Prozone Water Products CSS5 series User manual

T.O3 NATURAL TECHNOLOGY
Reduces Chemical Usage,
Improves Sanitation
Produces Crystal Clear Water
Copyright 2007
CSS5
Prozone has combined ozone and salt together
in one Complete Sanitation System for Spas
INSTALLATION GUIDE and
OPERATION MANUAL
- Residential Spas up to 1,000 Gallons
201987
Prozone Water Products: 3004 11th Ave. - Huntsville, AL - 35805 Phone: [phone] Website: www.prozoneint.com

2IMPORTANT SAFETY INSTRUCTIONS
Read and Follow All Safety Instructions
WARNING: Disconnect all power to pool equipment prior to installation, maintenance,
or removal of the CSS 5.
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.
SAVE THESE INSTRUCTIONS
C S S 5
• Read and be familiar with this manual before installing or operating your new CSS 5.
• 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.
• 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.฀
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, Philips Screw Driver, Flat Screw Driver, Pliers, Knife ฀

C S S 5
Installation
3
INTRODUCTION TO OZONE
PREPARING YOUR SPA
Draining and refilling of your spa is recommended, but not required unless bromine or Baquaspa was previously used.
Shock spa to 20 ppm with chlorine shock. DO NOT use non-chlorine shock.
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 – 8.0
Alkalinity 80 – 120 ppm
TDS < 1,000
Cyanuric Acid 30 – 70 ppm
Free Chlorine 0.5 – 1.5 ppm
Calcium Hardness < 300 ppm
Metals 0 ppm
Nitrates / Phosphates < 30 ppm
Your CSS 5 System produces both ozone and chlorine. The Ozone Generator produces ozone with light energy, the way the sun does. Therefore
it is only emitting pure O3 ozone that has no harmful by-products, unlike other ozone generators that use corona technology which produce
nitrous acid compounds and other harmful byproducts. 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, naturally occurring oxidizer and sanitizer
readily available. Pioneers of the original ozone generator cartridge, produced the first Ultraviolet Ozone Generating cartridge in 1977 for the
swimming pool and spa industry. The O3, naturally produced ozone, generated by the CSS 5 System serves as the primary sanitizer and oxidizer,
however, a small residual of free available chlorine is required at all times to control algae growth and provide a residual sanitizer requirement.
The CSS 5 System provides the necessary chlorine residual for your spa. A measured amount of pool grade salt is dissolved in the spa water. The
Chlorine is made by passing a very low voltage electric current through the salt water as it flows through the Cell and back in to the spa.
The CSS 5 System (Advanced Oxidation Processor™) produces and combines ozone and chlorine. These super oxide compounds, even stronger
oxidizers than ozone or chlorine alone, are injected in to the spa water through a patented Venturi Injection system.
ADDING SALT
Mix required amount ot salt with warm water in a bucket or pitcher. Ensure it is thoughly mixed and pour the mixture into the
spa, distributing it evenly, away from the skimmers. Repeat as necessary to dissolve all salt required. Add salt when spa water
temperature is 75 degrees or higher to ensure it dissolves fully. Use the chart below to determine the amount of salt required
for your spa. It is recommended that 2,600 ppm be used as a starting point. If salt levels reach > 4,000 ppm, the unit will shut
down automatically. CSS System should be reset, by turning the system off then back on again after 10 seconds, when salt is
added to the spa. DO NOT USE: Table salt, Kosher salt, or any Food grade salt unless it specially states “for swimming pools”.
Use ONLY swimming pool salt which may be purchased at pool and spa dealers or home improvement stores.
Start-Up Salt Requirements
Spa Size (Gallons)
200 300 400 450 600
Salt (ppm) Pounds of salt required if starting at 0 ppm
1,600 2.7 4.0 5.3 6.0 8.0
1,800 3.0 4.5 6.0 6.8 9.0
2,000 3.3 5.0 6.7 7.5 10.0
2,200 3.7 5.5 7.3 8.3 11.0
2,400 4.0 6.0 8.0 9.0 12.0
2,600 4.3 6.5 8.7 9.8 13.0
2,800 4.7 7.0 9.3 10.5 14.0
3,000 5.0 7.5 10.0 11.3 15.0
3,200 5.3 8.0 10.7 12.0 16.0
3,400 5.7 8.5 11.3 12.8 17.0
3,600 6.0 9.0 12.0 13.5 18.0
3,800 6.3 9.5 12.7 14.3 19.0
4,000 6.7 10.0 13.4 15.0 20.0

