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Ozone Systems - US Water Systems

1. e Defective solenoid Clean fan filter check fan e Check for constant power if not timer controlled Inspect and repair replace if necessary Individual drive indicator lights not on No power to drive module Blown fuse e Drive module burnt out e Check drive module see illustration Replace fuse Replace drive module Unit trips circuit breaker Incorrect wiring Incorrect circuit breaker e Check wiring see manual Check and if necessary replace with correct circuit breaker You receive an electrical shock upon touching the unit Incorrect wiring Unit not grounded Unit has been flooded e Check wiring see manual Ground unit in accordance with local codes e Return unit for major service or completely disassemble and clean Water in unit or ozone delivery tubing Insufficient vacuum Defective check valve s e Excessive back pressure on check valve Adjust injector vacuum Replace check valve s Back pressure not to exceed 40 psi if over 40 psi consult CWT distributor Ozone smell present e Insufficient vacuum Loose internal fittings Defective O ring seals in reaction chamber e Defective dielectrics Defective reaction chamber Adjust injector vacuum Inspect and tighten fittings e Check and replace if necessary e Check and replace if necessary e Check and replace if necessary You suspect
2. Ozone Systems Installation amp Maintenance Manual M 1500 P 2000 CD1500 8 CD2000 Corona Discharge Ozone Generator Ozone Systems ClearWater Tech LLC Integrated Ozone Systems 850 E Capitolio Way San Luis Obispo Ca 93401 805 549 9724 Fax 805 549 0306 E mail service cwtozone com www cwtozone com Copyright 2006 ClearWater Tech LLC Reproduction of any kind is prohibited 111520 REV012306 This Installation and Operation Manual is written to assist in the installation operation and maintenance of ozone delivery systems manufactured by ClearWater Tech LLC The equipment has been designed using the most modern materials and technology available Please read this manual carefully and in its entirety before proceeding with any instal lation operation or maintenance procedure associated with this equipment Failure to follow these instructions could result in personal injury damage to the equipment reduced product performance In an ongoing effort to improve reliability and operating efficiency ClearWater Tech may find it necessary to make changes to its products Therefore the information contained in this manual may not conform in every respect to earlier versions of ClearWaterTech ozone systems found in the field If you have any questions please contact your ClearWater Tech dealer or the ClearWater Tech service department OVERVIEW How Ozone is Generated Ozone is generated b
3. 2 120 VAC systems 120 VAC 60 Hz 6 AMP w o booster pump 22 AMP with 1 HP booster pump Connect 120 VAC 10 AMP 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 amp 6 Oxidation Reduction Potential ORP Controller 120 60Hz Use 18 AWG This 15 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 amp 8 Booster Pump 240 VAC 60 Hz 8 AMP I 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 imdicated The booster pump will be controlled by the interlock box many cases this feature 18 not be used the operation of the remaining equipment will not be affected Terminals 9 amp 10 Ozone Generator 240 VAC 60 Hz 2 AMP 120
4. 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 ter minal 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 Con nect the white neutral to terminal L3 Connect the green wire to ground ELECTRICAL INTERLOCK BOX OPTIONAL DIMENSIONS AND LAYOUT 28 240VAC ELECTRICAL CONNECTIONS WITH OPTIONAL ELECTRICAL INTERLOCK BOX Follow the instructions below and the wiring diagram on the previous page to wire your system Note All electrical connections should be made by a qualified electrical contractor All local state and national codes 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 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 amp 2 Main Power 240 VAC 60 Hz 2 Amps w o booster pump
5. Note It is not recommended that in ground pool be drained in the winter or after the first rain of a season Use a shock treatment instead of draining to avoid the possibil ity of severe damage resulting from floating 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 disinfectant must be maintained We recommend the use of bromine in indoor pools A bromine residual will act as a buffer when the ozone system 1s 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 1s not operating Chlorine needs to be maintained 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 1 0 PPM or Chlorine 1 0 to 2 0 PPM pH 7 2 7 6 Total Alkalinity 100 150 PPM Calcium Hardness 200 350 PPM Note
6. thermally protected reaction chambers inside the ozone generator some of the oxygen molecules are split while passing through the high voltage electrical field the corona forming single oxygen atoms These oxygen atoms then recombine with other oxygen molecules in the air stream forming 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 flow 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 18 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 creates the vacuum A Short Course in Fine Bubbles required to safely draw the ozone gas from the ozone generator and two it provides a means by which the ozone gas can become LESSON 1 The large bubble 20mm has D a volume of 4 19 and a surface area of D dissolved in water A very dynamic in
