LIT515 CD1500 CD2000 Manual

Ozone Systems

Installation & Operation Manual

CD1500 • CD2000

Corona Discharge Ozone Generators

Tested and certified by

WQA to NSF/ANSI 50 as a

component only.

ClearWater Tech, LLC.

Integrated Ozone Systems

850-E Capitolio Way, San Luis Obispo, Ca 93401 • 805-549-9724 • Fax: 805-549-0306 • E-mail: [email protected] • www.cwtozone.com

-1-

INTRODUCTION

This Installation and Operation Manual is

written to assist in the installation, operation

and maintenance of ozone delivery systems

manufactured by ClearWater Tech, LLC.

This 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

installation, operation or maintenance

procedure associated with this equipment.

Failure to follow these instructions could

result in personal injury, damage to the

equipment or 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 ClearWater Tech ozone system

found in the field. If you have any questions,

please contact your ClearWater Tech dealer or the

ClearWater Tech service department.

-2-

TABLE OF CONTENTS

Overview ......................................................................................................................... 3

Safety Information ......................................................................................................... 4

Theory of Operation/Product Description.................................................................... 6

Figure 1 – Complete Ozone System............................................................................. 6

Installation Procedures – Getting Started .................................................................... 8

Installation Procedures – Plumbing .............................................................................. 9

Figure 2 – Sidestream Plumbing Installation Diagram ............................................. 11

Figure 3 – Full Flow Plumbing Installation Diagram ............................................... 11

Figure 4 – Contact Column Installation Diagram ..................................................... 12

Figure 5 – Contact Column Exploded View .............................................................. 12

Installation Procedures – Electrical ............................................................................ 13

Figure 6 – External Loop Electrical Interface........................................................... 14

Installation Procedures – Pneumatic .......................................................................... 15

Figure 7 – Typical Pneumatic Hookup ...................................................................... 15

Figure 8 – Typical Oxygen Concentrator Detail ....................................................... 16

Figure 9 – Vacuum Break Detail............................................................................... 17

Start-Up and Calibration............................................................................................. 18

Figure 10 – Pneumatic Operation Parameters.......................................................... 20

Maintenance ................................................................................................................. 21

Figure 11 – CD15nx and CD30nx High Output Drive Module.................................. 23

Figure 12 – Ozone Generator Cooling Fan Assembly ............................................... 23

Figure 13 – 2” Reaction Chamber – Exploded View ................................................. 26

Troubleshooting ........................................................................................................... 27

Appendix A – Specifications ........................................................................................ 31

Appendix B – Parts List............................................................................................... 34

Appendix C – Maintenance Kit ................................................................................... 35

Appendix D – Logic Schematics .................................................................................. 36

Appendix E – Drive Module Input Voltages............................................................... 38

Appendix F – Warranty Information.......................................................................... 39

-3-

Electrical

Field

Oxygen (O

)

Ozone (O

)

OVERVIEW

How Ozone In Generated

Ozone is generated by exposing oxygen molecules (O

)

in an air stream to a controlled, high energy electrical

field. As the air stream passes through the electrical

field produced inside the ozone generator, some oxygen

molecules are split, forming single oxygen atoms (O

These oxygen atoms then recombine with other oxygen

molecules in the air stream, forming ozone (O

)

Properties of Ozone

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

. It is used to treat

drinking water, bottled water, swimming pool water, waste water, food and beverage processing water, and in

many other applications. Ozone is effective in performing the following:

• Disinfection – Bacterial disinfection,

inactivation of viruses and cysts.

• Oxidation of Inorganics – Precipitates, iron,

manganese, sulfides nitrides and organically-

bound heavy metals

• Oxidation of Organics – Including organics

causing color, taste, and odor problems. Some

detergents and pesticides, phenols, VOCs,

turbidity control and micro-floccuity control and

micro-flocculation of soluble organics.

Benefits 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 without 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.

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

Molecular Weight

Odor

Readily detectable at concentrations

above 0.02 ppm in air

Color

Bluish in ozone generator cell, but

ozone/air mixture exiting generator is

invisible – even at high ozone

concentrations.

Gas Density:

2.144 grams/liter at 32°F

(Approximately 150% that of oxygen).

Solubility

Only partially soluble in water, but

about 10-20 times more soluble than

oxygen (at 68°F).

-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 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

is designed to produce highly concentrated ozone.

While safety precautions have been taken, entering the

equipment area should be avoided if ozone gas is

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 VOLTAGE. DO NOT TAMPER WITH

OR DELIBERATELY BYPASS THE COVER 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. Proper care must be used by a qualified electrician when making any internal

adjustments or performing any maintenance procedures.

Safety Information

-5-

IMPORTANT SAFETY INSTRUCTIONS

When installing and using this electrical equipment, basic safety precautions should always be followed,

including the following:

1. READ AND FOLLOW ALL INSTRUCTIONS.

2. SAVE THESE INSTRUCTIONS.

3. All electrical connections should be made by a licensed, qualified electrician.

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

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

6. Install check valves and a vacuum break to prevent water from contacting the electrical equipment.

7. 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.

8. 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 to all local, state and national electrical

codes.

9. 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; failure to do so

may void the warranty.

-6-

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 may be part of a larger integrated ozone system. Such a system may

include the following components required for reliable, efficient ozone production and can be divided into four

general segments:

Complete Ozone System

Figure 1

Air preparation system Ozone generator Ozone injection/contacting Ozone destruct

SHOWN: CLEARWATER TECH CD2000 OZONE SYSTEM

Air Preparation System

ClearWater Tech ozone generators require a source of clean, dry, oil-free, oxygen-enriched air for effective ozone

production. To meet that need, ClearWater Tech employs pressure swing adsorption (PSA) technology with an

oil-less compressor to increase the concentration of oxygen and reduce the moisture 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 -60°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. In addition to oil and

water coalescent filters, a pounds per square inch (PSI) regulator must be installed when using plant air feed gas.

This regulator must be set to a maximum of 10 PSI.

Ozone Generator

ClearWater Tech ozone generators are designed to supply high concentrations of ozone gas. The oxygen feed gas

produced by the air preparation system is supplied to the ozone generator. The vacuum created a the ozone

injector draws the ozone gas created by the ozone generator into the water line.

As the feed gas enters the fused, 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

Booster Pump

Ozone Injector

Water Flow

Air Preparation

System

Ozone Generator

Vacuum

Break

Contact Vessel

Ball

Valve

Water

Trap

Ozone

Destruct

Unit

Off Gas

Vent

OPTIONAL DESTRUCT SYSTEM

-7-

oxygen atoms (O

). These oxygen atoms then recombine with other oxygen molecules in the air stream, forming

ozone. The modular, multiple reaction chamber design in the CD2000 allows the ozone generator to keep working

even if one of the chambers requires service.

Depending on the application, the ClearWater Tech ozone generator may be interlocked with an ORP controller,

PPM controller, pressure switch, timer or circulation pump. Other safety features are also built in, including

thermal protection.

Ozone Injection/Contacting

The ozone injector serves two purposes: One, it creates

the vacuum required to safely draw the ozone gas from

the ozone generator and two, it provides a means by

which the ozone gas can become dissolved in water. A

very dynamic injection process is required to

effectively dissolve ozone in water.

