Clarathon HCD-55 Spa Ozonator Kit Instruction Manual

1. Introduction

The Clarathon HCD-55 Spa Ozonator Kit is designed to provide ozone generation for hot tubs, swim spas, and cold plunge tanks up to 2500 gallons. This kit features dual ozone setpoints (50mg/Hr and 200mg/Hr) to accommodate various water volumes and is compatible with universal 120V/240V electrical systems. This manual provides essential information for the safe and effective installation, operation, and maintenance of your ozonator.

Image 1.1: Clarathon HCD-55 Spa Ozonator Kit, including the ozonator unit, tubing, clamps, and check valve.

2. Safety Information

Please read all safety instructions before installing or operating this device. Failure to follow these instructions may result in electric shock, fire, or serious injury.

• Electrical Safety: Always disconnect power to the spa or hot tub before performing any installation or maintenance. This unit operates on 120V or 240V; ensure proper wiring by a qualified electrician if you are unsure.
• Ozone Exposure: Ozone (O₃) is a powerful oxidizer. While beneficial for water sanitation, direct inhalation of high concentrations of ozone can be harmful. Ensure proper ventilation and installation to prevent ozone gas from accumulating in enclosed spaces.
• Proposition 65 Warning: This product may contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
• Water Contact: Prevent water from entering the ozonator unit. The check valve is crucial for preventing water backflow into the generator.
• Children and Pets: Keep the ozonator and its components out of reach of children and pets.

3. Package Contents

Verify that all components are present and undamaged before proceeding with installation:

• Clarathon HCD-55 Ozone Generator Unit
• 6 feet of Ozone Tubing (1/4 inch)
• Check Valve
• Hose Clamps (quantity 4)
• Zip Ties
• 6 ft. Power Cord with AMP-4 Connector

Image 3.1: All components included in the Clarathon HCD-55 Spa Ozonator Kit.

4. Setup and Installation

Installation of the Clarathon HCD-55 Ozonator is considered moderate difficulty. If you are not comfortable with electrical or plumbing work, consult a qualified professional.

4.1 Pre-Installation Steps

1. Disconnect Power: Turn off all power to your hot tub or spa at the circuit breaker.
2. Locate Installation Area: Choose a dry, protected location for the ozonator unit, away from direct water spray and excessive heat. Ensure there is enough space for mounting and tubing connections.
3. Identify Ozone Injector: Locate your spa's existing ozone injector (venturi) in the plumbing system. This is where the ozone tubing will connect.

4.2 Mounting the Ozonator

• Mount the ozonator unit vertically, if possible, to allow for proper drainage and air circulation.
• Use appropriate fasteners (not included) to secure the unit to a stable surface.

4.3 Tubing and Check Valve Connection

1. Connect one end of the 1/4" ozone tubing to the ozone output barb on the ozonator unit. Secure with a hose clamp.
2. Install the check valve into the ozone tubing. The arrow on the check valve must point towards the spa's ozone injector, ensuring ozone flows into the water and preventing water from flowing back into the ozonator. Secure both ends of the check valve with hose clamps.
3. Connect the other end of the ozone tubing to your spa's ozone injector barb. Secure with a hose clamp.
4. Create a small loop in the ozone tubing above the water line to act as a water trap, further preventing water from reaching the ozonator.

Image 4.1: Installation diagram for the Clarathon HCD-55 Ozonator.

4.4 Electrical Connection

• The HCD-55 features universal voltage (120V/240V) autosensing.
• Connect the provided 6 ft. power cord with the AMP-4 connector to the corresponding receptacle on your spa's control pack. Ensure the connector is fully seated.

Image 4.2: Detail of the AMP-4 electrical connector.

Image 4.3: Installation difficulty for the ozonator is rated as moderate.

4.5 Post-Installation

• Once installation is complete, restore power to the spa.
• Check for any leaks in the plumbing connections.
• Verify that the ozonator is operating. A faint ozone smell near the spa's water surface or a small indicator light on the unit (if present) may confirm operation.

5. Operating Instructions

The Clarathon HCD-55 Ozonator operates automatically when power is supplied through the spa's control system. It is designed to work in conjunction with your spa's filtration cycles.

• Automatic Operation: The ozonator will activate and generate ozone during the spa's programmed filtration cycles. No manual intervention is typically required for daily operation.
• Dual Setpoints: The HCD-55 offers dual ozone output setpoints (50mg/Hr and 200mg/Hr). The unit automatically adjusts its output based on the spa's requirements or may be pre-set to one of these levels. Consult your spa's manual or Clarathon support for specific details on setpoint selection if applicable to your model.
• Ozone Production: Ozone is produced by an internal corona discharge cell. This ozone is then injected into the spa water via the venturi system, assisting in water sanitation.

Image 5.1: Visual representations of ozone technology and the ozone molecule.

6. Maintenance

Regular maintenance ensures optimal performance and longevity of your ozonator.

• Replacement Interval: The Clarathon HCD-55 Ozonator has a recommended replacement interval of 30 months. Ozone generators gradually lose efficiency over time. Replacing the unit at this interval ensures continuous effective sanitation.
• Record Installation Date: It is recommended to write down the installation date on the label provided on the ozonator unit for easy tracking of its lifespan.

Image 6.1: Ozonator label for recording installation date and noting the 30-month replacement interval.

• Check Tubing and Check Valve: Periodically inspect the ozone tubing for kinks, cracks, or blockages. Ensure the check valve is functioning correctly and preventing water backflow. Replace if any damage is observed.
• Keep Unit Dry: Ensure the ozonator unit remains dry and free from moisture.

Image 6.2: Ozone works in conjunction with other sanitizers like bromine.

7. Troubleshooting

If your Clarathon HCD-55 Ozonator is not performing as expected, consider the following:

• No Ozone Smell/Output:
  • Verify power is supplied to the spa and the ozonator's power cord is securely connected.
  • Check if the spa's filtration cycle is active, as the ozonator typically operates during these times.
  • Inspect the ozone tubing for kinks, blockages, or damage.
  • Ensure the check valve is installed correctly and not blocked.
  • If the unit is older than 30 months, its ozone production may have significantly decreased, requiring replacement.
• Water in Ozone Tubing/Ozonator:
  • Immediately disconnect power to the ozonator and spa.
  • Inspect the check valve for proper installation and function. Replace if faulty.
  • Ensure the tubing loop (water trap) is correctly positioned above the water line.
• Unit Not Powering On:
  • Check the electrical connection at the spa pack.
  • Confirm the spa's control system is providing power to the ozonator outlet.

For persistent issues, contact Clarathon customer support.

8. Specifications

9. Warranty

The Clarathon HCD-55 Spa Ozonator Kit is backed by a 2-year warranty from the date of purchase. This warranty covers defects in materials and workmanship under normal use and service. Please retain your proof of purchase for warranty claims.

Image 9.1: Clarathon 2-Year Warranty.

The warranty does not cover damage resulting from improper installation, misuse, neglect, accident, or unauthorized repairs or modifications. The recommended replacement interval of 30 months is a guideline for optimal performance, not a warranty period extension.

10. Support

For technical assistance, troubleshooting beyond this manual, or warranty inquiries, please contact Clarathon customer support. Refer to the Clarathon website or your purchase documentation for current contact information.

When contacting support, please have your product model (HCD-55) and serial number available. The serial number can be found on the label on the ozonator unit (refer to Image 6.1).