Ozone Solutions TS Series User manual

TS SERIES
COMPACT TURNKEY OZONE GENERATOR
MODEL: TS-20
INSTALLATION & OPERATIONS MANUAL
451 Black Forest Road /Hull, Iowa 51239 USA
P 712.439.6880 /F 712.439.6733

TS SERIES /3
INSTALLATION & OPERATIONS MANUAL
IMPORTANT SAFETY INSTRUCTIONS, READ AND FOLLOW ALL INSTRUCTIONS.
Read this manual completely before attempting installation.
SAVE THESE INSTRUCTIONS.
CONTENTS
Introduction ....................................................................4
Theory of Operation .......................................................4
I. SAFETY
Precautions.....................................................................4
Personal Safety ..............................................................5
II. COMPONENTS
Diagram ..........................................................................6
Descriptions....................................................................6
III. INSTALLATION AND OPERATION
Requirements.................................................................7
Initial Start-up.................................................................7
Operator Instructions.....................................................8
Flow Meter corrected Flow ............................................8
IV. ADDITIONAL INFORMATION
Warranty .........................................................................8
Specications .................................................................8
Contact Information .......................................................9
APPENDIX A - MAINTENANCE..............................11
APPENDIX B - TROUBLESHOOTING.....................12
APPENDIX C - SAFETY DATA SHEET ....................13

4/TS SERIES
OZONE SOLUTIONS
INTRODUCTION
The TS Series Ozone Generators are a complete air
preparation and ozone generation system that includes
an integrated air compressor, oxygen sieve’s, and ozone
generator. No external oxygen supply is required. The
TS Series Ozone Generators are designed to produce
ozone from oxygen under pressure. While maximum
ozone production (by volume) will be achieve at high
pressures and ows. These turnkey systems use
oxygen from the oxygen sieve’s to achieve prime ozone
production at pressure up to 20 PSI.
THEORY OF OPERATION
The TS Series Ozone Generator produces ozone via
corona discharge. 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 TS Series is a controlled corona.
This spark, an intense corona, is produced by forcing a
high voltage source through a dielectric and a small air
gap. These actions take place in a chamber called the
corona cell.
The spark occurs at a higher-than-line voltage and much
higher-than-line frequencies. These changes in voltage
and frequency are accomplished with the circuit board
and transformer inside the generator. The oxygen feed
is forced through the small air gap along the dialectic
and intense corona. This process splits the oxygen
molecule and generates ozone. (See diagram on the
right.)
1. Air Compressor takes in ambient air & delivers it to
the oxygen sieve’s.
2. Compressed air enters the oxygen sieve’s in an
alternating sequence.
3. The oxygen sieve’s remove nitrogen from the air
using pressure swing adsorption, leaving 90-95%
oxygen. Efuent nitrogen is then vented to the
atmosphere.
4. 90-95% Oxygen leaves the oxygen sieve’s at up to
15 PSI pressure. Pressure & ow are regulated by
an internal needle valve downstream of the ozone
generator.
5. Oxygen enters the ozone cell where it is utilized to
produce high concentration ozone under pressure.
6. A needle valve will allow adjustment of ow from
the TS Series Ozone Generator.
7. Ozone exits the TS series via the OZONE OUT port
I. 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.
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.
Carefully review and familiarize yourself with the
following important safety information concerning the
Ozone Generator:
• Ozone is an extremely aggressive and powerful
oxidizer. The Occupational Safety and Health
Administration (OSHA) 8-hour exposure limit is
O2
O2
O2
O-O-
O3
++

