DYNE-A-MITE™ IT

3D SURFACE TREATER

ML0094-001-07

OWNER’S REFERENCE MANUAL

Enercon Industries Corp.

W140 N9752 Fountain Blvd.
P.O. Box 773
Menomonee Falls. WI 53051
Phone: (262) 255-6070
Fax: (262) 255-7784
E-mail: info@enerconind.com
Web-site: www.enerconind.com

3/25/2014
 TABLE OF CONTENTS
SECTION 1 –INTRODUCTION............................................................................................................................................................. 1
SAFETY AND WARNINGS..................................................................................................................................................... 1
SAFETY PRECAUTIONS ....................................................................................................................................................... 2
INTRODUCTION TO THE DYNE-A-MITE™ IT 3D TREATER SYSTEM (Figure 1) ............................................................... 3
EQUIPMENT SPECIFICATIONS............................................................................................................................................ 3
INFORMATION AND SAFETY LABELS (Figure 2) ................................................................................................................ 4
"AIR PLASMA" TREATMENT OF THREE-DIMENSIONAL OBJECTS .................................................................................. 5
GENERAL............................................................................................................................................................................... 5
IT DISCHARGE DESCRIPTION (Figures 3 & 4) ................................................................................................................. 5-6
EQUIPMENT CONFIGURATION ........................................................................................................................................... 6
SECTION 2 –INSTALLATION ............................................................................................................................................................... 7
UNPACKING AND INSPECTION ........................................................................................................................................... 7
DOCUMENTATION ................................................................................................................................................................ 7
OPTIONAL EQUIPMENT ....................................................................................................................................................... 7
SITE SELECTION .................................................................................................................................................................. 7
COMPRESSED AIR SUPPLY INSTALLATION (Figure 5) ..................................................................................................... 7
OPTIONAL CO2 INSTALLATION .......................................................................................................................................... 7
SAFETY INTERLOCKS (Figures 6 & 7) .............................................................................................................................. 7-8
PLASMA MONITORING CIRCUIT ......................................................................................................................................... 8
INSTALLATION OF THE DISCHARGE HEAD ....................................................................................................................... 8
IT DISCHARGE HEAD (Figure 8) ........................................................................................................................................ 8-9
GAP REQUIREMENTS .......................................................................................................................................................... 9
EXHAUST REQUIREMENTS ................................................................................................................................................. 9
IT SURFACE TREATER WIRING DIAGRAM (Figure 9) ..................................................................................................... 10
SECTION 3 –PRINCIPLES OF OPERATION .................................................................................................................................. 11
GENERAL............................................................................................................................................................................. 11
OPERATING INSTRUCTIONS ............................................................................................................................................. 11
INDICATOR COLOR CODING ............................................................................................................................................. 11
AIR PRESSURE REQUIREMENTS (Figure 10) ................................................................................................................... 11
FUSES ................................................................................................................................................................................. 11
SEQUENCE OF OPERATION (Figure 11) ........................................................................................................................... 12
REMOTE START / STOP (Figure 12) .................................................................................................................................. 12
FRONT PANEL CONTROLS (Figure 13) ............................................................................................................................. 13
SECTION 4 –MAINTENANCE ............................................................................................................................................................ 14
GENERAL............................................................................................................................................................................. 14
PREVENTIVE MAINTENANCE ............................................................................................................................................ 14
MONTHLY CHECKS ............................................................................................................................................................ 14
AIR SUPPLY COMPONENTS .............................................................................................................................................. 14
DISCHARGE HEAD NOZZLE (Figure 14) ............................................................................................................................ 14
QUARTERLY CHECKS ........................................................................................................................................................ 14
AIR VANE ELCTRODE ........................................................................................................................................................ 14
SECTION 5 –TROUBLESHOOTING ................................................................................................................................................. 15
GENERAL............................................................................................................................................................................. 15
TROUBLESHOOTING .......................................................................................................................................................... 15
TROUBLESHOOTING TRIP................................................................................................................................................. 15
INVERTER OHM CHECK PROCEDURE ............................................................................................................................. 16
FACTORY ASSISTANCE ..................................................................................................................................................... 16
SECTION 6 –PARTS LISTS................................................................................................................................................................ 17
GENERAL............................................................................................................................................................................. 17
HOW TO USE THIS PARTS LIST ........................................................................................................................................ 17
HOW TO ORDER PARTS .................................................................................................................................................... 17
SHIPPING INSTRUCTIONS FOR RETURNS ...................................................................................................................... 17
CUSTOMER SERVICABLE PARTS - IT DISCHARGE HEAD PARTS BREAKDOWN (Figure 15)...................................... 18
IT SURFACE TREATER PARTS BREAKDOWN (Figure 16) ............................................................................................... 19
SECTION 7 –MISCELLANEOUS ....................................................................................................................................................... 20
MAINTENANCE RECORD .............................................................................................................................................. 20-21
NOTES ............................................................................................................................................................................ 22-23
 SECTION 1 – INTRODUCTION

WARNING!
Please read carefully before installing or servicing.

DO NOT OPERATE THIS EQUIPMENT IN A HAZARDOUS ENVIRONMENT!