ClearWater Tech injection systems use only Mazzei®

injectors for maximum mass transfer efficiency. The

injector produces a cavitation effect, enabling the ozone

gas to join the water stream in the form of extremely

tiny bubbles. Lots of tiny bubbles increase the surface

area of the ozone thus increases the amount of area

available to ozonate the surrounding 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 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 system 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

is impractical to send the off-gas to atmosphere or reintroduce it to the water.

A Short Course in Fine Bubbles

Lesson 1 – The large bubble (20mm) has a

volume of 4.19 cm3 and a surface area of

12.6 cm2.

Lesson 2 – 296small bubbles (3mm) could be

made from the large bubble in lesson 1. They

would have a total surface area of 83.6cm2. This

is 6.6 times the surface a CD1500 • CD2000rea

of the large bubble.

Lesson 3 – Theoretically, 6.6 times as much

water could be ozonated with the same

amount of ozone!

-8-

Installation Procedures – 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

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.

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 configuration (see Figure 2) 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 configuration (see Figure 3) 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-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.

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, tabs, and/or mounting bar provided. Make sure suitable wall anchors are used to

support the weight of the system.

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:

• Ambient temperature range: 20°F (-6.5°C) to 95°F (35°C) continuous. If the temperature around the

equipment consistently exceeds 95°F (35°C), 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.).

-9-

Installation Procedures – Plumbing

The ozone system should be plumbed using either a sidestream or full flow

configuration. The sidestream loop method takes a portion of the water from the main

flow (see Figure 2) and diverts it into a sidestream downstream of the filter (if so

equipped). Ozone is introduced into the sidestream water and is allowed contact time

with the water before it is returned to the main flow at a point downstream of all other

equipment (heaters, solar panels, etc., if so equipped) in the circulation system. A

booster pump is usually employed to compensate for the flow restriction caused by the sidestream loop and the

injector manifold. If a halogen-type residual sanitizer is utilized, its injection point should be as far downstream as

possible from the point at which the sidestream water returns to the main flow. In a full flow configuration, the

same system components are usually involved and appear in the same order with respect to the direction of flow.

However, all the water in the main flow is allowed contact time with the ozone (see Figure 3). A booster pump

may be necessary to maintain proper flow requirements. If employed, the booster pump is located upstream of the

point at which the ozone injector manifold is installed.

NOTES:

• Adequate use of unions and isolation valves is

strongly recommended to facilitate

maintenance and repairs.

• Use Schedule 80 PVC for all plumbing

connections wherever possible. Plumbing size

requirements are dictated by the water flow

characteristics of the system.

• Make sure to use proper plumbing practices

and secure all plumbing and system equipment

according to local codes.

• Ozone is a powerful oxidizer and will degrade

certain materials. Use ozone-compatible

plumbing materials for section(s) of the system

that will come in contact with ozone dissolved

in water. The following is a list of materials that

are compatible with ozone:

• PVC • Stainless Steel (300 series)

• CPVC • Viton

• Kynar • EPDM

• Teflon • Concrete

• Depending on the application, other

components (psi gauge, flow meter, etc.) may be

installed to assist in monitoring system

parameters.

Step 1: Arrange the ozone system equipment (booster pump, injector and contact vessel) according to mechanical

print or as dictated by equipment layout and serviceability considerations. Do not secure booster pump

and contact vessel to housekeeping pads at this point. Dry fit plumbing as appropriate to insure proper fit

and location before making permanent connections.

Step 2: Install a tee or plumbing saddle into the main water line after the filter (if so equipped) and before the

flow diversion mechanism. The purpose of the mechanism is to restrict water flow so water is diverted

into the sidestream (see Figure 2). If such a mechanism is not present in the system (such as a heater

bypass valve, etc.), it will require installation of a valve (butterfly, gate or ball) or a flow controller.

Step 3: Plumb a line from the tee or plumbing saddle to the booster pump. For serviceability of the equipment in

the sidestream loop, be sure to install an isolation valve between the tee or saddle and the booster pump.

Step 4: Plumb from the booster pump to the injector manifold. Make sure to note the correct direction of flow,

indicated by a blue arrow on the inlet side of the manifold body. The check valve assembly is strapped to

the manifold using wire ties. Remove the assembly; using Teflon® tape, install it onto the top opening of

the injector.

Installation Procedures - Plumbing

-10-

Step 5: Plumb from the injector manifold to the inlet side of the contact vessel. To reduce possible backpressure

to the injector, minimize the number of elbows between the injector manifold and contact vessel. The

contact vessel is a specified size, determined by water flow requirements. ClearWater Tech contact

columns and the 30, 40, 80, and 120-gallon contact tanks have inlet and outlet fittings on the bottom of

the vessel and are designated with arrows showing the direction of flow. Note: The inlet and outlet

arrows on the contact tanks are under the base of the tank. The inlet on the 264, 463 and 850-gallon

tanks is located at the top with the outlet at the bottom.

Step 6: Using a tee or plumbing saddle, plumb from the outlet of the contact vessel back into the main water line.

For serviceability of the equipment in the side stream loop, be sure to install an isolation valve between

the outlet fitting on the contact vessel and before returning to the main water line.

Step 7: Secure the booster pump and contact vessel to solid mounting surfaces using appropriate hardware and

according to local codes. If installing a ClearWater Tech contact column, use a ClearWater Tech contact

column mounting kit and install according to the instructions below. If installing a contact tank, secure to

a solid horizontal surface using mounting flange or feet.

Step 8: Install the contact vessel venting system into the top of the vessel. If using the ClearWater Tech contact

column, the vent kit supplied includes fittings, a control valve and Teflon® tubing. The contact tank

venting system includes an air relief valve, fittings and a length of Teflon® tubing. Depending on

conditions, the vented gas may be directed to an ozone destruct system, to atmosphere or to the low-

pressure side of the water system. Note: Do not direct the tubing to the suction side of any pump in

the system.

Contact Column Installation (If so equipped)

Step 1: Make sure the following hardware items are included in the contact column mounting kit:

• 'L' bracket • Unistrut bar

• 1/2” concrete anchors • Protective end cap

• 6” clamp assemply • Mounting hardware

Step 2: Referring to Figure 4, mark the two holes for mounting the 'L' bracket to the wall. The bracket should be

located so that the 6” clamp assembly will be approximately 12” from the top of the contact column. Drill

a 1/2” hole at each of the marks, about 3 1/2” deep. Insert a concrete anchor into each hole with the

threaded end facing outward. Slip the 'L' bracket over the threaded ends of the anchors, followed by a

washer for each anchor. Secure the bracket to the wall by threading a nut onto each anchor and tightening.

Step 3: Cut the unistrut bar to the desired length and attach it to the 'L' bracket using hardware provided.

Step 4: Slip the two sides of the 6” clamp into the unistrut bar and then around the contact column. Tighten the

retaining bolt, securing the contact column to the unistrut bar.

Step 5: Slip the protective end cap over the exposed end of the unistrut bar.

