ClearWater Tech M-1500, P-2000, CD1500, CD2000 Ozone System Installation & Maintenance Manual

Ozone Systems

Installation & Maintenance Manual

M-1500, P-2000

CD1500 & CD2000

Corona Discharge Ozone Generator

Integrated Ozone Systems

O

Introduction

............................................................................................................................

This Installation and Operation Man u al is written to assist in the in stal la tion, operation and main te nance of ozone delivery sys tems man u fac tured by Clear Wa ter Tech, LLC. The equip ment has been de signed using the most mod ern ma te ri als and tech nol o gy available.

Please read this manual care ful ly and in its entirety before pro ceed ing with any in stal la tion, op er a tion or main te nance pro ce dure associated with this equip ment. Failure to follow these instructions could result in personal injury, damage to the equip ment or reduced product performance.

In an ongoing effort to improve reliability and operating ef fi cien cy, Clear Wa ter Tech may fi nd it nec es sary to make chang es to its prod ucts. Therefore, the in for ma tion con tained in this man u al may not con form in ev ery respect to earlier ver sions of ClearWaterTech ozone systems found in the fi eld. If you have any ques tions, please con tact your ClearWater

Tech deal er or the Clear Wa ter Tech ser vice department.

1

OVERVIEW

How Ozone is Generated

Ozone is generated by exposing oxygen molecules (O

2

) in an air stream to a controlled, high energy electrical fi eld. As the air stream passes through the electrical fi eld pro duced inside the ozone gen er a tor, some oxygen molecules are split, forming single oxygen atoms (O

1 oth er O

2

(O

3

).

). These oxygen atoms then recombine with

molecules in the air stream, form ing ozone

Oxygen (O

2

)

O

2

Electrical Field

O

2

O

1

O

1

Ozone (O )

O

3

O

Properties of Ozone

Ozone is the most powerful oxidizer available that can be safely used in water treatment.

1 It is used to treat drinking water, bottled water, swimming pool water, wastewater, food and beverage pro cess ing water, and in many other ap pli ca tions. Ozone is effective in performing the following water treatment functions:

• Disinfection – Bacterial dis in fec tion, in ac ti va tion

of vi rus es and cysts.

• Oxidation of Inorganics –

Pre cip i tates iron,

manganese, sul fi des, ni trites and organically-bound

heavy metals.

• Oxidation of Organics –

In clud ing or gan ics

causing col or, taste and odor prob lems, some

detergents and pes ti cides, phenols, VOCs, turbidity

control and microfl occulation of sol u ble or gan ics.

Molecular weight:

48

Odor:

Color:

Readily detectable at concentrations above 0.02 ppm in air

Gas Density:

Bluish in ozone generator cell, but ozone/air mixture exiting generator is invisible – even at high ozone concentrations.

2.144 grams/liter at 32°F (approx. 150% that of oxygen).

Solubility:

Only partially soluble in water, but about 10-20 times more soluble than oxygen (at 68°F).

Benefi ts of Ozone Use

• Ozone is generated on site – no transportation or storage is required.

• The most powerful oxidizer commercially available – very effective for

disinfection and oxidation with out handling problems.

• Ozone creates no potentially harmful by-products (such as THMs) – the only

by-product is oxygen.

• Ozone leaves no telltale taste or odor.

References

1. Water Quality Association, “Ozone for POU, POE and Small Water System Water Treatment Applications,” Lisle, IL, 1999.

2

THEORY OF OPERATION/PROD UCT DE SCRIP TION

ClearWater Tech ozone systems are designed for safe, effective use in a variety of water treatment applications. The CD1500 and CD2000 ozone generators have been tested and certifi ed by the Water Quality

Association according to NSF/ANSI 50. Each complete, integrated system includes the components re quired for reliable, ef fi cient ozone production and can be divided into four general segments:

• Air preparation system • Ozone generator • Ozone injection/contacting • Ozone destruct

Ozone Injector

Booster Pump

Water Flow

Ozone

Destruct

Unit

Ball Valve

Air Preparation System

Ozone Generator

CD4000P

Water Trap

Contact Vessel

Shown: ClearWater Tech CD4000P Ozone System

3

Air Preparation System

Theory of Operation/Product Description

(continued)

ClearWater Tech commercial cabinet ozone generators require a source of clean, dry, oxygen-enriched air for effective ozone pro duc tion. To meet that need, the rack-mount air prep a ra tion sys tems built by ClearWater Tech employ pressure swing adsorption (PSA) technology to increase the concentration of oxygen and reduce the moisture content in the feed gas (the air supplied to the ozone generator). This sub stan tial ly improves the output ca pa bil i ty of the ozone generator and prevents premature failure of key internal components. These air preparation systems deliver 90%+/-3% oxygen purity at -100°F dew point and at very low pneu mat ic pressures, minimizing noise and reducing com pres sor wear.

If “Plant Air” feed gas is to be used, in place of the ClearWater Tech air preparation system, the same air quality standards must be met to achieve the ozone output and longevity of the ozone generator. A PSI (pounds per square inch) regulator must be installed when using plant air feed gas. The regulator must be set to a maximum of 10 PSI.

Ozone Generator

ClearWater Tech pressurized ozone generators are designed to supply high concentrations of ozone gas (up to 10%) at 10 PSI.

The oxygen feed gas produced by the air preparation system is supplied to the ozone generator, which fl ows through a builtin fl ow meter. A stainless steel needle valve (preset inside the ozone generator), located on the stainless steel delivery line, is used to maintain optimum pneumatic parameters inside the reaction chambers. After this point the vacuum created at the ozone injector draws the ozone gas into the water line. The ozone generator is equipped with a pressure switch, which prevents its operation of the system if the pressure within the reaction chambers drops below 9 PSI.

As the feed gas enters the fused, thermally-protected reaction chambers inside the ozone gen er a tor, some of the oxygen molecules are split while passing through the high voltage electrical fi eld (the “co ro na”), forming single oxygen atoms (O

1

These oxygen atoms then recombine with other oxygen molecules in the air stream, form ing ozone. The modular, multiple

). reaction chamber design allows the ozone generator to keep working even if one or more of the chambers requires service.

Depending on the application, the ClearWater Tech ozone generator may be interlocked with an ORP controller, pressure switch, timer or circulation pump. The CD4000P is equipped with two three-way solenoid valves. While the valve on the right (closest to the cabinet wall) is for additional back fl ow prevention, the valve to the left is to depressurize and “off gas” residual ozone from the ozone reaction chambers. An internal off gas destruct (mounted inside the ozone generator) is used to destroy this residual ozone, (see Appendix - Section B). Other safety features are also built in, including a pressure switch and thermal protection.

Ozone Injection/Contacting

The ozone injector serves two purposes: One, it cre ates the vac u um required to safely draw the ozone gas from the ozone generator and two, it provides a means by which the ozone gas can be come dissolved in wa ter. A very dynamic injection pro cess is required to ef fec tive ly dissolve ozone in water.

A Short Course in Fine Bubbles

LESSON 1 - The large bubble (20mm) has a volume of 4.19 cm

12.6 cm 2 .

3 and a surface area of

LESSON 2 - 296 small bubbles (3mm) could be made from the large bubble in lesson 1. They would have a total surface area of 83.6 cm 2 . This is 6.6 times the surface area of the large bub ble.

ClearWater Tech injection systems use only Mazzei® in jec tors for maximum mass transfer ef fi cien cy. The in jec tor pro duc es a cav i ta tion effect, enabling the ozone gas to join the wa ter stream in the form of extremely tiny bub bles. These bubbles must be as small as possible in order to in crease the ratio of bubble surface area to the amount of ozone entering the water.

LESSON 3 - Theoretically, 6.6 times as much water could be ozonated with the same amount of ozone!

Depending on the application and the water treatment goals, a ClearWater Tech contacting system may also be re quired.

Some ox i da tion reactions take place so quick ly that they are limited only by the rate at which the ozone is dis solved in the water. Other reactions, such as disinfection, may require that a proper ozone re sid u al be main tained for a specifi c amount of time. A correctly-sized contact vessel is used for this purpose.