4
C S S 5
Installation
CAUTION: Make sure the voltage is the same as prescribed on the side of the Prozone ozone generator. Overvoltage will void
customer warranty.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
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13.
Turn pump OFF.
Install the CSS5 System under the skirt of the spa or immediately next to it. The unit should be mounted on a solid surface with wood
or sheet metal screws. Make sure the screws do not penetrate the exterior of the spa skirt.
Most spa’s come equipped with a factory installed, capped or plugged bypass system. Locate the two capped or plugged ¾” hoses
and uncap/unplug them.
Insert the Venturi Injector into the ¾” hose, coming from the pump, with the INLET side of the Venturi Injector facing towards the pump
and secure with a metal clamp.
Cut a 6” length of ¾” hose.
Connect one end of this 6” length of ¾” hose to the outlet side of the Venturi Injector and secure with a metal clamp.
Insert one end of the Chlorine Generator Cell into the other end of the 6” length of ¾” hose and secure with a metal clamp.
Connect other end of the Chlorine Generator Cell to the ¾” hose going back into the spa return and secure with a metal clamp.
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 a plastic clamps.
Connect the remaining section of ¼” polybraid hose to the INLET side of the Check Valve and the other end to the barb on the top of
the CSS5 unit. Secure both ends with black plastic clamps.
Connect the two wires, in the gray casing, to the terminals on the Chlorine Generator Cell and cover with heat shrink tubing.
Connect the power cable to the controller unit on your spa.
Electrical Installation: Your Prozone CSS5 System is designed to operate on either 120 or 240 VAC, 50/60 HZ. Wire Prozone CSS5
System to the control box on your spa or to the circulation pump or a timer. Use N.E.C. or local code grounding and installation
procedures for pool and spa equipment.
NOTE: If the optional muriatic acid kit is to be installed, port #2 on the Injector must first be drilled out before ¼” hose is connected.
Pump
CSS5
¾” Hose
Check Valve
¼” Hose
¼” Hose, connects to Injector port #1
Injector
Water Flow
¼” Hose, connects to
Injector port #2
Optional
Muriatic Acid Kit
Chlorine Generator Cell
Spa

