Clear Water CD15nx Installation & Operation Manual

Corona discharge ozone generators

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Ozone Systems

Installation & Operation Manual

CD15nx ● CD30nx

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

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Page 1 Ozone Systems Installation & Operation Manual CD15nx ● CD30nx 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 © 2024 - ClearWater Tech, LLC • Reproduction of any kind is prohibited • LIT548 • Rev 062524...
Page 2 NTRODUCTION This Installation and Operation Manual is In an ongoing effort to improve reliability and written to assist in the installation, operation operating efficiency, ClearWater Tech may find it and maintenance of ozone delivery systems necessary to make changes to its products. manufactured by ClearWater Tech, LLC.
Page 3: Table Of Contents
Figure 15 – Program Screen Guide ................30 Maintenance ........................35 Figure 16 – CD15nx and CD30nx High Output Drive Module ........37 Figure 17 – Ozone Generator Cooling Fan Assembly ..........37 Figure 18 – 2” Pressurized Reaction Chamber – Exploded View ....... 40 Troubleshooting .......................
Page 4: Overview
VERVIEW How Ozone In Generated Oxygen (O Ozone (O 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 Electrical molecules are split, forming single oxygen atoms (O Field...
Page 5: Safety Information
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 EYES, THROAT RESPIRATORY SYSTEM.
Page 6: Important Safety Instructions
Safety Information 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 Connect to a grounded, grounding type receptacle only. Do not bury cord. Warning – To reduce the risk of electrical shock, replace damaged cord immediately. Install at least 5ft from tub water using nonmetallic plumbing.
Page 7: Theory Of Operation/Product Description
ClearWater Tech ozone systems are designed for safe, effective use in a variety of water treatment applications. The CD15nx and CD30nx 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...
Page 8 The CD15nx and CD30nx ozone systems are pressurized ozone generators, which means there is a needle valve between the ozone reaction chambers and the injector to allow the ozone reaction chambers to be pressurized. This adjustable needle valve is used to maintain optimum pneumatic parameters inside the ozone reaction chambers.
Page 9: Installation Procedures - Getting Started
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.
Page 10: Installation Procedures - Plumbing
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.
Page 11 the injector. 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.
Page 12 Installation Procedures - Plumbing Side Stream Plumbing Installation Diagram Figure 2 Flow Diversion Mechanism Isolation Isolation Filter Valve Valve Ozone Injector Booster Pump Bypass Valve Contact Vessel Full Flow Plumbing Installation Diagram Figure 3 Service Loop Isolation Valve Isolation Isolation Valve Valve Ozone Injector...
Page 13 Installation Procedures - Plumbing Contact Column Installation Diagram Figure 4 6” Clamp Assembly Bolts, nuts & with bolt & nut washers (2 ea) Unistrut (cut to length) “L” Bracket Unistrut Protective End Cap Concrete Anchors with nuts & washers (2 ea) Contact Column Exploded View Figure 5 Column...
Page 14: Installation Procedures - Electrical
Installation Procedures – Electrical The CD15nx and CD30nx 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.
Page 15 Attempting to start a pressurized compressor can result in a stalled motor and current 3 to 4 times the rated value for the motor. The CD30nx and CD15nx either use the vacuum switch or the external loop as the air preparation signal. The default setting is the vacuum switch. Once the unit senses at least -3inHg on the outlet side, it will turn on the air preparation system.
Page 16 Installation Procedures - Electrical Step 4: 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 following will occur: •...
Page 17 Installation Procedures - Electrical Typical 4-20mA Output Signal Connection Using Provided 24VDC Terminals Figure 7 Current Limiting Resistor (600 Ohms Typcial) 4-20 mA Receiver External Loop Electrical Interface Figure 8 120 VAC Signal 240 VAC Signal Power from Power from OPR, PPM, OPR, PPM, pump or timer...
Page 18: Installation Procedures - Pneumatic
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 9). 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).
