Prozone PZ2-4 Thru PZ2-16 User manual

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
PZ2-4 Thru PZ2-16
Ozone Generator Systems
INSTALLATION GUIDE and
OPERATION MANUAL
- Commercial and Residential Pools
20348A

2IMPORTANT SAFETY INSTRUCTIONS
Read and Follow All Safety Instructions
WARNING: Disconnect all power to pool equipment prior to installation, maintenance,
or removal of the PZ2.
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
P Z 2 - 4 T h r u P Z 2 - 1 6
• Read and be familiar with this manual before installing, operating, or performing maintenance on the PZ2.
• 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.
• A pressure wire connector is provided in the control box inside the unit to permit connection of a minimum No. 8
AWG solid copper bonding conductor between this point and any metal equipment, metal enclosures of electrical
equipment, metal water pipe, or conduit within 5 feet of the unit as needed to comply with local requirements.
• 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.฀

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Installation
3
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. Install your PZ2 Ozonator so that dust, sand, debris, chemicals, or other foreign objects are not sucked into the
compressor's intake fan or hose (if equipped with Noise Attenuator).
2. Check electrical system: 240VAC double switched per N.E.C. standards; 120VAC single switched.
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 with a non-lithium-based material. The use of Calcium Hypochlorite or Sodium Hypochlorite is recommended.
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
INSTALLATION
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: Cordless Power Drill, Screw Driver, Adjustable Wrench, Pliers, Wall Mount Screw Anchors, Knife ฀

4
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Bypass / Venturi Injection Installation
Pump
Filter Heater
Pool
Bypass
Entrance
¾” Hose
Bypass
Exit
¼” Hose
Check Valve
Note: If using a Diatemateous Earth filter, install a ¾” ball valve in the ¾” hose line to the output side of the Venturi, as shown.
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¾” Ball Valve
(If using a DE filter)
1. Turn pump OFF.
2. Locate section of plumbing in which you choose to install the ENTRANCE leg of the bypass. Location should be in any
accessible area after the pump, but before the filter.
3. Install a PVC Tee that has ¾ FPT, with the threaded portion of the Tee facing upward, or an alternate method is to drill and tap
your existing plumbing for a ¾ FPT.
4. Locate section of 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).
5. Install a PVC Tee that has ¾ FPT, with the threaded portion of the Tee facing upward, or an alternate method is to drill and tap
your existing plumbing for a ¾ FPT.
6. Apply Teflon tape to the threads of the (2) ¾” MPT x ¾” HB fittings, part number 20678, and screw the fittings into the (2) PVC
Tees you just installed, (or the pipe you drilled and tapped in steps 3 and 5).
7. Cut a 6” length of ¾” hose and connect one end to the fitting on the entrance side of the bypass, (after the pump, before the
filter), and secure with a metal clamp.
8. Connect the other end of the 6” hose to the INLET side of the Venturi Injector and secure with a metal clamp.
9. Attach one end of the remaining ¾” hose to the OUTLET side of the Venturi Injector and secure with a metal clamp.
10. Attach other end of ¾” hose to the fitting on the exit side of the bypass, (after the filter/heater), and secure with a metal clamp.
11. Mount the PZ2 Ozone Generator(s) vertically on a wall with the compressor unit next to the Ozone Generator(s). Place system
at or above water level. If unit must be mounted below water level, loop the hose so that at some point it is above water level
(a solenoid control valve may be necessary).
12. Apply Teflon tape to the threads of the ½” MPT x ⅜” HB fitting, part number 20231, and screw it into the end of the Check
Valve that has the spring in it, (This is the INLET side of the Check Valve). Mark this end as “INLET”.
13. Apply Teflon tape to the threads of the ½” MPT x ¼” HB fitting, part number 20230, and screw it into the opposite end of the
Check Valve. (This is the OUTLET side of the Check Valve). Mark the end as “OUTLET”.
14. Cut a 6 inch length of ¼” hose and connect one end to the OUTLET side of the Check Valve (with the ¼” hose barb fitting) and
the other end to the open ozone port on the Venturi Injector (Marked #1). Secure with plastic clamps.
15. Cut a length of ⅜” braided hose long enough to reach between the Ozone Generator(s) and Check Valve.
16. Attach one end of the ⅜” braided hose to the Ozone Generator(s) and the other end to the INLET side of the Check Valve
and secure ends with plastic clamps.
17. Cut a length of ⅜” braided hose long enough to reach between the Ozone Generator(s) and compressor unit.
18. Attach this length of hose from the compressor unit to the Ozone Generator(s) and secure with plastic clamps.
19. Electrical Installation: System is either 120 or 240 VAC, 50/60 HZ. Wire Prozone ozone generator system to circulation pump switch
or timer. Prozone system and circulation pump should be started simultaneously. Use N.E.C. or local code grounding and
installation procedures for swimming pool equipment.
CAUTION: Make sure the voltage is the same as prescribed on the side of the Prozone ozone generator. Overvoltage will void
customer warranty.
⅜” Hose
PVC Tee PVC Tee
Venturi Injector
PZ2-4 PZ2-6 PZ2-8 PZ2-12 PZ2-16

