INSTALLATION, OPERATION

&
MAINTENANCE MANUAL
For

TUF Ozone Generator

Content
S.NO.

SUBJECT

1.0

INTRODUCTION

2.0

OZONE AND OZONE GENERATOR

3.0

INSTALLATION

4.0

OPERATION OF THE OZONATION SYSTEM

5.0

PRECAUTIONS
6.1
ENVIRONMENTAL
6.2
EQUIPMENT SAFETY
6.3
ELECTRICAL
6.4
OPERATIONAL
6.5
HUMAN SAFETY

6.0

PREVENTIVE MAINTENANCE

7.0

FAULT FINDING AND REMIDIES

7.1
OZONE GENERATOR NOT WORKING
7.2
OZONE GENERATOR WORKING BUT NO OZONE OUTPUT
7.3
OZONE GENERATOR WORKING BUT OZONE OUTPUT LOW

8.0

TECHNICAL SPECIFICATIONS OF OZONE GENERATOR

9.0

PHOTOGRAPHS

Page 2 of 17

1.0 INTRODUCTION
Ozone generators are used for numerous applications which include disinfection,
sterilization, deodorization, bleaching and improving the properties of environmental air,
water (drinking, process, medical, swimming pools, STP, ETP etc.) and the food items. The
ozone generator under subject can be utilized for the purpose of deodorization and smoke
reduction of the outgoing exhaust air from a specific location.
In the health conscious world of today more and more attention is being paid to improve the
quality of natural resources like air and water, the ozone generator is intended to deodorize
the exhaust air or can be used to preserve the freshness of air or water. In the selection of
disinfectant e.g. UV, Ionizers, Ozone, Chlorine and other Chemicals, the Ozone has emerged
out as a distinctive winner. Due to the fact that either other disinfectants cannot be used or
they are not as effective in getting desired level of disinfection.
The advantage of Ozone is its very strong oxidizing and disinfecting power, which is of great
benefit in the treatment of Air, Water & Food items. Ozone decomposes back to Oxygen
without leaving any undesirable reactants.
Present methods of air deodorization using either chemicals or perfume fresheners, is not a
very effective method. Thus what is needed is a way to economically deodorize and sterilize
the air to eliminate the odor and all kind of bacteria and virus. Today, many leading names
in the Air Quality Management Industry are turning to Ozone treatment to deodorize, and
sterilize the air.

Page 3 of 17

2.0 OZONE AND OZONE GENERATOR

2.1 WHAT IS OZONE GAS?
Ozone is a tri-atomic state of Oxygen, Each molecule of Ozone contains three atoms of
Oxygen and chemically written as O3. Its light blue in colour and high energy excited state
of Oxygen. Ozone gas is detectable due to its distinctive pungent odour. It converts back
naturally to Oxygen and this makes it the preferred choice for disinfection of Water, Air and
Food items.
Ozone is detectable due to its distinctive pungent odor. Below the lowest safe continuous
exposure limit of 0.1 ppm, there is no danger to the persons working in that environment.
Moreover the studies have shown that alertness and efficiency of an individual working in
Ozone environment increases appreciable.
2.2 HOW THE DISINFECTION TAKES PLACE BY OZONE
Ozone is very highly reactive and the strongest commercially available disinfecting agent.
Ozone is the most efficient broad-spectrum microbiological control substance available and
the fastest oxidizing agent. It can literally oxidize material, causing disinfection in presence
of water 3,200 times faster than Chlorine.
When brought in contact with Water or Air, it destroys the odorants and all kind of
bacteria viruses and cysts in a very short duration. This avoids any kind of decay caused
by bacteria and will give freshness to the air. Ozone is very unstable while reacting and
decomposes back to Oxygen. This property of Ozone provides major contribution towards a
cleaner environment.
With the trend being towards environment friendly process replacing traditional methods,
the uses of Ozone is increasing for Air Quality Management
2.3 CONSTRUCTION OF OZONE GENERATOR:
To convert break atmospheric Oxygen into Ozone we need some energy and this energy is
provided by high voltage discharge. When dry compressed oxy-rich air is passed through
two concentric electrodes, having a dielectric in between them and a high voltage is applied
between both the electrodes to produce a Corona discharge, produces ozone.
The Ozone Generator is built into a Stain less Sheet Cabinet. The components of the Ozone
Generator are mounted inside the cabinet. The major components are under:

Page 4 of 17

Oil Free Diaphragm Compressor:

An Oil Free Diaphragm Compressor to a pressure of 25 TO 30 PSI compresses the
filtered air. Compressor is manufactured from special grade aluminum for lightweight
and good strength. Diaphragm is made of 2-ply nylon reinforced neoprene rubber.
Valves are of MS 316.

