T.O3 NATURAL TECHNOLOGY
Reduces Chemical Usage,
Improves Sanitation
Produces Crystal Clear Water
Prozone Water Products: 2610 6th Street SW ·Huntsville, AL 35805·256-539-4570·www.prozoneint.com
Copyright 2007
PZ4
Ozone Generator Systems
- Residential Pools up to 15,000 Gallons
INSTALLATION GUIDE and
OPERATION MANUAL
20350
P Z 4
IMPORTANT SAFETY INSTRUCTIONS
Read and Follow All Safety Instructions
• Read and be familiar with this manual before installing or operating your new PZ4.
• Voltage must be determined before unit is installed.
• Replace damaged cord immediately.
• Do not bury cord.
• Connect only to a properly grounded, grounding type receptacle.
• 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. Install to
provide drainage of compartment for electrical components.
• Wear safety glasses when drilling and tapping holes for installation of unit.
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.
WARNING: Disconnect all power to pool equipment prior to installation, maintenance,
or removal of the PZ4.
WARNING: Do not permit children to operate this product
WARNING: To avoid risk of electric shock, fire, or injury, service should only be performed
by a qualified pool service professional.
WARNING: Installation must be performed in accordance with the National Electric Code
and any applicable local or state installation codes.
WARNING: When mixing acid with water, ALWAYS ADD ACID TO WATER, NEVER
WATER TO ACID.
NOTE: The instructions in this document provide general installation guides. Consult your dealer for specific installation instructions.
Additional information is available 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 turn to the Installation Kit Inventory
Section and verify that all listed parts are on hand.
Tools Needed: Power Drill with 7/8” hole saw, Screw Driver, Pliers, Knife
SAVE THESE INSTRUCTIONS
2
Installation
P Z 4
INTRODUCTION TO OZONE
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 that draws
the ozone into the venturi, mixing the bubbles as the water returns to the pool. It is operated automatically by connecting 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 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, it oxidizes a
large portion of the contaminants (usually referred to as bather load) which results 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. Baquacil may also be used in conjunction with the
Prozone system for water sanitation. Refer to the Baquacil manual for shocking instructions.
PREPARING FOR INSTALLATION
1.
Check for and correct all leaks in plumbing.
2.
3.
4.
5.
Balance the pH.
Backwash the filter on retrofit installation.
Shock the pool. The use of Calcium Hypochlorite is recommended, or hydrogen peroxide if Baquacil is used.
CAUTION: Make sure voltage is the same as prescribed on the side of the Prozone Ozone Generator.
The Table below summarizes the levels that are recommended by The Association of Pool and Spa Professionals
(APSP). It is important to maintain these levels in order to prevent corrosion or scaling and to ensure maximum enjoyment
of the pool. Test your water periodically. Take a water sample in to be professionally tested by a Pool and Spa
Professional at least once a month. See our web site for more information on Basic Pool Water Chemistry.
pH 7.2 – 7.6
Alkalinity 80 – 120 ppm
TDS < 1,000
Cyanuric Acid 30 – 70 ppm
Free Chlorine 0.5 – 1.5 ppm
Calcium Hardness 60 – 400 ppm
Metals 0 ppm
Nitrates / Phosphates < 30 ppm
SADDLE CLAMP ASSEMBLY
For bypass Entrance, (before Ball Valve)
Using 1-1/2” pipe, Assemble:
Venturi Injector (Note direction)
Saddle Clamp Top & Bottom
Top & Bottom Adapters
Bushing (Note direction)
Gasket
Screws (2)
Nuts (2)
Venturi Injector
(600207)
Screw (2)
(201863)
Saddle Clamp Top
(201155-4)
Bushing
(201155-5)
Top Adapter
(201155-2)
Gasket
(400076)
7/8” Dia. Hole
Bottom Adapter
(201155-3)
Saddle Clamp Bottom
(201155)
1/4-20 Nut (2)
(20703)
For bypass Exit, (after Ball Valve)
Using 1-1/2” pipe, Assemble:
PVC Pipe
Saddle Clamp Top & Bottom
Top & Bottom Adapters
Bushing (Note direction)
Gasket
Screws (2)
Nuts (2)
Note: For 2” pipe, do not use 1-1/2” adapters
and gasket and turn Bushings so small end
points toward Injector (for Entrance)
or PVC Pipe (for Exit).
