Ozone Solutions TG Series User manual

TG SERIES
WATER COOLED OZONE GENERATOR
MODEL: TG-75, TG-150, TG-300, TG-450, TG-600
INSTALLATION & OPERATIONS MANUAL
451 Black Forest Road /Hull, Iowa 51239 USA
P 712.439.6880 /F 712.439.6733

TG SERIES /3
INSTALLATION & OPERATIONS MANUAL
IMPORTANT SAFETY INSTRUCTIONS, READ AND FOLLOW ALL INSTRUCTIONS.
Read this manual completely before attempting installation.
SAVE THESE INSTRUCTIONS.
CONTENTS
SECTION 1
Safety Precautions .........................................................4
Introduction ....................................................................4
Theory of Operation .......................................................4
SECTION 2
Component Diagram......................................................5
Specications .................................................................5
Available Options............................................................6
Installation Guidelines...................................................6
Ventillation......................................................................6
SECTION 3
Remote Operation or Control.........................................6
Flow Meter Corrected Flow Chart..................................6
Start Up...........................................................................7
SECTION 4
HMI Main Screen ...........................................................7
HMI Alarm Screen ..........................................................8
HMI Alarm History Screen .............................................8
HMI Setpoint Screen......................................................8
SECTION 5
Maintenance and Service parts....................................8
Warranty .........................................................................8
Contact Information .......................................................9
APPENDIX A - CAD DRAWING..............................10
APPENDIX B - CORRECTED FLOW CHART..........11
APPENDIX C - PERFORMANCE CHARTS.............12
APPENDIX D - SAFETY DATA SHEET.................... 17

4/TG SERIES
OZONE SOLUTIONS
SECTION 1
SAFETY PRECAUTIONS
Ozone is a powerful oxidizing agent. Observe strict
operating procedures while using ozone equipment.
It is imperative that only ozone compatible 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 Generator is not weather
proof. The unit must be operated indoors or in an
enclosure 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 powerful
oxidizer. The Occupational Safety and Health
Administration (OSHA) 8 hour exposure 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 respiratory 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.
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 connections are secure and are
not leaking. 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.
THEORY OF OPERATION
The Ozone Generator produces ozone via the corona
discharge method. This process uses an electrical
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 O2molecules 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 ows through. The spark occurs at
a higher-than-line voltage and much higher-than-line
frequencies, which are increased and regulated by the
onboard electronics in the machine.
The basic fundamentals of ow and velocity of gas
through the corona cell allow for more ozone production
(g/hr) as oxygen ow increases. As the ow increases,
the concentration of ozone (% by weight) decreases.
Conversely, as the ow decreases, the concentration
of ozone increases. At very low oxygen ow rates, the
oxygen remains in the corona cell for a longer period
of time.
The contact time (CT value) allows a higher percentage
of oxygen to be converted into ozone. The ozone
production and concentration of the TG ozone machine
can be determined using the performance charts in
this manual.
While the ow 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 ow rate remains the same while under a higher
pressure, it allows an increased contact time (CT
value). With increased feed gas pressures, additional
electrical power is needed to create a spark in the
pressurized corona cell. The electronics of the TG series
automatically compensate for the varying pressure to
maximize the ozone output. While increased feed gas
pressure helps achieve a higher output, it also forces
the created ozone molecules back into oxygen at a
quicker rate.
NOTE: If the operator has asthma, he or she must
not enter an airspace that has a signicant ozone
concentration. Ozone can induce an asthma attack.

