ML0158 001 04 Blown Ion Pro Series Plasma Treater Operators Manual Rev A

Blown-ion™ Pro Series
PLASMA TREATER
ML0158-001-04
OWNERS REFERENCE MANUAL
MAILING ADDRESS: SHIPPING ADDRESS:

Enercon Industries Corp. Enercon Industries Corp.
P.O. Box 773 W140 N9572 Fountain Blvd.
Menomonee Falls, WI 53052-0773 Menomonee Falls, WI 53051
Phone: (262) 255-6070 ● Fax: (262) 255-7784 ● Web Site: www.enerconind.com
7/2/2018
TABLE OF CONTENTS
SECTION 1 – INTRODUCTION ........................................................................................................................................................... 1

SAFETY AND WARNINGS..................................................................................................................................................... 1
SAFETY PRECAUTIONS ....................................................................................................................................................... 2
INFORMATION AND SAFETY LABELS (Figure 1) ................................................................................................................ 3
SECTION 2 – INSTALLATION.............................................................................................................................................................. 4
UNPACKING AND INSPECTION ........................................................................................................................................... 4
DOCUMENTATION ................................................................................................................................................................ 4
OPTIONAL EQUIPMENT ....................................................................................................................................................... 4
SITE SELECTION .................................................................................................................................................................. 4
POWER SUPPLY PLACEMENT ............................................................................................................................................ 4
DISCHARGE HEAD INSTALLATION ..................................................................................................................................... 5
DISCHARGE HEAD (Figure 2) ............................................................................................................................................... 5
GAP REQUIREMENTS (Figure 3) .......................................................................................................................................... 5
COMPRESSED AIR SUPPLY (Figure 4) ................................................................................................................................ 5
CONTROL AND MONITORING CABLES (Figure 5) .............................................................................................................. 6
EXTERNAL CONTROL FUNCTIONS (Figure 6) .................................................................................................................... 6
EXTERNAL MONITORING FUNCTIONS (Figure 7) .............................................................................................................. 6
SYSTEM REQUIREMENTS ................................................................................................................................................... 7
EXHAUST REQUIREMENTS ................................................................................................................................................. 7
BLOWN ION PRO SURFACE TREATER WIRING DIAGRAM (Figure 8) .............................................................................. 8
STANDARD INTERCONNECTION LAYOUT (Figure 9) ........................................................................................................ 9
SECTION 3 – PRINCIPLES OF OPERATION ................................................................................................................................. 10
GENERAL............................................................................................................................................................................. 10
OPERATING INSTRUCTIONS ............................................................................................................................................. 10
AIR PRESSURE REQUIREMENTS (Figure 10) ................................................................................................................... 10
INTERLOCKS ....................................................................................................................................................................... 10
APPLYING INPUT VOLTAGE (Figures 11 - 14) .............................................................................................................. 10-11
SYSTEM SETUP (Figure 15)................................................................................................................................................ 11
TIME & DATE (Figures 16 & 17)...................................................................................................................................... 11-12
LANGUAGE (Figure 18) ....................................................................................................................................................... 12
START/STOP CONTROL (Figure 19) ............................................................................................................................. 12-13
INTERLOCKS (Figures 20 - 22) ...................................................................................................................................... 13-14
OPERATOR LOCKOUT ....................................................................................................................................................... 14
ENABLING / DISABLING LOCKOUT (Figures 23 & 24) ....................................................................................................... 14
PASSWORD ERRORS (Figure 25) ................................................................................................................................. 14-15
CHANGING PASSWORD (Figures 26 - 28) ......................................................................................................................... 15
FACTORY............................................................................................................................................................................. 15
MODES OF OPERATION..................................................................................................................................................... 15
LOCAL CONTROL MODE .................................................................................................................................................... 15
SINGLE HEAD LOCAL CONTROL MODE (Figures 29 - 31) .......................................................................................... 15-16
DUAL HEAD LOCAL CONTROL MODE (Figures 32 - 38) .............................................................................................. 16-17
REMOTE CONTROL MODE (Figures 39 & 40)............................................................................................................... 17-18
SINGLE HEAD REMOTE CONTROL MODE (Figures 41 - 43) ............................................................................................ 18
DUAL HEAD REMOTE CONTROL MODE (Figures 44 - 47) .......................................................................................... 18-19
NETWORK CONTROL MODE (Figures 48 & 49)............................................................................................................ 19-20
NETWORK CONTROL MODE SETUP ................................................................................................................................ 20
ETHERNET NETWORK CONFIGURATION (Figures 50 - 52) ........................................................................................ 20-21
SERIAL NETWORK CONFIGURATION (RS-485) (Figures 53 - 55) .................................................................................... 21
MODBUS DATA MAP ...................................................................................................................................................... 22-23
SINGLE HEAD NETWORK CONTROL MODE (Figures 56 - 58) ......................................................................................... 24
DUAL HEAD NETWORK CONTROL MODE (Figures 59 - 62) ....................................................................................... 24-25
AUTO START/STOP CONTROL MODE (Optional) (Figures 63 - 65) .................................................................................. 25
STANDARD MODE .............................................................................................................................................................. 26
EDGE MODE ........................................................................................................................................................................ 26
ON AND OFF DELAYS (Figure 66) ...................................................................................................................................... 26
SETTING THE ON DELAY .............................................................................................................................................. 26-27
SETTING THE OFF DELAY ................................................................................................................................................. 27
RUNNING IN AUTO START/STOP CONTROL MODE (Figures 67 & 68) ........................................................................... 27
LOCAL AUTO CONTROL - STANDARD MODE - AUTO AIR (Figures 69 - 76).............................................................. 27-28
REMOTE AUTO CONTROL - STANDARD MODE - AUTO AIR .......................................................................................... 28
LOCAL AUTO CONTROL - EDGE MODE - AUTO AIR .................................................................................................. 28-29
REMOTE AUTO CONTROL - EDGE MODE - AUTO AIR .................................................................................................... 29
