Genesis DEL ozone CD-2G User manual

CD–2G, CD–5G, & CD–7G
Installation & Operations Manual
3580 Sueldo Street, San Luis Obispo, CA 93401 | 800.676.1335 | [e-mail] | www.delozone.com
4-1391-01 Rev.D

Genesis CD–2G, CD–5G, & CD–7G Installation & Operations Manual
TABLE OF CONTENTS
SECTION 1 General Information
1A. Description ...............................................................1
1B. Specifications...........................................................1
SECTION 2 Installation
2A. Location....................................................................1
2B. Mounting ..................................................................1
2C. Electrical ..................................................................2
2D. Plumbing..................................................................2
SECTION 3 Operation
3A. Initial System Start-Up .............................................3
3B. Normal Operation.....................................................3
3C. System Shut-Down ..................................................3
SECTION 4 Maintenance & Service
4A. System Electro-Mechanical Overview .................... 3
4B. PM Schedule........................................................... 4
4C. Troubleshooting ...................................................... 4
4D. Contact Information................................................. 5
SECTION 5 Replacement Parts & Order Info
5A. Ordering Information ............................................... 5
Warranty ..................................................................... 6
Appendix
Appendix "A" (Safety) .................................................... 7
IMPORTANT SAFETY INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS.
• Read this manual completely before attempting installation.
• Risk of Electric Shock. Install the ozone unit and any metallic plumbing associated with the unit at least
5 ft from the inside wall of tub or pool, and no less than 1ft. above maximum water level.
• Risk of Electric Shock. Connect this ozone generator in accordance with the installation instructions.
Do not install within an enclosure that would restict ventilation.
• (Applicable to cord/plug connected units only) Risk of electric shock. Connect only to a properly grounded,
grounding type receptacle.
• Do not bury cord.
• Warning – To reduce the risk of electric shock, replace damaged cord immediately.
• Follow all applicable electrical codes.
• Electric shock hazard. Be sure to turn power OFF at power source before any service work is performed.
Failure to do so could result in serious injury or death.
• Warning – Short term inhalation of high concentrations of ozone and long term inhalation of low
concentrations of ozone can cause serious harmful physiological effects. DO NOT inhale ozone gas
produced by this device.
• For your safety, do not store or use gasoline, chemicals or other flammable liquids or vapors near this
or any other appliance.
• A spontaneous and violent ignition may occur if oil, grease or greasy substances come in contact with
oxygen under pressure. These substances must be kept away from oxygen regulators, cylinder valves
tubing and connections, and all other oxygen equipment.
SAVE THESE INSTRUCTIONS!
ALL Genesis™CD Ozone
Generators are NSF listed.

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Genesis CD–2G, CD–5G, & CD–7G Installation & Operations Manual
SECTION 1 General Information
1A. Description
The Genesis™Corona Discharge series ozone
generator described in this manual is designed
to provide the benefits of ozonated water in an
environmentally safe and effective manner. The
high quality, specially engineered components
ensure efficient ozone output and reliable
performance.
The Genesis™CD ozone generator is safe and
harmless to your equipment if installed properly.
1B. Specifications
For detailed specifications refer to the ozone
generator specification label located on the
inside of the door on the unit.
Ozone Output: CD–2G CD–5G CD–7G
Ozone output (+10%): 2 g/hr 5 g/hr 7 g/hr
Flow rate (max): 3 scfh 6 scfh 7 scfh
% weight O3: 2.5-3% 2-2.5% 3%
Power Requirements:
Domestic: 120 VAC 60Hz
Export: 230 VAC 50Hz
Overcurrent Protection: 10 A
Shipping Weight:
CD–2G Approx. 50 lbs. / 23 kg.
CD–5G Approx. 52 lbs. / 24 kg.
CD–7G Approx. 61 lbs. / 27.5 kg.
Location Requirements*:
Mounting: Wall mount in a clean, protected
area. Floor mounting kit optional.
Ambient Temp.: 40°F - 100°F (5°C - 38°C)
Ventilation: Room should provide 6 air
changes per hour minimum.
Clearance: Provide a minimum of 4" clearance
around unit.
* Protection from weather elements must be
provided for outdoor installations. Operating
outside of the recommended temp. ranges
may result in damage not covered under the
manufacturer’s warranty.
SECTION 2 Installation
2A. Location
The CD-2G, CD–5G, & CD–7G are designed
for wall mounting. See Figure 1. Mount generator
in a clean, protected area, either indoors or
outdoors. (See LOCATION REQUIREMENTS
Section 1B) They can also be mounted to the floor
or deck with optional feet. Locate generator out of
reach of sprinklers or drainage spouts. Allow
sufficient access for maintenance and all tubing
and electrical wires. Generators must not be
placed in locations where ambient ozone levels
exceed 0.01 PPM.
2B. Mounting
2B-1. Wall Mount Option
1. Attach the Wall Mounting Brackets to the base
and top of the enclosure using four 1/4" x 1" long
bolts and washers provided.
2. Refer to Figure 1. Mark the locations for the four
mounting bolts and install anchors appropriate
for the mounting surface.
Figure 1: Wall Mount
12.63
26.50
12.63

