Ozone Systems

Installation & Operation Manual

CD10 • CD10/AD • CD12 • CD12/AD
Corona Discharge Ozone Generators

Tested and certified by

WQA to NSF/ANSI 50 as a
component only.

ClearWater Tech
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 © 2012 - ClearWater Tech, LLC • Reproduction of any kind is prohibited • LIT221 • REV101012
INTRODUCTION
O3
This Installation and Operation Manual is In an ongoing effort to improve reliability and
written to assist in the installation, operation operating efficiency, ClearWater Tech may find it
and maintenance of ozone delivery systems necessary to make changes to its products.
manufactured by ClearWater Tech, LLC. Therefore, the information contained in this
This equipment has been designed using the manual may not conform in every respect to
most modern materials and technology earlier versions of ClearWater Tech ozone system
available. found in the field. If you have any questions,
please contact your ClearWater Tech dealer or the
Please read this manual carefully and in its ClearWater Tech service department.
entirety before proceeding with any
installation, operation or maintenance
procedure associated with this equipment.
Failure to follow these instructions could
result in personal injury, damage to the
equipment or reduced product performance.

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TABLE OF CONTENTS
Overview ............................................................................................................................. 3
Safety Information ............................................................................................................. 4
Theory of Operation/Product Description ...................................................................... 6
Figure 1 – Complete Ozone System ................................................................................ 6
Installation Procedures – Getting Started ....................................................................... 9
Installation Procedures – Plumbing ............................................................................... 10
Figure 2 – Side stream Plumbing Installation Diagram .............................................. 12
Figure 3 – Full Flow Plumbing Installation Diagram ................................................. 12
Figure 4 – Contact Column Installation Diagram ....................................................... 13
Figure 5 – Contact Column Exploded View ................................................................. 13
Installation Procedures – Electrical ............................................................................... 14
Figure 6 – External Loop Electrical Interface ............................................................. 16
Installation Procedures – Pneumatic ............................................................................. 17
Figure 7 – Hook-Up: Air preparation system to ozone generator ............................... 17
Figure 8 – Oxygen Concentrator.................................................................................. 18
Figure 9 – Vacuum Break Detail .................................................................................. 20
Figure 10 – Ozone Destruct System Detail .................................................................. 21
Start-Up and Calibration ................................................................................................ 22
Figure 11 – Ozone Generator LED Display ................................................................ 24
Figure 12 – Pneumatic Operation Parameters ............................................................ 25
Maintenance ..................................................................................................................... 26
Figure 13 – Ozone Generator Cooling Fan Assembly ................................................. 27
Figure 14 – CD10/AD and CD12/AD Heat Regenerative Air Dryer ........................... 32
Figure 15 – 1” Reaction Chamber – Exploded View ................................................... 33
Troubleshooting ............................................................................................................... 34
Appendix A – Specifications ........................................................................................... 38
Appendix B – Parts List .................................................................................................. 44
Appendix C – Maintenance Kit ...................................................................................... 46
Appendix D – Logic Schematics ..................................................................................... 48
Appendix F – Warranty Information ............................................................................ 52

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OVERVIEW
How Ozone In Generated
Oxygen (O2) Ozone (O2)
Ozone is generated by exposing oxygen molecules (O2)
O2 O1 O3
in an air stream to a controlled, high energy electrical + =
field. As the air stream passes through the electrical
field produced inside the ozone generator, some oxygen
Electrical
molecules are split, forming single oxygen atoms (O1). Field
These oxygen atoms then recombine with other oxygen O2 O1 O3
molecules in the air stream, forming ozone (O3) + =

Properties of Ozone
Ozone is the most powerful oxidizer available that can be safely used in water treatment1. It is used to treat
drinking water, bottled water, swimming pool water, waste water, food and beverage processing water, and in
many other applications. Ozone is effective in performing the following:

• Disinfection – Bacterial disinfection, Molecular Weight 48

inactivation of viruses and cysts. Readily detectable at concentrations
Odor above 0.02 ppm in air
• Oxidation of Inorganics – Precipitates, iron,
manganese, sulfides nitrides and organically- Bluish in ozone generator cell, but
ozone/air mixture exiting generator is
bound heavy metals Color
invisible – even at high ozone
concentrations.
• Oxidation of Organics – Including organics
causing color, taste, and odor problems. Some Gas Density: 2.144 grams/liter at 32°F
(Approximately 150% that of oxygen).
detergents and pesticides, phenols, VOCs,
turbidity control and micro-floccuity control and Only partially soluble in water, but
Solubility about 10-20 times more soluble than
micro-flocculation of soluble organics. oxygen (at 68°F).

Benefits of Ozone Use

• Ozone is generated on site – no transportation or storage is required

• The most powerful oxidizer commercially available – very effective for

disinfection and oxidation without handling problems.

• Ozone creates no potentially harmful by-products (such as THMs) – the only by-
product is oxygen.

• Ozone leaves no telltale taste or odor.

1
Water Quality Association, “Ozone for POU, POE and Small Water System Water Treatment Applications,” Lisle, IL, 1999

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Safety Information
Safety Warnings
Two aspects of ClearWater Tech ozone generators represent potential dangers – ozone gas and high voltage
electricity.

OZONE GAS – WARNING: HIGH CONCENTRATIONS OF OZONE GAS ARE

DANGEROUS TO HUMANS. LOW CONCENTRATIONS CAN
CAUSE IRRITATION TO THE EYES, THROAT AND
RESPIRATORY SYSTEM.

The ClearWater Tech CD10 and CD12 Series corona

discharge ozone generators are designed to operate under a
vacuum condition. While safety precautions have been taken,
entering the equipment area should be avoided if ozone gas is
detected. Ozone has a very distinctive odor and is detectable at
very low concentrations (0.02 ppm), which is far below
OSHA’s maximum permissible exposure level of 0.1 ppm.

HIGH VOLTAGE – WARNING: CLEARWATER TECH OZONE GENERATORS

OPERATE AT HIGH VOLTAGE. DO NOT TAMPER WITH
OR DELIBERATELY BYPASS THE COVER OR SAFETY
SWITCHES BUILT INTO THE OZONE GENERATOR
UNLESS INSTRUCTED TO DO SO BY THIS MANUAL. IF
CONTACT IS MADE WITH OPERATING HIGH VOLTAGE
COMPONENTS, ELECTRIC SHOCK WILL OCCUR.

ClearWater Tech corona discharge ozone generators take line voltage and convert it DC current. A high voltage
transformer then boosts the voltage. While each ozone generator has a cover safety switch and other safety
interlocks, proper care must be used by a qualified electrician when making any internal adjustments or
performing any maintenance procedures.

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 Safety Information

IMPORTANT SAFETY INSTRUCTIONS

When installing and using this electrical equipment, basic safety precautions should always be followed,
including the following:

1. READ AND FOLLOW ALL INSTRUCTIONS.

2. Connect to a grounded, grounding type receptacle only.
3. Do not bury cord.
4. Warning – To reduce the risk of electrical shock, replace damaged cord immediately.
5. Install at least 5ft from tub water using nonmetallic plumbing. Install ozone generator no less than 1 ft
above the maximum water level to prevent water from contacting electrical equipment. Install in
accordance with the installation instructions.
6. Warning: Short term inhalation of high concentration of ozone and long term inhalation of low
concentrations of ozone can cause serious harmful physiological effects. Do not inhale gas produced by
this device.
7. Warning: For indoor use only. This unit is not intended for outdoor use.
8. A wire connector is provided on this unit to connect a minimum 8 AWG (8.4 mm2) solid copper
conductor between this unit and any metal equipment, metal enclosures of electrical equipment, metal
water pipe, or conduit within 5 feet (1.5m) of the unit.
9. All field-installed metal components such as rails, ladders, drains or other similar hardware within 3
meters of the spa or hot tub shall be bonded to the equipment grounding bus with copper conductors
not smaller than No. 6 AWG.
10. All electrical connections should be made by a licensed, qualified electrician.
11. Before attempting any electrical connections, be sure all power is off at the main circuit breaker.
12. The electrical supply for this product must include a suitably rated switch or circuit breaker to open all
ungrounded supply conductors to comply with Section 422-20 of the National Electrical Code,
ANSI/NFPA 70-1987. The disconnecting means must be readily accessible to the operator(s) but
installed at least five feet from any open body of water.
13. The System should be sized appropriately for its intended use by a qualified professional familiar with
the application. This equipment must be validated by the manufacturer for its intended use; failure to
do so may void the warranty.
14. Install check valves and a vacuum break to prevent water from contacting the electrical equipment.
15. SAVE THESE INSTRUCTIONS.

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Theory of Operation/Product Description
ClearWater Tech ozone systems are designed for safe, effective use in a variety of water treatment applications.
The CD10, CD10/AD, and CD12 ozone generators have been tested and certified by the Water Quality
Association according to NSF/ANSI 50. Each complete, integrated system may include the components required
for reliable, efficient ozone production and can be divided into four general segments:

Complete Ozone System

Figure 1

Air preparation system Ozone generator Ozone injection/contacting Ozone destruct

Ozone Injector
Water Flow
Off Gas Vent Ozone Destruct
Booster Pump Ball Valve System Optional

Air Preparation
Ozone Generator
Option 1 Ozone
Destruct
Unit

Vacuum
Break Water Trap

Option 2
Contact Vessel

Shown: ClearWater Tech CD10 or CD12 with OXS80 (Option 1)

and CD10/AD or CD12/AD (Option 2) Ozone System

Air Preparation System

ClearWater Tech corona discharge ozone generators require a source of clean, dry, oil-free, oxygen-enriched or
dry air for effective ozone production. To meet that need, ClearWater Tech can provide any one of three types of
air preparation systems.
• The first type combines pressure swing adsorption (PSA) oxygen technology with oil-less compressor to
increase the concentration of oxygen and reduce the moisture content in the feed gas (the air supplied to the
ozone generator). This substantially improves the output capability of the ozone generator and prevents
premature failure of key internal components. These air preparation systems deliver 90%+/-3% oxygen purity
at -100°F dew point and at very low pneumatic pressures, minimizing noise and reducing compressor wear.
The PSA system is rated with a continuous duty cycle in conditions up to 90% relative humidity non-
condensing.