Installation Procedures - Plumbing

-11-

Sidestream Plumbing Installation Diagram

Figure 2

Full Flow Plumbing Installation Diagram

Figure 3

Flow Diversion

Mechanism

Filter

Isolation

Valve

Booster

Pump

Ozone Injector

Bypass Valve

Contact

Vessel

Isolation

Valve

Booster

Pump

Isolation

Valve

Service Loop

Isolation

Valve

Isolation

Valve

Ozone Injector

Bypass

Valve

Contact

Vessel

Installation Procedures - Plumbing

-12-

6” Clamp Assembly

with bolt & nut

Unistrut

(cut to length)

Unistrut

Protective

End Cap

Bolts, nuts &

washers (2 ea)

“L” Bracket

Concrete Anchors

with nuts &

washers (2 ea)

Column

Flange

Flange Bolts &

Washers (8 ea)

Diffuser

Riser Tube

Gasket

Flange Nuts &

Washers (8 ea)

Base Flange

Base

Contact Column Installation Diagram

Figure 4

Contact Column Exploded View

Figure 5

-13-

Installation Procedures – Electrical

The CD1500 and CD2000 ozone generators are equipped with universal regulated power

supplies that accept an input voltage from 90-250VAC at 47-63Hz, single phase (1ø).

ClearWater Tech has an assortment of IEC cords for various voltage requirements and outlet

configurations, for use around the world. All possible pre-wiring has been completed at the

factory. Logic schematics have been provided in the Appendix D.

Notes:

• All electrical connections should be made by a

licensed, qualified electrician. All local, state

and national codes must be observed.

• Make sure all power is off at the main circuit

breaker before making any electrical

connections

Step 1: Conforming to all local, state and national electrical codes, ground the ozone generator to a true earth

ground. Use solid copper bonding wire (usually #8 AWG) from the copper-bonding lug located on the

bottom of the ozone generator to the grounding point.

Step 2: Main Power: Plug the IEC end of the power

cord into the power entry module located at the

bottom of the ozone generator. The other end

can be plugged into any main power source

with input voltage from 90 to 250 VAC at 47 to

63 Hz, single phase. The power consumption of

the unit is shown in the chart on the right.

Step 3: External Loop: The external loop is a true dry contact interface. Note: The term ‘dry contact’ means

that this loop does not supply output nor accept input voltages. Warning: Supplying voltage to the

external loop will cause damage to the ozone generator and void warranty.

Under normal operation, when this loop has lost continuity the ozone production will stop and the ozone

output will drop to 0%.

Note: When the external loop has lost continuity, main power to the ozone generator will remain

“ON” giving power to the cooling fan(s).

When continuity is present through the external loop the ozone production will continue at whatever

percentage set by the manual ozone output control or the 4-20mA signal.

The external loop, a removable two-position plug with a white 18AWG wire located at the bottom panel

of the ozone generator (see Appendix A), can be interfaced to any control device, i.e., pressure switch,

vacuum switch, flow switch, float switch, ORP controller, PPM controller, or timer. To interface a control

device to the external loop, cut the white 18AWG wire in half. Connect the control device to each leg of

the external loop. If the control device used supplies an output voltage a single pole single throw (SPST)

normally-open relay may be used to create a dry contact interface, see Figure 6 below. Note: Attached to

the white 18 AWG external loop is a warning, “THIS CONNECTION IS A DRY CONTACT

ONLY, DO NOT APPLY VOLTAGE”.

Step 4: Manual Ozone Output Control: Turning the control knob counterclockwise will decrease the ozone

output down to 0% while turning the knob clockwise will increase the ozone output up to 100%. The

ozone output level is indicated by the “Ozone Output” LED(s) on the front cover of the ozone generator

(see Appendix, Section A).

Power Consumption

Input Voltage

90-250VAC 47-63Hz

CD1500

1.6-0.8 Amps

CD2000

2.8-1.4 Amps

Installation Procedures - Electrical

-14-

Step 5: Remote 4-20mA Control: A 4-20mA control signal to the ozone generator may be used to control the

ozone generator output. The ozone generator will automatically sense the 4-20mA input signal and

override the setting of the manual ozone output control. Based on the 4-20mA signal, ozone output will

increase or decrease: 4mA = 0% ozone output, 20mA = 100% ozone output. The ozone output level is

indicated by the “Ozone Output” LED(s) on the front cover of the ozone generator (see Appendix,

Section A). Note: If the remote 4-20mA signal fails or is missing, the system will default to the

manual ozone output setting. Check and adjust the manual ozone output control knob to avoid

over-ozonation.

Remote 4-20mA Control Setup:

Step 1: Mount the 4-20mA controller to a suitable vertical surface according to the installation manual

supplied with the controller.

Step 2: Wire the #22 AWG orange ‘positive’ (+) lead from the ozone generator to the 4-20mA controller

according to the manual supplied with the controller.

Step 3: Wire the #22 AWG purple ‘negative’ (-) lead from the ozone generator to the 4-20mA controller

according to the manual supplied with the controller.

Step 4: Complete the required programming and calibration steps as outlined in the installation manual

supplied with the 4-20mA controller.

Step 6: Air Preparation System Power: 120VAC systems only: plug the power cord into main power. 240VAC

systems only: the power cord must be hard wired to the main power source (Black-L1, White-L2/N and

Green-Ground). Notes: Be careful to not exceed the rated flow of the air preparation system. Doing

so will over draw the system and could lead to premature failure. Vacuum from the venturi must be

interrupted if the air prep system is not “ON;” failure to do so will damage the air prep system.

External Loop Electrical Interface

Figure 6

120 VAC Signal

Power from

OPR, PPM,

pump or timer

120V

Coil

Interface

Relay

External

Loop

240/220 VAC Signal

N/L2

Power from

OPR, PPM,

pump or

timer

240V

Coil

Interface

Relay

External

Loop

-15-

Booster Pump

Ozone Injector

Water Flow

Ozone Generator

Vacuum

Break

Air Prep In

Ozone Out

Air Prep

System

Installation Procedures – Pneumatic

This section outlines the steps required to complete the ozone system pneumatic hook-ups. The system

components include the air preparation system, ozone generator, vacuum break, and ozone injector manifold (see

Figure 7). The air preparation system provides the ozone generator with a source of dry, oil-free oxygen-enriched

air (90% +/- 3% oxygen purity at -60˚F dew point). The air is drawn from the ozone generator (where ozone is

produced from the oxygen in the air stream) and through the vacuum break by the suction created at the ozone

injector manifold.

Typical Pneumatic Hookup

Figure 7

Hook-Up: Air preparation system-to-ozone generator

Step 1: Setup the air preparation following the instructions provided with the air preparation system. Make sure

the air preparation system you select can deliver that amount of air flow required without over drawing

the sieve beds. Warning: Make sure to read and follow the operating instructions of the air

preparation system as damage could occur to the air preparation system if the flow rate is too high.

Step 2: Teflon® tape and attach brass barb provided to the PSA oxygen concentrator outlet (if so required). A

typical oxygen concentrator system is shown below in Figure 8 as a reference.