7. 11 AMP with 1 HP booster pump Use minimum 412 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 8 2 L2 Connect the green ground wire to the grounding bar Terminal 3 System Neutral Use minimum 812 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 amp 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 flow switch or timer Note To override the ORP control signal simply turn the ozone switch on the electrical interlock box to the ON position Terminals 7 8 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 in
8. VAC 60 Hz 4 AMP Hard wire the electrical 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 I 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 conforming 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 electrical interlock box to a true earth ground Grounding Bar 20 Electrical Connections continued ELECTRICAL SCHEMATIC WITH OPTIONAL ELECTRICAL INTERLOCK BOX 240 VAC 60 Hz Single Phase 1500 2 Amps without Booster Pump 7 Amps with 1 2 HP Booster Pump P 2000 10 Amps with 3 4 HP Booster Pump 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 vacuum type and will require adjust ment of the air flow through the system On the front of the electrical interlock box 15 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 paramet
9. corona discharge reaction chamber s clean glass dielectric s and replace O rings Every Five Years 1 2 Replace the glass dielectric s in the reaction chamber s and replace O rings Replace the desiccant in the AD 40 air dryer Replace the desiccant in the external indicating chamber on the AD 40 air dryer 32 SPECIFICATIONS 1500 Energy Required 105 V min 125 V max 120VAC models 50 60 Hz 1 6 Amps Energy Required 208 V min 240 V max 240 VAC models 50 60 Hz 0 8 Amps Dimensions 27 h x 9 25 w x 5 5 d Shipping Wt 32 Ibs CD 1500 OZONE GENERATOR COMPONENTS SPECIFICATIONS CD 1500 Energy Required 105 V min 125 V max 120VAC models 50 60 Hz 1 6 Amps Energy Required 208 V min 240 V max 240 VAC models 50 60 Hz 0 8 Amps Shipping Wt 32 lbs SPECIFICATIONS 0 2000 Energy Required 105 V min 125 V max 120VAC models 50 60 Hz 1 6 Amps Energy Required 208 V min 240 V max 240 VAC models 50 60 Hz 0 8 Amps Shipping Wt 49 lbs 2000 OZONE GENERATOR COMPONENTS SPECIFICATIONS 2000 Energy Required 105 V min 125 V max 120VAC models 50 60 Hz 2 8 Amps Energy Required 208 V min 240 V max 240 VAC models 50 60 Hz 1 4 Amps Dimensions 23 h x 20 25 w x 5 5 d Shipping Wt 32 Ibs 36 EXPLODED VIEW OF CORONA DISCHARGE REACTION CHAMBER POWER SUPPLY FOR M 1500 8 CD1500 8 Power Supply for Single Cell Units 100 120
10. generated on site no transportation or storage is required e The most powerful oxidizer commercially available very effective for disinfection and oxidation without handling problems e Ozone creates no potentially harmful by products such as THMs the only by product is oxygen e 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 THEORY OF OPERATION PRODUCT DESCRIPTION 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 certified by the Water Quality Association according to NSF ANSI 50 Each complete integrated system includes the components required for reliable efficient ozone production and can be divided into four general segments e Air preparation system Ozone generator Ozone injection contacting Ozone destruct Shown ClearWater Tech CD4000P Ozone System _ _ Theory of Operation Product Description continued Air Preparation System ClearWater Tech commercial cabinet ozone generators require a source of clean dry oxygen enriched air for effective ozone production To meet that need the rack mount air preparation systems built by ClearWater Tech employ pressure swing adsorption PSA technology to increase the concentration of oxygen and reduce the moisture
11. iron sulfide manganese and act as an efficient sanitizer in a variety of applications Ozone reacts to water borne contaminants significantly faster than other disinfectants and the primary by product is pure oxygen ClearWater Tech ozone systems are built with the finest components available All are air cooled and are most efficient 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 fittings and tubing for packing mate inadvertently lodged in any openings PRODUCT DESCRIPTION Ozone Generator The ozone generator houses the ozone reaction chamber s power supply and all elec
12. nut and Kynar center rod from the center of the reaction chamber The Teflon end caps can now be gently removed by slowly pulling straight out The glass dielectric will remain attached to one of the end caps If the dielectric tube is dirty clean the glass with Isopropyl alcohol Do not use a solvent that will leave an oily residue Clean the inside of the stainless steel reaction chamber with a wire brush as necessary then wipe with Isopropyl alcohol Be sure all solvents have evaporated prior to reassembly Re Installation of the Dielectric Tubes Inspect the O rings and replace as necessary Tighten the end caps so that they are approximately 1 8 from the aluminum extrusion Replace the reaction chambers and connect the air and ozone lines Connect the high voltage wire to the coil Readjust the system as necessary see operating instructions Maintenance Schedule Yearly Service l Replace the cooling fan filter s on the ozone generator 2 Replace the air inlet particulate filter 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 flange 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
