Ozone Generator Systems for Water Purification
Manufactured by
Prozone Pool Products
Huntsville, Alabama
Prozone® PZ7 Series
INSTALLATION GUIDE
and
OPERATION MANUAL
SAFETY
READ AND FOLLOW ALL INSTRUCTIONS.
IMPORTANT SAFETY INSTRUCTIONS
a.
b.
c.
d.
All applicable electrical codes must be followed during and after installation. All connections to be made by a qualified electrician.
Disconnect all power at the main circuit breaker before installing the PROZONE unit.
WARNING - To reduce the risk of injury, do not permit children to use this product unless they are closely supervised at all times.
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.
e. 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.
f. Wear safety glasses when drilling and tapping holes for installation of unit.
g. Turn off power at source breaker before servicing the unit.
h. 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.
2.
3.
4.
5.
6.
Check electrical system: 240VAC double switched per N.E.C. standards recommended; 120VAC single
switched.
Check for and correct all leaks in plumbing.
Check for Suction Line Check Valve. Equipment may draw air if no check valve is present.
Balance the pH.
Backwash the filter.
Shock the pool with a non-lithium-based material. The use of Calcium Hypochlorite or Sodium
Hypochlorite is recommended.
NOTE: If the pool has a Diatomaceous Earth (DE) filter, a 3/4" ball valve is recommended between the pump
and Venturi Injector.
NOTE: If the pump and filter are below the water level of the pool, see special note on Page 3.
PZ7 Saddle Tee Kit
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Installation Parts Lists
Saddle Tee Kit
ITEM
1
2
3
4
5
6
7
8
9
10
Qty
1
4
2
1
4
6ft
8ft
2
1
2
PART #
600002
20185
20067
20214
20109
20260
20264
20151
20314
400078
DESC
Injector, 684
Clamp, "C"
Clamp, HS-12
Check Valve, 1/4"
Screw, #8 x 3/4 SMS
Hose, 1/4" PBT
Hose, 3/4" CVT
Saddle Tee Assembly
1/2" Pipe Adapter
Neoprene Gasket
PZ7 INSTALLATION WITH BYPASS VENTURI INJECTOR
•
•
•
Before beginning installation, please refer to the Installation Kit parts list and verify that all listed parts are on hand.
Tools Needed: 7/8" Hole Saw, Tube Cutter, Screw Driver, Pliers, Wall Mount Screw Anchors, Knife, Teflon Tape
Additional information is available at www.prozoneint.com
Venturi Injector
Venturi Injector
Upper saddle tee
Upper saddle tee
Screws
Screws
Rubber Grommet
Note orientation
for 2” return line
Rubber Grommet
Note orientation for
1-1/2” return line
Neoprene Gasket
7/8” Drilled Hole
Nuts
Neoprene Gasket
7/8” Drilled Hole
Lower saddle tee
2” RETURN LINE
ASSEMBLY
1-1/2” Bushing
Nuts
Lower saddle tee
1-1/2” RETURN LINE
ASSEMBLY
BYPASS INSTALLATION FOR 2 OR 1-1/2 INCH HARD-PLUMBED POOL
For 2" return line
1. Directly after the pump and before the filter, mark a hole location on top of the pipe using the upper potion of a saddle tee as a guide.
2. After all existing equipment (including heater, chlorinator, etc), mark the second hole location using a saddle tee as a guide.
3. Using a 7/8" hole saw drill holes in the locations marked above. Do not use a flat blade as it may crack the pipe.
4. On the inside of the upper portion of the saddle tees, place the rubber grommet into the hole with the small diameter section directed up away from the pipe.
5. Place the neoprene gasket directly over the drilled holes in the return lines.
6. Assemble the saddle tees over the drilled holes and attach with the provided screws and nuts loosely inserted into their holes.
For 1-1/2" return line
1. Directly after the pump and before the filter, mark a hole location on top of the pipe using the upper potion of a 1-1/2" saddle tee adapter as a guide.
2. After all existing equipment (including heater, chlorinator, etc), mark the second hole location using a saddle tee adapter as a guide.
3. Using a 7/8" hole saw, drill holes in the locations marked above. Do not use a flat blade as it may crack the pipe.
4. On the inside of the upper portion of the saddle tees, place the rubber grommet into the hole with the small diameter section directed towards the pipe place the 1-1/2" adapter
over the small diameter section of the grommet.
5. Place the neoprene gasket directly over the drilled holes in the return lines.
6. Assemble the saddle tees over the drilled holes and attach with the provided screws and nuts loosely inserted into their holes.
Continue the installation
7. Insert the INLET end of the injector directly into the saddle adapter next to the pump and tighten screws.
8. Insert the 1/2“ pipe adapter into the other saddle adapter and tighten screws.
9. Insert the opposite end of the venturi injector into one end of 3/4 inch clear vinyl hose (8') and secure with a clamp.
10. Attach the loose end of the 3/4 inch hose to the 1/2“ pipe adapter, 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.
PZ7 Saddle Tee Kit
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OPERATION
A. PROZONE PZ7 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
PROBLEM
No light from Prozone unit
No bubbles from injector
Water in Ozone Generator
Cloudy water; foamy water; scum
PROBABLE CAUSE
Loose wiring
No power to unit
Defective lamp or other internal component
REMEDY
Check all wiring connections
Voltage compatibility
Check power source
Return unit to dealer
Excessive back pressure at pool return
Check for restrictions at pool wall returns
Filter not working
Check filter
Check valve failure
Verify check valve in venturi is operating properly
High back pressure on return line
Check for restrictions in line
Water chemistry out of balance
Total Dissolved Solids (TDS) level too high
Check readings and balance accordingly
Refer to dealer for proper water testing
Filter not working
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 a 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.
PZ7 Saddle Tee Kit
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FOR 1 1/2 INCH PVC POOL
PLUMBING INJECTOR CONNECTION
FOR 2 INCH PVC POOL
PLUMBING INJECTOR CONNECTION
20314-TUBE
20314-TUBE
20109-SCREW
20109-SCREW
20151-UPPER SADDLE TEE
20151-UPPER SADDLE TEE
GROMMET
NOTE ORIENTATION
IS REVERSE OF 2"
ASSEMBLY
201114-BUSHING (UPPER)
GROMMET
400078-NEOPRENE GASKET
NOTE ORIENTATION
IS REVERSE OF 1 1/2"
ASSEMBLY
400078-NEOPRENE GASKET
201114-BUSHING (LOWER)
7/8 INCH DIA. HOLE
20151-LOWER SADDLE TEE
20151-LOWER SADDLE TEE
#8 NUTS
#8 NUTS
DRAWING A-3
DRAWING A-4
PZ7 Saddle Tee Kit
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