Water Maze CLP Series User manual

OPERATOR’S MANUAL
For technical assistance or theWater Maze Dealer nearest you, call [phone] or
[phone] or consult our web page at www.wmaze.com
■ CLP-5023 ■ CLP-7023 ■ CLP-7033
CLP

CLP Manual • Form #96-6294 • Revised 7/04
CONTENTS
2
Introduction...................................................................................................................................5
Unpacking.....................................................................................................................................5
Safety Instructions .....................................................................................................................5-6
InstallationInstructions ............................................................................................................6,10
InstallationView ............................................................................................................................7
Electrical InstallationView.............................................................................................................8
Water Panel InstallationView ........................................................................................................9
Operation...............................................................................................................................10-13
CLP-5023 OperationView ..........................................................................................................14
CLP-7023/7033 OperationView..................................................................................................15
General Maintenance and Service.........................................................................................16-17
Ozone Generator ...................................................................................................................17-18
Ozone GeneratorTestingView....................................................................................................18
Corona Ozone Generator Breakdown.........................................................................................19
CD Ozone Generator.............................................................................................................20-22
Ozone GeneratorTwoTube View (CLP-5023).............................................................................23
Ozone Generator Four Tube View (CLP-7023/7033)...................................................................24
Chemical Maintenance Program.................................................................................................25
Daily Chemical Maintenance ......................................................................................................26
Centrifugal Pump ........................................................................................................................26
Pump Operation..........................................................................................................................26
PumpManitenance................................................................................................................26-27
Digital ORP/pH Controller, Standard, Model 250 ...................................................................27-28
ORP/pH Sensor Maintenance.....................................................................................................28
ORP/pH SensorTroubleshooting ................................................................................................29
Digital ORP/pH Controller, Optional, Model pH402 .....................................................................30
Operator Interface, Model pH402................................................................................................31
Digital ORP/pH Controller, Model pH402 ....................................................................................31
Digital ORP/pH Controller Error Codes, Model pH402...........................................................32-33
Calibration Procedures, Model pH402 ........................................................................................34
Cartridge Filter Assembly Breakdown (CLP-5023) .....................................................................35
Cartridge Filter Assembly Breakdown, 250 sq.ft.(CLP-7023/7033) ...........................................36

CONTENTS
3
CLP Manual • Form #96-6294 • Revised 7/04
Carbon Filter/Multi-Media Filter Breakdown (CLP-5023).............................................................37
DVK-4 4-WayValve #65-39-2582-07...........................................................................................38
Carbon Filter, Multi-Media Filter (CLP-7023)...............................................................................39
Multi-Media & Carbon Filter ExplodedView and Parts List .........................................................40
Filter Pump CLP-5023B, C;Ozone Pump CLP-7023B, C, CLP-7033B, C...................................41
Filter Pump CLP-7023A ..............................................................................................................42
Scot Filter Pump CLP-7023B, C;Scot Transfer Pump CLP-5023B, C .........................................43
Scot Filter &Transfer Pump CLP-7023A, B, C ............................................................................44
Scot Filter &Transfer Pump CLP-7033K .....................................................................................45
Scot Filter &Transfer Pump Specifications .................................................................................46
Little Giant Submersible Sump Pump #5-23486 (CLP-5023) .................................................47-48
Little Giant Submersible SumpPump #23484/#5-23485 (CLP-7023/7033)............................49-50
Ebara Sump Pump .....................................................................................................................51
Transfer Pump Breakdown #5-2363 (CLP-5023) ........................................................................52
Transfer Pump Breakdown #5-2365 (CLP-7023A) ......................................................................53
Transfer Pump Specifiocations....................................................................................................54
Ozone Generator Pump Assy.#5-2338 & 5-2362 (All Units) /Filter Pump #5-2338 (CLP-5023) ......55
Breakdown Drawings .............................................................................................................56-90
CLP-5023 Plumbing Assembly Breakdowns......................................................................56-63
CLP-7023 Plumbing Assembly Breakdowns......................................................................64-71
CLP-7033 Plumbing Assembly Breakdowns......................................................................72-79
Manifold Breakdown (CLP-5023A).....................................................................................80-81
Manifold Breakdown (CLP-7023/7033) ..............................................................................82-83
Ozone Generator Breakdown, 4Tube ................................................................................84-85
Control Panel Breakdown, 230V Models............................................................................86-87
Water Panel Breakdown ....................................................................................................88-90
Troubleshooting .....................................................................................................................91-98
CLP ........................................................................................................................................91
Pump ......................................................................................................................................92
Pump Motor ............................................................................................................................93
Ebara Sump Pump .................................................................................................................94
Filter .......................................................................................................................................95

CLP Manual • Form #96-6294 • Revised 7/04
CONTENTS
4
WaterSolenoid .......................................................................................................................96
Water Seals ............................................................................................................................97
CLP Maintenance .......................................................................................................................98
Warranty .....................................................................................................................................99
ModelNumber ______________________________
Serial Number ______________________________
Date of Purchase ____________________________
The model and serial numbers will be found on a decal attached to
theWater Maze.You should record both serial number and date of
purchase and keep in a safe place for future reference.

