CleanWater Tech CD1500P User manual

Ozone Systems
Installation & Operation Manual
CD1500P • CD2000P
Corona Discharge Ozone Generators
Tested and certified by
WQA to NSF/ANSI 50 as a
component only.
Testedand certified by
WQAto NSF/ANSI 50 as a
componentonly.
ClearWater Tech, LLC.
Integrated Ozone Systems
850-E Capitolio Way, San Luis Obispo, Ca 93401 • 805-549-9724 • Fax: [phone] • E-mail: [e-mail] • www.cwtozone.com
Copyright © 2005 -ClearWater Tech, LLC • Reproduction of any kind is prohibited • LIT546 • REV093010

1
THEORY OF OPERATION/PRODUCT DESCRIPTION CHAPTER 1
ClearWater Tech ozone systems are designed for safe, effective use in a variety of water treatment applications. The
CD1500P, and CD2000P ozone generators have been tested and certified by the Water Quality Association according to
NSF/ANSI 50. Each complete, integrated system may include the following components required for reliable, efficient
ozone production and can be divided into four general segments:
• Air preparation system • Ozone generator • Ozone injection/contacting • Ozone destruct
Air Preparation System
ClearWater Tech pressurized ozone generators require a source of clean, dry, oil-free, oxygen-enriched air for effective
ozone production. To meet that need, ClearWater Tech employs pressure swing adsorption (PSA) technology with an oil-
less compressor to increase the concentration of oxygen and reduce the moisture content in the feed gas (the air supplied
to the ozone generator). This substantially improves the output capability of the ozone generator and prevents premature
failure of key internal components. These air preparation systems deliver 90%+/-3% oxygen purity at -100°F dew point
and at very low pneumatic pressures, minimizing noise and reducing compressor wear.
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 pounds per square inch (PSI) regulator
must be installed when using plant air feed gas. This regulator must be set to a maximum of 10 PSI.
Ozone Generator
ClearWater Tech pressurized ozone generators are designed to supply high concentrations of ozone gas (up to 10%) at 10
PSI. The oxygen feed gas produced by the air preparation system is supplied to the ozone generator, which flows through
the built-in flow meter. A stainless steel needle valve, located externally at the ozone outlet, is used to maintain optimum
pneumatic parameters inside the ozone reaction chambers. After this point the vacuum created at the ozone injector draws
the ozone gas into the water line. The ozone generator is equipped with a pressure switch, which prevents operation if
pressure within the reaction chambers drops below 9 PSI.
As the feed gas enters the fused, thermally protected reaction chambers inside the ozone generator, some of the oxygen
molecules are split while passing through the high voltage electrical field (the “corona”), forming single oxygen atoms
(O1). These oxygen atoms then recombine with other oxygen molecules in the air stream, forming ozone. The modular,
multiple reaction chamber design allows the ozone generator to keep working even if one or more of the chambers
requires service.
Booster Pump Ozone Injector
Water Flow Off Gas
Vent Optional Destruct System
Ozone
Ball Destruct
Valve Unit
Air Ozone Generator
Preparation
Water Trap
Vacuum Break
Contact Vessel
Shown: ClearWater Tech CDCD2000P Ozone System

Theory of Operation/Product Description (continued)
2
Depending on the application, the ClearWater Tech ozone generator may be interlocked with an ORP controller, PPM
controller, pressure switch, timer or circulation pump. Other safety features are also built in, including thermal protection.
Ozone Injection/Contacting
The ozone injector serves two purposes: One, it creates the vacuum
required to safely draw the ozone gas from the ozone generator and
two, it provides a means by which the ozone gas can become
dissolved in water. A very dynamic injection process is required to
effectively dissolve ozone in water.
ClearWater Tech injection systems use only Mazzei® injectors for
maximum mass transfer efficiency. The injector produces a
cavitation effect, enabling the ozone gas to join the water stream in
the form of extremely tiny bubbles. These bubbles must be as small
as possible in order to increase the ratio of bubble surface area to
the amount of ozone entering the water.
Depending on the application and the water treatment goals, a ClearWater Tech contacting system may also be required.
Some oxidation reactions take place so quickly that they are limited only by the rate at which the ozone is dissolved in the
water. Other reactions, such as disinfection, may require that proper ozone residual be maintained for a specific amount of
time. A correctly-sized contact vessel is used for this purpose.
Ozone Destruct
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 to send the off gas
to atmosphere or reintroduce it to the water.

3
SAFETY INFORMATION CHAPTER 2
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 TO THE
EYES, THROAT AND RESPIRATORY SYSTEM.
This ClearWater Tech corona discharge ozone
generator is designed to operate under a pressure
condition. While safety precautions have been taken,
entering the equipment area should be avoided if ozone
gas is detected. Ozone has a very distinctive odor and is
detectable at very low concentrations (0.02 ppm), which
is far below OSHA’s maximum permissible exposure
level of 0.1 ppm.
HIGH VOLTAGE -WARNING: CLEARWATER TECH OZONE GENERATORS OPERATE
AT HIGH VOLTAGE. DO NOT TAMPER WITH OR DELIBERATELY
BYPASS THE COVER OR SAFETY SWITCHES BUILT INTO THE
OZONE GENERATOR UNLESS INSTRUCTED TO DO SO BY THIS
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.