Ozone Destruct

The ClearWater Tech off-gas destruct systems consists of two components - the ozone destruct unit (a heated chamber fi lled with manganese dioxide and copper oxide) and a water trap. Used in conjunction with a ClearWater Tech off gas vent, the ozone destruct system is an effective way to vent the contact vessel(s) when it is impractical to send the off gas to atmosphere or reintroduce it to the water.

4

SAFETY INFORMATION

SAFETY WARNINGS

Two aspects of ClearWater Tech ozone generators represent potential dangers – ozone gas and high voltage electricity.

OZONE GAS

- WARNING: HIGH CON CEN TRA TIONS OF OZONE GAS ARE DANGEROUS

TO HUMANS. LOW CONCENTRATIONS CAN CAUSE IR RI TA TION TO

THE EYES, THROAT AND RES PI RA TO RY SYS TEM.

This ClearWater Tech corona discharge ozone gen er a tor is designed to operate under a pressure con di tion. While safety precautions have been taken, entering the equip ment area should be avoid ed if ozone gas is de tect ed. Ozone has a very distinctive odor and is de tect able at very low con cen tra tions

(0.02 ppm), which is far below OSHA’s maximum permissible exposure lev el of 0.1 ppm.

CAUTION!

OZONE

GAS

HIGH VOLTAGE

-

WARNING: CLEARWATER TECH OZONE GENERATORS OPERATE

AT HIGH VOLTAGES. DO NOT TAMPER WITH OR DELIBERATELY

BYPASS THE DOOR OR SAFE TY SWITCH ES BUILT INTO THE

OZONE GENERATOR UNLESS INSTRUCTED TO DO SO BY THIS

MANUAL. IF CON TACT IS MADE WITH OPERATING HIGH

VOLTAGE COM PO NENTS, ELEC TRIC SHOCK WILL OC CUR.

ClearWater Tech corona discharge ozone gen er a tors take line voltage and convert it to 48 VDC. A high voltage transformer then boosts the voltage. While each ozone generator has a door switch and other safety in ter locks, proper care must be used by a qualifi ed electrician when making any in ter nal adjustments or per form ing any maintenance procedures.

5

Safety Information

(continued)

IMPORTANT SAFETY INSTRUCTIONS -

When installing and using this electrical equip ment, basic safety precautions should always be followed, including the following:

1.

6.

7.

8.

9.

2.

3.

4.

5.

READ AND FOLLOW ALL INSTRUCTIONS.

SAVE THESE INSTRUCTIONS.

All electrical connections should be made by a licensed, qualifi ed elec tri cian.

Before attempting any electrical connections, be sure all power is off at the main cir cuit breaker.

Install all electrical equipment at least fi ve feet from any open body of water using non-metallic plumbing.

Install check valves and a vacuum break to prevent water from con tact ing the electrical equipment.

The electrical supply for this product must include a suitably-rated switch or circuit breaker to open all ungrounded supply conductors to comply with Sec tion 422-20 of the National Electrical Code, ANSI/NFPA

70-1987. The disconnecting means must be readily ac ces si ble to the operator(s) but installed at least fi ve feet from any open body of water.

Be sure to bond (ground) the system using the copper bonding lug on the bot tom of the ozone generator. The system should be bonded with solid copper wire con form ing with all local, state and national electrical codes.

The system should be sized appropriately for its intended use by a qualifi ed pro fes sion al familiar with the application. This equipment must be validated by the man u fac tur er for its intended use.

6

INSTALLATION PROCEDURES -

Get ting Start ed

Unpacking

Compare the ozone system equipment received to the packing list pro vid ed. Be fore be gin ning any installation procedures, thoroughly inspect all com po nents for damage. If dam age is noticed, promptly no ti fy the freight car ri er and request an on-site in spec tion. In spect all packing ma te ri als for small parts be fore dis card ing.

In spect all plumb ing, fi t tings and tub ing for pack ing ma te ri al that may have be come lodged in open ings.

Equipment Placement

• When placing the ozone system components in the equipment room, make

sure to consider safety, main te nance requirements, local building and fi re

codes, etc. The components should be easily ac ces si ble by the operators,

in clud ing equipment access doors and elec tri cal hook-up boxes. All meters, gauges, indicator lights and

switch es should be visible and accessible. Di men sion al drawings of each air prep a ra tion sys tem and ozone

generator are in clud ed in Section A of the Appendix.

• The air preparation system and ozone generator should be located as close as possible to the point of ozone

injection. Ozone is an unstable gas and will begin reverting back to oxygen very quickly. To determine the

most favorable ozone injection point, the following items should be considered:

• Located downstream of all other existing water system components.

• Located upstream of the residual sanitizer injection point (if so equipped).

• In a Sidestream plumbing confi guration (see Figure 5-1) with recirculation, the pH adjustment

chemical injection point must be located downstream of the residual sanitizer injection point

(if so equipped).

• In a Full Flow plumbing confi guration (see Figure 5-2) without recirculation, locate downstream

of the pH adjustment chemical injection point

• Adequate protection from weather, dust and excessive heat.

• Like any electronic component, performance and longevity is enhanced by favorable operating conditions. Also,

since each air preparation system and ozone generator is air-cooled, a relatively dust-free, well ven ti lat ed area is

required. No caustic chemicals should be stored in the area surrounding the equipment. A minimum clearance of

six inches from the vents on either side of the ozone generator is required.

• The equipment is heavy and requires proper support. Therefore, a clean, dry, level surface should be

provided for the air preparation system and ozone generator. These components should be securely fastened to

the surface using the mounting holes and/or tabs provided.

not

contact with water and/or temperature extremes. Therefore, the equipment must be installed in an

environment consistent with the following operating parameters:

• Ambient temperature range: 20°F to 85°F continuous. If the temperature around the equipment

consistently exceeds 85°F, additional air cooling must be provided.

• Humidity: 0 – 90% relative humidity, non-condensing environment

• Line voltage: +/-10% of rated input

Note: Equipment installed in extreme environmental conditions will void manufacturer's warranty.

• Allow room for the peripheral equipment (booster pump, injector manifold, contact vessel, etc.).

7

Ozone is manufactured in the CD ozone generator by drawing in air, which is composed of 20% oxygen

(O

2

), and exposing it to multiple high voltage electrical discharges. This causes a percentage of the oxygen molecules to dissociate and re as sem ble as ozone (O

3

). The ozone is drawn into the water by an injector/ mixer, killing any bacteria, viruses or mold spores it contacts. Ozone is generated on-site, eliminating the need to store toxic and corrosive chemicals. The corona discharge method is the most effi cient way to produce large amounts of ozone.

3 - O

2

2 - O

3

Chemical Formula (simplifi ed) for Corona Discharge Ozone

In contrast to ultraviolet ozone generators, corona discharge systems produce a much higher concentration of ozone and in much larger quantities. In addition, the annual expense of replacing lamps and checking ballasts is un nec es sary with corona discharge systems. Corona discharge ozone generation is the most economical and effective method to use on most water treatment applications.

ClearWater Tech manufactures high output corona discharge systems capable of producing enough ozone to oxidize iron, sulfi de, manganese and act as an effi cient sanitizer in a variety of applications. Ozone reacts to water-borne con tam i nants sig nifi cant ly faster than other dis in fec tants and the pri ma ry by-prod uct is pure oxygen.

ClearWater Tech ozone systems are built with the fi nest components available. All are air cooled and are most effi cient when used with a venturi injection system to create the best possible contact and mixing of ozone while maintaining a high level of safety.

UNCRATING and INSPECTION

Shipping Terms

Unless special arrangements have been made, the ozone equipment will be shipped FOB ClearWater

Tech's factory in San Luis Obispo, CA. The freight charges will be prepaid and billed or shipped freight collect. Transfer of liability to the freight company and the customer occurs as the equipment leaves the factory loading dock and is accepted by the freight line.

Freight Inspection

All equipment should be thoroughly inspected immediately upon delivery. If any damage is noticed, promptly notify the freight line and request an on-site inspection.

