PZ4 Ozone Generator System Manual

INSTALLATION GUIDE and OPERATION MANUAL

TABLE OF CONTENTS

• Safety Instructions
• Introduction to Ozone
• Preparing for Installation
• Installation
• Operation
• Water Chemistry
• Troubleshooting Guide
• Installation Kit Inventory

SAFETY

SAFETY-IMPORTANT  INSTRUCTIONS 

1. All applicable electrical codes must be followed during and after installation. All connections to be made by a qualified electrician.
2. Disconnect all power at the main circuit breaker before installing the PROZONE unit.
3. DANGER - Risk of electric shock.

a)      Replace damaged cord immediately.

b)      Do not bury cord.

c)      Connect only to a properly grounded, grounding type receptacle.

d)      Install at least 5 feet from the inside wall of the tub or pool using non-metallic plumbing.

4. Wear safety glasses when drilling and tapping holes for installation of unit. 
5. Turn off power at source breaker before servicing the unit. Do not attempt to open or service system – return to dealer.

 SAVE THESE INSTRUCTIONS.

INTRODUCTION TO OZONE

Ozone (O₃) is generated by irradiating air or oxygen (O₂) with ultraviolet radiation. Ozone is a molecule of oxygen that is formed when three atoms of oxygen are bound together instead of the normal two atoms. The extra oxygen atom makes ozone the most powerful oxidizer and sanitizer readily available.

Since ozone is unstable and quickly decomposes to normal oxygen under normal conditions, it cannot be shipped or stored. Therefore, it must be manufactured on site for immediate use. In normal air it lasts about an hour. In normal pool water it lasts just long enough to purify the water - less than 1 second.

Although ozone is mainly thought of as a sanitizer, it acts primarily as an oxidizer in the pool environment. In a typical pool run on chlorine only, up to 90 percent of the chlorine may be used up in reactions unrelated to disinfection. The byproducts of these reactions are combined chlorines. Combined chlorines are the cause of eye irritation, odor, and the other unpleasant side effects of chlorination.

When ozone is used, it oxidizes a large portion of the contaminants (usually referred to as bather load) which result in the formation of combined chlorines. The result is that more chlorine is available for disinfection and less chlorine is required to maintain the pool. Ozone also provides some disinfection, but an ozone residual cannot be established, so the use of chlorine or bromine is always recommended.

PREPARING FOR INSTALLATION

1. Check for and correct all leaks in plumbing.
2. Balance the pH.
3. Backwash the filter on retrofit installation.
4. Shock the pool. The use of Calcium Hypochlorite is recommended, or hydrogen peroxide if Baquacil is used.
5. CAUTION:  Make sure voltage is the same as prescribed on the side of the Prozone Ozone Generator.

INSTALLATION       Tools Needed: Electric Drill with 7/8” hole saw (USE THIS SIZE ONLY), Screwdriver, Pliers, Box Knife

PZ4 SERIES WITH BYPASS VENTURI - PARTS LIST                             

Item   Qty

Units

Part Number

Description

1

1

ea

201155

Saddle Tee

2

ea.

201141

PVC Tee, 1 ½ inch x 1 ½ inch x ¾ inch Hose Barb, Gray

3            1                ea            600002                   Ozone Injector (Red)
4            2                ea            20067                      Metal Hose Clamp, ¾ inch
5            1                ea            20214                      Check Valve, ¼ inch x ¼ inch
6            4                ea            20185                      Clamp (Black Plastic), ½ inch
7            6                inches      201828                    Polybraided Hose, 1 ½ inch ID
8            6                ft             20260                      Polybraided Hose, ¼ inch ID
9            6                ft             20264                      Clear Vinyl Hose, ¾  inch ID
10          3                ea            20728                      Wire Tie, Black
11          3                ea            20109                      Screw, Stainless Steel, #8, ¾  inch
12          3                ea            20085                      Flat Washer, #10 
13          2                ea            200069                    Metal Hose Clamp, 1 ½ inch

BYPASS INSTALLATION
(NOTE:  A Prozone saddle clamp or tee can be used on the outlet side of the filter for aboveground pools)  

1.       Place saddle clamp (201155) on the hard plumbing directly after the pump.  Place screws to hold saddle in place but DO NOT FULLY TIGHTEN.

2.       Drill a 7/8 in hole in the hard plumbing aligned through the saddle clamp outlet. 

3.       Place the short end of the injector (600002) in the hole on top of the saddle clamp, pushing injector in as far as it will go, then tighten saddle clamp screws.