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 Theory of Operation/Product Description
• The second type is low pressure swing adsorption (LPSA) dry air technology which operates in the same way
as the PSA oxygen system but only delivers 20% oxygen purity at -60 to -90˚F dew point. The LPSA system is
rated with a continuous duty cycle in conditions up to 90% relative humidity non-condensing.
• The third type is a heat regenerative dry air system. The heat regenerative system operates via a vacuum
which draws in ambient air and dries it to a -10 to -20˚F dew point at 20% oxygen purity. The CD10/AD and
CD12/AD (“AD” represents Air Dryer) incorporate a heat regenerative air dryer system, rated with a duty
cycle of no more than 10 hours of operation in a 24 hour period in conditions up to 75% relative humidity non-
condensing. Due to the operation of the internal air dryer, continuous power must be applied to the CD10/AD
and CD12/AD for proper operation. As the ambient air travels through the dryer chambers the sieve material
inside traps the moisture from the air and allows the oxygen to pass to the ozone reaction chamber. The heat,
generated by the heating rods inside the dryer chamber, then evaporates the moisture that has been trapped in
the sieve and expels off the top of the sieve bed. The two dryer chambers and attached 3-way solenoid valve
operate on a timed cycle. Dryer chamber 1 heats first evaporating moisture for 1-1/2 hours, while the solenoid
is energized allowing the vacuum from the venturi to draw air flow through dryer chamber 2. During this time
the “AIR PREP” LED will flash and “DRYER 1” LED will be illuminated continuously. After the 1-1/2 hours
there is a 1/2 hour cool down period, power to dryer chamber 1 will be discontinued, correspondingly
“DRYER 1” LED will not be illuminated. Note: The “AIR PREP” LED will remain flashing throughout
the cycle. After the cool down period dryer chamber 2 will heat and the solenoid valve will de-energize,
allowing vacuum from the venturi to draw air flow through dryer chamber 1. During this time the “AIR
PREP” LED will flash and “DRYER 2” LED will be illuminated continuously. After 1-1/2 hours there is a 1/2
hour cool down period when power to dryer chamber 2 will be discontinued; correspondingly, “DRYER 2”
LED will not be illuminated. After this 1/2 hour cool down, the air dryer cycle will repeat.
If “Plant Air” feed gas is to be used in place of a ClearWater Tech air preparation system, the same air quality
standards must be met to achieve the ozone output and longevity of the ozone generator. A pounds per square
inch (PSI) regulator must be installed when using plant air feed gas. This regulator must be set to a maximum of 5
PSI.
The type of air preparation will effect 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, producing more grams per hour and concentration of ozone. Since a
PSA oxygen concentrator has an oxygen output that is nearly four and a half times greater than a standard air
dryer, it will yield the highest grams per hour with the highest concentrations. Greater ozone concentration
equates to higher solubility of the ozone gas in solution, which will yield a greater oxidation potential.

Ozone Generator
The feed gas produced by the either the PSA or LPSA air preparation system is supplied to the ClearWater Tech
ozone generator at a maximum pressure of 5 pounds per square inch (PSI). Note: If a heat regenerative air
dryer is used the feed gas will be at drawn through the ozone generator under vacuum. An external air flow
meter and vacuum gauge is recommended to be used to control and monitor the air flow and vacuum through the
ozone generator. At this point, the feed gas is drawn through the ozone generator by the vacuum created at the
ozone injector rather than by the pressure from the air preparation system compressors.
As the feed gas enters the thermally-protected reaction chambers inside the ozone generator, some of the oxygen
molecules are split while passing through the high voltage electrical field (the “corona”), forming single oxygen
atoms (O1). These oxygen atoms then recombine with other oxygen molecules in the air stream, forming ozone.
Depending on the application, the ClearWater Tech ozone generator may be interlocked with an oxidation
reduction potential (ORP) or parts per million (PPM) controller, pressure switch flow switch, timer, or circulation

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 Theory of Operation/Product Description
pump. Many safety features are also built in, including main power fuses, thermal protection, cover safety switch,
and back flow prevention.

Ozone Injection/Contacting
The ozone injector serves two purposes. One, it creates the
vacuum required to safely draw the ozone gas from the ozone
generator and two, it provides a means by which the ozone gas
can become dissolved in water. A very dynamic injection
process is required to effectively dissolve ozone in water.
ClearWater Tech injection systems use only Mazzei® injectors
for maximum mass transfer efficiency. The injector produces a
cavitation effect, enabling the ozone gas to join the water stream
in the form of extremely tiny bubbles. These bubbles must be as
small as possible in order to increase the ratio of bubble surface
area to the amount of ozone entering the water.
Depending on the application and the water treatment goals, a ClearWater Tech contacting system may also be
required. Some oxidation reactions take place so quickly that they are limited only by the rate at which the ozone
is dissolved in the water. Other reactions, such as disinfection, may require that proper ozone residual be
maintained for a specific amount of time. A correctly sized contact vessel is used for this purpose.

Ozone Destruct
The ClearWater Tech off-gas destruct systems consist of two components: the ozone destruct unit (a heated
chamber filled with manganese dioxide and copper oxide) and a water trap. Used in conjunction with a
ClearWater Tech off gas vent, the ozone destruct system is an effective way to vent the contact vessel(s) when it
is impractical to send the off gas to atmosphere or reintroduce it to the water.

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Installation Procedures – Getting Started
Unpacking
Compare the ozone system equipment received to the packing list provided. Before
beginning any installation procedures, thoroughly inspect all components for
damage. If damage is noticed, promptly notify the freight carrier and request an on-
site inspection. Inspect all packing materials for small parts before discarding.
Inspect all plumbing, fittings and tubing for packing material that may have
become lodged in openings.
Equipment Placement
When placing the ozone system components in the equipment room, make sure to consider safety, maintenance
requirements, local building and fire codes, etc. The components should be easily accessible by the operators,
including equipment access doors and electrical hook-up boxes. All meters, gauges, indicator lights, and switches
should be visible and accessible. Dimensional drawings of the air preparation system and ozone generator are
included in Section A of the Appendix.
The air preparation system and ozone generator should be located as close as possible to the point of ozone
injection (with in 20 feet is recommended). Ozone is an unstable gas and will begin reverting back to oxygen very
quickly. To determine the most favorable ozone injection point, the following items should be considered:
• Located downstream of all other existing water system components.
• Located upstream of the residual sanitizer injection point (if so equipped).
• In a Side stream plumbing configuration (see Figure 2) with recirculation, the pH adjustment chemical
injection point must be located downstream of the residual sanitizer injection point (if so equipped).
• In a Full Flow plumbing configuration (see Figure 3) without recirculation, locate downstream of the pH
adjustment chemical injection point.
• Adequate protection from weather, dust and excessive heat.
Like any electronic component, performance and longevity is enhanced by favorable operating conditions. Also,
since each air preparation system and ozone generator is air-cooled, a relatively dust-free, well-ventilated area is
required. No caustic chemicals should be stored in the area surrounding the equipment. A minimum clearance of
six inches from the vents on either side of the ozone generator is required.
The equipment is heavy and requires proper support. Therefore, a clean, dry, level surface should be provided for
the air preparation system and ozone generator. These components should be securely fastened to the surface
using the mounting holes and/or tabs provided.
The air preparation system and ozone generator are not designed to withstand outdoor elements, including direct
contact with water and/or temperature extremes. Therefore, the equipment must be installed in an environment
consistent with the following operating parameters:
• Ambient temperature range: 20°F to 95°F continuous. If the temperature around the equipment consistently
exceeds 95°F, additional air-cooling must be provided.
• Humidity: 0 - 90% relative humidity, non-condensing environment. Warning: 0 - 75% relative humidity,
non-condensing environment, must be observed for any heat regenerative air dryer.
• Line voltage: +/-10% of rated input
Note: Equipment installed in extreme environmental conditions will void manufacturer's warranty.
Allow room for the peripheral equipment (booster pump, injector manifold, contact vessel, etc.)

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Installation Procedures – Plumbing
The ozone system should be plumbed using either a side stream or full flow
configuration. The side stream loop method takes a portion of the water from the main
flow (see Figure 2) and diverts it into a side stream downstream of the filter (if so
equipped). Ozone is introduced into the side stream water and is allowed contact time
with the water before it is returned to the main flow at a point downstream of all other
equipment (heaters, solar panels, etc., if so equipped) in the circulation system. A
booster pump is usually employed to compensate for the flow restriction caused by the side stream loop and the
injector manifold. If a halogen-type residual sanitizer is utilized, its injection point should be as far downstream as
possible from the point at which the side stream water returns to the main flow. In a full flow configuration, the
same system components are usually involved and appear in the same order with respect to the direction of flow.
However, all the water in the main flow is allowed contact time with the ozone (see Figure 3). A booster pump
may be necessary to maintain proper flow requirements. If employed, the booster pump is located upstream of the
point at which the ozone injector manifold is installed.
NOTES:
• Adequate use of unions and isolation • Ozone is a powerful oxidizer and will degrade
valves is strongly recommended to certain materials. Use ozone-compatible
facilitate maintenance and repairs plumbing materials for section(s) of the system
that will come in contact with ozone dissolved in
water. The following is a list of the materials that
are compatible with ozone:
• Use Schedule 80 PVC for all pluming
connections wherever possible. Pluming • PVC • Stainless Steel (300 Series)
size requirements are dictated by the • CPVC • Viton
water flow characteristics of the system. • Kynar • EPDM
• Teflon • Concrete
• Make sure to use proper plumbing • Depending on the application, other components
practices and secure all plumbing and (psi gauge, flow meter, etc.) may be installed to
system equipment according to local codes. assist in monitoring system parameters.

Step 1: Arrange the ozone system equipment (booster pump, injector and contact vessel) according to
mechanical print or as dictated by equipment layout and serviceability considerations. Do not secure
booster pump(s) and contact vessel to housekeeping pads at this point. Dry fit plumbing as appropriate
to insure proper fit and location before making permanent connections.
Step 2: Install a tee or plumbing saddle into the main water line after the filter (if so equipped) and before the
flow diversion mechanism. The purpose of the mechanism is to restrict water flow so water is diverted
into the side stream (see Figure 2). If such a mechanism is not present in the system (such as a heater
bypass valve, etc.), it will require installation of a valve (butterfly, gate or ball) or a flow controller.
Step 3: Plumb a line from the tee or plumbing saddle to the booster pump. For serviceability of the equipment in
the side stream loop, be sure to install an isolation valve between the tee or saddle and the booster pump.
Step 4: Plumb from the booster pump to the injector manifold. Make sure to note the correct direction of flow,
indicated by a blue arrow on the inlet side of the manifold body. The check valve assembly is strapped to
the manifold using wire ties. Remove the assembly; using Teflon® tape, install it onto the top opening of
the injector.
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 Installation Procedures - Plumbing
Step 5: Plumb from the injector manifold to the inlet side of the contact vessel. To reduce possible backpressure
to the injector, minimize the number of elbows between the injector manifold and contact vessel. The
contact vessel is a specified size, determined by water flow requirements. ClearWater Tech contact
columns and the 30, 40, 80, and 120-gallon contact tanks have inlet and outlet fittings on the bottom of
the vessel(s) and are designated with arrows showing the direction of flow. Note: The inlet and outlet
arrows on the contact tanks are under the base of the tank. The inlet on the 264, 463 and 850-gallon
tanks is located at the top with the outlet at the bottom.
Step 6: Using a tee or plumbing saddle, plumb from the outlet of the contact vessel back into the main water
line. For serviceability of the equipment in the side stream loop, be sure to install an isolation valve
between the outlet fitting on the contact vessel and before returning to the main water line.
Step 7: Secure the booster pump and contact vessel to solid mounting surfaces using appropriate hardware and
according to local codes. If installing a ClearWater Tech contact column, use a ClearWater Tech contact
column mounting kit and install according to the instructions below. If installing a contact tank, secure to
a solid horizontal surface using mounting flange or feet
Step 8: Install the contact vessel venting system into the top of the vessel. If using the ClearWater Tech contact
column, the vent kit supplied includes fittings, a control valve and Teflon® tubing. The contact tank
venting system includes an air relief valve, fittings and a length of Teflon® tubing. Depending on
conditions, the vented gas may be directed to an ozone destruct system, to atmosphere or to the low-
pressure side of the water system. Note: Do not direct the tubing to the suction side of any pump in
the system.

