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ClearWater HDO3-I Installation & Operation Manual

Hdo3 series high dissolved ozone generation system
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Ozone Systems
Installation & Operation Manual
HDO
Series
3
High Dissolved Ozone Generation System
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 • LIT210 • REV121605

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  • Page 1 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 • LIT210 • REV121605...

  • Page 2: Ozone Generator

    -II - Only: The ClearWater Tech HDO3-I is equipped with a CD12 ozone generator where as the HDO3-II is equipped with CD2000 ozone generator. The oxygen feed gas produced by the air preparation system is supplied to the ozone generator at a maximum pressure of 5 pounds per square inch (psi).

  • Page 3: Control Panel

    By design, the operating water pressures of this system and the ClearWater Tech engineered contacting system allows for high levels of dissolved ozone to be maintained in the water in this single pass configuration.

  • Page 4: Safety Information

    SAFETY INFORMATION CHAPTER 2 SAFETY WARNINGS Two aspects of ClearWater Tech dissolved ozone systems 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.

  • Page 5: Important Safety Instructions

    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.

  • Page 6: Equipment Placement

    INSTALLATION PROCEDURES - Getting Started CHAPTER 3 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 7 INSTALLATION PROCEDURES – Plumbing CHAPTER 4 The HDO3 system anticipated results are based on water quality and gallons per minute (GPM) flow rate and water pressure. Based on desired dissolved ozone levels measured in parts per million (PPM), the system should be plumbed using either a sidestream or full flow configuration, see Figure 4-1 for desired ppm level at the suggested gpm flow rate.
  • Page 8 Plumbing (continued) Sidestream Plumbing Installation Diagram Figure 4-2 OPTIONAL: Pressure Reducing Valve Main Water Line Isolation Isolation Valve Valve Sidestream Water Line HDO3 Dissolved Ozone System Full Flow Plumbing Installation Diagram Figure 4-3 Optional Service Loop Isolation Valve Isolation Isolation Valve Valve OPTIONAL:...

  • Page 9: Installation Procedures - Electrical

    LED located on the 4-20mA control board inside the HDO3-II and HDO3-III ozone generators and the EXT LOOP LED on the front cover of the HDO3-I ozone generator (see Appendix-Section A, for location of 4- 20mA board) and turn off the “Ozone Output” LED(s) on the front cover. Note: When the external loop has lost continuity main power to the ozone generator will remain “ON”...
  • Page 10 Electrical (continued) avoid over-ozonation. The ozone generator 4-20mA control leads of the HDO3 system have been pre-wired at the factory to the dissolved ozone monitor/controller. The negative (-) input signal to the Purple wire of the ozone generator and the positive (+) input signal to the Orange wire of the ozone generator. Note: The dissolved ozone monitor/controller has been pre-programmed at the factory to 20mA or 100% ozone output.
  • Page 11 “in.Hg”). Also, maintaining the correct water flow and hydraulic pressures will ensure the highest possible level of dissolved ozone. The air from the air preparation system of the HDO3-I and HDO3-II flows toward the ozone generator under pressure, and from the ozone generator under vacuum (created by the ozone injector). The change from pressure to vacuum occurs at the SCFH meter of the air preparation system located on the bottom left side of the HDO3 system.
  • Page 12 (continued) Step 15: HDO3-I and HDO3-II – only: Adjust the “Ozone Injector – Vacuum Control” knob, located on the Control Panel (see Appendix-Section A), until the “Ozone Generator – Vacuum” gauge achieves -5 inHg. Due to the vacuum switch installed, the “Ozone Generator – Vacuum” gauge must achieve -3inHg before ozone will begin production (once the External Loop is re-connected).

  • Page 13: Operating Parameters

    Start-Up and Calibration (continued) -II and HDO -III - Ozone Generator Drive Board LED Function Figure 7-1 B Function 12V MAIN When illuminated, this “Green” LED indicates that main power is supplied to the drive module up to the “on board” POWER fuse of the drive board.
  • Page 14 Start-Up and Calibration (continued)

  • Page 15: Maintenance

    Calibration” steps 8-11. Ozone Generator: • Indicating Lights – HDO3-I Only: Check the indicator lights on the ozone generator. See Figure 7-1A for Ozone Generator LED Display function. • Indicating Lights – HDO3-II and HDO3-III Only: Check for illumination of the drive module "Ozone Output"...

