®
DEL AOP 25
INSTALLATION INSTRUCTIONS
& PRODUCT MANUAL
C-M-P.COM
4-2535-01 Rev.B
DEL AOP 25 Installation & Operations Manual
IMPORTANT SAFETY INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS
•
WARNING: Risk of electric shock. Install at least 5 feet from inside wall of pool using
nonmetallic plumbing. Install ozone generator no less than 1 foot above maximum water
level to prevent water from contacting electrical equipment.
•
WARNING: To reduce the risk of injury, do not permit children to use this product unless
they are closely supervised at all times.
•
WARNING: Short-term inhalation of high concentrations of ozone and long- term
inhalation of low concentrations of ozone can cause serious harmful physiological
effects. DO NOT inhale ozone gas produced by this device.
•
WARNING: Exposure to UV light from this device is harmful to skin and eyes. Do not
attempt to remove or service the UV lamp while it is lit.
•
WARNING: Electric shock hazard. Be sure to disconnect from power source before any
service work is performed. Failure to do so could result in serious injury or death.
•
At least two lugs, marked “BONDING LUGS,” are provided on the external surface of the
enclosure. To reduce risk of electric shock, connect the local bonding grid in the area
of the pool equipment to these terminals with an insulated or bare copper conductor
no smaller than No. 6 AWG.
•
All permanent electrical connections should be made by a qualified electrician in
accordance to all applicable electrical codes.
•
The unit must be installed in an outdoor location, or indoors in a forced air ventilated
room, and installed so that the orientation is exactly as shown in Figure 1 (see page 2).
•
Mount the unit so that it is inaccessible to anyone in the pool. Never attempt any service
while unit is wet.
•
Plastic ozone supply tubing is supplied with the unit. Never replace this tubing with
metal tubing.
•
For your safety, do not store or use gasoline, chemicals, or other flammable liquids or
vapors near this or any other appliance.
•
ENVIRONMENTAL NOTICE: UV Lamp CONTAINS MERCURY (Hg). Manage in
accordance with disposal laws. See: www.lamprecycle.org
SAVE THESE INSTRUCTIONS!
DEL AOP 25 Installation & Operations Manual
TABLE OF CONTENTS
SECTION 1 General Information
1A. Description................................................................................................ 1
1B. Specifications............................................................................................ 1
1C. Warranty Summary����������������������������������������������������������������������������������� 1
SECTION 2 Installation
2A. Location..................................................................................................... 1
2B. Wall Mounting............................................................................................ 2
2C. Plumbing................................................................................................... 2
2D. Main Power............................................................................................... 6
SECTION 3 Operation
3A. General...................................................................................................... 7
3B. Initial System Start-Up����������������������������������������������������������������������������� 7
3C. System Shut-Down���������������������������������������������������������������������������������� 7
SECTION 4 Maintenance & Service
4A. System Electro-Mechanical Overview....................................................... 8
4B. System Maintenance�������������������������������������������������������������������������������� 9
4C. Ozone Module Service��������������������������������������������������������������������������� 10
4D. UV Lamp and Quartz Tube Service�������������������������������������������������������� 11
4E. Troubleshooting....................................................................................... 14
APPENDIX A: Warranty....................................................................................... 16
DEL AOP 25 Installation & Operations Manual
SECTION 1 General Information
1A. Description
The DEL AOP 25 described in this manual is designed to provide the benefits
of ozonated and UV sterilized water in an environmentally safe and effective
manner. The high quality, specially engineered components ensure efficient
and reliable performance. As a result of proper use of the DEL AOP 25,
unpleasant effects of traditional chemical use are virtually eliminated. It is safe
and harmless to your equipment when installed properly.
1B. Specifications
Power Requirements:
110-240V, 50-60 Hz, 1Ø, 0.3 Amp
Water Flow rate:
5-20 GPM
Location Requirements:
Mounting: Wall or post mount in a clean, protected area.
Ambient Temp.: 30°F - 120°F (0°C - 50°C)
1C. Warranty Summary
Limited Warranty: Two (2) year warranty on the entire DEL AOP 25, except for
the UV lamp, which carries an 18 month warranty. See APPENDIX A: section
for limitations and details on obtaining warranty service.
SECTION 2 Installation
2A. Location
Mount in a clean, protected area, either indoors or outdoors (preferably out of
direct sunlight). Locate out of reach of sprinklers or drainage spouts. Mount
in the orientation shown in Figure 1, using the two mounting holes provided
inside the enclosure. Allow sufficient clearance in front for internal access,
and above for service of the UV Lamp and Quartz Tube (13 inches). The DEL
AOP 25 should be installed at least one (1) foot above the maximum water
level. See Section 2C-3. Check Valve Assembly, for plumbing instructions
based on mounting location.