13. operating power to air dryer e Switch not on Fuse blown Defective heater cartridge Check power connections amp breakers e Turn switch on Replace fuse Replace heater cartridge Desiccant indicator cartridge not blue in color Air leak e Desiccant saturated in storage Tighten fittings Reactivate desiccant as described in manual Air dryer not cycling Timer defective Relay defective Defective vacuum gauge Loose Kynar compression fittings 42 Replace timer Replace relay Replace vacuum gauge Tighten all Kynar fittings ELECTRICAL INTERLOCK BOX TROUBLESHOOTING PROBLEM SYMPTOM POSSIBLE CAUSE SOLUTION MAIN POWER light not on No power to electrical interlock box neutral in 120 VAC supply Light burnt out e Check power connections 8 breakers Hook up neutral Replace light MCT light not on 120 VAC signal not connected to terminal 4 Light burnt out neutral in 120 VAC supply e Jumper terminal from 1 to 4 Replace light Hook up neutral VACUUM SYSTEM light not on No power to electrical interlock box e No MCI e No neutral in 120 VAC supply No vacuum Light burnt out e Check power connections amp breakers e Jumper terminal from 1 to 4 Hook up neutral Adjust injector vacuum Check tubing for leaks or Check for booster pump operation or Turn to OFF and
14. recirculation the pH adjustment chemical injection point must be located downstream of the residual sanitizer injection point if so equipped e Ina Full Flow plumbing configuration see Figure 5 2 without recirculation locate downstream of the pH adjustment chemical injection point e Adequate protection from weather dust and excessive heat e ike 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 ventilated 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 e 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 e The air preparation system and ozone generator are not designed to withstand outdoor elements including direct contact with water and or temperature extremes Therefore the equipment must be installed in an environment consistent with the following operating parameters e Ambient temperature range 20 F to 85 F continuous If the temperature around the equipment consistently exceeds 85 additional air cooling must be provide
15. the ozone generator and the booster pump should be interlocked to the main 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 qualified electrical contractor All local state and national Ocodes 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 Terminals 1 2 and 3 Main Power 240 VAC systems 240 VAC 60 Hz 3 AMP w o booster pump 11 AMP with 1 HP booster pump Use minimum 12 AWG Connect 240 VAC 20 AMP service from the disconnect box or from a dedicated breaker on the main panel to the 240 VAC terminals I amp 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 controlled by the circulation pump timer by wiring the timer to terminals 1 amp
16. 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 Connect a suitable length of the 3 4 braided tubing provided to the barbed fitting on the fill drain fitting Make sure the open end of the tubing goes to safe proper drainage and that the tube has no flow restrictions Run the system to ensure the water level in the riser tube is stabilized Note The proper water level must be maintained in the water reservoir When full the reservoir contains about twice the amount of water required to fill the riser tube so it must always be kept at least half full An insufficient water level will result in a loss of vacuum preventing air flow through the ozone generator 14 Plumbing Connections continued Vacuum Break Detail I Port Cap per Tee g Clamps 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 mounting surface using isolation 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 flow 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 fo
17. 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 filter 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 15 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 organic contami nants especially with indoor pools These treatments are available from your ClearWater Tech distributor Ask for assistance in selecting the proper product 24 Ozone Generator Operation continued Properties of Bromine and Various Forms of Chlorine Comments Stabilizer Neutralizer Fast Required Dissolving Dissolving Type of Bromine of or Chlorine Available Oxidizer KU Gas Chlorine 100 Very Acidic Liquod Chlorine 12 Works well in floaters or feeders Can be used in vinyl pools Yes Muriatic Acid or CO Yes Dangerous Yes Does not have to Can be used to It makes HoCl superchlori
18. NY PRIOR TIME TECH LLC w w w ClearWater Tech LLC systems 850 Capitolio Way Suite E San Luis Obispo California 93401 805 549 9724 Fax 805 549 0306 48
19. S Getting Started Unpacking Compare the ozone system equipment received to the packing list provided Before beginning any installation procedures thoroughly inspect all components for damage If damage is noticed promptly notify the freight carrier and request an on site inspection Inspect all packing materials for small parts before discarding Inspect all plumbing fittings and tubing for packing material that may have become lodged in openings Equipment Placement e When placing the ozone system components in the equipment room make sure to consider safety maintenance requirements local building and fire codes etc The components should be easily accessible by the operators including equipment access doors and electrical hook up boxes All meters gauges indicator lights and switches should be visible and accessible Dimensional drawings of each air preparation system and ozone generator are included in Section A of the Appendix e 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 e Located downstream of all other existing water system components e Located upstream of the residual sanitizer injection point if so equipped e Ina Sidestream plumbing configuration see Figure 5 1 with