CLP OPERATOR’S MANUAL
5
#96-6294 • Revised 7/04
INTRODUCTION
Your owner’s manual has been prepared to provide you
with a simple and understandable guide for equipment
operationandmaintenance,based on thelatestproduct
informationavailableat thetime ofprinting.To keep your
machineintop runningcondition,followthespecificmain-
tenance and troubleshooting procedures given in this
manual.
NOTE: WATER MAZE reserves the right to make
changes at anytime without incurring any obligations.
Owner/User Responsibility:
The owner and/or user must have an understanding of
the manufacturer’s operating instructions and warnings
beforeusing this WATER MAZE machine.Warning infor-
mationshouldbe emphasized and understood.If theop-
eratoris notfluent inEnglish, themanufacturer’s instruc-
tions and warnings shall be read to and discussed with
theoperatorinthe operator’snative language bythe pur-
chaser/owner, making sure that the operator compre-
hends its contents.
The owner and/or user must study and maintain the
manufacturers’instructions for future reference.
This manual should be considered a permanent
part of the machine and should remain with the
machine if resold.
When ordering parts, please specify model and
serial number.
Thesemachinesare designed forinsideinstallationonly.
UNPACKING
1. CLP Machine Assembly
2. SludgeTub
3. SludgeTub Bag Support
4. Accessory and Plumbing Box
5. Cartridge Filter Elements (2)
6. Operator’s Manual
Note any damage to machine or components for claims
against the freight lines.
SAFETY INSTRUCTIONS
CAUTION: To reduce the risk of
injury, read operating instruc-
tions carefully before using.
1. Read the owner’s manual thor-
oughly. Failure to follow the in-
structionswill cause a malfunc-
tion of the machine and result
in death, serious injury and/or
property damage.
WARNING:Groundsystem before
connecting to the power supply.
WARNING: Wire the system for
correct voltage. See “Electrical”
section of this manual and motor
nameplate.
WARNING: Meet the National
Electrical Code and local codes
for all wiring.
WARNING: Follow the wiring instructions in this
manual when connecting the system to the power
lines.
WARNING: All wiring must be performed by a quali-
fied electrician.
2. Knowthe systemapplication, limitations, and poten-
tial hazards.
WARNING: Do not use to pump
concentrations of flammable or
explosive fluids such as gasoline,
fuel oil,kerosene,etc.Do not use
inexplosiveatmospheres.Pumps
should only be used with liquids
compatible with pump compo-
nent materials. Failure to follow
this warning can result in personal injury and/or
property damage.
3. WARNING: Risk of electric shock .
Allwiring shouldbeperformed bya qualified electri-
cian.
4. Never make adjustments on the machine while it is
in operation except for those prescribed in this
manual.
5. The main power must be brought from the circuit
breakerand wiredinto theelectrical boxon the CLP.
This line must be run through conduit to protect it
fromdamage.Apowerdisconnect should be located
next to the machine for maintenance purposes.
6. Beforeservicing the machine,refertoall the MSDS’s
on the material identified in the waste stream.You
must comply with all warnings and wear all protec-
tive clothing as stated on the MSDS’s.
7. Protect all electrical cords from sharp objects, hot
surfaces, oil, sunlight, and chemicals.Avoid kinking
thecords.Replaceor repair damagedor worncords
immediately. All wiring should be run through con-
duit.
8. Inlet water temperature must not exceed 85° F.
9. Disconnectthepowerbeforeservicingthismachine.
If the power disconnect is out-of-sight, lock it in the
open position and tag it to prevent unexpected
application of power.
WARNING
READ OPERATOR’S
MANUAL
THOROUGHLY
PRIORTO USE.
WARNING
KEEP WATER SPRAY
AWAY FROM
ELECTRICALWIRING.
WARNING
RISK OF EXPLOSION:
DO NOT SPRAY
FLAMMABLE LIQUIDS.
CAUTION

6 CLP OPERATOR’S MANUAL
#96-6294 • Revised 7/04
10.
WATER MAZE is not liable for modifications or the
use of components not purchased from WATER
MAZE.
11. Personal Safety:
a. Wearsafetyglasses and other applicableprotec-
tiveclothingatalltimeswhenworkingontheCLP.
Refer to item #6 under Safety Instructions.
b. Keep your work area clean, uncluttered and
properly lighted. Replace all unused tools and
equipment.
c. Keepvisitorsatasafedistancefromtheworkarea.
d. Maketheworkshopsafewith padlocksandmas-
ter switches.
12. Running the system without water will damage the
pumps and will void the warranty.
13. Release all pressure within the system before ser-
vicing any component.
14. Drain all liquids from component before servicing.
15. Checkhosesforweakorworncondition beforeeach
use,makingcertain thatall connections aresecure.
16. Periodically inspectpumpand system components.
Perform routine maintenance as required.
17. Do not touch an operating motor. Modern motors
are designed to operate at high temperatures.
18. Donothandleapumporpump motor with wethands
or when standing on a wet or damp surface, or in
water.
19. The pump motors are equipped with an automatic
resetting thermal protector and may restart unex-
pectedly.Tripping isanindication ofmotor overload-
ing as a result of operating the pumps at low heads
(low discharge restriction), excessively high or low
voltage, inadequate wiring, incorrect motor connec-
tions, or a defective motor or pump.
20. IMPORTANT NOTE: The sump pump is not a trash
pumpandis subjecttoprematurefailureunlesssump
pit baffling or additional protection is provided.
21. Do not stand on the bracket that supports the Elec-
trical Box, Ozone Generator and the ORP/pH Con-
troller. During installation and maintenance obtain
an OSHA approved ladder.
22. Keep machine from freezing.
23. Do not spray water directly at machine.
INSTALLATION INSTRUCTIONS
1. Locate the CLP on a containment pad to prevent
contamination.
2. Level the machine by using shims that will provide
ample support and will not corrode or deteriorate
over time.
3. Haveaqualifiedelectricianconnecttheproperpower
supplyto the electricalcontrolbox.Itisrecommended
that a ground fault circuit interrupter be installed in
the circuit breaker for the CLP.
NOTE: Electrician needs to locate where the power
supplywill enter theelectrical boxand punch ahole.
4. Connect the sludge tub assembly by placing the
sludge bag support into the sludge tub. Attach the
sludge bag onto the sludge inlet fitting using the
screw clamp provided.
5. Attachthe 2" flexhose to thesludgetub byscrewing
the hose barbs into the bulkhead connectors, then
attachthe 2" flexhose tothehosebarb using ahose
clamp. The return line should gravity return to the
catchbasin orconnectto thereturn line.The2" inlet
flexhose should connectbetweenthecone tank dis-
charge valve and the sludge bag inlet connector.
6. Build the inlet plumbing from the sump pump dis-
chargeport (min.1-1/2"pipe) to theCLP1-1/2" inlet
line. If the pipe is to be under the concrete, use 2"
pipe.Lower the sump pump into the sump pit.
NOTE: Installaunion on theinlet linenear thesump
so the pump can be easily removed for service.
7. Position the sump pump in the bottom of sump pit.
a. Elevate on astandor cinder blocks,6" offthe pit
floor,to keeppumpfromsuckinginrocksorother
heavy material that may plug pump or plumb-
ing.
b. Position the pump away from incoming water to
help prevent cavitation.
c. Tiea rope or chainto the pump handleand bring
out of the top of the pit for ease of pump
removal. Do not lift pump by power cords or
plumbing.Havea union installedon plumbingat
the top of the pit.Position union so it can easily
be reached and opened for pump removal.
8. The High Level Control Float #1 (black, normally
open)is theupperfloatwhichcontrolstheupperlimits
of the sump. It prevents the sump from flooding by
opening SV1, the rain water solenoid valve. The
Fresh Water Make-up Float #2 (grey, normally
closed)prevents the sump fromrunning dry byopen-
ing SV2, the fresh water solenoid valve.Float tether
length must be a minimum of 2" long.Turn-on point
for the Fresh Water Make-up Float must be at least
6"above the suctioninlet ofsumppump.The further
the water must travel before reaching the sump, the
higher the float must be placed above the suction
intake. On three phase units a third float is needed
toprotect the sumppump fromthepossibility of run-
ning dry. Position the Low Water Protect Float #7

