Ozone Solutions TG Series User manual

TG-Series
Water Cooled TG-300 Ozone Generator
TG Series: TG-75, TG-150, TG-300, TG-450, TG-600
Installation & Operations Manual
451 Black Forest Road, Hull, Iowa, 51239 | 712.439.6880 | [e-mail]
www.ozonesolutions.com
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Table of Contents
SECTION 1
Safety Precautions………………................. 4
Introduction …………………….................. 4
Theory of Operation……………………...4, 5
SECTION 2
Component Diagram…….………................ 5
Component Description…………. ............... 5
Specifications……………………................ 6
Available Options………………… ............. 6
Installation Guidelines…………… .............. 7
Wall Mounting………………. ..................... 7
Ozone/Oxygen Connections………….. ....... 7
Cooling Water Connections………………...7
Electrical Connections……………………...7
SECTION 3
Remote Operation or Control….................... 8
Flow-Meter Corrected Flow Chart……….8, 9
SECTION 4
HMI Setup Screen…............................................ 10
HMI Main Screen………………………………..10
HMI Alarm Screen…........................................... .11
HMI Alarm History Screen…….......................... .11
HMI Setpoint Entry Screen………………………11
Starting Up……………………………………….11
SECTION 5
Maintenance and Service Parts….. ...................... 12
Warranty…………………………. ..................... 12
Contact Information……………......................... 12
SECTION 6
Appendix A - CAD Drawings………………….. 13
Appendix B - Performance Charts………14 thru 18
IMPORTANT SAFETY INSTRUCTIONS READ AND FOLLOW ALL INSTRUCTIONS.
Read this manual completely before attempting installation.
SAVE THESE INSTRUCTIONS!

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SECTION 1
Safety Precautions
Ozone is a powerful oxidizing agent. Observe
strict operating procedures while using ozone
equipment. It is imperative that only ozone com-
patible materials are used in conjunction with
the ozone system.
Ensure that the Ozone Generator is in a well-
ventilated area. Do not allow rain or condensation
to contact the Ozone Generator. The Ozone Gener-
ator is not weather proof. The unit must be opera-
tor indoors or in an enclosure which is placed in a
non-condensing environment.
Carefully review and familiarize yourself with the
following important safety information concerning
the Ozone Generator:
1. Ozone is an extremely aggressive and power-
ful oxidizer. The Occupational Safety and
Health Administration (OSHA) 8-hour expo-
sure limit is 0.10-PPM. The OSHA 15-minute
exposure limit for ozone is 0.3 PPM. Above
0.3 PPM, there is the risk of damage to respira-
tory tissues.
2. People who have no sense of smell should not
operate this equipment.
3. Never attempt to verify ozone production by
directly breathing or smelling the ozone outlet
or the ozone-tubing outlet.
4. The Ozone Generator contains high voltages.
Unauthorized entry can result in serious injury
or death. For service instructions, contact
Ozone Solutions.
5. Make sure all tubing connections between the
Ozone Generator and the injection point are
secure and in good working condition. Failure
to do so could result in the discharge of ozone
into an undesired space.
Introduction
The Water Cooled Ozone Generator produces
ozone from oxygen via corona discharge. The TG
series is capable of generating 75- 600g/hr of
ozone with a feed gas of 90% oxygen Ozone has
many uses including pathogen inactivation and
destruction of odorous gases.
Ozone Generation from Corona Discharge
Theory of Operation
The Ozone Generator produces ozone via the co-
rona discharge method. This process uses an elec-
trical spark to split the molecular bond of natural
diatomic oxygen to form the atomic O- form of
oxygen. These O - atoms then bond to other O2
molecules to form O3 (ozone).
The spark inside the corona cell is a controlled
corona or spark. This spark is produced by forcing
a high voltage source through a dielectric and a
small air gap where the feed-gas flows through.
The spark occurs at a higher-than-line voltage and
much higher-than-line frequencies, which are in-
creased and regulated by the onboard electronics
in the machine.
The basic fundamentals of flow and velocity of
gas through the corona cell allow for more ozone
production (g/hr.) as oxygen flow increases. As
the flow increases, the concentration of ozone (%
by weight) decreases. Conversely, as the flow de-
creases, the concentration of ozone increases. At
very low oxygen flow rates, the oxygen remains in
the corona cell for a longer period of time.
Note: If the operator has asthma, he or she
must not enter an airspace that has a signifi-
cant ozone concentration. Ozone can in-
duce an asthma attack.