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DEL AOP 25 Installation & Operations Manual
2B. Wall Mounting
1. Wall mount near pool equipment.
2. Refer to Figure 1 to mark the locations for the two mounting screws.
3. Install screws (or other hardware appropriate for mounting surface)
through the two mounting holes built into the enclosure.
Allow Vertical Clearance
for UV Lamp Removal
System Active
Indicator
Water Outlet
Ozone Module
Indicators (2x)
Mounting
Holes (2x)
Ozone Output
Barb
Bonding Lugs
Main Power
Wires
½” Knockout
Water Inlet
Figure 1: Mounting (cover removed)
2C.Plumbing
Ozone Oxidation: Ozone gas is introduced to the water using a venturi Injector
in the pool circulation line. Suction developed by the Injector allows the DEL
AOP 25 to operate safely under vacuum.
Germicidal UV: The UV Lamp will sterilize water as it passes directly through
the DEL AOP 25.
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DEL AOP 25 Installation & Operations Manual
2C-1. By-Pass Plumbing
Install By-Pass plumbing to DEL AOP 25 as shown in Figure 2. Observe
and follow the correct flow directions on all components.
The DELCHECK variable rate check valve will ensure adequate by-pass
flow through the Injector, which will create suction to pull in the ozone.
It will also effectively limit the total by-pass flow to less than 20 GPM
for optimal germicidal UV effectiveness.
The recommended configuration is a dedicated pool return from the
DEL AOP 25. If a dedicated pool return is not possible, a connection
back to the main pool return may be used.
NOTE: For pools equipped with a heater, the by-pass plumbing tee to
the Injector should be installed BEFORE the heater. Any by-pass that
connects back to the main pool return should occur AFTER all other
equipment to avoid collection of gas in the system and possible failure
of pool system components.
2C-2. Pressure Test
If a pressure test is required, it should be performed prior to installing
the Check Valve Assembly tubing connections. Cap the Injector with
the ¾” pipe cap provided for the pressure test. Check inside the DEL
AOP 25 and all plumbing fittings for leaks. Repair any leaks before
continuing installation.
2C-3. Check Valve Assembly
1. Install Tube Adapter on the Injector.
2. Connect the Check Valve Assembly tubing that is closest to the Check
Valve to the Tube Adapter on the Injector.
3. Attach the other tubing end of the Check Valve Assembly to the Ozone
Outlet Barb on the DEL AOP 25.
NOTE: If the DEL AOP 25 must be mounted below the water line, the
Check Valve Assembly tubing must be run to a point above the water
line. This will prevent water from running back to the DEL AOP 25 when
the pool pump is not running, and provides protection in the event of
a failed Check Valve.
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DEL AOP 25 Installation & Operations Manual
Figure 2: Typical Plumbing (pool with heater)
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DEL AOP 25 Installation & Operations Manual
2C-4. Flow Test
1. Temporarily disconnect tubing from inlet side of the Check Valve and
attach Flow Meter Assembly (see Figure 3).
2. Hold the Flow Meter Assembly so that the clear plastic chamber is
vertical and pointed down.
3. Turn on the pool pump as this allows the Injector to pull a vacuum.
Under normal operation, the ball in the Flow Meter Assembly will
be floating between the Min and Max lines. At a minimum, the ball
should indicate at least a small amount of air flow. If you experience
complications, see Section 4E. Troubleshooting.
4. After the system flow has been verified, remove the Flow Meter
Assembly and reconnect the tubing to the inlet side of the Check
Valve. Secure all tube connections on the Check Valve Assembly with
tube clamps.
®
Flow Meter
Assembly
Figure 3: Flow Test
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DEL AOP 25 Installation & Operations Manual
2D. Main Power
Connect the DEL AOP 25 to the pool timing clock so that it operates
simultaneously with the pool pump. The circuit must be protected by a Ground
Fault Circuit Interrupter (G.F.C.I.) installed in accordance to electrical code.
The DEL AOP 25 has three wires provided for electrical connection. Ensure
that the AC power source is within the DEL AOP 25 input power
specifications and connect as shown on wiring decal: black wire to Line (or
Line 1), white wire to Neutral (or Line 2), and green wire to Ground.
A knockout (1/2” trade size) is supplied for appropriate wiring conduit/fittings
per local requirement.
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DEL AOP 25 Installation & Operations Manual
SECTION 3 Operation
3A. General
To achieve optimal performance from the DEL AOP 25, the pool must be as
clean as possible to start with.