Contact Column Installation (if so equipped)

Step 1: Make sure the following hardware items are included in the contact column mounting kit:
• 'L' bracket • Unistrut bar
• 1/2” concrete anchors • Protective end cap
• 6” clamp assembly • Mounting hardware
Step 2: Mark the two holes for mounting the 'L' bracket to the wall (see Figure 4). The bracket should be located
so that the 6” clamp assembly will be approximately 12” from the top of the contact column. Drill a 1/2”
hole at each of the marks, about 3 1/2” deep. Insert a concrete anchor into each hole with the threaded
end facing outward. Slip the 'L' bracket over the threaded ends of the anchors, followed by a washer for
each anchor. Secure the bracket to the wall by threading a nut onto each anchor and tightening.
Step 3: Cut the unistrut bar to the desired length and attach it to the 'L' bracket using hardware provided.
Step 4: Slip the two sides of the 6” clamp into the unistrut bar and then around the contact column. Tighten the
retaining bolt, securing the contact column to the unistrut bar.
Step 5: Slip the protective end cap over the exposed end of the unistrut bar.

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 Installation Procedures - Plumbing
Side stream Plumbing Installation Diagram
Figure 2

Flow Diversion
Mechanism

Filter Isolation Isolation

Valve Valve

Booster Ozone Injector

Pump

Bypass Valve

Contact
Vessel

Full Flow Plumbing Installation Diagram

Figure 3

Service Loop
Isolation
Valve
Isolation Isolation
Valve Ozone Injector Valve

Booster
Pump Bypass
Valve

Contact
Vessel

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 Installation Procedures - Plumbing
Contact Column Installation Diagram
Figure 4

6” Clamp Assembly Bolts, nuts &

with bolt & nut washers (2 ea)
Unistrut
(cut to length)

Unistrut “L” Bracket

Protective
End Cap
Concrete Anchors
with nuts &
washers (2 ea)

Contact Column Exploded View

Figure 5

Column

Flange Bolts
Column & Washers (8
Flange ea)

Diffuser

Riser Tube

Base Flange Gasket

Base Flange Nuts &
Washers (8 ea)

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 Installation Procedures - Electrical

Installation Procedures – Electrical

The CD10 and CD12 Series ozone generators are equipped with universal regulated power
supplies that accept an input voltage from 90-250VAC at 47-63Hz, single phase (1ø).
ClearWater Tech has an assortment of IEC cords for various voltage requirements and outlet
configurations, for use around the world. All possible pre wiring has been completed at the
factory. Logic schematics have been provided in the Appendix, Section D.

NOTES:
• All electrical connections should be made by a • The CD10/AD and CD12/AD must be
licensed, qualified electrician. All local, state energized by a constant unswitched power
and national codes must be observed. source for proper operation of the on-board
heat regenerative dry air system.
• Make sure all power is off at the main circuit • The air flow of the CD10/AD and CD12/AD
breaker before making any electrical must not be drawn through the unit for more
connections. than 10 hours in a 24 hour period for proper
operation of the on-board air dryer.

Step 1: Conforming to all local, state and national electrical codes, ground the ozone generator to a true earth
ground. Use solid copper bonding wire (usually #6 AWG) from the copper-bonding lug located on the
bottom of the ozone generator to the grounding point.
Step 2: Main Power: Plug in the IEC end of the power cord CD10 and CD12 Series Power Consumption
to the power entry module located at the bottom of Input Voltage 90-250VAC 47-63Hz
the ozone generator. The other end can be plugged CD10 1.1 - 0.7 amps
into any main power source with input voltage from CD10/AD 2.2 - 1.1 amps
90 to 250 VAC at 47 to 63 Hz, single phase. Note:
CD12 1.7 – 1.0 amps
The CD10/AD and CD12/AD must be energized by
CD12/AD 3.2 - 1.6 amps
a constant unswitched power source.
Step 3: External Loop (EXT LOOP): The external loop, noted on the front cover LED display as “EXT
LOOP”, is a true dry contact interface. Note: The term ‘dry contact’ means that this loop does not
supply output nor except input voltages. Warning: Supplying voltage to the external loop will
cause damage to the ozone generator and void warranty. Under normal operation the external loop
will effectively interrupt the ozone output, when the loop has lost continuity, this will also illuminate the
“EXT LOOP” LED and turn off the “Ozone Output” LED’s on the front cover. Note: When the
external loop has lost continuity main power to the ozone generator will remain “ON” giving
power to the cooling fan and the internal air dryer of the CD10/AD and CD12/AD. When continuity
is present through the external loop ozone, output will continue. This continuity will effectively turn
“OFF” 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 the external loop, cut the white 18AWG wire in half. Connect the control device to
each leg of the external loop. Note: External Loop control devices supplied by ClearWater Tech
may come equipped with a two-position male connector ready to be plugged into the female two-
position connector mounted to the chassis of the ozone generator. If the control device used supplies
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 Installation Procedures - Electrical
an output voltage a single pole single throw (SPST) normally open relay may be used to create a dry
contact interface (see Figure 6). Note: Attached to the white 18 AWG external loop is a warning,
“THIS CONNECTION IS A DRY CONTACT ONLY, DO NOT APPLY VOLTAGE”.
Step 4: Ozone Output Control: The CD10 and CD12 Series ozone generators are equipped with two options
for controlling the ozone output. The first is a manual 0-100% ozone output control and the second
option is a remote 4-20mA control signal. The manual ozone output control knob and remote 4-20mA
control leads (orange and purple), are located at the bottom of the ozone generator (see Appendix,
Section A).
1. Manual Ozone Output Control: Turning the control knob counterclockwise will decrease the ozone
output to down 0%, while turning the knob clockwise will increase the ozone output up to 100%. The
percent of ozone output is indicated by the “Ozone Output” LEDs on the front of the ozone generator,
with each LED representing 10% output (see Figure 11).
2. Remote 4-20mA Control: A 4-20mA control signal to the ozone generator may be used to control
the ozone generator output. The ozone generator will automatically sense the 4-20mA input signal and
override the setting of the manual ozone output control. Based on the 4-20mA signal, ozone output
will increase or decrease: 4mA = 0% ozone output, 20mA = 100% ozone output. The percent of ozone
output is indicated by the “Ozone Output” LEDs on the front of the ozone generator, with each LED
representing 10% output (see Figure 11). Note: If the remote 4-20mA signal fails or is missing, the
system will default to the manual ozone output setting. Check and adjust the manual ozone
output control knob to avoid over-ozonation.
Step 1: Mount the 4-20mA controller to a suitable vertical surface according to the installation
manual supplied with the controller.
Step 2: Wire the #22 AWG orange “positive” (+) lead from the ozone generator to the 4-20mA
controller according to the manual supplied with the controller.
Step 3: Wire the #22 AWG purple “negative” (-) lead from the ozone generator to the 4-20mA
controller according to the manual supplied with the controller.
Step 4: Complete the required programming and calibration steps as outlined in the installation
manual supplied with the 4-20mA controller.
Step 5: Air Preparation System Power - CD10 and CD12 only: 120VAC systems only: if a PSA oxygen
concentrator LPSA dry air system is used, plug power cord into main power. 240VAC systems only: if a
PSA oxygen concentrator or LPSA dry air system is used, the power cord must be hard wired to the
main power source (Black-L1, White-L2 and Green-Ground). Notes: The prescribed air flow must be
set to “atmospheric pressure” on either the PSA oxygen concentrator or LPSA dry air system
prior to use. Follow Step 4 of the “Start-up & Calibration” section. Warnings: Failure to calibrate
may lead to premature failure of the air preparation systems. Vacuum must be interrupted if the
air prep system is not “ON.” Failure to do so will damage the air prep system.
Air Preparation System - CD10/AD and CD12/AD only: The air dryer of the CD10/AD and
CD12/AD is powered by the main power of the unit.

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 Installation Procedures - Electrical
External Loop Electrical Interface
Figure 6
120 VAC Signal 240 VAC Signal
Power from L1 Power from L1
OPR, PPM, OPR, PPM,
pump or timer N pump or timer N

120V 240V
Coil Coil
Interface Interface
Relay Relay

External External
Loop Loop

-16-
Installation Procedures – Pneumatic
This section outlines the steps required to complete the ozone system pneumatic hook-ups. The system
components include the air preparation system, ozone generator, vacuum break, and ozone injector manifold (see
Figure 7). The air preparation system provides the ozone generator with a source of oil-free oxygen-enriched air
(90% +/- 3% oxygen purity at -100˚F dew point) or dry air (20% oxygen purity). The air is drawn from the ozone
generator (where ozone is produced from the oxygen in the air stream) and through the vacuum break by the
suction created at the ozone injector manifold.

Hook-Up: Air preparation system to ozone generator

Figure 7
Ozone Injector
Water Flow
Booster Pump

Air Preparation
Ozone Generator
Option 1 Ozone
Out

Vacuum
Break

Air Prep In

Option 2

Shown: ClearWater Tech CD10 or CD12 with OXU80 (Option 1)

and CD10/AD or CD12/AD (Option 2)

PSA Oxygen Concentrator or LPSA Dry Air - CD10 or CD12 only:

Step 1: Teflon® tape and attach brass barb provided to the PSA oxygen concentrator or LPSA dry air outlet, if
needed.
Step 2: Air Flow Gauge Assembly: Mount the standard cubic feet per hour (SCFH)/vacuum gauge assembly to
the ozone generator (ordered separately), following the installation instructions provided with the gauge
assembly.
Step 3: Using a suitable length of 3/8” braided tubing attach tubing to the barb located at the oxygen concentrator
or LPSA air dryer, then attach the other end of the tubing to the SCFH/vacuum gauge assembly. Secure
the tubing to the fittings with the hose clamps provided.

-17-
 Installation Procedures – Pneumatic
AD40 - Heat Regenerative Dry Air - CD10 or CD12 only:
Follow the installation procedures according to the Installation and Operation Manual provided with the AD40.

Heat Regenerative Dry Air - CD10/AD and CD12/AD only:

The CD10/AD and CD12/AD ozone generator (“AD” represents Air Dryer) has been pneumatically pre-plumbed
at the factory with an internal heat regenerative air dryer to provide simplicity of a “plug and play” ozone system.
The CD10/AD is also equipped with an internal moisture-indicating cartridge, which is visible through the view
window on the right side of the CD10/AD. This indicating cartridge is used as a reference to indicate the quality
of dry air. If the air dryer is not operating properly the silica will turn from blue and white in color to all white.
See Troubleshooting Guide. The CD10/AD and CD12/AD are also equipped with an “External Air Prep Loop,”
which can be used to interface the SCFH/vacuum gauge assembly by following the installation instructions
provided with the gauge assembly. This is the only necessary pneumatic connection. The air flow of the
CD10/AD and CD12/AD must not be drawn through the unit for more than 10 hours in a 24 hour period.
The CD10/AD and CD12/AD must be powered up for 24 hours prior to system start-up (no air flow should be
drawn through the system by the ozone injection manifold). This sieve material in the heat regenerative air dryer
must be evaporated of any moisture that has accumulated. Notes: If this step is not completed premature
failure of the heat regenerative air dryer system will occur. During this time the external loop connector
may be removed so that the ozone reaction chamber will not have power to it.