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The contact time (CT value) allows a higher per-
centage of oxygen to be converted into ozone. The
ozone production and concentration of the TG
ozone machine can be determined using the perfor-
mance charts in this manual.
While the flow-rate of the oxygen feed gas affects
the ozone output the most, the pressure of the feed
gas also effects the ozone output. Higher pressures
create higher concentrations of the feed gas which
result in a higher ozone output or concentration. If
the feed gas flow-rate remains the same while un-
der a higher pressure, it allows an increased con-
tact time (CT value).
With increased feed-gas pressures, additional elec-
trical power is needed to create a spark in the pres-
surized corona cell. The electronics of the TG se-
ries automatically compensate for the varying pres-
sure to maximize the ozone output.
While increased feed gas pressure helps achieve a
higher output, it also forces the created ozone mol-
ecules back into oxygen at a quicker rate.
SECTION 2
Component Diagram
Component Description
1. Mounting tabs for wall mounting – Can be
mounted to a wall or rack using the stainless
steel mounting tabs.
2. HMI Screen – Main screen to control the ozone
generator.
3. Enclosure Latch – will latch and lock door of
enclosure, a common flat blade screw-driver can
be used to open the enclosure.
4. Emergency Stop – Immediate push stop
5. Cooling Vents – filtered cooling vents are used
to cool the ozone generator and filter all air from
major dust.
6. Power Cord – 220V power cord will supply
power to the ozone generator.
7. Ozone Outlet – Refer to the Specifications table
for more information
8. Oxygen Inlet – Refer to the Specifications table
for more information
9. Cooling Water Out – Refer to the Specifica-
tions table for more information
10. Cooling Water In – Refer to the Specifications
table for more information
11. Mounting Feet – For bench/ table placement
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6
7
8
9
10
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Specifications
* - Single Phase, others are Three Phase.
Optional Accessories Description
Flowmeter 0-10 LPM, 0-20 LPM Acrylic Flowmeter or High Accuracy 0-10 LPM Aluminum
Flowmeter (which is best for precise flow control).
Pressure Gauge 0-30 PSI or 0-60 PSI that displays corona cell pressure.
Ozone Control Input 4-20 mA Input or 0-10 Volt Input allows you to control the generator output remotely.
Available Options
TG Model TG-75 TG-150 TG-300 TG-450 TG-600
Grams Per Hour 75 150 300 450 600
Feed-Gas Flow Rate (LPM) 0-15 0-30 0-60 0-90 0-120
Power (Volts A/C) 208-240*208-240*208-240*208-240 208-240
Power (Was) 600 1200 2400 3600 4800
Power (Amps) 35.5 15 10 20
Gas Connecons (In & Out-Inches) 3/8 Comp. 3/8 Comp. 3/8 Comp. 1/2 NFPT 1/2 NFPT
Cooling Required (BTU/Hr.) 2,000 4,100 8,200 12,300 16,600
Cooling Water (GPM @ 70F or colder)(71 PSI Max) O.75 11.5 22
Cooling Water Connecons (In & Out-Inches) 3/8 NFPT 3/8 NFPT 1/2 NFPT 1/2 NFPT 1/2 NFPT
Size (D, W, H) 11, 24, 24 13, 24, 24 17, 24, 30 17, 30, 36 17, 36, 42
Weight (Lbs.) 75 90 180 200 250
Specifications are subject to change without notice.

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Ozone/Oxygen Connections
1. Using a stainless steel, Teflon, or other high-
quality ozone-resistant tubing, connect to the
oxygen inlet and ozone outlet fittings.
2. If the connections are compression fittings,
then, with an open-ended wrench, tighten the
compression-fitting nuts as needed.
*Note: For Stainless steel ferrules;
After being tightened down properly, the ferrule
will become part of the tubing, since it can no
longer move freely on the tube.
Wall Mounting
To mount the machine on a wall:
1. Use the wall mount tabs on the top
of the unit to secure to a wall.
2. Ensure that the wall can support the
weight of the system.
Installation Guidelines
The Ozone Generator is not weather
proof; therefore, it must be operated
indoors in a non-condensing, dust-free
environment.
Ambient Temp.; The operating temper-
ature should be 40ºF to 95ºF, and the
storage temperature should be -20ºF to
170ºF.
Ventilation Needs; Approximately three
air changes per hour are recommended.
Proper ventilation will also help prevent
the accumulation of ozone in the event
of a leak.
Clear Space; Maintain 12-24 inches of
clear space around the machine for
proper ventilation and maintenance
service work to be performed.
Adequate power source; Connect the
machine to a grounded power source
that is rated for the required electric
current and voltage.
Cooling Water Connections
Refer to the specific model in the Specifications table
which will inform you of the water connection size.
If you need additional fittings to make the proper con-
nections, please contact us for that need.
Electrical Connections
Wire in the correct power source as listed in the Spec-
ifications table.