1. Backwash or clean filters one day before starting the DEL AOP 25.
2. Superchlorinate pool water using a chlorine based shock treatment.
3. Test pool chemistry and adjust pH between 7.4 and 7.6. Adjust total
alkalinity between 80 and 120 ppm.
4. Run pool filtration continuously for 24 hours prior to starting ozone
system.
3B. Initial System Start-Up
1. With the DEL AOP 25 cover off, turn on pool pump.
2. Check to ensure the DEL AOP 25 System Active indicator is on.
3. Check to ensure the DEL AOP 25 Ozone Module indicators are on.
4. Verify that ozone is being pulled into the Injector by checking for
bubbles at the return. If an MDV is installed, check the MDV for bubbles.
5. Verify the above steps for all system conditions (multi-speed pump
settings, etc.)
If you experience complications, see Section 4E. Troubleshooting.
Call 1-800-676-1335 or visit www.delozone.com for further assistance.
3C. System Shut-Down
If the system is to be shut-down for an extended period, disconnect the DEL
AOP 25 from the power source and disconnect the Check Valve Assembly
tubing from the Ozone Output Barb of the DEL AOP 25. When winterizing,
ensure that all water is drained from the DEL AOP 25.
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DEL AOP 25 Installation & Operations Manual
SECTION 4 Maintenance and Service
WARNING: Before performing any maintenance, make sure the
DEL AOP 25 is disconnected from the power source, the pool
pump is off, and water pressure is relieved.
4A. System Electro-Mechanical Overview
4A-1. DEL AOP 25 Components
Ozone Module: Each Ozone Module consists of an Ozone Power
Supply connected by two high voltage wires to an Ozone Cell.
UV Lamp: This is housed in a Quartz Tube, which is sealed inside of
the plumbing.
Ballast: Electronic Ballast provides power to the UV Lamp.
Flow Switch: Activates the Power Relay when adequate flow is
established through the DEL AOP 25.
Power Relay: Turns on the Ozone Modules and Ballast.
Power Relay
Ballast
UV Lamp
Ozone Module
Flow Switch
Figure 4: Components
(plumbing transparent for clarity)
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DEL AOP 25 Installation & Operations Manual
4B. System Maintenance
4B-1. Ordering Information
To locate a dealer nearest you, call 1-800-676-1335 or visit our website at
www.delozone.com.
Be prepared to provide the following information:
•
Name
•
Address
•
Model Number
•
Date Purchased
4B-2. Standard Replacement Parts List
1. UV Lamp Replacement Assembly....................................... 9-1100-01
2. Quartz Tube Replacement Kit.............................................. 9-1204-01
3. Sealing O-Ring..................................................................... 7-1871-01
4. Check Valve Assembly*....................................................... 9-0770-01
5. Ozone Module...................................................................... 9-1056-01
* Must be replaced every year.
4B-3. Regularly reinstall and check the Flow Meter Assembly for proper flow.
Always remove the Flow Meter Assembly after confirming flow.
4B-4. Regularly inspect Check Valve Assembly tubing for cracks or wear.
Also, check to make sure that no water is present between the Check Valve
and the DEL AOP 25. This indicates Check Valve failure. Replace the Check
Valve Assembly (replacement part number 9-0770-01) immediately.
WARNING: Trace amounts of nitric acid may be present in the
Check Valve Assembly and could be mildly corrosive. Allow
any moisture to be drawn out or dried up prior to servicing, if
possible. Wear proper protective gear.
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DEL AOP 25 Installation & Operations Manual
4C. Ozone Module Service
Replace Ozone Modules if the Ozone Module Indicator will not light, or after
15,000 hours of operation (15,000 hours equals approximately 5 years for
a pool system that operates 8 hours/day).
Follow the instructions below to replace Ozone Modules and refer to Figure 5.
1. Remove the Interconnect Tubing and Filters from the Ozone Cell
connections on the outside of the DEL AOP 25.
2. Remove the screws securing the Ozone Cells to the side of the
enclosure.
3. Disconnect the power connectors between the Ozone Power Supplies
and wire harness.
4. Remove the screws securing the Ozone Power Supply to the standoff
inside of the enclosure. Remove the Ozone Module.
5. Install the new Ozone Module by reversing these steps.
Ozone
Module
Interconnect
Tubing
Ozone Power
Supply
Ozone Cell
Filters (2)
Figure 5: Ozone Module Replacement
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DEL AOP 25 Installation & Operations Manual
4D. UV Lamp and Quartz Tube Service
4D-1. UV Lamp Removal
For maximum UV sanitization effect, replace the UV Lamp after 13,000
hours of operation.