Step 3: Using a suitable length of 3/8” braided tubing provided, attach one end of the tubing to the oxygen

concentrator system to one end of the indicator cartridge. Secure the tubing to the brass fittings with the

hose clamps provided.

Step 4: Using a suitable length of 3/8” braided tubing, attach tubing to the barb located on the oxygen

concentrator, then attach the other end of the tubing to the brass barb located at the bottom of the ozone

generator. Secure the tubing to the fittings with the hose clamps provided.

Installation Procedures - Pneumatic

-16-

Compressor Inlet Filter

Sieve Bed

Hour Meter

SCFH Air Flow Meter

Oxygen Outlet

Main Power Cord

Compressor

Typical Oxygen Concentrator Detail

Figure 8

Hook-Ups: Ozone generator-to-vacuum break & vacuum break-to-injector manifold

The ClearWater Tech vacuum break provides a positive atmospheric “break” between the ozone injector manifold

and the ozone generator, preventing water from flowing back into the ozone generator should the venturi check

valve fail. Under normal operating conditions, the vacuum break's flapper valve (see Figure 9) is closed, allowing

the vacuum created by the venturi to draw the output gas from the ozone generator. If the check valve at the

venturi begins to leak or fails completely, vacuum is interrupted and water will flow toward the ozone generator.

With the vacuum break properly installed between the venturi and the ozone generator, the water will flow down

the riser tube (away from the ozone generator) and out to drain, protecting the ozone generator from potential

water damage.

Step 1: Select a suitable vertical surface that is accessible and in close proximity to both the ozone generator and

the ozone injector manifold.

Step 2: Install the two Clic® mounting clamps provided onto the vertical surface so that the vacuum break is in a

vertical position and the drain holes are below the level of the ozone generators ozone outlet fitting. One

clamp should be located so it fits around the Riser Tube Elbow, and the other so it fits around the bottom

of the Lower Tee (see Figure 9).

Step 3: Remove the Fill Port Cap located on top of the Riser Tube and fill the Riser Tube with clean water (no

particulate matter) until "Fill Level" line indicated in Figure 9.

Step 4: Re-install the Fill Port Cap, using pliers or a wrench to tighten. Note: Do not over tighten as damage to

PVC fittings may occur.

Step 6: Connect one end of a suitable length of Teflon® ozone delivery line to the ozone generator’s ozone outlet

fitting (see Appendix, Section A). Attach the other end of the Teflon® delivery line to the fitting

threaded into the Upper Tee. As an additional backflow prevention measure, loop this length of tubing as

high as is practical between the two connection points.

Step 7: Connect one end of a second length of Teflon® delivery line to the fitting threaded into the Lower Tee.

The other end of the delivery line will be attached to the fitting located on top of the check valve

assembly.

Step 8: Adjustments to the valve on the ozone injector manifold will be necessary. These steps are covered in the

Start-up and Calibration Procedures.

Installation Procedures - Pneumatic

-17-

Vacuum Break Detail

Figure 9

Ozone Flow

Riser Tube

Drain Barb

Overflow Tube

Fill Level

Flapper Check Valve

Ozone

Outlet

Check Valve Assembly

Ozone Injection Manifold

Ozone Generator

Fill Port Cap

Upper Tee

Low Tee

Mounting Clamps

Riser Elbow

-18-

Start-Up and Calibration

The previous sections of this manual have involved comparatively static procedures – making electrical and

pneumatic connections, fitting pipe, etc. This section involves the dynamic process of starting up and balancing

the components of the ozone system, including initiating water flow, making air and water flow adjustments, etc.

Maximum performance and reliability is achieved when the prescribed air flow is maintained at the ozone

generator. Air from the air preparation system is flowing through the ozone generator under a slight vacuum

(created by the ozone injector manifold).

Air Preparation System, Ozone Generator & Ozone Injector

Warning: Disconnect the External Loop dry contact from the ozone generator while performing all start-up

procedures. Failure to do so may result in ozone escaping to atmosphere.

Step 1: Make sure all isolation valves in the ozone water system are open (Figures 2 or 3 show recommended

isolation valve locations).

Step 2: Start-up hydraulics. Allow the water system to reach hydraulic equilibrium (contact vessel full, off-gas

vent operating, etc.) and observe for plumbing leaks. Note: Water flow must be established through

the main water pump and the ozone system booster pump (if so equipped).

Step 3: Close the ball valve on the injector manifold about half way.

Step 4: Using your thumb, check for the presence of vacuum (suction) at

the ozone injection manifold check valve assembly or use a

ClearWater Tech vacuum test assembly to check vacuum at the

injector port. If no suction is present, continue to close the ball

valve on the injector manifold until vacuum is detected. If using the

vacuum test assembly, check the VAC/PSI gauge for vacuum. If

the needle is in the red zone on the pressure (PSI) side of the gauge,

gradually close the ball valve on the injector manifold until the

needle moves into the green zone. If the needle is in the red zone

on the vacuum (in.Hg) side of the gauge, gradually open the ball valve on the injector manifold until the

needle moves into the green zone. While vacuum is in the green zone you must be able to achieve proper

SCFH (Standard Cubic Feet per Hour) of air flow (see the “Pneumatic Operating Parameters” chart for

venturi SCFH required, Figure 10).

Step 5: Make sure electrical power is on to all ozone system electrical components. The main power switch of

the air preparation system must be in the “ON” position (if so equipped, see Figure 8). Setup the air

preparation following the instructions provided with the air preparation system. Make sure the air

preparation system you select can deliver that amount of air flow required without over drawing the

sieve beds. Warning: Make sure to read and follow the operating instructions of the air

preparation system as damage could occur to the air preparation system if the flow rate is too

high.

Step 6: Connect the Teflon® ozone delivery line from the vacuum break to the ozone inlet fitting located at the

ozone injection manifold check valve assembly.

Start-Up and Calibration

-19-

Step 7: Observe the air flow through the system using the flow meter on the front of the air preparation system

(See Figure 8). Using the needle valve on that flow meter make sure the flow is in a range that will not

over draw the sieve beds. Warning: Make sure to read and follow the operating instructions of the

air preparation system as damage could occur to the air preparation system if the flow rate is too

high.

Step 8: Perform a final check of all air connections from the air preparation system to the ozone injector

manifold. Repair leaks as required. Check all system water connections, including the ozone injector

manifold, vacuum break and contact vessel. Repair leaks as required. Note: The check valve at the

ozone injector manifold may make a humming noise. This is normal.

Step 10: Reconnect the External Loop connector to the ozone generator.

Step 11: See “Installation Procedures – Electrical” for instruction on how to adjust ozone output.

Ozone System Power Up

When the ozone system is powered up with the external loop connected to the ozone generator, the manual ozone

control allowing ozone production, the unit will begin generating ozone. The drive board’s Self-Resonating

Technology (SRT) will begin by characterizing the drive system at the temperature, pressures, and flows the

reaction chamber is currently experiencing. You will hear and audible sweep of the drive frequency from high to

low as the drive board maps the resonant point of the system. For best results bring the pressure and flow through

the system up to normal operation before powering up the ozone generator.

