CD20/02 manual - US Water Systems
Contents
1. e eo 825515252520 CD20 02 Corona Discharge NOTE Ozone For additional information Generator on wiring the Barrier Strip on the Electrical Interlock Box see the Electrical Interlock Box Barrier Strip Wiring Connections Section Ozone Generator connect to Terminals 3 amp 9 for 120V Sys or Terminals 9 amp 10 for 240V system Power cord for may be plugged into duplex outlet on bottom of electrical interlock box Workhorse 15 Oxygen Generator ORP Controller i to Terminals 5 amp 6 optional i i Terminal4 i 120 Signal 1 optional Oxygen Generato Connect to Terminals 3 amp 9 Pump connect to Terminals 7 amp 8 WhisperFlos Pump Electrical Interlock Box Terminal Strip Connections 230 VAC 50 60 HZ MODELS ONLY Note All electrical connections should be made by a qualified electrical contractor All local state and national electri cal codes must be observed 230 VAC 50 60 HZ SINGLE HOT LEG ONLY The pump if installed oxygen generator and ozone generator on the units come pre wired from the factory The instructions below are included in case the system ever needs to be rewired Wire the 230 VAC 30 AMP hot leg from the service disconnect box to terminal 1 on the2. fittings 24 ELECTRICAL INTERLOCK BOX TROUBLESHOOTING PROBLEM SYMPTOM POSSIBLECAUSE SOLUTION MAIN POWER light noton No power to electrical interlock box Check power connections and breakers Noneutral in 120 VAC supply Hookup neutral Lightburntout Replace bulb MCI light not on 120 VAC signal not connected Jumper terminal from 1 to 4 to terminal 4 Lightburnt out Replace bulb Noneutral in 120 VAC supply Hookup neutral VACUUMSYSTEM light No power to electrical interlock box Check power connections and breakers noron NoMCI Jumper terminal from 1 to 4 No neutral in 120 VAC supply Hookupneutral Novacuum Adjustinjector vacuum or Check tubing for leaks or Check for booster pump operation or Turn to OFF and back to reset Lightburntout Replace bulb ORP light not on No power to electrical interlock box Check power connections and breakers No MCI No neutral in 120 VAC supply Novacuum System setto MANUAL No 120 VAC power to terminals 5 and 6 Jumper terminal from 1 to 4 Hookup neutral Adjust injector vacuum or Check tubing for leaks or Check for booster pump operation or Turn to OFF and back to reset Switch to AUTO Hook up power to these terminals see manual level in excess of preset level Checkinputsignal Lightburntout Replace bulb Flow meter ball doesnot adjust Novacuum Adjust injector vacuum check pump Vacuum leak Check a
3. For example if the PSI gauge is in the pressure range the suction on the injector should be increased or the SCFH decreased at the needle valve on the SCFH gauge to evacuate the pressure being introduced to the ozone unit VAC PSI Gauge with the SCFH Gauge safe operating SCFH range Gauge Needle PSI Valve Note The ideal setting is to have the prescribed SCFH for your unit with the vacuum gauge in the 5 to 15 range After the system has run for several minutes make the final adjustments to the injector and or SCFH gauge Shutdown Procedure Once the system has been installed the entire skid can be turned ON and OFF from the ON OFF AUTO switch or the service disconnect box Note Do not change air flow adjustments 14 TYPICAL INSTALLATION ATMOSPHERIC TANK RECIRCULATION 1 When CD20 O2 unit is to be used for atmospheric tank recirculation observe all general installation steps and electrical connection instructions On an ozonated recirculation system all pumps and venturis should be protected by valves and unions to facilitate servicing In general low pressure check valves may be used on the venturi A typical recirculation system should inlet from the bottom of the tank and return to the bottom of tank forcing the water in a circular pattern even if the piping must extend over from the top of the tank to the bottom If an ORP monitor is to be used for ozone residual indication or control the se
4. feature designed to prevent the ozone unit from operating without the injector drawing the gas into the water After all the previous electrical and plumbing connections have been completed the system is ready for start up and calibration Starting position 1 2 6 Water flowing in the main line Open the ball valves to the ozone loop side stream Allow all air to bleed out of the system before activating the pump to avoid plumbing hammer in the system 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 Be sure the ozone switch on the ozone generator is ON the light will illuminate when energized Note The booster pump ozone generator and oxygen generator should now be operating The injector can now be adjusted for suction Observe the SCFH gauge and close the gate 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 ON OFF AUTO switch OFF and back to ON SCFH Settings Model Venturi SCFH Operating SCFH Vacuum 20 02 22 to 26 20 max 5 to 15 VAC PSI Gauge This gauge measures the relationship between the suction at the injector and the pressure of the oxygen feed gas Under ideal conditions this gauge should show a slight vacuum