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Remote Operation or Control
Use the 4-20mA option to re-
motely control the ozone output
from 0-100%.
When the Inverter is ON and
producing ozone there is a 24
VDC reference signal that can be
wired to a re mote location. This can
be wired using terminals “24 VDC(-
)” and “Green Light ” and “Red
Light”.
By using either a momentary or
latching relay, the ozone genera-
tor can be turned ON or OFF
remotely by bridging the terminals
“24 VDC (+)” and “Remote Stop” or
“Remote Start”.
Note: The use and type of the remote
control must be qualified prior to system purchase, so please contact Ozone Solutions for more information before in-
stalling a remote for your unit.
Flow-Meter Corrected Flow Chart
When setting the flow and pressure of the Ozone Generator, it is important to understand how the pressure will affect
the flow rate as displayed on the flow meter (s). If the actual discharge pressure is substantially above atmospheric
pressure, the reading can be adjusted to determine the precise flow rate, according to the following formula (using
PSIG):
Please refer to the Corrected Flow Chart in this manual, or contact Ozone Solutions if additional assistance is re-
quired.
This corrected flow can then be used in the appropriate Performance Chart to determine how much ozone you are
making. There can be up to a 10% error in this equation. Using an ozone analyzer in line with your ozone system
will provide the greatest level of accuracy and understanding of your ozone production.
SECTION 3
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2
3 4 5
6 7 7
Green means Disabled
12Allows system to operate despite a fault/alarm. Main use is to tune the board.
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3
4
5
7Green when touched. The appropriate inverter board ON led will light up proving
The O2 PSI LOW SETPOINT: Touching this eld will bring up the Setpoint Entry Screen allowing you to enter or edit the displayed value. NOTE- If the oxygen pressure drops below this level, the ozone generator will shut down. This MUST be set at a minimum of 5 PSI.
The O3 PSI LOW SETPOINT: Touching this eld will bring up the Setpoint Entry Screen allowing you to enter or edit the displayed value. NOTE- If the ozone pressure drops below this level, the ozone generator will shut down. This MUST be set at a minimum of 5 PSI.
Lapsed Ozone ush me aer touching
to stop the machine.
LOCAL or REMOTE control via a 0-10VDC signal. Terminals are inside the cabi-
The measured O2 PSI or Oxygen Pressure is only a readout value. NOTE– Adjust the external PSI regulator which can be on an Oxygen Concentra- tor or other Oxygen feed-source.
A
A
B
B
Green means ON, Red means O
B
C
CTouching this eld will bring up the Setpoint Entry Screen allowing you to enter
or edit the displayed value. NOTE- To operate the system on oxygen only, enter a zero (“0”) in this field.
D
D
The measured O3 PSI or Ozone gas Pressure is displayed. NOTE– The dierence between the Oxygen and Ozone Pressure can be 1-3 PSI.
Pressing either the Alarm 1 or Alarm History will bring up the ALARM SCREEN.
E
E
FF
Resets the non-acve alarms.
GWill bring you to the SETUP SCREEN.
G
HThis buon Starts or Stops the machine; The buon will be Green w/ the word
“START” when the machine is not yet operated. Aer pressing the green buon, it will then turn RED showing the word “STOP”. NOTE– When “STOP” is acvated, Oxygen will continue to flow.
H
Section 4
HMI Main Screen
HMI Setup Screen
NOTE– If the value in “D” is below the value shown in “4”, the machine will stop making Ozone. To keep adequate pressure against the Ozone Cell (s), adjust the manual nee- dle valve inside of the cabinet as needed.
This button when touched will exit the run-time program and bring you to the operating system.
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Starting up Here are tips for ensuring performance for the ozone generator: 1. Using an oxygen purity meter, measure the puri-
ty of the oxygen. When the meter measures 90% or higher. Since the purity value is not displayed on an HMI screen, and if you do not have an ox- ygen purity meter, flowing the oxygen through the system for a minute should be fine.
2. Set the flow and pressure to that which is ex-
pected for its operation while not exceeding the capacity of the ozone machine as shown in the performance charts in this manual.
3. Spraying soapy water on all of the gas connec-
tion points will ensure there are no leaks. Tighten or repair as needed.
4. Refer to the HMI screens to inform you when the
machine is making ozone or not.
5. If the machine is or has been making ozone gas
for awhile, do number 6 below. If it is not mak- ing ozone, go to #7.
6. To make sure the flow rate of the cooling water
is adequate, disconnect all power sources and open the cabinet door to access the ozone gener- ating cell (s). The cells must be cool to the touch.
7. If you encounter any problems with the operation
of the machine, please check the HMI alarm screen.
HMI Alarm Screen NOTE– You can highlight other alarm entries by selecting it with your finger.
Brings up the titled HMI Screen.
Un-Active posted alarms can be removed from the screen.