HIGH VOLTAGE is present within this equipment. Install according to local electrical codes to ensure
personnel safety. When SERVICING, technician must ensure that electrical power is disconnected and locked
out before working on equipment.
NXOX CONTAMINATES, such as NITROGEN DIOXIDE or NITRIC OXIDE, may be produced when certain
materials are treated. All reasonable precautions should be taken to ensure that any CONTAMINATES are
exhausted to a safe location (exterior of building recommended). If CO2 is used as the feed gas OZONE, an
OSHA restricted air contaminate, will be present in the exhaust airflow. INSTALLATION of this equipment
must be done in accordance with this manual, Enercon installation drawings and local codes to ensure the
safety of personnel in the area and in the building.

SAFETY AND WARNINGS

Before placing this equipment into operation, we Safety instructions in this manual are called out in
strongly recommend that you take the time to read colored safety boxes with bold-faced text for
this manual carefully in its entirety to ensure you emphasis. The signal words CAUTION,
understand all the safety and operational WARNING, and DANGER are used to indicate
requirements for using this equipment. hazard seriousness levels as follows:
Electricity and Electrostatic discharge have the
potential to cause severe personal injury or property
damage. CAUTION!
Before starting, operating or making any CAUTION is used to indicate the presence of a
adjustments, identify the components of the treater potentially hazardous situation which, if not
using this manual as a guide. avoided may result in minor personal injury or
property damage.
The operator should use common sense and good
working practices while operating and maintaining
this unit. Follow all codes and understand the
starting and stopping sequence. Check the safety
WARNING!
devices following the procedures contained in this WARNING is used to indicate a potentially
manual. hazardous situation which, if not avoided, can
Maintenance should only be performed by qualified result in serious injury or death.
personnel, adequately equipped with the proper
tools. Follow the maintenance schedules as outlined
in the manual to ensure problem-free operation after
DANGER!
startup. DANGER is used to indicate an imminently
The manufacturer of this equipment expresses hazardous situation which, if not avoided, will
concern that the equipment is installed, tested, result in serious injury or death.
operated and maintained by such personnel only that
is familiar with the handling and hazards of high
voltage equipment and familiar with the instructions
and safety precautions given herein.

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ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
SAFETY PRECAUTIONS
DO NOT Connect any external control or monitoring
DANGER! equipment, with the exception of appropriate test
equipment, to the internal circuits of this equipment.
The use of high voltage is necessarily employed in Connecting external equipment in this manner may
the operation of this equipment. Precautions have cause failure of this equipment and create a potential
been taken in the design of this equipment to make it hazard to personnel.
as safe as possible for both operator and service
personnel. However, since no amount of interlocks CONTACT:
and safety devices can be absolutely infallible,
precautionary measures must always be taken when Enercon Customer Service Department
working on this equipment. Phone Number: (262) 255-6070
Fax Number: (262) 255-2462
Do Not reach into the equipment or any electrical E-Mail Address: service@enerconmail.com
enclosure without first removing the power. Never Website: www.enerconind.com
apply power to the unit without the cover on and 24hr Customer Service is available.
securely in place.
Capacitors Store Charge: Never trust a capacitor
to be bled off completely. A meter or ground strap
should be used to check each stud or lead before
handling. Some capacitor studs, including those not
tied to bus work (not used), may build up a
considerable static charge. GROUND BEFORE
HANDLING!
DO NOT Stand In Water or On Grounded Surfaces
or Touch Ground Surfaces while Reaching in any
System Enclosure. A piece of wood or other
insulating material will act as an additional barrier to
stand on.

WARNING!
DO NOT Tamper With Safety Interlocks: Under no
circumstances should any safety interlocks be
defeated nor should any of the safety devices be
relied upon for removal of voltage from the
equipment.
Lockout: Use proper lockout and tag out procedures
prior to removing any covers, panels, or cords
provided for access. Ensure power cannot be
applied before entering. Use safety as the first
step.

CAUTION!
Familiarize Yourself Thoroughly with the
Equipment: Never attempt to work on this
equipment unless you are completely familiar with it.
Never assume that a circuit is dead. MAKE SURE!!!
Always Wear Appropriate Protective clothing and
Eyewear while working within the enclosure.

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ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
 INTRODUCTION TO THE DYNE-A-MITE™ IT 3D SURFACE TREATER SYSTEM

Figure 1

EQUIPMENT SPECIFICATIONS

TREATER MODEL
SPECIFICATIONS UNIT
3111IT 3112IT 3211IT 3212IT
Input Voltage VAC 120 ± 10% 240 ± 10% 120 ± 10% 240 ± 10%
Phase Ø Single Single Single Single
Input Frequency Hz 50/60 50/60 50/60 50/60
Input Current A 7 ** 3.5 ** 14 ** 7 **
Output Voltage * KV 3.4 3.4 3.4 3.4
Output Current * Ma 240 240 240 240
Output Power * W 480 480 480 480
Max. Ambient Temperature and Deg. F 104 104 104 104
Humidity for Continuous Deg. C 40 40 40 40
Operation % 80% relative humidity, non-condensing
Number of Discharge Heads EA 1 1 2 2
FT 6 6 6 6
Flexible Conduit ***
M 1.8 1.8 1.8 1.8
LBS 40 40 70 70
Weight (Net) Approx.
KG 18.14 18.14 31.75 31.75
LBS 70 70 100 100
Shipping Weight Approx.
KG 31.75 31.75 45.36 45.36
Inches 21 21 21 21
Width
Millimeters 533.4 533.4 533.4 533.4
Inches 10 10 10 10
Height
Millimeters 254 254 254 254
Inches 10 10 16 16
Depth
Millimeters 254 254 406.4 406.4
MIN MAX
Compressed Air PSI
60 80
MIN MAX
CO2† PSI
60 80
NOTE: *Output Voltage, Current and Power are listed as measured at the HV transformer for each discharge head and the Voltage and
Current levels are RMS values. ** Nominal rating, actual source voltage and impedance will determine the actual input current draw of
system. *** Standard length of flexible conduit between discharge head and control cabinet, custom lengths are available. † Use of CO2
requires a special discharge head for proper operation.