5
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Direct Injection Installation
Pump
Filter Heater
Pool
⅜” Hose
Check Valve
PVC Tee
PZ2-4 PZ2-6 PZ2-8 PZ2-12 PZ2-16
⅜” Hose
NOTE: There must be at least four feet of return line between the point where the ozone bubbles are injected and the pool. If there is
not four feet of return available, a flexible loop can be added to the return line.
1. Turn pump OFF.
2. Locate section of plumbing in which you choose to install the Direct Injection Fitting. Location should be in any accessible area
after the pump, filter, and heater, (if equipped).
3. Install a PVC Tee that has ¾ FPT, with the threaded portion of the Tee facing upward, or an alternate method is to drill and tap
your existing plumbing for a ¾ FPT, (Or ½ FPT and eliminate the PVC adapter fitting, part number 20303).
4. Apply Teflon tape to the threads of a ½” MPT x ⅜” HB fitting, part number 20231, and screw the fitting into the PVC adapter
fitting, ¾” MPT x ½” FPT, part number 20303.
5. Apply Teflon tape to the threads of the ¾” MPT x ½”FPT fitting, part number 20303, and screw the fitting into the PVC Tee you
just installed, (or the pipe you drilled and tapped in step 3).
6. Mount the PZ2 Ozone Generator(s) vertically on a wall with the compressor unit next to the Ozone Generator(s). Place system
at or above water level. If unit must be mounted below water level, loop the hose so that at some point it is above water level
(a solenoid control valve may be necessary).
7. Apply Teflon tape to the threads of a ½” MPT x ⅜” HB fitting, part number 20231, and screw it into the end of the Check Valve
that has the spring in it, (This is the INLET side of the Check Valve). Mark this end as “INLET”.
8. Apply Teflon tape to the threads of a ½” MPT x ⅜” HB fitting, part number 20231, and screw it into the opposite end of the
Check Valve, (This is the OUTLET side of the Check Valve). Mark this end as “OUTLET”.
9. Cut a 6 inch length of ⅜” braided hose and connect one end to the OUTLET side of the Check Valve and the other end to the
⅜” HB fitting you installed in your plumbing. Secure with plastic clamps.
10. Cut a length of ⅜” braided hose long enough to reach between the Ozone Generator(s) and Check Valve.
11. Attach one end of the ⅜” braided hose to the Ozone Generator(s) and the other end to the INLET side of the Check Valve
and secure ends with plastic clamps.
12. Cut a length of ⅜” braided hose long enough to reach between the Ozone Generator(s) and compressor unit.
13. Attach this length of hose from the compressor unit to the Ozone Generator(s) and secure with plastic clamps.
14. Electrical Installation: System is either 120 or 240 VAC, 50/60 HZ. Wire Prozone Ozone Generator system to circulation pump switch
or timer. Prozone system and circulation pump should be started simultaneously. Use N.E.C. or local code grounding and
installation procedures for swimming pool equipment.
CAUTION: Make sure the voltage is the same as prescribed on the side of the Prozone Ozone Generator. Overvoltage will void
customer warranty.

6
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Inventory Lists & Troubleshooting
PZ2 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. The
ozone is introduced into the water either by direct injection or through a bypass venturi system. For direct injection, the venturi injector
is inserted directly into the return line of the pool creating a suction (vacuum) that draws the ozone into the venturi as the water returns
to the pool. The 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. A check valve is employed to prevent water backup in the event of system failure. The system should be run 6-8 hours per day for
best effect. Run time may vary depending on usage.
INSTALLATION KIT INVENTORY
Note: For pools using a 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.
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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. Filter and backwash as necessary.
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P13 Installation Kit
PZ2-4 Thru PZ2-162 Series with Bypass / Venturi Injector
Description
Part Number
Quantity
884 Venturi Injector
600212
1
Plastic Clamp ½”
20185
2
Metal Clamp 1¼”
20067
4
Plastic Clamp ⅝”
20186
18
Polybraid Hose ¼”
20260
12”
Polybraid Hose ⅜”
20261
240”
Clear Hose ¾”
20264
120”
Fitting ½” MPT x ⅜” HB
20231
1
Fitting ½” MPT x ¼” HB
20230
1
Check Valve ½”
20215
1
Fitting ¾” MPT x ¾” HB
20678
2
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D12 Installation Kit
PZ2-4 Thru PZ2-16 Series with Direct Injection
Description
Part Number
Quantity
Plastic Clamp ⅝”
20186
20
Polybraid Hose ⅜”
20261
240”
Fitting ½” MPT x ⅜” HB
20231
3
Check Valve ½”
20215
1
Fitting ¾” MPT x ½” FPT
20303
1
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