Oxygen Concentrator
Figure 8
Sieve Bed

Compressor Inlet Filter

Hour Meter

Power Indicator Light

Solenoid Valve

SCFH Air Flow Meter and

Adjustment Valve

Compressor

Oxygen Outlet

Main Power Cord

Shown: Aerous 15 Shown: Aerous 15
(Cover Removed)

-18-
 Installation Procedures – Pneumatic
Hook-Ups: Ozone generator-to-vacuum break & vacuum break-to-injector manifold
The ClearWater Tech vacuum break provides a positive atmospheric “break” between the ozone injector manifold
and the ozone generator, preventing water from flowing back into the ozone generator should the venturi check
valve fail. Under normal operating conditions, the vacuum break's flapper valve (see Figure 9) is closed, allowing
the vacuum created by the venturi to draw the output gas from the ozone generator. If the check valve at the
venturi begins to leak or fails completely, vacuum is interrupted and water will flow toward the ozone generator.
With the vacuum break properly installed between the venturi and the ozone generator, the water will flow down
the riser tube (away from the ozone generator) and out to drain, protecting the ozone generator from potential
water damage.
Step 1: Select a suitable vertical surface that is accessible and in close proximity to both the ozone generator and
the ozone injector manifold.
Step 2: Install the two Clic® mounting clamps provided onto the vertical surface so that the vacuum break is in a
vertical position and the drain holes are below the level of the ozone generators ozone outlet fitting. One
clamp should be located so it fits around the Riser Tube Elbow, and the other so it fits around the bottom
of the Lower Tee, (see Figure 9).
Step 3: Remove the Fill Port Cap located on top of the Riser Tube and fill the Riser Tube with clean water (no
particulate matter) to "Fill Level" line (see Figure 9).
Step 4: Re-install the Fill Port Cap, using pliers or a wrench to tighten. Note: Do not over- tighten as damage to
PVC fittings may occur.
Step 5: Install the check valve with compression fitting (located in the parts kit or attached to the ozone generator
with a wire tie) into the stainless steel ozone outlet located at the bottom of the ozone generator.
Step 6: Connect one end of a suitable length of Teflon® ozone delivery line to the fittings installed into the ozone
outlets (see Step 5 above). Attach the other end of the Teflon® delivery line to the fitting threaded into
the Upper Tee. As an additional backflow prevention measure, loop this length of tubing as high as is
practical between the two connection points.
Step 7: Connect one end of a second length of Teflon® delivery line to the fitting threaded into the Lower Tee.
Attach the other end of the delivery line to the fitting located on top of the check valve assembly, which
was installed at the injector manifold.
Step 8: Adjustments to the valve on the ozone injector manifold will be necessary. These steps are covered in
Chapter 7, “Start-up and Calibration Procedures.”

-19-
 Installation Procedures – Pneumatic
Vacuum Break Detail
Figure 9
Fill Port Cap

Ozone Generator Upper Tee

Lower Tee

Drain
Ozone Flow Holes
Ozone Output Drain
Ozone Flow Barb Mounting Clamp Locations
Fill Level

Riser Tube

Flapper Valve
Injector Manifold Riser Elbow

Hook-Up: Contact vessel-to-ozone destruct system (if so equipped)

The ClearWater Tech ozone off-gas destruct system consists of two components: the ozone destruct unit (a heated
chamber filled with manganese dioxide and copper oxide) and a water trap. Used in conjunction with the
ClearWater Tech off-gas vent, this two-stage ozone destruct system is an efficient way to properly vent the ozone
system contact vessel (see Figure 10).

NOTES:
• The ozone destruct unit must have constant • It is normal for small amounts of water to drain
power to function properly. Make sure it is from the water trap, so it must be plumbed to
plugged into an unswitched 120VAC outlet or waste appropriately
wired to unswitched 240VAC power. Once up
to temperature, the unit will remain warm to
the touch.

Step 1: Select a suitable vertical surface adjacent to the ozone system contact vessel. Using the Clic® mounting
clamps provided, mount the water trap to the surface.
Step 2: Using the mounting tabs, mount the ozone destruct unit adjacent to the water trap.
Step 3: Using Teflon® tape, install the small ball valve into the opening (at the tee or inlet) of the water trap.
Using Teflon® tape, install the thread-by-compression fitting provided into the small ball valve.
Step 4: Using the compression fitting, attach one end of a suitable length of the Teflon® tubing to the
compression fitting on top of the contact vessel (the fitting is threaded directly into the cap of the contact
column and is threaded into the off-gas vent on the top of a contact tank). Attach the other end of the
tubing to the inlet of the small ball valve (see Step 3 above) in the water trap.
Step 5: Using the compression fitting provided, attach another suitable length of Teflon® tubing to the fitting on
top of the water trap. Attach the other end of the tubing to the inlet compression fitting on the bottom of
the ozone destruct unit.

-20-
 Installation Procedures – Pneumatic
Step 6: Attach a suitable length of braided tubing to the fitting on the bottom of the water trap. Terminate the
other end to appropriate waste or drain.
Step 7: Plug the ozone destruct unit into an unswitched 120VAC outlet or wire to unswitched 240VAC power
and allow it to warm up. Warning: The destruct unit will be warm to the touch when in operation.

Ozone Destruct System Detail

Figure 10

Off Gas Vent

Ball Valve
Teflon Tubing

Ozone
Destruct Unit
Use Unswitched
Continuous Power
To Waste

Contact Vessel

Water Trap

-21-
Start-Up and Calibration
The previous sections of this manual have involved comparatively static procedures:
making electrical and pneumatic connections, fitting pipe, etc. This section involves
the dynamic process of starting up and balancing the components of the ozone system,
including initiating water flow, making air and water flow adjustments, etc.
Maximum performance and reliability is achieved when the prescribed air flow is maintained at the ozone
generator while the system is operating under a slight vacuum (measured in inches of mercury, or “in.Hg”). Air
from the air preparation system is flowing toward the ozone generator under pressure, and from the ozone
generator under vacuum (created by the ozone injector manifold). The change from pressure to vacuum occurs at
the SCFH/vacuum gauge assembly mounted to the CD10 or CD12. Note: If an external heat regenerative dry
air system, CD10/AD, or the CD12/AD is used, the air flow will be completely dependant upon the vacuum
draw of the ozone injector manifold. If the vacuum level is too high but air flow levels are correct, opening the
ball valve on the injector manifold(s) slightly will decrease the vacuum by increasing the amount of water flowing
through the bypass of the ozone injector manifold. Similarly, if the vacuum level is too low, closing the ball valve
on the injector manifold(s) slightly will increase the vacuum.

Air Preparation System, Ozone Generator & Ozone Injector

Step 1: Make sure all isolation valves in the ozone water system are open (Figures 2 or 3 show recommended
isolation valve locations).
Step 2: Start up hydraulics. Allow the water system to reach hydraulic equilibrium (contact vessel(s) full, off-gas
vent(s) operating, etc.) and observe for plumbing leaks. Note: Water flow must be established through
the main water pump and the ozone system booster pump (if so equipped).
Step 3: Close the ball valve on the injector manifold about half way.
Step 4: Make sure electrical power to all ozone system electrical components is on. The main power switch of the
air preparation system must be in the “ON” position, if so equipped (see Figure 8).
PSA Oxygen Concentrator and LPSA Dry Air: Systems must be set to “atmospheric pressure” prior to
full start up of the system. Disconnect the oxygen delivery line from each oxygen concentrator (if
delivery has already been attached).
Step 1: Check to make sure the compressor of the PSA or LPSA air preparation system is operating.
Step 2: Using the air flow gauge adjustment valve on the PSA or LPSA air preparation system (see
Figure 8), adjust the air flow according to the “air prep system air flow” specifications (see Figure
12).
Note: When the system is under normal operation, the air flow will drop from the initial setting due
to the air preparation system being under back pressure. DO NOT READJUST THE AIR FLOW
GAUGE ADJUSTMENT VALVE.
CD10/AD and CD12/AD: Unit must be powered up for 24 hours prior to system start-up (no air flow
should be drawn through the system by the ozone injection manifold until this step has been completed).
The sieve material in the heat regenerative air dryer must be evaporated of any moisture that has
accumulated. If the external loop has been removed during this step, replace external loop. Note: If this
step is not completed premature failure of the heat regenerative air dryer system may occur.

-22-
 Start-Up and Calibration
Step 5: Using the ClearWater Tech SCFH/vacuum gauge assembly, check
the VAC/PSI gauge for vacuum. If the needle is in the red zone on
the pressure (PSI) side of the gauge, gradually close the ball valve
on the injector manifold until the needle moves into the green zone.
If the needle is in the red zone on the vacuum (in.Hg) side of the
gauge, gradually open the ball valve on the injector manifold until
the needle moves into the green zone. While vacuum is in the green
zone you must be able to achieve proper Standard Cubic Feet per
Hour (SCFH) of air flow (see the “Pneumatic Operating
Parameters, Ozone generator air flow,” Figure 12).
Step 6: Using the ball valve on the ozone injector manifold and the air flow adjustment valve on the ozone
generator, make final adjustments to vacuum and air flow levels.
Step 7: Perform a final check of all air connections from the air preparation system to the ozone injector
manifold. Repair leaks as required. Check all system water connections, including the ozone injector
manifold, vacuum break and contact vessel. Repair leaks as required. Note: The check valve at the
ozone generator and ozone injector manifold may make a humming noise. This is normal.
Step 8: Observe all indicating LEDs on the front cover of the ozone generator (see Figure 11) for proper
operation and adjust the manual ozone output knob to desired level setting.

-23-
 Start-Up and Calibration
Ozone Generator LED Display
Figure 11
LED Function CD10 CD10/AD CD12 CD12/AD
OZONE The ten LEDs represent 0-100%, MAX MAX MAX MAX

OUTPUT minimum to maximum ozone output.

Each LED is equal to 10% output.
These LEDs can be adjusted with the
manual output control knob located at
the bottom of the ozone generator or
OZONE OZONE OZONE OZONE
automatically with a remote 4-20mA OUTPUT OUTPUT OUTPUT OUTPUT
control signal.
POWER Main Power is “ON” to the ozone
generator, when LED is illuminated.
HV Power is being sent to the high voltage MIN MIN MIN MIN

DRIVE drive board, when the LED is

illuminated. POWER POWER POWER POWER

EXT The External Loop has continuity HV DRIVE HV DRIVE HV DRIVE 1 HV DRIVE 1
LOOP through it when the LED is not EXT LOOP EXT LOOP EXT LOOP HI TEMP 1
illuminated, which indicates ozone is HI TEMP HI TEMP HI TEMP 1 HV DRIVE 2
being produced. The External Loop
does not have continuity, when the AIR PREP HV DRIVE 2 HI TEMP 2

LED is illuminated, which indicates no DRYER 1 EXT LOOP EXT LOOP

ozone production. DRYER 2 HI TEMP 2 AIR PREP

HIGH The High Temp LED will not be DRYER 1

TEMP illuminated during normal operation. If DRYER 2

the ozone generator’s internal
temperature is in excess of 150˚F the
High Temp LED will illuminate,
which will also discontinue ozone
production.
AIR CD10/AD and CD12/AD Only: The
PREP Dryer Timer LED will flash
continuously during normal operation
and indicates that the dryer timer cycle
is operating correctly.
DRYER 1 CD10/AD and CD12/AD Only:
DRYER 1 LED will be illuminated
when dryer chamber #1 is heating.
DRYER 2 CD10/AD and CD12/AD Only:
DRYER 2 LED will be illuminated
when dryer chamber #2 is heating.