4
IMPORTANT SAFETY INSTRUCTIONS
When installing and using this electrical equipment, basic safety precautions should always be followed, including the
following:
1. READ AND FOLLOW ALL INSTRUCTIONS.
2. SAVE THESE INSTRUCTIONS.
3. All electrical connections should be made by a licensed, qualified electrician.
4. Before attempting any electrical connections, be sure all power is off at the main circuit breaker.
5. Install all electrical equipment at least five feet from any open body of water using non-metallic plumbing.
6. Install check valves and a vacuum break to prevent water from contacting 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) the system using the copper-bonding lug on the bottom of the ozone generator.
The system should be bonded with solid copper wire conforming to all local, state and national electrical
codes.
9. 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; failure to do so
may void the warranty.

5
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. Inspect all plumbing, fittings
and tubing for packing material that may have become lodged in openings.
Equipment Placement
• When placing the ozone system components in the equipment room, make sure to consider safety, maintenance
requirements, local building and fire codes, etc. The components should be easily accessible by the operators,
including equipment access doors and electrical hook-up boxes. All meters, gauges, indicator lights, and switches
should be visible and accessible. Dimensional drawings of each air preparation system and ozone generator are
included in Section A of the Appendix.
• The air preparation system and ozone generator should be located as close as possible to the point of ozone
injection. Ozone is an unstable gas and will begin reverting back to oxygen very quickly. To determine the most
favorable ozone injection point, the following items should be considered:
• Located downstream of all other existing water system components.
• Located upstream of the residual sanitizer injection point (if so equipped).
• In a Sidestream plumbing configuration (see Figure 4-1) with recirculation, the pH adjustment
chemical injection point must be located downstream of the residual sanitizer injection point (if so
equipped).
• In a Full Flow plumbing configuration (see Figure 4-2) without recirculation, locate downstream of the
pH adjustment chemical injection point.
• Adequate protection from weather, dust and excessive heat.
• Like any electronic component, performance and longevity is enhanced by favorable operating conditions. Also,
since each air preparation system and ozone generator is air-cooled, a relatively dust-free, well-ventilated area is
required. No caustic chemicals should be stored in the area surrounding the equipment. A minimum clearance of
six inches from the vents on either side of the ozone generator is required.
• The equipment is heavy and requires proper support. Therefore, a clean, dry, level surface should be provided for
the air preparation system and ozone generator. These components should be securely fastened to the surface
using the mounting holes and/or tabs provided.
• The air preparation system and ozone generator are not designed to withstand outdoor elements, including direct
contact with water and/or temperature extremes. Therefore, the equipment must be installed in an environment
consistent with the following operating parameters:
• Ambient temperature range: 20°F to 95°F continuous. If the temperature around the equipment
consistently exceeds 95°F, additional air-cooling must be provided.
• Humidity: 0 –90% relative humidity, non-condensing environment
• Line voltage: +/-10% of rated input
Note: Equipment installed in extreme environmental conditions will void manufacturer's warranty.
• Allow room for the peripheral equipment (booster pump, injector manifold, contact vessel, etc.).

6
INSTALLATION PROCEDURES – Plumbing CHAPTER 4
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 4-1) 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. A booster pump is usually employed to compensate for the flow restriction
caused by the sidestream loop and the injector manifold. If a halogen-type residual sanitizer is
utilized, its injection point should be as far downstream as possible from the point at which the sidestream water returns to
the main flow. In a full flow configuration, the same system components are usually involved and appear in the same
order with respect to the direction of flow. However, all the water in the main flow is allowed contact time with the ozone
(see Figure 4-2). A booster pump may be necessary to maintain proper flow requirements. If employed, the booster pump
is located upstream of the point at which the ozone injector manifold is installed.
NOTES:
• Adequate use of unions and isolation valves is
strongly recommended to facilitate maintenance
and repairs.
• Use Schedule 80 PVC for all plumbing connections
wherever possible. Plumbing size requirements
are dictated by the water flow characteristics of
the system.
• Make sure to use proper plumbing practices and
secure all plumbing and system equipment
according to local codes.
• Ozone is a powerful oxidizer and will degrade certain
materials. Use ozone-compatible plumbing materials
for section(s) of the system that will come in contact
with ozone dissolved in water. The following is a list of
materials that are compatible with ozone:
• PVC • Stainless Steel (300 series)
• CPVC • Viton
• Kynar • EPDM
• Teflon • Concrete
• Depending on the application, other components (psi
gauge, flow meter, etc.) may be installed to assist in
monitoring system parameters.
Step 1: Arrange the ozone system equipment (booster pump, injector and contact vessel) according to mechanical print
or as dictated by equipment layout and serviceability considerations. Do not secure booster pump and contact
vessel to housekeeping pads at this point. Dry fit plumbing as appropriate to insure proper fit and location
before making permanent connections.
Step 2: Install a tee or plumbing saddle into the main water line after the filter (if so equipped) and before the flow
diversion mechanism. The purpose of the mechanism is to restrict water flow so water is diverted into the
sidestream (see Figure 4-1). If such a mechanism is not present in the system (such as a heater bypass valve,
etc.), it will require installation of a valve (butterfly, gate or ball) or a flow controller.
Step 3: Plumb a line from the tee or plumbing saddle to the booster pump. For serviceability of the equipment in the
sidestream loop, be sure to install an isolation valve between the tee or saddle and the booster pump.
Step 4: Plumb from the booster pump to the injector manifold. Make sure to note the correct direction of flow, indicated
by a blue arrow on the inlet side of the manifold body. The check valve assembly is strapped to the manifold
using wire ties. Remove the assembly; using Teflon® tape, install it onto the top opening of 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. Note: The inlet and outlet arrows on the contact tanks are under the
base of the tank. The inlet on the 264, 463 and 850-gallon tanks is located at the top with the outlet at the
bottom.
Step 6: Using a tee or plumbing saddle, plumb from the outlet of the contact vessel back into the main water line. For
serviceability of the equipment in the side stream loop, be sure to install an isolation valve between the outlet
fitting on the contact vessel and before returning to the main water line.
Step 7: Secure the booster pump and contact vessel to solid mounting surfaces using appropriate hardware and
according to local codes. If installing a ClearWater Tech contact column, use a ClearWater Tech contact