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ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
INFORMATION AND SAFETY LABELS
This page contains representative examples of the
typical placement of the labels that appear on your
Dyne-A-Mite™ IT Treater System. These labels are
designed to provide technical and safety information
required for operation of this equipment. If for any
reason a label is removed, defaced, painted over or
underlying parts are replaced, we recommend you
obtain a replacement label from Enercon and re-
apply them in the locations shown.
NA0133
NA0141

NA0136

NA1020-01

CARBON DIOXIDE
60-80 PSI (4.1 - 5.5 bar)

Rating Plate:
Contact Customer Service with the
System Serial Number for a
Replacement

Figure 2

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ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
 “AIR PLASMA” TREATMENT OF THREE-DIMENSIONAL OBJECTS
GENERAL
Before placing this equipment into operation, we conical, and the outer body approaches the shape of
ask you to please refer to Pages 1 and 2 of this a circle (Figure 4). The distance from the head, the
manual to become familiar with all of this objects geometry, and the velocity of the
equipments safety requirements and precautions. compressed air, or CO2 source can affect the size
and shape of the arc produced.
Due to their non-polar molecular structure, most
polymers, such as polyethylene or polypropylene, IT DISCHARGE HEAD
have poor surface wetting characteristics (surface
tension). When products made of these materials
need to be printed, coated, or bonded (glued), the
processes typically fail due to the materials inherent
surface wetting characteristics.
Manufacturers and converters of plastic films have
overcome this problem for several decades by
exposing polymer surfaces to a process known as
surface treatment. In order to improve the bond
DISCHARGE
characteristics of three dimensional surfaces they
need to be treated using a plasma discharge. For
this process Enercon offers Air Plasma (electrical
ionization of air), Variable Chemistry Plasma - VCP
(electrical ionization of an air/gas mixture), and
Flame Plasma (flame ionization of hydrocarbon gas) BLOWN ION
DISCHARGE HEAD
3D Surface Treater Systems.
IT DISCHARGE DESCRIPTION
An electrode, arranged in a circular pattern, is ELECTRODE
connected to the secondary winding of a High
Voltage (HV) transformer. The HV transformer steps
up the primary voltage to 3.4 KV on the secondary
that will create a continuous arc in the opening
between the points of the electrode and ground. The
arc ionizes the supplied compressed air, or CO2, TRANSFORMER

resulting in the plasma discharge (Figure 3).

120/240 VAC
The flow of the compressed air, or CO2, causes the 50/60 HZ

discharge to spread through the opening in the COMPRESSED AIR OR CO 2

discharge heads nozzle. The size and shape of the
discharge depends on the HV transformers Figure 3
secondary voltage, the velocity of the air/gas mixture ELECTRODES

supplied, and the geometry (shape) of the electrode

and nozzle.
As a general rule of thumb, the higher the secondary
voltage and air/gas mixture velocity, the further the
discharge can extend and spread. However, if the 1/2" - 3/4"
air/gas mixture velocity is too high, the discharge can
break up prematurely and reduce the useful treat
width of the discharge.
The arc generated is conical in shape, much like the
flame from a torch. In a typical production setup, the
object surface to be treated is typically placed 1/4” COMPRESSED AIR
DISCHARGE HEAD DISCHARGE ARC
(6.4mm) to 3/4” (19.5mm) from the front of the treat
head. The treatment pattern on a stationary object is Figure 4

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ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
The plasma discharge contains a high concentration
of highly energized ions. This energy, when applied
to a polymer surface, is capable of creating free
radicals on those surfaces exposed to the plasma.
This process changes the surface tension of the
polymer allowing the treated surface the ability to
effectively cross-link with inks, coatings, or
adhesives.
EQUIPMENT CONFIGURATION
The equipment consists of a cabinet which
incorporates the high voltage power supply with the
necessary control circuits, as well as the Air
Pressure and Flow Controls and HV transformers.
The discharge heads are connected to the control
cabinet by means of a sturdy flexible conduit,
typically six feet in length. This provides for
convenient and space saving installation of the
discharge heads in a fixed location, or on a robotic
platform that follows certain contours or patterns to
treat selected areas of objects. Enercon’s Dyne-A-
Mite™ IT Treater Systems are easy to set up and
maintain. The units have interlocks, cycling, remote
control, loss of treat alarm contacts and optional
machine controls for complete integration with
existing production machines and their controls.