TS SERIES /5
INSTALLATION & OPERATIONS MANUAL
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.
• People who have no sense of smell should not
operate this equipment.
• Never attempt to verify ozone production by directly
breathing or smelling the ozone outlet.
• The Ozone Generator contains high voltages.
Tampering can result in serious injury or death. For
service instructions, contact Ozone Solutions.
Oxygen itself is not combustible, however it greatly
accelerates the burning of combustible materials.
Therefore, precautions should be taken to avoid a re
in the area of the generator
• Smoking should not be permitted in the area where
the system is located.
• All oxygen connections and hoses should be kept
clean and free of grease, oil and other combustible
materials.
• Valves controlling oxygen ow should be opened
and closed slowly to avoid the possibility of res
or explosions that can result from adiabatic
compression.
• When bleeding a tank or line, stand clear and do
not allow oxygen to embed itself within clothing. A
spark could cause the oxygen embedded clothing
to ignite.
High pressure gasses may be present within the
system. Valves should be opened and closed slowly,
and safety glasses and hearing protection should be
worn at all times while gasses are being vented.
Do not attempt to modify or enhance the performance
of a generator in any way.
PERSONAL SAFETY
Flushing ozone from the system
Safety warnings regarding ozone gas are found at the
beginning of this manual. The Ozone System produces
a large amount of ozone, which can be inadvertently
“stored” within the Ozone Generators, manifolds, and
ozone lines.
Eventually the ozone (even while in the system) will
safely revert back to oxygen, but in the right conditions
the ozone can remain in the system for 24 hours or
even longer. In the event that maintenance must
be performed on the components in contact with
ozone, the following is recommended for reducing the
possibility of exposure to the ozone.
Whenever possible it is recommended that the machine
run with maximum permissible air and oxygen ow for
at least 10 minutes with the Ozone Generator OFF in
order to ush out most residual ozone.
In most circumstances, a very small amount of ozone
will be contained within the system after shutdown;
therefore, exposure will be minimal.
If the machine cannot be operated prior to maintenance
or repair, a waiting period of 12 to 24 hours (if ozone
has been produced recently) is recommended to allow
the ozone to decay by reverting back into oxygen.
Isolating energy sources
The Ozone Generator has electrical and mechanical
hazards, and maintenance or repair should not take
place unless all energy sources have been turned off,
disconnected, and/or drained. Energy sources include,
but are not limited to:
• Electrical power
• Oxygen Concentrator sieve beds
• Ozone Generator internal capacitors

6/TS SERIES
OZONE SOLUTIONS
II. COMPONENTS
DIAGRAM
DESCRIPTIONS
1. Power Switch
2. Air Pressure Gauge
3. Oxygen Pressure Gauge
4. Hour Meter
5. Oxygen Pressure Regulator
6. Flowmeter
7. Ozone Output Control
8. Ozone Production Light
9. Sieve Beds
10. Ozone Generation Cell
11. Connection for Ozone Dial
12. Timer
13. Inlet Air Filter
14. Ozone Outlet
15. Air Compressor
1
6
32
5
7
4
12
10
13
15
99
14
11
8