Vacuum Break

Check the water level in the vacuum break, making sure it is above the flapper valve (see Figure 9). If water is not

pressing downward on the flapper valve it will open, causing a loss of vacuum. A loss of vacuum means ozone

cannot flow from the vacuum break, which in turn can cause an ozone leak. Note: If the vacuum break must be

refilled with water disconnect the External Loop from the ozone generator and disconnect the Teflon®

ozone delivery line from the ozone inlet fitting of the vacuum break. Once the vacuum break is filled,

reconnect the ozone delivery line first, then reconnect the External Loop.

Ozone Destruct System

Adjust the small ball valve at the tee of the water trap (see Figure 1) so that only a small amount of water is

“spitting” into the trap. This will indicate that the contact vessel is full and only a very small amount of water is

allowed to escape.

Start-Up and Calibration

-20-

Pneumatic Operating Parameters

Figure 10

CD1500

Operating Range

Optimum

Air prep system air flow

Ozone generator total air flow (Air prep gauge)

Injector manifold air flow

Injector manifold injector

5 to 6 scfh

6 to 7.2 cfh

5 to 6 scfh

-3 to -8 in. hg.

6 scfh

7.2 cfh

6 scfh

-5 inches

CD2000

Operating Range

Optimum

Air prep system air flow

Ozone generator total air flow (Air prep gauge)

Injector manifold air flow

Injector manifold injector

10 to 12 scfh

12 to 14.4 cfh

10 to 12 scfh

-3 to -8 in. hg.

12 scfh

14.4 cfh

12 scfh

-5 inches

-21-

Maintenance

Maintenance of the ozone system is critical to its longevity and operating efficiency. While all

system components are built to provide years of reliable service with minimum maintenance,

following the procedures outlined below is strongly recommended.

All maintenance procedures have been segmented by interval: daily, monthly, semi-annual

and annual. Daily procedures involve quick, visual checks for changes in normal operating

conditions. Monthly, semi-annual and annual procedures include cleaning and/or replacement of certain critical

parts.

NOTES:

• The ozone generator warranty states that it

“does not extend to any product or part

which has been damaged or rendered

defective as a result of use of parts not sold by

ClearWater Tech, or service or unit

modification not authorized by ClearWater

Tech” Please contact your ClearWater Tech

dealer if you have any questions about any

maintenance procedure before you begin that

procedure.

• CAUTION: Observe all common safety

practices and review the “Safety Warnings and

Instructions” section before attempting any

maintenance procedure that requires the use of

tools and/or shutting down the ozone system.

Daily Procedures

Air Preparation System

• Power Switch: Check the power switch on the air preparation system (see Figure 8), if so equipped.

• Indicator Cartridge: Inspect the air preparation system indicator cartridge. A change in the blue crystals to a

light pink or white color indicates the presence of moisture in the feed gas coming from the air preparation

system. If such a change is observed, refer to the Troubleshooting Guide.

• Air Flow: Check the air flow gauge on the air preparation system (see Figure 8). Make sure the air flow is

within the acceptable SCFH range for the unit. See the Pneumatic Operating Parameters in Figure 10.

Warning: Make sure to read and follow the operating instructions of the air preparation system as

damage could occur to the air preparation system if the flow rate is too high.

Ozone Generator

• Check the ozone level to make sure it remains at the correct set point

• Air Flow: Check the air flow gauge located on the front control panel. Compare the CFH flow on the flow

gauge to the Pneumatic Operating Parameter in Figure 10 to insure the proper output is being achieved.

Warning: Make sure to read and follow the operating instructions of the air preparation system as

damage could occur to the air preparation system if the flow rate is too high

• Vacuum: Check the vacuum level in the system. Adjust if necessary by following steps outlined in the “Start-

Up & Calibration” section.

Vacuum Break

• Water Level: Check the water level in the vacuum break. Make sure it is above the flapper valve in the

overflow tube. Fill as required by removing the threaded fitting on top of the riser tube until water is up to the

‘Fill Level’ in the overflow tube (see Figure 9).

Maintenance

-22-

Injection Manifold

• Check Valve: Inspect the Teflon® ozone delivery line that runs between the vacuum break and the check

valve assembly on the suction port of the ozone injector manifold. If water is observed in the delivery line

near the check valve assembly, the check valve has failed. See Troubleshooting Guide.

Monthly Procedures

Air Preparation System

• Cooling Fan Operation: Check to make sure the cooling fan mounted on the side panel of the air preparation

system is operating (if so equipped). If not, refer to the Troubleshooting Guide.

• Cover Filter: Check the cover filter element mounted on the side of the air preparation system and clean as

required. Operating conditions in the equipment area will dictate the frequency required for this procedure.

Remove the filter element and clean with soap and water, drying them completely before re-installing.

Ozone Generator

• Drive Module Operation: The Drive Module is made up of two components: the drive board and the drive

transformer. Check for illumination of the drive module "Ozone Output" LED(s) (for LED locations, see

Figure 11); if not illuminated see Troubleshooting Guide. This procedure is to observe the complete operating

function of the drive module(s). Remove the cover and override the safety switch. CAUTION: Do not touch

anything inside the ozone generator while the system is energized and the cover removed! Please consult

your ClearWater Tech dealer before attempting this procedure.

 Main Power LED: When illuminated, this “Green” LED indicates that main power is supplied to the drive

module up to the “on board” fuse of the drive board.

 Transformer Power LED: When illuminated, this “Green” LED indicates that 48V Buss power is

available to the drive module transformer (XFMR) from the “on board” fuse of the to the drive

transformer.

 Ozone Output LED: The “Amber” ozone output LED will illuminate when ozone drive is being

generated. The LED will also pulse as the output increases or decreases with either the Manual Ozone

Output Control located on the bottom of the ozone generator (see Appendix A), or from a Remote 4-

20mA signal (see “Installation Procedures – Electrical”).

 Fault LED: When illuminated, this “Red” LED indicates that there is a fault with the drive module or the

Ozone Reaction Chamber. If this LED is illuminated, refer to the Troubleshooting Guide. Notes: If the

drive module goes to a fault condition, the drive board will restart every 15 seconds. If the fault is

not remedied the drive module will continue to go into a fault mode. When the drive module is in

fault mode ozone will not be generated.

Before proceeding further replace the ozone generator cover.

• Cooling Fan Operation: Check to make sure the two cooling fans (mounted on the bottom panel of the ozone

generator cabinet) are operating. If not, refer to the Troubleshooting Guide.

• Cooling Fan Filters: Check the cooling fan filter elements mounted on the bottom of the ozone generator (see

Appendix A) and clean as required. Operating conditions in the equipment area will dictate the frequency

required for this procedure. Remove the filter element and clean with soap and water, drying them completely

before re-installing (see Figure 12).

Booster Pump(s)

• Strainer Baskets: Check and clean the strainer basket in the booster pump(s) as required (if so equipped)

Maintenance

-23-

CD1500 and CD2000 High Output Drive Module

Figure 11

Ozone Generator Cooling Fan Assembly

Figure 12

Drive Board

Transformer Output Connector

Ozone Output LED

In/Out Signal Header

Fuse

Transformer – XFMR LED

Drive Board Main Power LED

Fault LED

24VDC Output Connector

Variable Input Connector

DC Power Input Connector

Fan

Ozone Generator Bottom Panel

Finger Guard

Fan Filter Element

Fan Filter Grill

Maintenance

-24-

System Shutdown Procedures

CAUTION: The ozone generator operates at high voltage. Follow these steps carefully before performing

any semi-annual or annual maintenance procedures.