CLP OPERATOR’S MANUAL
7
#96-6294 • Revised 7/04
CLP INSTALLATION VIEW
FS#1
FS#2
Inlet
Line
Sump
Pump
Sump Pit Sump Pump
Installation
(3 Phase)
FS#7
FS#1
FS#2
Inlet
Line
Sump
Pump
Sump Pit Sump Pump
Installation
(Single Phase)

8 CLP OPERATOR’S MANUAL
#96-6294 • Revised 7/04
CLP ELECTRICAL INSTALLATION VIEW
ALL MODELS
Electrical
Grounding
Bolt
For
Detail See
Ozone
Generator
Illus.
Electrical Power Supply
Provided By Qualified
Electrician

CLP OPERATOR’S MANUAL
9
#96-6294 • Revised 7/04
WATER PANEL INSTALLATION VIEW
SV1
SV2
Water Panel
(All Models)
To Permitted Sewer
or Storage Tank
To Pressure Washer
Fresh Water Supply

10 CLP OPERATOR’S MANUAL
#96-6294 • Revised 7/04
(black, normally open) 6" above the suction inlet of
sumppump.Singlephase sump pumpshavea float
built into them.
Floats must travel their complete arc without:
• Water going over the top of the pit.
• Touching side walls or bottom.
• The pit running out of water.
• Interferingwithelectricalwiring, plumbing,bottom
or side walls of sump, or any object. Attach the
floats to the PVC line on the sump pump.
Check to assure the floats can operate freely.
(See CLP InstallationView.)
9. Run the electrical cords from the sump pump and
floatsto theelectrical junction boxesnear thereturn
lineand attachwires.(See electricaldiagram).If the
sump pump and floats are located farther then 20
feet from the electrical junction boxes, then have an
electrician install watertightjunctionboxes withcon-
duit and proper sized wire to extend the electrical
connections.
10. Connectthefreshwater line (3/4"GHM garden hose
not provided) to the “Fresh Water Makeup” port on
the water panel (seeWater Panel Illustration).
11. Connect the “Outlet to Pressure Washers” to your
pressure washer by using a 5/8" garden hose (not
provided). Valve #7 behind the water panel should
remain closed until start-up.(On CLP-7033 you will
need a 1" line or hose.)
12. Connect the “Rain Water Overflow” to the sewer or
storage (line not provided).Valve #8 behind the wa-
ter panel should remain halfway open.
CAUTION:DischargePermitsarerequiredandmustbe
obtainedbeforeanytreatedwaterisdischarged.
13. Connect a hose to “Rinse Water” outlet if it is to be
used. Make sure valve #6 behind the water panel
stays closed until rinse water is needed (hose not
provided).
NOTE: The use of rinse water in a closed loop sys-
tem will overfill the system and will lead to an over-
flow situation causing the rainwater overflow valve
to open.
OPERATION
• The 1/2 HP (CLP-7023/7033) sump pump pushes
the water from the sump and sends it to the CLP.
(1/3 HP for CLP-5023)
• The solids settle in the bottom of the cone.
• The oil and grease are separated out by the coa-
lescing cones.
• The 3/4 HP Ozone pump takes water from the CLP,
ozonates it and returns it to the CLP cone tank.
Float Level Controls:
(See InstallationView and CLP Flow Operation Illustra-
tions)
Sump Pit (FS1 and FS2)
FS1,Top Float, N/O, Black - Down position turns “off”
the rain water overflow solenoid. Up position turns “on”
the rain water overflow solenoid.
FS2, Bottom Float (Middle Float on Three Phase),
N/C, Grey - Down position turns “on” the Fresh Water
Makeup.Theuppositionturns“off”theFreshWaterMakeup.
FS7, Bottom Float (Three Phase Only), N/O, Black -
Down position turns “off” the sump pump. Up position
turns “on”the sump pump.
Tank 1
FS3,Top Float, N/C,Grey - Downposition turns“on”the
sump pump.The up position turns“off” the sump pump.
FS4,Top Float, N/O, Black - Down position turns “off”
the filter pump.Up position turns “on”the filter pump.
Tank 2
FS5, Top Float, N/C, Grey - Down position turns “on”
the filter pump.Up position turns “off” the filter pump.
FS6, Bottom Float, N/O, Black - Down position turns
“off”the transfer pump.Up position turns “on”the trans-
fer pump.
Valve Location and Function:
(See CLP OperationViews)
It is extremely important to know the location and func-
tionof the valveson theCLP.Improperpositioning of the
valves can cause overflow or damage which could re-
sult in time consuming clean-up and repairs.Study the
section on “Valve Location and Function.”
•Valve 1 - Flow ControlValve
Thisvalve controls theamount of waterallowedinto
theCLPfrom the sumppump.Adjust2-4gpm above
your demand on the system.(See Page 14)
•Valve 2 & 3 - Ozone Pump
Shouldbeopenatalltimes.NOTE:Onlytobeclosed
when removing or repairing the ozone pump.(See
Page 56)
•Valve 4 - Oil Skimming Bucket
Valve should be closed except when draining off oil.
(See Page 15)
•Valve 5 - TankValve
Thisvalveshouldonlybeopenedwhendrainingsludge.
(See Page 15)
•Valve 6 - RinseWater ControlValve
Thisvalveisopened onlywhenrinse waterisneeded.
(See Pages 84, 85)

