Ozotech AIO3 Systems Operating instructions

AIO3Ozone Installation & Programming Guide
AIO3Systems
with Enhanced Oxidation Generator

-IC-
AIO-OZONE Installation & Programming Guide
Enhanced Oxidation Generator (EOG) Models...........................................................................................................Page IC
Installation of EOG Unit...............................................................................................................................................Page 1
EOG Indicator Lights...................................................................................................................................................Page 5
AIO Controller Ozone Programming Settings .............................................................................................................Page 6
EOG CD Cell Cleaning Steps .......................................................................................................................................Page 8
Maintaining the EOG Unit ...........................................................................................................................................Page 9
Important Safeguards.................................................................................................................................................Page 9
Maintenance Parts .....................................................................................................................................................Page 9
Index
Ozotech EOG
AIO3-OZONE-OZOTECH-KIT (Comes installed on system)
AIO3-OZONE-OZOTECH-FIELD-KIT (Dealer install kit)
No integrated power supply jack.
Nelsen EOG
AIO3-OZONE-NELSEN-KIT (Comes installed on system)
AIO3-OZONE-NELSEN-FIELD-KIT (Dealer install kit)
Comes with integrated power supply jack and integrated
power supply cord.
Reference 1
Reference 2
No power
supply jack
With power
supply jack
Integrated Control Valve
Power Supply Cord
Enhanced Oxidation Generator
Power Supply Cord
Enhanced Oxidation Generator
Power Supply Cord
Enhanced Oxidation Generator(EOG) Models

-1- AIO-OZONE Installation & Programming Guide
Step 1: For both the Ozotech & Nelsen EOG Models: Unplug
the power supply for the control valve from the wall outlet.
Step 2: Remove the cover from the control valve, Photo A.
Installation of EOG Unit (For Dealer Install Kits)
Photo D Thumbs Push Up on Tabs
Forefingers
Here
Photo A
Photo B
Photo C
Step 4: For the Nelsen EOG Model, Reference 2 on previ-
ous page, disconnect the power supply from the control
board, Photo C.
Step 5: Unsnap the top of the drive bracket using your
thumbs and forefingers to expose the backplate. Remove
the power supply by pulling it through the back of the
backplate, Photo D.
Step 3: For the Ozotech EOG Model, Reference 1 on
previous page, leave the power supply connected to the
control board, Photo B. Move to Step 6

-2-
AIO-OZONE Installation & Programming Guide
Step 7: Remove the Domed Screen from the Brine Fitting
and remove the Brine Fitting from the Control Valve.
Remove the white Check Valve from the Brine Fitting and
install the Black Ozone Compatible Check Valve in the fit-
ting as shown and replace Brine Fitting, Photos F, G & H.
Step 6: If you have not already done so. Unsnap the top
of the drive bracket using your thumbs and forefingers to
expose the backplate. Photo E.
Photo E Thumbs Push Up on Tabs
Forefingers
Here
Photo I
Photo J
Photo K
Photo F
Top of bracket
Screw goes to back of bracket
Step 8: Install the EOG brackets, Photo I, to the control
valve, Photos J & K and tighten the screw to secure
bracket in place.
Photo H
Photo G
Installation of EOG Unit continued

-3- AIO-OZONE Installation & Programming Guide
Photo N
Photo M
Tube
connection
Photo L
Brackets
Step 9: Connect the power supply cord to the bottom
power supply jack (DO NOT PLUG INTO WALL OUTLET).
Now slide the EOG unit onto the brackets Photo L.
Photo O
Installation of EOG Unit continued
Step 10: Attach the tubing to connection where inlet
screen and short gray tube was removed, Photo L.
Step 11: At this point if you are using the Optional
Integrated power supply with the Nelsen model, replace
the power supply cord by feeding it through the backplate
where original power supply ran, Photo N.
Step 12: Route the gray EOG wire through the hole along
with the power supply as shown in Photo O.