Step 1: Turn off power to any peripheral system hydraulic components and air prep system.

Step 2: Turn the Main Power switch on the ozone generator to the “OFF” position.

Step 3: Disconnect the power to the ozone system either at the service disconnect box (if so equipped) or main

circuit breaker.

Semi-Annual Procedures

CAUTION: Follow system shutdown procedures (outlined above) before performing any of the following

steps.

Air Preparation System

• Air Inlet Filter: Replace the air compressor inlet filter on the air preparation system module (see Figure 8).

Note: Manufacturers' recommended replacement interval is 4,000 hours of operation. Operating

conditions in the equipment area will dictate the required frequency of this procedure.

Annual Procedures

CAUTION: Follow system shutdown procedures before performing any of the following steps.

Air Preparation System

• Compressors: Following the procedures outlined in the compressor rebuild kit, rebuild the two compressor

heads on each air preparation system module (see Figure 8). Note: Manufacturers' recommended interval

is 5,000 to 12,000 hours of operation. Compressor performance and/or operating conditions in the

equipment area will dictate the required frequency of this procedure.

Ozone Generators

• Cooling Fan Filters: Clean or replace the cooling fan filter elements as required.

• Inline Filter: Replace the inline particulate filter.

• Reaction Chambers: Remove and disassemble the reaction chamber(s) according to the steps outlined below

(see Figure 13). Check the chamber interior and dielectric tube for oil, dirt or moisture.

Reaction Chamber Removal and Disassembly

Note: Disassembly and service of the reaction chamber is a technical, delicate and critical procedure.

Please consult your ClearWater Tech dealer before attempting this procedure.

Step 1: Make sure all power to the ozone generator has been disconnected according to the “System Shutdown

Procedures” outlined above.

Step 2: Unplug the electrical connections from the drive module.

Step 3: Disconnect tubing connections from the fittings on both ends of the reaction chamber

Step 4: Remove the 4 nuts holding the reaction chamber to the chassis.

Step 5: Remove the reaction chamber from the ozone generator.

Step 6: Disconnect the high voltage lead from the drive module.

Step 7: Remove retaining screws from the two end caps (4 each).

Step 8: Using a gentle back-and-forth twisting motion, remove the non-high voltage end cap (the one without

the white power lead attached) from the heat sink/cathode assembly.

Maintenance

-25-

Step 9: Remove the high voltage end cap and dielectric from the heat sink/cathode assembly.

Step 10: With contact brush attached, remove the brush adapter nut from the high voltage end cap.

Step 11: Inspect the dielectric, end caps and cathode for breakage, corrosion or debris. Clean and/or replace parts

as necessary. If cleaning and/or parts replacement is not required, re-assemble the reaction chamber per

the instructions below.

Assembly and Re-installation

Step 1: Make sure the glass dielectric is clean (free of dust, dirt, grease, oils, etc.).

Step 2: Prepare the end caps for re-assembly by replacing the O-rings. Thread the hex brush adapter nut, with

contact brush attached, onto the end of the high voltage end cap (cap with the white power lead attached)

center screw.

Step 3: Using a gentle twisting motion, press the non-high voltage end cap onto the heat sink/cathode assembly

until flush with the heat sink cooling fins. Note: See Figure 13 for correct orientation of end cap.

Step 4: Slide the four end cap retaining screws through the holes in the non-high voltage end cap, aligning them

with the heat sink screw bosses. Thread screws into screw bosses until heads are snug against the end

cap.

Step 5: Roll the high voltage anode (foil-like material) lengthwise, preserving the longer dimension. Insert the

rolled anode into the dielectric. Center the anode in the dielectric (approximately 1/2” from either end of

the glass), making sure it is rolled squarely.

Step 6: Slide the dielectric into the heat sink/cathode assembly. Seat the dielectric into the O-rings of the non-

high voltage end cap by applying pressure with a gentle twisting motion. (There must not be any dirt,

debris, oils or fingerprints on the dielectric upon re-installation).

Step 7: Slowly insert the high voltage end cap assembly into the dielectric. Note: Do not bend center wire of

the brush during this procedure. It is normal for the bristles to bend. Using a gentle twisting motion,

press the high voltage end cap onto the heat sink/cathode assembly until flush with the heat sink cooling

fins.

Step 8: Slide the four end cap retaining screws through the holes in the end cap, aligning them with the heat sink

screw bosses. Thread screws into screw bosses until heads are snug against the end cap.

Step 9: Re-install complete reaction chamber assembly into the ozone generator by following the “Removal and

Disassembly” instructions in reverse order, from Step 6 to Step 2. Follow steps outlined in the “Start-Up

and Calibration” section to re-start the ozone system.

Maintenance

-26-

2” Reaction Chamber – Exploded View

Figure 13

Vacuum Break

• Cleaning: Disconnect ozone delivery lines. Remove the vacuum break from mounting clamps. Disconnect the

overflow tube from flapper valve, open flapper and clean the seat with a soft cloth. Remove riser tube

threaded fitting and flush riser tube with water. Re-assemble and re-install vacuum break, making sure to add

water to correct level (see Figure 9).

Injector Manifold

• Check Valve: Replace the check valve located at the ozone injection manifold. Note: Because the system is

in the shutdown mode, no vacuum is present at the injector. Therefore, it is normal for some water to

be flowing from the injector during this procedure.

Contact Vessel

• Cleaning: Contact Column only. Inspect the diffuser slots at the top of the contact column riser tube. If they

are clear, no further maintenance is required. If the slots are fouled, disassemble the column and clean as

required, following the steps outlined below (see Figure 5).

Step 1: Make sure the isolation valves before and after the contact column are closed.

Step 2: Disconnect the vent line from the top of the contact column.

Step 3: Remove the bolts in the 6” base flange.

Step 4: Remove the column, lifting it over the interior riser tube.

Step 5: Remove and clean the diffuser.

Step 6: Inspect the flange gasket and replace if necessary.

Step 7: Reassemble the contact column and attach vent lines.