CLP OPERATOR’S MANUAL
11
#96-6294 • Revised 7/04
•Valve 7 - Outlet to PressureWasherValve
After start-up, this valve is left fully open all of the
time. Controls water to the pressure washer. (See
Pages 84, 85)
•Valve 8 - RainWater OverflowValve
Left open partially. When SV#1 opens, water is al-
lowed to discharge while still providing water for the
pressure washer.(See pages 84, 85)
•Valve 9 - FreshWater InletValve
Left fully open. When SV#2 opens, fresh water is
added to tank #2.(See Pages 84, 85)
•Valve 10 - Recycle Flow ControlValve
This valve is used to control the volume of water
going back to the collection pit for recycling through
the system when the timer activates the solenoid,
SV3,forrecycling thesystem.Set thesameas valve
#11. There is no flow meter, so check when filter
andtransferpumparerunninginrecycle mode.Open
valve far enough to maintain water level in tank #2.
(See Page 82)
•Valve 11 - Filter Flow ControlValve
This valve controls the amount of water allowed to
flow through the filters.Set the valve to the same or
two below valve #1.(See page 14)
•Valve 12 & 13 - Filter ControlValve
When set on Filter, this valve allows water to pass
through the filter.When set on Backwash, the water
passesthroughthefilterinreverse,then passes back
to the catch basin. Leave on filter unless
backwashing.(See page 14)
•Valve 14
Leaveclosed.When openedallows pressurizedwa-
tertoflush sediment fromthe conetank. (See pages
14, 15)
•Valve 15
Leave closed.This valve when opened allows pres-
surizedwaterto flush out the sludge hose.(Seepage
15)
•Valve 16
Leave closed. Open when cleaning cartridges to
drain water from cartridge cannister.(See page 15)
•A pressure switch, PS#2, is set at 15 PSI to acti-
vateanalarmtoindicate thatthefiltersareobstructed
and need to be backwashed.This switch is located
between the Multi-Media Filter and the Filter Pump.
Float Override Switch:
The Float Override Switch is located on the electrical
box.This switch manually turns the timer solenoid valve
(SV3) “ON” lowering the water level in Tank #2 which
returns water to the catch basin. When FS5 in tank #2
drops, the filter pump will come “ON.” Water from Tank
#1 is used to backwash the Multi-Media and Carbon Fil-
ters.TheFloat OverrideSwitch mustbepushedand held
until the filter pump comes “ON.”
Filling System withWater:
Valve 1 - Open Valve 12 - Filter Position
Valve 11 - Open Valve 13 - Filter Position
On initial start up, or if the system has been drained of
water, it will be necessary to fill the system and piping
with fresh water.This is done as follows:
Open valves, 1, 11, 12, and 13.
Make sure the sump is full of water.
Adjust the valve positions as noted above. Turn on the
pump to allow water to fill the system.
Whenthe CLPcone tankbecomes full, waterwill flowto
Tank 1.
Running:
Valve 1 - Open Valve 12 - Filter Position
Valve 7 - Open Valve 13 - Filter Position
Valve 11 - Open
Adjust valves as shown above.
WhenwaterbeginstoflowthroughtheCLP,adjust Valve1
so that the flow meter reads 5 - 30 gpm depending on the
machine. Record the hours from the hour meter and the
flowrateintotheoperationlog.TheCLPisnowoperational.
Adjustvalve#11toread5-30gpmdependingonmachine.
Backwash Multi-Media Filter:
Valve 1 - Open Valve 12 - BackWash
Valve 7 - Open Valve 13 - Filter
Valve 11 - Open
Position valves for backwash as shown above.Push the
Float Override Switch until the filter pump comes “ON.”
Adjust flow to 30 GPM usingValve 11.
The water is now flowing in reverse through the Multi-
Media Filter taking all the impurities back to the catch
basin.Turn “OFF”the filter pump.Return valves to filter-
ingmode.