Unpacking

Typically, the equipment will arrive on a pallet. Compare the components with the packing list. Thoroughly inspect all packing materials prior to discarding. Inspect all plumbing fi ttings and tubing for packing material inadvertently lodged in any openings.

8

PRODUCT DESCRIPTION

Ozone Generator

The ozone generator houses the ozone reaction chamber(s), power supply and all electrical components directly related to the production of ozone. Ozone is produced when the feed gas is exposed to a high voltage electrical current inside the reaction chamber.

The ClearWater Tech ozone system may be equipped with a heat regenerative desiccant air dryer. Corona discharge ozone generators are much more effective, produce more ozone and require far less maintenance if an air preparation unit is included. The air preparation system lowers the dew point of the feed gas. Moist feed gas (air) will cause nitric acid to form inside the generator which decreases ozone production and if not removed, causes corrosion and eventual failure of the generator’s internal components. The ability of the ozone generator to produce ozone is drastically re duced as the dew point rises above -60°C.

The ozone gas is injected into the fi ltered water return line by means of the injector manifold. This allows the ozone to be injected into the water under a vacuum condition which is the safest technology available.

Contact Vessel

(optional)

To maximize the effectiveness of ozone, it must be thoroughly mixed and have adequate time to react with the contaminants in the water before being fi ltered or utilized. Contact vessels are designed to achieve this necessary mixing and contact time. ClearWater Tech supplies several different types of contact vessels for a variety of applications.

Booster Pump

(optional)

If excessive back pressure is created in the water line by fi lters, pressure tanks or other system parameters, a booster pump may be necessary to create a suffi cient pressure dif fer en tial across the venturi. This booster pump is used in con-

junc tion with a side stream ozone injection loop.

Electrical Interlock Box

(optional)

The electrical interlock box is a multi-function electrical enclosure. It houses the Motor Control Interlock (MCI), ORP

In ter lock and the Vacuum Interlock. The enclosure also acts as the air preparation monitoring station, controlling the amount of intake air and monitoring the vacuum.

9

PLUMBING CONNECTIONS

Full Flow Plumbing Connections

Refer to the ‘Full Flow Installation’ diagram on the next page and follow the instructions below if the ozone is being in ject ed directly into the full fl ow of the pool’s return line:

1. Tap into the return line after the pump, fi lter, and heater. The ozone injection point should be the last com po nent in line and as far as possible from the residual sanitizer injection point.

2. Glue in the proper injector, noting the direction of fl ow (indicated by an arrow on the injector).

3. Once the injector is installed, the vacuum may be adjusted as described in the “ozone generator operation” section. If the system is equipped with the optional electrical interlock box, the vacuum can be observed on the VAC/PSI gauge located above the SCFH gauge on the electrical interlock box.

Note: The ozone generator will only energize for 15 seconds or until a vacuum is attained.

Tubing Installation

1. Install braided tubing from the air dryer to the AIR INLET fi tting on the bottom of the ozone generator (or the bottom of the electrical interlock box if so equipped). If you are not using an electrical interlock box, skip Step 2 and go to Step 3.

2. If equipped with the electrical interlock box, continue running the braided tubing from the electrical interlock box to the brass barb fi tting on the bottom of the ozone generator.

3. Install the check valve assembly into the injector. Connect the 1/4” Tefl on ® tubing from the OZONE OUT fi tting on the bottom of the ozone generator to the check valve assembly on the injector. Secure by tightening the fi tting around the

1/4” Tefl on ® tubing after insertion. (If equipped with the electrical interlock box, install the 1/4” Tefl on ® tubing from the OZONE OUT fi tting on the bottom of the ozone generator to the stainless steel solenoid valve located on the top of the electrical interlock box. Continue running the Tefl on ® line from the solenoid valve to the check valve assembly on the

injector.

Independent Ozone Loop Plumbing Connections

Refer to diagrams (pgs 7-8) and follow the instructions below if the ozone is being in ject ed into an in de pen dent ozone loop.

If circumstances allow (new construction, pre-plumbed for an ozone loop), the ideal confi guration is for the ozone loop to be completely independent from the pool’s circulation system. Otherwise, the feed water for the side stream is pulled from the main return

the circulation pump and returned at a point

after

the fi lter and heater. This is done so the booster pump is not attempting to draw water through the fi lter and from the circulation pump when the circulation pump is not operating. The pH ad just ment point will always be the last item in this se quence.

Use Schedule 80 PVC for plumbing connections when possible. It is recommended that unions and valves are used where practical.

Ozone rapidly deteriorates many compounds; the following is a list of materials that may be used with ozone in an aqueous solution.

Viton Tefl on ® Sch. 40 PVC Stainless Steel EPDM

Silicon Kynar Sch. 80 PVC Concrete Hepalon

NOTE: Be sure to use good plumbing practices and install unions and isolation valves wherever the sit u a tion dic tates, i.e. pump removal, etc. Secure all plumbing with unistrut or similar hard ware.

1. In the main water return line, before the circulation pump (or a pre-plumbed independent suction fi tting if new construction) install a tee and an isolation valve.

2. Install the booster pump. Secure the pump on a housekeeping pad with the appropriate mount ing hard ware.

3. If an auxiliary control relay (i.e. fl ow switch) is being used, install it into the line after the ozone booster pump.

4. Install the injector manifold after the ozone booster pump, making sure to note the correct fl ow di rec tion of the injector manifold. Remove the tie wraps that secure the check valve assembly to the injector manifold and thread the check valve assembly onto the opening of the venturi.

10

11

12

13

Plumbing Connections - continued

OPTIONAL VACUUM BREAK INSTALLATION

Location

Select a suitable vertical surface that is accessible and in close proximity to the ozone generator and venturi manifold on which to mount the vacuum break.

Installation Steps

1. Install the two mounting Clic

®

clamps provided on the vertical surface so that the vacuum break will be in a vertical position and the height of the fi ll/drain valve fi tting will be below the level of the ozone generator bulk head check valve. One clamp should be located directly above the vacuum break’s bottom end cap and the other just below the fi ll/drain fi tting tee.

2. Install the two reducer bushings provided into the riser tee, one into the side tapping and the other into the top tapping.

Be sure to use 2-3 wraps of Tefl on

®

tape on the male threads.

3. Install the PVC ball valve provided into the reducer bushing in the side tapping on the riser tee. Be sure to use 2-3 wraps of

Tefl on

®

tape on the male threads. This valve controls the amount of water that is drawn up into the riser tube by the suction of the venturi. It can also be used to isolate the venturi should a check valve fail.

4. Install the 90º Kynar

®

fi tting provided into the reducer bushing on the top tapping on the riser tee. Be sure to use 2-3 wraps of Tefl on

®

tape on the male threads.

5. Place the two-inch diameter water reservoir into the mounting Clic

®

clamps and secure. Check to make sure the height of the fi ll/drain fi tting is below the level of the ozone generator bulkhead check valve.

6. Slide the riser tube into the water reservoir.

7. Attach one end of a suitable length of 1/4” Tefl on

®

tubing provided to the 90º Kynar

® com pres sion fi tting on the top of the riser tee. Attach the other end of the tubing to the bulkhead check valve on the bottom of the ozone gen er a tor. The length of the tubing will depend on the distance between the vacuum break and the ozone gen er a tor.

8. Initiate water fl ow through the system (e.g., start the circulation pump or boost er pump) so water is fl owing through the venturi injector. Adjust the suction at the venturi with a hand-held SCFH gauge, matching the air fl ow to the correct specifi cation as outlined on pages 17 and 18.

9. Close the PVC ball valve on the riser tee. Using the straight compression fi tting provided, attach another suitable length of 1/4” Tefl on

®

tubing to the outlet of the PVC ball valve. Attach the other end of the tubing to the compression fi tting on the venturi check valve assembly.

10. Turn the fi ll/drain fi tting so the opening faces upward and add water to the water reservoir until it begins to overfl ow out of the fi ll/drain fi tting. Now turn the fi tting so the opening faces downward.

11. Slowly open the PVC ball valve on the riser tee, allowing the water level in the riser tube to rise to a level no closer than two inches from the bottom of the riser tee.