LOCAL AUTO CONTROL - STANDARD MODE (Figures 77 - 84).................................................................................. 29-30
REMOTE AUTO CONTROL - STANDARD MODE .............................................................................................................. 30
LOCAL AUTO CONTROL - EDGE MODE ........................................................................................................................... 30
REMOTE AUTO CONTROL - EDGE MODE ........................................................................................................................ 30
STATUS CONTROL ............................................................................................................................................................. 30
SINGLE HEAD SYSTEM STATUS (Figures 85 & 86) .......................................................................................................... 31
DUAL HEAD SYSTEM STATUS (Figures 87 & 88) ......................................................................................................... 31-32
LINKED HEADS STATUS SCREENS (Figure 89) ................................................................................................................ 32
UNLINKED HEADS STATUS SCREENS (Figures 90 - 92) ............................................................................................ 32-33
PLASMA INTEGRITY MONITOR (Figure 93) ....................................................................................................................... 33
SOFTWARE (Figures 94 - 96) ......................................................................................................................................... 33-34
LOGGING ............................................................................................................................................................................. 34
FAULT LOG (Figure 97) .................................................................................................................................................. 34-35
EVENT LOG (Figure 98) ....................................................................................................................................................... 35
EXPORTING THE LOGS ..................................................................................................................................................... 35
CLEARING THE LOGS (Figure 99) ...................................................................................................................................... 35
CALCULATOR (Figure 100) ............................................................................................................................................ 35-36
DATA (Figures 101 & 102) ................................................................................................................................................... 36
LINE MONITOR (Figures 103 - 106) ............................................................................................................................... 36-37
HELP (Figure 107) ................................................................................................................................................................ 37
ELECTRODE (Figures 108 &109) ........................................................................................................................................ 37
INFO (Figure 110) ............................................................................................................................................................ 37-38
SECTION 4 – OPTIONAL EQUIPMENT ........................................................................................................................................... 39
GENERAL............................................................................................................................................................................. 39
STANDARD OPTIONS ......................................................................................................................................................... 39
OPTIONAL STACK LIGHT (Figure 111) ............................................................................................................................... 39
OPTIONAL FOOT SWITCH (Figure 112) ............................................................................................................................. 39
SECTION 5 – MAINTENANCE ........................................................................................................................................................... 40
GENERAL............................................................................................................................................................................. 40
PREVENTIVE MAINTENANCE ............................................................................................................................................ 40
MONTHLY CHECKS ............................................................................................................................................................ 40
DISCHARGE HEAD NOZZLE .............................................................................................................................................. 40
QUARTERLY CHECKS ........................................................................................................................................................ 40
ELECTRODE AND AIR VANE.............................................................................................................................................. 40
CORRECTIVE MAINTENANCE ........................................................................................................................................... 40
FACTORY RESTORE (Figure 113) ................................................................................................................................. 40-41
SECTION 6 – TROUBLESHOOTING ................................................................................................................................................ 42
GENERAL............................................................................................................................................................................. 42
FAULTS (Figure 114) ........................................................................................................................................................... 42
HEAD SPECIFIC FAULTS ................................................................................................................................................... 42
SINGLE HEAD SYSTEM (Figure 115) ................................................................................................................................. 42
DUAL HEAD SYSTEM - HEADS LINKED (Figure 116) ................................................................................................... 42-43
DUAL HEAD SYSTEM - HEADS UNLINKED (Figure 117) .................................................................................................. 43
HEAD SPECIFIC FAULT LIST ............................................................................................................................................. 43
SYSTEM FAULTS (Figure 118) ............................................................................................................................................ 43
SYSTEM FAULT LIST .......................................................................................................................................................... 43
TROUBLESHOOTING WITH THE HELP MENU............................................................................................................. 43-44
INVERTER OHM CHECK PROCEDURE ............................................................................................................................. 45
FACTORY ASSISTANCE ..................................................................................................................................................... 45
SECTION 7 – PART BREAKDOWNS................................................................................................................................................ 46
GENERAL............................................................................................................................................................................. 46
HOW TO USE THIS PARTS LIST ........................................................................................................................................ 46
HOW TO ORDER PARTS .................................................................................................................................................... 46
SHIPPING INSTRUCTIONS FOR RETURNS ...................................................................................................................... 46
SINGLE HEAD BLOWN ION PRO PART BREAKDOWN (Figure 119) ................................................................................ 47
DUAL HEAD BLOWN ION PRO PART BREAKDOWN (Figure 120) .................................................................................... 48
DISCHARGE HEAD PART BREAKDOWN (Figure 121) ...................................................................................................... 49
OPTIONAL STACK LIGHT AND FOOT SWITCH PART BREAKDOWN (Figure 122) ......................................................... 50
SECTION 8 – MISCELLANEOUS ...................................................................................................................................................... 51
MAINTENANCE RECORD .............................................................................................................................................. 51-52
NOTES ............................................................................................................................................................................ 53-54
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 insure
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). 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 colored safety boxes with bold-faced text for emphasis.