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ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
 SECTION 2 – INSTALLATION

UNPACKING AND INSPECTION

IMPORTANT: Your Dyne-A-Mite™ IT Surface
Treater System may have been shipped in more CAUTION!
than one container, so compare the items received
DO NOT restrict airflow to sides and bottom of
with the packing slip to ensure that all items that
unit.
shipped were received. The carrier accepted
responsibility for this shipment when the carrier DO NOT enclose this equipment unless proper
signed the Bill of Lading at the origin of shipment. If ventilation and cooling are provided.
external damage to the packaging was detected, it
should have been noted on the freight bill before COMPRESSED AIR SUPPLY INSTALLATION
signing it to acknowledge receipt. If you give the The Dyne-A-Mite™ IT Surface Treater requires a
carrier a clear receipt for goods that have been compressed air supply from a clean, dry source. The
damaged or lost in transit, you do so at your own risk compressed air supply is connected to the ¼” tube
and expense. fitting on the back of the power supply (Figure 5).
All packages and crating should be carefully opened 1
4" COMPRESSED
AIR FITTING
and all items thoroughly inspected for damage. Be
extra careful if using a sharp instrument to open
packaging or when removing the protective wrapping
from the equipment. If concealed loss or damage is
discovered after delivery, notify your freight carrier at
once to file a claim and request an inspection. This is
absolutely necessary for the carrier to consider your
claim. The carrier’s agent should make an inspection
and issue a loss or damage report. Enercon should
also be contacted as soon as possible to expedite
the shipment of replacement parts.
CONTACT: Figure 5
Enercon Customer Service Department
OPTIONAL CO2 SUPPLY INSTALLATION
Phone Number: (262) 255-6070
The Dyne-A-Mite™ IT Surface Treater can be
Fax Number: (262) 255-2462
ordered with an optional CO2 discharge head to
E-Mail Address: service@enerconmail.com
allow running the system with a CO2 supply instead
Website: www.enerconind.com
of a compressed air supply. In this case the Dyne-A-
24hr Customer Service is available.
Mite™ IT Surface Treater requires a CO2 supply
from a clean, dry source. The CO2 supply is also
DOCUMENTATION connected to the ¼” tube fitting on the back of the
A system folder containing any printed drawings and power supply (Figure 5).
CD-ROM was also provided with your system.
SAFETY INTERLOCKS
OPTIONAL EQUIPMENT The Dyne-A-Mite™ IT Surface Treater circuitry is
Some optional items were available for purchase designed to accommodate external safety and
with your Dyne-A-Mite™ IT Surface Treater System remote control devices (See Figure 6). Any safety
and the same care should be used when opening interlocks must be connected to CN1 using the
these boxes. For installation and setup of options Customer Interface Cable provided with the system.
included with your system refer to this manual and If more than one safety interlock is to be installed,
any system drawings provided. they must be installed in series. In order for the
treater to operate, all interlock switches must be
SITE SELECTION satisfied (closed).
Careful consideration must be taken when selecting
the site for the equipment. Items such as ventilation
space, ambient temperature, and cleanliness should
be taken into account.
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ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
 CUSTOMER INTERFACE CABLE (REAR OF CONNECTOR)
ORANGE
BROWN
REMOTE START/STOP WARNING!
CONTACT
We strongly recommend that safety precautions
1 7 LOSS OF PLASMA CONTACT such as enclosures and/or light barrier sensors
WHITE N.C. = NO PLASMA are installed in the proximity of the high voltage
2 8 6 OPEN = PLASMA PRESENT
CONTACT RATINGS discharge to assure that no person can come
3 5
BLACK
120 VAC - 0.5 AMPS within close proximity to the electrodes or the
4
24 VDC - 1 AMP plasma during operation.
BLUE Also, no attempts should be made to
CUSTOMER SAFETY
RED INTERLOCKS disassemble the discharge head for any reason
without the consent of the manufacturer.
Figure 6
If the interlocks are not met the INTERLOCK LED The effective treatment area provided by each
will be lit on the front panel and the unit will not start discharge head is approximately ½” (12.7mm) to ¾”
either from the front panel or using remote (19.5mm) in diameter. The size and shape of the
Start/Stop. area may change somewhat depending upon the
distance of the discharge head from the surface to
NOTE:
be treated, its geometry, and the PSI of the
A defeat connector is supplied to disable the
compressed air source.
interlock circuit by installing the connector on CN1
(Figure 7). To install external interlocks the Defeat IT DISCHARGE HEAD
connector must be removed and replaced by the The discharge head should be securely mounted to
Customer Interface Cable provided (See Figure 6). the production line by means of a sturdy clamp and
post style mounting system (Figure 8). The
DEFEAT
CONNECTOR
discharge head is shown with our optional Universal
Mounting Bracket to demonstrate the manner in
which the discharge head body should be supported.
FRONT VIEW
REAR VIEW

Ø0.16"

Ø2.0"
9.11"
Ø1.0" Ø2.0"
Ø0.30"

Figure 7
Ø1.69"
PLASMA MONITORING CIRCUIT 2.75" 4.67"

The status of the plasma can be monitored remotely

by use of the loss of plasma contact (See Figure 9).
NOZZLE
The loss of plasma contact is an internal, normally
closed, dry contact that opens when plasma is
DISCHARGE
present at the discharge head. This circuit is HEAD BODY
designed for your use, to drive an external ASSEMBLY
monitoring device or alarm circuit and is rated for 24
NOZZLE
VCD – 1 Amp or 120 VAC – 0.5 amps (If used these BODY
voltages must be supplied by the customer). You can
connect to this circuit across pins 5 & 8 on CN1,
using the Customer Interface Cable supplied with
your system (See Figure 6).

