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ClearWater CD-2000 Installation & Maintenance Manual

Corona discharge ozone generator
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Ozone Systems
Installation & Maintenance Manual
CD-2000
Corona Discharge Ozone Generators
ClearWater Tech, LLC
Integrated Ozone Systems
850-E Capitolio Way, San Luis Obispo, Ca 93401 • 805-549-9724 • Fax: 805-549-0306 • E-mail: service@cwtozone.com • www.cwtozone.com
Copyright © 2005 - ClearWater Tech, LLC. • Reproduction of any kind is prohibited • LIT520 • REV 062005

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Summary of Contents for ClearWater CD-2000

  • Page 1 Integrated Ozone Systems 850-E Capitolio Way, San Luis Obispo, Ca 93401 • 805-549-9724 • Fax: 805-549-0306 • E-mail: service@cwtozone.com • www.cwtozone.com Copyright © 2005 - ClearWater Tech, LLC. • Reproduction of any kind is prohibited • LIT520 • REV 062005...
  • Page 2 Therefore, the information contained in this manual may not conform in every respect to earlier versions of ClearWaterTech ozone systems found in the field. If you have any questions, please contact your ClearWater Tech dealer or the ClearWater Tech service department.
  • Page 3 OVERVIEW How Ozone is Generated Oxygen (O Ozone (O Ozone is generated by exposing oxygen molecules ) in an air stream to a controlled, high energy electrical field. As the air stream passes through the electrical field produced inside the ozone Electrical Field generator, some oxygen molecules are split, forming single oxygen atoms (O...
  • Page 4 If “Plant Air” feed gas is to be used, in place of the ClearWater Tech air preparation system, the same air quality standards must be met to achieve the ozone output and longevity of the ozone generator. A PSI (pounds per square inch) regulator must be installed when using plant air feed gas.
  • Page 5 The ClearWater Tech off-gas destruct systems consists of two components - the ozone destruct unit (a heated chamber filled with manganese dioxide and copper oxide) and a water trap. Used in conjunction with a ClearWater Tech off gas vent, the ozone destruct system is an effective way to vent the contact vessel(s) when it is impractical...

  • Page 6: Safety Information

    MANUAL. IF CONTACT IS MADE WITH OPERATING HIGH VOLTAGE COMPONENTS, ELECTRIC SHOCK WILL OCCUR. ClearWater Tech corona discharge ozone generators take line voltage and convert it to 48 VDC. A high voltage transformer then boosts the voltage. While each ozone generator has a door switch and other safety interlocks, proper care must be used by a qualified electrician when making any internal adjustments or performing any maintenance procedures.
  • Page 7 Safety Information (continued) IMPORTanT safETy InsTRUcTIOns - When installing and using this electrical equipment, basic safety precautions should always be followed, including the following: READ AND FOLLOW ALL INSTRUCTIONS. SAVE THESE INSTRUCTIONS. 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 all electrical equipment at least five feet from any open body of water using non-metallic plumbing. Install check valves and a vacuum break to prevent water from contacting the electrical equipment. The electrical supply for this product must include a suitably-rated switch or circuit breaker to open all ungrounded supply conductors to comply with Section 422-20 of the National Electrical Code, ANSI/NFPA 70-1987. The disconnecting means must be readily accessible to the operator(s) but installed at least five feet from any open body of water. Be sure to bond (ground) the system using the copper bonding lug on the bottom of the ozone generator. The system should be bonded with solid copper wire conforming with all local, state and national electrical codes.

