Prozone PZ7 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
PZ7
Ozone Generator Systems
INSTALLATION GUIDE and
OPERATION MANUAL
- Residential Pools up to 40,000 Gallons
20352-1

2
IMPORTANT SAFETY INSTRUCTIONS
Read and Follow All Safety Instructions
WARNING: Disconnect all power to pool equipment prior to installation, maintenance,
or removal of the PZ7.
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
PZ7
• Read and be familiar with this manual before installing or operating your new PZ7.
• 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.
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

PZ7
Installation
3
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.
2.
3.
4.
5.
Check for and correct all leaks in plumbing.
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
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).
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)
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)
Venturi Injector
(600002)
Screw (2)
(201863)
Saddle Clamp Top
(201155-4)
Saddle Clamp Bottom
(201155)
Bushing
(201155-5)
Top Adapter
(201155-2)
Bottom Adapter
(201155-3)
Gasket
(400076)
7/8” Dia. Hole
1/4-20 Nut (2)
(20703)
PVC Pipe
(20314)
Screw (2)
(201863)
Saddle Clamp Top
(201155-4)
Saddle Clamp Bottom
(201155)
Bushing
(201155-5)
Top Adapter
(201155-2)
Bottom Adapter
(201155-3)
Gasket
(400076)
7/8” Dia. Hole
1/4-20 Nut (2)
(20703)

4
PZ7
Saddle Clamp Installation
CAUTION: Make sure the voltage is the same as prescribed on the side of the Prozone ozone generator. Overvoltage will void
customer warranty.
7/8” Hole Saw
INSTALLATION ASSEMBLY USING
P15 SADDLE CLAMP KIT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
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
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).
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.
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).
Repeat steps 3 & 4.
Remove both Saddle Clamp Assemblies.
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). Tighten both screws.
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. Tighten both screws.
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.
Mount the PZ7 Ozone Generator on a wall or surface at least 1 foot above maximum water level to prevent water from contacting the
electrical equipment. Unit orientation will not affect performance.
Electrical Installation: Your Prozone PZ7 System is designed to operate on 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.
NOTE: If your filtration system uses a Diatemateous Earth (DE) or cartridge filter, install a ¾” Ball Valve (not included) in the ¾” Hose on the
output side of the Venturi Injector as shown. This allows the bypass to be closed when back flushing or adding DE. It may be necessary to
install a Ball Valve (not included) in the main line between the Entrance and Exit of the bypass, (entire installation is moved after filter or heater
if equipped). The Ball Valve will need to be adjusted to ensure adequate flow through the bypass.
Pump
Filter Heater
Pool
Bypass
Entrance
¾” Hose
Bypass
Exit
¼” Hose
Check Valve
¾” Ball Valve
(If using a DE filter)
Venturi Injector
¼” Hose
PZ7
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.
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 side of
the PZ7 Ozone Generator. Secure both ends with black plastic clamps.

5
PZ7
PVC Tees Installation
INSTALLATION ASSEMBLY USING
P11 PVC TEES KIT
CAUTION: Make sure the voltage is the same as prescribed on the side of the Prozone ozone generator. Overvoltage will void
customer warranty.
Pump
Filter Heater
Pool
Bypass
Entrance
¾” Hose
Bypass
Exit
¼” Hose
Check Valve
¾” Ball Valve
(If using a DE filter)
Turn pump OFF.
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.
Install a PVC Tee that has ¾ FPT, with the threaded portion of the Tee facing upward.
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).
Install a PVC Tee that has ¾ FPT, with the threaded portion of the Tee facing upward.
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 installed in steps 3 and 5.
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.
Connect the other end of the 6” hose to the INLET side of the Venturi Injector and secure with a metal clamp.
Attach one end of the remaining ¾” hose to the OUTLET side of the Venturi Injector and secure with a metal clamp.
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.
PVC Tee PVC Tee
Venturi Injector
¼” Hose
PZ7
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Mount the PZ7 Ozone Generator on a wall or surface at least 1 foot above maximum water level to prevent water from contacting the
electrical equipment. Unit orientation will not affect performance.
NOTE: If your filtration system uses a Diatemateous Earth (DE) or cartridge filter, install a ¾” Ball Valve (not included) in the ¾” Hose on the
output side of the Venturi Injector as shown. This allows the bypass to be closed when back flushing or adding DE. It may be necessary to
install a Ball Valve (not included) in the main line between the Entrance and Exit of the bypass, (entire installation is moved after filter or heater
if equipped). The Ball Valve will need to be adjusted to ensure adequate flow through the bypass.
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.
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 side of
the PZ7 Ozone Generator. Secure both ends with black plastic clamps.
Electrical Installation: Your Prozone PZ7 System is designed to operate on 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.

6
PZ7
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 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.
P15 Saddle Clamp Installation Kit
P11 PVC Tees Installation Kit
Description
Part Number
Quantity
684 Venturi Injector
600002
1
Plastic Clamp ½”
20185
4
Metal Clamp 1¼”
20067
2
Polybraid Hose ¼”
20260
72”
Clear Vinyl Hose ¾”
20264
96”
Check Valve
20214
1
PVC Pipe ½” x 3”
20314
1
Screw # 8 x ¾” PPSMS
20109
4
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 1½” PPMS
201863
4
Nut ¼-20
20703
4
Description
Part Number
Quantity
684 Venturi Injector
600002
1
Plastic Clamp ½”
20185
4
Metal Clamp 1¼”
20067
4
Polybraid Hose ¼”
20260
72”
Clear Vinyl Hose ¾”
20264
96”
Check Valve
20214
1
PVC Fitting 2” SL x ¾” FPT
201095
2
PVC Fitting 2” SP x 1½” SL
201114
4
PVC Fitting ¾” MPT x HB
20678
2
Screw # 8 x ¾” PPSMS
20109
4