Plumbing (continued)
7
column mounting kit and install according to the instructions below. If installing a contact tank, secure to a solid
horizontal surface using mounting flange or feet.
Step 8: Install the contact vessel venting system into the top of the vessel. If using the ClearWater Tech contact column,
the vent kit supplied includes fittings, a control valve and Teflon® tubing. The contact tank venting system
includes an air relief valve, fittings and a length of Teflon® tubing. Depending on conditions, the vented gas
may be directed to an ozone destruct system, to atmosphere or to the low-pressure side of the water system.
Note: Do not direct the tubing to the suction side of any pump in the system.
Contact Column Installation (if so equipped)
Step 1: Make sure the following hardware items are included in the contact column mounting kit:
• 'L' bracket
• 1/2” concrete anchors
• 6” clamp assembly
• Unistrut bar
• Protective end cap
• Mounting hardware
Step 2: Referring to Figure 4-3, mark the two holes for mounting the 'L' bracket to the wall. The bracket should be
located so that the 6” clamp assembly will be approximately 12” from the top of the contact column. Drill a
1/2” hole at each of the marks, about 3 1/2” deep. Insert a concrete anchor into each hole with the threaded end
facing outward. Slip the 'L' bracket over the threaded ends of the anchors, followed by a washer for each
anchor. Secure the bracket to the wall by threading a nut onto each anchor and tightening.
Step 3: Cut the unistrut bar to the desired length and attach it to the 'L' bracket using hardware provided.
Step 4: Slip the two sides of the 6” clamp into the unistrut bar and then around the contact column. Tighten the retaining
bolt, securing the contact column to the unistrut bar.
Step 5: Slip the protective end cap over the exposed end of the unistrut bar.
Sidestream Plumbing Installation Diagram
Figure 4-1
Flow Diversion
Mechanism
Filter Isolation Isolation
Valve Valve
Booster Ozone Injector
Pump
Bypass Valve
Contact
Vessel
Isolation
Service Loop Valve
Isolation Isolation
Valve Ozone Injector Valve
Booster Bypass
Pump Valve
Contact
Vessel
Full Flow Plumbing Installation Diagram
Figure 4-2

Plumbing (continued)
8
Column Column Flange Bolts & Flange Washers(8 ea.) Diffuser Riser Tube Base Flange Gasket Base Flange Nuts & Washers (8ea.) Contact Column Exploded View Figure 4-4
Contact Column Installation Diagram Figure 4-3 6” Clamp Assembly Bolts, nuts & with bolt & Nut washers (2ea.) Unistrut (cut to length) Unistrut “L” Bracket Protective End cap Concrete Anchors with nuts &
washers (2ea.)

