ClearWater HDO3-I Installation & Operation Manual Download Page 1

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Ozone Systems

Installation & Operation Manual

HDO

Series

High Dissolved Ozone Generation System

ClearWater Tech, LLC.

Integrated Ozone Systems

850-E Capitolio Way, San Luis Obispo, Ca 93401 • 805-549-9724 • Fax: 805-549-0306 • E-mail: [email protected] • www.cwtozone.com

Summary of Contents for HDO3-I

Page 1: ...ne Generation System ClearWater Tech LLC Integrated Ozone Systems 850 E Capitolio Way San Luis Obispo Ca 93401 805 549 9724 Fax 805 549 0306 E mail service cwtozone com www cwtozone com Copyright 2005 ClearWater Tech LLC Reproduction of any kind is prohibited LIT210 REV121605 ...

Page 2: ...y low pneumatic pressures minimizing noise and reducing compressor wear The air preparation system affects ozone production in grams per hour and more importantly ozone concentration also known as percent by weight Since ozone is produced with oxygen the greater the percent of oxygen that enters the ozone generator will produce more grams per hour and concentration of ozone Since the HDO3 Series o...

Page 3: ...fficient contacting of the ozone gas with the water and off gas any residual ozone By design the operating water pressures of this system and the ClearWater Tech engineered contacting system allows for high levels of dissolved ozone to be maintained in the water in this single pass configuration The HDO3 systems incorporate a water pressure relief valve and positive atmospheric vacuum break as sta...

Page 4: ...ry 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 OPERATIN...

Page 5: ...e 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 bon...

Page 6: ...equired 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 HDO3 Series systems The HDO3 Series systems are designed for specific voltage requirements and to withs...

Page 7: ... fpt 1 fpt 1 1 4 fpt 1 fpt Step 1 Arrange the HDO3 system according to mechanical print or as dictated by equipment layout and serviceability considerations Do not secure the system to equipment pad 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 for the sidestream c...

Page 8: ...Installation Diagram Figure 4 3 HDO3 Dissolved Ozone System OPTIONAL Pressure Reducing Valve Optional Service Loop Isolation Valve Isolation Valve Isolation Valve Isolation Valve Main Water Line Sidestream Water Line HDO3 Dissolved Ozone System Isolation Valve OPTIONAL Pressure Reducing Valve ...

Page 9: ... 20mA board and the EXT LOOP LED 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 t...

Page 10: ...O3 series systems are equipped with an integral dissolved ozone monitor controller This monitor controller is equipped with alarm relays that can be used to interlock other devices based on dissolved ozone levels Main power and the 4 20mA control interface to the ozone generator have been pre wired at the factory The unit has also been pre programmed at the factory to supply a constant 20mA 100 oz...

Page 11: ...lve located towards the bottom backside of the HDO3 system see Appendix Section A by turning it counter clockwise Step 6 Start up hydraulics Allow the water in the system to reach hydraulic equilibrium contact vessel full off gas vent operating etc and observe for plumbing leaks If the inlet water supply is not under pressure be sure the HDO3 booster pump is flooded with water so that the booster ...

Page 12: ...observed in the vacuum break do NOT re connect the External Loop dry contact See Troubleshooting Guide Step 20 Approximately 20 seconds after the External Loop has been re connected the dissolved ozone monitor controller should begin registering a steady increase in the dissolved ozone level Adjust the dissolved ozone level by either setting the dissolved ozone controller to a desired set point or...

Page 13: ...ne Generator Vacuum Ozone Injector Vacuum High Pressure Side Water Water Supply Inlet Pressurized Non Pressurized 2 Low Pressure Side Water Water Supply Inlet Pressurized Non Pressurized 2 6 to 8 scfh 6 to 8 scfh 3 to 8 in Hg 5 to 25 in Hg 55 65 35 45 PSI 15 25 0 5 PSI 8 scfh 8 scfh 5 in Hg 15 in Hg 60 40 PSI 20 5 PSI HDO3 II Operating Range Optimum Air Preparation Air Flow flow meter left side of...