carefully read this manual in its entirety to ensure The signal words CAUTION, WARNING, and
you understand all the safety and operational DANGER are used to indicate hazard seriousness
requirements for using this equipment. levels as follows:
Electricity and electrostatic discharge have the
potential to cause severe personal injury or property CAUTION!
damage.
CAUTION is used to indicate the presence of a
Before installing, wiring, starting, operating or making potentially hazardous situation which, if not
any adjustments, identify the components of the avoided may result in minor personal injury or
Plasma Treater using this manual as a guide. property damage.
The operator should use common sense and good
working practices while operating and maintaining
this unit. Follow all codes, pipe adequately, and WARNING!
understand the starting and stopping sequence.
WARNING is used to indicate a potentially
Check the safety devices following the procedures
hazardous situation which, if not avoided, can
contained in this manual.
result in serious injury or death.
Only qualified personnel, equipped with the proper
tools and protective gear should perform system
maintenance. Follow the maintenance schedules as DANGER!
outlined in the manual to ensure problem free
operation after start-up. DANGER is used to indicate an imminently
hazardous situation which, if not avoided, will
The manufacturer of this equipment expresses result in serious injury or death.
concern that the equipment be installed, tested,
operated and maintained only by personnel that are
familiar with the handling and hazards of high
voltage equipment, and are familiar with the
instructions and safety precautions contained within
this manual.
1
ML0158-001-04 Blown-ion™ Pro Series Plasma Treater Rev. A Enercon Industries
SAFETY PRECAUTIONS
Never assume that a circuit is dead. MAKE SURE!!!
DANGER! Always Wear Appropriate Protective clothing and
The use of HIGH VOLTAGE is necessarily employed Eyewear while working within the enclosure.
in the operation of this equipment. Precautions have Do not connect any external control or monitoring
been taken in the design of this equipment to make it equipment, with the exception of appropriate test
as safe as possible for both operator and service equipment, to the internal circuits of this equipment.
personnel. However, since no amount of interlocks Connecting external equipment in this manner may
and safety devices can be absolutely infallible, cause failure of this equipment and create a potential
precautionary measures must always be taken when hazard to personnel.
working on this equipment.
Do not reach into the equipment, or any electrical
enclosure, without first removing the power. Never
apply power to the unit without all covers on and
securely in place.
Lockout / Tag Out: To insure that power cannot be
applied to the equipment, remove external voltage
supplies and use the appropriate Lockout / Tag Out
procedures prior to removing any access covers,
panels, or entering the equipment in any manner.
ALWAYS use safety as the first step.
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, 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
circumstance should any of your system’s safety
interlocks be defeated nor should any of the safety
devices be relied upon for removal of voltage from
the equipment.
Test and Verify: Test all system safety interlocks to
ensure they are fully functional before placing
equipment back into production after maintenance,
troubleshooting, or an extended shutdown.
CAUTION!
Familiarize Yourself Thoroughly with the
Equipment: Never attempt to work on this
equipment unless you are completely familiar with it.
2
INFORMATION AND SAFETY LABELS
This page contains representative examples of the
typical placement of the labels that appear on your
Blown-ion™ Pro Series Plasma Treater. 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. NA0141
NA0133
Rating Plate
NA0136
NA0369-01
Figure 1
3
SECTION 2 – INSTALLATION
UNPACKING AND INSPECTION
The carrier accepted responsibility for your shipment when opening these packages. For installation and
when they signed the Bill of Lading at the point of setup of options included with your system refer to all
origin of the shipment. supplied manuals and your system drawings.
If external damage to the packaging was detected it
SITE SELECTION
should have been noted on the freight bill before you
Careful consideration must be taken when selecting
signed acknowledging receipt. If you give the carrier
the site for the equipment. Items such as ventilation
clear receipt for goods that have been damaged or
space, ambient temperature, and cleanliness should
lost in transit, you do so at your own risk and
be taken into account.
expense.