-4-
AIO-OZONE Installation & Programming Guide
Power Supply Jack
Installation of EOG Unit continued
Photo R
Thumbs
Here
Photo P
Photo Q
Step 13: Make sure the EOG unit is not plugged in, con-
nect the EOG unit’s 2 wire leads to Relay 1 on the control
valve. The black wire connects to COM and the red wire
connects to RLY1. See Photo P inset.
Step 14: Connect power supply to the control board if not
already connected as when using Ozotech Model,
Photo Q.
Step 15: Both the gray wire and power supply must fit
into the wire chases. Snap the bracket back into place.
(Do Not Press on Control Board, use the bracket to snap
into place.) Photo R.
Step 16: For the Ozotech EOG Unit reconnect the control
valve power supply to the wall outlet. Connect the EOG
power supply cord to power supply jack and plug the EOG
into the wall outlet. Skip to Step 17 if using Nelsen Unit
with optional integrated power supply cord.
Ozotech EOG Model
Wire
chases

-5- AIO-OZONE Installation & Programming Guide
Power Supply Jack
Power Supply Jack
for Control Valve
Installation of EOG Unit continued
EOG Unit Indicator Light- Photo 1
Green Light Blinking Slowly - Standby mode
Green Light Blinking Quickly - High voltage startup
Green Light Solid - High voltage is ON & stable; CD cell
producing ozone
Red Light Solid - Unstable high voltage; CD cell may
need cleaned
Green/Red Light Alternating Twice/Second - HV is ON,
but current is low
Red Light Flashing - NO or NC contacts are shorted
Orange Light - 1 year timer has expired; clean CD cell,
then push reset button to reset timer Photo 2.
Note: Holding reset for 3 seconds will change pulsing
green LED to solid green if the cell is in good operating
order. If LED changes to solid red, the cell needs cleaned.
Photo 2
Photo 1
Step 17: For Nelsen Unit using the integrated power sup-
ply cord connect the control valve power supply cord to
the power supply jack. Plug in the EOG to the wall outlet.
Once you power either system, the pulsing green LED
may turn to pulsing orange. Pressing the reset button will
reset it to pulsing green.
Nelsen EOG Model
At this point installation of your Enhanced Oxidation Gen-
erator is complete. Continue to page 8 for programming
instructions.
Flashing Green/Red means that the circuit is looking for
an optimum frequency to operate within. It is still making
ozone in the mode and will eventually go to solid green
or red.