Resets posted alarms which are latched.
1
HMI Alarm History Screen The Alarm History screen keeps a history of all ozone system alarms. This running log can be of good use or history when needing to service or trouble-shoot the ma- chine. NOTE- This logged history cannot be deleted or cleared.
2
The Alarm screen displays ozone system alarms.
The Alarm History screen lists all the ozone system alarms.
HMI Set-Point Entry Screen This Set-Point Entry Screen comes up when you touch fields;
in the Setup Screen, and
In the Main Screen.
Enter the desired value into the top field and touch the button with the bent arrow.
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2
1
3
1
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Maintenance and Service Parts
As long as the feed gas is kept dry, dust free, and
pure, the Ozone Generator will not need mainte-
nance. Ensure strict maintenance procedures of the
oxygen generator as specified in the oxygen genera-
tor manual.
There are no serviceable parts inside the TG Series.
If any part fails to operate or other problems arise
call Ozone Solutions for service and repair.
Warranty
Ozone Solutions warrants all new equipment as-
sembled, manufactured, and sold to be free from
defects in material and workmanship under nor-
mal use and service for a period of one (1) year
after date of sale to the original purchaser.
Some products may have a specific warranty period
other than what is outlined in this document. For
such products, the manufacturer warranty will super-
sede this warranty. Ozone Solutions will honor the
manufacturer’s warranty, but if and when advised by
the manufacturer, may have the customer deal direct-
ly with the manufacturer.
This warranty covers all parts that are not outlined in
a product maintenance schedule. This warranty will
be void if any piece of the equipment is used in a
manner other than what is explicitly outlined in the
product manuals.
If any part of the equipment manufactured by Ozone
Solutions proves to be defective during the warranty
period, please contact Ozone Solutions at 1-888-892-
0303, or [e-mail].
Prior authorization is required before working on or
shipping a product back to us. Failure to get prior
authorization may result in denial of your claim.
Once authorized, you may return the defective equip-
ment to Ozone Solutions with the transportation
charges prepaid. If Ozone Solutions finds the equip-
ment to be defective, it will be repaired or replaced at
our discretion, free of charge, to the original purchas-
er (F.O.B. factory).
This warranty shall not place any liability on Ozone
Solutions for any transportation charges, labor, or
cost for, or during the replacement of any parts. The
replaced part (s) or product will then continue the
original warranty duration. The replaced parts will
not start a new one (1) year coverage period.
The purchaser by acceptance of the equipment will
assume all liability for the consequences of its use or
misuse by the purchaser, employees, or others. This
warranty shall not apply to any piece of equipment,
or part thereof sold by this company which has been
subject to any accident caused in transit, alterations
by unauthorized service, negligence, abuse, or dam-
age by flood, fire, or act of God.
This warranty shall constitute the entire warranty
and/or agreement between Ozone Solutions and the
original purchaser, and in lieu of all other warran-
ties, expressed or implied, either oral or written, in-
cluding the warranty of merchantability and fitness
for a particular use and of all other obligations or
liabilities on our part. Ozone Solutions neither as-
sumes nor authorizes any other person or entity to
assume for us any liability associated with the sale
of its products or equipment.
The term “original purchaser,” as used in this war-
ranty, means whom the product was originally sold
to by Ozone Solutions or by an authorized dealer.
Ozone Solutions reserves the right to make changes
in its products without notice. Because of this,
Ozone Solutions is not obligated to replace warranty
defective part (s) and/or product with the same origi-
nal part or product.
V8a.
Contact Information
Ozone Solutions, Inc.
451 Black Forest Road
Hull, IA 51239 USA
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Website: www.ozonesolutions.com
Section 5

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Appendix A - CAD Drawings

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Appendix B - Performance Charts

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Appendix B - Performance Charts

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Appendix B - Performance Charts

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Appendix B - Performance Charts

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Appendix B - Performance Charts

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451 Black Forest Road, Hull, Iowa, 51239 | 712.439.6880 | [e-mail]
www.ozonesolutions.com
©2016, Ozone Solutions. All Rights reserved. Ozone Solutions is a registered trademark. This
publication may not be reproduced in part or whole without written permission of Ozone Solutions