Although the locations of most components are often
All packages should be carefully opened and all
predetermined, it must be verified that all
items thoroughly inspected for damage. If concealed
components are installed within the guidelines of
loss or damage is discovered after delivery, you
your system drawings, this manual and any other
must notify your carrier at once to request an
supplied documentation to ensure proper and safe
inspection. The carrier agent should make an
operation.
inspection and issue a loss or damage report. This is
absolutely necessary for the carrier to consider your POWER SUPPLY PLACEMENT
claim. The Power Supply is designed to be placed on a
Your Plasma Treating System may have shipped in clean, level surface that is sufficient to support the
more than one container, so you will need to equipment’s weight. The maximum distance the
compare the packing slip with the items received to power supply can be placed from your product line
ensure that all items that shipped were actually will be limited to the length of the conduit provided
received. with your discharge head. See Figure 9 for an
If any issues are found, Enercon Industries should example of a typical system installation.
be contacted as soon as possible to expedite the The placement of the power supply should allow a
shipment of replacement parts. minimum of 12” (30.5 cm) of clearance around and
NOTE: over the power supply to allow for proper cooling.
Be extra careful if using a sharp instrument when Do not place the power supply or discharge head(s)
opening boxes or removing any protective wrapping in an enclosure unless appropriate ventilation is
from the equipment. supplied to allow for proper cooling.
CONTACT:
Enercon Customer Service Department
Phone Number: (262) 255-6070
CAUTION!
Fax Number: (262) 255-7784 Do not restrict airflow to sides and bottom of
E-Mail Address: service@enerconmail.com unit.
Website: www.enerconind.com Do not enclose this equipment unless proper
24hr Customer Service is available ventilation and cooling are provided.
Enercon Parts Department
Phone Number: (262) 255-6070
Fax Number: (262) 255-7784
WARNING!
E-Mail Address: parts@enerconmail.com We strongly recommend that safety
precautions such as enclosures and / or light
DOCUMENTATION
barrier sensors are installed in the proximity of
A system folder was provided with your equipment.
the high voltage discharge to assure that no
The folder contains printed drawings and documents,
person can come within close proximity to the
and a USB Flash Drive with digital copies of your
electrodes or the plasma during operation.
systems Manual(s) and digital copies of the printed
drawings and documents. Also, no attempts should be made to
disassemble the discharge head for any reason
OPTIONAL EQUIPMENT without the consent of the manufacturer.
Several options were available for your Corona
Treating System and the same care should be used
4
WARNING!
DISCHARGE HEAD INSTALLATION
The discharge head is connected to the control
cabinet by means of a single custom engineered When mounting the discharge head, no
cable which contains the high voltage wire, ground additional holes should be drilled, nor should any
wire and the compressed air supply tube. other modifications be made to the body of the
The effective treatment area provided by each head to accommodate mounting.
discharge head is approximately ½” (12.7mm) to ¾” Do not ground the body of the discharge head
(19.5mm) in diameter. The size and shape of the when mounting.
area will change somewhat in relation to the distance Use of incorrect mounting material, or mounting
of the discharge head from the surface to be treated, methods, may damage the equipment or cause
its geometry, and the speed of the of treatment serious injury.
application.
GAP REQUIREMENTS
DISCHARGE HEAD The gap between the front surface of the discharge
The discharge head should be securely mounted to head and the product surface is dependent upon the
the production line by means of a sturdy non- application, but the recommended gap range is ½”
conductive clamp and post style mounting system (12.7mm) to ¾” (19.5mm) (Figure 3).
(Figure 2). The discharge head is shown with 1
2"(12.7mm) to 3 4"
Enercon’s optional mount to show the manner in (19.5mm) Gap
which the discharge head body should be supported.
Ø 0.15"
Ø 2" Ø 2" Figure 3

Ø 0.35"
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 ¾” (19.5mm), dependant on the
2.6" 4.19"
positioning of the discharge head. For this reason,
NON-CONDUCTIVE
the application of the Blown-ion™ Pro Series
MOUNTING CLAMP Treating System is somewhat limited to smaller
treatment areas and objects.
DISCHARGE HEAD
The Blown-ion™ Pro Series Treating System can
BODY ASSEMBLY
NOZZLE treat a large variety of irregularly shaped objects or
surfaces and can reach into cavities, delivering a
very intense treatment to small areas.
COMPRESSED AIR SUPPLY
NOZZLE The Blown-ion™ Pro Series Treating System requires
BODY
a compressed air supply from a clean, dry source. The
compressed air supply must be connected to the ⅜”
tube fitting on the back of the power supply (Figure 4).
COMPRESSED AIR
70-90 PSI
(4.8-6.2 BAR)
3
8" Compressed
Figure 2 Air Fitting
DANGER!
High Voltage is present within the discharge
head! Figure 4
5
CONTROL AND MONITORING CABLES EXTERNAL MONITORING FUNCTIONS
The Blown-ion™ Pro Series Treating System gives To use the External Monitoring functions you will
you the ability to externally control and monitor need to use the External Monitoring Cable provided
certain functions and conditions of the system. To with your system. The external monitoring functions
use these features you will need the provided include Ready, Failure, and Plasma Monitoring. The
External Control and External Monitoring cables. monitoring circuits require you to provide the 24VDC
Refer to the information in this manual and your for any monitoring and/or alarm circuits.
system drawings for the proper wiring of the cables The monitoring circuits include both a Normally Open
and connect them to the connectors on the back of (N.O.) and Normally Closed (N.C.) contact for each
the power supply (Figure 5). function, which can be used to monitor the system
with a PLC or to drive an alarm circuit (Figure 7).
