Ozone Generator Failure Symptoms and Troubleshooting Guide

Ozone Generator Failure Symptoms and Troubleshooting Guide

Ozone generators are durable, high-performance systems designed for long-term operation—especially in industrial environments where continuous ozone production is required. However, like all industrial equipment, they can show signs of malfunction, wear, or performance loss over time.
Recognizing these symptoms early helps prevent costly downtime and ensures the generator continues operating safely and efficiently.

Here are the most common ozone generator failure symptoms and the recommended troubleshooting steps for each.

1. Significant Drop in Ozone Output

Symptoms:

  • Odor removal or disinfection performance is noticeably weaker

  • Low g/h or g/Nm³ values during measurement

  • Unstable ozone output readings

Possible Causes:

  • Moisture entering the system

  • Dirty air filters

  • Low oxygen purity from the concentrator

  • Aging or contaminated corona discharge cells

Troubleshooting:

✔ Replace or clean filters
✔ Check oxygen concentrator pressure and purity
✔ Inspect cell temperatures
✔ Ensure air dryer or moisture traps are functioning

2. Generator Overheating

Symptoms:

  • Internal temperature alarms

  • Device shutting down automatically

  • Sudden fluctuations in ozone output

Possible Causes:

  • Fan failure

  • Blocked cooling channels

  • Excessive ambient temperature

  • Overloaded generator

Troubleshooting:

✔ Clean or replace cooling fans
✔ Remove dust from radiators and vents
✔ Improve airflow around the generator
✔ Verify cooling system operation

3. Unusual Ozone Smell in the Facility

A strong ozone smell inside the facility usually indicates leakage.

Symptoms:

  • Staff experience eye or nose irritation

  • Noticeable sharp ozone odor during operation

Possible Causes:

  • Leaking hoses or fittings

  • Non-compatible hose materials

  • Loose connectors

Troubleshooting:

✔ Inspect all hoses (use PTFE or stainless steel only)
✔ Tighten fittings and replace faulty O-rings
✔ Install an ambient ozone leak detector

4. Poor Performance from the Oxygen Concentrator

Symptoms:

  • Lower oxygen purity

  • Low or unstable pressure readings

  • Loud or irregular compressor noise

Possible Causes:

  • Moisture buildup

  • Worn-out zeolite bed

  • Compressor issues

  • Air leaks

Troubleshooting:

✔ Perform scheduled concentrator maintenance
✔ Replace moisture filters
✔ Check compressor pressure
✔ Inspect hoses for leaks

5. Electrical Problems or Cell Arcing

Symptoms:

  • Crackling or sparking sound from inside the generator

  • Sudden shutdowns

  • Zero ozone production

Possible Causes:

  • Moisture inside the ozone cell

  • Insulation breakdown

  • Voltage instability

  • End-of-life corona cell

Troubleshooting:

✔ Inspect dielectric surfaces inside the cell
✔ Ensure complete dryness
✔ Check voltage supply and grounding
✔ Replace the ozone cell if damaged

6. PLC or Sensor Errors

Symptoms:

  • Error codes on touchscreen

  • System refusing to start

  • Unexpected shutdowns

Possible Causes:

  • Incorrect sensor calibration

  • Faulty pressure or temperature sensors

  • Software issues

Troubleshooting:

✔ Recalibrate sensors
✔ Install the latest PLC firmware
✔ Check all electronic connections

7. Low Gas Flow or Blockage in the System

Symptoms:

  • Low flow rate on the flowmeter

  • Weak ozone discharge

  • Reduced injection efficiency

Possible Causes:

  • Blocked filters

  • Pinched or clogged hoses

  • Dirty venturi injector

Troubleshooting:

✔ Replace filters
✔ Clean or replace hoses
✔ Flush the venturi injector

8. Ineffective Ozone Destruct Unit

Symptoms:

  • Residual ozone smell after shutdown

  • Weak airflow through the destruct unit

  • No heat from the catalyst heater (if included)

Possible Causes:

  • Saturated catalyst

  • Blocked airflow

  • Heater malfunction

Troubleshooting:

✔ Inspect the catalytic material
✔ Clean internal pathways
✔ Test the heater system

Conclusion: Early Detection Prevents Major Failures

Even minor performance changes in an ozone generator can indicate underlying problems. Early detection and regular system checks ensure:

✔ stable ozone production
✔ longer equipment lifespan
✔ safe operation
✔ lower maintenance costs
✔ uninterrupted industrial processes

A properly maintained ozone generator delivers maximum efficiency and reliability for years.