Since 1977


Ozone & Advanced Oxidation Systems  

 

PZ1, PZ3 & PZ6 Installation Guide
Prozone Pool Products
2610 6th Street
Huntsville, Alabama 35806
Tele: (256) 539-4570
Fax: (256) 539-4225
 

Ozone Water Purification Systems

INSTALLATION GUIDE
Prozone PZ1, PZ3 and PZ6 Series
 

READ AND FOLLOW ALL INSTRUCTIONS.

IMPORTANT SAFETY INSTRUCTIONS
  1. All applicable electrical codes must be followed during and after installation. All connections to be made by a qualified electrician.
  2. Disconnect all power at the main circuit breaker before installing the PROZONE unit.
  3. WARNING - To reduce the risk of injury, do not permit children to use this product unless they are closely supervised at all times.
  4. DANGER - Risk of electric shock.
    1. Replace damaged cord immediately.
    2. Do not bury cord.
    3. Connect only to a properly grounded, grounding type receptacle.
  5. A wire connector is provided on the unit to connect a minimum No. 8 AWG (8.4 mm2) solid copper conductor between this unit and any metal equipment, metal enclosures of electrical equipment, metal water pipes, or conduit within 5 feet (1.5 m) of the unit.
  6. Wear safety glasses when drilling and tapping holes for installation of unit.
  7. 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 directly inhale ozone gas produced by this device.
  8. Turn off power at source breaker before servicing the unit.
  9. 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 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 spa 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 reduction of combined chlorines. 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. Check electrical system: timer set properly; 240VAC double switched per N.E.C. standards recommended; 120VAC single switched
  2. Check for and correct all leaks in plumbing.
  3. Check the filters: clean or replace.
  4. Add non-lithium-based shock. The use of Calcium Hypochlorite or Sodium Hypochlorite is recommended.
  5. For best results, drain water and fill with fresh water. It is easier to clean unused water, though the ozonator will still remove substantial impurities from fresh tap water!
  6. Start all equipment.

Note: For spas and other water containers not ozone-ready, or for temporary or simple installation, a PZV ozonator system may be purchased. With this system, a diffuser is inserted into the ozone generator output hose and the diffuser merely hung over the side of the spa.

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: Screw Driver, Pliers, Knife

PZ1, PZ3 & PZ6 SERIES FOR OZONE-READY SPAS




Install the Prozone Ozone Generator unit 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 screws do not penetrate the exterior of the spa skirt.

Spas With 1/4 Inch or 3/8 Inch Ozone Fitting

  1. Cut six (6) inches (15cm) (plus or minus 1 inch) off one end of the 1/4 inch or 3/8 inch hose.
  2. Attach one end of the 6 inch length of 1/4 inch or 3/8 inch hose to the ozone fitting or hose provided on the spa.
    NOTE: Virtually all spas manufactured today come with this ozone fitting or hose. If you are unable to locate it, attach the ozone feed line to one of the spa return lines nearest to the footwell using suitable plumbing fittings. This type installation may require adjustment of the air control for proper operation. Some spas may be configured for a bypass venturi injector type installation. See following section for suggested bypass venturi injector installation.
  3. Attach the other end of the 6 inch length of 1/4 inch or 3/8 inch hose to the check valve with flow towards the spa and secure with a clamp.
  4. Attach one end of the remaining 5 foot 6 inch (1.7m) length of 1/4 inch hose to the 1/4 inch ozone output fitting on the Prozone ozone generator and secure with a clamp.
  5. Make a loop in the hose and secure it above the water level of the spa. You may need to tie the hose up to keep it in place.
  6. Attach the remaining end of the hose to the inlet side of the check valve; secure with a clamp.
  7. (Optional) Some ozone generators have a small hole to accommodate a fiber optic (FO) cable which may be bought separately. One end of the FO is the indicator. On the other end strip approximately 3/4 inch insulation . Decide where you want to locate the indicator (usually some place on the spa control panel). Drill a 3/16 inch hole; insert FO cable through this hole until it stops. Route the cable under the skirt to the ozone generator and carefully insert it 3 to 5 inches into the hole next to the nipple located on the ballast end of ozone generator (PZ3). The PZ1 ozone generator has a small hole in the end plate or on side of case. Once the cable has been installed, apply a small amount of silicon cement under the indicator to secure it in place.
  8. System is 120 or 240 VAC, 50/60 HZ. Wire Prozone ozone generator system to the low speed side of the 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 spa equipment.