Heatless Air Dryer and Oxygen enrichment unit (Regenerative Type):

The dryer and Oxygen enrichment unit removes water vapors from the compressed air
and some amount of Nitrogen, continuously and automatically. The unit consists of two
cylindrical chambers packed solidly with desiccant (Molecular sieves). The Molecular
sieves drying and oxygen enrichment process is a modern and state of the art process of
purification of air. In the process the air is passed alternatively, first through one
chamber and then through the other.
When the main stream is passing through one chamber, purging the dried air to remove
the accumulated moisture in the desiccant is regenerating the other chamber.
Changeover is accomplished by a microprocessor through the operation of a four port
four ways Solenoid Valve. These Air dryer and oxygen enrichment unit are to be replaced
within 3 years of continuous service.

Ozone Cells
The Ozone Generator uses a Corona discharge Ozone Cell made up of Stainless Steel
electrode and Quartz dielectric. A high voltage is applied between the electrodes, which
is generated by a High Voltage Transformer.
The dry oxygen enriched air is fed at one end of the Ozone Cell and the outgoing gas
from the first cell is fed to the other Cell. The gas coming out from the final Cell is
Ozone rich. The cells are forced air-cooled.

High Voltage Transformer and Supply System

A High Voltage Transformer is used to develop 7-10 K Volts on single-phase AC supply.
The high voltage is applied between the electrodes of the Ozone Cells to develop a
Corona discharge through which the dried air is passed.

Power Fuse
This fuse protests the Power System and other components from any damage by shortcircuiting or over current run.

Page 5 of 17

Cabinet Cooling Fans

For Cooling the Ozone Cells and other components in the cabinet two numbers 105 CFM
Ventilation Fans are provided on the bottom side of the top portion of the cabinet.

Indicators
Following Indicators and LED lamps are provided for long life at the Control Panel for
control, indication and fault annunciation.

Air flow indicator

Ozone on

Blown fuse

Low cut off

Hi cut off

Page 6 of 17

3.0 INTALLATION
3.1 LOCATION

The Ozone generator should be located in a covered area.

Ozone unit is to be in the wall installed preferably at a reasonable height so that the
operation of the machine can be controlled.

The place of installation should be clean, dry and well ventilated.

Spillage of water or excessive moisture near these units should be strictly avoided.

3.2 POWER CONNECTION

An industrial power socket with a circuit breaker of 5 Amps is to be provided close to

the Ozonator preferably on the right hand side of it.

Electrical Supply Voltage to Ozone Generator should be between 200 to 240 Volts.

The Ozonator should be provided a proper earth in addition to the earth provided in the
electrical supply.

3.3 CONNECTING OZONE OUTPUT TO THE APPLICATION POINT

Ozone output is on the left side of the cabinet.

The Ozone output coming out from Ozone generator is taken through an Ozone resistant
pipe it can be connected to the diffuser at the point of application.

Page 7 of 17

4.0 OPERATION OF THE OZONATION SYSTEM

4.1 START-UP

Switch ON Main Switch at electrical outlet from where the Ozonator is getting electrical
supply.

Switch on main Switch Mounted on the front panel. The power On LED would glow
along with the Hi-low LED.

The system will take a delay of 5 sec. prior to start.

4.2 OPERATIONAL PARAMETERS

OPERATING PARAMETERS AND THE ADJUSTMENTS:
The Ozone Generator will be operating with following parameters: (for TUF-A0005G
OXY)
Ozone Output
:
1.0 to 5.0 gm/hr
Output Pressure
:
0.4 to 0.6 kg/cm
Total Gas Flow
:
Approx. 5 - 7 L.P.M.

After the start up and reaching the ozone concentration the Ozonation system will work
continuously.

4.3 SHUT DOWN

Simply Shut Off Control Switch to shut down the ozone generator.

Page 8 of 17

5.0 PRECAUTIONS
The warranty of the equipment voids if any form of tampering or mishandling is carried out
on the Ozonation system.
5.1 ENVIRONMENTAL
The equipment should be kept in a clean, dry and in dust free environment.
There should not be any Spillage of water or excessive moisture near the Ozonation
system.
The Ozone generator as well as the accessories of the system should be kept away from
direct radiations from sunlight or any other heat source.
5.2 EQUIPMENT SAFETY

There is no user serviceable part inside the Ozonation system and thus any unauthorized
person or electrician is not permitted to open the equipment for carrying out any repairs
in the equipment.
Do not place any cover on the equipment when they are being operated and a free
passage of air inflow and outflow should be ensured.
Ozone diffusers are to be checked for any kind of blockages.

5.3 ELECTRICAL
Electrical Supply Voltage to ozone Generator should be between 200 to 240 Volts. The
Ozonation system will perform best at 220 Volts, thus a stabilized power supply is
recommended for smooth operation and long life of the equipment.

There should not be any loose connections or appearance of spark in the equipment and
in the supply points.

The cabinet should be opened during operation by an authorized qualified / trained

engineer.

A proper Earth is most important and in absence of the same, serious damages may
result to equipment and operator. Ozone Generator should not be operated without a
proper Earth Point.

A proper Earthling point is required to be provided near the Ozonator and connected to
its SS cabinet, in addition to the earth terminal provided in the mains supply cord. This
is very important.

Page 9 of 17

5.4 HUMAN SAFETY

Ozone Generator produces very high voltage and thus no one should open the cabinet
and touch the equipment when it is switched on. This could result in a fatal electric
shock.
The ozone concentration in the environment should not be more than 0.1 ppm at any
instant of time. This limit is as per the OSHA standards.