Page 19 Installation Procedures - Pneumatic Typical Oxygen Concentrator Detail Figure 10 PRESSURE CONTROL RELIEF BOARD VALVE COMPRESSOR SIEVE COOLING BEDS COIL PRESSURE START-UP REGULATOR CAPACITOR EXHAUST SILENCER POWER SUPPLY SOLENOID VALVE INTAKE COALESCING FILTER FILTER Hook-Ups: Ozone generator-to-vacuum break & vacuum break-to-injector manifold The ClearWater Tech vacuum break provides a positive atmospheric “break”...
Page 20 Installation Procedures - Pneumatic 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, in step 6 of the “Start-up and Calibration Procedures.”...
Page 21: Start-Up And Calibration
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 while the system is operating under pressure.
Page 22 Startup and Calibration power until this connection is made and vacuum is present. See the Ozone Generator Program Setup section for more information on configuring how the CD30nx and CD15nx control the air preparation system. Step 7: Using the stainless steel ozone outlet needle valve located at the bottom the ozone generator (see Appendix A), adjust the backpressure of the ozone reaction chambers to 10 PSI.
Page 23 Startup and Calibration Ozone Output Charts Figure 12 CD15nx Ozone Output (g/h) Vs. Feed Gas Flow Rate CD15nx Ozone Concentration By Weight Vs. Feed Gas Flow Rate 10.00% 9.00% 8.00% 7.00% 6.00% 5.00% 4.00% 3.00% 2.00% 10 12 14 16 18...
Page 24: Ozone Generator Program Setup
Ozone Generator Program Setup The CD15nx and CD30nx are equipped with a sophisticated System Information and Diagnostics (S.I.D.) control board, which monitors the ozone drive systems, inlet and outlet pressure, and remote 4-20mA control signal, allows the operator flexibility in how the system is configured, and provides output signals which can be used to monitor the system remotely.
Page 25 Ozone Generator Program Setup Ozone Output Screen When either of the control buttons are pushed individually the screen will automatically go to this the output screen, to see actual and desired ozone output. Pushing or holding down the left side control button will decrease the ozone output.
Page 26: Master Alarm
Ozone Generator Program Setup Setup Screen 2 – Master Alarm Screen Title Master Alarm Current Configuration – Pushing the left side control button will cycle through the following options of what initiates the master alarm: Master Alarm: • 0% O3 – Master alarm will trip when the actual ozone output is 0% for any 0% O3 ->...
Page 27 Ozone Generator Program Setup Setup Screen 3 – Ozone Control Screen Title Current Ozone Control Method – Pushing the left side control button will cycle through the following options of how the system controls the ozone output: O3 Control: • 4-20mA>Manual – In this mode the 4-20mA current loop input signal, if 4-20mA>Manual ->...
Page 28 Your ozone system is equipped to control the air prep system using the Switched Power Output on the terminal strip (terminals 9 and 10). This screen will allow you to configure what trigger the CD30nx or CD15nx uses to turn on the air preparation system.
Page 29: Fault Status
Ozone Generator Program Setup Setup Screen 7 – Fault Information This screen will assist the ClearWater Tech service technician with diagnosing the system in the event that it experiences a fault condition. Screen Title Fault Code – This area will display a code providing the ClearWater Tech service Fault Status: technician valuable information regarding the fault event.
Page 30: Total Run Time
Ozone Generator Program Setup Setup Screen 9 – Service Run Time This screen shows the number of hours the unit has been in operation since the last service. When a complete annual service has been provided the “Service Run Time” should be reset. Screen Title Service Run Time –...
Page 31 Ozone Generator Program Setup Program Screen Guide Figure 15 Main Screen Both Control Buttons Left Control Right Control Left Control Button: Make Language Setup Neither Button Button A Change Button Right Control Button Pushed for Left Control Ozone Output approximately Master Alarm Setup Button: Make 15 seconds...
