Pentair CD-15G, CD-25G Installation And User Manual
™
INTELLIZONE
COMMERCIAL OZONE GENERATOR
Models CD-15G, CD-25G - All Models
INTELLIZONE
COMMERCIAL OZONE SYSTEM
ADVANCED SANITATION S OLUTIONS
TM
IMPORTANT SAFETY INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS
SAVE THESE INSTRUCTIONS
INSTALLATION AND
USER'S GUIDE
TABLE OF CONTENTS
SECTION 1 General Information
Description .....................................................................1
Specifications .................................................................1
SECTION 2 Installation
Location ..........................................................................1
Mounting .........................................................................1
Electrical .........................................................................2
Plumbing .........................................................................2
SECTION 3 Operation
Initial System Start-Up ....................................................3
Normal Operation ...........................................................3
System Shut-Down .........................................................3
IMPORTANT SAFETY INSTRUCTIONS
SECTION 4 Maintenance & Service
System Electro-Mechanical Overview ........................... 3
PM Schedule ................................................................. 7
Troubleshooting ............................................................. 7
Contact Information ....................................................... 7
SECTION 5 Replacement Parts & Order Info
Ordering Information...................................................... 7
Warranty ..................................................................... 8
Appendix
Appendix A (Troubleshooting Guide) ............................ 8
Warranty .................................................................... 12
Appendix B (Safety) ................................................... 13
READ AND FOLLOW ALL INSTRUCTIONS.
• Read this manual completely before attempting installation.
• Risk of Electric Shock. Install the ozone unit and any metallic plumbing associated with the unit at least
5 ft from the inside wall of tub or pool.
• Risk of Electric Shock. Connect this ozone generator in accordance with the installation instructions.
Do not install within an enclosure that would restict ventilation.
• (Applicable to cord/plug connected units only) Risk of electric shock. Connect only to a properly grounded,
grounding type receptacle.
• Do not bury cord.
• Warning – To reduce the risk of electric shock, replace damaged cord immediately.
• Follow all applicable electrical codes.
• Electric shock hazard. Be sure to turn power OFF at power source before any service work is performed.
Failure to do so could result in serious injury or death.
• Warning – Short term inhalation of high concentrations of ozone and long term inhalation of low
concentrations of ozone can cause serious harmful physiological effects. DO NOT inhale ozone gas
produced by this device.
• For your safety, do not store or use gasoline, chemicals or other flammable liquids or vapors near this
or any other appliance.
• A spontaneous and violent ignition may occur if oil, grease or greasy substances come in
contact with oxygen under pressure. These substances must be kept away from oxygen
regulators, cylinder valves tubing and connections, and all other oxygen equipment.
SAVE THESE INSTRUCTIONS!
INTELLIZONE™ COMMERCIAL OZONE GENERATOR Installation and User's Guide
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SECTION 1 General Information
Description
The IntelliZone™ Commercial Ozone Gererator (Models
CD-15G and CD-25G (521659, 521660, 521761 and
521762) described in this manual is designed to provide
the benefits of ozonated water in an environmentally
safe and effective manner. The high quality, specially
engineered components ensure efficient ozone output
and reliable performance.
Thos ozone generator is safe and harmless
to your equipment if installed properly.
24.1 613
A
31112.3
24.4 620
A
DIM "A" = 6 [152] MIN CLEARANCE
11.7 297
DOOR SWING
621R24.5
SECTION 2 Installation
Location
The ozone generator is designed for either floor or wall
mounting in a clean, protected area, either indoors or
outdoors. Locate generator out of reach of sprinklers or
drainage spouts. Allow sufficient access for maintenance
and all tubing and electrical wires. The generator must
not be placed in locations where ambient ozone levels
exceed 0.01 PPM.
Mounting
NOTE: Do not remove compressor packing
material until unit has been mounted.
Wall Mount Option
1. Attach two mounting brackets to wall using
anchors appropriate for mounting surface.
See Figure 2.
2. Using 1/4"-20 bolts (with washers as shown)
secure generator to mounts.
Floor Mount Option
1. Use the four 1/4"-20 bolts with washers to
secure feet to bottom of cabinet.
2. Stand upright and securely fasten to concrete
slab using appropriate anchors and bolts.
39.2 995
MOUNTING
BRACKETS (2)
1024.0
MIN. CLEARANCE
(IF WALL MOUNTED) 4.0 102
Figure 1
Specifications
For detailed specifications refer to the ozone
generator specification label located on the inside
of the door on the unit.
Location Requirements*:
Mounting: Floor or wall mount in a clean, protected
area using supplied brackets.
Ventilation: Room should provide 6 air changes
per hour
Ambient Temp.: 40–100˚F (5–38˚C)
* Protection from weather elements must be provided
for outdoor installations. Operating outside of the
recommended temp. ranges may result in damage
not covered under the manufacturer’s warranty.