3
PVC Pipe
(20314)
Screw (2)
(201863)
Saddle Clamp Top
(201155-4)
Bushing
(201155-5)
Top Adapter
(201155-2)
Gasket
(400076)
7/8” Dia. Hole
Bottom Adapter
(201155-3)
Saddle Clamp Bottom
(201155)
1/4-20 Nut (2)
(20703)
INSTALLATION ASSEMBLY USING
P24 STANDARD ABOVE GROUND KIT
Air
Flow
P Z 4
Above Ground Pool Installation
7/8” Hole Saw
¼” Hose
¾” Hose
Flow
Check Valve
¼” Hose
Injector
Pump
PZ4
1.
Turn pump OFF.
Locate section of existing plumbing in which you choose to install the ENTRANCE leg of the bypass. Location should be in any
2.
accessible area after the pump, but before the filter.
Install Saddle Clamp Top & Bottom, (and adapters if needed), without Bushing, (this will be used as a guide for your installation hole).
3.
4.
Drill a 7/8” hole through one wall of the pipe, using power drill, being careful not to drill too deep to avoid penetrating the opposite side
of the plumbing.
Remove the Saddle Clamp Assembly.
5.
Using components listed, mount the Saddle Clamp Assembly on Entrance bypass location with the INLET side of the Venturi Injector
6.
mounted in the Saddle Clamp Bushing, (ozone ports should be facing upward), and tighten both screws.
1½” Polybraid Tubing over the 1½” barb on the OUTLET side of the filter, (remove existing hose if necessary).
Place
7.
Place one end of the
8.
filter. Secure both ends of the
Attach one end of
9.
¾” barb on the PVC Tee and secure with a metal clamp.
Cut a 6” length of
10.
end to the OUTLET side of the Check Valve, (Make sure you can blow air through the Check Valve towards the Injector port). Secure
both ends with black plastic clamps.
Connect the remaining section of
11.
the PZ4 Ozone Generator. Secure both ends with black plastic clamps.
Install the PZ4 Ozone Generator on base of pump pack using the metal screws and washers.
12.
Connect the PZ4 Ozone Generator system to the circulation pump or timer. The Prozone system and the circulation pump should
13.
start simultaneously. Use N.E.C. or local code grounding and installation procedures for swimming pool equipment.
¼” Polybraid Hose and connect one end to the open ozone port (Marked #1) on the Venturi Injector and the other
Clamp
Filter
Saddle Clamp
Assembly
Water Flow
1½” PVC Tee into the 1½” Polybraid hose and the other end into the system tubing which was removed from the
1½” Hose with the large metal hose clamps.
¾” Clear Hose the Venturi Injector and secure with a metal clamp. Attach other end of the ¾“ Clear Hose to the
¼” Polybraid Hose to the INLET side of the Check Valve and the other end to the barb on top of
Clamp
1½” Hose
1½” x 1½” x ¾”
Hose Barb Tee
Clamps
CAUTION: Make sure the voltage is the same as prescribed on the side of the Prozone ozone generator. Overvoltage will void
customer warranty.
4
P Z 4
In-Ground Pool Installation
INSTALLATION ASSEMBLY USING
P15 STANDARD IN-GROUND KIT
Check Valve
¼” Hose
PZ4
Air
Flow
¼” Hose
Injector
Pump
Saddle Clamp
Assembly
7/8” Hole Saw
¾” Hose
Flow
Clamp
Filter
Water Flow
Clamp
Saddle Clamp
Assembly
1.
Turn pump OFF.
Locate section of existing plumbing in which you choose to install the ENTRANCE leg of the bypass. Location should be in any
2.
accessible area after the pump, but before the filter.
Install Saddle Clamp Top & Bottom, (and adapters if needed), without Bushing, (this will be used as a guide for your installation hole).
3.
4.
Drill a 7/8” hole through one wall of the pipe, using power drill, being careful not to drill too deep to avoid penetrating the opposite side
of the plumbing.
5.
Locate section of existing plumbing in which you choose to install the EXIT leg of the bypass. Location should be in any accessible
area after the filter, and heater (if equipped).
6.
Repeat steps 3 & 4.
7.
Remove both Saddle Clamp Assemblies.
8.