-6-
AIO-OZONE Installation & Programming Guide
AIO Controller - Ozone Programing Settings
Press NEXT and DOWN
simultaneously and release.
Press NEXT and DOWN
simultaneously for 5
seconds and release. If the
screen in Step 2 does not appear, the lock on the valve is
activated.
To unlock, press DOWN, NEXT, UP and CLOCK in
sequence, then press NEXT and DOWN simultaneously
for 5 seconds and release. Press NEXT and DOWN
simultaneously for 5 seconds and release.
Step 1
CLOCK NEXT UP DOWN REGEN
CLOCK NEXT UP DOWN REGEN
Use UP or DOWN to select
FILTERING REGEN.
Press NEXT to go to
Step 3.
Press REGEN to exit
Configuration Settings.
Step 2
Use UP or DOWN to set
2nd backwash to OFF.
Press NEXT to go to
Step 6.
Press REGEN to return to
previous step.
Step 5
CLOCK NEXT UP DOWN REGEN
TIMESET
SOFTENING
FILTERING
TODAY
NORMAL
GAL
MIN
x1000
NOR
CAPACITY
BACKWASH BRINEFILL RINSE
REMAINING
PAM
Use UP or DOWN to set
RINSE to OFF.
Press NEXT to go to
Step 7.
Press REGEN to return to
previous step.
Step 6
CLOCK NEXT UP DOWN REGEN
TIMESET
SOFTENING
FILTERING
TODAY
NORMAL
GAL
MIN
x1000
NOR
CAPACITY
BRINEFILL RINSE
REMAINING
PAM
Use UP or DOWN to set
FILL to OFF.
Press NEXT to go to
Step 8.
Press REGEN to return to
previous step.
Step 7
CLOCK NEXT UP DOWN REGEN
TIMESET
SOFTENING
FILTERING
TODAY
NORMAL
GAL
MIN
x1000
NOR
CAPACITY
FILL
REMAINING
PAM
Use UP or DOWN to set
REGEN to OFF.
Press NEXT to go to
Step 9.
Press REGEN to return to
previous step.
Step 8
CLOCK NEXT UP DOWN REGEN
TIMESET
SOFTENING
FILTERING
REGEN
TODAY
NORMAL
GAL
MIN
x1000
NOR
CAPACITY
BACKWASH BRINEFILL RINSE
REMAINING
PAM
Use UP or DOWN to adjust
backwash time.
Press NEXT to go to
Step 4.
Press REGEN to return to
previous step.
Step 3
CLOCK NEXT UP DOWN REGEN
TIMESET
SOFTENING
FILTERING
REGEN
TODAY
NORMAL
GAL
MIN
x1000
NOR
CAPACITY
BACKWASH
REMAINING
PAM
Step 4 alternates between
the two displays shown.
Use UP or DOWN to adjust
brine time.
Press NEXT to go to
Step 5.
Press REGEN to return to
previous step.
Step 4 TIMESET
SOFTENING
FILTERING
REGEN
TODAY
NORMAL
GAL
MIN
x1000
NOR
CAPACITY
BACKWASH
REMAINING
PAM
BRINE
TIMESET
SOFTENING
FILTERING
REGEN
TODAY
NORMAL
GAL
x1000
NOR
CAPACITY
BACKWASH
REMAINING
PAM
BRINE
CLOCK NEXT UP DOWN REGEN
CLOCK NEXT UP DOWN REGEN
TIMESET
SOFTENING
FILTERING
REGEN
TODAY
NORMAL
GAL
MIN
x1000
NOR
CAPACITY
BRINE
REMAINING
PAM
Step 9 alternates between
the two displays shown.
Use UP or DOWN to set
RELAY 1 to ON.
Press NEXT to go to
Step 10.
Press REGEN to return to
previous step.
Step 9 TIMESET
SOFTENING
FILTERING
REGEN
TODAY
NORMAL
GAL
MIN
x1000
NOR
CAPACITY
BACKWASH BRINEFILL RINSE
REMAINING
PAM
CLOCK NEXT UP DOWN REGEN
TIMESET
SOFTENING
FILTERING
REGEN
TODAY
NORMAL
GAL
MIN
x1000
NOR
CAPACITY
BACKWASH BRINEFILL RINSE
REMAINING
PAM

-7- AIO-OZONE Installation & Programming Guide
AIO Controller - Ozone Programing Settings Continued
Step 10
CLOCK NEXT UP DOWN REGEN
TIMESET
SOFTENING
FILTERING
REGEN
TODAY
NORMAL
GAL
MIN
x1000
NOR
CAPACITY
BACKWASH
REMAINING
PAM
Step 10 sets Relay
Actuation Time, when the
EOG unit turns on.
Relay activates after the
beginning of regeneration
cycle and then deactivates after a set period of time. The
start of the regeneration is defined as the first backwash
cycle or DN brine cycle, whichever comes first.
Set for 15 minutes or 1 minute after the time set in
Step 3. This means the relay will turn on the EOG unit
1 minute after the air/ozone draw starts.
Use UP or DOWN to set RELAY 1 to 15.
Press NEXT to go to Step 11.
Press REGEN to return to previous step.
Step 11 indicates the length
of time the EOG unit is
activated.
Use UP or DOWN to adjust
the amount of time to 37:00
minutes.
Press NEXT to go to Step 12.
Press REGEN to return to previous step.
Step 11
CLOCK NEXT UP DOWN REGEN
TIMESET
SOFTENING
FILTERING
REGEN
TODAY
NORMAL
GAL
MIN
x1000
NOR
CAPACITY
BACKWASH
REMAINING
PAM
Step 12 alternates between
the two displays shown.
Use UP or DOWN to set
RELAY 2 to OFF.
Press NEXT to EXIT
Configuration Settings.
Press REGEN to return to
previous step.
Step 12 TIMESET
SOFTENING
FILTERING
REGEN
TODAY
NORMAL
GAL
MIN
x1000
NOR
CAPACITY
BACKWASH BRINEFILL RINSE
REMAINING
PAM
CLOCK NEXT UP DOWN REGEN
TIMESET
SOFTENING
FILTERING
REGEN
TODAY
NORMAL
GAL
MIN
x1000
NOR
CAPACITY
BACKWASH BRINEFILL RINSE
REMAINING
PAM