External Monitoring Cable Connector
(Rear View of Connector)
Orange/Black - N.O. Red/Green - N.O.

Head # 2 Head # 1
Blue - N.C. Green - N.C.
PLASMA READY
MONITORING Red - COM Green/Black - COM
Orange - N.O. White - N.O.
Head # 1 Head # 2
Black - N.C. 1 2 Blue/Black - N.C.
PLASMA READY
3 4 5 6
MONITORING White/Red - COM Black/Red - COM
7 8 9 10 11
Green/White - N.O.
12 13 14 15
Head # 2 Red/White - N.C. 16 18
White/Black - N.O.
17
FAILURE Blue/White - COM Black/White - N.C. Head # 1
FAILURE
Red/Black - COM
Figure 7
Figure 5 READY – The Ready circuit will notify you when all
of the system functional requirements, such as air
EXTERNAL CONTROL FUNCTIONS
flow and interlocks, are met. When the system
To use the External Control functions you will need
requirements are met, the contacts will change state.
to use the External Control Cable provided with your
system. The external control functions include FAILURE – The failure circuit will notify you when
Customer Interlock, Remote Start/Stop, Remote system fault has occurred, or when an interlock has
Enable, Remote Reset and Air Flow Enable. opened while the system was running.
You will need to provide Normally Open (N.O.) dry PLASMA MONITORING – The Plasma Monitoring
contacts for all of the external control functions, circuit contacts will be in their de-energized state
where the closure of the contact will activate the whenever the input voltage is removed from the
function, and opening of the contact will deactivate power supply, when the input voltage is applied but
the function (Figure 6). the system is not running, or when the power supply
External Control Cable Connector is running but the discharge is not within the system
Green
(Rear View of Connector) parameters. The circuit contacts will change state
1A Green/Black only when the system is running and the discharge is
2A Black/Red
1 2
within the system parameters.
Blue 3 4 5 6 White
1B Blue/Black 7 8 9 10 11
NOTE:
White/Black 1D
2B Red 12 13 14 15 2D
The Head #2 wiring for both the External Control and
White/Red
Orange 16 17 18 External Monitoring cables will only be available on
1C Orange/Black Dual Head systems.
2C Red/Green
Figure 6
External Control Wiring Functions
1A Head #1 Remote Reset
2A Head #2 Remote Reset
1B Head #1 Remote Start/Stop
2B Head #2 Remote Start/Stop
1C Head #1 Remote Enable
2C Head #2 Remote Enable
1D Head #1 Customer Interlock
2D Head #2 Customer Interlock
6
SYSTEM REQUIREMENTS
atmospheric pressure, Air Quality: < 20 ppm hydrocarbons,
Single Head Blown-ion™ Pro Specifications
with a range of 70 – 90 psi (4.8 – 6.2 Bar).
Input Voltage ± 10%* 120/208/240VAC 1Ø
NOTE:
Input Frequency 50/60 Hz
Much of the information listed in the Equipment
Max. Input Current 7 Amps / 3.5 Amps Specifications table can change depending on
Max. Output Voltage 3.4 KV RMS variables such as the actual source voltage supplied
Max. Output Current 240 mA RMS or the actual length of your discharge head conduit.
Max. Output Power 500 Watts The Output Voltage, Output Current and Output
Output Freq. Range** 20-60 kHz Power specifications are listed as they will be
6 – 12 Ft measured at the HV transformer for each discharge
Flexible Conduit ***
1.8 – 3.6 M head.
Weight (Net) Approx. 60 lbs. (27.2 kg) The Blown-ion™ Pro Series Treating System is
Width 19 3/8” (492 mm) designed to operate in an ambient temperature range
Height 12 19/32” (320 mm) of 41º - 104F (5º - 40C) @ 80% relative humidity,
Depth 17 ¼” (438 mm) non-condensing by providing forced air-cooling.
Compressed Air † 70-90 psi EXHAUST REQUIREMENTS
Dual Head Blown-ion™ Pro Specifications Depending upon the product you are treating, NXOX
Input Voltage ± 10%* 120/208/240VAC 1Ø CONTAMINATES such as *NITROGEN DIOXIDE or
Input Frequency 50/60 Hz *NITRIC OXIDE may be produced.
Max. Input Current 14 Amps / 7 Amps *These byproducts are commonly seen in low
Max. Output Voltage 3.4 KV RMS concentrations in many plasma treating applications,
Max. Output Current 240 mA RMS but they are listed here only as examples. Detailed
Max. Output Power 1 kW (500 W per head) testing would be required to determine what, if any,
Output Freq. Range** 20-60 kHz specific byproducts and their concentrations are
6 – 12 Ft produce by your treating process.
Flexible Conduit ***
1.8 – 3.6 M
Weight (Net) Approx.