20. V Pt PS150 208 240V Pt PS155 POWER SUPPLY FOR P2000 amp CD2000 Ge Power Supply for Multi Cell Units 100 120V Pt PS300 208 240V Pt PS305 SOLENOID VALVE ON OPTIONAL ELECTRICAL INTERLOCK BOX PARTS LIST FOR M 1500 2000 CD 1500 8 CD 2000 PART CKV20 FA40 FA41 FA42 FA43 FA44 FLT34 RCC6 RCC20 RCC70 RCC80 RCC103 RCC108 ORS30 DRM10 DRM12 DESCRIPTION Check valve CD 1 4 kynar FPT low pressure Fan Cooling CD filter element only 4 Fan Cooling CD 120V 50 60 Hz 4 Fan Cooling CD 240V 50 60 Hz 4 Fan Cooling CD external finger guard 4 Fan Cooling CD internal finger guard 4 Filter inline particulate 1 4 for one to three cell CD systems Complete CD reaction chamber 2 does not include fittings Cathode with heat sink and feet Dielectric only all CD reaction chamber 2 High voltage lead all 2 CD reaction chambers High voltage end cap with O Rings Non high voltage end cap with O Rings O Ring package Drive Module M 1500 or P 2000 complete with HV transformer and mounting bracket Drive Module CD 1500 or CD 2000 HO complete with HV transformer and mounting bracket HVTI00 coil only for 2 CD reaction chamber HWS2012 Mounting screws for reaction chamber FTK325 FUS20 PS150 PSISS PS300 PS305 DES12 DES16 SV200 SV500 15 ADP20 ASP158 ASP156 Fitting Kynar elbow for reaction chamber Fuse CD 5 Am
21. amp CD 2000 Corona Discharge Ozone Generators ClearWater TECH 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 distributor Inspect the ozone delivery line check valves daily for water seepage and replace the injector check valve yearly Clean the ozone generator cabinet air filters These filters must be cleaned regularly Depending on the location of the unit it may be necessary to clean the air filters monthly On the bottom of the cabinet are filter elements see illustration below These are air intake elements for the cooling fans and may therefore require the most frequent cleaning elements may be cleaned with soap and water and should be dried completely before reinstalling Note In a clean environment these procedures may only need to be performed every three months IMPORTANT CLEAN THESE FILTERS REGULARLY FAILURE TO DO SO WILL PROMOTE OVERHEATING AND WILL VOID THE WARRANTY e 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 Teflon ozone delivery line s should be inspected daily to insure water 1s not flowing ba
22. back to reset Replace light ORP light not on No power to electrical interlock box e No MCI e No neutral in 120 VAC supply No vacuum System set to MANUAL No 120 VAC power to terminals 5 and 6 e ORP level in excess of preset level Light burnt out e Check power connections amp breakers e Jumper terminal from 1 to 4 Hook up neutral e Adjust injector vacuum or Check tubing for leaks or Check for booster pump operation or Turn to OFF and back to reset e Switch to AUTO Hook up power to these terminals see manual e Check input signal Replace light Flow meter ball does not adjust e No vacuum Vacuum leak In and out hoses reversed e Defective solenoid Defective check valve 43 Adjust injector vacuum e Check and tighten fittings Switch hoses Inspect and repair or replace solenoid e Check and replace check valve DRIVE MODULE WIRING FOR M 1500 amp P 2000 DRIVE MODULE WIRING FOR CD 1500 amp CD2000 POWER SUPPLY WIRING FOR 120 1500 POWER SUPPLY WIRING FOR 240VAC M 1500 46 POWER SUPPLY WIRING FOR 120 P 2000 POWER SUPPLY WIRING FOR 240VAC P 2000 47 ClearWater Tech LLC Limited One Year Warranty Summary of the Warranty ClearWater Tech LLC makes every effort to assure that its products meet high quality and durability standards and warrants the products it manufactures agai
23. ck into the ozone generator Check valves should be replaced yearly Note The only time it is possible for water to flow back toward the ozone generator 18 during a system shutdown Always inspect for water seepage during this time e Dielectric tubes Dielectric tubes are located in the reaction chambers of the ozone generator These tubes should be inspected periodical ly and cleaned if necessary Once each year remove one reaction chamber and inspect the dielectric tube for debris If the tube is clean and free of any debris oil or dirt it may be replaced and no further maintenance is required If the tube 1s 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 dielectric 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 1s required 31 Removal of the Dielectric Tubes Disconnect all the power to the system including panel breakers service disconnect box and main circulation pump interlock Unplug the electrical terminal on the back of the drive module disconnect the polypropylene barbed air fitting and the Kynar ozone fitting Remove the ozone reaction chamber s from the back plate Disconnect the high voltage wire from the coil Remove the stainless steel
24. content in the feed gas the air supplied to the ozone generator This substantially improves the output capability 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 pneumatic pressures minimizing noise and reducing compressor 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 flows through a built in flow 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