Note: There is a 30 minute period where Dryer #1 and Dryer #2 are off. This is normal. The dryers are in
a cool down phase before switching.

-24-
 Start-Up and Calibration
Vacuum Break
Check the water level in the vacuum break, making sure it is above the flapper valve (see Figure 9). If water is not
pressing downward on the flapper valve it will open, causing a loss of vacuum. The water level in the vacuum
break should remain static with no air bubble movement. A loss of vacuum means ozone cannot be drawn
through the vacuum break, which in turn can cause an ozone leak (see Troubleshooting Guide).

Ozone Destruct System

Adjust the small ball valve at the tee of the water trap (see Figure 10) so that only a small amount of water is
“spitting” into the trap. This will indicate that the contact vessel is full and only a very small amount of water is
allowed to escape. Do not close this valve completely. Doing so may cause back pressure on the contact vessel
and injection manifold, which will cause a loss of vacuum (see Troubleshooting Guide).

Pneumatic Operating Parameters

Figure 12

CD10 Operating Range Optimum

Air prep system air flow 3 to 4 SCFH 4 SCFH
Ozone generator air flow 3 to 4 SCFH 4 SCFH
Vacuum gauge -3 to -8 in Hg -5 in Hg

CD10/AD Operating Range Optimum

Ozone generator air flow 3 to 4 SCFH 4 SCFH
Vacuum gauge -3 to -8 in Hg -5 in Hg

CD12 Operating Range Optimum

Air prep system air flow 6 to 8 SCFH 8 SCFH
Ozone generator air flow 6 to 8 SCFH 8 SCFH
Vacuum gauge -3 to -8 in Hg -5 in Hg

CD10/AD Operating Range Optimum

Ozone generator air flow 6 to 8 SCFH 8 SCFH
Vacuum gauge -3 to -8 in Hg -5 in Hg

-25-
Maintenance
Maintenance of the ozone system is critical to its longevity and operating efficiency. While all
system components are built to provide years of reliable service with minimum maintenance,
following the procedures outlined below is strongly recommended.
All maintenance procedures have been segmented by interval: daily, monthly, semi-annual
and annual. Daily procedures involve quick visual checks for changes in normal operating
conditions. Monthly, semi-annual and annual procedures include cleaning and/or replacement of certain critical
parts.

NOTES:
• The ozone generator warranty states that it • CAUTION: Observe all common safety
“does not extend to any product or part which practices and review the “Safety Warnings
has been damaged or rendered defective as a and Instructions” (Chapter 2) before
result of use of parts not sold by ClearWater attempting any maintenance procedure that
Tech, or service or unit modification not requires the use of tools and/or shutting down
authorized by ClearWater Tech.” Please the ozone system.
contact your ClearWater Tech dealer if you
have any questions about any maintenance
procedure before you begin that procedure.

Daily Procedures
Air Preparation System
• Power Switch: Check the power switch on the air preparation system (if so equipped), or inline particulate filter
inside the ozone generator (see Appendix A). Note: The air prep system must always have main power
when vacuum is being drawn through the ozone system.
• Indicator Cartridge: Inspect the air preparation system indicator cartridge (if so equipped). A change in the blue
crystals to light pink or white in color indicates the presence of moisture in the feed gas coming from the air
preparation system. If such a change is observed, refer to the Troubleshooting Guide.
• Air Flow: Check the air flow gauge on the air preparation system (see Figure 8). Make sure the air flow is
within the SCFH range shown on the “Air prep system air flow” line of the “Pneumatic Operating Parameters”
chart (Figure 12). Adjust if necessary by following Step 4 of the “Start-Up & Calibration” section.
Ozone Generator
• Indicator Lights: Check the indicator lights on the ozone generator. (see Figure 11 for Ozone Generator LED
Display function)
• Air Flow: Check the SCFH/vacuum gauge assembly attached to the ozone generator. Make sure air flow is
within the SCFH range shown on the “Ozone generator air flow” line of the “Pneumatic Operating Parameters”
(see Figure 12). Adjust if necessary by following Step 5-6 of the “Start-Up & Calibration” section.
• Vacuum: Check the SCFH/vacuum gauge assembly attached to the ozone generator. Make sure pressure is
within then range shown on the “Pressure” line of the “Pneumatic Operating Parameters” chart (see Figure 12).
Adjust if necessary by following Step 5-6 of the “Start-Up & Calibration” section.

-26-
 Maintenance
Vacuum Break
• Water Level: Check the water level in the vacuum break. Make sure it is up to the fill line. Fill as required by
removing the threaded fitting on top of the riser tube until water is up to the fill level in the riser tube (see
Figure 9).
Injection Manifold
• Check valve: Inspect the Teflon ozone delivery line that runs between the vacuum break and the check valve
assembly on the suction port of the ozone injector manifold. If water is observed in the delivery line near the
check valve assembly, the check valve has failed. See Troubleshooting Guide.
Ozone Destruct System
• Water Trap: Check water trap for excessive water. It should be no more than half full. If excessive water is
observed, see Troubleshooting Guide.
• Ozone Destruct Unit: Check to make sure the power indicator light located on the right side of the unit is
illuminated. Note: Unit must be plugged into an unswitched outlet. Cover of unit will be warm to the
touch.

Monthly Procedures
Air Preparation System
• Cooling Fan Operation: Check to make sure the cooling fan mounted on the side panel of the air preparation
system is operating. If not, refer to the Troubleshooting Guide.
• Cover Filter: Check the cover filter element mounted on the side of the air preparation system and clean as
required. Operating conditions in the equipment area will dictate the frequency required for this procedure.
Remove the filter element and clean with soap and water, drying them completely before re-installing.
Ozone Generator
• Cooling Fan Operation: Check to make sure the cooling fan mounted on the bottom panel of the ozone
generator is operating. If not, refer to the Troubleshooting Guide.
• Cooling Fan Filters: Check the cooling fan filter element mounted on the fan assembly located at the bottom
panel of the ozone generator and clean as required. Operating conditions in the equipment area will dictate the
frequency required for this procedure. Remove the filter element and clean with soap and water, drying them
completely before re-installing (see Figure 13).
Booster Pump(s)
• Strainer Baskets: Check and clean the strainer basket in the booster pump (if so equipped) as required.

Ozone Generator Cooling Fan Assembly

Figure 13
Fan

Ozone Generator Bottom Panel

Finger Guard

Fan Filter Element

Fan Filter Grill

-27-
 Maintenance
System Shutdown Procedures
CAUTION: The ozone generator operates at high voltages. Follow these steps carefully before performing
any semi-annual or annual maintenance procedures.
Step 1: Turn off power to any peripheral system hydraulic components and air prep system.
Step 2: Turn the Main Power switch on the ozone generator to the “OFF” position. The LED display on the front
cover should not be illuminated.
Step 3: Disconnect the power to the ozone system either at the service disconnect box (if so equipped) or main
circuit breaker.

Semi-Annual Procedures
CAUTION: Follow system shutdown procedures (outlined above) before performing any of the following
steps.
Air Preparation System
• Air Inlet Filter, PSA Oxygen Concentrator or LPSA Dry Air - Replace the air compressor inlet filter on the air
preparation system module (see Figure 8). Note: Manufacturers' recommended replacement interval is
4,000 hours of operation. Operating conditions in the equipment area will dictate the required frequency
of this procedure.

Annual Procedures
CAUTION: Follow system shutdown procedures before performing any of the following steps.
Air Preparation System
• Compressors, PSA Oxygen Concentrator or LPSA Dry Air: Following the procedures outlined in the
compressor rebuild kit, rebuild the two compressor heads on each air preparation system module. Note:
Manufacturers' recommended interval is 5,000 to 12,000 hours of operation. Compressor performance
and/or operating conditions in the equipment area will dictate the required frequency of this procedure.
• Air Dryer: CD10/AD and CD12/AD only: Replace sieve material according to the steps outlined below (see
Figure 14). Note: You will need to remove the unit from the wall in order to pour out the media. Allow
the air dryer chambers to cool completely and read all steps before continuing.
Step 1: Straighten out the ends of the dryer chambers using pliers.
Step 2: Using a snap ring tool, remove the top snap rings.
Step 3: Remove the top screens; the o-ring pick is handy for this. The bottom snap ring may be left
remaining within the air dryer chambers.
Step 4: Turn the ozone generator over to pour the old sieve material from the dryer chambers and dispose.
Note: When removing the sieve material, be sure not to discard the bottom screens.
Step 5: Re-seat/Re-install the bottom screens. Note: The heater rod must be put through the center of the
bottom screens.
Step 6: Fill chamber with new sieve material to 3/4” to 1” below the top of the dryer chambers. You will
have more media than needed.
Step 7: Re-install the top screens.
Step 8: Using a snap ring tool, place the top snap rings snug against the top screen.
Step 9: Bend the ends of the dryer chambers in-ward for added retention of the sieve material (optional).
Step 10: The ozone generator must be turned on for 24 hours prior to system start-up to eliminate any moisture
trapped in the new sieve material.