  • Page 16: Monthly Procedures

    Figure 8-2 thru 8-4). Check the chamber interior and dielectric tube for oil, dirt or moisture. Note: Disassembly and service of the reaction chamber(s) is a technical, delicate and critical procedure. Please consult your ClearWater Tech dealer before attempting this procedure.
  • Page 17 Maintenance (continued) Reaction Chamber Removal and Disassembly HDO3-I only: Step 1: Make sure all power to the ozone generator has been disconnected according to the “System Shutdown Procedures” outlined above. Step 2: Disconnect tubing connections from the fittings on both ends of the reaction chambers.
  • Page 18 Maintenance (continued) Assembly and Re-installation HDO3-II and HDO3-III only: 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.
  • Page 19 Maintenance (continued) 2” Vacuum Reaction Chamber - Exploded View -II, Figure 8-3 Ozone Outlet Fitting Bottom End Cap And O-rings Heat Sink and Cathode Glass Dielectric End Cap Retaining Screw and Washer High Voltage Anode Contact Brush Oxygen Inlet Fitting Brush Adapter Nut High Voltage End Cap and O-rings...

  • Page 20: Troubleshooting

    TROUBLE SHOOTING CHAPTER 9 AIR PREPARATION PROBLEM/SYMPTOM POSSIBLE CAUSE SOLUTION Compressor not operating - No power to HDO3 System - Check main power to system - Incorrect wiring to the HDO3 system - See 'Installation Procedures'- Electrical - Main Power switch is in the “OFF” position - Turn Main Power switch to the “ON”...
  • Page 21 Troubleshooting (continued) CONTROL PANEL and OZONE GENERATOR – HDO continued PROBLEM/SYMPTOM POSSIBLE CAUSE SOLUTION ‘High Pressure – Side Water’ gauge - High Pressure not within operating parameters • Inlet water supply pressure regulator out of - Adjust or repair as required (Control Panel) adjustment or inoperable •...
  • Page 22 Troubleshooting (continued) CONTROL PANEL and OZONE GENERATOR – HDO PROBLEM/SYMPTOM POSSIBLE CAUSE SOLUTION Fan not operating - Fan obstructed - Remove obstruction - Main mother board not operating - Check main power, check fuses. Repair or replace as required - Fan inoperable - Replace fan Unit flooded with water - Defective check valve...
  • Page 23 Troubleshooting (continued) CONTROL PANEL and OZONE GENERATOR – HDO -II and HDO -III continued PROBLEM/SYMPTOM POSSIBLE CAUSE SOLUTION ‘Ozone Injector – Vacuum’ not within - High vacuum - Slightly open the ‘Ozone Injector- Operating parameters (Control Panel) Vacuum Control’ knob - Low vacuum - Slightly close the ‘Ozone Injector- Vacuum Control’...
  • Page 24 Troubleshooting (continued) CONTROL PANEL and OZONE GENERATOR – HDO -II and HDO -III continued PROBLEM/SYMPTOM POSSIBLE CAUSE SOLUTION Ozone Output, “Amber” - If the Transformer (XFMR) Power LED - Check all wires and connectors LED not illuminated is not illuminated, the “Ozone Output” LED will not illuminate - The Manual Ozone Output potentiometer - See ‘Installation Procedures’...
  • Page 25 Troubleshooting (continued) OZONE INJECTION/CONTACTING/VACUUM BREAK PROBLEM/SYMPTOM POSSIBLE CAUSE SOLUTION Water backflow past injector - Defective injector check valve - Replace injector check valve check valve Water bubbling in vacuum - Insufficient ‘Ozone Injector – Vacuum’ - See 'Start-Up & Calibration' break - Debris on seat of vacuum break flapper valve - See 'Maintenance Procedures' –...