-8-
AIO-OZONE Installation & Programming Guide
Periodic cleaning of the CD cell within your Ozotech
product is important and will keep your generator
operating effectively and efficiently. Cleaning the cell can
be done quickly…in six easy steps. Disconnect Power
Supply from wall outlet.
Step 1: Remove the cell from the unit by snipping the
zip-tie, Photo 1.
EOG CD Cell Cleaning Process
Photo 1
Photo 2
Photo 3
Photo 4
Photo 5
Step 2: Remove the cell from the metal clips, Photo 2.
Step 3: Disconnect the wire connection on the bottom of
the cell, Photo 3.
Step 4: Pull the Tygon tubing from the cell itself
Photo 4-5.

-9- AIO-OZONE Installation & Programming Guide
Photo 7
Maintaining the EOG Unit
Maintenance Parts
EOG Important Safeguards
The EOG ozone generator is delivered factory tested,
calibrated, and adjusted for maximum efficiency and
long life. Simple maintenance and appropriate operating
conditions are the only requirements to keep the unit
functioning within manufacturer's specifications.
The EOG CD (Corona Discharge) cell should be cleaned
every 12 months. Refer to the Ozotech Service Manual for
in-depth instructions for proper cleaning. A cleaning kit is
also available.
Check Valves - Both check valves, OZONE-BARB CV and
OZONE-BRINE CV, need to be changed every 12 months.
Failure to do so increases chances of a check valve failing
and possible water leakage.
OZONE-BARB CV....Ozone 3/16" X 3/16" Barb Check Valve
OZONE-BRINE CV .....................................Ozone Brine Check Valve
OZONE-CLEANING KIT.................. Ozone CD Cell Cleaning Kit
OZONE-CD CELL ................................................... Replacement CD Cell
WARNING - DO NOT install the EOG unit on
any system using Birm® filter media. Ozone
will strip the properties from the media
rendering it useless.
WARNING -DO NOT install the EOG unit on any
other control valve other than specialty Clack
based controls. Internal components may not be
compatible with Ozone.
CAUTION -When re-installing electronic
control board in the valve, make sure the wiring
is fully seated in the wire chase. Wires that are
not fully seated will prevent control board
bracket from seating in the valve and covers
not fitting correctly.
EOG CD Cell Cleaning Continued
Photo 6
Step 5: Insert a piece of clear tubing at one end of the
cell and place the open end in a cup of warm water. At
the other end of the cell, insert a piece of eight-inch clear
tubing fitted with the plastic syringe. Now you’re ready
to flush the cell. Pull back the syringe to draw water into
the cell and push in to flush water back out. Refresh
water with clean warm water. You’ll need to continue this
process until the water in the cup is completely clear.
Photo 6
Step 6: Once the cell has been completely flushed and the
water is clear, it’s time to dry the cell. Use a compressed
gas duster (or computer dust spray) by placing the nozzle
into one of the barbs on the cell and depressing the trig-
ger until the moisture is gone from the cell, Photo 7.
Now that the CD cell is clean, it can be reassembled and
secured with a zip-tie.

AIO INTEGRATED-OZONE Installation & Programming Guide Part#AIO3-OZONE-PROGRAM GUIDE