9
INSTALLATION PROCEDURES – Electrical CHAPTER 5
The CD1500P and CD2000P 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. All possible pre-wiring has been completed
at the factory. Logic schematics have been provided in
the Appendix-Section D.
• All electrical connections should be made by a
licensed, qualified electrician. All local, state and
national codes must be observed.
• Make sure all power is off at the main circuit
breaker before making any electrical connections.
Step 1: Conforming to all local, state and national electrical codes, ground the ozone generator to a true earth ground.
Use solid copper bonding wire (usually #8 AWG) from the copper-bonding lug located on the bottom of the
ozone generator to the grounding point.
Step 2: Main Power: Plug the IEC end of the power cord into the
power entry module located at the bottom of the ozone
generator. The other end can be plugged into any main
power source with input voltage from 90 to 250 VAC at 47
to 63 Hz, single phase.
Step 3: External Loop (EXT LOOP): The external loop is a true dry contact interface. Note: The term ‘dry
contact’ means that this loop does not supply output nor except input voltages. Warning: Supplying
voltage to the external loop will cause damage to the ozone generator and void warranty. Under normal
operation, the external loop will effectively interrupt the ozone output when the loop has lost continuity; this
will also illuminate the LED located on the 4-20mA control board inside the ozone generator (see Appendix,
Section A, for location of 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” giving power to
the cooling fan(s). When continuity is present through the external loop, ozone output will continue. This
continuity will effectively turn “OFF” the LED of the 4-20mA board and will again illuminate the “Ozone
Output” LED(s).
The external loop, a removable two-position plug with a white 18AWG wire located at the bottom panel of the
ozone generator (see Appendix, Section A), can be interfaced to any control device, i.e., pressure switch,
vacuum switch, flow switch, float switch, ORP controller, PPM controller, or timer. To interface a control
device to the external loop, cut the white 18AWG wire in half. Connect the control device to each leg of the
external loop. Note: External Loop control devices supplied by ClearWater Tech may come equipped
with a two-position male connector ready to be plugged into the female two-position connector mounted
to the chassis of the ozone generator. If the control device used supplies an output voltage a single pole
single throw (SPST) normally-open relay may be used to create a dry contact interface (see Figure 5-1,
“External Loop Electrical Interface”). Note: Attached to the white 18 AWG external loop is a warning,
“THIS CONNECTION IS A DRY CONTACT ONLY, DO NOT APPLY VOLTAGE”.
Step 4: Ozone Output Control: The CD1500P and CD2000P ozone generators are equipped with two options for
controlling the ozone output. The first option is a manual 0-100% ozone output control and the second is a
remote 4-20mA control signal. The manual ozone output control knob and remote 4-20mA control leads
(orange and purple) are located at the bottom of the ozone generator (see Appendix, Section A).
1. Manual Ozone Output Control: Turning the control knob counterclockwise will decrease the ozone output down to
0% while turning the knob clockwise will increase the ozone output up to 100%. The ozone output level is indicated
by the “Ozone Output” LED(s) on the front cover of the ozone generator (see Appendix, Section A).
2. Remote 4-20mA Control: A 4-20mA control signal to the ozone generator may be used to control the ozone
generator output. The ozone generator will automatically sense the 4-20mA input signal and override the setting of
the manual ozone output control. Based on the 4-20mA signal, ozone output will increase or decrease: 4mA = 0%
ozone output, 20mA = 100% ozone output. The ozone output level is indicated by the “Ozone Output” LED(s) on the
front cover of the ozone generator (see Appendix, Section A). Note: If the remote 4-20mA signal fails or is
missing, the system will default to the manual ozone output setting. Check and adjust the manual ozone
output control knob to avoid over-ozonation.
Power Consumption
Input Voltage
90-250VAC 47-63Hz
CD1500P
1.6 -0.8 amps
CD2000P
2.8 -1.4 amps

Electrical (continued)
10
Step 1: Mount the 4-20mA controller to a suitable vertical surface according to the installation manual supplied
with the controller.
Step 2: Wire the #22 AWG orange ‘positive’ (+) lead from the ozone generator to the 4-20mA controller according
to the manual supplied with the controller.
Step 3: Wire the #22 AWG purple ‘negative’ (-) lead from the ozone generator to the 4-20mA controller according
to the manual supplied with the controller.
Step 4: Complete the required programming and calibration steps as outlined in the installation manual supplied
with the 4-20mA controller.
Step 5: Air Preparation System Power: 120VAC systems only: plug the power cord into main power. 240VAC
systems only: the power cord must be hard wired to the main power source (Black-L1, White-L2/N and Green-Ground).
Notes: The prescribed air flow of the air prep system must be set to “atmospheric pressure” prior to use, follow
Step 5 of the ‘Start-up & Calibration' section. Warnings: Failure to calibrate may lead to premature failure of the
air preparation system. Vacuum from the venturi must be interrupted if the air prep system is not “ON;” failure
to do so will damage the air prep system.
External Loop Electrical Interface
Figure 5-1
120 VAC Signal
L1 Power from ORP, PPM,
pump or timer
N
120V
Coil
Interface Relay
External Loop
240 VAC Signal
L1 Power from ORP, PPM,
pump or timer
L2
240V
Coil
Interface Relay
External Loop

11
Compressor Inlet Filter
SCFH Air Flow Meter Compressor
ATF Module (sieve bed)
Oxygen Outlet
Power Switch Hour Meter
(if so equipped)
Main Power Cord
INSTALLATION PROCEDURES – Pneumatic CHAPTER 6
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 6-1). The air preparation system provides the
ozone generator with a source of dry, oil-free oxygen-
enriched air (90% +/-3% oxygen purity at -100˚F dew
point). The air is drawn from the ozone generator (where
ozone is produced from the oxygen in the air stream) and
through the vacuum break by the suction created at the
ozone injector manifold.
Figure 6-1
Hook-Up: Air preparation system-to-ozone generator
Step 1: Teflon® tape and attach brass barb provided to the PSA oxygen concentrator outlet.
Step 2: Teflon® tape and attach brass barbs to both sides of indicator cartridge (ordered separately).
Step 3: Mount indicator cartridge on a suitable flat surface using the Clic® mounting clamps provided. Notes: The
indicator cartridge must be mounted vertically. The indicator cartridge does not have a direction of
flow. An external moisture-indicating cartridge is used as a reference to indicate the quality of the dry air, if
the air prep system is not operating properly the silica will turn from blue and white in color to all white. See
Troubleshooting Guide.
Step 4: Using a suitable length of 3/8” braided tubing provided, attach one end of the tubing to the oxygen concentrator
system to one end of the indicator cartridge. Secure the tubing to the brass fittings with the hose clamps
provided.
Step 5: Using a suitable length of 3/8” braided tubing, attach tubing to the brass barb located at the other end of the
indicator cartridge then attach the other end of the tubing to the brass barb located at the bottom of the ozone
generator. Secure the tubing to the fittings with the hose clamps provided.
Oxygen Concentrator Detail
Figure 6-2
Booster Pump Ozone Injector
Water Flow
Ozone Generator
Air Prep System
Vacuum Break
Air Prep In Ozone Out Shown: ClearWater Tech CD2000P Ozone System