Width
70 lbs. (31.75 kg)
19 3/8” (492 mm)
WARNING!
Height 12 19/32” (320 mm) It is recommended that any contaminates be
Depth 17 ¼” (438 mm) exhausted outside of building.
Compressed Air † 70-90 psi Ensure that exhaust of blower is not located
near any fresh air intakes or HVAC equipment
A standard Blown-ion™ Pro Series Treating System
where exhaust air can be recirculated into the
is designed to run using any of the input voltages
building.
listed without requiring modifications to the
equipment. Enercon recommends exhausting the area
This may change if your Blown-ion™ Pro Series immediately around each plasma discharge head. All
Treating System has been supplied with flexible reasonable precautions should be taken to ensure
conduit longer than 12 ft. (3.6 M). that any CONTAMINATES are exhausted to a safe
* READ THE RATING PLATE ON THE BACK OF location (exterior of building recommended). The
THE POWER SUPPLY BEFORE CONNECTING TO exhaust requirements will be dictated by Federal,
AN INPUT VOLTAGE SOURCE! State, and Local codes.
** When Idle you may see 70 kHz displayed, this is
where the Start Frequency is typically set for the
system.
***
These are the standard lengths of flexible conduit
run between the discharge head and control cabinet.
If required, custom lengths may have been provided.
†
The compressed air supply must be filtered and meet the
following specifications; Dew Point: < 32° F (0° C) @
7
Blown-ion™ Pro SERIES SURFACE TREATER WIRING DIAGRAM
SOL 1
Red
Air Flow
Solenoid Black
SW 1
Blue
Pressure
Switch Brown
Discharge
Head #1
Orange Black
Red
Blue
White
Brown
White
Brown
Black
Blue
Control
Red Orange
Board
HV Xfrmr 1 Power Board
USB
Socket
Discharge
Head #2 RJ45
Socket
Display
Board
I/O Board
SOL 2
Red
Air Flow
Solenoid White
SW 2
Blue
Pressure
Orange
Switch
HV Xfrmr 2
Power Board
Figure 8
8
STANDARD INTERCONNECTION LAYOUT
Item # Description
1 Blown-ion™ Pro Power Supply
2 Blown-ion™ Discharge Head (2 Maximum)
3 Enercon Supplied Mounting (Optional)
4 Discharge Head Output Power and Air Cable
5 Network Cable (Ethernet or Serial, only required for Network Control – Provided by Customer)
6 External Monitoring Cable
7 External Control Cable
8 External Indicator Cable (Optional)
9 Auto Control Cable (Optional)
10 Option Cable (Optional)
11 USB Storage Device (Not Required for Operation – Provided by Customer)
12 Fused Disconnect (Provided by Customer)
13 System Ground (All System Components Must Be At The Same Ground Potential)
12
2
2
4
4
13
3
3
10
9
1
8
7
6
11
Figure 9
9
SECTION 3 – PRINCIPLES OF OPERATION
GENERAL INTERLOCKS
Before operating this equipment, please read this Your system interlocks are crucial to the safe
section completely. Also, please refer to SECTION 1, operation of your Blown-ion™ Pro Series Treating
Pages 1 and 2, to become familiar with all safety System. Air Flow is a system interlock and a
requirements and precautions for this equipment. customer interlock circuit is available to allow an
external interlock, or a series of external interlocks,
OPERATING INSTRUCTIONS and there may be additional Interlocks on your
The Blown-ion™ Pro Series Treating System has system associated with included options.
been designed for ease of operation, utilizing a Regardless of the number, or type, of interlocks your
touchscreen interface for the operator to control and system utilizes, it is critical that you test and verify
monitor the surface treating system. the function of all interlocks before you put your
Blown-ion™ Pro into production.
AIR PRESSURE REQUIREMENTS
The customer supplied compressed air source must Refer to your system drawings to identify your
meet the following, Dew Point: < 32° F @ atmospheric system’s interlocks and SECTION 5 for test
pressure, Air Quality: < 20 ppm hydrocarbons, with a procedures on your system interlocks.
range of 70 to 90 psi (4.8 – 6.2 Bar). The compressed
air source is reduced to a regulated 40 psi (2.75 Bar) APPLYING INPUT VOLTAGE
using an internal pressure regulator. The initial Power Up of your Blown-ion™ Pro Series
Treating System should only be attempted once all
NOTE: system components and options have been installed
Internal flow/pressure requirements are factory set and properly interconnected.
and should not require any adjustment.
Apply input voltage to the system by lifting the circuit
If any of the components in the air path are damaged breaker on the front of the unit into the ON position
or replaced, the original factory settings may need to (Figure 11).
be adjusted. Always consult Enercon prior to making
adjustments to flow/pressure settings (Figure 10).
Item # Description
1 Pressure Regulator – See NOTE: above.
2 Flow Control – See NOTE: above.
1 2
Single Head
Figure 11
2 Once the input voltage is applied, the Enercon logo
2 and loading screen will be displayed as the program
loads. The system will then default to the Home
1 Screen and the head(s) will be disabled by default
2 and Air Interlock Open will be displayed.