Page 14: ...Start Up and Calibration continued 13 Quick Reference Guide Rosemont Dissolved Ozone Monitor Controller Figure 7 3 ...

Page 15: ... Air Preparation Air Flow line of the Operating Parameters chart see Figure 7 2 This meter is set at atmospheric pressure see Start Up and Calibration steps 8 11 Ozone Generator Indicating Lights HDO3 I Only Check the indicator lights on the ozone generator See Figure 7 1A for Ozone Generator LED Display function Indicating Lights HDO3 II and HDO3 III Only Check for illumination of the drive modul...

Page 16: ...e inlet and outlet of the HDO3 system Semi Annual Procedures CAUTION Follow system shutdown procedures before performing any of the following steps Air Preparation System Air Inlet Filter Replace the air compressor inlet filter see Appendix Section A Note Manufacturers recommended replacement interval is 4 000 hours of operation Operating conditions in the equipment area will dictate the required ...

Page 17: ...ation of the end cap on the heat sink cathode assembly The stainless steel clamp on the HDO3 III reaction chamber end caps must not be removed Step 8 With contact brush attached remove the brush adapter nut from the high voltage end cap Step 9 Inspect the dielectric end caps and cathode for breakage corrosion or debris Clean and or replace parts as necessary Re assemble the reaction chamber per th...

Page 18: ...tion press the high voltage end cap onto the heat sink cathode assembly until flush with the heat sink cooling fins Note Orientation of the end cap on the heat sink cathode assembly 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 c...

Page 19: ...l Clamp Contact Brush Brush Adapter Nut High Voltage End Cap and O rings End Cap Retaining Screw and Washer Oxygen Inlet Fitting Viton Washer Stainless Steel Washer High Voltage Lead Heat Sink and Cathode Ozone Outlet Fitting Bottom End Cap And O rings Heat Sink and Cathode Glass Dielectric High Voltage Anode Contact Brush Oxygen Inlet Fitting High Voltage Lead Brush Adapter Nut High Voltage End C...

Page 20: ...section Low fee gas flow rate above Make adjustments with the Feed gas Flow Rate needle valve and the Ozone Injector Vacuum Control knob High Pressure Side Water and Low Pressure Side Water gauges have Equalized Excessive backpressure downstream of the ozone injector or HDO3 system Ozone Generator Vacuum not High vacuum Slightly open the Ozone Injector within Operating parameters Control Vacuum Co...

Page 21: ...output control board pins are properly inserted into the output control board Main Power LED is not illuminated LED display board is inoperable Replace LED display board but all other LED s are illuminated Circuit breaker trips Incorrect wiring to HDO3 System See Installation Procedures Electrical Circuit breaker amperage does not Replace with correct circuit breaker match system draw See Installa...

Page 22: ...gh Pressure Side Water and Low Pressure Side Water gauges have Equalized Excessive backpressure downstream of the ozone injector or HDO3 system HDO3 III only Ozone Generator Pressure gauge is too high Slightly open the Ozone Injector Vacuum Control knob then adjust the Feed Gas Flow Rate meter Ozone Generator Vacuum not High vacuum Slightly open the Ozone Injector within Operating parameters Contr...

Page 23: ...n stream of the Remove backpressure downstream HDO3 system Low Pressure Contact tank backpressure valve is open Close the back pressuring valve slightly Dissolved Ozone Monitor Controller See the monitor controller I O manual not operating Ozone Generator Main Power light No power to HDO3 System Check main power to system is not illuminated or System is not Installation Procedures Electrical ON Lo...

Page 24: ...Replace drive board Failed drive transformer Replace drive transformer Broken dielectric Replace dielectric Water in ozone reaction chamber Clean dielectric and replace O rings Excessive dirt or debris in the ozone Clean dielectric and replace O rings reaction chamber Loose or disconnected High Voltage Tighten or Attach High Voltage lead lead to transformer to transformer High temp Limit See Troub...