5. for this position The system will not operate without a true neutral Also connect the neutral lead from the oxygen generator to this terminal 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 Runa 120 VAC line from the motor starter to this terminal Should this feature not be used simply install a jumper from terminal 1 to terminal 4 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 Note To override the ORP control signal simply turn the ozone switch on the electrical interlock box to the ON position Terminals 7 amp 8 Booster Pump Out Use 12 AWG inside 1 2 watertight flex conduit The booster pump will stay on in either the ON or AUTO position on the switch on the electrical interlock box Terminal 9 Ozone Generator Out and Oxygen Generator Out Use 18 AWG On the M 15 O2 these are pre wired at the factory On the P 20 O2 you must wire these after the electrical interlock box has been mounted to the wall Terminal 10 Ozone Generator Out Use 18 AWG On the M 15 O2 these pre wired at the factory On the P 20 O2 you must wire these after the electrical interlock box has been mounted to the wall The duplex
6. 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 youexcept 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 extension 27 Exclusive Warranty There is no other expressed warranty on CWT products and or parts Neither this warranty or 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 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 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 consequentia
7. CleaiWater Ozone Systems Ozone System CD 20 02 Corona Discharge Ozone Generator Installation amp Owner s Manual BOX 15330 San Luis Obispo 93406 Copyright 1994 ClearWater Tech Inc Reproduction of any kind is prohibited Rev 10 00 IMPORTANT SAFETY INSTRUCTIONS 10 PLEASE FOLLOW ALL INSTALLATION INSTRUCTIONS All plumbing connections should be made by a licensed qualified plumber All 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 the provided ozone check valves 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 Sec tion 422 20 of the National Electrical Code ANSI NFPA 70 1987 The means of disconnecting the equipment must be readily accessible to the operator s Be sure to bond ground the system using the copper bonding lug on the bottom of the components The system should be bonded with solid copper wire conforming with all local state and national electrical codes Ambient temperature around the equipment should be between 40 and 100 F 4 5 to 38 C If the equipment is installed in an environment with tempera tures over 100 F additional air cooling must be provided In
8. already completed Install the 1 4 Teflon tubing from the solenoid valve located on the upper right side of the electrical interlock box to the injector All tubing connections between the oxygen generator and the ozone generator and the electrical interlock box have been completed at the factory Check Valve Selection The ozone check valve is an important component in preventing damage to the ozone generator All ClearWater Tech CD 2000 ozone generators are equipped with a Kynar low pressure check valve on the ozone outlet A second check valve should be installed on the venturi injector ozone inlet This check valve should be matched to the application A low pressure Kynar check valve is appropriate for applications where the system pressure will not exceed 40 psi Higher line or system pressure installations require a stainless steel check valve Note The cracking pressure the pressure at which the valve opens of any stainless steel or Kynar check valves not sourced through ClearWater Tech must not exceed 0 5 Ib 0 33 Ib is recommended 20 02 EXPLODED VIEW OF TUBING amp PLUMBING CONNECTIONS Ozone Inlet Eloow Ozone 1 4 Teflon u Out from Tubing from Electrical O m Ozone o Interlock Generator Box to to Electrical 9 Injector Interlock 1 5 02