1
The Home screen is the main operational screen for
all of the operational modes on your Blown-ion™ Pro
Series Treating System.
The Single Head Home screen will display the
Dual Head Status , Enabled / Disabled , and
Start / and Stop pushbuttons. If an
interlock or fault condition exists, it will be
Figure 10
displayed on the screen (See Figure 12).
10
Single Head background. Inactive pushbuttons will be grayed out
with black text. You will be able to navigate to any of
the other screens by pressing the appropriate active
icon on the bar.
SYSTEM SETUP
You may need to perform some initial setup for the
system before placing it into production. Depending
on your productions needs, some setting changes
may be required between products being treated.
You will be able to enter the Settings screen from
any of the other screens by pressing Settings
in the navigation bar and the Settings screen will be
Figure 12
displayed. The Settings screen will be the same for
The Dual Head Home screen will also display the both Single and Dual Head systems (Figure 15).
Status , Enabled / Disabled , Start
/ and Stop pushbuttons, and any interlock
or fault condition for each head. The discharge head
numbers and either the linked or unlinked
icon will also be displayed (Figures 13 & 14).
Dual Head – Linked
Figure 15
NOTE:
The Settings screen displays the same functions
and layout for single and dual head systems and the
Settings pushbutton will be inactive when the
system is running or any discharge head is primed.
Figure 13
TIME & DATE
Dual Head – Unlinked
On the Settings screen, press Time & Date icon
and the Time & Date screen will be displayed
(Figure 16).
Figure 14
A navigation bar is located at the
bottom of the Home, Info, Data, Settings and Head
#X Control screens. The pushbuttons on the bar are Figure 16
active when displayed in full color with the current On the Time & Date screen you will be able to adjust
screen’s icon being highlighted by a light blue the systems Date, date format, and Time.
11
For any Date or Time adjustments pressing the On the Language screen you will be able to see all
MONTH, DAY, YEAR, HOURS, or MINUTES display of the available languages for your system, with the
will open the data entry keypad for the selected selection box of the active language checked .
parameter (Figure 17).
To change the selected language for your system,
press the unchecked selection box of the
language you wish to use.
Once you have selected the new language, press
to accept the new language and the system will
reboot and all screens will be displayed in the new
language, or press to cancel any changes and
return to the Settings screen.
START/STOP CONTROL
The Blown-ion™ Pro Series Treating System allows
several options to Start and Stop the power supply.
Figure 17 You will be able to Start/Stop the power supply from
the front panel touch screen (Local), using an
Enter the current Date or Time information using the external contact (Remote), or using a network
keypad and press to accept the new setting command (Network).
and return to the Time & Date screen, or press
to return to the Time & Date screen without On the Settings screen press the Control Mode
making any changes. icon and the Start/Stop Control screen will be
displayed (Figure 19).
To change the date format, press the unchecked
selection box in either date format display.
Once you have finished making changes to the
time and date, press to accept the new
settings and return to the Settings screen, or
press to return to the Settings screen
without making any changes.
LANGUAGE
The Blown-ion™ Pro Series Treating System will be
shipped with the default language enabled, but you
can easily change the language from the touch
screen. Figure 19
On the Settings screen press the Language On the Start/Stop Control screen the selection box
icon and the Language screen will be displayed of the active start/stop mode will be checked . To
(Figure 18). change the start/stop mode, simply press the
unchecked selection box of the desired mode and
that box will be checked .
Press to enable the selected mode and return to

the Settings screen, or press to return to the
Settings screen without making any changes.
On the Settings screen press to return to the
Home screen and verify the Start Control: mode is
displayed correctly in the ribbon at the top of the
screen .
Each Start/Stop Control mode requires a specific
input that is listed on the Start/Stop Control screen
Figure 18
and in the table below.
12
Mode Description NOTE:
Uses the Touch Screen Start and Stop Auto Start/Stop Control requires the use of the Auto
Local
pushbuttons. Control cable or the optional Enercon foot switch.
Requires closure of a N.O. dry contact from a remote
Remote source. INTERLOCKS
Network
Requires either an Ethernet or Serial network signal The Blown-ion™ Pro Series Treating System has the
through the RJ45 connector.
capability to be interlocked with other equipment on
Auto
Start/Stop
Requires an Auto Start Command your production line. Systems typically ship with the
interlock function disabled, as it will require use of
Local the External Control Cable to take advantage of the
On the Start/Stop Control screen, select Local interlock function.
start control, and press to enable the Local start On the Settings screen, press the Interlock icon
control mode and return to the Settings screen. On and the Interlock screen will be displayed.
the Settings screen press to return to the Home
On the Single Head Interlock screen you will be
screen.
able to enable or disable the interlocks for the
On the Home screen verify that the correct mode is system (Figure 20).
displayed in the Single Head
top ribbon.
Remote
On the Start/Stop Control screen, select
Remote start control, and press to enable the
Remote start control mode and return to the
Settings screen. On the Settings screen press
to return to the Home screen.
On the Home screen verify that the correct mode is
displayed in the
top ribbon.