25. d e Humidity 0 90 relative humidity non condensing environment e Line voltage 10 of rated input Note Equipment installed in extreme environmental conditions will void manufacturer s warranty e Allow room for the peripheral equipment booster pump injector manifold contact vessel etc CORONA DISCHARGE CD OZONE SYSTEMS Ozone is manufactured in the CD ozone generator by drawing in air which is composed of 20 oxygen O and exposing it to multiple high voltage electrical discharges This causes a percentage of the oxygen molecules to dissociate and reassemble as ozone O 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 efficient way to produce large amounts of ozone 3 0 gt 2 0 Chemical Formula simplified 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 unnecessary 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
26. dicated 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 equipment will not be affected Terminals 9 amp 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 amp 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 conforming with all local state and national electrical codes normally a 48 AWG ground the compo nents to the grounding bar on the electrical interlock box and bond the electrical interlock box to a true earth ground 29 Ozone Systems Maintenance A Trouble Shooting Manual Parts amp Warranty M 1500 P 2000 CD 1500
27. e back pressure is created in the water line by filters pressure tanks or other system parameters a booster pump may be necessary to create a sufficient pressure differential across the venturi This booster pump is used in con junction 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 Interlock and the Vacuum Interlock The enclosure also acts as the air preparation monitoring station controlling the amount of intake air and monitoring the vacuum 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 injected directly into the full flow of the pool s return line 1 Tap into the return line after the pump filter and heater The ozone injection point should be the last component in line and as far as possible from the residual sanitizer injection point 2 Glue in the proper injector noting the direction of flow 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
28. e is no defect or that the damage to the product and or part resulted from causes not within the scope of this limited warranty then you must bear the cost of repair or replacement of damaged product and or part and all return freight charges Any unauthorized attempt by the end user to repair manufactured 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 Exclusive Warranty There is no other expressed warranty on products and or parts Neither this warranty or any other warranty expressed implied including any implied warranties or merchantability of fitness shall extend beyond the warranty period 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 Disclaimer of Incidental and Consequential Damages No responsibility 18 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 exclusion or limitation of incidental or consequential damages so that above limitation or exclusion may not apply to you Legal Remedies of Purchaser This warranty gives you specific 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 ATA
29. ers 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 18 ready for startup and calibration Starting Position 1 Water flowing 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 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 SCFH gauge and adjust the air flow using the needle valve on the SCFH gauge Closing this valve will lower the air flow and raise the vacuum If proper flow and vacuum cannot be achieved readjust the bypass valve on the injector manifold until you achieve the SCFH specified for the ozone generator being installed see chart below Note The system will only operate for 15 seconds without vacuum To reset the time sequence turn the OFF AUTO switch OFF and back to ON Model Operating SCFH 1500 CD1500 8 12 2000 CD2000 16 20 VACIPSI Gauge This gau
30. ety Information continued 5 RU CTIO NS When installing and using this electrical equipment basic safety precautions should always be followed including the following gt W P S N READ AND FOLLOW ALL INSTRUCTIONS SAVE THESE INSTRUCTIONS electrical connections should be made by a licensed qualified electrician Before attempting any electrical connections be sure all power is off at the main circuit breaker Install all electrical equipment at least five feet from any open body of water using non metallic plumbing Install check valves and a vacuum break to prevent water from contacting 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 Section 422 20 of the National Electrical Code ANSI NFPA 70 1987 The disconnecting means must be readily accessible to the operator s but installed at least five feet from any open body of water Be sure to bond ground the system using the copper bonding lug on the bottom of the ozone generator The system should be bonded with solid copper wire conforming with all local state and national electrical codes The system should be sized appropriately for its intended use by a qualified professional familiar with the application This equipment must be validated by the manufacturer for its intended use INSTALLATION PROCEDURE
31. from the pool s circulation system Otherwise the feed water for the side stream is pulled from the main return before the circulation pump and returned at a point after the filter and heater This is done so the booster pump is not attempting to draw water through the filter and from the circulation pump when the circulation pump is not operating The pH adjustment point will always be the last item in this sequence 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 Teflon 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 situation dictates i e pump removal etc Secure all plumbing with unistrut or similar hardware l Inthe main water return line before the circulation pump or a pre plumbed independent suction fitting 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 mounting hardware 3 Ifan auxiliary control relay i e flow 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 flow directio