9. ction of water flow and if possible install the injector at the end of as long and straight a length of pipe as possible Unions should be used to facilitate periodic maintenance checks of the injector for buildups of oxidized particulate iron manganese sulfur etc Any venturi injector used on a well water system should be equipped with a good quality stainless steel check valve at the injector itself as well as a secondary safety check valve at the outlet fitting of the ozone generator These check valves should be in spected on a monthly basis and replaced or rebuilt as necessary 5 Venturi injector performance is critical to successful ozonation For the venturi to function correctly there must be proper pressure and flow to create the needed suction at the injector suction port A pressure differential of at least 25 PSI is required between the well or booster pump and the back pressure created by the system Follow the venturi adjustment procedures outlined in this manual 6 The contacting vessel used should be ozone compatible and have an adequately sized air vent of suitable mate rials preferably stainless steel If the vessel is installed indoors care should be taken to vent the contact vessel to the outdoors or install a suitable ozone destruct device This contactor should be inspected and cleaned on regular basis 7 Often the venturi water well systems with bladder style pressure tanks will only draw air during a portion o
10. duit Terminal 9 Ozone Generator Out and Oxygen Generator Out 230 VAC 50 60 Hz 18 AWG Pre wired at the factory Terminal 10 Ozone Generator and Oxygen Generator Neutral 18 AWG Pre wired at the factory 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 Electrical Interlock Box Wiring Connections eppssppesmeemee 2 3 4 5 6 7 8 10 230 VAC 50 60 HZ SINGLE HOT LEG Line In 230VAC Dryer ORP Neutral In B Neutral Dryer ERE Jumper MCI 230 VAC ORP Line In 230 VAC signal ORP Neutral signal Booster Pump Line Out 230V Booster Pump Neutral Ozone Oxygen Generators Out 230VAC 0 Ozone Oxygen Generators Neutral Jumper is user installed 12 AWG 02 2 GROUNDING BAR 20 02 ELECTRICAL WIRING CONNECTIONS 230 VAC 50 60 HZ MODELS ONLY E 14 Service Disconnect or from a i dedicated breaker in the main panel Electrical NOTE This must be TRUE NEUTRAL Interlock m i BOX i l 2 Or LI m Neutral 5 to Term 3 L2 to Term 2 L1 to Term 1 CD20 02 Corona Discharge NOTE Ozone For additional in
11. e feed gas creating oxygen enriched air while also lowering 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 will cause corrosion and eventual failure of the generator s internal components The ability of the ozone generator to produce ozone is drastically decreased when the dew point rises above 80 C Electrical Interlock Box The electrical interlock box is a multifunction electrical enclosure It houses the main terminal strip for the service disconnect booster pump or control switch motor control interlock MCI ORP interlock or optional ozone monitor 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 Injector Manifold optional The ozone gas is drawn into the water line by means of a venturi injector manifold This allows the ozone to be injected into the water under a vacuum condition which is the safest most efficient technology available The venturi utilized in the injector manifold operates via a pressure differential much like a carburetor The amount of ozone drawn into it depends on the water flow and pressure on the inlet and outlet sides A pressure differential of at least 25 psi must be maintained between the well or booster pump and system back pressure for the venturi to operate correctly Proper fu
12. electrical outlets on the bottom of the electrical interlock box are 120V 60 Hz single phase circuits and remain energized during normal operation for chemical controllers Do not exceed 10 amps total for these two circuits 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 Electrical Interlock Box Wiring Connections FOR 120 VAC MODELS FOR 240 VAC MODELS 1 Line In 120V 1 Line In 240V 2 Neutral In Jumper 2 Line In 240V 3 Neutral In amp 3 Neutral In amp Oxygen Generator Neutral Oxygen Generator Neutral 4 MCIIn 4 MCIIn 5 ORP Line In 5 ORP Line In 6 ORP Neutral 6 ORP Neutral 7 Booster Pump Line Out 120V 7 Booster Pump Line Out 240V 8 Booster Pump Neutral 8 Booster Pump Line Out 240V 9 Ozone Generator Out 120V amp 9 Ozone Generator Out 240V amp Oxygen Generator Out 120V Oxygen Generator Out 120V 10 Ozone Generator Neutral 10 Ozone Generator Out 240V Jumper is user installed 12 AWG CD 20 02 ELECTRICAL WIRING CONNECTIONS 120 240 VAC 60 HZ MODELS ONLY ae io Service Disconnect or from a dedicated breaker in the main panel Electrical Interlock m i Os i os Neutral OF to Term 3 L2 to Term 2 L1 to Term 1 NOTE This must be a TRUE NEUTRAL i