High Voltage End Cap

High Voltage

Lead

Contact Brush

Brush Adapter Nut

Oxygen Inlet Fitting

High Voltage Anode

Glass Dielectric

End Cap Retaining

Screw and Washer

Heat Sink and Cathode

Bottom End Cap

Ozone Outlet Fitting

Troubleshooting

Air Preparation

Problem/Symptom

Possible Cause

Solution

Unit not operating

• No power to system

• Power switch in “OFF” position

• Incorrect wiring

• Check main power to system

• Turn switch to “ON” position

• See “Installation Procedures –

Electrical”

Low air flow or no air flow

• Flow meter out of adjustment

• Fouled compressor inlet filter

• Compressor not functioning

• Adjust flow meter, see “Start-Up

and Calibration – Step 5”

• Replace inlet filter

• Rebuild or replace as required

Compressor pressure relief valve

making noise

• Pressure relief valve not operating

• Excessive back pressure in system

• Pinched tubing

• Compressor not functioning

• ATF not operating

• Replace pressure relief valve

• Check the check valve for proper

operation, replace as required

• Replace tubing

• Rebuild or replace as required

• Repair or replace ATF as required

Unit is making excessive noises

• Unit not properly secured to floor

• Shipping damage

• Fan Blocked

• Packaging material not removed

• Place unit on a flat level surface

• Locate damage and repair/replace

parts

• Clear obstructions

• Remove packaging material

Ozone Generator

Problem/Symptom

Possible Cause

Solution

System is not “ON”

• No power to unit

• Power switch in “OFF” position

• Blown Fuse

• Incorrect wiring

• Check main power to system

• Turn switch to “ON” position

• Replace fuse

• See “Installation Procedures –

Electrical”

Circuit breaker trips

• Incorrect wiring

• Circuit breaker amperage does not

match draw

• Unit flooded with water

• See “Installation Procedures –

Electrical”

• Replace with correct circuit breaker

• Asses damage, correct cause and

rebuild as required

Receive an electric shock upon

touching the unit

• Incorrect wiring

• Unit not grounded

• Unit flooded with water

• See “Installation Procedures –

Electrical”

• Ground unit according to local codes

• Asses damage, correct cause and

rebuild as required

Drive Board 12V Green Power LED

does not illuminate.

• No power to drive module from

power supply

• Loose wires or connectors

• Blown drive module “on board” fuse

• Check main power to unit

• Test voltage from power supply to

drive module (see “Appendix E –

Drive Module Input Voltages”)

• Check for loose wires or connectors

• Replace “on board” fuse

Troubleshooting

Ozone Generator - Continued

Problem/Symptom

Possible Cause

Solution

Drive Board XFRM Green Power LED

does not illuminate

• No power to the drive module from

power supply

• Loose wires or connectors

• Blown drive module “on board” fuse

• Check main power to unit

• Test voltage from power supply to

drive module (see “Appendix E –

Drive Module Input Voltages”)

• Check for loose wires or connectors

• Replace “on board” fuse

Drive Board Ozone LED does not

illuminate

• Unit is under the control of a remote

4-20mA current signal

• Manual Ozone Output is turned

down to 0%

• Loose wires or connectors

• Drive board in “Fault” mode

• Check the remote signal

• Disconnect the remote signal

• Turn up the manual ozone output

control by pressing the right hand

button. See “Ozone Generator

Program Setup – Output Screen”

• See Troubleshooting, “Drive Board

Power Problem” above

• See Troubleshooting, “System

Fault” below

A 4-20mA control signal is being used

but does not appear to adjust the ozone

output.

• The 4-20mA signal is not being

sensed correctly

• Check for loose wires or

connections

• See “Installation Procedures –

Electrical”

Drive Board in Fault, Single Flash

The drive board can not get enough

power into the reaction chamber.

• Loose wire harness connection from

the drive board to the drive

transformer

• Drive board incorrectly characterized

the system on startup

• Loose or disconnected High Voltage

Lead to transformer

• Excessive dirt or debris in ozone

reaction chamber

• Water in ozone reaction chamber

• Broken dielectric

• Failed drive board

• Failed drive transformer

• Check all wires and connectors

• With pressure and flow at normal

operating conditions, restart the

ozone generator.

• Attach High Voltage Lead to

transformer

• Clean the dielectric and replace O-

rings

• Clean the dielectric and replace O-

rings

• Replace dielectric

• Replace drive board

• Replace drive transformer

Drive Board in Fault, Double Flash

The drive board’s feedback had a series

of sudden dips indicative of unusual

arcing occurring somewhere in the

system.

• Loose wire harness connection from

the drive board to the drive

transformer

• Loose or disconnected High Voltage

Lead to transformer

• Excessive dirt or debris in ozone

reaction chamber

• Water in ozone reaction chamber

• Broken dielectric

• Failed drive board

• Failed drive transformer

• Check all wires and connectors

• Attach High Voltage Lead to

transformer

• Clean the dielectric and replace O-

rings

• Clean the dielectric and replace O-

rings

• Replace dielectric

• Replace drive board

• Replace drive transformer

Troubleshooting

Ozone Generator - Continued

Problem/Symptom

Possible Cause

Solution

Drive Board in Fault, Triple Flash

The thermal switch on the board has

closed indicating that it was exposed to

temperatures exceeding 140F.

• Unit is overheating

• Check fan for proper operation and

clean fan filter

• Check operating temperature

• See “Installation Procedures –

Getting Started, Equipment

Placement”

Fan not operating

• Fan obstructed

• Power supplies not operating

• Fan inoperable

• Remove obstruction

• Check main power, check fuses,

repair and replace as required

• Replace fan

Low air flow or no air flow

• Air preparation system not operating

properly

• Air preparation system being

powered from ozone unit

• Fouled inline filter

• Air leak

• Incorrect wiring to air prep system

• See “Start Up and Calibration – Step

5”

• See “Ozone Generator Program

Setup – Setup Screen 5”

• Change inline filter

• Check all fittings, tighten as needed

• See “Installation Procedures –

Electrical”

Unit flooded with water

• Defective check valve

• Vacuum break incorrectly setup

• Defective vacuum break

• Replace check valve(s)

• See “Installation Procedures –

Pneumatic, Hook-Ups”

• Replace vacuum break

• Assess damage, repair as required

Ozone smell detected in or around

ozone generator

• Insufficient vacuum at venturi

• Loose internal fittings

• Defective O-ring seals in reaction

chamber(s)

• Defective dielectrics

• Adjust injector see “Start-Up and

Calibration – Steps 1-4”

• Check all fittings, tighten as needed

• Check and replace as required

Ozone Injection/Contacting

Problem/Symptom

Possible Cause

Solution

Water backflow past injector check

valve

• Defective check valve

• Replace check valve

Water bubbling in vacuum break

• No vacuum

• Debris on seat of vacuum break

flapper valve

• See “Start-Up and Calibration”

• Clean seat of flapper. See

“Maintenance Procedures – Annual”

Low Vacuum

• Hydraulics/Pneumatics out of

adjustment

• Defective check valve

• Hydraulic back pressure

• Defective solenoid valve

• No water in vacuum break

• Booster pump not functioning

properly

• See “Start-Up and Calibration –

Steps 1-4”

• Replace check valve

• Back wash filter (if so equipped)

• Check for obstruction in venturi

• Rebuild or replace as required

• Fill vacuum break with water. See

“Start-Up and Calibration – Vacuum

Break”

• Check booster pump (contact

dealer)

Troubleshooting

Ozone Injection/Contacting – Continued

Problem/Symptom

Possible Cause

Solution

High Vacuum

• Hydraulics/Pneumatics out of

adjustment

• Change in hydraulics – excessive

water flow through ozone injector

• See “Start-Up and Calibration –

Steps 1-4”

• See “Start-Up and Calibration –

Steps 1-4”

Ozone smell detected in or around

vacuum break or ozone injector

• No vacuum

• Loose fittings

• Broken fittings

• Adjust injector see “Start-Up and

Calibration – Steps 1-4”

