INSTALLATION GUIDE and OPERATION MANUAL

PZ7 Series

Ozone Generator Systems

TABLE OF CONTENTS

• Safety Instructions
• Introduction to Ozone
• Preparing for Installation
• Installation
• Operation
• Chemistry
• Trouble Shooting
  

SAFETY

IMPORTANT SAFETY INSTRUCTIONS

READ AND FOLLOW ALL 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. WARNING - To reduce the risk of injury, do not permit children to use this product unless they are closely supervised at all times.
4. DANGER - Risk of electric shock.
   1. Replace damaged cord immediately.
   2. Do not bury cord.
   3. Connect only to a properly grounded, grounding type receptacle.
5. Install at least 5 feet from the inside wall of the pool using non-metallic plumbing.  The ozone generator is to be located one foot above the maximum water level to prevent water from contacting electrical equipment.
6. Wear safety glasses when drilling and tapping holes for installation of unit.
7. Turn off power at source breaker before servicing the unit.
8. 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 reverts to normal oxygen under normal conditions, it cannot be shipped or stored.  Therefore, it must be manufactured on site for immediate use.  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 using chlorine only, up to 90 percent of the chlorine may be used up in reactions unrelated to disinfection.  The byproduct of these reactions is combined chlorine (chloramines).  Combined chlorine is 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 reduction of combined chlorine.  The result is that more chlorine is available for disinfection and less chlorine is required to maintain the pool which eliminates the harmful byproducts.  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 electrical system: 240VAC double switched per N.E.C. standards recommended; 120VAC single switched
2. Check for and correct all leaks in plumbing.
3. Check for Suction Line Check Valve. Equipment may draw if no check valve is present.
4. Balance the pH.
5. Backwash the filter.
6. Shock the pool. The use of Calcium Hypochlorite (CaCl) is recommended.

NOTE: If the pool has a Diatomaceous Earth (DE) filter, a 3/4" ball valve (not furnished) must be installed on each end of the Venturi Bypass Line.

NOTE: If the pump and filter are below the water level of the pool, see special note on Page 3.

INSTALLATION

NOTE:  The instructions in this document provide general installation guides.  Consult your dealer for specific installation instructions.  Additional information is available on the Internet at www.prozoneint.com.  Check system for any visible shipping damage.  If damage has occurred, contact the delivery company and your dealer immediately.  Before beginning installation, please refer to the Installation Kit Inventory section and verify that all listed parts are on hand.

Tools Needed: Hacksaw or PVC Tube Cutter, Screwdriver, Pliers, Wall Mount Screw Anchors, Knife, Teflon Tape, PVC Cement

PZVII SERIES WITH BYPASS VENTURI

Parts Lists
PVC Tee Kit
ITEM Qty   PART #     DESC
1          1     600002       Injector, 684-V3 Venturi
2          4     20185        Clamp, "C"
3          4     20067        Clamp, HS-12
4          1     20214        Check Valve, 1/4"
5          4     20109        Screw, #8 x 3/4 SMS
6          6 ft  20260        Hose, 1/4" PBT
7          8 ft  20264        Hose, 3/4" CVT
8          2     201095      Tee, 2 x 3/4 FPT
9          4     201114      Bushing, 2" x 1-1/2" sxsp

10        2     20176        Fitting, 3/4" mpt x 3/4" HB Nylon

(Click for Larger Image)

BYPASS INSTALLATION FOR 2 OR 1-1/2 INCH HARD-PLUMBED POOL

1. Splice pipe directly after the pump and before the filter, and install PVC tee. For 1-1/2" pipe use provided bushings. Apply PVC cement to the joint, following the manufacturer's instructions to insure proper adhesion.

2. Apply Teflon tape to the threaded end of one 3/4 inch MPT x 3/4 inch HB fitting.

3. Screw fitting snugly into the top of this PVC tee.

4. After all existing equipment (including heater, chlorinator, etc), splice return pipe and install second PVC Tee. For 1-1/2" pipe use provided bushings. Apply PVC cement to the joint, following the manufacturer's instructions to insure proper adhesion.