13. ery tubing Defective check valve s Replace check valve s Excessive back pressure on check valve Back pressure not to exceed 40 psi if over 40 psi consult ClearWater Tech distributor Ozone smell present Insufficient vacuum Adjustinjector vacuum Loose internal fittings Defective O ring seals in reaction chamber Defective dielectrics Defective reaction chamber Inspect and tighten fittings Check and replace if necessary Check and replace if necessary Check and replace if necessary You suspect that no ozone is being produced Drive module failure Dielectric failure Touch the bottom of the coil replace if it is not warm Inspect and replace if necessary 23 OZONE GENERATOR TROUBLESHOOTING continued PROBLEM SYMPTOM POSSIBLECAUSE SOLUTION Unit seems noisy Not properly secured to wall floor Shipping damage Fan blocked Bolt it firmly into place Locate and repair Check and clear obstructions Flow meter will not adjust Air preparation not operating Defective solenoid Defective check valve Make sure air prep package is set properly Inspect and repair or replace solenoid Check and replace check valve Vacuum gauge reads on pressure side Insufficient vacuum Output solenoid defective Defective vacuum gauge Loose Kynar compression fittings to ozone delivery line Adjust injector vacuum Check and replace or rebuild Replace vacuum gauge Tighten all Kynar
14. f the pump cycle sometimes less than half the cycle This is common and will only effect efficiency if the ozone generator is undersized If both the ozone generator and contacting vessel are properly sized this shorter period of ozonation will still allow proper mixing with the water drawn during the pump cycle If your system parameters will not allow for this the situation can be partially remedied by lowering the overall system pres sure Installation of a booster pump will alleviate the problem For additional information on venturi injector manifold selection contact vessel sizing or filtration consult your ClearWater Tech representative Typical Commercial Single Pass Ozone Contacting and Filtration System Contact Tank Pressure Tank and Filter size will vary by application ClearWater Tech CD20 02 Ozone Generator with AD 40 Air Dryer ELE IE 7 r 2 Existing onoo Water Service 1 Riser Water Inlet inlet from Well E BG added in field To Service Use gt Stainless Steel Zz Off Gas Vent gt mn Contact A Tank Multi ulti E Pressure N Tank Media N Filter 4 N gelo Pressure Switch System Check Valve Coupler CleaiWater 20 2 MAINTENANCE amp TROUBLE SHOOTING MANUAL PARTS amp WARRANTY MAINTENANCE Ozone Generator A word of caution There is extremely high voltage inside the ozone genera
15. formation Generator on wiring the Barrier Strip on the Electrical Interlock Box see the Electrical Interlock Box Barrier Strip Wiring Connections Section Ozone Generator connect to Terminals 3 amp 9 for 120V System or Terminals 9 amp 10 for 240V system 5 215 5 6 712155 6 20 Power cord for ORP may be plugged into duplex outlet on bottom of electrical Workhorse 15 Oxygen Generator Controller i toTerminals 5 amp 6 1 optional MCI to j Terminal 4 i 120V Signal optional Oxygen Generato Connect to Terminals 3 amp 9 Pump connect to Terminals 7 amp 8 WhisperFloe Pump INITIAL VENTURI INJECTOR MANIFOLD CALIBRATION ClearWater Tech air preparation and ozone generation systems Models 15 2 CD20 O2 are a vacuum type and will require adjustment of the air flow through the system An SCFH Standard Cubic Feet per Hour gauge is 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 drawn into the water Follow the directions and illustration below to optimize flow through the injector 1 2 Install the tube fitting into the upper hole on the back side of the SCFH gauge With the pump running disconnect the tubing from the o
16. l 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 6 ClearWaterTech LLC 850 Capitolio Way Suite E San Luis Obispo California 93401 Tila FOREN LOATY CT Tikes SOREN CACY FAOFXE
17. lejeisisisjsjels e s ejo i CD 15 02 o Corona BOY Discharge Ozone OZONE Generator 3 8 Brass Oxygen Outlet 3 8 pp Oden Inlet Nipple Ozone Outlet Elbow 3 8 Brass Oxygen Inlet Nipple behind Ozone 3 8 Braided Outlet Elbow Tubing from Electrical Interlock Box to Ozone Generator AS 12 Oxygen Generator OXYGEN 3 8 Braided Tubing from Oxygen Generator to Electrical Interlock Box Oxygen Outlet Plumb Water Line from Pump Outlet to Injector Plumb Water Line into Pump Inlet 2 minimum WhisperFloe Pump Electrical Interlock Box Terminal Strip Connections 120 240 VAC 60 HZ MODELS ONLY Note All electrical connections should be made by a qualified electrical contractor All local state and national electrical codes must be observed 120 240 VAC 60 HZ ONLY The pump if installed oxygen generator and ozone generator on the units come pre wired from the factory The instructions below are included in case the system ever needs to be rewired Wire a 240 VAC 30 AMP circuit from the service disconnect box to the 240 VAC terminals on the terminal strip located in the electrical interlock box Use 12 AWG L1 is Terminal 1 L2 is Terminal 2 Note Be sure to ground the unit to the bonding lug Continue to wire the remaining equipment as outlined and illustrated below Terminal 3 System Neutral Use minimum 12 AWG Provide a true neutral lead
