Bench test set-up with ozone example

We recently set-up some equipment for a customer to perform his own bench testing with ozone.  Below is a description of this set-up and the parts used.  Hopefully, this helps you learn more about the possibilities with ozone and how you can set this up yourself.

More info on ozone bench-test set-ups at this link.


Ozone system for bench testing
Diagram of ozone bench-scale equipment for laboratory testing

The above diagram shows the equipment used and basic plumbing of this equipment. This specific set-up was designed to use ozone gas to treat a dry product. The test column in this application would have a dry edible product in it, ozone would be used to provide disinfection of this food product. Using the ozone analyzer the actual level of ozone passing through the column can be verified, also the ozone analyzer could measure ozone leaving the column to determine the level of ozone consumed by the product.

This system uses an air dryer and a larger air pump as gas flows up to 30 LPM will be used. Target ozone levels of 20 – 200 ppm will be used in this gas flow through the product. The high gas flow and tall colum will help “float” the product to achieve great contact with ozone gas and the product being tested.

ozone bench-test
Example of ozone equipment for lab set-up

The images above and below show the actual products used.  These are the same components shown in the diagram above.  As usual, real-life is not as seamless and tidy as a diagram.  This does give a great example of how this can be set-up in your lab and how much space this may consume.

The ozone products used are:

VMD air dryer 

The VMD-30 air dryer is a vacuum driven heat regenerative air dryer that will provide air dried to -40-deg F dew point at a flow up to 30 LPM.  Perfect to ensure the air fed into the ozone generator is dry, and consistent.  This will ensure reliable ozone levels and measurements.

HTU-500 Ozone Generator

The HTU-500 ozone generator is a great small lab-scale ozone generator.  This unit will operate on air or oxygen, and at pressure or vacuum.  Great versatility for lab scale project.

UV-106M Ozone Analyzer

Measures ozone in air using UV absorption technology.  This unit will measure ozone up to 1,000 ppm accurately with a resolution of only 0.01 ppm.  This great tool can be used for this bench-test set-up and later when this system goes to full scale.


A basic diaphragm compressor was used for this application.  We added a flowmeter with a valve to adjust air flow between 0-30 LPM.  It is important the compressor used does not leak air into itself so we can ensure the dry air is pushed through the ozone generator.

Ozone test column

The ozone test column, shown below, is constructed of 2″ clear PVC and CPVC fittings.  This same column can be used for water tests with only minor differences.  The height of this column ensures ozone gas will pass through the product or water placed in the column for a great distance, this ensures better contact or mass transfer of the ozone.  The cap on top can ensure safety and catch any excess ozone to be measured by a UV ozone analyzer.  A stainless steel diffuser is placed in the TEE at the bottom of this column.  This diffuses the ozone gas into the air or water to ensure great mixing.


ozone equipment for lab scale equipment
Ozone treatment column for bench-test
Column manufactured from PVC to test ozone in lab scale applications
PVC column for ozone bench-test applications

Demonstration of the C-30ZX ozone monitor response speed and alarm function

The C-30ZX ozone monitor is a fixed mount device that will measure ozone from 0-0.14 ppm in 0.02 ppm increments.  This monitor features an internal relay and audible alarm.  The internal relay is user settable at any level from 0.02 – 0.14 in 0.02 ppm increments.  This relay can be used to indicate a remote alarm or shut-down the ozone generation source.  The audible alarm will also sound simultaneously when the relay is set-point is triggered.

The video below displays the response time and the audible alarm triggering.

The EcoSensors C-30ZX is a wall-mounted ozone detector with an instant LED readout, audible safety alarm, and relay switch. The range of ozone measured by this meter is 0-.14 PPM. The main purpose of this sensor is for personnel safety, as 0.14 PPM ozone is the maximum exposure limit allowed by OSHA during an 8-hour work shift.

C-30ZX Ozone Monitor

Purchase EcoSensors C-30ZX Ozone Detector here

The C-30ZX has a rapid readout response to changes in ozone levels. Notice how quickly the LED light readout indicates an increase in the ozone level as the sensor moves near the ozone generator. Then, as it moves away, notice how the LED lights almost instantly reflect the lower levels of ozone.