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Genesis CD–2G, CD–5G, & CD–7G Installation & Operations Manual
3. Install the four mounting bolts through the Wall
Mounting Brackets and into the anchors.
2B-2. Floor Mount (optional)
The enclosure can be floor mounted to a solid,
flat surface using the optional Floor Mounting Kit
Part Number 9-5004.
2C. Electrical
Refer to the unit's specification label and local
electrical codes for information on proper electrical
connection.
2C-1. External Control
Make sure that the control switch is properly
rated for the ozone generator. A pair of control
contacts is provided inside the ozone generator.
Refer to wiring diagram and Figure 4 for proper
connection.
2D. Plumbing
Ozone gas is introduced to the circulation line
using a venturi injector. Suction developed by the
venturi allows the CD generator to operate safely
under vacuum.
2D-1. Injector Assembly
Plumb the Injector and/or Degas Assembly into the
water line according to the installation instructions
for that assembly. The Injector/Degas Assembly
must be installed in the main return line after all
other pool equipment.
2D-2. Water Check Valve (optional item)
If the pool equipment is mounted above the water
line, a 1/3# DELCheck check valve (P/N: CO-0101)
must be installed between the pump outlet and
the injector assembly.
2D-3. Ozone Gas Line
1. Install the ozone check valve (contained in parts
bag) into the ozone output fitting on the
generator. Apply Teflon tape, Mil T-27730A or
equivalent, to threads. Flow direction is away
from the generator. Install elbow or straight
MPT-to-compression fitting (contained in parts
bag) onto check valve. Insert one end of ozone
tubing into the fitting, hold the tubing in place
and tighten the fitting.
NOTE: Use a back-up wrench when
tightening all fittings.
2. The injector assembly is also equipped with a
compression fitting. Connect the other end of
ozone tubing to the injector suction port as
described in Step 1. See Figure 2a.
NOTE: The ozone gas supply line must have a
back flow prevention device (such as a check
valve) installed between the ozone generator
cabinet and the point of injection to prevent
water from backing up into the generator system.
An ozone supply check valve is included.
Figure 2a: with Injector Assembly in Main Line
Figure 2b: with DVX

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Genesis CD–2G, CD–5G, & CD–7G Installation & Operations Manual
SECTION 3 Operation
3A. Initial System Start-Up
Upon completing all of the generator system
connections, you are ready to begin start-up
procedures.
1. Check electrical fittings.
2. Check for proper voltage.
3. Turn on circulation pump.
4. Check for leaks.
5. With the ozone isolation valve closed, adjust
injector bypass valve and/or filtration sidestream
valve to flow water through the injector.
6. Open ozone isolation valve.
7. Turn ozone generator on.
NOTE: If your Injector Assembly is equipped
with a ball valve, close the valve by turning
the handle clockwise until the proper suction
is indicated as described in Section 3B.
3B. Normal Operation
At this point, the system's cooling fans will
start-up and the oxygen concentrator will begin
operating. The green power indicator should
be illuminated and the red vacuum indicator
should turn off when sufficient vacuum is
obtained. The green ozone indicator should
then illuminate.
If the indicator lights are OK and the flowmeter is
reading the proper flow (refer to specification label
in unit), then the ozone generator is producing
ozone and the injector assembly is injecting the
ozone into the pool return/inlet line.
Make further adjustments to the injector bypass
valve until vacuum light turns off and the ozone
light turns on. NOTE: Do not exceed the max air/
oxygen flow rate specification as indicated on
the specification sticker.
If you experience complications, see
TROUBLESHOOTING Section 4C or call
1-800-676-1335 for assistance.
3C. System Shut-Down
The following sequence of steps must be followed
for servicing or for storage.
1. Unplug the ozone generator.
2. Close the ozone isolation valve on the ozone
supply line.
WARNING: Pool pump flow must not be shut-
down when the ozone generator is operating.
Doing so may cause water to back flow into the
system and damage the generator module.
SECTION 4 Maintenance & Service
4A. System Electro-Mechanical Overview
Refer to Figure 4 for component locations.
4A-1. Indicator Lights
1. Main Power: Green light indicates that power
is being supplied to the ozone generator.
Compressor should be running.
2. Ozone Power: Green light indicates that power
is being supplied to the high voltage Corona
Discharge circuit and that ozone is being
produced.
3. Vacuum: Red light indicates a vacuum fault.
When sufficient suction is being supplied from
the venturi injector, the red light will turn off.
4A-2. Internal Components
1. Corona Discharge (CD) Module: The generator
module consists of a high voltage electrode
wrapped around a Teflon core inserted in a
ceramic insulating tube. The assembly is
encased in a thermally protected aluminum
heat sink.
2. Power Supply: The fuse protected, self-
regulated, high voltage/high frequency power
supply provides the ideal electrical signal for
efficient ozone production.
3. Air Compressor: Compressor produces and
supplies compressed air to oxygen concentrator.
4. Oxygen Concentrator: Supplies concentrated,
dry, oxygen feed gas to the ozone generator.
5. Lo Limit Vacuum Switch: If the vacuum in the
ozone output supply line falls below 2 in. Hg the
switch will open causing the system to shut-down.
6. Ventilation Fan: Cooling fan operates whenever
the ozone generator is plugged in.
7. Intake Screens: Easily removable screens keep
debris from entering the enclosure. See Figure 3.