18. nction of the venturi ozone system will occur only if the pressure differential is maintained For highest efficiency at least 10 of vacuum at the venturi suction port and 25 psi at the venturi outlet must be maintained ClearWater Tech stocks a complete line of high efficiency venturi injectors from 4 100 GPM Contacting Vessel optional Ball Valve 1584K Venturi 9 1 26 3 4 8 5 8 To maximize the effectiveness of ozone it must be thoroughly mixed and have adequate time to react with the contami nants in the water before returning to usage or further processing The contacting vessel is designed to achieve this necessary mixing and contact time A variety of contacting vessels are available for different applications from Clear Water Tech Booster Pump optional The ClearWater Tech CD20 O2 ozone system may include a booster pump A variety of booster pumps are available from ClearWater Tech to match different applications CD20 02 UNIT DIAGRAM 20 25 Electrical Interlock Box ORP Control or other optional equipment can be mounted here Duplex Electrical Outlets for ORP Controller 10 amps total max 68 50 CD20 02 Corona Discharge Ozone Generator Workhorse 15 Oxygen Generator WhisperFlo Pump 19 50 VIEW FRONT VIEW Ozone Out from Electrical Interlock Box to Injector INSTALLATION Placement of Equipment Select a l
19. nd tighten fittings Inand outhoses reversed Defective solenoid Defective check valve Switch hoses Inspect and repair or replace solenoid Check and replace check valve 25 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 commenc ing 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 v End user name v Complete address including telephone number v Date installed v Complete model and serial number information v 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 par
20. nsor should be mounted between the tank isolation valve and the pump inlet This is also a good location for a flow meter Observe the manufac turers recommendations for flow meter installation Depending on water quality and ozone generator size a 24 hour timer or delay timer is a useful accessory that can be easily adapted to the CD20 O2 For additional information on tank turnover times alternative tech niques or accessories consult your ClearWater Tech representative Circulator for Treatment and Storage Tanks up to 20 000 Gallons Isolation Valve A lt Sample Ozone A y Injector Pressure Check Valve Unions b b Isolation Valve ORP Probe 15 INSTALLATION ON A TYPICAL WATER WELL 1 When the CD20 02 ozone generator is used for well water treatment be sure to observe all general installation and electrical connection instructions in this manual 2 When installing an ozone treatment system a submersible well water system with a bladder type pressure tank arrange all components per the typical single pass diagram on the following page 3 All piping between the injector manifold and the filtration system should be schedule 80 PVC for ozone compat ibility Do not use galvanized steel or copper as they can be corroded by repeated exposure to high levels of ozone 4 Care should be taken when installing the ozone venturi injector manifold Be sure that the arrows the injec tor body match the correct dire
21. ocation for the ozone skid that is as close as possible preferably within ten feet to the ozone injection point Arrange the skid in a manner suitable for convenient electrical access and allowing for service of the air preparation system The CD 20 O2 enclosure is not rain proof so it is important to choose a location that will keep the system away from direct weather and excessive heat A suitable concrete equipment pad should be provided Three mounting holes are located on the bottom skid rails allowing the unit to be secured to the floor Mounting hardware is not provided Installation Materials Use Schedule 80 PVC or suitable ozone resistant materials for all plumbing connections whenever possible Also it is recommended that unions and valves are used wherever practical Ozone rapidly deteriorates a variety of compounds the following is a list of materials that may be used with ozone in gaseous phase at high concentrations Viton Teflon Stainless Steel EPDM Silicon Kynar Hepalon With ozone in aqueous phase at low concentrations Viton Teflon Stainless Steel EPDM Silicon Kynar Concrete Hepalon Schedule 40 PVC Schedule 80 PVC NOTE Besure to use good plumbing practices and install unions and isolation valves wherever the situationdictates ie pump or injector removal etc Secure all plumbing with unistrut or similar hardware Tubing Installation Install the check valve assembly onto the injector if not