Follow the instructions below for UV Lamp replacement and refer to
Figure 6.
1. Make sure the unit is disconnected from power and the lamp has
cooled before performing maintenance.
UV Lamp
UV Lamp
Retainer
Quartz Tube
Sealing O-Ring
Quartz Tube
Adapter
Figure 6: Lamp and Quartz Tube Removal
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DEL AOP 25 Installation & Operations Manual
2. Disconnect the power connector between the UV Lamp and wire
harness.
3. Gently pull on the UV Lamp wires until the top of the UV Lamp is out
of the UV Lamp Retainer. Grasp the white ceramic end of the UV Lamp
and pull until it is fully removed. If the UV Lamp will be reused, avoid
touching the UL Lamp glass with your bare hands. Handle the UV
Lamp carefully and set aside. If discarding, dispose of properly (see
Important Safety Instructions at the beginning of this manual).
4D-2. Installing the UV Lamp
1. Make sure to only handle the new UV Lamp by the ceramic ends.
Clean the UV Lamp with a lint free cloth and rubbing alcohol before
installation if needed.
2. Carefully push the UV Lamp into the UV Lamp Retainer until the top
of the UV Lamp is past the tabs on the UV Lamp Retainer.
3. Reconnect the UV Lamp power connector to the wire harness.
4D-3. Quartz Tube Removal and Cleaning
CAUTION: Wear proper eye and skin protection for servicing
glass components. If broken glass is trapped in the pool system,
do not operate the pool. Contact a service professional to have
the glass removed.
NOTE: Damage caused by a broken Quartz Tube is not covered under
the DEL AOP 25 Limited Warranty.
The UV Lamp is housed in a Quartz Tube. If the Quartz Tube becomes
dirty, its ability to transmit rays from the UV Lamp will be diminished and
decrease system performance. The Quartz Tube should be removed
from the DEL AOP 25 at least once a year for inspection and cleaning.
1. Make sure the DEL AOP 25 is drained of pool water and has cooled
before performing maintenance on the Quartz Tube.
2. Remove the UV Lamp as described in Section 4D-1. UV Lamp
Removal.
3. Remove the two screws and washers from the top of the UV Lamp
Retainer, and pull the UV Lamp Retainer out of the Quartz Tube Adapter.
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DEL AOP 25 Installation & Operations Manual
NOTE: Any remaining water in the DEL AOP 25, or the plumbing system
above the level of the DEL AOP 25, will drain when the UV Lamp Retainer
is removed.
4. Grasp the inside of the Quartz Tube and pull it out of the housing. Make
sure the Sealing O-Ring does not get lost during Quartz Tube removal.
5. Inspect the Quartz Tube for cracks and replace if cracks are found.
Inspect the Sealing O-Ring for nicks or hardness and replace if
necessary.
6. Clean the Quartz Tube exterior with a mild solution of muriatic acid
and water in a ratio of four parts water to one part acid (4:1). DO NOT
USE ABRASIVE CLEANERS.
CAUTION: Follow the directions for safe use and handling of
muriatic acid on the acid bottle label. Never add water to acid.
Always add acid to water.
7. After cleaning the Quartz Tube, wash it off with water and wipe dry
with a soft towel.
8. Make sure the inside of the Quartz Tube is dry before installing the
UV Lamp.
4D-4. Quartz Tube Installation
1. Place the Sealing O-Ring on the Quartz Tube 3/4 inch from the open
end.
2. Insert the Quartz Tube partially into the Quartz Tube Adapter. Place the
UV Lamp Retainer over the open end of the Quartz Tube and slowly
push in until it is touching the Quartz Tube Adapter.
3. Reinstall the two screws and washers and tighten until the UV Lamp
Retainer is seated completely against the Quartz Tube Adapter.
4. Turn on the pool pump and check the joint around the UV Lamp
Retainer for leaks.
5. If it leaks, please contact DEL Customer Support at 1-800-676-1335.
6. Once you have confirmed that there are no leaks, turn off the pool
pump and install the UV Lamp as described in Section 4D-2.
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DEL AOP 25 Installation & Operations Manual
4E. Troubleshooting
Knowledge of electrical applications is required for troubleshooting. Contact a
certified electrician if you are unsure of your ability to service the equipment.
Improper servicing will void the Warranty.
Symptom: “SYSTEM ACTIVE” indicator not lit when the pool system is on.
1. No power to the DEL AOP 25 from the power source.
a. Check breaker at the power distribution box.
b. Check for loose connections or wiring breaks from the power
distribution box to the DEL AOP 25.
c. The G.F.C.I. has been tripped. Reset the G.F.C.I.