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Genesis CD–2G, CD–5G, & CD–7G Installation & Operations Manual
4B. Preventative Maintenance Schedule
The Genesis™Corona Discharge ozone system
requires very little maintenance beyond general
housekeeping practices.
DAILY:
1. Check ozone generator for proper operation.
2. Make sure red indicator light is not illuminated.
3. Make sure flow meter is indicating proper air flow.
MONTHLY:
1. Clean intake screens.
2. Perform general cleaning of cabinet interior.
3. Visually inspect compressor filter element.
Replace as required.
4. Visual inspection of all plumbing, mechanical,
and wiring in system.
ANNUALLY:
1. Replace/replace ozone supply line check valve.
2. Replace oxygen supply line check valve.
3. Verify oxygen output.
EVERY 8,750 HOURS:
1. Rebuild air compressor.
4C. Troubleshooting
Knowledge of electrical applications is required
for troubleshooting. Contact a certified electrician
if you are unsure of your ability to service the
equipment. Improper servicing will void generator
warranty. If any condition persists, call
1-800-676-1335 for technical assistance.
Symptom: “POWER” light out when system
plugged in and door is closed.
1. No power to the generator:
a. Check the circuit breaker at the facility power
distribution box.
b. Check for loose connections or wiring
breaks from the power distribution box
to the generator.
Symptom: “OZONE” indicator light out.
1. Ozone power fuse is bad.
a. Check fuse and replace if necessary.
2. Loss of vacuum.
a. Check red vacuum indicator light. If light is on
refer to corresponding symptom and
corrective action below.
3. Ozone cell high temperature.
a. Check operation of ventilation fan.
b. Check intake screens for obstruction of air flow.
Symptom: “VACUUM” indicator light is on
indicating out of range vacuum being supplied.
1. Injector not supplying adequate suction.
a. Check pump and ensure water is flowing
through injector.
b. Check by-pass valve and adjust if necessary
to obtain proper pressure differential in order
to re-establish suction.
Figure 3: Intake Screen Replacement