12 CLP OPERATOR’S MANUAL
#96-6294 • Revised 7/04
Backwash Carbasorb Filter:
Valve 1 - Open Valve 12 - Filter
Valve 7 - Open Valve 13 - BackWash
Valve 11 - Open
Turn “ON” the filter pump. Adjust flow to 15 GPM using
Valve 11. Position valves and operate for backwash as
shownabove.
The water is now flowing in reverse through the Carba-
sorb Filter taking all the impurities back to the catch ba-
sin.Turn “OFF”the filter pump.Return to filtering mode.
Note: The carbon is very light. Using excessive water
flow will wash the carbon out of the filter and into the
catch basin. If you see carbon coming out of the filter
using 15 gpm, lower the flow rate to 10 gpm.Turn “ON”
the filter pump and adjust the flow rate to 5-30 GPM de-
pending on the CLP you have.
Check List Before Starting: Yes No
1. Is inlet line connected from
the sump pump to the inlet
of the CLP? ___ ___
2. Is the voltage correct? ___ ___
3. Is the recycle line connected? ___ ___
4. Is the Fresh Water Make-up
hose connected? ___ ___
5. Is the Outlet to Pressure
Washer hose connected. ___ ___
Start-Up:
• Make sure that the CLP is level.
• Turn on the Fresh Water Makeup hose.
• After checking for proper power supply voltage,
turn on the circuit breaker to the CLP Machine.
Note: Make sure all switches are turned ”OFF”.
• Fill the sump pit with water, and check that the
water level does not drop, which would indicate
the pit is not sealed.
• Turn the sump pump switch on the electrical con-
trol panel to the “ON” position.
• Adjust the flow of water into the CLP using valve
#1 from 5 to 30 GPM (ideal is 10 GPM depending
on model), by reading the indicator marks on the
inlet flow meter.
• Turn the filter pump switch “ON”.Tank #2 should
fill and FS5 will turn off the filter pump when in the
up position. FS3 in tank #1 will turn off the sump
pump when in the up position.
• Adjustvalve11 so thatthefilter flowmeterhas the
same or lower flow rate than the inlet GPM flow
rate.
• Turn “ON” the transfer pump. The pump should
pressurizeand shutoff.NOTE:Whenthe pumpis
put into operation the pressure switch may need
tobeadjusted.The3/4hppumpandthe2hppump
are normally set at 20 psi ON and 40 psi OFF.
• Check to assure the oil skimmer is adjusted prop-
erly.Adjust if needed by screwing the funnel up or
down, or angling the pipe to allow a small amount
of water to free flow. If oil starts to build up on top
of the cone tank, adjust the skimmer to allow in-
creased flow. NOTE: Only adjust the oil skimmer
when the sump pump is running.
• Turn“ON” the filter timer inside the electrical con-
trol panel by pulling out some pins and rotating
thetimertothosepinstoensurethewaterrecycles
from Tank #2 back to the catch basin. Each pin
pulled out will activate the solenoid valve for one
half hour.This prevents stagnant water inside the
filters from producing an odor. The timer pins
should be set to come “ON” when the machine
won’t be operational. Set the timer to the correct
timewhen testing iscompleted.Adjustvalve10 to
the desired flow rate.
• Turn “ON” the Ozone Generator timer inside the
electrical control panel by pulling out the pins on
thefaceof the timerand rotatingthe timerto those
pins to activate the ozone generator as needed to
control bacteria. Each pin pulled will activate the
ozone generator for one half hour. After the test-
ing is completed, rotate the timer to the correct
time.
• Place the ORP/pH probes in the bracket inside
the CLP tank.Remove the liquid filled cap on the
endoftheprobeandslide into bracketholes.Make
sure the tank is full of water and the probes are
kept wet. Run the connector through the hole in
the tank wall near the bracket and attach the con-
nectors to the controller. The connector with the
white tag near it is the ORP and is connected to
the top stud on the controller.The other is the pH
and is connected to the bottom stud on the con-
troller.
• A pressure switch, PS#1, on the inlet line is set at
1 PSI which will allow the pH pump to come“ON”
topump chemical intothe inletlineif the controller
is calling for a pH adjustment.
• Look over the entire CLP for leaks.The machine
was hydrostatically tested at the factory but may
have been damaged in shipment.

CLP OPERATOR’S MANUAL
13
#96-6294 • Revised 7/04
Ozone Generator Operation:
Turn the OzoneGenerator switchon.The indicator lights
on the Ozone Generator will have dim green lights or no
lights if the machine is working and bright green lights if
the ozone generator has malfunctioned.
Setting the Ozone Generator:
AnSCFH(Standard Cubic FeetperHour) gauge isused
toaccurately measure theamount of airflowingthrough
the ozone delivery line. In other words, the amount of
ozone being injected into the water.
1. With the pump running, disconnect the tubing from
theozonecheckvalveand connectthetubing tothe
bottom fitting on the gauge. This tube is from the
ozone generator.
2. While holding the gauge vertically, connect the tub-
ing from the ozone injector to the top of the gauge
and read the amount indicated on the gauge.
NOTE:You are measuringsuction somakesure the
tubing is attached properly.
3. Begin adjusting the metering valve until 40 SCFH
flow for the Series 400 and 20 SCFH flow for Series
200 is achieved on the SCFH gauge.
4. Reconnect the tubing to the ozone check valve.