22. owing back into the ozone generator Check valves should be replaced or rebuilt yearly or when a maintenance problem has oc curred with the air preparation system Note On a properly installed system the only time it is possible for water to flow back toward the ozone generator is during a system shutdown Always inspect for water seepage during this time MAINTENANCE continued Dielectric tubes Dielectric tubes are located in the reaction chambers of the ozone generator These tubes should be inspected periodically and cleaned if necessary Once each year remove one reaction chamber and inspect the dielectric tube for debris If the tube is clean and free of any debris oil or dirt it may be replaced and no further mainte nance is required If the tube is dirty or cracked all dielectric tubes must be inspected and cleaned Cracked dielectrics should be replaced Please consult your ClearWater Tech distributor as the improper installation of the 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 is required Removal of the Dielectric Tubes 1 8 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
23. res high output corona discharge systems capable of producing enough ozone to oxidize iron sulfide manganese and act as an efficient sanitizer in a variety of applications Ozone reacts to water borne con taminants 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 material inadvertently lodged in any openings PRODUCT DESCRIPTION 20 02 is a skid mo
24. stallation with out additional air cooling in an environment where temperatures exceed 100 F for any continuous 24 hour period will void the warranty 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 SAVE THESE INSTRUCTIONS 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 manufactu
25. t 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 444444 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
26. terminal strip located in the electrical interlock box Wire the neutral to terminal 2 Use 12 AWG for both 1 and 2 Note Be sure to ground the unit to the bonding lug Continue to wire the remaining equipment as outlined and illustrated below Terminal 3 Dryer ORP Neutral Use minimum 12 AWG Provide a true neutral lead for this position The system will not operate without a true neutral Terminal 4 MCI Motor Control Interlock 230 VAC 50 60 Hz Use 18 AWG This is an interlock from the main circulation pump to the ozone system Run the 230 VAC line from the motor starter to this terminal Should this feature not be used simply install a jumper from terminal 1 to terminal 4 Note The unit will not function without 230 VAC signal to this location Terminal 5 Oxidation Reduction Potential ORP Controller In 230 VAC 50 60Hz Use 18 AWG This is control voltage only 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 Terminal 6 Oxidation Reduction Potential ORP Controller Neutral 230 VAC 50 60Hz Use 18 AWG Terminal 7 Booster Pump Out 230 VAC 50 60 Hz 12 AWG inside 1 2 watertight flex conduit The booster pump will stay on in either the ON or AUTO position on the switch on the electrical interlock box Terminal 8 Booster Pump Neutral 12 AWG inside 1 2 watertight flex con
27. 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 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 guo N 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 Replace the particulate air filter located inside the ozone generator cabinet annually Air Preparation Contact your ClearWater Tech distributor for annual service of the air compressor If the unit must be returned to ClearWater Tech for repair or evaluation follow the steps outlined below gre e ur Make sure the main power to the unit is disconnected Disconnect the ozone delivery line Disconnect the po
28. tor 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 All 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 Fan Filter Element Pt 4 FA40 eee 4 snaps on and off REGULARLY FAILURE TO DO SO WILL PROMOTE OVERHEATING AND WILL VOID THE WARRANTY Check valves The system is equipped with two check valves one at the ozone generator ozone outlet and one on the venturi injector Depending on water pressure these check valves will be either Kynar up to 35 psi or stainless steel over 35 psi 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 regularly to insure water is not fl