TG SERIES /5
INSTALLATION & OPERATIONS MANUAL
SECTION 2
COMPONENT DIAGRAM
1. Mounting tabs - can be used to mount the machine
to a wall or rack
2. HMI screen - main screen to control the ozone
generator
3. Enclosure latch - will latch and lock door of
enclosure, a common at blade screwdriver can be
used to open the enclosure
4. Emergency stop switch - immediate push stop
5. Cooling vents - ltered cooling vents to maintain
proper air ow through the enclosure
6. Power cord - 220V power cord
7. Ozone outlet
8. Oxygen inlet
9. Cooling water out
10. Cooling water in
SPECIFICATIONS
Model TG-75 TG-150 TG-300 TG-450 TG-600
O3Production (g/hr) 75 150 300 450 600
O2Feed Rate (lpm) 0-15 0-30 0-60 0-90 0-120
Voltage (VAC) 208-240* 208-240* 208-240* 208-240 208-240
Power (Watts) 600 1,200 2,400 3,600 4,800
Gas Connections 3/8”
Compression
3/8”
Compression
1/2” FNPT 1/2” FNPT 1/2” FNPT
Cooling Connections 3/8” FNPT 3/8” FNPT 1/2” FNPT 1/2” FNPT 1/2” FNPT
Cooling Required (BTU) 2,000 4,100 8,200 12,300 16,600
Cooling Water (GPM @ 70F or
cooler)
0.75 1 1.5 2 2
Size (inches; D,W,H) 11x24x24 13x24x24 17x24x30 17x30x36 17x36x42
Weight (lbs) 75 90 180 200 250
*Single phase AC power
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6/TG SERIES
OZONE SOLUTIONS
AVAILABLE OPTIONS
Optional
Accessories
Description
Flow meter 0-10 LPM, 0-20 LPM, or high
accuracy 0-10 LPM ow meter
Pressure gauge 0-30 PSI or 0-60 PSI gauge to
display corona cell pressure
Ozone control
input
4-20 mA input or 0-10 volt input
for remote operation
INSTALLATION GUIDELINES
The Ozone Generator is not weather proof; therefore, it
must be operated indoors in a non-condensing, dust-
free environment. The operating temperature should
be 40ºF to 95ºF, and the storage temperature should
be -20ºF to 170ºF.
VENTILLATION
Approximately three air changes per hour is the
recommended ventillation for the TG series of ozone
generators. Proper ventillation will ensure the machine
remains cool, and can help prevent the accumulation
of ozone in the event of a leak.
Maintain 12-24 inches of clear space around the
machine; especially around the ltered vents
SECTION 3
REMOTE OPERATION OR CONTROL
1. Use the 4-20 mA option to remotely control the
ozone output from 0-100%
2. When the inverter is ON and producing ozone, there
is a 24 VDC reference signal that can be wired to a
remote location. This can be wired using terminals
“24 VDC(-)” and “Green Light” and “Red Light”
3. By using either a momentary or latching relay, the
ozone generator 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
qualied prior to system purchase, so please contact
Ozone Solutions for more information before installing
a remote for your unit.
FLOW METER CORRECTED FLOW CHART
When setting the ow and pressure of the Ozone
Generator, it is important to understand how the
pressure will affect the ow rate as displayed on the
ow meter(s). If the actual discharge pressure is
substantially above atmospheric pressure, the reading
can be adjusted to determine the precise ow rate,
according to the following formula (using PSIG):
Please refer to the Corrected Flow Chart in the
appendices of this manual, or contact Ozone Solutions
if additional assistance is required. This corrected ow
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
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TG SERIES /7
INSTALLATION & OPERATIONS MANUAL
analyzer in line with your ozone system will provide the
greatest level of accuracy and understanding of your
ozone production.
START 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, owing the oxygen through the system
for a minute should be ne.
2. Set the ow 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 ow 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.