  • Page 8: Installation Procedures

    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.
  • Page 9 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.
  • Page 10 Check Valve Selection The ozone check valve is an important component in preventing damage to the ozone generator. All ClearWater Tech CD2000 ozone generator is equipped with a Kynar low pressure check valve on the ozone outlet. A second ®...
  • Page 11 To maximize the effectiveness of ozone, it must be thoroughly mixed and have adequate time to react with the contaminants in the water before being filtered or utilized. Contact vessels are designed to achieve this necessary mixing and contact time. ClearWater Tech supplies several different types of contact vessels for a variety of applications. Booster Pump...
  • Page 12 PlUMBInG cOnnEcTIOns Full Flow Plumbing Connections Refer to the ‘Full Flow Installation’ diagram on the next page and follow the instructions below if the ozone is being injected directly into the full flow of the pool’s return line: 1. Tap into the return line after the pump, filter, and heater. The ozone injection point should be the last component in line and as far as possible from the residual sanitizer injection point. 2. Glue in the proper injector, noting the direction of flow (indicated by an arrow on the injector). 3. Once the injector is installed, the vacuum may be adjusted as described in the “ozone generator operation” section. If the system is equipped with the optional electrical interlock box, the vacuum can be observed on the VAC/PSI gauge located above the SCFH gauge on the electrical interlock box. Note: The ozone generator will only energize for 15 seconds or until a vacuum is attained. Tubing Installation 1. Install braided tubing from the air dryer to the AIR INLET fitting on the bottom of the ozone generator (or the bottom of the electrical interlock box if so equipped). If you are not using an electrical interlock box, skip Step 2 and go to Step 3. 2. If equipped with the electrical interlock box, continue running the braided tubing from the electrical interlock box to the brass barb fitting on the bottom of the ozone generator. 3. Install the check valve assembly into the injector. Connect the 1/4” Teflon tubing from the OZONE OUT fitting on the ® bottom of the ozone generator to the check valve assembly on the injector. Secure by tightening the fitting around the 1/4” Teflon tubing after insertion. (If equipped with the electrical interlock box, install the 1/4” Teflon...
  • Page 16 OPTIONAL VACUUM BREAK INSTALLATION Plumbing Connections - continued Location Select a suitable vertical surface that is accessible and in close proximity to the ozone generator and venturi manifold on which to mount the vacuum break. Installation Steps 1. Install the two mounting Clic clamps provided on the vertical surface so that the vacuum break will be in a vertical position and ® the height of the fill/drain valve fitting will be below the level of the ozone generator bulk head check valve. One clamp should be located directly above the vacuum break’s bottom end cap and the other just below the fill/drain fitting tee. 2. Install the two reducer bushings provided into the riser tee, one into the side tapping and the other into the top tapping. Be sure to use 2-3 wraps of Teflon tape on the male threads. ® 3. Install the PVC ball valve provided into the reducer bushing in the side tapping on the riser tee. Be sure to use 2-3 wraps of Teflon tape on the male threads. This valve controls the amount of water that is drawn up into the riser tube by the suction ® of the venturi. It can also be used to isolate the venturi should a check valve fail. 4. Install the 90º Kynar fitting provided into the reducer bushing on the top tapping on the riser tee. Be sure to use 2-3 ® wraps of Teflon tape on the male threads. ® 5. Place the two-inch diameter water reservoir into the mounting Clic clamps and secure. Check to make sure the height of the ®...
  • Page 17 Plumbing Connections - continued Vacuum Break detail Ozone Flow Fill Port Cap Ozone Generator Upper Tee Ozone Flow Lower Tee Check Valve Assembly Venturi Mounting Clamps Drain Port Ozone Injector Manifold Flapper Valve Riser Tube Elbow...
  • Page 18 Plumbing Connections - continued OPTIONAL CONTACT COLUMN INSTALLATION Location The contact column(s) should be installed after the injector manifold(s), within three (3) feet of a wall or solid mounting surface using isolation valves to facilitate cleaning the diffuser, if needed. There should be as few elbows as possible between the injector(s) and the contact column(s).
  • Page 19 MOUNTING CONTACT COLUMN TO WALL USING UNISTRUT MOUNTING SYSTEM 1/2" Holes Drilled Into Wall (3 .5" to 4" deep) 6' Clamp Assembly with Bolt & Nut Bolts, Nuts & Washers (2 each) Unistrut (may get cut to length desired) Unistrut "L"...
  • Page 20 Installation of Contact Column Vent Line Drill and tap a 1/4” MPT hole into the main water return line after the heater. This hole should be drilled into a location with less pressure than the ozone loop so that the contact column will continually bleed ozone gas buildup on top of the column to be mixed back into the main water line. (Do not install this vent line on the suction side of the pump.) Install the Teflon vent line from the Kynar fitting on the ® ® top of the contact column to the location drilled into the main water line. Vent Line Installation Detail Compression Elbow Fitting Needle Valve (may be installed anywhere along vent line) Vent Line Contact...