  • Page 26: Specifications

    Shown: ClearWater Tech Workhorse 12C Air Prep System with Cover Compressor Inlet Filter Oxygen Concentrator Sieve Bed (ATF) Compressor Compressor Cooling Coil Shown: ClearWater Tech Workhorse 12C Air Prep System with out Cover AIR PREP UNIT OXYGEN OUTPUT/SCFH – I (Workhorse 8C) 90% (+/-3%) @ 8 scfh, 5PSI –...
  • Page 27 Appendix (continued) Section A – Specifications Control Panel HDO3-I and HDO3-II A. Ozone Generator - Vacuum B. Ozone Injector – Vacuum C. High Pressure – Side Water D. Dissolved Ozone Monitor/Controller E. Feed Gas Flow Rate F. Ozone Injector – Vacuum Control G.
  • Page 28 (Left Side) Outlet Bonding/Ground Lug Water Supply Inlet (Left Side) Shown: ClearWater Tech HDO3 - I Ozone Generation System (Wire harness omitted for clarity) OZONE SYSTEM SPECIFICATIONS OZONE OUTPUT 66” h x 20” w x 29” d, 280lbs 8g/h @ 3%...
  • Page 29 Manual Ozone Output Adjustment Knob External Loop Connector Remote 4-20mA Connector Power Entry Module – OFF/ON Switch, Cord Input, Fuse Carrier Fan and Fan Filter Bonding/Ground Lug Ozone Outlet Shown: ClearWater Tech CD12 Ozone Generator (Wire harness omitted for clarity)
  • Page 30 High Dissolved Ozone Water Outlet Bonding/Ground Lug (Left Side) Water Supply Inlet Shown: ClearWater Tech HDO3-II Ozone Generation System (Wire harness omitted for clarity) OZONE SYSTEM SPECIFICATIONS OZONE OUTPUT 66” h x 20” w x 29” d, 300 lbs 20g/h @ 4%...
  • Page 31 Air Prep Inlet Manual Ozone Output Adjustment Knob Main Power Light External Loop Connector Remote 4-20mA Connector Ozone Outlet Fitting Fuse Carriers Main Power Switch - OFF/ON Bonding/Ground Lug Condulet – Main Power Leads Shown: ClearWater Tech CD2000 Ozone Generator...
  • Page 32 High Dissolved Ozone Water Outlet Bonding/Ground Lug (Left Side) Water Supply Inlet Shown: ClearWater Tech HDO3-III Ozone Generation System (Wire harness omitted for clarity) OZONE SYSTEM SPECIFICATIONS OZONE OUTPUT -III 66” h x 20” w x 29” d, 300 lbs...
  • Page 33 Fan and Fan Filter Air Prep Inlet Manual Ozone Output Adjustment Knob Main Power Light External Loop Connector Remote 4-20mA Connector Ozone Outlet Fitting Bonding/Ground Lug Power Entry Module – OFF/ON Shown: ClearWater Tech CD2000P Ozone Generator Switch, Cord Input, Fuse Carrier...

  • Page 34: Parts List

    24VDC – HDO3-I, HDO3-III Dielectric Anode 2” – HDO3-III RCC71 Cooling Fan – Oxygen Concentrator, FA41 120VAC 60Hz, HDO3-I, HDO3-II, Non-High Voltage End Cap – HDO3-I RCC57 HDO3-III Cooling Fan – Oxygen Concentrator, FA42 High Voltage End Cap – HDO3-I...

  • Page 35: Maintenance Kit

    APPENDIX - Section C Maintenance Kit ASPHD10A - Maintenance Kit – HDO Part # Description OXS350 Oxygen Concentrator – Replacement Compressor Inlet Filter OXS356 Oxygen Concentrator – Compressor Rebuild Kit OXS360 Oxygen Concentrator – Compressor Pressure Relief Valve OXS370 Oxygen Concentrator – Cover Filter FA40 Filter –...
  • Page 36 Main Power Magnetic Switch Contactor Dissolved Ozone Monitor Ozone Generator Oxygen Concentrator Booster Pump Shown: Electrical Schematic - HDO3-I, HDO3-II and HDO3-III Line Side Note: This system is not dual voltage rated. System voltage is 120VAC 60Hz or 220VAC 50Hz.
  • Page 37 Appendix (continued) Section D - Logic Schematics -II Ozone Generator – CD12 G N/L2 L1 Power Entry Module with Fuses Cover Safety Switch External Loop Mother Board Vacuum Switch Manual Ozone Output Control Output Control Board Remote 4-20mA Ozone Output LED Display Control Board...
  • Page 38 Appendix (continued) Section D - Logic Schematics -II Ozone Generator – CD2000 N/L2 Cover Safety Switch Fuse Fuse Main Power Switch Main Power Light Voltage Selector Switch Power Manual Ozone Supply Output Control +24 VDC 0 VDC Remote 4-20mA - 24VDC Ozone Output 4-20mA Control...
  • Page 39 Appendix (continued) Section D - Logic Schematics -III Ozone Generator – CD2000P N/L2 Power Entry Module With Fuses Cover Safety Switch Power Supply Power Supply Manual Ozone Output Control Remote 4-20mA Ozone Output Control External Loop Pressure Switch 4-20mA Control Drive Board Drive Board Board...
  • Page 40 APPENDIX - Section E Drive Board Input Voltage – HDO -II and HDO -III Shown: Dual HO Drive Module...
  • Page 41 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;...

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Hdo3-iiiHdo3-ii

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