Page 25: ...m of ozone injector Back pressure in hydraulic line Check for obstructions downstream of ozone injector Booster pump not functioning properly Check booster pump contact dealer Ozone smell detected around Insufficient vacuum at venturi See Start Up Calibration vacuum break or ozone injector Loose fittings Check all tighten as required Outlet water Supply Pressure Low Pressure Side Water gauge is in...

Page 26: ...System with out Cover AIR PREP UNIT OXYGEN OUTPUT SCFH HDO3 I Workhorse 8C 90 3 8 scfh 5PSI HDO3 II Workhorse 15C 90 3 15 scfh 5PSI HDO3 III Workhorse 12C 90 3 12 scfh 12PSI Cover Filter Front of Unit SCFH Air Flow Meter Oxygen Outlet Fitting Hour Meter Power Cord Compressor Inlet Filter Oxygen Concentrator Sieve Bed ATF Compressor Compressor Cooling Coil ...

Page 27: ...one Monitor Controller E Feed Gas Flow Rate F Ozone Injector Vacuum Control G Low Pressure Side Water H Main Power Switch OFF ON A F E D C B G H A Ozone Generator Pressure B Ozone Injector Vacuum C High Pressure Side Water D Dissolved Ozone Monitor Controller E Feed Gas Flow Rate F Ozone Injector Vacuum Control G Low Pressure Side Water H Main Power Switch OFF ON A B C D E F G H ...

Page 28: ...Break Fill Port Cap Contact Tank Ozone Generator Vacuum Break Water Pressure Relief Valve Behind Vacuum Break Dissolved Ozone Probe Main Power Cord Contact Tank Backpressure Valve Oxygen Concentrator Oxygen Concentrator Cooling Fan Vacuum Break Drain Barb Vacuum Break Fill Level Cover Filter Ozone Off Gas Line To Destruct System Vacuum Break Flapper Valve Booster Pump Oxygen Concentrator Flow Mete...

Page 29: ...0mA Connector Power Entry Module OFF ON Switch Cord Input Fuse Carrier Bonding Ground Lug Fan and Fan Filter Ozone Outlet LED Display Board Under Cover High Voltage Transformer Reaction Chambers High Voltage Drive Boards Board Retainer Bracket Output Control Board Inline Particulate Filter Main Mother Board Vacuum Switch Cover Safety Switch External Loop Remote 4 20mA Control Leads Connected to Di...

Page 30: ...m Break Fill Port Cap Contact Tank Ozone Generator Vacuum Break Water Pressure Relief Valve Behind Vacuum Break Dissolved Ozone Probe Main Power Cord Contact Tank Backpressure Valve Oxygen Concentrator Oxygen Concentrator Cooling Fan Vacuum Break Drain Barb Vacuum Break Fill Level Cover Filter Ozone Off Gas Line To Destruct System Vacuum Break Flapper Valve Booster Pump Oxygen Concentrator Flow Me...

Page 31: ...ower Supply Vacuum Switch 4 20mA Control Board Cover Safety Switch External Loop Remote 4 20mA Control Leads Connected to Dissolved Ozone Monitor Controller Air Prep Inlet Manual Ozone Output Adjustment Knob Main Power Light External Loop Connector Remote 4 20mA Connector Fuse Carriers Bonding Ground Lug Fan and Fan Filter Ozone Outlet Fitting Main Power Switch OFF ON Condulet Main Power Leads Ozo...

Page 32: ...um Break Fill Port Cap Contact Tank Ozone Generator Vacuum Break Vacuum Break Drain Barb Vacuum Break Fill Level Dissolved Ozone Probe Contact Tank Backpressure Valve Main Power Cord Oxygen Concentrator Oxygen Concentrator Cooling Fan Water Pressure Relief Valve Behind Vacuum Break Cover Filter Ozone Off Gas Line To Destruct System Vacuum Break Flapper Valve Booster Pump Oxygen Concentrator Flow M...