Figure 2: Wall Mount
INTELLIZONE™ COMMERCIAL OZONE GENERATOR Installation and User's Guide
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Electrical
Refer to the units specification label and local
electrical codes for information on proper electrical
connection.
120V Models
Main power circuit: Unit is supplied with a
standard power cord. Plug cord into standard
120V grounded, gounding type receptacle only.
230V Models
Main power circuit: 230V models are supplied
with an IEC 6032 C-14 Type power receptacle.
A power cord, having at least a 10AMP rating, with
a IEC 60320 C-13 Type plug and a country specific
plug is required to power generator.
Figure 3: Country Specific Plug
(Australia shown for reference only)
Plumbing
Ozone gas is introduced to the circulation line using
a venturi in-line injector. Suction developed by the
venturi injector allows the generator to operate
safely under vacuum. See installation manual
for Model 521683 or 521684 for proper venturi
installation.
Ozone Gas Line
1. Connect ozone tubing to generator outlet fitting.
(3/8" stainless steel compression fitting.)
2. Connect opposite end of ozone tubing to injector
suction port. (Suction port fitting: 3/8" stainless
steel compression fitting.) See Figure 4.
NOTE: The ozone gas supply line must be
made of PTFE or stainless steel and have a
back flow prevention device (such as a check
valve) installed between the ozone generator
cabinet and the point of injection to prevent
water from backing up into the generator
system. An ozone supply check valve is
included with the Model 521683 or 521684
system.
Figure 4: Plumbing Schematic - Example of Swimming Pool Application
INTELLIZONE™ COMMERCIAL OZONE GENERATOR Installation and User's Guide
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Cooling Water
Cooling Water Flow: .1 Gpm (.4 Lpm)
Colling water Pressure: 15–40 psi (103–275 kPa)
Cooling Water Temp.: 5–90˚F (10–32˚C)
1/4" FPT connections are supplied on the
generator. See Figure 4, 5a, 6a. Be sure that
the tubing is appropriately matched with the marked
inlet and outlet ports. Carefully match and connect
to water plumbing as shown in Figure 4. Alternate
method using connections at injector may be used.
SECTION 3 Operation
Initial System Start-Up
Upon completing all of the generator system
connections, you are ready to begin start-up
procedures.
1. Check electrical fittings.
2. Check for proper voltage.
3. Turn on circulation pump.
4. Check for leaks.
5. With the ozone isolation valve closed, adjust the
injector bypass valve and/or filtration sidestream
valve to flow water through the injector.
6. Check cooling water.
7. Open the ozone isolation valve.
8. Turn main power switch to "ON" position.
9. Adjust injector by-pass to attain required vacuum.
(Red "Vacuum" light will go out.) Gas flow
(as indicated by the flow meter on the door of
the unit) should correspond with the rating listed
for the specific model on the specification label.
Normal Operation
With the power switch on, the system’s
compressors and cooling fans will start-up, the
oxygen concentrator will begin operating, and
the output solenoid valve will open. With the
injector adjusted to attain the correct gas flow,
the ozone generator should be producing ozone
and injecting it into the process line.
Both (2) green indicator lights should be lit. If
an optional ORP Controller is installed, it should
be displaying a reading from the sensor probe
and will automatically cycle the generator on and
off as needed to maintain water quality. Residual
ORP levels will vary per application.
However, the system will not start under any of
the following conditions:
1. The system will not start-up if the door is not
secured. A door interlock switch is incorporated
into the system enclosure.
2. If the optional ORP/DO3 controller is installed the
system will not produce ozone if the measured
level is already above the setpoint of the controller.
3. The system will not produce ozone if there is not
enough vacuum being generated by water flow
through injector. The red "Vacuum" light will go
out when proper vacuum is attained.
If you experience complications, see APPENDIX
A, TROUBLESHOOTING GUIDE or call
800.831.7133 for assistance.
System Shut-Down
The ozone generator is a specialized water
cooled device that must be properly protected
during shut-down/storage periods. The
following sequence of steps must be used for
servicing or for storage.
1. Toggle the main system power switch to the
“OFF” position to shut-down generator.
2. Close the ozone isolation valve to prevent water
back flow.
3. After the generator has been shut-down, the
process water circulation pump may be turned
off.
4. If the system is going to be shut-down and
stored during freezing weather, it is very
important that the cooling water be drained to
protect it from rupture or damage.
NOTE: Process water flow must not be shut-
down when the ozone generator is operating.
Doing so may cause water to backflow into
the system and damage the generator cells.
SECTION 4 Maintenance & Service
System Electro-Mechanical Overview
Refer to Figure 5a and 6a for component locations.
Indicator Lights
1. Main Power: Green light indicates that power is
being supplied to the ozone generator.