• Check all fittings, tighten as needed

• Check and replace as required

Shown: ClearWater Tech OXS90 Air

Preparation System with out Cover

Appendix A – Specifications

Air Preparation System (Aerous 15 Shown)

Air Prep System

Specifications

Oxygen Output/SCFH

Aerous 8

19.75” H x 11.89” W x 13.75” D

68 lbs (with cover)

90% (+/-3%) @ 8 scfh, 10 PSI

Aerous 15

20.50” H x 12.64” W x 15.10” D

75 lbs (with cover)

90% (+/-3%) @ 15 scfh, 10 PSI

Compressor Inlet Filter

Hour Meter

Power Indicator Light

SCFH Air Flow Meter and

Adjustment Valve

Main Power Cord

Oxygen Outlet

Sieve Beds

Solenoid Valves

Compressor

Control Board

Appendix A - Specifications

CD1500 – Ozone Generator

Shown: ClearWater Tech CD1500 Ozone Generator

OZONE GENERATOR

SPECIFICATIONS

OZONE OUTPUT/SCFH

CD1500

27” h x 9.25” w x 5.5” d, 32 lbs

10g/h, 3%

@ 7scfh PSA Oxygen

Mounting Hole Measurement

17.75” h x 10.50” w

Ozone Output LED

Drive Board and Drive

Transformer (Under Boards)

Power Supplies

Reaction Chambers

4-20mA Control Board

Inline Particulate Filter

Cover Safety Switch

External Loop

Fan and Fan Filter

Remote 4-20mA Connector

Manual Ozone Output Adjustment Knob

External Loop Connector

Air Prep Inlet

Ozone Output

Main Power Light

Power Entry Module – OFF/ON Switch,

Cord Input, Fuse Carrier

Bonding/Ground Lug

Appendix A - Specifications

CD2000 – Ozone Generator

Shown: ClearWater Tech CD2000 Ozone Generator

OZONE GENERATOR

SPECIFICATIONS

OZONE OUTPUT/SCFH

CD2000

23.7” h x 20.25” w x 5.5” d, 49 lbs

20g/h, 4%

@ 14scfh PSA Oxygen

Mounting Hole Measurement

13.5” h x 21.75” w

Ozone Output LEDs

Fan and Fan Filter

Ozone Output

Air Prep Inlet

Fan and Fan Filter

Main Power Light

Manual Ozone Output Adjustment Knob

External Loop Connector

Remote 4-20mA Connector

Power Entry Module – OFF/ON Switch,

Cord Input, Fuse Carrier

Bonding/Ground Lug

Drive Board and Drive Transformers (Under

Boards)

Reaction Chambers

Power Supplies

Inline Particulate Filter

4-20mA Control Board

Cover Safety Switch

External Loop

Appendix B – Parts List

Air Preparation System

Ozone Generator – CD1500 and CD2000

Description

Part Number

Reaction Chamber – Complete

RCC7

Dielectric Anode 2”

RCC71

Non High Voltage End Cap

RCC107

High Voltage End Cap

RCC102

O-ring Set

ORS30

Drive Module Transformer

HVT275

Drive Module Board

CCA1231

Power Supply – CD2000

PSR822

Power Supply – CD1500

PSR820

Cooling Fan – 24VDC

FA46

Cooling Fan Filter

FA40

Inline Particulate Filter

FLT34

Fuse, Bussmann – 5 amp, 250VAC Slow Blow, Main Power

FUS20

Fuse, Littelfuse Minifuse 297005 – 5 amp, 32VAC, Drive Board

FUS75

Description

AEROUS 8

Part Number

AEROUS 15

Part Number

Control PCB 120 VAC 60Hz

OXU372

OXU377

Control PCB 220/240 VAC 50/60Hz

OXU386

OXU378

Solenoid Valve Assembly

OXU379

Compressor 120VAC 60Hz

OXU373

OXU340

Compressor 220/240 VAC 50/60Hz

OXU374

OXU345

Encloser Filter

OXU350

OXU351

Inlet Filter Package

OXU371

Maintenance Kit

ASP70A

ASP75A

Rebuild Kit

ASP71A

ASP76A

Appendix C – Maintenance Kit

Air Preparation System

ASP70A – Maintenance Kit – AEROUS 8

Part Number

Quantity

Description

OXS371

Oxygen Concentrator – Replacement Compressor Inlet Filter

OXS350

Oxygen Concentrator – Replacement Enclosure Filter

ASP71A – Rebuild Kit – AEROUS 8

Part Number

Quantity

Description

OXS379

Oxygen Concentrator – Solenoid Valve Assembly

OXS375

Oxygen Concentrator – Sieve Bed

ASP75A – Maintenance Kit – AEROUS 15

Part Number

Quantity

Description

OXS371

Oxygen Concentrator – Replacement Compressor Inlet Filter

OXS351

Oxygen Concentrator – Replacement Enclosure Filter

ASP71A – Rebuild Kit – AEROUS 15

Part Number

Quantity

Description

OXS379

Oxygen Concentrator – Solenoid Valve Assembly

OXS381

Oxygen Concentrator – Sieve Bed

Ozone Generator

ASP125C – Maintenance Kit – CD1500 Ozone Generator

Part Number

Quantity

Description

CKV21

Check Valve

FA40

4in Fan

FLT34

Filter – Inline particulate filter

FUS20

Fuse – Bussmann – 5 amp, 250VAC Slow Blow, Main Power

ORG10

O-ring – 2” CD reaction chamber, small

ORG110

O-ring – 2” CD reaction chamber, large

ASP128F – Maintenance Kit – CD2000 Ozone Generator

Part Number

Quantity

Description

CKV22

Check Valve

FA40

4in Fan

FLT34

Filter – Inline particulate filter

FUS20

Fuse – Bussmann – 5 amp, 250VAC Slow Blow, Main Power

ORG10

O-ring – 2” CD reaction chamber, small

ORG110

O-ring – 2” CD reaction chamber, large

Appendix D – Logic Schematics

CD1500

Appendix D – Logic Schematics

CD2000

Appendix E – Drive Module Input Voltages

24VDC

48VDC

- G +

Appendix F – Warranty Information

ClearWater Tech, LLC. Limited One-Year Warranty

Summary of the Warranty

ClearWater Tech, LLC (“CWT”) makes every effort to assure that its products meet high quality and durability standards 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

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:

• An accident, misuse, alteration or abuse

• An act of God such as flood, 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

• Use of parts not sold by CWT

• Service or unit modification not authorized by CWT

• Check valve/solenoid valve failure

• Damage which may occur during shipping

• Failure to meet service requirements as outlined in the I &

O manual

Obtaining Service Under the Warranty

Any product and/or part not performing satisfactorily may be returned to CWT 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 there 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 CWT 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.

Exclusive Warranty

There is no other expressed warranty on CWT products and/or parts. Neither this warranty, nor any other warranty, expressed or

implied,including any implied warranties or merchantability of fitness, shall extend beyond the warranty period. Some states do not

allow limitation 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 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 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 AT ANY PRIOR TIME.