INSTALLATION OF THE DISCHARGE HEAD

The discharge head is connected to the control
cabinet by means of a single flexible conduit which
contains the high voltage wire, ground wire and the
compressed air or CO2 supply.
Figure 8
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ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
 *These byproducts are commonly seen in low
WARNING! concentrations in many plasma treating applications,
When mounting the discharge head, no but they are listed here only as examples. Detailed
additional holes should be drilled, nor should any testing would be required to determine what, if any,
other modifications be made to the body of the specific byproducts and their concentrations are
head to accommodate mounting. produce by your treating process.
High voltage is present within the discharge
head!
Use of incorrect mounting material, or mounting
methods, may damage the equipment or cause
serious injury.
GAP REQUIREMENTS
The gap between the front surface of the discharge
head and the product surface is dependent upon the
application, but the recommended gap range is 1/4”
(6.4mm) to 3/4” (19.5mm). If the object moves in front
of the discharge head, which is usually the case, the
maximum effective treat area provided by the nozzle is
round and approximately 3/4” (19.5mm), dependant on
the positioning of the discharge head. For this reason,
the application of the Dyne-A-Mite™ IT Surface
Treater is somewhat limited to smaller treatment areas
and objects. The Dyne-A-Mite™ IT Surface Treater
can treat a large variety of irregularly shaped objects or
surfaces and can reach into cavities, delivering a very
intense treatment to small areas.
EXHAUST REQUIREMENTS
Depending upon the product you are treating, NXOX
CONTAMINATES such as *NITROGEN DIOXIDE or
*NITRIC OXIDE may be produced. In applications
that utilize CO2 as the feed gas, OZONE is a
byproduct, in addition to the possible NXOX
Contaminates, and must be exhausted outside of the
building.
Enercon recommends exhausting the area
immediately around each plasma discharge head,
especially in applications where the discharge head
is enclosed or CO2 is used. All reasonable
precautions should be taken to ensure that any
CONTAMINATES are exhausted to a safe location
(exterior of building recommended). The exhaust
requirements will be dictated by Federal, State, and
Local codes.

WARNING!
It is recommended that any contaminates,
especially ozone in CO2 applications, be
exhausted outside of building.
Ensure that exhaust of blower is not located
near any fresh air intakes or HVAC equipment
where exhaust air can be recirculated into the
building.
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ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
 DYNE-A-MITE™ IT SURFACE TREATER WIRING DIAGRAM

OPTIONAL HEAD
CONTROL SWITCH MAIN CONTROL BOARD
LOSS OF PLASMA
CONTACT NOT INSTALLED ON SINGLE HEAD UNITS.
REMOVE JUMPERS IN OPTIONAL HEAD INSTALL JUMPER FOR
CONTROL SWITCH IS USED. REMOTE MODE

+24 VDC

+24 VDC

+24 VDC
SW2 FAN
JP2
TB5 TB4 TB3 TB2 TB1
CUSTOMER INTERFACE CONNECTOR
(SHOWN FROM REAR OF CONNECTOR)

PSW

DISCHARGE
HEAD #1
CN1

CUSTOMER PROVIDED
REMOTE START/STOP CONTACT WIRE COLORS
PIN 1 - BROWN
PIN 2 - ORANGE
PIN 3 - RED
TO CUSTOMER ALARM
PIN 4 - BLUE
120 VAC - 0.5 AMPS
PIN 5 - BLACK
POWER BOARD #1 HEAD 24 VDC - 1 AMP
PIN 6 - YELLOW
PIN 7 - GREEN
CUSTOMER SAFETY PIN 8 - WHITE
INTERLOCK
CUSTOMER INTERFACE CABLE
(REAR OF CONNECTOR)
#1 IGBT
HV XFMR
#1

DISCHARGE
HEAD #2 LOAD

LINE FILTER
(CE ONLY)

LINE
POWER BOARD #2 HEAD
F1 F2

#2 IGBT ON / OFF
SWITCH
FAN

HV XFMR INPUT
VOLTAGE
#2

Figure 9

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ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
 SECTION 3 – PRINCIPLES OF OPERATION
GENERAL
Before operating this equipment, we
recommend reading this section in its entirety to
ensure you understand all the safety and operational
requirements for using this equipment. Also, please
refer to SECTION 1 – INTRODUCTION, Pages 1
and 2, to become familiar with all safety
requirements and precautions.
OPERATING INSTRUCTIONS
The Dyne-A-Mite™ IT Surface Treater has a discrete
graphic overlay front operating panel (See Figure
13). When main power is applied to the treater,
indicator lights or status indicators will be lit
depending on the status of the treater and existing
treater faults. The push button switches that operate
Internal flow/pressure requirements are factory
set and should not require any adjustment. If any
of the components in the air flow path are damaged
or replaced, the original factory settings may need to
be adjusted. Always consult Enercon prior to making
adjustments to flow/pressure settings (Figure 10).
Item # Description
1 Flow Control – See NOTE:
2 Pressure Switch – See NOTE:
3 Pressure Regulator – See NOTE:
3
H t o LO

the treater are also covered by the overlay and are

C US
K P

activated by pressing the overlay surface in the 2

appropriate location. The table on Page 14 gives a
description of the function of each button and 1
indicator.

INDICATOR COLOR CODING

The LED indicators on the front panel of the Dyne-A-
Mite™ IT Surface Treater will illuminate when
activated. The STANDBY will illuminate YELLOW 50 100

when power is applied to the unit. The RUN LED will

illuminate GREEN when the unit is running. The 0
PSI
150

REMOTE LED will illuminate YELLOW when the

remote START/STOP mode is activated. The
INTERLOCK and FAULT LEDs will illuminate RED
when their designated faults occur (See the
Troubleshooting Section for a more detailed
explanation of fault conditions).