2. Insufficient flow through the DEL AOP 25.
a. Check the pool pump and ensure water is flowing through the
Injector (5 GPM minimum).
b.Check to ensure that the pump skimmer and filter are clean.
c. Ensure that there is no debris clogged inside the Injector.
Symptom: No gas flow.
1. Injector not supplying adequate suction.
a. Check the pool pump and ensure water is flowing through the
Injector.
b. Check to ensure that the pump skimmer and filter are clean.
c. Check to ensure that the Injector is plumbed in the right direction.
d. Ensure that there is no debris clogged inside the Injector.
2. Tubing is impaired.
a. Check for kinks or clogs.
b.Check for cracks or cuts.
c. Check connections.
d.Ensure that the Check Valve is installed with the arrow pointing
towards the Injector.
e. Be sure that the Check Valve has not become fouled with debris.
Disconnect the Check Valve Assembly from the Tube Adapter on the
Injector. With the pump running, test the end of the Tube Adapter
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DEL AOP 25 Installation & Operations Manual
with your thumb, and feel for suction. Wash your hands immediately
afterwards to remove any residual nitric acid. If there is sufficient
suction without the Check Valve Assembly connected, replace the
Check Valve Assembly.
Symptom: Ozone tubing becomes yellow/brown and brittle.
1. The high concentration of ozone created by the corona discharge ozone
generators, as well as environmental conditions like UV sunlight, will
tend to deteriorate the supplied tubing. This is normal and acceptable,
as long as the tubing doesn’t become cracked and leak. Because of
this, DEL recommends replacing the Check Valve Assembly every year.
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DEL AOP 25 Installation & Operations Manual
APPENDIX A:
DEL AOP
LIMITED 2 YR WARRANTY
The limited warranty set forth below applies to products manufactured by DEL and sold by DEL or its authorized
dealers. This limited warranty is given only to the first retail purchaser of such products and is not transferable to any
subsequent owners or purchasers of such products.
DEL warrants that it or its authorized dealers will repair or replace, at its option, any part, other than the UV lamps, of
such products proven to be defective in materials or workmanship within TWO (2) year from the date of retail purchase of
such products. UV lamps warranted within 18 months. ANY REPAIR OR REPLACEMENT WILL BE WARRANTED
ONLY FOR THE BALANCE OF THE ORIGINAL WARRANTY PERIOD.
NOTE: USE ONLY DEL AUTHORIZED DEL REPLACEMENT PARTS. USE OF ANY OTHER PART(S) WILL VOID
THIS WARRANTY.
Any replaced parts must be returned to DEL for warranty evaluation.
THIS LIMITED WARRANTY DOES NOT INCLUDE ANY OF THE FOLLOWING:
(a)
Any repair or replacement of such parts necessitated by faulty installation, improper maintenance, improper
operation, misuse, abuse, negligence, accident, fire, flood, repair materials, and/or unauthorized accessories.
(b)
(c)
(d)
Any such products installed without regard to required local codes and accepted trade practices.
Damage to unit caused by water backflow;
Any implied warranty of merchantability or implied warranty of fitness for particular purpose, and such
warranties are hereby disclaimed.
DEL shall not be liable under any circumstances for loss of use of such product, loss of profits. direct damages,
indirect damages, consequential damages, and / or incidental damages.
This warranty gives you specific legal rights. You may have other rights which vary from state to state.
(e)
TO OBTAIN WARRANTY SERVICE:
Customer Service Number:
Fax Number:
Email
(800) 676-1335
(805) 541-8459
warrantysupport@delozone.com
PROVIDE:
1. Customer name, mailing address, and telephone.
2. Installer/Mechanical Contractor or Dealer name.
3. Unit Part Number, Serial Number or Manufacture Date, and date of purchase.
4. The date of failure.
5. A description of the failure.
After this information is provided, DEL may release a RETURN GOODS AUTHORIZATION (RGA) NUMBER. After receiving the RGA number the part
in question must be returned to DEL, freight prepaid, with the RGA number clearly marked on the outside of the package. All preauthorized defective
parts must be returned to DEL within thirty (30) days. Under no circumstances may any product be returned to DEL without prior authorization. Returns
without the assigned RGA number on the outside of the package will be refused and shipped back to the sender at their expense. Upon receipt of
preauthorized returned goods, DEL will repair or replace, at DEL’s option, the defective product(s) and return them (freight prepaid for products under
warranty). Buyer’s acceptance of the product and use thereof constitutes acceptance of these terms.
4-2006-01_Rev.C
16
EPA Estab. No. 071472-CA-001
800.676.1335
o3info@delozone.com
www.delozone.com
®
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