14 CLP OPERATOR’S MANUAL
#96-6294 • Revised 7/04
Oil Skimmer
Funnel
pH Pump
Pressure
Switch
Valve 1
Valve 14
Valve 13
Valve 3
Valve 12
Valve 4
Inlet Flow
Meter
Pressure
Switch
(PS#2)
Filter Flow Meter
CLP OPERATION VIEW
CLP-5023
ORP/pH
Bracket
Collection Pit
Sump Pit
Valve 11

CLP OPERATOR’S MANUAL
15
#96-6294 • Revised 7/04
Valve 14
Oil Skimmer
Funnel
pH Pump
Pressure Switch
Valve 12
Valve 13
CLP OPERATION VIEW
CLP-7023/7033
ORP/pH
Bracket
Filter
Flow
Meter
Valve 16
Valve 5
Valve 15
Valve 4

16 CLP OPERATOR’S MANUAL
#96-6294 • Revised 7/04
GENERAL MAINTENANCE
AND SERVICE
Periodic Maintenance:
•Oil Skimmer Collection Drum
Monitorthelevel of oil in the collection drum.Empty
it as required.
•Solids Removal
Settled solids are collected in the bottom of the
cone of the CLP.The solids must be removed pe-
riodically as dictated by the dirt load coming into
the machine.The procedure for removal is as fol-
lows:
• OpenValve#5.Fill up thebag, thenshut thevalve.
Repeat as needed.
• Checkthe electricalcordsto ensuretheyare safe,
no damage or cracking.
• Check inlet and outlet pipes for leaks or damage.
Cartridge Filter:
The Water Maze Cartridge Filter is a high performance
industrial filter. Manufactured from durable, corrosion-
proof materials, it is designed for continuous or intermit-
tent operation. The Cartridge Filter utilizes a reusable,
reinforced polyester filter cartridge element to provide a
high degree of water clarity and long filter cycles with
absolute minimum care.
Filtering:
Filtration starts as soon as flow is steady through the
filter.As the filter cartridge removes dirt from the water,
the accumulated dirt causes a resistance to flow. As a
result, the gauge pressure will rise and the flow will de-
crease. When the pressure rises 8 - 10 psi above the
starting pressure, or when flow decreases below the
desired rate, clean or replace the filter cartridges.Note:
There is an alarm on the system that will sound when a
pressure of 15 psi is reached. Clean the filters before
the alarm sounds.
Remove/Replace Cartridges:
Removing Cartridge Elements
1. Shut off the pump.
2. Open the drain valve and allow water to drain from
filter.NOTE:To assist drainingprocess,openairvent
a few turns.(No drain valve on CLP-5023)
3. Disassembly:
a. Unscrew the lock-ring from the top of the filter
and lift off.
b. To removefilter cover, tap itonthe sideto break
the seal.
4. To Remove Cartridge
a. Slide the cartridge element off the Dirt Catcher
assembly.
b. Clean cartridge (see section on Cleaning Car-
tridges).
Reinstalling Cartridges:
1. Flushand drain anydirtor debris from thebottomof
the filter tank.
2. Carefully replace cartridge element back over the
Dirt Catcher assembly.Make sure“This Side Up” is
visible on cartridge element.
3. Replace the cartridge element and the Dirt Catcher
back in the filter tank, making sure the Dirt Catcher
assembly is fully seated.
4. Makesure theFilter Headflanged sealingsurfaceis
clean and the O-ring is in place. NOTE:The O-ring
will need to be lubricated periodically.
5. Replacethefiltercover,making sureitisfully seated.
6. Replace the lock-ring and secure hand tight.
7. Close the drain valve, set valves and follow instruc-
tions for“Filling System with Water”.
Cleaning Cartridges:
The cartridge filter element can be cleaned by pressure
washing inside and out with no more than 1000 psi of
pressure, or use a garden hose. After hosing the car-
tridge,forbestresults,allowthecartridgetodryandcare-
fullybrushpleatedsurfaceareastoremovefineparticles.
If calcium or mineral deposits are excessive, the car-
tridge mayberestored to“likenew”conditionbysoaking
in muriatic acid. Use commercially available 20% muri-
atic acid added to water in a 1 to 1 ratio. Use a plastic
container and take extreme care when handling clean-
ing agents as they are harmful to eyes, skin and cloth-
ing.
Safety glasses and protective gloves must be worn
during this cleaning operation. After cleaning, flush
with water. NOTE: SEE ITEM 6 UNDER SAFETY IN-
STRUCTIONS.
A spare “standby”cartridge filter element is an excellent
investment. It provides convenience and assures that
your filter will always be ready to operate at peak effi-
ciency. For best results, use only genuine Water Maze
cartridges in your filter.
Ebara Pump Maintenance and Repair
Before performing any maintenance operations discon-
nectthe plugand/or switchpump off.Thepump mustbe
dismantledonlybyEbaratechnicians.Failuretoobserve
this rule renders the guarantee invalid. The same ap-
plies to repair jobs and/or replacements.