Pneumatic (continued)
12
Hook-Ups: Ozone generator-to-vacuum break & vacuum break-to-injector manifold
The ClearWater Tech vacuum break provides a positive atmospheric “break” between the ozone injector manifold and the
ozone generator, preventing water from flowing back into the ozone generator should the venturi check valve fail. Under
normal operating conditions, the vacuum break's flapper valve (see Figure 6-3) is closed, allowing the vacuum created by
the venturi to draw the output gas from the ozone generator. If the check valve at the venturi begins to leak or fails
completely, vacuum is interrupted and water will flow toward the ozone generator. With the vacuum break properly
installed between the venturi and the ozone generator, the water will flow down the riser tube (away from the ozone
generator) and out to drain, protecting the ozone generator from potential water damage. Note: All Teflon® delivery
lines that are secured by a stainless steel compression fittings require a tubing insert (inserts are located in the
Vacuum Break parts bag). This insert will prevent crushing of the tubing, which may create an ozone leak. All
stainless steel compression fittings must be tightened no more than 1-1/4 turns past finger tight.
Step 1: Select a suitable vertical surface that is accessible and in close proximity to both the ozone generator and the
ozone injector manifold.
Step 2: Install the two Clic® mounting clamps provided onto the vertical surface so that the vacuum break is in a
vertical position and the drain holes are below the level of the ozone generators ozone outlet fitting. One clamp
should be located so it fits around the Riser Tube Elbow, and the other so it fits around the bottom of the
Lower Tee (see Figure 6-3).
Step 3: Remove the Fill Port Cap located on top of the Riser Tube and fill the Riser Tube with clean water (no
particulate matter) until "Fill Level" line indicated in Figure 6-3.
Step 4: Re-install the Fill Port Cap, using pliers or a wrench to tighten. Note: Do not over tighten as damage to PVC
fittings may occur.
Step 6: Connect one end of a suitable length of Teflon® ozone delivery line to the ozone outlet needle valve (see
Appendix, Section A). Notes: The compression fitting ferrules are zip tied to the ozone outlet needle
valve. Attach the other end of the Teflon® delivery line to the fitting threaded into the Upper Tee. As an
additional backflow prevention measure, loop this length of tubing as high as is practical between the two
connection points.
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 Chapter 7, “Start-up and Calibration Procedures.”
Step 8: Adjustments to the valve on the ozone injector manifold will be necessary. These steps are covered in Chapter
7, “Start-up and Calibration Procedures.”
Vacuum Break Detail
Figure 6-3
Ozone Generator
Ozone Flow Fill Port Cap
Upper Tee
Ozone Outlet Ozone Flow
Lower Tee
Riser Tube
Drain Barb
Check Valve Assembly Overflow Tube Mounting Clamps
Fill
Level
Riser Elbow
Ozone Injection Manifold
Flapper Check Valve

13
START-UP & CALIBRATION CHAPTER 7
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. Air from the air preparation system is flowing through the ozone generator under
pressure, and from the ozone generator under a slight vacuum (created by the ozone injector manifold). The change from
pressure to vacuum occurs after the stainless steel ozone outlet needle valve on the ozone generator.
Air Preparation System, Ozone Generator & Ozone Injector
Warning: Disconnect the External Loop dry contact from the ozone generator while performing all start-up
procedures. Failure to do so may result in ozone escaping to atmosphere.
Step 1: Make sure all isolation valves in the ozone water system are open (Figures 4-1 or 4-2 show recommended
isolation valve locations).
Step 2: Start-up hydraulics. Allow the water system to reach hydraulic equilibrium (contact vessel full, off-gas vent
operating, etc.) and observe for plumbing leaks. Note: Water flow must be established through the main
water pump and the ozone system booster pump (if so equipped).
Step 3: Close the ball valve on the injector manifold about half way.
Step 4: Using your thumb, check for the presence of vacuum (suction) at the
ozone injection manifold check valve assembly or use a ClearWater
Tech vacuum test assembly to check vacuum at the injector port. If no
suction is present, continue to close the ball valve on the injector
manifold until vacuum is detected. If using the vacuum test assembly,
check the VAC/PSI gauge for vacuum. If the needle is in the red zone
on the pressure (PSI) side of the gauge, gradually close the ball valve on
the injector manifold until the needle moves into the green zone. If the
needle is in the red zone on the vacuum (in.Hg) side of the gauge,
gradually open the ball valve on the injector manifold until the needle
moves into the green zone. While vacuum is in the green zone you must
be able to achieve proper SCFH (Standard Cubic Feet per Hour) of air flow (see the “Pneumatic Operating
Parameters” chart for venturi SCFH required, Figure 7-1).
Step 5: Make sure electrical power is on to all ozone system electrical components. The main power switch of the air
preparation system must be in the “ON” position (if so equipped) (see Figure 6-2). The air preparation
system must be set to “atmospheric pressure” prior to full start up of the system. Disconnect the oxygen
delivery line from each oxygen concentrator (if delivery has already been attached). Note: This should have
been completed in Step 5 of “Installation Procedures -Electrical.”
Step 1: Check to make sure the compressor of the air preparation system is operating.
Step 2: Using the air flow gauge adjustment valve on the air preparation system (see Figure 6-2), adjust the
air flow according to the “Air prep system air flow” specifications outlined in Figure 7-1. Note: When the
system is under normal operation, the air flow will drop from the initial setting due to the air
preparation system being under back pressure. DO NOT READJUST THE AIR FLOW GAUGE
ADJUSTMENT VALVE.
Step 6: Connect the Teflonozone delivery line from the vacuum break to the ozone inlet fitting located at the ozone
injection manifold check valve assembly.
Step 7: Using the stainless steel ozone outlet needle valve located at the bottom the ozone generator (see Appendix,
Section A), adjust the backpressure of the ozone reaction chambers to 10 PSI. Check the PSI gauge on the
front panel of the ozone generator, which measures this backpressure. If there is insufficient backpressure the
needle valve may be closed slightly; similarly, if there is too much backpressure the valve may be opened
slightly. Note: The lock nut on the needle valve must be loosened prior to adjustment and tightened
after adjustment. Due to the pressure switch installed, the PSI gauge must achieve 9 PSI before ozone will
begin production.