DANGER!
High voltage is present within the cabinet. Figure 10
Only qualified personnel should be allowed to NOTE:
work on the equipment with the cover open. Internal flow/pressure requirements are factory set
For safety purposes, disconnect power and and should not require any adjustment.
verify all capacitors are discharged before FUSES
working on the power supply. The system fuses are located on the back of the unit
The DC Bus Capacitors discharge very slowly. directly below CN1. They are located in line with the
input voltage wiring (See Figure 9).
AIR PRESSURE REQUIREMENTS Fuse # 1 Head
The customer supplied compressed air source
F1 250 VAC 10 Amp Slow-Blow
should be 60 to 80 psi coming into the treater. This
F2 250 VAC 10 Amp Slow-Blow
compressed air source is then internally reduced Fuse # 2 Head
down to a regulated 40 PSI via an internal pressure F1 250 VAC 15 Amp Slow-Blow
regulator; CO2 settings will be the same. F2 250 VAC 15 Amp Slow-Blow

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ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
SEQUENCE OF OPERATION
Once the system Installation and Set-Up is complete (Figure 12). The START button on the front of
the sequence of operation for the unit is as follows: the unit must be pressed to qualify the unit for a
1. Apply Compressed Air or CO2 to the unit and remote start. The contact can then be closed to start
plug the unit into an appropriate outlet. the unit and opened to stop the unit. If the STOP
NOTE: button is pressed, or an interlock opens, the START
Each Dyne-A-Mite™ IT Surface Treater is built to button must be pressed again to re-qualify the
use either Compressed Air or CO2, compressed air unit.
cannot be used on a CO2 system, and CO2 cannot
be used on a compressed air system. CUSTOMER INTERFACE CABLE
(REAR OF CONNECTOR)
2. Apply power to the unit by placing the disconnect
switch on the front of the unit into the ON position ORANGE
(Figure 11).
BROWN
ON REMOTE START/STOP
1 7 CONTACT

2 8 6
OFF
3 5
4

Figure 12
NOTE:
Cycling of the discharge can reduce the life
expectancy of the air vane electrode. If the unit is
Figure 11 cycled, increase the frequency of electrode
3. Once input power is applied the STANDBY LED inspection as required.
will be lit on the front panel. If the unit is set up
for Remote Start/Stop the REMOTE LED will also
be lit and the REMOTE START/STOP sequence
of operation will need to be followed.
4. Ensure that no Fault LEDs are lit, if either the
INTERLOCK or FAULT LEDs are lit press the
STOP button to clear the fault. If the fault
does not clear, refer to the troubleshooting section
for further details.
5. Once the Interlocks are met press the START
button to start the unit. Once the unit is started the
RUN LED will be lit and a plasma discharge will
be present at the tip of the discharge head. The
STANDBY LED will remain lit also.
6. Press the STOP button to turn off the
discharge. The RUN LED will extinguish

REMOTE START / STOP (Cycling)

Remote Start/Stop requires installing the jumper
across JP2 on the control board to place the unit in
the REMOTE mode (See Figure 9).
Then a N.O. contact must be placed across CN1
pins 1 and 2 for the Remote Start/Stop signal
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ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
 FRONT PANEL CONTROLS

Figure 13

Item # Control Description

START

A Start Pushbutton, pressing START puts unit in RUN mode.

STOP

B Stop Pushbutton, pressing STOP clears faults and stops unit.

When LED is lit, power is applied to the power supply and it is in

C
the STANDBY mode.
When LED is lit the unit is in the RUN mode and discharge is
D
present at the discharge head(s).

E When LED is lit the unit is in the REMOTE start mode.

When LED is lit the safety interlock(s) is open. Also Illuminates

F
with the FAULT LED when the pressure switch is not satisfied.
When LED is lit a System Fault has occurred. Also Illuminates
G with the INTERLOCK LED when the pressure switch is not
satisfied. The STOP button must be pressed to reset the fault.

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ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
 SECTION 4 – MAINTENANCE

GENERAL
Before performing maintenance on this nozzle for signs of buildup and remove the nozzle to
equipment, please read this section completely. inspect its interior (Figure 14).
Also, please refer to SECTION 1 – INTRODUCTION,
Pages 1 and 2, to become familiar with all safety
requirements and precautions for this equipment.
The Dyne-A-Mite™ IT Surface Treater is designed to
require minimal maintenance. However, to insure
long-range reliability, it is a good practice to have a
planned maintenance program. This section will
include recommended preventative and corrective
maintenance procedures. Clean Nozzle

PREVENTIVE MAINTENANCE
When operated under normal conditions, the Dyne-
A-Mite™ IT Surface Treater will require little or no
service at all. It is important, however, that the
discharge heads are frequently checked to assure
that it is free from any dust or dirt build-up. Any
accumulation of dirt in the air passage between
blower and electrodes can cause serious arcing and Coated Nozzle
subsequent damage to the assembly and the high Figure 14
voltage bearing wires and parts.
Clean the nozzle using isopropyl alcohol and a
It is recommended that a Preventative Maintenance Scotch Brite™ pad or stiff bristle bottle brush.
Program is set up and followed to insure proper Extremely heavy buildup can be removed using a
system operation. media blaster. If the buildup cannot be completely
removed you will need to replace the Nozzle.
DANGER! NOTE:
If heavy buildup is found on a regular basis, you may
Never attempt to perform maintenance on this wish to perform this check more frequently.
equipment unless electrical power is locked
out and tagged out. QUARTERLY CHECKS
Inspect for loose connections, excessive dust build-
MONTHLY CHECKS up, and evidence of excessive heating. Dry,
compressed air is convenient for removing dust from
AIR SUPPLY COMPONENTS the equipment. Verify the cooling fans are working
Remove the cabinet cover and inspect the Filter properly.
Regulator, Mist Separator, and Micro Mist Separator
for damage or contamination. Drain any oil or water AIR VANE ELECTRODE
and replace filters as required. Remove the Nozzle Body from the Discharge Head
Body to inspect the Air Vane Electrode. Replace as
DISCHARGE HEAD NOZZLE required. Heavy cycling of the system will require
Under heavy use, or when there are contaminates more frequent replacement of the Air Vane Electrode
present in the compressed air source, the nozzle of (See Figure 15).
the IT discharge head may gradually become coated
with a hard buildup. If the buildup becomes too
heavy, the plasma discharge can be affected.
To help prevent the nozzle from becoming coated,
ensure that your compressed air source is clean and
that the Filter / Regulator components are inspected
and cleaned on a regular basis. Inspect the tip of the