Page 32 Ozone Generator Program Setup Company Selection Screen This screen will allow the company information displayed on the main screen to be modified. To access this screen, hold down the left hand control button while powering up the unit. Once an X appears on the left hand side of the display screen, release the left hand control button.
Page 33: Phone Number
Ozone Generator Program Setup Setup Screen 3 – Custom Company Web Site Input Current Company Web Site (16 Characters Max) www.website.com Cursor – This indicates which character is currently selected for adjustment. Pushing the left side control button will cycle through the character options beginning with the character shown.
Page 34: Menu Navigation
Ozone Generator Program Setup Menu Navigation Pushing the left side control button will decrease the ozone output if the unit is under manual control Pushing the right side control button will increase the ozone output if the unit is under manual control Pushing both buttons (the left side control button and the right side control button) at the same time will take you to the setup screen In the setup screen, pushing the left side control button cycle through the different...
Page 35 Ozone Generator Program Setup Entering the Company Selection Screen Push down the left side control button while powering up the unit. When an X appears on the left hand side, release the left side control button. When an X appears on the right hand side, push the left side control button again. When prompted, release the left hand an X appears on the left hand side, release Please Release the left side control button.
Page 36: Maintenance
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.
Page 37: Monthly Procedures
Maintenance 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 11).
Page 38 Remove the filter element and clean with soap and water, drying them completely before re-installing (see Figure 17). Booster Pump(s) • Strainer Baskets: Check and clean the strainer basket in the booster pump(s) as required (if so equipped) CD15nx and CD30nx High Output Drive Module Figure 16 Drive Board Transformer Output Connector...
Page 39 Maintenance 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. The Ozone Generator Information screen should not be illuminated.
Page 40 Maintenance to gently pry the end cap off, as long as equal pressure is applied to each side of the end cap. Note: The stainless steel straps should not be removed. Step 8. Remove the high voltage end cap and dielectric from the heat sink/cathode assembly. Step 9.
Page 41 Maintenance 2” Pressurized Reaction Chamber – Exploded View Figure 18 End Cap Retaining Screw and Washer Ozone Outlet Fitting Viton Washer Stainless Steel Washer Bottom End Cap Stainless Steel Clamp (HDO3-III Only) Heat Sink and Cathode Glass Dielectric High Voltage Anode Contact Brush Brush Adapter Nut Oxygen Inlet Fitting...
Page 42 Maintenance 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 11).
Page 43: Troubleshooting
Troubleshooting Air Preparation Problem/Symptom Possible Cause Solution • No power to system • Check main power to system Unit not operating • Power switch in “OFF” position • Turn switch to “ON” position • Incorrect wiring • See “Installation Procedures – Electrical”...
Page 44 Troubleshooting Ozone Generator - Continued Problem/Symptom Possible Cause Solution • No power to Board 1 (Left Side) • Check main power to unit Drive Board Power Problem • Test voltage from power supply to Information Display indicates: drive module from power supply System Problem –...
Page 45 Troubleshooting Ozone Generator - Continued Problem/Symptom Possible Cause Solution • Loose wire harness connection • Check all wires and connectors System Fault B or E The drive board’s feedback had a from the drive board to the drive series of sudden dips indicative of transformer •...
Page 46 Troubleshooting Ozone Injection/Contacting – Continued Problem/Symptom Possible Cause Solution • Hydraulics/Pneumatics out of • See “Start-Up and Calibration – Low Vacuum adjustment Steps 1-4” • Defective check valve • Replace check valve • Hydraulic back pressure • Back wash filter (if so equipped) •...