12. Connect a suitable length of the 3/4” braided tubing provided to the barbed fi tting on the fi ll/drain fi tting. Make sure the open end of the tubing goes to safe, proper drainage and that the tube has no fl ow restrictions.

13. Run the system to ensure the water level in the riser tube is stabilized.

of water required to fi ll the riser tube, so it must always be kept at least half full. An insuffi cient water level will result in a loss of vacuum, preventing air fl ow through the ozone generator.

14

Vacuum Break Detail

Ozone Generator

Ozone Flow

Plumbing Connections - continued

Ozone Flow

Check Valve Assembly

Venturi

Ozone Injector Manifold

Drain Port

Flapper

Valve

15

Riser Tube

Elbow

Plumbing Connections - continued

OPTIONAL CONTACT COLUMN INSTALLATION

Location

The contact column(s) should be installed after the injector manifold(s), within three (3) feet of a wall or solid mount ing surface using iso la tion valves to facilitate cleaning the diffuser, if needed. There should be as few elbows as possible between the injector(s) and the contact column(s). Be sure to note the fl ow direction of the column(s).

Mounting To a Wall or Other Solid Mounting Surface Using the Hardware Kit

Refer to the diagrams on the next pages and follow these instructions:

1. Locate the following items from the hardware kit:

• ‘L’ bracket

• two 1/2” concrete anchors with nuts and washers

• unistrut and protective end cap

• 6” clamp assembly with nut and bolt

2. Mark the two holes for the ‘L’ bracket on the wall. The ‘L’ bracket should be in located above the center of the length of th contact column. A foot or so from the top is ideal. Drill two 1/2” holes where you marked, about 3 1 /

2

” to 4” deep. Insert one concrete anchor into each hole with the threaded end sticking out. Slip the ‘L’ bracket over these threaded ends and tight en down with the nuts and washers provided. This will cause the ends of the concrete anchors in the wall to expand and thus secure the ‘L’ bracket to the wall.

3. Bolt the unistrut to the ‘L’ bracket with two bolts, nuts and washers. NOTE: The unistrut may be cut to length if desired.

4. Slip the two 6” clamp pieces into the unistrut around the contact column. Tighten bolt.

5. Attach the protective end cap to the exposed end of the unistrut.

16

MOUNTING CONTACT COLUMN TO WALL USING UNISTRUT MOUNTING SYSTEM

6' Clamp Assembly with Bolt & Nut

Unistrut (may get cut to length desired)

1/2" Holes Drilled Into

Wall (3 .5" to 4" deep)

Bolts, Nuts & Washers

(2 each)

Unistrut

Protective

End Cap

Contact Column

"L" Bracket

Concrete Anchors with

Nuts & Washers (2 each)

Wall

MOUNTING TWO CONTACT COLUMNS TO WALL USING UNISTRUT MOUNTING SYS TEM

6' Clamp Assemblies

(2)with Bolt & Nut

1/2" Holes Drilled Into

Wall (3 .5" to 4" deep)

Bolts, Nuts & Washers

(2 each)

Unistrut (may get cut to length desired)

Unistrut

Protective

End Cap

Contact Columns

"L" Bracket

Concrete Anchors with

Nuts & Washers (2 each)

Wall

17

Installation of Contact Column Vent Line

1.

2.

Drill and tap a 1/4” MPT hole into the main water re turn line after the heat er. This hole should be drilled into a location with less pressure than the ozone loop so that the contact column will continually bleed ozone gas build up on top of the column to be mixed back into the main water line. (Do not install this vent line on the suc tion side of the pump.)

Install the Tefl on ® vent line from the Kynar ® fi tting on the top of the con tact col umn to the location drilled into the main water line.

Vent Line Installation Detail

Compression

Elbow Fitting

Needle Valve

(may be installed anywhere along vent line)

Vent Line

Contact

Column

Compression Fitting

Water Return Line

18

ELECTRICAL CONNECTIONS

GENERAL INFORMATION

Please read the following important information before making any electrical connections:

1. All electrical work should be done by a licensed electrician.

2. All local codes must be observed.

3. The M-1500, CD-1500, P-2000, and CD-2000 are available in 120 VAC and 240 VAC models. Be sure to install the proper model for each application.

4. Before attempting any electrical hook-up, be sure the power is OFF at the main circuit box.

5. Ground the ozone generator using the copper grounding lug on the bottom of the unit. Solid copper wire conforming with all local, state, and national electrical codes should be used.

The ozone generator should be wired so that the ozone comes ‘ON’ when the main circulation pump comes on for fi ltration. This can be accomplished by utilizing the optional elctrical interlock box to interface with a fl ow switch, ORP monitor, timer or motor control interlock (MCI) to the main circulation pump. If the optional electrical interlock box is not used, the ozone generator should be wired to the main circulation pump’s power source (or timer if a timer is used).

circulation pump.

The ozone generators come standard ready to be hard wired using 1/2” liquid tight conduit.

ELECTRICAL CONNECTIONS WITH OPTIONAL ELECTRICAL INTERLOCK BOX

Note: All electrical connections should be made by a qualifi ed electrical contractor. All local, state and national

0codes must be observed.

Inside the electrical interlock box (at the bottom, toward the center) is a terminal strip. All the peripheral equipment is wired to this block (with the exception of the air dryer). All possible pre-wiring to the terminal block has been done. Refer to the diagram on the following page for details.

A dedicated 20 AMP circuit should be run from the main electrical panel to the electrical interlock box or from the main electrical panel into a service disconnect box before wiring to the interlock box.

pump. Use minimum #12 AWG. Connect 240 VAC, 20 AMP service from the disconnect box or from a ded i cat ed breaker on the main panel to the 240 VAC terminals 1 & 2 to the 240V terminals on the terminal strip in the electric interlock box. Connect the white neutral wire to terminal 3 and connect the green wire to the grounding bar in the electric interlock box. The system can be con trolled by the circulation pump timer by wiring the timer to terminals 1 & 2. service to terminal 1 on the terminal strip. Connect the white neutral wire to terminal 2 and connect a #12 AWG jumper wire from terminal 2 to terminal 3. Connect the green wire to the grounding bar.

Terminal 4: MCI (Motor Control Interlock) - 120 VAC, 60 Hz. Use # 18 AWG. This is an interlock from the main circulation pump to the ozone system. Run a 120 VAC line from the motor starter to this terminal. Should this feature not be used, simply install a jumper from L1 to this terminal. The unit will not function without a 120 VAC signal to this location.

Terminals 5 & 6: Oxidation Reduction Potential (ORP) Controller - 120 VAC, 60Hz. Use #18 AWG. This is control voltage only (120 VAC) from the controller to a relay integrated into the ozone system. Note: To override the ORP control signal, simply

turn the ozone switch on the electrical interlock box to the ON position.

19

Electrical Connections - continued

Terminals 7 & 8: Booster Pump - 240 VAC, 60 Hz, 8 AMP, 1 HP. Use minimum #14 AWG. 120 VAC, 60 Hz, 16 AMP, use minimum #12 AWG. Wire from the terminal strip to the booster pump as indicated. The booster pump will be controlled by the interlock box. In many cases this feature is not be used; the operation of the remaining equipment will not be affected.

Terminals 9 & 10: Ozone Generator - 240 VAC, 60 Hz, 2 AMP or 120 VAC, 60 Hz, 4 AMP. Hard wire the electrical cord on the ozone generator to the terminal strip as indicated. The ozone generator will be controlled by the electrical interlock box.

Air Dryer: 120 VAC, 60 Hz, 1 AMP. Plug the air dryer into a standard wall outlet 120 VAC, 60 Hz. The air dryer should remain energized at all times with the exception of long term shutdown for service. The air dryer can be hard wired to the electrical interlock box utilizing terminals 1 (120V) and 3 (neutral).

Using a bonding wire con form ing with all local, state and national electrical codes (normally a #8 AWG), ground the components to the grounding bar on the electrical interlock box and bond the elec tri cal in ter lock box to a true earth ground.