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ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
 SECTION 5 – TROUBLESHOOTING
GENERAL
Before performing troubleshooting on this
equipment, please read this section completely.
Also, please refer to SECTION 1 – INTRODUCTION,
Pages 1 and 2, to become familiar with all safety
requirements and precautions for this equipment.
It is a natural tendency to adjust internal settings
when electronic equipment is not functioning
properly. Avoid this temptation. The Enercon
Dyne-A-Mite™ IT Surface Treater is specifically
designed to eliminate the need of making any
internal adjustments. The control circuitry provided
automatically compensates for a change in external
conditions.

TROUBLESHOOTING
SYMPTOM SOLUTION
1. Insure the main power switch is on.
2. Insure unit is plugged into power source.
3. Insure power source has power available.
Standby does not illuminate.
4. Check the fuses F1 & F2.
1. Verify the standby light is illuminated when the start button is depressed.
2. Verify interlocks are satisfied.
3. Verify the REMOTE light is not illuminated.
The RUN light does not illuminate when
the START button is pressed. 4. Verify FAULT light is not illuminated.
5. Contact Enercon for further assistance.

The interlock light illuminated.
The Fault light is illuminated.
1. Check to insure the defeat connector is installed on the back of the unit.
2. Verify the external interlock, (if applicable) is satisfied.
1. Perform the Inverter ohm checks on page 13.
2. The Power Board may be failed, contact Enercon.
3. The Control Board may be failed, contact Enercon.

1. Pressure has dropped below the set point, check the compressed
air/CO2 source and pressure regulator.
2. The Pressure Switch may be failed or misadjusted, contact Enercon.
The INTERLOCK and FAULT lights are
illuminated.

TROUBLESHOOTING TRIP LEDs

SYMPTOM SOLUTION TRIP LED LOCATIONS
1. Inspect Discharge Head for arcing. I3 TRIP UP3 TRIP
D33 D32
I1 TRIP or I2 TRIP Repair / Replace. I2 TRIP
D27
UP2 TRIP
D25

Illuminated 2. Inspect HV wiring for arcing. Repair / I1 TRIP

D26
UP1 TRIP
D24

Over Current Trip Replace. R42

ENV3 TRIP
D23
ENV2 TRIP
3. Replace HV Transformer. Q13 D16
ENV1 TRIP
D15
R30

UP1 TRIP or UP2 TRIP 1. Board requires set-up, repair or Q12

Illuminated replacement. R25

Q11

Under Current Trip 2. Airflow set too high for set point. R20
R19 R18
Q10
Q9 Q8
D6 D5 D4 D3
1. Inspect Discharge Head. Repair /
R15
Replace.
ENV1 TRIP or ENV2 TRIP
2. HV Transformer Issue, Contact
Illuminated
Enercon. 1 TB1 10
Under Frequency Trip
3. Power Board Issue, Contact Enercon.
4. Control Board Issue, Contact Enercon.

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ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
INVERTER OHM CHECK PROCEDURE FACTORY ASSISTANCE
 Any “Zero” ohm reading will constitute a bad If the steps in this section have failed to determine
Semi-Conductor. the problem, the factory should be contacted for
 Gate leads must be replaced with devices. assistance.
 Meter Required: Standard Analog VOM-OR-
DVOM with Diode Test. Enercon Customer Service Department
Phone Number: (262) 255-6070
DANGER! Fax Number: (262) 255-2462
E-Mail Address: service@enerconmail.com
Ensure all power is disconnected and locked Website: www.enerconind.com
out from unit before performing ohm check 24hr Customer Service is available.
procedures.

CAUTION!
Always use the NEW Gate Leads supplied with the
replacement Inverter Device.
Always apply an EXTREMELY thin layer of thermal
compound to the base of the device before
mounting it to the heat sink.
A packet of compound is attached the inverter.
Apply a dab of thermal compound to the center of
the base of the device and spread the compound
around the entire surface of the device.
Wipe away any excess, as excess compound can
be detrimental and cause device failure.
Mount the inverter device securely to the heat sink
and torque the bolts to 30 in/lbs (3.39 N-m).

Meter Lead VOM DVOM

Hook-Up (Rx1 Scale) (Diode Test)
(+)A to (-)B OPEN OPEN
(-)A to (+)B  20 .4V
(+)A to (-)C  20 .4V
(-)A to (+)C OPEN OPEN
(+)B to (-)C  40 .8V
(-)B to (+)C OPEN OPEN
*(+)D to (-)E Slight Deflection, Then OPEN OPEN
*(+)G to (-)F Slight Deflection, Then OPEN OPEN
(+)=Positive (black) meter lead. (-)=Negative (red) meter lead.
*Measure with gate leads disconnected, meter at its highest
resistance scale.