    CAUTION: Make sure the voltage is the same as prescribed on the side of the Prozone ozone generator. Overvoltage will void customer warranty. The supply cord cannot be replaced. If the cord is damaged the appliance should be scrapped.

PZ1, PZ3 & PZ6 WITH BYPASS VENTURI INJECTOR

Tools Needed: Pliers, Screwdriver, Knife






Note: This installation is for spas which have been plumbed for a bypass venturi injector type installation.
  1. Install the Prozone Ozone Generator unit 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 screws do not penetrate the exterior of the spa skirt.
  2. Locate the two capped or plugged 3/4 inch hoses and unplug them.
  3. If the venturi injector is model V3, insert the injector between the two hoses, making sure INPUT side is toward pump; secure with clamps. If Mazzie injector, make sure flow is away from the pump (an arrow on the side of the injector indicates flow direction).
  4. Cut a 6 inch length of 1/4 inch hose and attach one end to the ozone fitting on the injector. If V3 injector attach hose to port 1 (port 2 should be capped.) Attach other end of 6 inch hose to output side of check valve (flow away from ozone generator); secure with clamps.
  5. Attach one end of the remaining length (approximately 6 feet) of 1/4 inch hose to the ozone output fitting on the ozone generator; make a loop and secure it above the water level of the spa; attach the other end to the input side of the check valve (flow away from ozone generator); secure with clamps.
  6. Electrical Installation: System is 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 spa equipment.

    CAUTION:
    Make sure the voltage is the same as prescribed on the side of the Prozone ozone generator. Overvoltage will void customer warranty. The supply cord cannot be replaced. If the cord is damaged the appliance should be scrapped.

SPAS PLUMBED WITH PVC PIPE (BYPASS INSTALLATION)

Tools Needed: Cordless Electric Drill, ½ inch Drill Bit, Adjustable Wrench, Screwdriver, Pliers, Knife

  1. Directly after pump and before filter, attach one 1-1/2 inch or 2 inch brass saddle clamp using attached screws.
  2. After all existing equipment (including heater, chlorinator, etc), attach second 1-1/2 inch or 2 inch brass saddle clamp to return line using attached screws.
  3. Drill a 1/2 inch hole in the pipe through the hole in top of each saddle clamp.
  4. Apply Teflon tape to threaded end of each 3/4 inch mpt x 3/4 inch hb fitting.
  5. Screw these fittings snugly in top of each saddle clamp.
  6. Cut a 6 inch (15cm) length (plus or minus 1 inch) of 3/4 inch hose and install it on the barb fitting on the saddle clamp nearest to pump; secure with a clamp.
  7. If the venturi injector is model V3, insert the INPUT end of injector into 6 inch length of hose. If Mazzie injector, make sure flow is away from saddle; secure with a clamp; (an arrow on the side of injector indicates flow direction).
  8. Insert opposite end of venturi injector into remaining length of 3/4 inch hose and secure with screw-type clamp.
  9. Attach loose end of 3/4 inch hose to the barb fitting on the return line saddle clamp and secure with a clamp.
  10. Install the Prozone Ozone Generator unit 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 screws do not penetrate the exterior of the spa skirt.
  11. 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 ozone generator)and the other end to the ozone fitting on the venturi injector. If V3 injector attach hose to port 1 (port 2 should be capped); secure hose with clamps.
  12. Attach one end of the remaining length (approximately 6 feet) of 1/4 inch hose to the ozone fitting on the ozone generator; make a loop and secure it above the water level of the spa; attach the other end to the input side of the check valve; secure with clamps.
  13. Electrical Installation: System is 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 spa equipment.