-28-
 Maintenance
Indicating Media Replacement (CD10/AD only)
Step 1: Using wrench, loosen and disconnect the compression fitting located at the top of the indicating media
chamber.
Step 2: With a flat-head screwdriver, unlock the two gray clamps securing the indicating media chamber.
Step 3: Pull the chamber free of the clamps, the chamber will only be held within the unit by the bottom cap.
Rotate the chamber downwards to position the bottom cap to be at the top of the chamber.
Step 4: Secure the bottom cap with channel lock pliers and turn the chamber counter-clockwise to unscrew it.
Be mindful to not spill the indicating media.
Step 5: Remove the indicating chamber from the unit, remove the interior screen and dispose of the media.
Step 6: Remove the Teflon tape from the bottom cap’s threads and re-tape the threads with 2-3 wraps.
Step 7: Refill the indicating chamber with new blue and white indicating crystals. You will have more media
than needed.
Step 8: Replace the interior screen and reinstall the chamber following steps 1 through 4 in reverse order.
Ozone Generators
• Cooling Filters: Clean or replace the cooling fan filter elements as required.
• Inline Particulate Filter: Replace the inline particulate filter.
• Reaction Chambers: Remove and disassemble the reaction chamber according to the steps outlined below (see
Figure 15). Check the chamber interior and dielectric tube for oil, dirt or moisture.
Reaction Chamber Removal and Disassembly
Note: Read through all the steps before disassembling the reaction chamber.
Step 1: Make sure all power to the ozone generator has been disconnected according to the “System Shutdown
Procedures” outlined above.
Step 2: Disconnect the high voltage lead from the reaction chamber(s).
Step 3: Disconnect the tubing connections on both ends of the reaction chamber(s).
Step 4: Remove the 4 nuts securing each chamber and remove the reaction chamber from ozone generator.
Step 5: Make note or mark the position of the end caps and their elbow fittings on the reaction chambers, during
re-assembly the end caps will need to return to original positions. Note: The orientation of the end
caps and the chamber itself is different between the two CD12 chambers.
Step 6: Remove retaining screws and washers from the two end caps (3 each).
Step 7: Using a gentle back-and-forth twisting motion, remove the non-high voltage end cap (the one without
the high voltage attachment screw) from the heat sink/cathode assembly. A flat-head screwdriver may be
used to gently pry the end cap off, as long as equal pressure is applied to each side of the end cap.
Step 8: Remove the high voltage end cap and dielectric from the heat sink/cathode assembly.
Step 9: The high voltage end cap can be removed by holding the glass and turning the end cap counter-
clockwise approximately 6 turns. Pull the end cap off the glass. Push the contact brush out of the
dielectric glass. A screwdriver can be used to push the brush, and pliers to pull it out once the opposing
end is exposed.
Step 10: Inspect the dielectric, end caps and cathode for breakage, corrosion or debris; then follow the assembly
and re-installation steps below.

-29-
 Maintenance
Reaction Chamber Assembly and Re-installation:
Step 1: Remove o-rings from end caps, clean the dielectric glass, end caps and interior of the stainless steel
cathode cylinder. Use denatured alcohol, shop towels to clean and be sure to remove all old o-ring
debris. A 1” ball hone can be used to clean the major debris out of the cathode if there is heavy buildup.
Step 2: Prepare the end caps for re-assembly by replacing the o-rings. Thread the hex brush adapter nut, with
contact brush attached, onto the end of the high voltage end cap (cap with the high voltage attachment
screw) center screw. Re-tape the threads of the elbow fittings if needed.
Step 3: Using a gentle twisting motion, press the non-high voltage end cap onto the heat sink/cathode assembly
until flush with the heat sink cooling fins. Turn the end cap to the correct orientation.
Step 4: Slide the three end cap retaining screws with washers through the holes in the non-high voltage end cap,
aligning them with the heat sink screw bosses. Thread screws into screw bosses until heads are snug
against the end cap.
Step 5: Next we focus on assembling the rest of the subcomponents, before installing them into the reaction
chamber. Slowly insert the brush (installed onto the high voltage end cap) into the dielectric glass. Note:
Go slowly in order to prevent or minimize bending the center wire of the brush during this
procedure. It is normal for the bristles to bend flat against the dielectric glass. Fully seat the dielectric
glass into the high voltage end cap. Clean the glass with denatured alcohol once more, and do not
retouch the glass without re-cleaning.
Step 6: Hold the reaction chamber upright on a flat surface, empty high voltage side up. Grasp the high voltage
end cap and lower the glass into the reaction chamber. Press directly downwards on the high voltage end
cap to fully seat the dielectric assembly; the end caps should be flush with the heat sink cooling fins.
Turn the end cap to the correct orientation.
Step 8: Slide the three end cap retaining screws with washers 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 the complete reaction chamber assembly into the ozone generator by securing the reaction
chamber to its mounts, securing delivery line and connecting the high voltage insulated wire.
Vacuum Break
• Cleaning: Disconnect ozone delivery lines. Remove the vacuum break from mounting clamps. Disconnect the
overflow tube from flapper valve, open flapper and clean the seat with a soft cloth. Remove riser tube threaded
fitting and flush riser tube with water. Re-assemble and re-install vacuum break, making sure to add water to
correct level (see Figure 9).
Injector Manifold
• Check Valve: Replace the check valve located at the ozone injection manifold. Note: Because the system is in
the shutdown mode, no vacuum is present at the injector. Therefore, it is normal for some water to be
flowing from the injector during this procedure.

-30-
 Maintenance
Contact Vessel
• Cleaning, Contact Column only: Inspect the diffuser slots at the top of the contact column riser tube. If they are
clear, no further maintenance is required. If the slots are fouled, disassemble the column and clean as required,
following the steps outlined below (see Figure 5).
Step 1: Make sure the isolation valves before and after the contact column(s) are closed.
Step 2: Disconnect the vent line from the top of the contact column(s).
Step 3: Remove the bolts in the 6” base flange.
Step 4: Remove the column, lifting it over the interior riser tube.
Step 5: Remove and clean the diffuser.
Step 6: Inspect the flange gasket and replace if necessary.
Step 7: Reassemble the contact column and attach vent lines.
Ozone Destruct System
• Off-Gas Vent: Disconnect tubing from top of off-gas vent and remove vent from contact vessel. Disassemble
vent and clean inside thoroughly. The float assembly maybe disassembled cleaned, making sure all ports and
orifices are clean and free of debris. Clean O-rings or replace as required. Re-assemble and mount vent onto
the contact vessel
• Ozone Destruct Unit: Under normal operating conditions, this unit may require no annual maintenance.
However, if a strong odor of ozone can be detected in the air immediately surrounding the unit, the catalyst
may require replacement. Follow the directions included with the ozone destruct rebuild kit.

-31-
 Maintenance
CD10/AD and CD12/AD Heat Regenerative Air Dryer
Figure 14

Dry Air Outlet

Solenoid Valve

Solenoid Valve Top Dryer Heater Rod

Connector (2 Position, Red)
(3 Position, Red)

Bottom Dryer Heater Rod

(2 Position White)

Bottom Screen

Sieve Material Top Dryer Chamber

(Not Shown)

Heater Rod

Bottom Dryer Chamber

Bottom Snap Ring

Top Screen
Top Snap Ring

-32-
 Maintenance
1” Reaction Chamber - Exploded View
Figure 15

End Cap Retaining Screws and Washers

Ozone Outlet Fitting

Bottom End Cap and O-rings

Heat Sink and Cathode

Glass Dielectric

Contact Brush

Brush Adapter Nut

High Voltage End Cap and O-Rings
High Voltage Terminal

Oxygen Inlet Fitting

-33-
Troubleshooting
Air Preparation – PSA Oxygen Concentrator or LPSA Dry Air
Problem/Symptom Possible Cause Solution
Unit not operating -No power to system -Check main power to unit
-Power switch in “OFF” position -Turn switch to “ON” position
-Insufficient vacuum through ozone -Adjust injector
generator (if vacuum switch is equipped -See “Start-Up & Calibration – Step 5”
with system) -See “Installation Procedures – Electrical”
-Incorrect wiring
Low air flow or no air flow -Flow meter out of adjustment -Adjust flow meter
-See “Start-Up & Calibration – Step 4”
-Fouled compressor inlet filter -Replace inlet filter
-Compressor not functioning -Rebuild of replace as required
Compressor pressure relief -Excessive backpressure in system -Inspect check valves for proper operation &
valve making noise replace as required
-Pinching tubing -Replace tubing
-Compressor not functioning -Rebuild or replace as required
-Sieve bed (ATF) not functioning -Replace as required
Indicator cartridge desiccant -Moisture has entered air prep system -Check & tighten fittings
has changed from blue & -Rebuild/replace all compressor(s) or sieve
white to all pink or white bed as required
-Replace indicating desiccant
Unit is making excessive -Shipping damage -Located damage and repair/replace parts
noise -Fan blocked -Clear Obstructions
-Packaging material not removed -Remove packaging material

Air Preparation – Heat Regenerative Dry Air (CD10/AD and CD12/AD Only)
Problem/Symptom Possible Cause Solution
Air Prep LED not flashing -Air dryer board not functioning -Replace air dryer board
Dryer 1 or 2 LED not -Air dryer board not functioning -Replace air dryer board
illuminated -Dryer 1 LED will not illuminate when -See “Theory of Operation and Product
Dryer 2 LED is illuminated Description - Air Preparation System”
-Dryer 1 is in cool down mode -See “Ozone Generator LED Display, Figure
-Dryer 2 LED will not illuminate when 11”
Dryer 1 LED is illuminated
-Dryer 2 LED is in cool down mode
Dryer chamber(s) not -Heating element not functioning -Replace Heating element
heating
Indicating desiccant -Unit does not have constant power -Unit must have constant power
cartridge has changed from -Excessive air flow -Adjust flow meter
blue & white to all pink or See “Start-Up & Calibration – Step 5”
white. Moisture has entered -Excessive duty cycle -Duty cycle must not exceed 10 hours in a 24
air prep system. hour period
-Excessive relative humidity -Relative humidity must not exceed 75%
-Solenoid valve not operating -Replace solenoid valve
-Air dryer board not functioning -Replace air dryer board

-34-
 Troubleshooting
Ozone Generator
Problem/Symptom Possible Cause Solution
LED display is not -No power to unit -Check circuit breakers
illuminated -Main power switch is in the “OFF” -Turn switch to the “ON” positioning
position
-Blown fuse(s) -Replace fuse(s)
-Incorrect wiring -See “Installation Procedures – Electrical”
-LED display board ribbon cable is -Connect ribbon cable (be sure all of the pins
disconnected from output control board are properly inserted into the output control
board)
‘Main Power’ LED is not -LED display board is inoperable -Replace LED display board
illuminated, but all other
LED’s are illuminated
Circuit breaker trips -Incorrect wiring -See “Installation Procedures-Electrical”
-Circuit breaker amperage does not match -Replace with correct circuit breaker
draw
-Unit flooded with water -Assess damage, correct cause and rebuild as
required
‘HV Drive’ LED is not -No power to the high voltage drive board -Check board to be sure it is attached securely
illuminated to the mother board
-Bad high voltage drive board, replace as
required
‘External Loop’ LED is -The external loop does not have -See “Installation Procedures – Electrical, Step
illuminated continuity 3” for function
‘Ozone Output’ LED’s are -The manual 0-100% output potentiometer -Adjust potentiometer clock wise to desired
not illuminated is set to 0% output set point
-Remote 4-20mA controller is sending a -No solution required, controller will adjust
4mA signal, which will indicated 0% LED’s automatically
output
‘Hi Temp’ LED illuminated -Unit is overheating -Check fan for proper operation and clean fan
filter
-Check operating temperature
-See “Installation Procedures – Getting
Started, Equipment Placement”
Internal Mother Board -No power to mother board -See “Installation Procedures – Electrical”
‘Power’ LED not -Inoperable mother board -Replacement Mother Board
illuminated -Blown mother board fuse -Replace fuse
Receive an electrical shock -Incorrect wiring -See “Installation Procedures-Electrical”
upon touching the unit -Unit not grounded -Ground unit according to local codes
-Unit flooded with water -Assess damage, correct cause and rebuild as
required
Fan not operating -Debris caught in fan -Remove debris
-Fan inoperable -Replace fan
Low air flow or no air flow -Air prep system not operating properly -See “Start Up & Calibration-Step 4”
-Fouled inline filter
-Air leak -Change inline filter
-Check all fittings, tighten as required