29. unit Check breakers Switch not turned on Check switch Blown fuse Replace fuse on bottom of unit Cover door interlock not active Incorrect wiring connections Check door interlock switch replace cover Check wiring see manual Unit does not stay on Insufficient vacuum should be 5 to 15 on SCFH gauge Defective solenoid Defective check valve Adjust injector vacuum check pump be sure check valves are properly installed Inspect and repair replace ifnecessary Inspect and replace if necessary Unit overheating Clean fan filter check fan Unit cycles on and off Overheating Clean fan filter check fan Defective power Check for constant power if not timer controlled Defective solenoid Inspect and repair replace ifnecessary Individual drive indicator lights not on No power to drive module Blown fuse or lamp Drive module burnt out Check drive module see illustration Replace fuse or lamp Replace drive module Unit trips circuit breaker Incorrect wiring Incorrect circuit breaker Check wiring see manual Check and if necessary replace with correct circuit breaker You receive an electrical shock Incorrect wiring Check wiring see manual pon eouchme Unit not grounded Ground unitin accordance with local codes Unit has been flooded Return unit for major service or completely disassemble and clean Water in unit or Insufficient vacuum Adjust injector vacuum ozone deliv
30. unted system comprised of the ozone generator air preparation system and an electrical interlock box for the efficient production and control of ozone gas The feed gas is approximately 9076 oxygen at 14 standard cubic feet per hour SCFH supplied by the self contained oxygen generator The ClearWater Tech System can be interlocked with an ORP controller ozone monitor booster pump or a variety of other controls The ozone generator will automatically shut down if the cooling system fails or if the vacuum to the unit is interrupted CD20 O2 CORONA DISCHARGE OZONE SYSTEM CD 20 O2 corona discharge ozone system consist of three main skid mounted components e Ozone Generator Air Preparation Unit Electrical Interlock Box In addition to this basic unit optional equipment includes Ozone Injector Manifold Contact Vessel s Booster Pump Controller Ozone Generator The ozone generator houses the ozone reaction chamber s power supply and all electrical systems 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 is fed with oxygen enriched dry air Corona discharge ozone generators are much more effective produce more ozone and require far less maintenance when the air preparation unit is included The air preparation system separates the majority of the nitrogen from th
31. wer lines inside the electrical interlock box Wire nut all disconnected wires Prepare for shipment and ship according to the instructions provided by your ClearWater Tech distributor Annual maintenance agreements for your ClearWater Tech system are available from your ClearWater Tech dis tributor 20 EXPLODED VIEW OF CORONA DISCHARGE REACTION CHAMBER Fitting Kynar Elbow High Voltage Endcap with O Rings High Voltage Contact Dielectric Cathode with Heat Sinks amp Feet Non High Voltage End Cap with O Rings Fitting Kynar Elbow Yt Mounting Screws ELECTRICAL INTERLOCK BOX SOLENOID VALVE ce GUS a SEE REE Nut Washer Coil 1 l Wrench Nut Loo required for COMPLETE i sleeve removal SOLENOID VALVE li Assembled includes all parts 5 I except Wrench Nut lt Sleeve l 120V Pt SV100 l 240V Pt SV110 MM eee T E 1 m Spring SOLENOID REBUILD KIT SV500 Plunger i l Flange Seal diio esee ierit i l Valve Body l i nem CEDENS EE 22 OZONE GENERATOR TROUBLESHOOTING PROBLEM SYMPTOM POSSIBLECAUSE SOLUTION Unit does not turn on No power to
32. zone outlet of the ozone generator and connect the tubing to the fitting on the gauge While holding the gauge vertically read the amount indicated on the gauge Note Do not obstruct the bottom air hole on the gauge The optimum flow is 14 SCFH for the CD 20 O2 If the flow exceeds 35 SCFH install an ozone resistant metering valve to restrict the flow to the correct amount The injector has a ball valve to adjust the amount of flow To adjust the SCFH simply install the gauge as above and open the ball valve completely With the pump running begin closing the ball valve until the optimum flow is achieved on the SCFH gauge If possible remove the ball valve handle to prevent tampering with the setting NN AS N NS e e NN ANY a X N uin X En Injector Manifold with Check Valve Do Not Block Lower Hole Attach Ozone Line KEEP GAUGE VERTICAL INITIAL START UP AND CALIBRATION The air preparation system on the ClearWater Tech Model CD 20 O2 is plumbed and wired at the factory On both models the air flow will need final adjustment On the front of the electrical interlock box is a VAC PSI gauge and an SCFH Standard Cubic Feet per Hour gauge On the side of the oxygen generator is a 0 100 flow gauge The side stream booster pump ozone system will only function for 15 seconds due to an electrical interlock relay without vacuum from the venturi injector This is a safety
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