The C-30ZX has an audible alarm that can be switched on. In this case, the alarm is set to sound at .1 ppm. The alarm can be manually switched off – or, it will also stop sounding as soon as the ozone levels are below the alarm set point.

Bump tester for ozone monitors – ozone puffer

The video below shows the basic functions of the Ozone Puffer.  This is a great tool to use to bump test your ozone monitors quickly without taking them out of service or carrying dangerous calibration gasses to the sensor.

Ozone monitors should be bump tested periodically to ensure they have a positive response to ozone gas and will react to ozone as they should.  Bump testing does not take the place of calibration but is done in-between calibrations to ensure your ozone monitor will react to ozone if, or when a dangerous level of ozone is released into the airspace.

The Ozone Puffer is used for field ozone detector bump tests.

O3 Bump Test Puffer

Purchase Ozone Puffer here

The Ozone Puffer generates ozone internally and then delivers that ozone directly to the ozone sensor. The purpose of the test is not to test the detector’s accuracy, but to ensure that the sensor is responding to ozone.

The Ozone Puffer has 4 features: ozone generator button, LED readout, puffer button, and tubing. To activate the Puffer, hold down the ozone generator button until the LED readout appears as a red number 9. Release the generator button and allow the LED readout to blink about 30 times. When the blinking stops, the Puffer is ready. Quickly press the puffer button while holding the tip of the tubing near the ozone sensor inlet. This delivers a large amount of ozone directly to the ozone sensor. Watch the ozone detector’s readout to ensure that the reading quickly goes up. The purpose is to ensure that the ozone detector is responding to ozone.

Tools for ozone monitor calibration and bump-testing

Ozone monitors and sensors should be calibrated every 6-months to 1-year. This calibration can be done by our technicians to a NIST traceable standard. However, if this is something you prefer to perform on-site we have a few tools you can use to perform calibrations on-site, or bump-test your ozone monitor between calibration intervals.

Learn more about ozone monitor calibration on our main website HERE.

Model 306 Calibration Source

The Model 306 Calibration Source is a UV based ozone source that is portable and easy to use.  This device will provide a known quantity of ozone gas in a sample stream of 3 LPM.  Three usable settable ozone ranges are available to choose from for calibration.  This will allow the calibration of most ozone sensors that have a calibration adapter or a flow-cell where gas can flow to or through the sensor for calibration. This device requires no zero air cylinder and can use ambient air for ozone sensor calibrations.  The accuracy of this device is 2% which is superior to any other portable calibrator available on the market.

Calibrate Ozone monitors with the Model 206
306 Calibration Source

A23-14 Ozone Calibrator

The A23-14 Ozone calibrator is used to calibrate your ozone sensors. This device creates a known level of ozone with the factory calibrated ozone generator. Easy to use, and portable this unit can be carried to your ozone sensor.  Accurate to within 5-10% depending upon the application.

A23-14 Ozone Calibration Kit for field calibration of ozone sensors

Ozone Puffer

The ozone puffer is a simple to use tool to bump-test ozone sensors. Portable and battery powered, this is the easiest method to quickly bump-test your sensor between calibration intervals.  Battery powered unit requires no power cord and is completely portable.

Bump testing is a great method to ensure your sensor is responding to ozone when necessary. Bump testing is not a replacement for calibration. However, bump testing can be done between calibrations to ensure proper response of your ozone sensor, and ensure that a sensor failure has not occured. We suggest bump testing your ozone monitor as often as daily in extremely critical applications. Weekly or montly internvals are common for bump testing your sensor between annual calibration periods.

A23-14 Ozone Calibration Kit for field calibration of ozone sensors
Ozone Puffer.

OG-3 Checker

The OG-3 Calibration Checker is primarily used for Eco-Sensors devices. This will create a known ozone level for bump testing or checking calibration of your sensor between calibration intervals.

OG-3 Ozone calibration checker for accurate bump testing ozone monitors
OG-3 Checker 

Ozone Chambers

We can also provide complete ozone chambers to be used for calibration purposes.  We build standard and custom ozone chambers for ozone exposure testing.  These chambers can also be used for calibrating one, or multiple ozone sensors at one time.  Using a calibration chamber any level of ozone desired can be chosen and entered into the control system, the chamber will maintain that ozone level, by placing your ozone sensors inside the chamber you can validate the readings of your ozone sensors and adjust accordingly.