4.       Place 1 ½ in Polybraid Tubing (201828) over the 1-1/2 barb on the outlet side of the filter (remove existing hose if necessary).

5.       Place one end of the 1 ½ in PVC Tee (201141) into the 1-1/2 in Polybraided Hose (201828) and the other end into the system tubing which was removed from the filter. Secure both ends of the 1 ½ inch Hose (20264) with the large Metal Hose Clamps (200069).

6.       Connect one end of the ¾ in Clear Vinyl Hose (20264) to the outlet of the Injector (60002) and the other end to the ¾ in barb on the PVC Tee (201141).

7.       Secure both ends of the ¾ inch Clear Vinyl Hose (20264) with the small Metal Hose Clamps (20067).

8.       Cut a 5 inch length from the ¼ inch Polybraided Hose (20260).

9.       Connect the pieces of Polybraid Hose (20260) by inserting the Check Valve (20214) and securing with a Black Plastic Clamp (20185). Make sure you can blow air through the check valve towards the Injector Port.     

10.   Connect the short end of the Polybraid/Check Valve assembly to the open barb on the Injector (600002) with the Black Clamp (20185). 

11.   Connect the remaining end of the ¼ in Polybraid Hose to the ¼ in Barb on top of the ozonator and secure with a Black Clamp (20185). 

12.   Install Ozone Generator on base of pump pack using the metal screws (20085) and washers (20085). Plug the Prozone Ozone Generator system to the circulation pump switch or timer. The Prozone system and the circulation pump should be started simultaneously. Use N.E.C. or local code grounding and installation procedures for swimming pool equipment.

Saddle Clamp Assembly

OPERATION

A. PROZONE PZ4 OZONE GENERATOR OPERATION

The Prozone system produces ozone when air is drawn across a special high-energy vacuum ultraviolet (VUV) lamp, converting some air to ozone. A venturi injector is inserted on the return line, by-passing water back into the return line of the pool which creates suction (vacuum) that draws the ozone into the venturi mixing the bubbles as the water returns to the pool. It is operated automatically by plugging the Prozone system directly to the circulation pump or plugging into a timer. A check valve is employed to prevent water back up in the event of system failure. A siphon loop is recommended for added backpressure resistance. The system should run 8-12 hours per day for good results; 24 hours per day for optimum water clarity and minimum chemical usage.

Although ozone is mainly thought of as a sanitizer, it also acts primarily as an oxidizer in the pool environment. In a typical pool using chlorine only, up to 90 percent of the chlorine may be used up in reactions unrelated to disinfection. The byproducts of these reactions are combined chlorines. Combined chlorines are the cause of eye irritation, odor, and the other unpleasant side effects of chlorination.

When ozone is used in conjunction with any halogen, it oxidizes a large portion of the contaminants (usually referred to as bather load) which result in the formation of combined chlorine. The result is that more free chlorine residual is available and less chlorine is required to maintain the pool. Ozone also provides disinfection, but an ozone residual cannot be established, so the use of chlorine or bromine is always recommended. Baquacil may also be used in conjunction with the Prozone system for water sanitation. Refer to the Baquacil manual for shocking instructions. 

B. WATER CHEMISTRY

• pH - 7.2 to 7.6. Ozone is pH neutral and will not cause the pH value of the water to fluctuate.
• Total Alkalinity - Total alkalinity is an important factor in water chemistry. Any level outside the ideal range can cause the pH reading to bounce or to be inaccurate. Therefore, the TA should be adjusted into the ideal range before any pH readings are made.

Sanitizers - A chlorine level of .5 ppm to 1 ppm is recommended

TROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE No light from Prozone unit Loose wiring No power to unit Defective lamp or other internal component Check all wiring connections Voltage compatibility Check power source Return unit to dealer No bubbles from injector or no evidence of ozone in pool   Excessive back pressure at pool return Filter not working Check for restriction at pool wall returns Check filter Water in Ozone Generator Check valve failure Verify check valve in venturi is operating properly – install/raise siphon loop Cloudy water; foamy water; scum Water chemistry out of balance Total Dissolved Solids (TDS) level too high Filter not working Check readings and balance accordingly Refer to dealer for proper water testing Clean or replace filter NOTE: Cloudy water may occur when the ozone generator is started. Filter and backwash as necessary.