5
C S S 5
Start-Up & Operation
฀
START-UP
After salt has been added to your spa, it is recommended that the system be run for 48 hours to ensure adequate amount of chlorine is generated.
For outdoor spas, the addition of cyanuric acid will help stablize the chlorine level as chlorine is unstable and will evaporate out of the water over time.
Verify the ozonator is working by checking for a blue glow around the top and/or bottom of the gaskets between the end plates and body of the unit.
Monitor the filter closely during the initial start-up period. Depending on water quality, the ozonation process may generate considerable amounts of
precipitants which must be removed by filtration and may clog filter if not cleaned often during this stage.
After the 48 hour start-up period, backwash or clean the filter and perform a Cell cleaning.
฀
NORMAL OPERATION
CSS5-1: Chlorine levels are adjusted by increasing or decreasing the salt level in the spa.
CSS5-2: Chlorine levels are adjusted using the adjustment knob on top of the unit and maintaining recommended salt levels.
The recommended run time to generate adequate amounts of chlorine is 6-8 hours per day. Increased run times of 12 hours per day are
recommended for highly loaded spas. The system will generate chlorine and ozone ONLY when the spa pump is running.
The CSS System is designed to produce a low level of chlorine that ensures the spa has adequate disinfection. This quantity of chlorine can be
as much as 90 percent less than what is required in a chlorine-only spa with no ozonator.
Normal test kits measure chlorine residual (combined chlorine, which is chlorine combined with bather load). Since ozone will normally keep bather
load at very low levels, combined chlorines will be at very low levels, making detection difficult. For water testing, DPD liquid test kits work the best, as
opposed to test strips. The best idication of proper operation is water clarity. If cloudy or odorous conditions persist, drain or shock spa, check filter and
operate complete sanitation system continuously for 48 hours. To get an accurate chlorine reading, a water sample should be taken to your pool/spa
dealer for testing (test strips will not be accurate enough for this). Water should be tested every two weeks to maintain maximum water quality and
enjoyment.
Salt chlorine generators may naturally increase the pH of the spa. Monitor pH regularly and adjust if it is not between 7.2 and 7.6.
NOTE: The pH value is a very important factor for ensuring maximum chlorine readings. As pH increases above 8.0, chlorine readings will decrease
rapidly. Optimum pH is 7.6. Muriatic acid is used to reduce pH value and when added to the spa, using the optional acid injection kit, will help to keep
the Chlorine Generator Cell plates clean.
Water with high calcium levels will result in scaling of the Chlorine Generator Cell plates (high pH will worsen the effect of high calcium).
Shocking the spa is required periodically (normally about every 30-60 days) using dichloride. DO NOT use non-chlorine shock or calcium hypo-chloride.
CSS System should be reset, by turning the system off then back on again after 10 seconds, when salt is added to the spa.
Chlorine Generator Cell should be checked periodically for blockages or obstructions and cleaned as necessary.
฀
CLEANING THE CELL
The auto reversing feature of your CSS System will help to keep the Chlorine Generator Cell clean and will also generate percipitants.
Calcium build-up can occur on the edges of the chlorine generation plates. This is normal as long as it is not sufficient to block flow. If it appears
that calcium build-up will affect the water flow pattern, then the Cell can be cleaned as follows:
1. Detach ozone feed line to the Injector from the Check Valve.
2. Insert this end into a small bottle (4-6 oz) of DILUTED Muriatic acid while the spa is operating.
3. Allow suction to draw 4-6 onces of acid into the Cell and shut off circulation pump.
4. Allow system to sit for 5-10 minutes.
5. Reconnect ozone tube to Check Valve.
6. Restart system.
7. Alternately, Cell can be removed and dropped into a container of Muriatic acid.

6
C S S 5
Inventory Lists & Troubleshooting
INSTALLATION KIT INVENTORY
TROUBLESHOOTING GUIDE
PROBLEM PROBABLE CAUSE REMEDY
Loose wiring Check all wiring connections
No power to unit Check voltage compatibility
Check power source
No light from Prozone 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
No bubbles from injector or
no evidence of ozone in spa
Filter not working Check filter
Water in Ozone Generator Check Valve failure Verify Check Valve is installed properly with syphon loop
Water chemistry out of balance Check readings and balance accordingly
Total Dissolved Solids (TDS) level too high Refer to dealer for proper water testing
Cloudy water; foamy water; scum
Filter not working Clean or replace filter
NOTE: Cloudy water may occur when the ozone generator is started. Filter and backwash as necessary.
฀
P28 Installation Kit
Description Part Number Quantity
684 Venturi Injector 600002 1
Plastic Clamp ½” 20185 2
Metal Clamp 1¼” 20067 4
Polybraid Hose ¼” 20260 72”
Polybraid Hose ¾” 20264 96”
Check Valve 20214 1
Screw #8 x ¾” PPSMS 20109 4
WATER TREAMENT PROCESS
Water treatment is accomplished by two processes: Oxidation and Disinfection.
Oxidation: Oxidation is a process by which chlorine or ozone react with contaminants in the spa (referred to as bather loading). Bather loading
consists of sweat, mucus, oils, urine, cosmetics, and other contaminants shed by spa users. They worsen water quality and provide an enviroment
which promoters the growth of microorganisms. In a chlorine only spa, this reaction creates combined chlorines, which are the source of odors
and irritation. Combined chlorines are normally removed by a process called breakpoint clorination (shocking). Upwards of 90 percent of chlorine
can be consumed in oxidation reactions. Ozone, which is the most powerful oxidant available, replaces chlorine as the primary oxidant in the spa.
Ozone reacts with bather loading and precipitates it so that it can be removed by filtration and generates breakpoint oxidation continually on the
combined chlorine.
Disinfection: Disinfection is the process by which microorganisms are killed. Although most people associate water treatment with disinfection, it
actually consumes relatively little chlorine. Ozone is the most powerful sanitizer readily available.
Water Treatment: Water treatment equals oxidation plus disinfection. The CSS System provides both functions: Ozone for oxidation and
chlorine for disinfection. The system is designed so that ozone does most of the work in the water treatment process, at the point of contact.
The chlorination level is set so that only enough of a residual is produced to kill remaining microorganisms in the spa. The amount of chlorine
required for this process is very low, less then 0.5 ppm.