5. Apply Teflon tape to the threaded end the other 3/4 inch MPT x 3/4 inch HB fitting.

6. Screw fitting snugly into the top of the other PVC tee.

7. Cut a 6 inch length of 3/4 inch clear vinyl hose and connect one end to the 3/4 inch hose barb fitting on the tee nearest the pump. Secure with a clamp.

8. Insert the INPUT end of the V3 injector into the 6 inch length of hose. Then secure with a clamp.

9. Insert the opposite end of the venturi injector into the remaining 7-1/2 foot length of the 3/4 inch clear vinyl hose and secure with a clamp.

10. Attach the loose end of the 3/4 inch hose to the 3/4 inch hose barb fitting on the other tee. Secure with a clamp.

11. Mount the PZ7 Ozone Generator one foot above the maximum water level to prevent water from contacting electrical equipment.  Be sure to mount the system close enough for 6 feet of 1/4 inch air hose to reach the injector.

12. Cut a 6 inch length of 1/4 inch hose and connect one end to the output side of the 1/4 inch check valve (flow away from the Ozone Generator-output side is the longer side) and the other end to the ozone fitting on the injector; secure with a clamp. Attach the air hose to port 1 (port 2 should be capped).

13. Attach one end of the remaining length of 1/4 inch hose to the output fitting on the Ozone Generator and the other end to the input side of the check valve. Make sure flow is away from the Ozone Generator. Secure with clamps.

14. Electrical Installation: Most models have a universal ballast and are multi-voltage. Wire 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.

CAUTION:  Make sure voltage is the same as prescribed on the side of the Prozone Ozone Generator. Most models have a universal ballast and are multi-voltage.

OPERATION

A. PROZONE PZVII SERIES OZONE GENERATOR OPERATION

The Prozone system works when air is drawn across a high-energy vacuum ultraviolet (VUV) lamp, converting some air to ozone.  A bypass venturi system takes water directly after the circulation pump (highest pressure point), bypasses part of the water flow past filters, heater, etc. through a venturi injector, through contact tubing and then returns the water back to the pool return line. The system is installed on the return water line and operates during regular filtration cycles.  It is operated automatically by wiring the Prozone system directly to the circulation pump.  A check valve is employed to prevent water back up in the event of system failure.  The system should be run a minimum of 12 hours per day. For best water quality 24 hour circulation/ozonation is recommended.

 

B. RECOMMENDED WATER CHEMISTRY AND POOL CARE

pH - 7.2 to 7.6.  Ozone is pH neutral and will not cause the pH value of the water to fluctuate.

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

Shock - Non-lithium-based material such as Calcium Hypochlorite or Sodium Hypochlorite, etc.

The use of other chemicals is not usually required, and they could react with the ozone causing cloudy water.

Brush pool regularly so that algae, spores, etc can be oxidized, as ozonation occurs in the return line.

 

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 resistance at pool wall returns Check filter
Water in Ozone Generator	Check valve failure	Verify check valve in venturi is operating properly
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.

SPECIAL NOTE: In some instances when the pump and filter are below the water level in the pool, pump prime may be lost when the filtration system is powered down.  (This can be caused by the air draw through the injector).  One method of correcting this is to install an electrically operated, normally closed solenoid valve in the air line between the Ozonator and the Venturi Injector.  Cut the 1/4 inch hose between the Ozonator and the Injector and install the solenoid valve using compatible fittings).  The voltage rating of the valve should be according to the locally available voltage.   If there is a controller that turns the pool circulation pump on/off, the solenoid valve should be connected to this.  If there is spare set of relay contacts in the controller, connect the solenoid's power leads to these relay contacts.  If there is no extra set of relay contacts available, connect the solenoid power leads to the same terminal as the circulation pump.  The solenoid valve should close when the circulation pump turns off or if power is lost.