Page 33: ...re Switch 4 20mA Control Board Cover Safety Switch External Loop Remote 4 20mA Control Leads Connected to Dissolved Ozone Monitor Controller Air Prep Inlet Manual Ozone Output Adjustment Knob Main Power Light External Loop Connector Remote 4 20mA Connector Bonding Ground Lug Power Entry Module OFF ON Switch Cord Input Fuse Carrier Fan and Fan Filter Ozone Outlet Fitting Ozone Output LED s Pressure...

Page 34: ...C5040 High Voltage Drive Board HDO3 I ELPC5042 Description Part LED Display Board HDO3 I ELPC5052 Complete Board Set HDO3 I ELPC5062 High Voltage Transformer HDO3 I ELTR105 Power Supply 48VDC 450w HDO3 II PS450 Power Supply 48VDC 300w HDO3 III PSR822 Drive Module Transformer HDO3 II HDO3 III HVT200 Drive Module Board HDO3 II HDO3 III ELPC5210 4 20mA Control Board HDO3 II HDO3 III ELPC5430 Cooling ...

Page 35: ...sure Relief Valve OXS370 1 Oxygen Concentrator Cover Filter FA40 2 Filter Cooling Fan filter FLT34 1 Filter Inline Particulate Filter ORG10 4 O Ring 2 CD Reaction Chamber Small ORG110 8 O Ring 2 CD Reaction Chamber Large FUS20 5 Fuse Bussmann MDL 5 5 amp 250VAC Slow Blow Main Power FUS66 2 Fuse Littelfuse Minifuse 297003 3 amp 32VAC Drive Board ASPHD30A Maintenance Kit HDO3 III Part QTY Descriptio...

Page 36: ... Shown Electrical Schematic HDO3 I HDO3 II and HDO3 III Line Side Note This system is not dual voltage rated System voltage is 120VAC 60Hz or 220VAC 50Hz Main Power Switch Magnetic Contactor Ozone Generator Dissolved Ozone Monitor Oxygen Concentrator Booster Pump ...

Page 37: ...itch Mother Board 0 VDC 5 VDC 12 VDC 24 VDC 100 VDC Fan Output Control Board LED Display Board High Voltage Board High Voltage Transformer Reaction chamber Manual Ozone Output Control Remote 4 20mA Ozone Output Control External Loop Power Entry Module with Fuses High Voltage Board High Voltage Transformer Reaction chamber Vacuum Switch ...

Page 38: ...er Supply Fan 4 20mA Control Board Remote 4 20mA Ozone Output Control Manual Ozone Output Control External Loop High Voltage Transformer Fuse Fuse Main Power Switch Main Power Light Fan Voltage Selector Switch Vacuum Switch 24 VDC 0 VDC 24VDC Variable Output Signal Reaction Chamber High Voltage Transformer Drive Board Reaction Chamber Drive Board ...

Page 39: ...Module With Fuses Cover Safety Switch Power Supply Power Supply Fan Fan 24VDC 24VDC 24VDC 24VDC Manual Ozone Output Control Remote 4 20mA Ozone Output Control External Loop 4 20mA Control Board Variable Output Signal Drive Board High Voltage Transformer Reaction Chamber Reaction Chamber High Voltage Transformer Drive Board Pressure Switch ...

Page 40: ...39 APPENDIX Section E Drive Board Input Voltage HDO3 II and HDO3 III Shown Dual HO Drive Module ...

Page 41: ...enced with the product and or part must be clearly described The RGA number must appear prominently on the exterior of the shipped box es The product and or part must be packaged either in its original packing material or in comparable and suitable packing material if the original is not available You are responsible for paying shipping charges to CWT and for any damages to the product and or part...

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