-35-
 Troubleshooting
Ozone Generator
Problem/Symptom Possible Cause Solution
Low air flow or no air flow -Air prep system not operating properly -See “Start Up & Calibration-Step 4”
-Fouled inline filter
-Air leak -Change inline filter
-Check all fittings, tighten as required
Low vacuum -Hydraulics/Pneumatics out of adjustment -See “Start-Up & Calibration”
-Back wash filter (if so equipped), look for
-Defective check valve(s) obstruction through the ozone loop.
-No water in vacuum break -Replace check valves
-Fill vacuum break with water – See “Start-Up
& Calibration – Vacuum Break”
-Defective O-ring seals in reaction -Check & Replace as required
chamber(s)
-Loose internal fittings -Check all fittings, tighten as required
-Defective dielectrics -Check & replace as required
High vacuum -Hydraulics/Pneumatics out of adjustment -See “Start-Up & Calibration”
-Change in hydraulics – excessive water
flow through ozone injector -See “Start-Up & Calibration”
Unit flooded with water -Defective check valve(s) -Assess damage, repair as required, replace
check valve(s)
-No vacuum break -Repair unit as required and install Vacuum
break
-Vacuum break flapper valve stuck -See “Maintenance Procedures-Annual,
Vacuum Break”
Hydraulics out of adjustment -See “Start-Up & Calibration”
Ozone small detected from -Insufficient vacuum at venturi -Adjust injector See “Start-Up & Calibration”
or near ozone generator -Check all fittings, tighten as required
-Loose internal fittings -Check & replace as required
-Defective O-ring seals in reaction
chamber(s) -Check & replace as required
-Defective dielectrics

Ozone Injector/Contacting
Problem/Symptom Possible Cause Solution
Water backflow past -Defective check valve(s) -Replace check valve(s)
injector check valve(s)
Water bubbling in vacuum -Insufficient vacuum at venturi -See “Start-Up & Calibration”
break -Debris on seat of vacuum break flapper -See “Maintenance Procedures –Annual,
valve Vacuum Break”
No vacuum at venturi inlet -Ozone injector out of adjustment -See “Start-Up & Calibration”
port -Low water flow through ozone injector -Check for obstructions upstream of ozone
-Back pressure in hydraulic line injector
-Check for obstructions downstream of ozone
-Booster pump not functioning properly injector
-Check booster pump (contact dealer)
Ozone smell detected -Insufficient vacuum at venturi -See “Start-Up & Calibration”
around vacuum break or -Loose fittings -Check all, tighten as required
ozone injector

-36-
 Troubleshooting
Ozone Destruct
Problem/Symptom Possible Cause Solution
Excessive water in water -Failed off gas vent -Clean vent or replace as required
trap -Failed spring check valve in water -Replace water trap
trap
Back pressure on drain line -Remove back pressure
Ozone destruct unit not -No power to unit -Check main power to unit
operating -Switch not “ON” -Turn switch to “ON” position
-Fuse blown -Replace fuse
-Incorrect wiring connections -See “Installation Procedures-Electrical”
Ozone destruct unit trips -Incorrect wiring -See “Installation Procedures-Electrical”
circuit breaker -Incorrect circuit breaker -Replace with correct circuit breaker
-Water break flow into unit -Assess damage and rebuild as needed
Ozone destruct indicator -Lamp burned out -Replace lamp
lights not on -Switch not “ON” -Turn switch to “ON” position
-Blown fuse -Replace fuse
-Incorrect wiring -See “Installation Procedures-Electrical
Receive an electrical -Incorrect wiring -See “Installation Procedures-Electrical”
shock from ozone -Unit not grounded -Ground unit according to local codes
destruct -Unit flooded with water -Assess damage, correct cause and rebuild
as required

-37-
Appendix A – Specifications
Air Preparation System (Aerous 15 Shown)

Compressor Inlet Filter

Hour Meter
Power Indicator Light
SCFH Air Flow Meter and
Adjustment Valve
Main Power Cord
Oxygen Outlet

Sieve Beds

Solenoid Valves

Compressor

Control Board

Air Prep System Specifications Oxygen Output/SCFH

19.75” H x 11.89” W x 13.75” D
Aerous 8 90% (+/-3%) @ 8 SCFH, 10 PSI
68 lbs (with cover)
20.50” H x 12.64” W x 15.10” D 90% (+/-3%) @ 15 SCFH, 10
Aerous 15
75 lbs (with cover) PSI

-38-
 Appendix A - Specifications
Air Preparation System (Workhorse 12C Shown)

SCFH Air Flow Meter and

Adjustment Valve
Fan
Oxygen Outlet
Cover Filter
Main Power Cord
Hour Meter

Compressor Inlet Filter

Compressor
Cooling Coil
ATF

Air Prep System Specifications Oxygen Output/SCFH

15.5” H x 17” W x 16” D
OXS80 (Workhorse 8C) 90% (+/-3%) @ 8 SCFH
45 lbs (with cover)
15.5” H x 17” W x 16” D
PDA20 (LPSA20) 20% (+/-3%) @ 20 SCFH
45 lbs (with cover)

-39-
 Appendix A - Specifications

-40-
 Appendix A - Specifications
CD10

LED Display Board

(Under Cover)

High Voltage Transformer

Reaction Chamber
High Voltage Drive Board
Board Retainer Bracket
Control Board
Main Mother Board
Inline Particulate Filter
Cover Safety Switch
External Loop
Remote 4-20mA Control
Leads

Air Prep Inlet

Manual Ozone Output Adjustment Knob
Remote 4-20mA Connector
Fuse Carrier
External Loop Connector
Ozone Outlet and Check Valve
Bonding/Ground Lug

Fan and Fan Filter

Power Entry Module – OFF/ON
Switch, Cord Input, Fuse Carrier

Shown: ClearWater Tech CD10 Ozone Generator (Wire harness omitted for clarity)

OZONE GENERATOR SPECIFICATIONS OZONE OUTPUT/SCFH

CD10 19” h x 9” w x 5” d, 9.5 lbs 1.3 g/h, 1% @ 4 SCFH, Dry Air
4 g/h, 3% @ 4 SCFH, Oxygen
Mounting Hole Measurement 14” h x 11” w

-41-
 Appendix A - Specifications
CD10/AD
LED Display Board
(Under Cover)
High Voltage
Transformer
Reaction Chamber
High Voltage Drive Board
Board Retainer Bracket
Control Board
Main Mother Board
Inline Particulate Filter
(Under indicating
cartridge)
Air Dryer (#1 Front, #2
back) and solenoid valve
Indicating Desiccant
Cartridge

Cover Safety Switch

External Loop
Remote 4-20mA Control
Leads

Bonding/Ground Lug
Fuse Carrier
External Air Prep Loop
Manual Ozone Output Adjustment Knob
Remote 4-20mA Connector

Fan and Fan Filter External Loop Connector

Ozone Outlet and Check Valve
Power Entry Module – OFF/ON
Switch, Cord Input

Shown: ClearWater Tech CD10/AD Ozone Generator (Wire harness omitted for clarity)

OZONE GENERATOR SPECIFICATIONS OZONE OUTPUT/SCFH

CD10/AD 19” h x 11.5” w x 5” d, 14.5 lbs 1.3 g/h, 1% @ 4 SCFH
Mounting Hole Measurement 13” h x 13.5” w

-42-
 Appendix A - Specifications
CD12
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
Cover Safety Switch
External Loop
Remote 4-20mA
Control Leads

Air Prep Inlet

Manual Ozone Output Adjustment Knob
Remote 4-20mA Connector
External Loop Connector
Ozone Outlet and Check Valve
Fuse Carrier
Power Entry Module – OFF/ON Switch, Cord Input
Bonding/Ground Lug
Fan and Fan Filter

Shown: ClearWater Tech CD12 Ozone Generator (Wire harness omitted for clarity)
OZONE GENERATOR SPECIFICATIONS OZONE OUTPUT/SCFH
CD12 21.5” h x 11.5” w x 5” d, 14.5 lbs 3 g/h, 1% @ 8 SCFH, Dry Air
8 g/h, 3% @ 8 SCFH, Oxygen
Mounting Bracket Measurement 15.5” h x 13.5” w

-43-
 Appendix A - Specifications

CD12/AD
LED Display Board
(Under Cover)
High Voltage
Transformer
Reaction Chambers
High Voltage Drive
Boards
Board Retainer
Bracket
Control Board
Air Dryer/
Solenoid Valve
Inline Particulate Filter
Main Mother Board
Remote 4-20mA
Control Leads
Cover Safety Switch
External Loop

Manual Ozone Output Adjustment Knob

Fuse Carrier
Ozone Outlet and Check Valve
Power Entry Module – OFF/ON Switch, Cord Input
External Air Prep Loop
Remote 4-20mA Connector
Bonding/Ground Lug
External Loop Connector
Fan and Fan Filter

Shown: ClearWater Tech CD12/AD Ozone Generator (Wire harness omitted for clarity)

OZONE GENERATOR SPECIFICATIONS OZONE OUTPUT/SCFH

CD12/AD 22”h x 13.5”w x 8.25”d, 20 lbs 2.6 g/h, 1% @ 8 SCFH
Mounting Bracket Measurement Z-Bar Mount

-44-
Appendix B – Parts List
SeaQual Air Preparation System OSX80 and LPSA20
Description Part Number
Compressor Inlet Filter OXS350
Enclosure Filter OXS370
Compressor Rebuild Kit OXS356
Pressure Relief Valve OXS362
Compressor Vibration Mount OXS366
Indicating Desiccant Refill (if so equipped) DES16

Aerous 8 Air Preparation System OXU80

Description Part Number
Enclosure Filter OXU350
Compressor Inlet Filter OXU370
Pressure Relief Valve OXS362
Sieve Bed (Single) Aerous 8 OXU375
Solenoid Valve OXU379
Control Board Aerous 8 120V OXU372
Control Board Aerous 8 220/240V OXU386
Replacement Compressor 120V OXU373
Replacement Compressor 220/240V OXU374

Air Preparation System – CD10/AD and CD12/AD

Description Part Number
Complete Air Dryer Assembly – CD10/AD ADP100
Complete Air Dryer Assembly – CD12/AD ADP203
Air Dryer Heating Rod ADP20
Solenoid Valve, 3-way, 24VDC SV220
Indicating Desiccant Refill DES16
Dryer Sieve Desiccant Refill – CD10/AD DES12
Indicating Desiccant Cartridge Screen – CD10/AD SCN20
Dryer Media Screen – CD10/AD SCN30
Dryer Media Screen – CD12/AD SCN40
Dryer Media Retaining Ring – CD10/AD HW137
Dryer Media Retaining Ring – CD12/AD HRR187
Dryer Chamber Retaining Spring – CD10/AD SPG110
Dryer Chamber Retaining Spring – CD12/AD SPG100