CLP OPERATOR’S MANUAL
17
#96-6294 • Revised 7/04
To ensure correct functioning and long life of the pump,
the intake mouth must not be blocked and the impeller
must be kept clean.
a). If the intake mouth is blocked it must be cleaned;
always wear gloves to protect your hands.
b). If the impeller is dirty proceed as follows:
• Wearprotectiveglovesto avoidcuttingyourhands;
• Unscrew the six socket head screws (not the nut
because it is welded to the pump body)
• Slip off the pump body
• Remove the O-ring
• The impeller is now uncovered; check that it is
clean; also check that the space between the im-
peller and the protective casing is clean.
To reassemble, perform the operations listed above in
reverseorder.
Winterizing:
Ifa heated areais notprovided in areaswhere subfreez-
ing temperatures can be expected, the entire machine
must be drained.
Testing Carbon:
Remove the valve from the Carbasorb Filter and extract
a carbon sample.Place carbon sample in the 4 oz.plas-
tic bottle.(Fill the bottle 1/4 full of carbon, about 1 inch.)
Fillthe 2 oz.bottlewith waterand add 1dropof chlorine.
Dip the chlorine test paper into the solution to ensure
you have at least 100 parts per million of chlorine in the
mixture. Addthis solution to the carboninthe 4 oz.bottle.
Cap and shake it periodically over a period of three min-
utes. After three minutes, dip a new piece of chlorine
test paper into the solution. Compare the color with the
color chart that comes with the test paper. If you get a
reading, order new carbon. There may be some dark
discoloration from the carbon. Do not confuse this
with the color caused by the chlorine.
OZONE GENERATOR
Ozone...Nature’s Purification Agent:
Ozone is produced in nature or artificially by man.In the
earth’s atmosphere, ozone is formed when oxygen is
exposed to ultraviolet light or an electrical charge as
during thunderstorms. Ozone’s primary function in na-
ture is to purify the air we breathe and screen us from
harmful rays of the sun. In a similar fashion, the CLP
system uses ozone to disinfect water because Ozone
has a number of characteristics that make it ideal for
water treatment.
Ozone’s Characteristics:
Ozone is well suited for water treatment, and it’s unique
characteristics are described below:
• Ozone works up to 3,000 times faster than chlo-
rine to kill bacteria and destroy harmful microor-
ganisms.
• Ozone is a more powerful oxidizing agent than
chlorine and bromine, having a better ability to re-
move water contamination.
• Ozonewillnotformharmfulby-products,likeTHM’s
(aproblemindrinkingwater),or chloramines, (by-
productsofchlorinethatare responsibleforodors,
skin irritations and burning eyes.)
• Ozone will not alter the water’s pH, reducing pH
fluctuations.
• Ozonecoagulatessmall particlesin water so clar-
ity is dramatically improved.
• Ozone acts as a deodorizer removing unpleasant
odors from water.
How the CLP Ozone SystemWorks:
Because ozone is unstable, it cannot be packaged and
used at a later date. For this reason, ozone is always
produced where it is utilized.
Point-of-use ozone generation is simple.This powerful
disinfectant is produced from ambient air surrounding
the generator using special ultraviolet lamps located in-
side the system’s cabinet. To generate the ozone, air
movementis created throughthe useofan aircompres-
sor or water venturi. As air passes over these unique
lamps, the oxygen contained in the air is converted.The
resulting ozone gas is subsequently introduced to the
water in the inlet pipeline, where oxidation and disinfec-
tion immediately take place.
Ozone Generator Maintenance:
CAUTION: Never look at the unshielded ozone lamp
while operating the machine.This lamp can cause se-
vereeyeand skin damage.The indicator light willbe a
dimgreenornot lit at all when operating properly.The
light glows a bright green when there is a failure.See
product description for location of the indicator light.
Testing the Lamp:(See OzoneGeneratorTestingIllus.)
To test the ozone lamp, use a voltmeter set on ohms.
First remove the ozone cover and unplug the lamp plug
from the ozone lamp. NOTE: There are two filaments -
an upper and a lower - inside the lamp.Place one of the
voltmeter leads on one of the lamp prongs and, with the
other lead, touch all of the three remaining prongs. If
continuity is not achieved on both upper and lower fila-
ments, replace the ozone lamp (Part #6-0534).

18 CLP OPERATOR’S MANUAL
#96-6294 • Revised 7/04
To test the power pack, use a voltmeter set on the cor-
rect voltage (120V or 240V).Place one of the voltmeter
leadsinto the lampplug wherethe whitewiregoes into it
andplug the othervoltmeterleadintothelampplugwhere
thebluewire goes intoit.Ifno voltageis presentreplace
the ozone ballast (Part #6-05231 - 120V, Part #6-05232
- 240V).When ordering an ozone ballast, you also need
the 4-pin connector (Part #6-05233).
Replacing the lamp: (See Ozone Generator Break-
down)
Lampreplacements are availablefrom your
WaterMaze
Dealer should they need to be replaced.Simply turn off
the power to the CLP at the breaker, remove the screws
on the power pack cover and remove the cover.Discon-
nect the plug on the end of the ozone lamp.Now, loosen
the lamp holder locking ring from around the end of the
lamp by turning it counterclockwise and remove it. Re-
move the lamp by grabbing the rubber bushing around
the end of the lamp and pulling it straight out. Remove
OZONE GENERATOR
TESTING Four Pin
Connector
Ballast
Ozone Lamp
Prongs
the rubber bushing from the lamp and install it on your
new lamp, making sure the outer edge of the bushing is
flush with the outer edge of the silver end cap on the
lamp.Now, slide the lamp back into the reaction cham-
ber.The lamp holder may now be reinstalled and tight-
ened. Reinstall the plug onto the lamp and replace the
power pack cover. Caution: Keep the lamp free of fin-
gerprints and dust particles by only handling the metal
end caps on the lamp.You can clean the lamp with rub-
bing alcohol and a soft cloth. A dirty lamp will not allow
maximum ozone output.
SPECIFICATIONS:
Energy Required 110V: 105VAC MIN., 125VAC MAX.,
.800AMP/Ballast
Energy Required 220V: 210VAC MIN., 230V MAX.,
.450AMP/Ballast
Power Consumption: 20Watts
Average Lamp Life: 9,000 Hours

