ClearWater CD15/O2, Installation & Maintenance Manual

Page 1: ...service cwtozone com www cwtozone com Copyright 2006 ClearWater Tech LLC Reproduction of any kind is prohibited LIT554 REV012306 ClearWater Tech LLC Integrated Ozone Systems Installation Maintenance Manual M 15 O2 P 20 O2 CD15 O2 CD20 O2 Corona Discharge Ozone Generator Ozone Systems ...

Page 2: ...cedure 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 versi...

Page 3: ...xposing oxygen molecules O2 in an air stream to a controlled high energy electrical field As the air stream passes through the electri cal field produced inside the ozone generator some oxygen molecules are split forming single oxygen atoms O1 These oxygen atoms then recombine with other O2 molecules in the air stream forming ozone O3 Properties of Ozone Ozone is the most powerful oxidizer available...

Page 4: ...FETY INFORMATION ClearWater Tech corona discharge ozone generators take line voltage and convert it to 48 VDC A transformer then takes that current and boosts the voltage While each ozone generator has a door switch and other safety interlocks proper care must be used by a qualified electrician when making any internal adjustments or performing any maintenance procedures ClearWater Tech corona disc...

Page 5: ...g 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 t...

Page 6: ...one generators have been tested and certified by the Water Quality Association according to NSF ANSI 50 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...

Page 7: ... 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 ...

Page 8: ...7 M 15 02 UNIT DIAGRAM ...

Page 9: ...8 CD15 02 UNIT DIAGRAM ...

Page 10: ...9 P 20 02 UNIT DIAGRAM ...

Page 11: ...10 CD 20 02 UNIT DIAGRAM ...

Page 12: ...le 40 PVC Schedule 80 PVC NOTE Be sure to use good plumbing practices and install unions and isolation valves wherever the situation dictates i e 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 already completed Install the 1 4 Teflon tubing from the solenoid valve located on the upper r...

Page 13: ...12 M 15 02 CD 15 02 ENLARGED VIEW OF TUBING PLUMBING CONNECTIONS ...

Page 14: ...13 P 20 2 CD 20 02 ENLARGED VIEW OF TUBING PLUMBING CONNECTIONS ...

Page 15: ...ature 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 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 o...

Page 16: ...15 M 15 02 CD 15 02 INTERLOCK WIRING CONNECTIONS ...

Page 17: ...16 P 20 2 CD 20 02 INTERLOCK WIRING CONNECTIONS ...

Page 18: ...m 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 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...

Page 19: ...uge vertically read the amount indicated on the gauge Note Do not obstruct the bottom air hole on the gauge The optimum flow is 10 to 15 SCFH for the M 15 O2 and the CD 15 02 and 15 to 20 SCFH for the P 20 O2 and CD 20 02 If the flow exceeds 35 SCFH install an ozone resistant metering valve to restrict the flow to the correct amount 4 The injector has a ball valve to adjust the amount of flow To adjus...

Page 20: ...itch the main service disconnect box to the ON position 4 Turn the ozone generator ON at the switch located on the front of the electrical interlock box 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 5 The injector can now be adjusted for suction Observe the SCFH gauge...

Page 21: ...20 Maintenance Trouble Shooting Manual Parts Warranty Ozone Systems M 15 02 P 20 02 CD 15 02 CD 20 02 Corona Discharge Ozone Generators ...

Page 22: ...quire 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 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 ...

Page 23: ...d by slowly pulling straight out The glass dielectric will remain attached to one of the end caps 6 If the dielectric tube is dirty clean the glass with Isopropyl alcohol Do not use a solvent that will leave an oily residue 7 Clean the inside of the stainless steel reaction chamber with a wire brush as necessary then wipe with Isopropyl alcohol 8 Be sure all solvents have evaporated prior to reass...

Page 24: ...23 M 15 O2 OZONE GENERATOR COMPONENTS POWER SUPPLY FOR M 15 O2 Power Supply for Single Cell Units 100 120V Pt PS160 208 240V P PS 165 ...

Page 25: ...24 CD 15 O2 OZONE GENERATOR COMPONENTS POWER SUPPLY FOR CD 15 O2 Power Supply for Single Cell Units 100 120V Pt PS160 208 240V P PS 165 ...

Page 26: ...25 P 20 O2 OZONE GENERATOR COMPONENTS POWER SUPPLY FOR P 20 O2 Power Supply for Muli Cell Units 100 120V Pt PS300 208 240V P PS 305 ...

Page 27: ...26 CD 20 O2 OZONE GENERATOR COMPONENTS POWER SUPPLY FOR CD 20 O2 Power Supply for Muli Cell Units 100 120V Pt PS300 208 240V P PS 305 ...

Page 28: ...27 ENLARGED VIEW OF CORONA DISCHARGE REACTION CHAMBER ...

Page 29: ...28 ELECTRICAL INTERLOCK BOX SOLENOID VALVE ...

Page 30: ...mp Drive module burnt out Replace drive module Unit trips circuit breaker Incorrect wiring Check wiring see manual Incorrect circuit breaker Check and if necessary replace with correct circuit breaker You receive an electrical shock Incorrect wiring Check wiring see manual upon touching the unit Unit not grounded Ground unit in accordance with local codes Unit has been flooded Return unit for major...

Page 31: ... not adjust Air preparation not operating Make sure air prep package is set properly Defective solenoid Inspect and repair or replace solenoid Defective check valve Check and replace check valve Vacuum gauge reads on Insufficient vacuum Adjust injector vacuum pressure side Output solenoid defective Check and replace or rebuild Defective vacuum gauge Replace vacuum gauge Loose Kynar compression fitti...

Page 32: ...r Check for booster pump operation or Turn to OFF and back to reset Light burnt out Replace bulb ORP light not on No power to electrical interlock box Check power connections and breakers No MCI Jumper terminal from 1 to 4 No neutral in 120 VAC supply Hook up neutral No vacuum Adjust injector vacuum or Check tubing for leaks or Check for booster pump operation or Turn to OFF and back to reset Syst...

Page 33: ...32 DRIVE MODULE WIRING FOR M 15 O2 P 20 O2 ...

Page 34: ...33 DRIVE MODULE WIRING FOR CD 15 O2 CD 20 O2 ...

Page 35: ...wer supply 150 watt for a single CD cell M 1500 100V 120V 50 60 Hz PS155 Power supply 150 watt for a single CD cell M 1500 208V 240V 50 60 Hz PS160 Power supply 150 watt for a single CD cell M 15 AD 100V 120V 50 60 Hz PS165 Power supply 150 watt for a single CD cell M15 AD 208V 240V 50 60 Hz PS300 Power supply 300 watt for one to three CD cells 100V 120V 50 60 Hz PS305 Power supply 300 watt for on...

Page 36: ...mber 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 s...