  • Page 21: Electrical Connections

    ElEcTRIcal cOnnEcTIOns GENERAL INFORMATION Please read the following important information before making any electrical connections: 1. All electrical work should be done by a licensed electrician. 2. All local codes must be observed. The M-1500, CD-1500, P-2000, and CD-2000 are available in 120 VAC and 240 VAC models. Be sure to install the proper model for each application. Before attempting any electrical hook-up, be sure the power is OFF at the main circuit box. Ground the ozone generator using the copper grounding lug on the bottom of the unit. Solid copper wire conforming with all local, state, and national electrical codes should be used. The ozone generator should be wired so that the ozone comes ‘ON’ when the main circulation pump comes on for filtration. This can be accomplished by utilizing the optional elctrical interlock box to interface with a flow switch, ORP monitor, timer or motor control interlock (MCI) to the main circulation pump. If the optional electrical interlock box is not used, the ozone generator should be wired to the main circulation pump’s power source (or timer if a timer is used). If a side stream booster pump is used, the ozone generator and the booster pump should be interlocked to the main circulation pump. The ozone generators come standard ready to be hard wired using 1/2” liquid tight conduit. ELECTRICAL CONNECTIONS WITH OPTIONAL ELECTRICAL INTERLOCK BOX Note: All electrical connections should be made by a qualified electrical contractor. All local, state and national 0codes must be observed.
  • Page 22 Electrical Connections - continued Terminals 7 & 8: Booster Pump - 240 VAC, 60 Hz, 8 AMP, 1 HP. Use minimum #14 AWG. 120 VAC, 60 Hz, 16 AMP, use minimum #12 AWG. Wire from the terminal strip to the booster pump as indicated. The booster pump will be controlled by the interlock box. In many cases this feature is not be used; the operation of the remaining equipment will not be affected. Terminals 9 & 10: Ozone Generator - 240 VAC, 60 Hz, 2 AMP or 120 VAC, 60 Hz, 4 AMP. Hard wire the electrical cord on the ozone generator to the terminal strip as indicated. The ozone generator will be controlled by the electrical interlock box. Air Dryer: 120 VAC, 60 Hz, 1 AMP. Plug the air dryer into a standard wall outlet 120 VAC, 60 Hz. The air dryer should remain energized at all times with the exception of long term shutdown for service. The air dryer can be hard wired to the electrical interlock box utilizing terminals 1 (120V) and 3 (neutral). Using a bonding wire 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.
  • Page 23 Electrical Connections - continued ELECTRICAL SCHEMATIC WITH OPTIONAL ELECTRICAL INTERLOCK BOX 240 VAC, 60 Hz, Single Phase M-1500: 2 Amps without Booster Pump, 7 Amps with 1/2 HP Booster Pump P-2000: 10 Amps with 3/4 HP Booster Pump Service disconnect Connections: or from a dedicated Electrical Wiring...
  • Page 24 INITIAL STARTUP AND CALIBRATION WITH OPTIONAL ELECTRICAL INTERLOCK BOX ClearWater Tech air preparation and ozone generation system CD2000 is a vacuum type and will require adjustment of the air flow through the system. On the front of the electrical interlock box is a VAC/PSI gauge and an SCFH (Standard Cubic Feet per Hour) gauge. These two instruments are all that are required to keep the system operating within the correct parameters. The ozone system will not function without a minimum of 3” vacuum from the venturi injector (due to an electrical vacuum interlock relay). This is a safety feature designed to prevent the ozone generator from operating without the injector drawing the gas into the water. After all the previous electrical and plumbing connections have