Using components listed, mount one Saddle Clamp Assembly on Entrance bypass location with the INLET side of the Venturi Injector
mounted in the Saddle Clamp Bushing, (ozone ports should be facing upward).
9.
Using components listed, mount the other Saddle Clamp Assembly on Exit bypass location with the ½” x 3” PVC pipe mounted in the
Saddle Clamp Bushing.
10.
Attach one end of ¾” clear hose to Venturi Injector and secure with a metal clamp. Attach other end of ¾”clear hose to ½” x 3” PVC
pipe and secure with a metal clamp.
11.
Cut a 6” length of ¼” Polybraid Hose and connect one end to the open ozone port (Marked #1) on the Venturi Injector and the other
end to the OUTLET side of the Check Valve, (Make sure you can blow air through the Check Valve towards the Injector port). Secure
both ends with black plastic clamps.
12.
Connect the remaining section of
the PZ4 Ozone Generator. Secure both ends with black plastic clamps.
13.
Install the PZ4 Ozone Generator on base of pump pack using the metal screws and washers.
14.
Connect the PZ4 Ozone Generator system to the circulation pump or timer. The Prozone system and the circulation pump should
start simultaneously. Use N.E.C. or local code grounding and installation procedures for swimming pool equipment.
¼” Polybraid Hose to the INLET side of the Check Valve and the other end to the barb on top of
CAUTION: Make sure the voltage is the same as prescribed on the side of the Prozone ozone generator. Overvoltage will void
customer warranty.
5
6
P Z 4
Inventory Lists & Troubleshooting
Quantity
1
4
2
72”
96”
1
1
4
2
2
2
2
2
2
4
4
Description
Part Number
Quantity
684 Venturi Injector
600002
1
Plastic Clamp ½”
20185
4
Metal Clamp 1-¼”
20067
2
Metal Clamp 2”
20069
2
Polybraid Hose ¼”
20260
72”
Clear Vinyl Hose ¾”
20264
72”
Polybraid Hose 1½”
201828
6”
Check Valve
20214
1
PVC Fitting 1½” x 1½” x ¾” HB
201141
1
Screw #8 x ¾” PPSMS
20109
3
Washer #10
20085
3
Wire Tie 6”
20728
3
Saddle Clamp, Outer Top
201155-4
1
Saddle Clamp, Outer Bottom
201155
1
Saddle Clamp, Inner Top
201155-2
1
Saddle Clamp, Inner Bottom
201155-3
1
Saddle Clamp Gasket
400076
1
Saddle Clamp Bushing
201155-5
1
Screw #14 x 1-½” PPMS
201863
2
Nut ¼-20
20703
2
INSTALLATION KIT INVENTORY
P24 Installation Kit
PZ4 Standard Above Ground Pool
P15
Installation Kit
PZ4 Standard In-Ground Pool
Description Part Number
684 Venturi Injector 600002
Plastic Clamp ½” 20185
Metal Clamp 1-¼” 20067
Polybraid Hose ¼” 20260
Clear Vinyl Hose ¾” 20264
Check Valve 20214
PVC Pipe ½” x 3” 20314
Screw #8 x ¾” PPSMS 20109
Saddle Clamp, Outer Top 201155-4
Saddle Clamp, Outer Bottom 201155
Saddle Clamp, Inner Top 201155-2
Saddle Clamp, Inner Bottom 201155-3
Saddle Clamp Gasket 400076
Saddle Clamp Bushing 201155-5
Screw #14 x 1-½” PPMS 201863
Nut ¼-20 20703
TROUBLESHOOTING GUIDE
PROBLEM PROBABLE CAUSE REMEDY
No light from Prozone unit
No bubbles from injector or
no evidence of ozone in pool
Water in Ozone Generator Check Valve failure Verify Check Valve in Venturi is operating properly
Cloudy water; foamy water; scum
NOTE: Cloudy water may occur when the ozone generator is started. Filter and backwash as necessary.
Loose wiring Check all wiring connections
No power to unit
Defective lamp or other internal component Return unit to dealer
Excessive back pressure Check for kinks or clogs in hose or plumbing
Leak in fitting Replace fitting
Filter not working Check filter
Water chemistry out of balance Check readings and balance accordingly
Total Dissolved Solids (TDS) level too high Refer to dealer for proper water testing
Filter not working Clean or replace filter
Check voltage compatibility
Check power source
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