from the venturi injector inlet (or equivalent) and seal to begin to pressurize
the generator and ozone delivery tubing. Using a suitable leak check solution (available through
your Ozotech, Inc., dealer) check for leaks at the tube/chamber interface, tubing connections, etc.
Immediately correct any leaks prior to placing your unit back in service.

7.2 Intake Filter Maintenance

Located on the bottom of the chassis, the intake filters remove dust particles from the air drawn into the
chassis, important in maintaining proper internal chassis environment. Proper cooling of internal
components requires filters to be clean, dry and intact. Replace as needed.

7.3 Chassis Maintenance

Proper maintenance of your generator chassis will provide more than aesthetic advantages. Dust and
moisture within the chassis can create a path for high voltage arcs, (corona). A clean internal
environment will reduce the likelihood of high voltage arcs outside of the corona region.

To Maintain Chassis:
1. Disconnect unit from power source. Allow generator and room to clear of ozone gas.
2. Turn door latches with a large, standard screw-driver. Swing door open.
3. Using a clean, dry cloth, carefully wipe off the inside of the chassis and all internal components.
Make certain that the tops of the Corona Cells, the face of the transformers, and the High
Voltage wires are thoroughly cleaned (Refer to Figure 3).
4. Using a damp cloth, clean the outside of the unit. A mild detergent may be used.
5. Thoroughly dry chassis, inside and
out.

7.4 Check Valve Replacement

Protecting your ozone generator from water infiltration

CHECK VALVE
is vital. Ozone Generators will fail if water is allowed
to enter the Corona region. Water infiltration can
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be avoided by proper installation and

maintenance of a back flow prevention device between
the ozone generator Ozone Outlet and the venturi
injector (or diffuser).

We strongly suggest that the check valve is closely inspected as often as possible; such as each time
maintenance of any type is performed. If water is visible between the check valve and the ozone
generator, or cracks are visible in the check valve body, replacement should be performed
immediately, regardless of elapsed time since last replacement.

Frequency of Replacement
Every 3 months

To Replace Check Valve

1. Disconnect unit from power source. Allow the ozone generator, and the room to clear of ozone
gas.
2. Remove tubing from hose adapter on each end of the check valve.
3. Trim approximately one inch from the end of each tube, to remove distortion caused by the hose
adapter.
4. Locate two new hose adapters supplied with the maintenance kit, and apply Teflon tape (or
equivalent) to male threads.
5. Install one hose adapter into each end of the check valve, using care to avoid damage to the check
valve body.
6. Place new check valve assembly in-line, between ozone generator and venturi injector.
Check valve flow direction must point toward venturi.
 17

8.0 Spare Parts

Description Part # Qty.

CD Cells 40155 4, 6, or 8

AIM Driver (115 VAC) 40153 1

AIM Driver (230 VAC) 40154 1

4-20 mA Add on Board 40156 1

Transformer (115 VAC) 40147-P 2, 3 or 4

Transformer (230 VAC) 40147-01-P 2, 3 or 4

Transformer 2:1 40075 1

Flow meter (0-20 SCFH) 30247 1

Instrument Panel TBD 1

CD Manifold Assy. 33241-AIM 40, 60 or 80 4, 6 or 8

Check Valve Kit 43355-01 1

Fuse Kit TBD 1

Vacuum Prevention devise 45268 1

Inlet filter media 38097 2

Note: Spare Parts are listed for only the most commonly purchased models. For Options not
included in this section, consult your Dealer.

9.0 Troubleshooting Guide
Symptom
Indicator light does not turn on.
Unit keeps blowing fuses.
Unit does not produce adequate concentration of
ozone.
Possible Cause
Unit is not connected to power source, or is
connected to improper power source.
Safety Interlock Switch is not engaged by
chassis lid.
Fuse is blown.
Light is not receiving power.
Light has failed
Electrical short circuit.
Incorrect fuse value and type are being used.
Unit is connected to improper power source.
Corona Discharge Cells were not installed.
Corona outside of the Cell/Manifold has
established due to dirt or moisture within
chassis. Corona Discharge Cell is in need of
maintenance.
Air flow rate is too high.
Unit is running too hot due to insufficient
cooling air flow.
18
Remedy
Refer to label on side of chassis for
voltage/frequency requirements.
Connect unit to proper power source.
Remove lid. Bend up interlock arm.
Visually inspect unit, and compare to wiring
diagram. Inspect Corona Discharge Cell for
damage. Inspect wire from High Voltage
Transformer to Corona Discharge Cell for
disconnection or burn marks. Repair any and
all problems prior to placing unit in service,
or contact factory for service information.
Connect l i g h t l e a d s to power source
per wiring diagram.
Refer to Spare/Replacement Parts for
replacement part information.
Visually inspect unit, and compare to wiring
diagram. Inspect Corona Discharge Cell for
damage. Inspect wire from High Voltage
Transformer to Corona Discharge Cell for
disconnection or burn marks. Repair any and
all problems prior to placing unit in service,
or contact factory for service information.
Compare fuse to label on side of unit.
Replace w i t h a p p r o p r i a t e s i z e /type
f u s e . Refer to Spare/Replacement Parts for
replacement part information.
Refer to label on side of chassi s for
voltage/frequency requirements.
Install per Installation Manual. (Corona
Discharge Cells are shipped in a separate
container to avoid damage).
Perform Corona Discharge Cell maintenance
and Chassis maintenance in accordance with
this manual.
Adjust air flow meter to lower setting,
within range specified in Air Flow
Specification section of this manual.
Refer to Air Flow Specification section of
this manual.