    CAUTION: Make sure the voltage is the same as prescribed on the side of the Prozone ozone generator. Overvoltage will void customer warranty. The supply cord cannot be replaced. If the cord is damaged the appliance should be scrapped.

OPERATION

A. PROZONE PZ1, PZ3 & PZ6 SERIES OZONE GENERATOR OPERATION

The Prozone system produces ozone when air is drawn across a special high-energy vacuum ultraviolet (VUV) lamp, converting some air to ozone. The ozone is introduced into the water either by direct diffusion (sparging) or with a bypass venturi system. With direct diffusion, air/ozone is forced through a porous metal disk which creates extremely fine bubbles. As the bubbles rise, the ozone is absorbed into the water where it reacts. The ozone is introduced via the "ozone-ready" air venturi inherent in virtually all spas manufactured today. The ozonation process will occur only when the spa pump is running. This is the only time that suction is created to draw the ozone from the ozone generator into the spa water. The longer the spa pump runs in filtration cycle, the more ozone the spa water receives.

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.

Ideal daily operating time will vary between spas because of variables such as bather load, spa size, and application. As a minimum, the ozone generator should be run at least 6 hours per day.

B. WATER CHEMISTRY

  • 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 Hypoclorite or Sodium Hypochlorite, etc.

The use of other chemicals is not usually required and they could cloud the spa water.

TROUBLESHOOTING
PROBLEM  PROBABLE CAUSE REMEDY
No light from Prozone unit Power not connected

No power to unit



Defective lamp or other internal component

Check electrical connections, Voltage Incompatibility

Check power source

Return unit to dealer

No bubbles from injector

or no evidence of ozone in spa

Air control leaks

No suction to unit

Filter not working

Tighten air control

Size jet orifices properly

Clean/replace filter

Cloudy water Ozone generator operation time too short

Water chemistry out of balance

Total Dissolved Solids (TDS) level too high

Filter not working

Increase operation time

Check readings and balance accordingly

Refer to dealer for proper water testing

Clean or replace filter

INSTALLATION KIT INVENTORY

PZ1, PZ3 & PZ6 SERIES FOR OZONE-READY SPAS

Hose, Polybraid, 1/4 or 3/8 inch 6 feet (1.82m) Valve, Check, 1/4 inch or 1/4 X 3/8 inch 1 each
Clamp, Plastic, Black, 0.500 or 0.626 inch 4 each Screw SST, #8 x 3/4 inch 4 each
(Optional) Fiber Optic 3 feet (.91m)

PZ1, PZ3 & PZ6 SERIES FOR SPAS PLUMBED WITH PVC PIPE ( BYPASS INSTALLATION)

 
Tee, Saddle, 1-1/2 or 2 inch x 3/4 inch 2 each Injector, 3/4 inch HB 1 each
Hose, Polybraid, 1/4 inch 6 feet (1.82m) Hose, Clear Vinyl, 3/4 inch 8 feet
Fitting, 3/4 inch MPT x 3/4 inch HB 2 each Clamp, Hose, Metal, 1.25 inch 4 each
Clamp, Plastic, Black, 0.500 inch 2 each Screw, SST, #8 x 3/4 inch PPSMS 4 each
(Optional) Fiber Optic 3 feet (.91m) Valve, Check, 1/4 inch 1 each

PZ1, PZ3 & PZ6 SERIES FOR SPAS PLUMBED TO ACCEPT BYPASS VENTURI INJECTOR

Injector, 3/4 inch HB 1 each Hose, Polybraid, 1/4 inch 6 feet (1.81m)
Clamp, Plastic, Black, 0.500 inch 4 each Screw, SST, #8 x 3/4 inch 4 each
(Optional) Fiber Optic 3 feet (0.91m) Valve, Check, 1/4 inch 1 each


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