Start-up and Calibration (continued)
14
Step 8: The CFH gauge on the front panel of the ozone generator will monitor the CFH air flow rate. By setting the
oxygen concentrator SCFH and ozone generator back pressure PSI, there will be no adjustments of CFH air
flow. See “Air prep system air flow” specifications outlined in Figure 7-1.
Step 9: Perform a final check of all air connections from the air preparation system to the ozone injector manifold.
Repair leaks as required. Check all system water connections, including the ozone injector manifold, vacuum
break and contact vessel. Repair leaks as required. Note: The check valve at the ozone injector manifold
may make a humming noise. This is normal.
Step 10: Reconnect the External Loop connector to the ozone generator. Note: The Ozone LED(s) will not illuminate
until the External Loop has been replaced.
Step 11: Observe all indicating LED(s) on the front cover of the ozone generator. Adjust the manual ozone output
knob to desired level setting.
Vacuum Break
Check the water level in the vacuum break, making sure it is above the flapper valve (see Figure 6-3). If water is not
pressing downward on the flapper valve it will open, causing a loss of vacuum. A loss of vacuum means ozone cannot
flow from the vacuum break, which in turn can cause an ozone leak. Note: If the vacuum break must be refilled with
water disconnect the External Loop from the ozone generator and disconnect the Teflon® ozone delivery line from
the ozone inlet fitting of the vacuum break. This will keep the pressure from the oxygen concentrator from pushing
out the water and shutting down ozone production.
Ozone Destruct System
Adjust the small ball valve at the tee of the water trap (see Figure 6-4) so that only a small amount of water is “spitting”
into the trap. This will indicate that the contact vessel is full and only a very small amount of water is allowed to escape.
Pneumatic Operating Parameters Figure 7-1
CD1500P Operating Range Optimum
Air prep system air flow
Ozone generator total air flow (gauge –front cover)
PSI gauge (gauge –front cover)
Injector manifold air flow
Injector manifold injector
5 to 6 scfh
2 to 6 cfh
9 to 12 psi
4 to 6 scfh
-3 to -8 in. hg.
6 scfh
3 cfh
10 psi
6 scfh
-5 inches
CD2000P Operating Range Optimum
Air prep System air flow
Ozone generator total air flow (gauge –front cover)
PSI gauge (gauge –front cover)
Injector manifold air flow
Injector manifold injector
10 to 12 scfh
4 to 6 cfh
9 to 12 psi
10 to 12 scfh
-3 to -8 in. hg.
12 scfh
6 cfh
10 psi
12 scfh
-5 inches

15
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.
Daily procedures involve quick, visual checks for changes in normal operating conditions. Monthly,
semi-annual and annual procedures include cleaning and/or replacement of certain critical parts.
NOTES:
• The ozone generator warranty states that it “does
not extend to any product or part which has been
damaged or rendered defective as a result of use
of parts not sold by ClearWater Tech, or service
or unit modification not authorized by
ClearWater Tech” Please contact your
ClearWater Tech dealer if you have any
questions about any maintenance procedure
before you begin that procedure.
• CAUTION: Observe all common safety practices
and review the “Safety Warnings and Instructions”
in Chapter 2 before attempting any maintenance
procedure that requires the use of tools and/or
shutting down the ozone system.
Daily Procedures
Air Preparation System
• Power Switch: Check the power switch on the air preparation system (see Figure 6-1), if so equipped.
• Indicator Cartridge: Inspect the air preparation system indicator cartridge. A change in the blue crystals to a light
pink or white color indicates the presence of moisture in the feed gas coming from the air preparation system. If
such a change is observed, refer to the Troubleshooting Guide.
• Air Flow: Check the air flow gauge on the air preparation system (see Figure 6-1). Make sure the air flow is
within the SCFH range shown on the “Air prep System Air Flow” line of the “Pneumatic Operating Parameters”
chart (Figure 7-1). Adjust if necessary by following the steps outlined in the “Start-Up & Calibration” section.
Ozone Generator
• Indicator Lights: Check the Main Power indicator light at the bottom of the ozone generator and Ozone LED(s) at
the cover of the ozone generator (see Appendix, Section A). The Main Power light should be illuminated when
main power to the ozone generator is present and the main power switch is “On.” The Ozone Output LED(s)
should be illuminated when the External Loop has continuity, the Manual Ozone Output Adjustment Knob is at a
desired setting (other than 0%) or a Remote 4-20mA Control Signal is sensed. See Troubleshooting Guide.
• Air Flow: Check the air flow gauge at the ozone generator cover. Make sure air flow is within the CFH (cubic feet
per hour) range shown on the “Ozone generator air flow” line of the “Pneumatic Operating Parameters” (see
Figure 7-1). Adjust if necessary by following steps outlined in the “Start-Up & Calibration” section.
• Pressure: Check the PSI gauge located on the ozone generator cabinet door. Make sure pressure is within the
range shown on the “PSI Gauge” line of the “Pneumatic Operating Parameters” chart (see Figure 7-1). Adjust if
necessary by following steps outlined in the “Start-Up & Calibration” section.
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 6-3).
Injection Manifold
• Check Valve: Inspect the Teflonozone delivery line that runs between the vacuum break and the check valve
assembly on the suction port of the ozone injector manifold. If water is observed in the delivery line near the
check valve assembly, the check valve has failed. See Troubleshooting Guide.
Monthly Procedures
Air Preparation System
• Cooling Fan Operation: Check to make sure the cooling fan mounted on the side panel of the air preparation
system is operating. If not, refer to the Troubleshooting Guide.
MAINTENANCE CHAPTER 8