120 VAC MODELS

1. Line in 120V

2 Neutral in

3. Neutral in

4. MCI in

5. ORP Line in

6. ORP Neutral

7. Booster Pump Out 120V

8. Booster Pump Neutral

9. Ozone Generator Out 120V

10. Ozone Generator Neutral

240 VAC MODELS

1. Line in 240V

2. Line in 240V

3. Neutral In

4. MCI in

5. ORP Line in

6. ORP Neutral

7. Booster Pump Line Out 240V

8. Booster Pump Line OUt 240V

9. Ozone Generator Out 240V

10. Ozone Generator Out 240V

Grounding Bar

20

Electrical Connections - continued

ELECTRICAL SCHEMATIC WITH OPTIONAL ELECTRICAL INTERLOCK BOX

240 VAC, 60 Hz, Single Phase

M-1500: 2 Amps without Booster Pump, 7 Amps with 1/2 HP Booster Pump

P-2000: 10 Amps with 3/4 HP Booster Pump

Connections:

Electrical Wiring

Braided Air Line

Tefl on

®

Ozone Line

AD-40 Air Dryer, Dry air or Oxygen

Vacuum

Gauge

SCFH

Gauge

Covered

Duplex

Convenience

Outlets

Ozone Generators

Electrical

Interlock

Box

Ozone

Outlet

120 VAC signal to the ozone generator form the ORP controller

Service disconnect or from a dedicated breaker in the main panel

120 VAC signal from the motor starter of the main circulation pump

L1

L2

Neutral

21

INITIAL STARTUP AND CALIBRATION WITH OPTIONAL ELECTRICAL INTERLOCK BOX

ClearWater Tech air preparation and ozone generation systems Models M-1500 and P-2000 are a vac u um type and will require ad just ment of the air fl ow through the system. On the front of the electrical interlock box is a VAC/PSI gauge and an SCFH (Standard Cubic

Feet per Hour) gauge. These two instruments are all that are required to keep the system operating within the correct parameters.

The ozone system will not function without a minimum of 3” vacuum from the venturi injector (due to an electrical vacuum interlock relay). This is a safety feature designed to prevent the ozone generator from operating without the injector drawing the gas into the water.

After all the previous electrical and plumbing connections have been completed, the system is ready for startup and cal i bra tion.

1.

Water fl owing in the main line.

2.

Open the valves to the ozone loop (if so equipped).

3.

Switch the main service disconnect box to the ON position.

4.

Turn the ozone generator ON at the switch located on the front of the electrical interlock box. Note: The dryer should already be ON as it is wired for continuous operation. The booster pump and ozone generator should now be operating.

5.

The injector can now be adjusted for suction. Observe the SCFH gauge and adjust the air fl ow using the needle valve on the SCFH gauge. Closing this valve will lower the air fl ow and raise the vacuum. If proper fl ow and vacuum cannot be achieved, readjust the bypass valve on the injector man i fold until you achieve the SCFH spec i fi ed for the ozone gen er a tor being in stalled (see chart below). Note: The system will only operate for 15 seconds without vacuum.

To reset the time sequence, turn the ‘ON OFF AUTO’ switch OFF and back to ON.

This gauge measures the relationship between the suction at the injector and the resistance to drawing the dry air and ozone through the system. Under ideal conditions, this gauge should show a very slight vacuum.

Safe

Operating

Range

Ideal

SCFH

Gauge

VAC

Needle

Valve

PSI

22

INITIAL START-UP WITHOUT OPTIONAL ELECTRICAL IN TER LOCK BOX

The air preparation and ozone generation systems on ClearWater Tech Model CD-1500 is a vac u um type and will require ad just ment of the air fl ow through the system. An SCFH (Standard Cubic Feet per Hour) gauge is used to accurately measure the amount of air fl owing through the ozone delivery line on single speed injectors (in other words, the amount of ozone being injected into the water). Follow the directions and illustration below to optimize fl ow through the injector:

1. With the pump running, disconnect the ozone line from the outlet on the ozone generator and con nect it to the fi tting on the back of the SCFH gauge provided (see drawing).

2. While holding the gauge vertically, read the amount indicated on the gauge. The optimum fl ow is 11 to 15 SCF for the CD-1500. Note: Do not obstruct the bottom air hole on the gauge.

3. On a single pump system, the injector will have a ball valve to adjust the amount of fl ow. To adjust the SCFH, simply install the gauge as above and open the gate valve completely. With the pump running, begin closing the gate valve until the optimum fl ow is achieved on the SCFH gauge. If possible, remove the gate valve handle to prevent tampering with the setting.

Attach Ozone Line

Keep

Gauge

Vertical

Injector Manifold with check valve

Do not block lower hole

23

OZONE GENERATOR OP ER A TION

After the installation has been completed, the pool operating parameters should remain the same as before. The in di ca tor light on the ozone generator (and on the electrical interlock box, if so equipped) will be illuminated if the units are func tion ing properly.

It is recommended that the pool be super-chlorinated prior to starting the ozone system to insure any organic buildup has been eliminated.

System Running Time

On residential pools, the ozone generator should operate for six to eight hours per day. Normally, the ozone system will run whenever the pool fi ltration system is operating. Since commercial pool and spa fi ltration systems normally operate 24 hours a day, the ozone system will run continuously on a commercial pool.

Understanding Your Water

If a high concentration of any mineral (such as calcium or iron) exists in the water, it is necessary to treat it before starting the ozone system. ClearWater Tech suggests a water sample be taken to your ClearWater Tech distributor for analysis. Specifi c rec om men da tions will be made relative to the product(s) needed to remove these minerals from the water. Note: This should be required only

when the pool is drained and refi lled.

If the water is clean and clear, the ozone system may be started immediately. If the water is dirty and cloudy, it is rec om mend ed that it be drained and the fi lters thoroughly cleaned before refi lling and starting the system. Note: It is not rec om mend ed that an in-ground

pool be drained in the winter or after the fi rst rain of a season. Use a shock treatment instead of draining to avoid the possibility of severe damage resulting from “fl oating” the pool out of the ground.

Ozone and Bromine

Ozone has a short “half-life”, which means it dissipates very quickly. Therefore, a small residual of another dis in fec tant must be maintained. We recommend the use of bromine in indoor pools. A bromine residual will act as a buffer when the ozone system is not operating. Bromine needs to be maintained at only 1.0 PPM (parts per million) so that the trace amount of the product in the water will not be noticed. Chlorine will also work as a residual oxidizer and may be used effectively in conjunction with the ozone system (see below and chart on following page).

Ozone and Chlorine

For outdoor pools, we recommend the use of chlorine to supplement the ozone. A chlorine residual will act as a buffer when the ozone system is not operating. Chlorine needs to be main tained at 1.0 to 2.0 PPM (parts per million - see below). To decide which form of chlorine to use in your pool, refer to the chart on the following page.

Water Preparation

To properly prepare the water for the ozone system, make the following adjustments and maintain the levels outlined below:

Bromine

or

Chlorine pH

Total Alkalinity

Calcium Hardness

1.0 PPM

1.0 to 2.0 PPM

7.2 - 7.6

100-150 PPM

200-350 PPM

Note: If any unusual reactions are experienced when ozone is introduced to the water (such as abnormal color or odor), please wait a few

days to give the ozone and fi lter system time to work. If the situation continues, your ClearWater Tech distributor should be consulted.

Algae

Always maintain the recommended residual levels of bromine or chlorine (at least 1.0 PPM) to help control algae. Brushing pool sides once a week is also effective, as is any algaecide. Note: Please consult your ClearWater Tech distributor before using any algaecide.

Shock Treatment

If an unusually high bather load causes cloudiness in the water, it is recommended that a chlorine shock treatment be used to assist the ozone in cleaning the water. Routine, periodic shocking is recommended to prevent buildup of or gan ic contaminants, especially with indoor pools. These treat ments are avail able from your ClearWater Tech dis trib u tor. Ask for as sis tance in selecting the proper product.

24

Ozone Generator Operation - continued

Properties of Bromine and Various Forms of Chlorine

Type of Bromine or Chlorine

% of

Available

Oxidizer pH Stabilizer

Required?

Neutralizer Fast

Dissolving? Dissolving?