32. ge measures the relationship between the suction at the injector and the resistance to drawing the dry air and ozone through the system Under 1deal conditions this gauge should show a very slight vacuum 22 INITIAL START UP WITHOUT OPTIONAL ELECTRICAL INTERLOCK BOX The air preparation and ozone generation systems on ClearWater Tech Model CD 1500 is a vacuum type and will require adjustment of the air flow through the system An SCFH Standard Cubic Feet per Hour gauge 1s used to accurately measure the amount of air flowing 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 flow through the injector 1 With the pump running disconnect the ozone line from the outlet the ozone generator and connect it to the fitting 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 flow 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 flow 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 flow is achieved on the SCFH gauge If possible remove the gate valve handle to prevent tampering with the sett
33. 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 fitting 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 fitting on the bottom of the ozone generator 3 Install the check valve assembly into the injector Connect the 1 4 Teflon tubing from the OZONE OUT fitting on the bottom of the ozone generator to the check valve assembly on the injector Secure by tightening the fitting around the 1 4 Teflon tubing after insertion If equipped with the electrical interlock box install the 1 4 Teflon tubing from the OZONE OUT fitting 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 Teflon 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 injected into an independent ozone loop If circumstances allow new construction pre plumbed for an ozone loop the ideal configuration is for the ozone loop to be com pletely independent
34. he riser tee Be sure to use 2 3 wraps of Teflon tape on the male threads Place the two inch diameter water reservoir into the mounting Clic clamps and secure Check to make sure the height of the fill drain fitting is below the level of the ozone generator bulkhead check valve Slide the riser tube into the water reservoir Attach one end of a suitable length of 1 4 Teflon tubing provided to the 90 Kynar compression fitting 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 generator The length of the tubing will depend on the distance between the vacuum break and the ozone generator Initiate water flow through the system e g start the circulation pump or booster pump so water is flowing through the venturi injector Adjust the suction at the venturi with a hand held SCFH gauge matching the air flow to the correct specification as outlined on pages 17 and 18 Close the PVC ball valve on the riser tee Using the straight compression fitting provided attach another suitable length of 1 4 Teflon tubing to the outlet of the PVC ball valve Attach the other end of the tubing to the compression fitting on the venturi check valve assembly Turn the fill drain fitting so the opening faces upward and add water to the water reservoir until it begins to overflow out of the fill drain fitting Now turn the fitting so the opening faces downward Slowly open the PVC ball
35. ing 23 OZONE GENERATOR OPERATION After the installation has been completed the pool operating parameters should remain the same as before The indicator light on the ozone generator and on the electrical interlock box if so equipped will be illuminated if the units are functioning properly It is recommended that the pool be super chlorinated prior to starting the ozone system to insure any organic buildup has been elimi nated 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 filtration system 1s operating Since commercial pool and spa filtration 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 1t before starting the ozone system ClearWater Tech suggests a water sample be taken to your ClearWater Tech distributor for analysis Specific recommend ations 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 refilled If the water is clean and clear the ozone system may be started immediately If the water is dirty and cloudy it is recommended that it be drained and the filters thoroughly cleaned before refilling and starting the system
36. ixed back into the main water line Do not install this vent line on the suction side of the pump 2 Install the Teflon vent line from the Kynar fitting on the top of the contact column to the location drilled into the main water line Vent Line Installation Detail 18 ELECTRICAL CONNECTIONS GENERAL INFORMATION Please read the following important information before making any electrical connections 1 electrical work should be done by a licensed electrician All local codes must be observed 3 The M 1500 CD 1500 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 filtration This can be accomplished by utilizing the optional elctrical interlock box to interface with a flow 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 5 power source or timer if a timer is used If a side stream booster pump is used