Maintenance (continued)
16
• Cover Filter: Check the cover filter element mounted on the side of the air preparation system and clean as
required. Operating conditions in the equipment area will dictate the frequency required for this procedure.
Remove the filter element and clean with soap and water, drying them completely before re-installing.
Ozone Generator
• Drive Module Operation: The Drive Module is made up of two components: the drive board and the drive
transformer. With the ozone generator cover removed, check for illumination of the drive module "Ozone Output"
LED(s) (for LED locations, see Figure 8-1); if not illuminated see Troubleshooting Guide. This procedure is to
observe the complete operating function of the drive module(s). Before checking drive module function, remove
the ozone generator cover and depress the cover safety switch located on the ozone generator chassis (see
Appendix, Section A). CAUTION: This overrides the cover safety switch. The ozone generator will remain
energized with the cover removed. Do not touch anything inside the ozone generator while this switch is
activated! Please consult your ClearWater Tech dealer before attempting this procedure.
- Main Power LED: When illuminated, this “Green” LED indicates that main power is supplied to the drive
module up to the “on board” fuse of the drive board.
- Transformer Power LED: When illuminated, this “Green” LED indicates that 48V Buss power is available to
the drive module transformer (XFMR) from the “on board” fuse of the to the drive transformer.
- Ozone Output LED: The “Amber” ozone output LED will illuminate when ozone drive is being generated.
The LED will also pulse as the output increases or decreases with either the Manual Ozone Output Control
located on the bottom of the ozone generator (see Appendix, Section A), or from a Remote 4-20mA signal (see
“Installation Procedures –Electrical”).
- Fault LED: When illuminated, this “Red” LED indicates that there is a fault with the drive module or the
Ozone Reaction Chamber. If this LED is illuminated, refer to the Troubleshooting Guide. Notes: If the drive
module goes to a fault condition, the drive board will restart every 30 seconds. If the fault is not
remedied the drive module will continue to go into a fault mode. When the drive module is in fault mode
ozone will not be generated. Before proceeding further, release the cover safety switch and replace the
ozone generator cover.
• Cooling Fan Operation: Check to make sure the two cooling fans (mounted on the bottom panel of the ozone
generator cabinet) are operating. If not, refer to the Troubleshooting Guide.
• Cooling Fan Filters: Check the cooling fan filter elements mounted on the bottom of the ozone generator (see
Appendix, Section A) and clean as required. Operating conditions in the equipment area will dictate the frequency
required for this procedure. Remove the filter element and clean with soap and water, drying them completely
before re-installing (see Figure 8-2).
Booster Pump(s)
• Strainer Baskets: Check and clean the strainer basket in the booster pump(s) as required (if so equipped)
Drive Module High Output (H.O.)
Figure 8-1
Transformers –XFMR (under
boards)
Drive Board
Ozone Output LED
Fuse
Transformer –XFMR LED
Drive Board Main Power LED
Fault LED
24VDC Output Connector
Variable Input Connector
DC Power Input Connector