Bromine

Gas Chlorine

61%

100%

7.4

Very

Acidic

No Yes (Muriatic No

Yes

Acid or CO

2

)

Yes Yes

Liquod Chlorine

(Sodium

Hypochlorite)

Calcium

Hypochlorite

12%

65%

13

11.8

Yes

Comments

Works well in fl oaters or feeders-Can be used in vinyl pools

Dangerous

Yes Does not have to Can be used to

It makes HoCI superchlorinate

instantly

Yes Yes No - Must be Extreme oxidizer -

(Muriatic predissolved or Do NOT use in a vinyl

Acid) broadcast can pool - Can be used

cloud in a feeder

Sodium Dichlor

Trichlor

Lithium

Hypochlorite

56% 6.8-7 No

(Built in)

No Yes - Will not

cloud water

Can be used to

superchlorinate

90% 2.8-3 No Yes No Works well in fl oaters

(Built in) (Soda Ash) Very slow Cannot be used to

superchlorinate

35% 10.7 Yes Yes Yes Cannot be used in a

(Muriatic Will not cloud feeder - Can be used

Acid) in vinyl-lined pools

25

M-1500 OZONE GENERATOR DIMENSIONS AND LAYOUT

Front and Bottom Views

M-1500

OZONE GENERATOR

26

P-2000 OZONE GENERATOR DIMENSIONS AND LAYOUT

Front and Bottom Views

P-2000

OZONE GENERATOR

27

ELECTRICAL CONNECTIONS

The in stal la tion should be done by a licensed electrician. All local codes must be observed.

The units come standard ready to be hard wired, using 1/2" liquid tight conduit.

The ozone generator should be wired so that the ozone generator is on when the pump is on or when water is fl owing through the venturi. This can be done by using the electrical interlock box to interface with a fl ow switch, ORP monitor or timer; or by using the motor control interlock (MCI) to work with a main pump.

IMPORTANT: The M-1500 & P-2000 are available in 120 volt and 240 volt models. Be sure you have the proper system for your application. Before attempting any electrical hookup, be sure the power is OFF at the main circuit box!

To hard wire a 120V system, connect the black “hot” wire to terminal L1. Connect the white neutral wire to the L2 terminal. Connect a 12 AWG jumper wire from terminals L2 to L3. Then run the green ground wire to the grounding bar.

To hard wire a 240 VAC system, connect the black wire to terminal L1 and connect the red wire to terminal L2. Connect the white neutral to terminal L3. Connect the green wire to ground.

28

240VAC ELECTRICAL CONNECTIONS WITH OPTIONAL ELECTRICAL IN TER LOCK BOX

Follow the instructions below and the wiring diagram on the previous page to wire your system. Note: All electrical con nec tions should be made by a qualifi ed electrical contractor. All local, state and national codes must be ob served.

Inside the electrical interlock box (at the bottom, toward the center) is a terminal strip. All the peripheral equipment is wired to this block (with the exception of the air dryer, which should be wired separately for continuous operation). All possible pre-wiring to the terminal block has been done.

A dedicated 20 AMP circuit should be run from the main electrical panel to the electrical interlock box or from the main electrical panel into a service disconnect box before wiring to the interlock box.

Terminals 1 & 2: Main Power - 240 VAC, 60 Hz, 2 Amps w/o booster pump, 11 AMP with 1 HP booster pump. Use minimum #12 AWG. Connect 240 VAC, 20 AMP from the disconnect box or from a dedicated breaker on the main panel to the 240 VAC terminals 1 (L1) & 2 (L2). Connect the green ground wire to the grounding bar.

Terminal 3: System Neutral - Use minimum #12 AWG. Provide a true neutral lead for this position. A true neutral runs from this terminal to the neutral bus bar in the main breaker panel. Do not ground this terminal or jumper to the ground. Note: The unit will not function without true neutral to this location.

Terminal 4: MCI (Motor Control Interlock) - 120 VAC, 60 Hz. Use # 18 AWG. This is an interlock from the main pump to the ozone system. Run a 120 VAC line from the motor starter relay to this terminal. Should this feature not be used, simply install a jumper from L1 to this terminal. Note: The unit will not function without a 120 VAC signal to this location.

Terminals 5 & 6: Oxidation Reduction Potential (ORP) Controller - 120 VAC, 60Hz. Use #18 AWG. This is control voltage only (120 VAC) from the controller to a relay integrated into the ozone system. These terminals may also be used to operate the system using a 120V signal from a fl ow switch or timer. Note: To override the ORP control signal, simply turn the ozone switch on the electrical in ter lock box to the ON position.

Terminals 7 & 8: Booster Pump - 240 VAC, 60 Hz, 8 AMP, 1 HP. Use minimum #14 AWG. Wire from the terminal strip to the booster pump as indicated. The booster pump will be controlled by the interlock box. If you are using a pump of over 1 HP, you will need to use a magnetic starter relay with these terminals providing the control voltage to the magnetic starter relay. In many cases this feature is not be used; the operation of the remaining equip ment will not be affected.

Terminals 9 & 10: Ozone Generator - 240 VAC, 60 Hz, 2 AMP. Hard wire the ozone generator to the terminal strip as indicated. The ozone generator will be controlled by the electrical interlock box.

Air Dryer: 120 VAC, 60 Hz, 1 AMP. Plug the air dryer into a standard wall outlet 120 VAC, 60 Hz. The air dryer should remain energized at all times with the exception of long term shutdown for service. The air dryer can be hard wired to the electrical interlock box utilizing terminals 1 (120V) and 3 (neutral) or can be plugged directly into the convenience outlet on the bottom of the electrical interlock box if terminals 1 & 2 are NOT timer controlled. If possible, the air dryer should be plugged in 24 hours prior to system startup in order to pre-dry the desiccant beds.

Using a bonding wire con form ing with all local, state and national electrical codes (normally a #8 AWG), ground the components to the grounding bar on the electrical interlock box and bond the elec tri cal in ter lock box to a true earth ground.

29

Ozone Systems

......................................................................................................................................

Maintenance & Trouble Shooting Manual

Parts & Warranty

M-1500, P-2000

CD-1500 & CD-2000

Corona Discharge Ozone Generators

30

MAINTENANCE

Ozone Generator Care

A word of caution: There is extremely high voltage inside the ozone generator. If you suspect a problem, disconnect the power to the unit at the service disconnect box or main electrical panel and immediately contact your ClearWater Tech dis trib u tor. Inspect the ozone delivery line check valves daily for water seepage and replace the injector check valve yearly.

• Clean the ozone generator cabinet air fi lters:

These fi lters must be cleaned regularly. Depending on the location of the unit, it may be necessary to clean the air fi lters monthly. On the bottom of the cabinet are fi lter elements (see illustration below). These are air intake el e ments for the cooling fans and may therefore require the most frequent cleaning. All elements may be cleaned with soap and water and should be dried completely before reinstalling. Note: In a clean en vi ron ment, these procedures may only need to

be performed every three months. IMPORTANT: CLEAN THESE FILTERS REG U LAR LY! FAILURE TO DO

SO WILL PROMOTE OVERHEATING AND WILL VOID THE WAR RAN TY!

• Check valves:

The system is equipped with two check valves: one at the ozone generator ozone outlet and one on the venturi injector. The purpose of these check valves is to prevent water from backing up into the ozone generator. The Tefl on ® ozone delivery line(s) should be inspected daily to insure water is not fl owing back into the ozone gen er a tor. Check valves should be replaced yearly. Note: The only time it is possible for water to fl ow back toward the ozone generator is during a system shutdown. Always inspect for water seepage during this time.

Fan

Cabinet Bottom Plate

Fingerguard

Fan Filter Element

Fan Filter Grill

(snaps on and off)

• Dielectric tubes:

Dielectric tubes are located in the reaction chambers of the ozone generator. These tubes should be inspected periodically and cleaned if necessary. Once each year, remove one reaction chamber and inspect the di elec tric tube for debris. If the tube is clean and free of any debris, oil or dirt, it may be replaced and no further main te nance is required. If the tube is dirty or cracked, all dielectric tubes must be inspected and cleaned. Cracked dielectrics should be replaced. Please consult your ClearWater Tech distributor, as the improper installation of the di elec tric may cause safety problems!