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Genesis CD–2G, CD–5G, & CD–7G Installation & Operations Manual
Symptom: CD Module is not operating. Ozone
output has dropped.
1. No power to the generator module from the
power supply:
a. Check fuse(s).
b. Check H.V. cables for breaks or loose
connections, replace if necessary.
c. Check for power at input terminals of the H.V.
power supply.*
* CAUTION: HIGH VOLTAGE.
Symptom: No air flow through the generator. The
air flow meter indicates 0 scfh flow.
1. Injector not set properly.
a. Adjust injector by-pass valve until proper air
flow is indicated.
2. Air compressor is not operating properly.
a. Listen for air compressor operation.
b. Check all tubing connections from the air
compressor through the system for leaks.
3. Ozone supply tubing damaged.
a. Check tubing for blockage or kinks.
b. Check for loose or damaged fittings.
4D. Contact Information
For Technical assistance:
Call: 1-800-676-1335 ext. 293
Email: [email protected]
Visit: www.delozone.com
SECTION 5 Replacement Parts &
Order Information
5A. Ordering information
For replacement parts call DEL at 1-800-676-1335.
Be prepared with the following information:
• Customer Name
• Customer Address
• DEL Model Number
• DEL Serial Number
• Date Purchased
• Proof of Purchase
OZONE CHECK VALVE
(BACK SIDE OF COMPRESSOR)
COMPRESSOR
PRESSURE RELIEF VALVE
( FLOW)
VACUUM SWITCH
PRESSURE SWITCH
DOOR SWITCH
OXYGEN CHECK VALVE
ASSEMBLY
HV POWER SUPPLY
OZONE OUT
FAN
OZONE CELL
CONCENTRATOR
MAIN FUSE/FUSEHOLDER
AIR FILTER
OXYGEN
(CD-7GV ONLY)
AUXILLARY FUSE
CONTROL CONTACTS
15.6
27.5
INDICATOR LIGHTS
DOOR LATCH
FLOWMETER
DOOR LATCH
Figure 4: Component Locations

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Genesis CD–2G, CD–5G, & CD–7G Installation & Operations Manual
DEL OZONE
COMMERCIAL PRODUCT
LIMITED TWO YEAR WARRANTY
The limited warranty set forth below applies to products manufactured by DEL OZONE – 3580 Sueldo Street, San Luis
Obispo, California 93401, and sold by DEL OZONE or its authorized dealers. This limited warranty is given only to the first
retail purchaser of such products and is not transferable to any subsequent owners or purchasers of such products.
Systems sized 65 grams or greater require factory commissioning and startup to maintain warranty as set forth below.
DEL OZONE warrants that DEL or DEL authorized dealers will repair or replace, at DEL’s option, any part of such
products proven to be defective in materials or workmanship within two (2) years of the date of receipt. Parts are covered
under the two (2) year warranty when and only when the stated maintenance requirements are met. Contact tanks and
degas valves have a ninety (90) day warranty. Compressor(s) must be maintained per operation and maintenance
manual. Required maintenance includes a compressor rebuild after one (1) year or every 8,760 hours, which ever is
reached first. Warranty does not include parts for compressor(s) rebuild kit(s), or other consumable items. See owner’s
manual for complete maintenance details. This Warranty specifically excludes any components not manufactured by DEL
OZONE that are external to the products covered, such as pumps, air compressors, monitors, tanks, or related
components. DEL OZONE will assist with warranty claims for such components purchased through DEL OZONE; limited
to the extent of the manufacturer’s standard warranty. ANY REPAIR OR REPLACEMENT WILL BE WARRANTED ONLY
FOR THE BALANCE OF THE ORIGINAL TWO (2) YEAR WARRANTY PERIOD
.
NOTE: USE ONLY DEL AUTHORIZED DEL REPLACEMENT PARTS. USE OF ANY OTHER PART(S) WILL VOID
THIS WARRANTY.
Any replaced parts must be returned to DEL OZONE for warranty evaluation.
THIS LIMITED WARRANTY DOES NOT INCLUDE ANY OF THE FOLLOWING:
(a) Any labor charges for troubleshooting, removal, or installation of such parts.
(b) Any repair or replacement of such parts necessitated by faulty installation, improper maintenance, improper
operation, misuse, abuse, negligence, accident, fire, flood, repair materials, and/or unauthorized accessories.
(c) Any such products installed without regard to required local codes and accepted trade practices.
(d) Damage to unit caused by water backflow;
(e) Any implied warranty of merchantability or implied warranty of fitness for particular purpose, and such
warranties are hereby disclaimed.
(f) DEL Ozone shall not be liable under any circumstances for loss of use of such product, loss of profits, direct
damages, indirect damages, consequential damages, and / or incidental damages.
This warranty gives you specific legal rights. You may have other rights which vary from state to state.
Extended Warranties and Service Agreements are available. Contact DEL for additional details.
TO OBTAIN WARRANTY SERVICE:
DEL OZONE
3580 Sueldo, San Luis Obispo, CA 93401
Customer Service Number: [phone]
Fax Number: [phone]
E mail [email protected]
PROVIDE:
1. Project, contact name, mailing address and telephone.
2. Installer/Mechanical Contractor.
3. Unit Part Number, Serial Number, and date of purchase.
4. The date of failure.
5. A description of the failure.
After this information is provided, DEL Ozone may release a RETURN GOODS AUTHORIZATION (RGA) NUMBER. After receiving the RGA number
the part in question must be returned to DEL Ozone, freight prepaid, with the RGA number clearly marked on the outside of the package. All
preauthorized defective parts must be returned to DEL Ozone within thirty (30) days. Under no circumstances may any product be returned to DEL
Ozone without prior authorization. Returns without the assigned RGA number on the outside of the package will be refused and shipped back to the
sender at their expense. Upon receipt of preauthorized returned goods, DEL Ozone will repair or replace, at DEL Ozone’s option, the defective product(s)
and return them (freight prepaid for products under warranty). Buyer’s acceptance of the product and use thereof constitutes acceptance of these terms.
4-1370-01_Rev.D