Page 47: Appendix A - Specifications
Appendix A – Specifications Air Preparation System (AEROUSnx Shown) PRESSURE CONTROL RELIEF BOARD VALVE COMPRESSOR SIEVE COOLING BEDS COIL PRESSURE START-UP REGULATOR CAPACITOR EXHAUST SILENCER POWER SUPPLY SOLENOID VALVE INTAKE COALESCING FILTER FILTER Air Prep System Specifications Oxygen Output/SCFH 16.6” H x 17.1” W x 15.7” D AEROUSnx 90% (+/-3%) @ 15 SCFH, 10 PSI 50 lbs (22.7 kg)
Page 48 Left side control button Right side control button External Loop Connector Ozone Outlet Air Preparation Inlet Backpressure Needle Valve Cooling Fan And Filter Power Entry Module – OFF/ON Switch, Cord Input, Fuse Carrier Bonding/Ground Lug Shown: ClearWater Tech CD15nx Ozone Generator -47-...
Page 49 Input and Output Terminal Block Pressure Switch High Voltage Drive Transformers Vacuum Switch Air Preparation Control Relay Leveling Feet Shown: ClearWater Tech CD15nx Ozone Generator Ozone Generator Specifications Ozone Output/SCFH 15g/h, 5.5% @ 7 scfh, 10PSI CD15nx 21” h x 10.2” w x 9.8” d, 28 lbs...
Page 50 Appendix A - Specifications CD30nx – Ozone Generator Pressure Gauge (PSI) Feed Gas Flow Meter (CFH) System Information Display (S.I.D.) Knockouts for external connections Left side control button Right side control button External Loop Connector Ozone Outlet Air Preparation Inlet Backpressure Needle Valve Cooling Fan And Filter Power Entry Module –...
Page 51 Appendix A - Specifications CD30nx – Ozone Generator Inline Particulate Filter Reaction Chambers Drive Board (Board 1) Left Side Drive Board (Board 2) Right Side Power Supplies Input And Output Terminal Block Pressure Switch High Voltage Drive Transformers Vacuum Switch Air Preparation Control Relay Leveling Feet Shown: ClearWater Tech CD30nx Ozone Generator...
Page 52: Appendix B - Parts List
Appendix B – Parts List Air Preparation System Aerous Replacement Parts Description Part Number Control Board CCA1787 Power Supply PSR12 Solenoid Valve Assembly SV600 Cooling Coil Service Assembly TUB42SA OXU500 Sieve Bed Assembly TBK140 Tubing Kit AC110 Compressor OXS362 Pressure Relief Valve (45PSI) FUS55 Fuse FLT67...
Page 53 Appendix B – Parts List Ozone Generator CD15nx and CD30nx Replacement Parts Description Part Number Reaction Chamber – Complete RCC10 Dielectric Anode 2” RCC71SA Non High Voltage End Cap RCC115 High Voltage End Cap RCC110 O-ring Set ORS40 Drive Module Transformer...
Page 54: Appendix C - Maintenance Kit
Oxygen Concentrator – Replacement Solenoid Valve OXU500 Oxygen Concentrator – Replacement Sieve Beds OXS353 Oxygen Concentrator – Compressor Rebuild Kit Ozone Generator ASPM370A – Maintenance Kit – CD15nx Ozone Generator Part Quantity Description Number FA40 Filter – Fan filter, element only FLT34 Filter –...
Page 55: Appendix D - Logic Schematics
Appendix D – Logic Schematics G L2/N L1 CD15nx Power Entry Module With Fuses External Loop Power Supply Power Supply Vacuum Switch Pressure Switch Left Control Button Control Right Control Button Information Display Input 4-20mA Control Signal – Board Output 4-20mA Ozone Signal –...
Page 56 Appendix D – Logic Schematics CD30nx G L2/N L1 Power Entry Module With Fuses External Loop Power Supply Power Supply Vacuum Switch Pressure Switch Left Control Button Control Right Control Button Information Display Input 4-20mA Control Signal – Board Output 4-20mA Ozone Signal –...
Page 57: Appendix E - Drive Module Input Voltages
Appendix E – Drive Module Input Voltages 24VDC 24VDC 48VDC -56-...
Page 58: Appendix F - Warranty Information
Appendix F – Warranty Information ClearWater Tech, LLC. Limited Three-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 three (3) years, 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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