2. Ozone Power: Green light indicates that power
is being supplied to the high voltage Corona
Discharge circuits and that ozone is being
produced.
3. Vacuum: Red light indicates a low vacuum fault
condition. (Refer to APPENDIX A
TROUBLESHOOTING).
4. High Coolant Temperature: Red light indicates
INTELLIZONE™ COMMERCIAL OZONE GENERATOR Installation and User's Guide
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cell temperature is over 110F - resulting from
loss of cooling water flow. (Refer to APPENDIX
"B", TROUBLESHOOTING GUIDE.)
5. Water Backflow Detected: Red light indicates
water backflow from injector into generator.
(Refer to APPENDIX "B", TROUBLESHOOTING
GUIDE.)
External Components
1. Main Power Switch: Power switch is used for
system start-up and shut-down. Switch activates
the control system allowing the generator to
start up.
2. Flowmeter: Flowmeter controls and indicates
the oxygen flow through the system.
3. Circuit Breaker: Circuit breaker protects the
generator from over current conditions. Push
the breaker button to reset.
Internal Components
1. Variable Output Switch (optional): Adjusts
high voltage power supplied to the ozone
generator module controlling ozone output
concentration. Located on the outside of the
enclosure door.
External Devices that Control Ozone Production
The devices turn ozone production on or off
based on programmed level set points. Refer
to Figure 5b and 6b for connection details.
1. ORP Controller (optional): The ORP controller
receives a millivolt (mV) signal from the ORP
sensor mounted in the process water line. ORP
(Oxidation-Reduction Potential) is a measure
of the relative oxidation strength of the water.
As ozone is added to the water system the ORP
level will rise. As ozone is used up in the water
system the ORP level will drop. The ORP
controller continuously analyzes the sensor
signal, compares it to the setpoint that has
been programmed, indicates the ORP level on
the digital display, and relays the signal to the
ozone generator.
2. Dissolved Ozone Monitor (optional):
Monitoring system designed for the continuous
measurement of ozone gas in solution. The
operating range of the system may be selected
by the user from 0-2.00 PPM or from 0-20.00
PPM. The basic sensing element used is
polarographic membraned sensor which
measures ozone directly.
External Devices that Control System
Power
The devices turn power to the ozone generator
on or off. Examples of such devices would be an
ambient ozone monitor or flow switch. Refer to
Figure 5b and 6b for connection details.
Internal Components
1. Ozone Cell Assembly: Cells are made of two
aluminum halves. Enclosed in the aluminum
halves are a ceramic tube, coil type high voltage
electrode and a PTFE rod.
2. High Voltage Supply(s): Power supplies raise
incoming line voltage and frequency to deliver it
to the cells. Each power supply is rated at 100W.
3. Air Compressors: Compressors produce and
supply compressed air to oxygen concentrator.
4. Oxygen Concentrator: Supplies concentrated,
dry, oxygen feed gas to the ozone generator.
5. Low Limit Vacuum Switch: If the vacuum in the
ozone output supply line falls below 1.5 in. Hg
the switch will open causing the system to shut
down.
6. Vacuum Regulator: Regulates the oxygen
flow into the generator cell based on a vacuum
setpoint (factory set to 3-5 in. Hg). When the
sufficient suction is being developed by the
injectors downstream the regulator will allow full
flow to pass. As suction is reduced, flow is
restricted proportionally to maintain the vacuum
set point. If suction is lost completely, flow is
cut off.
7. Water Backflow: The backflow detector senses
water present in ozone tubing in generator. If
water is detected, system will close solenoid
valve to prevent additional water backflow from
occuring. Water in the generator will cause
severe damage to the high voltage electrodes.
8. Ventilation Fan: Cooling fan operates when
main power switch is “ON”.
9. Air Filter: Filter cleans ventilation air entering
the enclosure.
10. Door Interlock Switch: Interlock switch will
shut down entire system if door is opened.
Securing the door will bring the system back
into operation.
11. Relay Panel: Contains control relays for system
interlocks, indicator lights and main power
control.
12. Hour Meter: Indicates total system operating
time in hours.
INTELLIZONE™ COMMERCIAL OZONE GENERATOR Installation and User's Guide
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Figure 5a: Component Locations (ALL MODELS EXCEPT 521761 and 521762)
Relay Panel
Remove jumper if ORP controller or dissolved
ozone monitor is used. Connect dry contact
leads from controller/monitor or leave open
if 5 pin external interface connector is used.
Remove jumper and connect dry contact leads
if external device is used. (ambient ozone, flow
switch, etc.)
Figure 5b: Connection Details for External Control Devices (ALL MODELS EXCEPT 521761 and 521762)
INTELLIZONE™ COMMERCIAL OZONE GENERATOR Installation and User's Guide
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