CH-3 Ozone Mobile Chamber
CH-Series Ozone Chamber


Should you have any further questions on ozone monitor calibration please call our office.  We would be glad to help with your specific needs or to meet any specific criteria you have.

Introduction to the C-30ZX Ozone Monitor

The C-30ZX ozone monitor is a fixed mount ozone detector with a control relay and audible alarm designed to measure ozone from 0-0.14 ppm of ozone in 0.02 ppm increments.  This is a great monitor to use for ozone safety applications where the OSHA 8 hour TWA limit is the primary concern.  The video below shows the basic functions and operation of the C-30ZX ozone monitor.

The EcoSensors C-30ZX Ozone Meter is a fixed monitor with an audible safety alarm and a relay switch. This monitor detects ozone in the range of 0-.14 PPM, which is the OSHA safety limit for ozone exposure during an 8-hour work shift.

C-30ZX Ozone Monitor

Purchase EcoSensors C-30ZX Ozone Detector Here

The ozone level is indicated by an LED readout, which at the low level is green, at the mid-ozone level is yellow, and at the top of its range, 0.14 ppm, is red to indicate danger. The audible safety alarm can be switched on or off. The C-30ZX Ozone Meter is powered on by plugging it in. The only way to power off this detector is to unplug it. The C-30ZX Ozone Meter is designed to be mounted, plugged in, and powered on continuously. It does not have a battery. The calibration certificate is included in the package. The calibration certificate includes the date of calibration, the data involved in the calibration process, and the serial number of the ozone detector unit. This ozone meter should always be powered on for 24 hours before using it for an accurate ozone detecting. The warm-up phase allows the oxidation to burn off the ozone sensor. Once the oxidation has burned off, the sensor can accurately detect ozone.

The C-30ZX monitor reads ozone from 0 – 0.14 ppm and indicates ozone levels with LED bars that illuminate as the ozone levels. 0.1 ppm is the 8-hour OSHA exposure limit for ozone making the C-30ZX an ideal monitor for measuring low-range ozone levels for safety.

Introduction to the EZ-1Z Handheld Ozone Detector

We created a new video about the EZ-1X handheld ozone detector.  This shows the basic functions and what comes in the box with the EZ-1X ozone detector.

The EcoSensors EZ-1X Ozone Detector is a portable detector used for personal safety in the workplace. It responds instantly to ozone in the air, with an LED readout that goes from zero to 0.14 PPM. 0.14 PPM ozone is the OSHA recommended safety level for an 8-hour shift. The LED lights go from green, to yellow, to red indicating the upper OSHA ozone limit is being reached.

EZ-1X handheld ozone sensor

Purchase the EcoSensor EZ-1X Ozone Safety Detector here

Included in the package for the EZ-1X Ozone detector is the monitor itself, the calibration certificate, and the charging cord. The calibration certificate includes the serial number of the unit, data about the calibration process, and the date of calibration. This document needs to be kept for your records, as the ozone monitor should be recalibrated yearly. The EZ-1X ozone detector should be plugged in and fully charged before being used for a work shift. Once fully charged, the EZ-1X detector has a battery life of 8 hours. The monitor needs to go through an initial warmup phase – plugged in and powered on for at least 24 hours before first use. This allows the oxidation to burn off the ozone sensor, allowing the sensor to read ozone levels accurately. The green LED light will automatically light up when the EZ-1X ozone detector is plugged in, indicating that the meter is powered on while also charging. The switch should be in the “AC Power and Bat Chg” position while this ozone detector is plugged in.

When the EZ-1X is plugged in, and the green light is ON it is actually ON and sensing ozone, and can be left that way indefinitely.

The EZ-1X detector reads ozone from 0 – 0.14 ppm and indicates ozone levels with LED bars that illuminate as the ozone levels. 0.1 ppm is the 8-hour OSHA exposure limit for ozone making the EZ-1X an ideal monitor for measuring low-range ozone levels for safety.