CLP OPERATOR’S MANUAL
19
#96-6294 • Revised 7/04
CORONA OZONE GENERATOR
EXPLODED VIEW
Cooling Vents
Cooling
Fan Grill
Power Entry
Module
ON/OFF
Switch
Ozone Outlet
Fitting & Check
Valve
Ozone
Outlet
Tubing
Dryer
Board
Reaction
Chamber
Feed Gas Inlet to
Reaction Chamber Transformer
Mother
Board
Variable
Ozone
Outlet
Control
SCFH Gauge (Attached
to External Air Prep.
Access Loop)
Check Valve
Replacement
Part # 2-30159
To Mazzi
Injector
Air Dryer
Indicating
Desiccant
Cartridge
Cooling
Fan, Filter
& Grill
Ozone Output
Indicator Lights
Operation
Status
Indicator
Lights
Air Dryer
Chambers
(2)
Bottom View
of Unit
Air Inlet
Particulate
Filter

20 CLP OPERATOR’S MANUAL
#96-6294 • Revised 7/04
CD OZONE GENERATOR
The ozone generator houses the ozone reaction cham-
ber, power supply and all electrical components directly
related to the production of ozone. Ozone is produced
when oxygen is exposed to ultraviolet light or to an elec-
trical charge. The ozone is drawn into the water by an
injector/mixer killing any bacteria, viruses or spores it
contacts. Ozone acts as a deodorizer by removing un-
pleasant odors from water.It will not alter the water's pH
nor will it form harmful by-products like THM's (a prob-
lem in drinking water) or chloramines(by-products of
chlorineresponsibleforodors, skin irritationandburning
eyes).
Because ozone is unstable, it cannot be packaged and
used at a later date.For this reason, ozone is generated
on site, eliminating the need to store toxic and corrosive
chemicals.
Initial Start-up and Calibration
Afterthe installation hasbeen completed,thewatersys-
tem operating parameters should remain the same as
before installation of the ozone generator. The cooling
fan will start and the air dryer portion of the unit will be-
gin to produce heat if the unit is functioning properly.
Theairpreparationsystem on the
CD10/AD is a vacuum type and
will require adjustment of the air
flow through the system.A SCFH
(Standard Cubic Feet per Hour)
gauge is used to adjust airflow.
The SCFH gauge is mounted to
the side of the CD10/AD.
Adjusting Air FlowThrough the
Injector
Use the SCFH gauge to accu-
rately measure the amount of air
flowing through the ozone deliv-
ery line on single speed injectors
(in other words, the amount of
ozone being injected into the wa-
ter) to optimize flow through the
injector.
Theinjector has aball valve to adjustthe amountof flow.
Withthepump runningbegin opening orclosing thegate
valve until the optimum flow is achieved on the SCFH
gauge.The optimum flow is 3 to 6 SCFH.
Ozone Generator Operation
On the front of the CD10/AD are a series of LED's.The
ten triangular red LED's indicate the setting of the vari-
ableozoneoutputcontrol,from minimum (0% ozoneout-
put) to maximum (100% ozone output).These are con-
trolled by the variable ozone output control on the bot-
tom of the CD10/AD, (described on next page). Below
theten ozoneoutput LED'sare sevencolored rectangu-
lar LED's, which indicate the unit's operational status as
follows:
POWER: Green LED indicates that the unit is receiving
electrical power. HV DRIVE: Green LED indicates
powertotheunit'sdriveboard,which
means that the reaction chamber is
receiving power.
EXT LOOP: Orange LED indicates
when the ozone drive is disabled by
an owner specified external control,
such as a vacuum switch, flow
switch, ORP controller, ambient
ozonedetector,pumpswitchortimer.
Thereisa two-pinconnector located
on the bottom of the unit for the pur-
pose of interfacing with any external
device you might include in the sys-
tem.The CD10/AD provides a 5 volt
DC fully isolated current to an exter-
nal device.Therefore, use dry con-
tactsonly forthispurpose.Atno time
should a fully energized circuit be
used for this function.
HIGHTEMP: Red LED indicates an
operatingtemperature which has ex-
ceeded normal operating range.
Thereisa thermalswitchintegratedintothesystemwhich
will turn off the ozone drive board when an excessive
temperatureconditionoccurs.Whenthe unit coolsdown,
itwill resetthe thermal switchand restartthe ozonepor-
tion of the unit.
AIR PREP:YellowLED indicatespowertothe dryercon-
trol board.This LED will blink during normal operation.
DRYER 1 & DRYER 2:The air dryer built into the CD10/
AD has two drying chambers.The control circuit is de-
signed to energize a chamber for approximately 2-1/2
hours, followed by a 20minute cooling downperiod, dur-
ing which time the other chamber is energized.The yel-
low LED for either chamber will turn off while that cham-
ber is in its cooling cycle.
Variable Ozone Output Control
Onthebottom of the unit,betweentheozoneoutlet/check
valveand theexternalcontrolloop,is thedial whichcon-
trols the variable ozone output of the CD10/AD.By turn-
ingthis dial clockwise,theamount of ozoneproduced by
the CD10/AD increases and the rectangular "OZONE
OUTPUT" indicator LED's light up vertically, indicating
the percentage of maximum ozone output being gener-
ated. If all of the LED's are lit, the unit is producing the
maximum amount of ozone (100%).By turning the dial
MAX
OUTPUT
MIN
OZONE
POWER
HV DRIVE
EXT LOOP
HIGHTEMP
AIR PREP
DRYER 1
DRYER 2
AttachTube
from Ozone
Injector
From Ozone Generator.
Keep Gauge Vertical