SECTION 4
HMI MAIN SCREEN
1. Inverter/Ozone Generator Status
2. Start/Stop Button - Used to start or stop the
machine. When “STOP” is activated, oxygen will
continue to ow
3. Measured Oxygen Pressure
4. Measured Ozone Pressure
5. Alarm Screen Button - Will take you to the HMI
alarm screen. Refer to the HMI alarm screen
section for more information
6. Ozone Output level - displays the value which has
been entered into the HMI setpoint screen. To
modify the value, tap this eld, which will bring
up the setpoint screen. To operate the system on
oxygen only, enter a zero (0) into this eld
7. O2PSI Low Setpoint - displays the value which
has been entered into the HMI setpoint screen. To
modify the value, tap this eld, which will bring up
the setpoint screen. If ozone pressure drops below
this level, the ozone generator will shut down. This
MUST be set at a minimum of 5 PSI
8. O3PSI Low Setpoint - displays the value which
has been entered into the HMI setpoint screen. To
modify the value, tap this eld, which will bring up
the setpoint screen. If ozone pressure drops below
this level, the ozone generator will shut down. This
MUST be set at a minimum of 5 PSI
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8/TG SERIES
OZONE SOLUTIONS
HMI ALARM SCREEN
1. Troubleshooting Tips - will display troubleshooting
tips for the highlighted alarm. You can highlight
other alarms by tapping on them
2. Alarm Delete - inactive alarms can be deleted
3. Exit Runtime - will exit the run-time program and
bring you to the operating system
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 troubleshoot the
machine. This logged history cannot be deleted or
cleared.
HMI SETPOINT SCREEN
The setpoint screen comes up when you touch elds
[6], [7], or [8] on the HMI main screen. Enter the desired
value into the top eld then tap the enter/return key.
SECTION 5
MAINTENANCE AND SERVICE PARTS
As long as the feed gas is kept dry, dust free, and
pure, the Ozone Generator will not need maintenance.
Ensure strict maintenance procedures of the oxygen
generator as specied in the oxygen generator 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
assembled, manufactured, and sold to be free from
defects in material and workmanship under normal
use and service for a period of one (1) year after date
of sale to the original purchaser.
Some products may have a specic warranty period
other than what is outlined in this document. For
such products, the manufacturer warranty will
supersede this warranty. Ozone Solutions will honor
the manufacturer’s warranty, but if and when advised
by the manufacturer, may have the customer deal
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TG SERIES /9
INSTALLATION & OPERATIONS MANUAL
directly 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
712.439.6880, or ser[email protected].
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 equipment
to Ozone Solutions with the transportation charges
prepaid. If Ozone Solutions nds the equipment to
be defective, it will be repaired or replaced at our
discretion, free of charge, to the original purchaser
(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 damage by ood, re,
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
warranties, expressed or implied, either oral or written,
including the warranty of merchantability and tness
for a particular use and of all other obligations or
liabilities on our part. Ozone Solutions neither assumes
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 warranty,
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 original part or product.
CONTACT INFORMATION
Ozone Solutions, Inc.
451 Black Forest Road
Hull, IA 51239 USA
Phone: [phone]
Fax: [phone]
Email: [email protected]
Website: www.ozonesolutions.com