been completed, the system is ready for startup and calibration. Starting Position: Water flowing in the main line. Open the valves to the ozone loop (if so equipped). Switch the main service disconnect box to the ON position. Turn the ozone generator ON at the switch located on the front of the electrical interlock box. Note: The dryer should already be ON as it is wired for continuous operation. The booster pump and ozone generator should now be operating. The injector can now be adjusted for suction. Observe the SCFH gauge and adjust the air flow using the needle valve on the SCFH gauge. Closing this valve will lower the air flow and raise the vacuum. If proper flow and vacuum cannot be achieved, readjust the bypass valve on the injector manifold until you achieve the SCFH specified for the ozone generator being installed (see chart below). Note: The system will only operate for 15 seconds without vacuum. To reset the time sequence, turn the ‘ON OFF AUTO’ switch OFF and back to ON.
  • Page 25 INITIAL START-UP WITHOUT OPTIONAL ELECTRICAL INTERLOCK BOX The air preparation and ozone generation systems on ClearWater Tech Model CD2000 is 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 injected into the water). Follow the directions and illustration below to optimize flow through the injector: With the pump running, disconnect the ozone line from the outlet on the ozone generator and connect it to the fitting on the back of the SCFH gauge provided (see drawing). While holding the gauge vertically, read the amount indicated on the gauge. The optimum flow is 11 to 15 SCF for the CD2000. Note: Do not obstruct the bottom air hole on the gauge. On a single pump system, the injector will have a ball valve to adjust the amount of flow. To adjust the SCFH, simply install the gauge as above and open the gate valve completely. With the pump running, begin closing the gate valve until the optimum flow is achieved on the SCFH gauge. If possible, remove the gate valve handle to prevent tampering with the setting. Attach Ozone Line Keep Gauge Vertical Injector Manifold with check valve Do not block lower hole...
  • Page 26 Note: If any unusual reactions are experienced when ozone is introduced to the water (such as abnormal color or odor), please wait a few days to give the ozone and filter system time to work. If the situation continues, your ClearWater Tech distributor should be consulted.
  • Page 27 Ozone Generator Operation - continued Properties of Bromine and Various Forms of Chlorine Type of Bromine % of Stabilizer Neutralizer Fast Comments or Chlorine Available Required? Dissolving? Dissolving? Oxidizer Bromine 61% 7.4 No Yes (Muriatic No Works well in floaters Acid or CO or feeders-Can be used in vinyl pools Gas Chlorine 100%...
  • Page 28 CD2000 OZONE GENERATOR DIMENSIONS AND LAYOUT Front and Bottom Views...
  • Page 29 ELECTRICAL CONNECTIONS The installation should be done by a licensed electrician. All local codes must be observed. The units come standard ready to be hard wired, using 1/2" liquid tight conduit. The ozone generator should be wired so that the ozone generator is on when the pump is on or when water is flowing through the venturi.
  • Page 30 240VAC ELECTRICAL CONNECTIONS WITH OPTIONAL ELECTRICAL INTERLOCK BOX Follow the instructions below and the wiring diagram on the previous page to wire your system. Note: All electrical connections should be made by a qualified electrical contractor. All local, state and national codes must be observed. Inside the electrical interlock box (at the bottom, toward the center) is a terminal strip.
  • Page 31 Ozone Systems Maintenance & Trouble Shooting Manual Parts & Warranty CD-2000 Corona Discharge Ozone Generators...