Since the air that is introduced into the reaction chambers is high quality, the dielectric tubes should remain clean for at least one year before inspection is required.

31

Removal of the Dielectric Tubes

1. Disconnect all the power to the system, including panel breakers, service disconnect box and main cir cu la tion pump interlock.

2. Unplug the electrical terminal on the back of the drive module, disconnect the polypropylene barbed air fi tting and the Kynar ® ozone fi tting.

3. Remove the ozone reaction chamber(s) from the back plate.

4. Disconnect the high voltage wire from the coil. Remove the stainless steel nut and Kynar ® center rod from the center of the reaction chamber.

5. The Tefl on ® end caps can now be gently removed by slowly pulling straight out. The glass dielectric will remain attached to one of the end caps.

6. If the dielectric tube is dirty, clean the glass with Isopropyl alcohol. Do not use a solvent that will leave an oily residue.

7. Clean the inside of the stainless steel reaction chamber with a wire brush as necessary, then wipe with Isopropyl alcohol.

8. Be sure all solvents have evaporated prior to reassembly.

Re-Installation of the Dielectric Tubes

1. Inspect the O-rings and replace as necessary.

2. Tighten the end caps so that they are approximately 1/8" from the aluminum extrusion.

3. Replace the reaction chambers and connect the air and ozone lines.

4. Connect the high voltage wire to the coil

5. Readjust the system as necessary (see operating instructions).

Maintenance Schedule

Yearly Service

1. Replace the cooling fan fi lter(s) on the ozone generator

2. Replace the air inlet particulate fi lter on the ozone generator

3. Replace the check valves

4. Remove and clean the glass dielectric in reaction chamber

5. Rebuild the solenoid valve on the electrical interlock box

6. Replace the fl ange gasket and clean the diffuser in the contact column

7. Regenerate the desiccant in the external indicating chamber on the AD-40 air dryer

Every Three Years

1. Replace the cooling fan(s) in the ozone generator

2. Disassemble and hone corona discharge reaction chamber(s), clean glass dielectric(s) and replace O-rings

Every Five Years

1. Replace the glass dielectric(s) in the reaction chamber(s) and replace O-rings

2. Replace the desiccant in the AD-40 air dryer

3. Replace the desiccant in the external indicating chamber on the AD-40 air dryer

32

M-1500 OZONE GENERATOR COMPONENTS

Dimensions:

Shipping Wt:

33

CD-1500 OZONE GENERATOR COMPONENTS

Dimensions:

Shipping Wt:

34

CD-2000 OZONE GENERATOR COMPONENTS

Dimensions:

Shipping Wt:

35

P-2000 OZONE GENERATOR COMPONENTS

Dimensions:

Shipping Wt:

36

EXPLODED VIEW OF CORONA DISCHARGE REACTION CHAMBER

37

POWER SUPPLY FOR M-1500 & CD1500

POWER SUPPLY FOR P2000 & CD2000

Power Supply for

Single-Cell Units

(100-120V Pt# PS150)

(208-240V Pt# PS155)

Power Supply for

Multi-Cell Units

(100-120V Pt# PS300)

(208-240V Pt# PS305)

38

SOLENOID VALVE (ON OPTIONAL ELECTRICAL INTERLOCK BOX)

39

PARTS LIST FOR M-1500, P-2000, CD-1500 & CD-2000

PART# DESCRIPTION

CKV20 Check valve CD 1/4" kynar - FPT, low pressure

FA40

FA41

FA42

FA43

FA44

Fan - Cooling, CD fi lter element only - 4"

Fan - Cooling, CD 120V 50/60 Hz - 4"

Fan - Cooling, CD 240V 50/60 Hz - 4"

Fan - Cooling, CD external fi nger guard - 4"

Fan - Cooling, CD internal fi nger guard - 4"

FLT34 Filter - inline particulate 1/4", for one to three cell CD systems

RCC6 Complete CD reaction chamber, 2” (does not include fi ttings)

RCC20 Cathode with heat sink and feet

RCC70 Dielectric only, all CD reaction chamber, 2”

RCC80 High voltage lead, all 2” CD reaction chambers

RCC103 High voltage end cap with O-Rings

RCC108 Non-high voltage end cap with O-Rings

ORS30 O-Ring package

DRM10 Drive Module - M-1500 or P-2000 complete, with HV transformer and mounting bracket

DRM12 Drive Module - CD-1500 or CD-2000 HO complete, with HV transformer and mounting bracket

HVT100 H.V. coil only for 2" CD reaction chamber

HWS2012 Mounting screws for reaction chamber

FTK325 Fitting, Kynar elbow for reaction chamber

FUS20 Fuse - CD, 5 Amp, slow blow

PS150 Power supply - 150 watt for M-1500 or CD-1500 100V-120V, 50/60 Hz

PS155 Power supply - 150 watt for M-1500 or CD-1500 208V-240V, 50/60 Hz

PS300 Power supply - 300 watt for P-2000 or CD-2000, 100V-120V, 50/60 Hz

PS305 Power supply - 300 watt for P-2000 or CD-2000, 208V-240V, 50/60 Hz

DES12 Desiccant, AD-40 heating chamber recharge, nonindicating

DES16 Desiccant, indicating chamber recharge, 1lb

SV200 Solenoid - 3 Way valve for air dryer w/o fi ttings,120V 50/60 Hz

SV500 Solenoid valve rebuild kit for Electrical Interlock Box

TM15 Timer solid state for the dryer 2” cube

ADP20 AD-40, part - heating element

ASP158 Maintenance Kit for M-1500 & CD-1500

ASP156 Maintenance Kit for P-2000 & CD-2000

40

OZONE GENERATOR TROUBLESHOOTING

PROBLEM/SYMPTOM

Unit does not turn on

Unit does not stay on

POSSIBLE CAUSE

•

No power to unit

•

Switch not turned on

•

Blown fuse

•

Cover/door interlock not active

•

Incorrect wiring connections

SOLUTION

•

Check breakers

•

Check switch

•

Replace fuse on bottom panel

•

Check door interlock switch

replace cover

•

Check wiring (see manual)

•

Unit overheating

•

Clean fan fi lter, check fan

•

Insuffi cient vacuum

•

Adjust injector vacuum, be sure

(should be -5 to -15 on SCFH gauge) check valves are properly installed

•

Defective solenoid

•

Defective check valve

•

Inspect and repair/replace if necessary

•

Inspect and replace if necessary

Unit cycles on and off

Individual drive indicator lights not on

Unit trips circuit breaker

You receive an electrical shock

•

Incorrect wiring upon touching the unit

•

Unit not grounded

•

Unit has been fl ooded

Water in unit or ozone delivery tubing

Ozone smell present

•

Overheating

•

Defective power

•

Defective solenoid

•

No power to drive module

•

Blown fuse

•

Drive module burnt out

•

Incorrect wiring

•

Incorrect circuit breaker

•

•

•

•

•

•

Clean fan fi lter, check fan

•

Check for constant power if not

timer controlled

Inspect and repair/replace if necessary

Check drive module (see illustration)

•

Replace fuse

•

Replace drive module

Check wiring (see manual)

•

Check and, if necessary, replace with

correct circuit breaker

Check wiring (see manual)

•

Ground unit in accordance with local

codes

Return unit for major service or

completely disassemble and clean

•

Insuffi cient vacuum

•

Defective check valve(s)

•

•

Adjust injector vac u um

Replace check valve(s)

•

Excessive back pressure on check valve

•

Back pressure not to exceed 40 psi -

if over 40 psi consult CWT distributor

•

Insuffi cient vacuum

•

Loose internal fi ttings

•

Defective O-ring seals in

•

Adjust injector vacuum

•

Inspect and tighten fi ttings

•

Check and replace if necessary

You suspect that no ozone

•

•

•

Defective dielectrics

•

Defective reaction chamber

Drive module failure

Dielectric failure

41

•

Check and replace if necessary

•

Check and replace if necessary

•

Touch the bottom of the coil replace if it is not warm

•

Inspect and replace if necessary

OZONE GENERATOR TROUBLESHOOTING

(continued)