10 /TG SERIES
APPENDIX A - CAD DRAWING

TG SERIES /11
APPENDIX B - CORRECTED FLOW CHART

12 /TG SERIES
APPENDIX C - PERFORMANCE CHARTS
OZONE GENERATOR PERFORMANCE TEST
TG SERIES OZONE GENERATORS
Ozone Concentration (% by weight) Ozone Production (g/hr)
Ozone Flow (lpm) PSI TG-75 TG-75
5.00 10 9.50 40.76
7.50 10 8.20 52.77
10.00 10 6.90 59.20
15.00 10 5.80 74.65
20.00 10 5.00 85.80
Test was performed at 72°F, running for over an hour. Cooling water at 10 gph flow rate and 70°F.
Additional Equipment: Ozone Analyzer API 454 and API 460H
0.00
2.00
4.00
6.00
8.00
10.00
5.00 7.50 10.00 15.00 20.00
OZONE CONCENTRATION
OZONE FLOW
OZONE CONCENTRATION
0.00
20.00
40.00
60.00
80.00
100.00
5.00 7.50 10.00 15.00 20.00
OZONE PRODUCTION
OZONE FLOW
OZONE PRODUCTION

TG SERIES /13
OZONE GENERATOR PERFORMANCE TEST
TG SERIES OZONE GENERATORS
Ozone Concentration (% by weight) Ozone Production (g/hr)
Ozone Flow (lpm) PSI TG-150 TG-150
6.50 20 9.10 50.75
10.00 20 8.20 70.36
20.00 20 6.90 118.40
30.00 20 5.80 149.29
40.00 20 5.00 171.60
Test was performed at 72°F, running for over an hour. Cooling water at 20 gph flow rate and 70°F.
Additional Equipment: Ozone Analyzer API 454 and API 460H
0.00
2.00
4.00
6.00
8.00
10.00
6.50 10.00 20.00 30.00 40.00
OZONE CONCENTRATION
OZONE FLOW
OZONE CONCENTRATION
0.00
50.00
100.00
150.00
200.00
6.50 10.00 20.00 30.00 40.00
OZONE PRODUCTION
OZONE FLOW
OZONE PRODUCTION

14 /TG SERIES
OZONE GENERATOR PERFORMANCE TEST
TG SERIES OZONE GENERATORS
Ozone Concentration (% by weight) Ozone Production (g/hr)
Ozone Flow (lpm) PSI TG-300 TG-300
10.00 20 11.00 94.38
20.00 20 9.90 169.88
40.00 20 8.50 291.72
50.00 20 7.50 321.75
60.00 20 6.50 334.62
80.00 20 5.00 343.20
Test was performed at 72°F, running for over an hour. Cooling water at 30 gph flow rate and 70°F.
Additional Equipment: Ozone Analyzer API 454 and API 460H
0.00
2.00
4.00
6.00
8.00
10.00
12.00
10.00 20.00 40.00 50.00 60.00 80.00
OZONE CONCENTRATION
OZONE FLOW
OZONE CONCENTRATION
0.00
50.00
100.00
150.00
200.00
250.00
300.00
350.00
400.00
10.00 20.00 40.00 50.00 60.00 80.00
OZONE PRODUCTION
OZONE FLOW
OZONE PRODUCTION

TG SERIES /15
OZONE GENERATOR PERFORMANCE TEST
TG SERIES OZONE GENERATORS
Ozone Concentration (% by weight) Ozone Production (g/hr)
Ozone Flow (lpm) PSI TG-450 TG-450
30.00 20 8.20 211.07
60.00 20 6.90 355.21
90.00 20 5.80 447.88
120.00 20 5.00 514.80
150.00 20 4.20 540.54
Test was performed at 72°F, running for over an hour.
Additional Equipment: Ozone Analyzer API 460H
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
30.00 60.00 90.00 120.00 150.00
OZONE CONCENTRATION
OZONE FLOW
OZONE CONCENTRATION
0.00
100.00
200.00
300.00
400.00
500.00
600.00
30.00 60.00 90.00 120.00 150.00
OZONE PRODUCTION
OZONE FLOW
OZONE PRODUCTION

16 /TG SERIES
OZONE GENERATOR PERFORMANCE TEST
TG SERIES OZONE GENERATORS
Ozone Concentration (% by weight) Ozone Production (g/hr)
Ozone Flow (lpm) PSI TG-600 TG-600
40.00 20 8.20 281.42
80.00 20 6.90 473.62
120.00 20 5.80 597.17
160.00 20 5.00 686.40
200.00 20 4.20 720.72
Test was performed at 72°F, running for over an hour. C
Additional Equipment: Ozone Analyzer API 460H
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
40.00 80.00 120.00 160.00 200.00
OZONE CONCENTRATION
OZONE FLOW
OZONE CONCENTRATION
0.00
100.00
200.00
300.00
400.00
500.00
600.00
700.00
800.00
40.00 80.00 120.00 160.00 200.00
OZONE PRODUCTION
OZONE FLOW
OZONE PRODUCTION

TG SERIES /17
APPENDIX D - SAFETY DATA SHEET

18 /TG SERIES
OZONE SOLUTIONS
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TG SERIES /19
INSTALLATION & OPERATIONS MANUAL
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OZONE SOLUTIONS
451 Black Forest Road /Hull, Iowa 51239 USA
P 712.439.6880 /F 712.439.6733
E [email protected]
www.ozonesolutions.com
© 2018, 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.