7
INSTALLATION KIT INVENTORY
TROUBLESHOOTING GUIDE
PROBLEM PROBABLE CAUSE REMEDY
Loose wiring Check all wiring connections
No power to unit Check voltage compatibility
Check power source
No light from Prozone 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
No bubbles from injector or
no evidence of ozone in pool
Filter not working Check filter
Water in Ozone Generator Check Valve failure Verify Check Valve in Venturi is operating properly
Water chemistry out of balance Check readings and balance accordingly
Total Dissolved Solids (TDS) level too high Refer to dealer for proper water testing
Cloudy water; foamy water; scum
Filter not working Clean or replace filter
NOTE: Cloudy water may occur when the ozone generator is started. Clean filter and backwash as necessary.
Run the circulation system for 48-72 hours before reverting to your normal cycle.
P12 Installation Kit
PZ2-4V Bypass with Saddle Clamps P33 Installation Kit PZ2-4V Bypass with PVC Tees
Note: For pools with Diatomaceous Earth filter and Bypass / Venturi Injector installation, add (1) ¾” Ball Valve, (2) ¾” MPT x HB fittings,
and (2) 1 ¼” metal clamps.
Description
Part Number
Quantity
784 Venturi Injector Assembly 600207 1
Plastic Clamp ½” 20185 2
Plastic Clamp ⅝” 20186 4
Metal Clamp 1-½” 20068 2
Polybraid Hose ¼” 20260 12”
Clear Vinyl Hose ¾” 20264 96”
Polybraid Hose ⅜” 20261 144”
Check Valve - ½” 20215 1
Check Valve - ⅜” 20730 1
Fitting ½” MPT x ¼” HB 20230 1
Fitting ½” MPT x ⅜” HB 20231 1
PVC Tee 2” SL x ¾” FPT 201095 2
PVC Fitting 2” SP x 1-½” SL 201114 4
PVC Fitting ¾” MPT x HB 20678 2
Description Part Number Quantity
784 Venturi Injector 600207 1
Plastic Clamp ½” 20185 2
Plastic Clamp ⅝” 20186 4
Metal Clamp 1-¼” 20067 2
PVC Pipe ½” x 3” 20314 1
Polybraid Hose ¼” 20260 12”
Clear Vinyl Hose ¾” 20264 96”
Polybraid Hose ⅜” 20261 144”
Check Valve - ½” 20215 1
Check Valve – ⅜” 20730 1
Fitting ½” MPT x ¼” HB 20230 1
Fitting ½” MPT x ⅜” HB 20231 1
Saddle Clamp, Outer Top 201155-4 2
Saddle Clamp, Outer Bottom 201155 2
Saddle Clamp, Inner Top 201155-2 2
Saddle Clamp, Inner Bottom 201155-3 2
Saddle Clamp Gasket 400076 2
Saddle Clamp Bushing 201155-5 2
Screw #14 x 1-½” PPMS 201863 4
Nut ¼-20 20703 4
C S S 5
Inventory Lists & Troubleshooting