TS SERIES /7
INSTALLATION & OPERATIONS MANUAL
III. INSTALLATION AND OPERATION
REQUIREMENTS
Location
Ensure that the Ozone Generator is in a well-ventilated
area. This system is not weather proof; therefore a
dust-free, non-condensing, enclosed environment is
required for operation.
There are ventillation openings on the sides and
bottom of the cabinet, which provide ltered air into the
cabinet and exhaust out of the cabinet. A minimum of
eight (8) inches of clear space should be provided to
the left and right sides of the unit, and two (2) inches
from the bottom. The cabinet door must be able to fully
swing open for future maintenance and service.
If mounting the machine, ensure the wall or support
system can withstand the weight of the unit.
Temperature & Humidity
Water must not be allowed to condense in or on
the machine. For best performance, the operating
temperature should be between 40ºF and 95ºF with
a maximum relative humidity of 85%. The storage
temperature should be between -20ºF and 170ºF.
If humidity levels are expected to exceed 85%, it is
recommended that a quality air dehumidier should
be installed in the area of the generator.
Note: Operation outside of specied temperature and
humidity ranges will not be warranted.
Ventillation
Proper ventillation is necessary to ensure safe
conditions for workers around the machine. As the
oxygen concentrator operates, it purges nitrogen into
the area around the system. For systems installed
in conned spaces (less than 2000 cubic feet),
approximately three (3) air changes per hour is
recommended.
Mechanical Connections
The TS series unit can provide gaseous ozone out of
the 1/4” Swagelok tube compression bulkhead on the
left side of the enclosure. Only use ozone compatible
tubing and ttings to direct the ow of ozone to the nal
point of use.
Electrical
The system requires 110V, 60Hz, 15 amp power. A
power cord is attached and stored on the right side of
the enclosure. The power cord can be omitted if direct
wiring is desired. It is required that a 15 Amp circuit be
dedicated to each unit. Additionally, the unit must be
plugged into this circuit using only the supplied power
cord, and without additional extension cords.
INITIAL START-UP
Once the unit has been installed in a suitable location
in accordance with this manual, it is ready to run.
Complete the following instructions to start up the
system and prepare it for your process.
1. Set the variable output knob to the “0” position so
that ozone is not produced.
2. Ensure that all electrical connections and ozone
tubing connections are complete.
3. Set the system switch to on. The compressor and
oxygen concentrator on board the system will start.
4. The oxygen pressure gauge on the TS system
will indicate increasing pressures as the oxygen
concentrator starts.
5. Check all external ozone tubing connections
for possible leaks or restrictions. Leaks can be
detected by using a spray bottle to apply soapy
water to ttings.
6. Observe the oxygen ow and oxygen pressure on
the system while it is running. Ensure that any
ancillary equipment connected to the system is
also running. Pressure will decrease slightly (1-2
PSI) after the ozone generator has run for about 10
minutes, as the air compressor warms up. Adjust
ow via needle valve in order to maintain 1-10 liters
per minute of ow and 10-15 PSI oxygen pressure.
7. Once ow is properly adjusted, the air pressure
gauge will continuously cycle between 15 and
40 PSI. This is due to the cycling of the oxygen
concentrator, and is normal expected operation.
8. Turn the variable ozone output knob to the “2” or
“3” position to start producing a limited amount of
ozone. After 2-3 seconds, the ozone indicator lamp
should illuminate.

8/TS SERIES
OZONE SOLUTIONS
9. Once ozone is being produced and the system is
behaving properly, the ozone output can be slowly
increased to the level required by your process.
OPERATOR INSTRUCTIONS
For local operation, the system can be started by
activating the switch on the door of the machine.The
0-10 knob can be used to vary the ozone production
level. An indication lamp on the door will light up
when power is supplied to the cell and ozone is being
produced. For further instruction, please refer to the
initial start-up procedure.
If desired, the production of ozone can be controlled
from a remote location. Contact Ozone Solutions to set
up remote connections to the unit.
FLOW METER CORRECTED FLOW
The oxygen ow meter indicates the ow rate of
oxygen leaving the oxygen concentrator and passing
through the ozone generator. This ow meter indicates
volumetric ow of the uid (oxygen) through it. Since
the oxygen is under pressure, the indicated ow needs
to be mathematically adjusted to determine actual ow
at atmospheric pressure.
The following equation can be used to determine the
actual ow through the system:
The TS series operates as given below:
Air Pressure 15-40 PSI
Oxygen Pressure 15-25 PSI
Oxygen Flow 6 LPM (indicated)
Lower than normal air pressure or oxygen pressure
is usually a sign of improper system setup (too much
oxygen/ozone ow) or air compressor wear. The
oxygen concentrator will rarely cause low pressure
issues. For more information on low pressure issues
see the “Maintenance and Troubleshooting” section of
this manual.
IV. ADDITIONAL INFORMATION
SPECIFICATIONS
TS-Series O3Production
(g/hr)
Flow Rate
(lpm)
Power
(watts)
Current
(amps) Output Connection Dimensions - WxDxH (inches)
Weight
(lbs)
TS-20 20 0-10 760 15 1/4” Compression 17x10x28 85
WARRANTY
Ozone Solutions warrants all 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
supercede this warranty. Ozone Solutions will honor
the manufacturer’s warranty, but if and when advised
by the manufacturer, may have the customer deal
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 call Ozone Solutions at 712.439.6880,
or email ser[email protected].

TS SERIES /9
INSTALLATION & OPERATIONS MANUAL
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 /TS SERIES