Maintenance (continued)
17
Ozone Generator Cooling Fan Assembly
Figure 8-2
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 Main Power
Light at the bottom of the ozone generator and “Ozone Output” LED(s) at the front cover should not be
illuminated.
Step 3: Disconnect the power to the ozone system either at the service disconnect box (if so equipped) or main circuit
breaker.
Semi-Annual Procedures
CAUTION: Follow system shutdown procedures (outlined above) before performing any of the following steps.
Air Preparation System
• Air Inlet Filter: Replace the air compressor inlet filter on each air preparation system module (see Figure 6-2).
Note: Manufacturers' recommended replacement interval is 4,000 hours of operation. Operating conditions
in the equipment area will dictate the required frequency of this procedure.
Annual Procedures
CAUTION:Follow system shutdown procedures before performing any of the following steps.
Air Preparation System
• Compressors: Following the procedures outlined in the compressor rebuild kit, rebuild the two compressor heads
on each air preparation system module (see Figure 6-2). Note: Manufacturers' recommended interval is 5,000
to 12,000 hours of operation. Compressor performance and/or operating conditions in the equipment area
will dictate the required frequency of this procedure.
Ozone Generators
• Cooling Fan Filters: Clean or replace the cooling fan filter elements as required.
• Inline Filter: Replace the inline particulate filter.
• Reaction Chambers: Remove and disassemble one reaction chamber according to the steps outlined below (see
Figure 8-3). Check the chamber interior and dielectric tube for oil, dirt or moisture. Note: CWT pressurized
reaction chambers are anodized blue.
Removal and Disassembly
Note: Disassembly and service of the reaction chamber is a technical, delicate and critical procedure. Please
consult your ClearWater Tech dealer before attempting this procedure.
Step 1: Make sure all power to the ozone generator has been disconnected according to the “System Shutdown
Procedures” outlined above.
Step 2: Unplug the electrical connections from the drive module.
Step 3: Remove the 4-20mA control board with mounting bracket from the reaction chamber of the CD1500P.
Step 4: Disconnect tubing connections from the fittings on both ends of the reaction chamber.
Step 5: Disconnect the high voltage lead from the drive module.
Step 6: Remove reaction chamber from ozone generator.
Step 7: Remove retaining screws from the two end caps (4 each).
Step 8: Using a gentle back-and-forth twisting motion, remove the non-high voltage end cap (the one without the white
power lead attached) from the heat sink/cathode assembly. Note: The stainless steel clamp must not be
removed.
Step 9: Remove the high voltage end cap and dielectric from the heat sink/cathode assembly. Note: The stainless
steel clamp must not be removed.
Fan Filter Grill
Fan
Finger Guard
Ozone Generator Bottom Panel
Fan Filter Element

Maintenance (continued)
18
Step 10: With contact brush attached, remove the brush adapter nut from the high voltage end cap.
Step 11: Inspect the dielectric, end caps and cathode for breakage, corrosion or debris. Clean and/or replace parts as
necessary. If cleaning and/or parts replacement is not required, re-assemble the reaction chamber per the
instructions below.
Assembly and Re-installation
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.
Step 3: Using a gentle twisting motion, press the non-high voltage end cap onto the heat sink/cathode assembly until
flush with the heat sink cooling fins. Note: See Figure 8-3 for correct orientation of end cap.
Step 4: Slide the four end cap retaining screws through the holes in the non-high voltage end cap, aligning them with
the heat sink screw bosses. Thread screws into screw bosses until heads are snug against the end cap.
Step 5: Roll the high voltage anode (foil-like material) lengthwise, preserving the longer dimension. Insert the rolled
anode into the dielectric. Center the anode in the dielectric (approximately 1/2” from either end of the glass),
making sure it is rolled squarely.
Step 6: Slide the dielectric into the heat sink/cathode assembly. Seat the dielectric into the O-rings of the non-high
voltage end cap by applying pressure with a gentle twisting motion. (There must not be any dirt, debris, oils or
fingerprints on the dielectric upon re-installation).
Step 7: Slowly insert the high voltage end cap assembly into the dielectric. Note: Do not bend center wire of the
brush during this procedure. It is normal for the bristles to bend. Using a gentle twisting motion, press the
high voltage end cap onto the heat sink/cathode assembly until flush with the heat sink cooling fins.
Step 8: Slide the four end cap retaining screws through the holes in the end cap, aligning them with the heat sink screw
bosses. Thread screws into screw bosses until heads are snug against the end cap.
Step 9:Re-install complete reaction chamber assembly into the ozone generator by following the “Removal and
Disassembly” instructions in reverse order, from Step 6 to Step 2. Follow steps outlined in Chapter 7, “Start-
Up and Calibration,” to re-start the ozone system.
2” Pressurized Reaction Chamber - Exploded View
Figure 8-3
Ozone Outlet
Fitting
Bottom End Cap
Glass Dielectric
High Voltage Anode
Stainless Steel Clamp
Contact Brush
Brush Adapter Nut
High Voltage End Cap
End Cap Retaining
Screw and Washer
Oxygen Inlet Fitting
Viton Washer
Stainless Steel
Washer
High Voltage
Lead
Heat Sink and Cathode

Maintenance (continued)
19
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 6-3).
Injector Manifold
• Check Valve: Replace the check valve located at the ozone injection manifold. Note: Because the system is in
the shutdown mode, no vacuum is present at the injector. Therefore, it is normal for some water to be
flowing from the injector during this procedure.
Contact Vessel
• Cleaning: Contact Column only. Inspect the diffuser slots at the top of the contact column riser tube. If they are
clear, no further maintenance is required. If the slots are fouled, disassemble the column and clean as required,
following the steps outlined below (see Figure 4-4).
Step 1: Make sure the isolation valves before and after the contact column are closed.
Step 2: Disconnect the vent line from the top of the contact column.
Step 3: Remove the bolts in the 6” base flange.
Step 4: Remove the column, lifting it over the interior riser tube.
Step 5: Remove and clean the diffuser.
Step 6: Inspect the flange gasket and replace if necessary.
Step 7: Reassemble the contact column and attach vent lines.