Page 10 of 17

6.0 PREVENTIVE MAINTENACE

6.1 DAILY CHECK UP SCHEDULE

Clean the cabinet from all the sides, front panel and the surrounding areas.

Carefully watch for presence of moisture or water closer or in the Ozone generator, if
yes find the reason and rectify it.

Before switching the Ozonation system checks the status of the input supply and if
normal run the system.

After start of the Ozone generator check for the following points.
Any abnormal sound or typical observation, find the reason and rectify it.
Ozone output in gms/hr as per the required level.
Required ozone level in the environment

6.2 WEEKLY CHECK UP SCHEDULE

Following points are required to be checked up on weekly basis in addition to the daily
check up mentioned above.
The Ozone generator is to be cleaned from inside by switching it of with the help of a
soft cloth or a brush.
Check for any sparks near the ozone cells, incase of sparks clean the place to rectify the
problem.

Page 11 of 17

7.0 FAULT FINDING AND REMEDIES

7.1 OZONE GENERATOR NOT WORKING
SYMPTOMS: - Power On
Switching on the Ozone generator.

indicator

YELLOW

LED

not

glowing

after

CONCLUSION: - Power supply is not reaching the Ozone generator.

CHECK UP

ACTIONS TO BE TAKEN

No supply in the mains socket

Rectify power supply

Damaged mains cord

Replace mains connecting wire

Damaged power inlet socket

Replace the socket

Loose connections

Connect properly

IF ALL THE ABOVE POINTS ARE OK

CONTACT US

SYMPTOMS:-Power On indicator
ON LED green does not glow.

glows

after

switching

on

but

system

CONCLUSION:-Power supply is up to the Ozone generator, however not reaching the

Circuitry or Control supply is not there
CHECK UP

ACTIONS TO BE TAKEN

Control switch off

Switch On the switch on the front panel

Blow fuse RED LED

Replace the Fuse with 2A fuse

No air supply to the Ozone machines

rectify the Air line

Any loose connections

Connect properly

If all the above points are OK

Contact factory

7.2 OZONE GENERATOR WORKING BUT OZONE OUTPUT LOW

SYMPTOMS: - No ozone output while the Ozone generator is working
CONCLUSION: - HT supply may be defective.
CHECK UP

ACTIONS TO BE TAKEN

Control switch is off

Switch ON the switch on the front panel

BLOWN FUSE LED glowing

Replace with 5A fuse

Loose connection

Connect properly

IF ALL THE ABOVE POINTS ARE OK

CONTACT US

Page 12 of 17

7.3 OZONE GENERATOR WORKING BUT OZONE OUTPUT LOW

SYMPTOMS: - No ozone output while the Ozone generator is working and Digital
Display shows normal reading.
CONCLUSION: - HT transformer may not be getting supply or may be defective.
CHECK UP
Check for the Blown fuses in the cabinet
Check the input supply to the transformer

ACTIONS TO BE TAKEN
Replace the fuse with 5 A Fuse
If abnormal change the transformer

Check the ozone cells for leakage

Correct it or replace cell.

If all the above points are OK

Contact factory

7.4 OZONE GENERATOR NOT WORKING POWER ON LED IS GLOWING

SYMPTOMS
CONCLUSION

::-

LED of Power On is glowing along with Hi-Low cutoff LED

abnormal voltage.

CHECK UP

ACTIONS TO BE TAKEN

Check for the Blown fuses in the cabinet

Replace the fuse with 5 A Fuse

Check Feed gas flow

Correct the Feed Flow

Check the voltage abnormality

Correct it

If all the above points are OK

Contact factory

Page 13 of 17

8.0 ANNEXURE
TECHNICAL SPECIFICATIONS OF OZONE GENERATOR
OZONE PRODUCTION
Ozone Output
Oxygen Enrichment
Ozone Flow Rate
Ozone Concentration

1~20 gm/hr
Yes
5~12.5 LPM
15~20 mg/l

SYSTEM DESIGN
Feed Gas
Dryness
Electrodes Material
Enclosure

Dry oxygen enriched Air

-20 C
SS 316
SS 304

UTILITIES
Power (Watts)
Voltage (Volts)
Voltage Surge
Frequency (Hz)
Phase

570 ~ 1050
220 15%
Nil
50 2%
Single

DIMENSIONS
Height mm
Width mm
Depth mm

700
680
250

WEIGHT
In Kg. Approx.

35 ~ 42

Page 14 of 17

Cooling Fan

Ozone Cell

Top view of TUF-A0005G OXY Ozone

Generator (Cover Open)
15
Page

of 17

Back view of
front cover

Air dryer & O2

enrichment unit
Control
circuit

Air Pump

Dry feed gas

Reservoir

H.T. Transformer

Front view of TUF-A0005G OXY Ozone

Generator (Cover Open)
(Covers Open)
16 17
Page

of

Front panel of TUF-A0005G OXY Ozone

Generator
Page 17 of 17