  • Page 32: Maintenance

    MaInTEnancE Ozone Generator Care A word of caution: There is extremely high voltage inside the ozone generator. If you suspect a problem, disconnect the power to the unit at the service disconnect box or main electrical panel and immediately contact your ClearWater Tech distributor. Inspect the ozone delivery line check valves daily for water seepage and replace the injector check valve yearly. • Clean the ozone generator cabinet air filters: These filters must be cleaned regularly. Depending on the location of the unit, it may be necessary to clean the air filters monthly. On the bottom of the cabinet are filter elements (see illustration below). These are air intake elements for the cooling fans and may therefore require the most frequent cleaning. 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:...

  • Page 33: Maintenance Schedule

    Removal of the Dielectric Tubes Disconnect all the power to the system, including panel breakers, service disconnect box and main circulation pump interlock. Unplug the electrical terminal on the back of the drive module, disconnect the polypropylene barbed air fitting and the Kynar ® ozone fitting. Remove the ozone reaction chamber(s) from the back plate. Disconnect the high voltage wire from the coil. Remove the stainless steel nut and Kynar center rod from the center of the ® reaction chamber. The Teflon end caps can now be gently removed by slowly pulling straight out. The glass dielectric will remain ® attached to one of the end caps. If the dielectric tube is dirty, clean the glass with Isopropyl alcohol. Do not use a solvent that will leave an oily residue. Clean the inside of the stainless steel reaction chamber with a wire brush as necessary, then wipe with Isopropyl alcohol. Be sure all solvents have evaporated prior to reassembly. Re-Installation of the Dielectric Tubes Inspect the O-rings and replace as necessary. Tighten the end caps so that they are approximately 1/8" from the aluminum extrusion. Replace the reaction chambers and connect the air and ozone lines. Connect the high voltage wire to the coil Readjust the system as necessary (see operating instructions). Maintenance Schedule Yearly Service Replace the cooling fan filter(s) on the ozone generator Replace the air inlet particulate filter on the ozone generator Replace the check valves Remove and clean the glass dielectric in reaction chamber Rebuild the solenoid valve on the electrical interlock box Replace the flange gasket and clean the diffuser in the contact column Regenerate the desiccant in the external indicating chamber on the AD-40 air dryer...
  • Page 34 CD-2000 OZONE GENERATOR COMPONENTS SPECIFICATIONS: CD-2000 Energy Required: 105 V min., 125 V max. (120VAC models) 50/60 Hz, 1.6 Amps Energy Required: 208 V min., 240 V max. (240 VAC models) 50/60 Hz, 0.8 Amps Dimensions: 23" h x 20.25" w x 5.5" d Shipping Wt: 49 lbs.
  • Page 35 EXPLODED VIEW OF CORONA DISCHARGE REACTION CHAMBER...
  • Page 36 POWER SUPPLY FOR P2000 & CD2000 Power Supply for Multi-Cell Units (100-120V Pt# PS300) (208-240V Pt# PS305)
  • Page 37 SOLENOID VALVE (ON OPTIONAL ELECTRICAL INTERLOCK BOX)
  • Page 38 PARTS LIST FOR CD-2000 PART# DESCRIPTION CKV20 Check valve CD 1/4" kynar - FPT, low pressure FA40 Fan - Cooling, CD filter element only - 4" FA41 Fan - Cooling, CD 120V 50/60 Hz - 4" FA42 Fan - Cooling, CD 240V 50/60 Hz - 4" FA43 Fan - Cooling, CD external finger guard - 4" FA44 Fan - Cooling, CD internal finger guard - 4" FLT34 Filter - inline particulate 1/4", for one to three cell CD systems RCC6 Complete CD reaction chamber, 2” (does not include fittings) RCC20 Cathode with heat sink and feet RCC70 Dielectric only, all CD reaction chamber, 2” RCC80 High voltage lead, all 2” CD reaction chambers RCC103 High voltage end cap with O-Rings RCC108 Non-high voltage end cap with O-Rings ORS30 O-Ring package DRM10 Drive Module - M-1500 or P-2000 complete, with HV transformer and mounting bracket DRM12 Drive Module - CD-1500 or CD-2000 HO complete, with HV transformer and mounting bracket HVT100 H.V. coil only for 2" CD reaction chamber...
  • Page 39 OZONE GENERATOR TROUBLESHOOTING PROBLEM/SYMPTOM POSSIBLE CAUSE SOLUTION Unit does not turn on No power to unit Check breakers • • Switch not turned on Check switch • • Blown fuse Replace fuse on bottom panel • • Cover/door interlock not active Check door interlock switch •...
  • Page 40 OZONE GENERATOR TROUBLESHOOTING (continued) PROBLEM/SYMPTOM POSSIBLE CAUSE SOLUTION Unit seems noisy Not properly secured to wall/floor Bolt it firmly into place • • Shipping damage Locate and repair • • Fan blocked Check and clear obstructions • • Flow meter will not adjust Air preparation not operating Make sure air prep package is •...
  • Page 41 ELECTRICAL INTERLOCK BOX TROUBLESHOOTING PROBLEM/SYMPTOM POSSIBLE CAUSE SOLUTION ‘MAIN POWER’ light not on No power to electrical interlock box Check power connections & breakers • • No neutral in 120 VAC supply Hook up neutral • • Light burnt out Replace light •...
  • Page 42 DRIVE MODULE WIRING FOR CD2000...
  • Page 43 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 •...