PROBLEM/SYMPTOM

Unit seems noisy

Flow meter will not adjust

Vacuum gauge reads on pressure side

POSSIBLE CAUSE

•

Not properly secured to wall/fl oor

•

Shipping damage

•

Fan blocked

•

Air preparation not operating

•

Defective solenoid

•

Defective check valve

•

Internal regulator out of adjustment

•

Insuffi cient vacuum

•

Output solenoid defective

•

Defective vacuum gauge

•

Loose Kynar

SOLUTION

•

Bolt it fi rmly into place

•

Locate and repair

•

Check and clear obstructions

•

Make sure air prep package is

set properly

•

Check and repair (use solenoid bypass

•

Check and replace

•

Check and adjust regulator

•

Adjust injector vacuum

•

Check and replace or rebuild

•

Replace vacuum gauge

•

Tighten all Kynar

AIR DRYER TROUBLESHOOTING

PROBLEM/SYMPTOM

Air dryer not operating

POSSIBLE CAUSE

•

No power to air dryer

•

Switch not on

•

Fuse blown

•

Insuffi cient vacuum

•

Solenoid valve defective Air dryer not producing dry air fl ow

Air dryer cold when operating

Desiccant indicator cartridge not blue in color

Air dryer not cycling

•

No power to air dryer

•

Switch not on

•

Fuse blown

•

Defective heater cartridge

•

Air leak

•

Desiccant saturated in storage

•

Timer defective

•

Relay defective

•

Defective vacuum gauge

•

Loose Kynar

®

compression fi ttings

SOLUTION

•

Check power connections

•

Turn switch on

•

Replace fuse

•

Adjust injector vacuum

•

Replace solenoid valve

•

Check power connections & breakers

•

Turn switch on

•

Replace fuse

•

Replace heater cartridge

•

Tighten fi ttings

•

Reactivate desiccant (as described

•

Replace timer

•

Replace relay

•

Replace vacuum gauge

•

Tighten all Kynar

®

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ELECTRICAL INTERLOCK BOX TROUBLESHOOTING

PROBLEM/SYMPTOM POSSIBLE CAUSE

‘MAIN POWER’ light not on

•

No power to electrical interlock box

•

No neutral in 120 VAC supply

•

Light burnt out

•

120 VAC signal not connected ‘MCI’ light not on

‘VACUUM SYSTEM’ light not on

•

Light burnt out

•

No neutral in 120 VAC supply

•

No power to electrical interlock box

•

No MCI

•

No neutral in 120 VAC supply

•

No vacuum

•

Light burnt out

‘ORP’ light not on

•

No power to electrical interlock box

•

No MCI

•

No neutral in 120 VAC supply

•

No vacuum

•

System set to “MANUAL”

•

No 120 VAC power to terminals

•

ORP level in excess of preset level

•

Light burnt out

Flow meter ball does not adjust

•

No vacuum

•

Vacuum leak

•

In and out hoses reversed

•

Defective solenoid

•

Defective check valve

SOLUTION

•

Check power connections & breakers

•

Hook up neutral

•

Replace light

•

Jumper terminal from #1 to #4

•

Replace light

•

Hook up neutral

•

Check power connections & breakers

•

Jumper terminal from #1 to #4

•

Hook up neutral

•

Adjust injector vacuum, or

Check tubing for leaks, or

Check for booster pump operation, or

Turn to “OFF” and back to reset

•

Replace light

•

Check power connections & breakers

•

Jumper terminal from #1 to #4

•

Hook up neutral

•

Adjust injector vacuum, or

Check tubing for leaks, or

Check for booster pump operation, or

Turn to “OFF” and back to reset

•

Switch to “AUTO”

•

Hook up power to these terminals

•

Check input signal

•

Replace light

•

Adjust injector vacuum

•

Check and tighten fi ttings

•

Switch hoses

•

Inspect and repair or replace solenoid

•

Check and replace check valve

43

DRIVE MODULE WIRING FOR M-1500 & P-2000

44

DRIVE MODULE WIRING FOR CD-1500 & CD2000

45

POWER SUPPLY WIRING FOR 120VAC M-1500

POWER SUPPLY WIRING FOR 240VAC M-1500

46

POWER SUPPLY WIRING FOR 120VAC P-2000

POWER SUPPLY WIRING FOR 240VAC P-2000

47

ClearWater Tech, LLC Limited One-Year Warranty

ClearWater Tech, LLC (“CWT”) makes every effort to assure that its products meet high quality and durability stan dards and warrants the products it manufactures against defects in materials and workmanship for a period of one (1) year, commencing on the date of original shipment from CWT, with the following exceptions: 1) The warranty period shall begin on the installation date if the in stal la tion is performed within 90 days of the original shipment from CWT; 2) The warranty period shall begin on the date of the bill of sale to the end user if the installation date is more 90 days after the original shipment date. To validate the warranty, a warranty card, accompanied by a copy of the bill of sale, must be returned to CWT and must include the following information:

•

End user name

•

Complete address, including telephone number

•

Date installed

•

Complete model and serial number information

•

Name of company from which the unit was purchased

Repairs and replacement parts provided under this warranty shall carry only the unexpired portion of this warranty or 90 days, which ev er is longer.

This warranty does not extend to any product and/or part from which the factory assigned serial number has been removed or which has been damaged or rendered defective as a result of:

•

an accident, misuse, alteration or abuse

•

an act of God such as fl ood, earthquake, hurricane, lightning or other disaster resulting only from the forces of nature

•

normal wear and tear

•

operation outside the usage parameters stated in the product user’s manual

•

check valve/solenoid valve failure

•

use of parts not sold by CWT

•

service or unit modifi cation not authorized by CWT

•

damage which may occur during shipping

•

failure to meet service requirements as outlined in the I & O manual

Any product and/or part not performing satisfactorily may be returned to CWT for evaluation. A Return Goods Au tho ri za tion (RGA) number must fi rst be obtained by either calling or writing your local authorized dealer, dis trib u tor or CWT direct, prior to shipping the product. The problem experienced with the product and/or part must be clearly described. The RGA number must appear prom i nent ly on the exterior of the shipped box(es). The product and/or part must be packaged ei ther in its original packing material or in comparable and suitable packing material, if the orig i nal is not available. You are responsible for paying shipping charges to CWT and for any damages to the product and/or part that may occur during shipment. It is recommended that you insure the shipment for the amount you originally paid for the product and/or part.

If, after the product and/or part is returned prepaid and evaluated by CWT, it proves to be de fec tive while under war ran ty, CWT will, at its election, either repair or replace the defective prod uct and/or part and will return ship at lowest cost transportation prepaid to you except for shipments going outside

the 50 states of the United States of America. If upon in spec tion, it is determined that there is no defect or that the damage to the product and/or part re sult ed from causes not within the scope of this limited warranty, then you must bear the cost of repair or re place ment of damaged product and/or part and all return freight charges. Any un au tho rized attempt by the end user to repair CWT man u fac tured products without prior permission shall void any and all warranties. For service, contact your authorized dealer or distributor or CWT direct at (805) 549-9724, extension 23.

There is no other expressed warranty on CWT products and/or parts. Neither this warranty, or any other warranty, ex pressed or implied, including any implied warranties or merchantability of fi t ness, shall extend beyond the war ran ty pe ri od. Some states do not allow limitations on how long an implied warranty lasts, so that the above limitation or exclusion may not apply to you.

No responsibility is assumed for any incidental or consequential damages; this includes any damage to another product or products resulting from such a defect. Some states do not allow the ex clu sion or limitation of incidental or con se quen tial damages, so that above limitation or exclusion may not apply to you.

This warranty gives you specifi c legal rights and you may also have other rights which vary from state to state.

THIS STATEMENT OF WARRANTY SUPERSEDES ALL OTHERS PROVIDED TO YOU AT ANY PRIOR TIME.

ClearWater Tech, LLC.

850 Capitolio Way Suite E, San Luis Obispo, California 93401 • (805) 549-9724 • Fax: (805) 549-0306

48