-45-
 Appendix B – Parts List

Ozone Generator
Description Part Number
Reaction Chamber – Complete CD10, CD10/AD RCC17
Reaction Chamber – Complete CD12 Left, CD12/AD Top, CD12/AD Bottom RCC18
Reaction Chamber – Complete CD12 Right RCC19
Dielectric Anode Assembly, 1” (Glass, Brush and Brush Adapter) RCC76SA
Non-High Voltage End Cap (Bottom) RCC57
High Voltage End Cap (Top) RCC53
O-ring Set ORS50
Mother Board CCA1325SA
Air Dryer Board – CD10/AD ELPC5020SA
Air Dryer/Control Board – CD12/AD CCA1232SA
Air Dryer/Control Board – CD12/AD Independent Control CCA1377SA
4-20mA Interface Board – CD10, CD12, CD10/AD ELPC5031SA
LED Display Board – CD12/AD CCA1350SA
LED Display Board – CD10 ELPC5054SA
LED Display Board – CD10/AD ELPC5050SA
LED Display Board – CD12 ELPC5052SA
High Voltage Drive Board – CD10, CD10/AD, CD12, CD12/AD ELPC5040SA
High Voltage Drive Board – CD12/AD Independent Control CCA1149SA
High Voltage Drive Board – CD12, CD12/AD, CD12/AD Independent Control ELPC5042SA
Complete Board Set – CD10 ELPC5064SA
Complete Board Set – CD10/AD ELPC5060SA
Complete Board Set – CD12 ELPC5062SA
Complete Board Set – CD12/AD ELPC5066SA
High Voltage Transformer – CD10, CD10/AD ELTR100
High Voltage Transformer – CD12, CD12/AD ELTR105
Check Valve – 1/4fpt X 1/4mpt CKV22
Cooling Fan FA47
Cooling Fan Filter FA40
Inline Particulate Filter FLT34
Fuse, Bussmann MDL-5 – 5 amp, 250VAC Slow Blow, Main Power FUS20
Fuse, Littlefuse 239003 – 3amp, 250VAC Slow Blow, Mother Board – HDO3-I FUS15

-46-
Appendix C – Maintenance Kit
ASP80 – Maintenance Kit – OXS80 Sequal Air Prep
Part Number Quantity Description
OXS350 1 Oxygen Concentrator – Replacement Compressor Inlet Filter
OXS356 1 Oxygen Concentrator – Compressor Rebuild Kit
OXS360 1 Oxygen Concentrator – Compressor Pressure Relief Valve
OXS370 1 Oxygen Concentrator – Cover Filter

ASP86 – Maintenance Kit – LPSA20 Sequal Air Prep

Part Number Quantity Description
OXS350 1 Oxygen Concentrator – Replacement Compressor Inlet Filter
OXS356 1 Oxygen Concentrator – Compressor Rebuild Kit
OXS360 1 Oxygen Concentrator – Compressor Pressure Relief Valve
OXS370 1 Oxygen Concentrator – Cover Filter

ASP70A – Maintenance Kit – Aerous 8 Air Prep

Part Number Quantity Description
OXU350 1 Oxygen Concentrator – Replacement Enclosure Filter
OXU370 1 Oxygen Concentrator – Replacement Compressor Inlet Filter

ASP111B – Maintenance Kit – CD10

Part Number Quantity Description
FA40 1 Filter – Cooling Fan Filter
FLT34 1 Filter – Inline Particulate Filter
ORS50 1 O-Ring Set
CKV22 1 Check Valve – 1/4fpt X 1/4mpt
CKV21 1 Check Valve – 1/4fpt X 1/4 fpt
FUS20 5 Fuse, Bussmann MDL-5 – 5 amp, 250VAD Slow Blow, Main Power
FUS15 1 Fuse, 3A, 250VAC Slow Blow, 5X20mm

ASP110B – Maintenance Kit – CD10/AD

Part Number Quantity Description
FA40 1 Filter – Cooling Fan Filter
FLT34 1 Filter – Inline Particulate Filter
ORS50 1 O-Ring Set
CKV22 1 Check Valve – 1/4fpt X 1/4mpt
CKV21 1 Check Valve – 1/4fpt X 1/4 fpt
DES16 1 Indicating Desiccant Refill
DES12 1 Dryer Sieve Desiccant Refill
FUS20 5 Fuse, Bussmann MDL-5 – 5 amp, 250VAD Slow Blow, Main Power
FUS15 1 Fuse, 3A, 250VAC Slow Blow, 5X20mm

-47-
 Appendix C – Maintenance Kit

-48-
 Appendix C – Maintenance Kit
ASP112 – Maintenance Kit – CD12
Part Number Quantity Description
FA40 1 Filter – Cooling Fan Filter
FLT34 1 Filter – Inline Particulate Filter
ORS50 2 O-Ring Set
CKV22 1 Check Valve – 1/4fpt X 1/4mpt
CKV21 1 Check Valve – 1/4fpt X 1/4 fpt
FUS20 5 Fuse, Bussmann MDL-5 – 5 amp, 250VAD Slow Blow, Main Power
FUS15 1 Fuse, 3A, 250VAC Slow Blow, 5X20mm

ASP115A – Maintenance Kit – CD12/AD

Part Number Quantity Description
FA40 1 Filter – Cooling Fan Filter
FLT34 1 Filter – Inline Particulate Filter
ORS50 2 O-Ring Set
CKV22 1 Check Valve – 1/4fpt X 1/4mpt
CKV21 1 Check Valve – 1/4fpt X 1/4 fpt
DES12 1 Dryer Sieve Desiccant Refill
FUS20 5 Fuse, Bussmann MDL-5 – 5 amp, 250VAD Slow Blow, Main Power
FUS15 1 Fuse, 3A, 250VAC Slow Blow, 5X20mm

-49-
Appendix D – Logic Schematics
CD10 G L2/N L1

Power Entry
Module

Fuse

External Loop Cover Safety

Switch

Mother Board
0 VDC

5 VDC
12 VDC
24 VDC
100 VDC
Manual
Ozone Output Fan
Control

Control Board

Remote 4-
20mA Ozone
Output
LED Display
Control
Board

High Voltage
Board

High Voltage
Transformer

Reaction
Chamber

Shown: Electrical Schematic

CD10 Line Side

-50-
 Appendix D – Logic Schematics
CD10/AD
G L2/N L1

Power Entry
Module

Fuse

External Loop Cover Safety

Switch

Mother Board
0 VDC

0 VDC
5 VDC
12 VDC
24 VDC
100 VDC
Manual Ozone
Output Control Fan
Solenoid
Valve
Control Board

Remote 4-
Dryer #1
20mA Ozone
Output Control
LED Display
Board Dryer #2

High Voltage
Board

High Voltage
Transformer

Reaction
Chamber
Shown:
Electrical Schematic
CD10/AD Line Side

-51-
 Appendix D – Logic Schematics
CD12
G L2/N L1

Power Entry
Module

Fuse

External Loop Cover Safety

Switch

Mother Board
0 VDC

0 VDC
5 VDC
12 VDC
24 VDC
100 VDC
Manual Ozone
Output Control Fan

Control Board

Remote 4-
20mA Ozone
Output Control
LED Display
Board

High Voltage High Voltage

Board 1 Board 2

High Voltage High Voltage

Transformer 1 Transformer 2

Reaction Reaction
Shown: Chamber 1 Chamber 2
Electrical Schematic
CD12 Line Side

-52-
 Appendix D – Logic Schematics
CD12/AD
G L2/N L1

Power Entry
Module

Fuse

External Loop Cover Safety

Switch

Mother Board
0 VDC

0 VDC
5 VDC
12 VDC
24 VDC
100 VDC
Manual Ozone
Output Control Fan
Solenoid
Valve
Control Board

Remote 4-
Dryer #1
20mA Ozone
Output Control
LED Display
Board Dryer #2

High Voltage High Voltage

Board 1 Board 2

High Voltage High Voltage

Transformer 1 Transformer 2

Reaction Reaction
Chamber 1 Chamber 2
Shown:
Electrical Schematic
CD12/AD Line Side

-53-
Appendix E – Warranty Information
ClearWater Tech, LLC. Limited Three-Year Warranty
Summary of the Warranty
ClearWater Tech, LLC (“CWT”) makes every effort to assure that its products meet high quality and durability standards and warrants
the products it manufactures against defects in materials and workmanship for a period of three (3) years, commencing on the date of
original shipment from CWT, with the following exceptions: 1) The warranty period shall begin on the installation date if the
installation is performed within 90 days of the original shipment from CWT; 2) The warranty period shall begin on the date of the bill
of sale to the end user if the installation date is more 90 days after the original shipment date. To validate the warranty, a warranty
card, accompanied by a copy of the bill of sale, must be returned to CWT and must include the following information:
• End user name • Complete model and serial number information
• Complete address, including telephone number • Name of company from which the unit was purchased
• Date installed
Repairs and replacement parts provided under this warranty shall carry only the unexpired portion of this warranty or 90 days,
whichever is longer.
Items Excluded from the Warranty
This warranty does not extend to any product and/or part from which the factory assigned serial number has been removed or which
has been damaged or rendered defective as a result of:
• An accident, misuse, alteration or abuse • Use of parts not sold by CWT
• An act of God such as flood, earthquake, hurricane, • Service or unit modification not authorized by CWT
lightning or other disaster resulting only from the forces of • Check valve/solenoid valve failure
nature • Damage which may occur during shipping
• Normal wear and tear • Failure to meet service requirements as outlined in the I &
• Operation outside the usage parameters stated in the O manual
product user’s manual
Obtaining Service Under the Warranty
Any product and/or part not performing satisfactorily may be returned to CWT for evaluation. A Return Goods Authorization (RGA)
number must first be obtained by either calling or writing your local authorized dealer, distributor or CWT direct, prior to shipping the
product. The problem experienced 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 that may occur during shipment. It is recommended that you insure the shipment for the
amount you originally paid for the product and/or part.
If, after the product and/or part is returned prepaid and evaluated by CWT, it proves to be defective while under warranty, CWT will,
at its election, either repair or replace the defective product and/or part and will return ship at lowest cost transportation prepaid to you
except for shipments going outside the 50 states of the United States of America. If upon inspection, it is determined that there is no
defect or that the damage to the product and/or part resulted from causes not within the scope of this limited warranty, then you must
bear the cost of repair or replacement of damaged product and/or part and all return freight charges. Any unauthorized attempt by the
end user to repair CWT manufactured products without prior permission shall void any and all warranties. For service, contact your
authorized dealer or distributor or CWT direct at (805) 549-9724.
Exclusive Warranty
There is no other expressed warranty on CWT products and/or parts. Neither this warranty, nor any other warranty, expressed or
implied, including any implied warranties or merchantability of fitness, shall extend beyond the warranty period. Some states do not
allow limitation on how long an implied warranty lasts, so that the above limitation or exclusion may not apply to you.
Disclaimer of Incidental and Consequential Damages
No responsibility is assumed for any incidental or consequential damages; this includes any damage to another product or products
resulting from such a defect. Some states do not allow the exclusion or limitation of incidental or consequential damages, so that
above limitation or exclusion may not apply to you.
Legal Remedies of Purchaser
This warranty gives you specific legal rights and you may also have other rights, which vary from state to state.
THIS STATEMENT OF WARRANTY SUPERSEDES ALL OTHERS PROVIDED TO YOU AT ANY PRIOR TIME.

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