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Genesis CD–2G, CD–5G, & CD–7G Installation & Operations Manual
APPENDIX “A”
SAFETY

8
Genesis CD–2G, CD–5G, & CD–7G Installation & Operations Manual
4-0697_ Rev.D
OZONE
Material Safety Data Sheet
SECTION I: MATERIAL IDENTIFICATION
IDENTITY:OZONE (Gaseous)
ISSUED: February, 1992
FORMULA: O3
REVISED: May 12, 2014
Description (origin/uses):Occurs in atmosphere from UV light action on oxygen at high altitude. Commercially obtained by
passing air between electrodes carrying a high voltage alternating current. Also found as a by-product in welding areas, high
voltage equipment, or UV radiation.
Ozone is used as an oxidizing agent in air and water disinfection: for bleaching textiles, oils, and waxes; organic synthesis as in
processing certain perfumes, vanillin, camphor; for mold and bacteria control in cold storage.
Cautions:A powerful oxidizing agent, ozone generally exists as a gas and is highly chemically reactive. Inhalation produces
various degrees of respiratory effects from irritation to pulmonary edema (fluid in lungs) as well as affecting the eyes, blood, and
central nervous system.
Manufacturer/Supplier:On-site generation, equipment available from various suppliers, including:
DEL Ozone
3580 Sueldo Street
San Luis Obispo, CA 93401
Phone: [phone]
FAX: [phone]
SECTION II: INGREDIENTS AND HAZARDS
Ozone, CAS No. 10028-15-6: NIOSH RTECS No. RS8225000
1991 OSHA PELs
8-hr TWA: 0.1 ppm vol. (0.2 mg/m3)
15-min STEL: 0.3 ppm vol (0.6 mg/m
3
)
1991-1992 ACGIH TLV
Ceiling: 0.1 ppm (0.2 mg/m3)
1990 IDLH
10 ppm
1990 NIOSH REL
Ceiling: 0.1 ppm vol. (0.2 mg/m3)
1990 DFG (Germany) MAK
TWA: 0.1 ppm (0.2 mg/m3)
Category 1: Local Irritant
Peak Exposure Limit: 0.2 ppm
5 min momentary value, 8 per shift
Other Designations: Triatomic oxygen: CAS No. 10028-15-6, NIOSH RTECS No. RS8225000
SECTION III: PHYSICAL DATA
Boiling Point: . . . . . . .
Vapor Pressure: . . . . .
Vapor Density (AIR = 1):
Solubility in Water: . . .
-169°F
>1 ATM
1.6
0.49 ml @ 32°F (0°C),
3 ppm @ 20 °C
Melting Point: . . . . . . . .
% Volatile by Volume: . .
Molecular Weight: . . . . .
pH: . . . . . . . . . . . . . . . .
Critical Temperature: . .
-315.4°F (-193°C)
100%
48 Grams/Mole
Not Listed
10.22°F (-12.1°C)
Appearance and Odor:Colorless to blue gas (greater than -169°F): characteristic odor often associated with electrical sparks or
lightning in concentrations of less than 2 ppm and becomes disagreeable above 1-2 ppm. CAUTION: Olfactory fatigue develops
rapidly, so do not use odor as a preventative warning device.
SECTION IV: FIRE AND EXPLOSION HAZARD DATA
Flash Point: . . . . . . . .
Extinguishing Media: .
Nonflammable
Use large amounts of water spray or fog to put out fires involving ozone. Use appropriate fire-fighting
techniques to deal with surrounding material.
Special Fire Fighting Procedures:Wear a self contained breathing apparatus with full face pieces operated in a pressure-
demand or other positive-pressure mode.
Unusual Fire/Explosion Hazards:Decomposition of ozone into oxygen gas, (O2), can increase strength of fire.
SECTION V: REACTIVITY DATA
Stability:Ozone is not stable. Hazardous polymerization cannot occur.