37. jection process is required to effectively dissolve ozone in water 12 6 cm LESSON 2 296 small bubbles 3mm could be made from the large bubble in lesson 1 They would ClearWater Tech injection systems use only Mazzei injectors for ore oaza aaa Rz Oe maximum mass transfer efficiency The injector produces a cavitation imes he suface arga ot ine large bubble effect enabling the ozone gas to join the water stream in the form of LESSON 3 Theoretically 6 6 times as much water could be ozonated with the same extremely tiny bubbles These bubbles must be as small as possible oo in order to increase the ratio of bubble surface area to the amount of ozone entering the water Depending on the application and the water treatment goals a ClearWater Tech contacting system may also be required Some oxidation reactions take place so quickly that they are limited only by the rate at which the ozone is dissolved in the water Other reactions such as disinfection may require that a proper ozone residual be maintained for a specific 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 filled 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 i
38. llowing items from the hardware kit IL bracket e two 1 2 concrete anchors with nuts and washers e unistrut and protective end cap 6 clamp assembly with nut and bolt 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 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 tighten 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 D bracket to the wall Bolt the unistrut to the L bracket with two bolts nuts and washers NOTE The unistrut may be cut to length if desired Slip the two 6 clamp pieces into the unistrut around the contact column Tighten bolt Attach the protective end cap to the exposed end of the unistrut 16 MOUNTING CONTACT COLUMN WALL USING UNISTRUT MOUNTING SYSTEM MOUNTING TWO CONTACT COLUMNS TO WALL USING UNISTRUT MOUNTING SYSTEM Installation of Contact Column Vent Line 1 Drill and tap 1 4 hole into the main water return line after the heater This hole should be drilled into a location witt less pressure than the ozone loop so that the contact column will continually bleed ozone gas buildup on top of the column to be m
39. n 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 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 10 11 12 15 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 fill drain valve fitting 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 fill drain fitting tee 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 Teflon tape on the male threads 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 Teflon 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 Install the 90 Kynar fitting provided into the reducer bushing on the top tapping on t
40. nate instantly Yes No Must be Extreme oxidizer Muriatic predissolved or Do NOT use in a vinyl Acid broadcast can pool Can be used es Yes Yes No No Sodium Hypochlorite 7 4 13 Calcium Hypochlorite 65 cloud in a feeder Sodium Dichlor 56 6 8 7 Yes Will not Can be used to Built in cloud water superchlorinate 2 8 3 10 7 Trichlor 90 Yes No Works well in floaters Built in Soda Ash Very slow Cannot be used to superchlorinate Lithium Yes Yes Yes Cannot be used ina Hypochlorite Muriatic Will not cloud feeder Can be used Acid in vinyl lined pools 1500 OZONE GENERATOR DIMENSIONS AND LAYOUT Front and Bottom Views 1500 OZONE GENERATOR ai te ac 26 P 2000 OZONE GENERATOR DIMENSIONS AND LAYOUT Front and Bottom Views 2000 OZONE GENERATOR ELECTRICAL CONNECTIONS The installation 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 flowing through the venturi This can be done by using the electrical interlock box to interface with a flow switch ORP monitor or timer or by using the motor control interlock MCI to work with a main pump IMPORTANT The M 1500 8 P 2000 are available in 120 volt and 240 volt models Be sure you have the proper sys tem for your application
41. nst defects in materials and workmanship for a period of one 1 year commencing on the date of original shipment from with the following exceptions 1 The warranty period shall begin on the installation date if the installation 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 whichever is longer Items Excluded from the Warranty 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 e an accident misuse alteration or abuse e anact of God such as flood earthquake hurricane lightning or other disaster resulting only from the forces of nature e normal wear and tear e operation outside the usage parameters stated in the product user s manual check valve solenoid valve failure e useof pa
42. p slow blow Power supply 150 watt for M 1500 or CD 1500 100V 120V 50 60 Hz Power supply 150 watt for M 1500 or CD 1500 208V 240V 50 60 Hz Power supply 300 watt for P 2000 or CD 2000 100V 120V 50 60 Hz Power supply 300 watt for 2000 or CD 2000 208V 240V 50 60 Hz Desiccant AD 40 heating chamber recharge nonindicating Desiccant indicating chamber recharge 11b Solenoid 3 Way valve for air dryer w o fittings 120V 50 60 Hz Solenoid valve rebuild kit for Electrical Interlock Box Timer solid state for the dryer 2 cube AD 40 part heating element Maintenance Kit for M 1500 amp CD 1500 Maintenance Kit for P 2000 amp CD 2000 40 OZONE GENERATOR TROUBLESHOOTING PROBLEM SYMPTOM POSSIBLE CAUSE SOLUTION Unit does not turn on No power to unit e Switch not turned on Blown fuse e Cover door interlock not active Incorrect wiring connections e Check breakers e Check switch Replace fuse on bottom panel e Check door interlock switch replace cover e Check wiring see manual Unit does not stay on Unit overheating Insufficient vacuum should be 5 to 15 on SCFH gauge e Defective solenoid e Defective check valve Clean fan filter check fan Adjust injector vacuum be sure check valves are properly installed Inspect and repair replace if necessary Inspect and replace if necessary Unit cycles on and off Overheating Defective power