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ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
 SECTION 6 – PARTS LISTS

GENERAL SHIPPING INSTRUCTIONS FOR RETURNS

This Section of your manual contains illustrated part
breakdowns of the various components that make up
the Dyne-A-Mite™ IT Surface Treater System. If
standard options are offered with your system they
will be represented with parts breakdown illustrations
as well, but special order options typically will not.
The illustrations, and their associated part tables, are
primarily provided for replacement part identification,
but can also be useful in locating items that are
identified as being required for operation, or requiring
maintenance or adjustment.
HOW TO USE THE PART LISTS
1. Refer to the illustrated part breakdowns to identify
the desired illustration.
2. Visually locate the desired part in the illustration
and identify the parts Item #.
3. Refer to the part table and find the Item # to
identify the Enercon Part #, Description, and
Quantity.
Enercon has 2 facilities that perform repairs and
process credits. Before shipping parts or equipment
back, contact Enercon’s Customer Service
Department for a Return Material Authorization
(RMA) number, the proper shipping address, and
any special shipping instructions.
If possible, use the original packaging material the
parts or equipment were shipped with. If that is not
available, use a fiberboard box and adequate
packing materials to support the items weight and
prevent movement during shipping.
Ensure both the shipper and receiver addresses are
clearly printed on top of package along with the RMA
number.
Parts must be sent Prepaid.

HOW TO ORDER PARTS

Due to possible changes in the part numbers and
quantities in your system, we request that you have
all of the following information available when placing
an order. We do understand that some information
may be unavailable, but be aware that this may
cause delays in shipping your order.
1. Locate the Model Number and Serial Number of
your unit on the system Rating Plate; refer to
Figure 2 on page 4 of this manual.
2. The Part Number and Date of this manual; both
are located on front cover of this manual. The
Part Number is also located in the footers on
each page of the manual.
3. The Part Number of the desired part, the page
number it was found on, and the parts
Description.
NOTE:
All of the replacement parts provided are
manufactured with the same precision as the parts
supplied with the original equipment.
4. To place a part order contact:

Enercon Parts Department

Phone Number: (262) 255-6070
Fax Number: (262) 255-2462
E-Mail Address: parts@enerconmail.com

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ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
 CUSTOMER SERVICEABLE PARTS – IT DISCHARGE HEAD PARTS BREAKDOWN

1
2

3
4
6
7 8

9 10
5
11

12

Figure 15

ITEM # PART # DESCRIPTION QTY.

1 FD4074-16 Nozzle 1
2 FD4075-13 Nozzle To Body 1
3 RN2079 O-Ring 1
4 FD5018-12 Air Vane Electrode 1
5 FD5018-15 Air Vane Electrode Tip Extension – CO2 only 1
6 FD5018-11 Air Vane Electrode Base 1
7 FD4076-19 Electrode Holder w/Air Vane Divider 1
8 FD4076-17 Electrode Holder Part “B” 1
9 FD4616-87 Spacer 1
10 CP5150 High Voltage Capacitor 1
11 LM4991-01 Banana Jack Assembly 1
12 LM5541-06* Discharge Head Body Assembly 1
NOTE: *Figure 15 shows the standard nozzle supplied with the discharge head. Part numbers and quantities may change, please have
your equipment serial number available when contacting Customer Service.*Standard Length -06 = 6ft cable length, the dash number
changes to represent the cable length for your discharge head.

18
ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
 IT SURFACE TREATER PARTS BREAKDOWN

6A, B 8 9
10
3 2

6A

Figure 16
QTY.
ITEM # PART # DESCRIPTION
1 HD 2 HD
1 LM4666-XX Control Board 1 1
2 TF0400-04 HV Transformer 1 2
3 LM3589-04 Inverter 1 2
4 LM4665-01 Power Board 1 2
5 LM4824-03 Pressure Regulator & Filter 1 1
6A FA0082 120 VAC Cooling Fan 1 2 -3**
6B FA0086 240 VAC Cooling Fan 1 2
7 SW0150 Pressure Switch* 1 2
8 SW0191 Main Disconnect Switch 1 1
9 LF0200 115 VAC Line Reactor N/A 0-1**
10 EM0080 Line Filter – CE units only (Not Shown) 1 1
*The Pressure switch is included with the pressure regulator, but can be purchased separately if needed. Part numbers and quantities
may change, please have your equipment serial number available when ordering parts. **These line inductor components are only
required on 120VAC Dual Head Systems.

Enercon Parts Department

Phone Number: (262) 255-6070
Fax Number: (262) 255-2462
E-Mail Address: parts@enerconmail.com

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ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
 SECTION 7 – MISCELLANEOUS

MAINTENANCE RECORD
Quarterly Checks

Inspect For Loose Connections Inspect For Evidence Of Overheating Remove Excessive Dust And Dirt.

Date Issues Found Corrective Actions Required Verified By

20
ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
 MAINTENANCE RECORD
Quarterly Checks

Inspect For Loose Connections Inspect For Evidence Of Overheating Remove Excessive Dust And Dirt.

Date Issues Found Corrective Actions Required Verified By

21
ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
 NOTES

22
ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES
 NOTES

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ML0094-001-07 Dyne-A-Mite IT Surface Treater ENERCON INDUSTRIES