43. rts not sold by e damage which may occur during shipping e service or unit modification not authorized by CWT e failure to meet service requirements as outlined in the I amp O manual Obtaining Service Under the Warranty Any product and or part not performing satisfactorily may be returned to for evaluation A Return Goods Authorization RGA number must first be obtained by either calling or writing your local authorized dealer distributor 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 prominently on the exterior of the shipped box es The product and or part must be packaged either in its original packing material or in comparable and suitable packing material if the original 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 defective while under warranty CWT will at its election either repair or replace the defective product 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 inspection it is determined that ther
44. s impractical to send the off gas to atmosphere or reintroduce it to the water SAFETY INFORMATION SAFETY WARNINGS Two aspects of ClearWater Tech ozone generators represent potential dangers ozone gas and high voltage electricity OZONE GAS WARNING HIGH CONCENTRATIONS OF OZONE GAS ARE DANGEROUS TO HUMANS LOW CONCENTRATIONS CAN CAUSE IRRITATION TO THE EYES THROAT AND RESPIRATORY SYSTEM This ClearWater Tech corona discharge ozone generator 18 designed to operate under a pressure condition While safety precautions have been taken entering the equipment area should be avoided if ozone gas 18 detected Ozone has a very distinctive odor and is detectable at very low concentrations 0 02 ppm which is far below OSHA s maximum permissible exposure level of 0 1 ppm HIGH VOLTAGE WARNING CLEARWATER TECH OZONE GENERATORS OPERATE AT HIGH VOLTAGES DO NOT TAMPER WITH OR DELIBERATELY BYPASS THE DOOR OR SAFETY SWITCHES BUILT INTO THE OZONE GENERATOR UNLESS INSTRUCTED TO DO SO BY THIS MANUAL IF CONTACT IS MADE WITH OPERATING HIGH VOLTAGE COMPONENTS ELECTRIC SHOCK WILL OCCUR ClearWater Tech corona discharge ozone generators 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 interlocks proper care must be used by a qualified electrician when making any internal adjustments or performing any maintenance procedures Saf
45. that no ozone is being produced Drive module failure Dielectric failure 41 Touch the bottom of the coil replace if it is not warm Inspect and replace if necessary OZONE GENERATOR TROUBLESHOOTING continued PROBLEM SYMPTOM POSSIBLE CAUSE SOLUTION Unit seems noisy Not properly secured to wall floor Shipping damage Fan blocked Bolt it firmly into place Locate and repair e Check and clear obstructions Flow meter will not adjust Air preparation not operating Defective solenoid Defective check valve Internal regulator out of adjustment e Make sure air prep package is set properly e Check and repair use solenoid bypass kit described in manual e Check and replace e Check and adjust regulator Vacuum gauge reads on pressure side Insufficient vacuum Output solenoid defective Defective vacuum gauge Loose Kynar compression fittings AIR DRYER TROUBLESHOOTING PROBLEM SYMPTOM POSSIBLE CAUSE e Adjust injector vacuum e Check and replace or rebuild Replace vacuum gauge Tighten all Kynar fittings SOLUTION Air dryer not operating No power to air dryer e Switch not on Fuse blown Insufficient vacuum e Check power connections e Turn switch on Replace fuse Adjust injector vacuum Air dryer not producing dry air flow e Solenoid valve defective Replace solenoid valve Air dryer cold when
46. trical 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 Air Preparation 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 reduced as the dew polnt rises above 60 C Injector Manifold The ozone gas is injected into the filtered 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 maximize the effectiveness of ozone it must be thoroughly mixed and have adequate time to react with the contaminants in the water before being filtered 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 excessiv
47. y exposing oxygen molecules C in an air stream to a controlled high energy electrical field As the air stream passes through the electri cal field produced inside the ozone generator some oxygen molecules are split forming single oxygen atoms These oxygen atoms then recombine with other O molecules in the air stream forming ozone 03 Properties of Ozone Ozone is the most powerful oxidizer available that can be safely used in water treatment It is used to treat drink ing water bottled water swimming pool water wastewater food and beverage processing water and in many other applications Ozone 18 effective in performing the following water treatment functions e Oxidation of Inorganics Precipitates iron manganese sulfides nitrites and organically bound Odor Readily deseable at concentrations above 02 ppm in air heavy metals Bluish in ozone generator cell but ozone air mixture exiting generator is invisible even at high ozone concentrations e Oxidation of Organics Including organics Gas Density 2 144 grams liter at 32 approx 150 that of oxygen causing color taste and odor problems some detergents and pesticides phenols VOCs turbidity Solubility Only partially soluble in water but about 10 20 times more control and microflocculation of soluble organics E AA e Disinfection Bacterial disinfection inactivation of viruses and cysts Benefits of Ozone Use Ozone is

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