NOTE:
Figure 20
Remote Start Control will require use of the External
Control cable. On the Dual Head Interlock screen you will be able
to enable or disable the interlocks for the
Network system and link or unlink the head
On the Start/Stop Control screen, select controls (Figure 21).
Network start control, and press to enable the Dual Head
Network start control mode and return to the
Settings screen. On the Settings screen press
to return to the Home screen.
On the Home screen verify that the correct mode is
displayed in the
top ribbon.
Auto Start/Stop
On the Start/Stop Control screen, select Auto
Start/Stop start control; you will also need to have
Local or Remote start control selected, and either
Standard Mode or Edge Mode selected as well.
The ability to choose Auto Start/Stop Control Mode Figure 21
is disabled if Network control mode is selected. NOTE:
You will also be able to link or unlink the head controls
On the Home screen verify that the correct mode is from the Home screen.
displayed in the
top ribbon. This will change depending on your Auto Once you have finished making changes on the
Start/Stop choices. interlock screen, press to accept the changes
13
and return to the Settings screen, or press to enabled . The default password is
return to the Settings screen without making any 1234.
changes.
When the Interlocks are enabled you will need to
provide a N.O. dry contact for each head on your
system using the External Control cable (Figure 22).
External Control Cable Connector
1 2 (Rear View of Connector)
3 4 5 6 White
7 8 9 10 11
White/Black Head # 1
12 13 14 15 Head # 2
White/Red
16 17 18
Figure 24
Figure 22 Pressing on the password entry keypad
The contact(s) must be open when the interlock screen will cancel the entry and return you to the
condition is not met and closed when the interlock Operator Lockout screen without changing the
condition is met. condition.
Disabling the Operator Lockout is performed in the
OPERATOR LOCKOUT same manner by pressing and
The Blown-ion™ Pro Series Treating System
entering the password. Once you press the
includes the ability to protect most system settings
Operator Lockout Status will be displayed as
by allowing them to be locked out. The Operator
Lockout uses password protection to help you disabled . Once enabling or
ensure that no changes can be made to system disabling the Operator Lockout is complete, press
settings by anyone other than authorized personnel. to return to the Settings screen.
Enabling/Disabling Lockout When Operator Lockout is enabled, the icons on the

Settings screen will still allow you to navigate to all
On the Settings screen press the Lockout icon of the setting screens, but with the exception of the
and the Operator Lockout screen will be displayed Operator Lockout and Calculator screens, the
(Figure 23). Figure 23 shows the Operator Lockout functions will be disabled, or severely restricted.
screen with lockout disabled. When you select one of the locked setting screens,
Locked will be displayed in the top ribbon of the
screen .
Password Errors
If you incorrectly enter the password you will be
taken to the Error data entry keypad (Figure 25)
when you press .
Figure 23
To enable Lockout press on
the Operator Lockout screen and the Password
Entry screen will be displayed (Figure 24).
Enter the password and press and you will
return to the Operator Lockout screen and the
operator lockout status will be displayed as Figure 25
14
NOTE:
The Password Keypad screen does not have a
lockout function for how many times a password can
be entered incorrectly. The default password is 1234.
Changing The Password
Since the default password is listed several times in
this manual, it is recommended that you change your
password to prevent unauthorized access to the
secure screens and functions.
On the Operator Lockout screen (Refer to Figure
23), press the Change Password icon
and the initial Keypad for changing the password will Figure 28
be displayed (Figure 26). Once the password has been successfully changed,
press to return to the Settings screen.
FACTORY
The Factory settings function is password protected
and is not discussed in this manual, as changes to
any factory settings can have adverse effects on the
equipment if not performed properly. You will need to
contact Enercon customer service to discuss the
changes you wish to make, and to obtain a factory
settings procedure and password.
MODES OF OPERATION
There are 4 Modes of Operation for the Blown-ion™
Figure 26
Pro Series Treating System; Local, Remote,
Enter the current password and press . If the Network and Auto Start/Stop. The operational
correct password was entered, the second Keypad mode is determined by the Start/Stop Control Mode
screen will be displayed (Figure 27). you have selected (Refer to START/STOP
CONTROL).
DANGER!
When running, high voltage is present within the
plasma discharge.
The operation of the Blown-ion™ Pro Series Treating
System will typically be controlled and monitored
from the Home screen. Once you have the correct
mode selected, press the Home icon on the
navigation bar to display the Home screen.
LOCAL CONTROL MODE
Figure 27 When Local is the selected Start/Stop Mode,
Enter the new password and press and the will be displayed
third Keypad screen will be displayed asking you to at the top of the Home screen.
verify the new Password. On that screen, reenter the
Single Head Local Control Mode
new password and press .
On a single head system the Home screen will only
If the password verification was successful you will display the control and monitoring layout for a single
be taken back to the Operator Lockout screen and it discharge head (See Figure 29).
should verify that the password has been
successfully changed (Figure 28).
15
control and monitoring layouts for two linked or
unlinked discharge heads (Figures 32 & 33).
Figure 29
When displayed from power up, the Home screen
will show the head DISABLED and the Air Figure 32
Interlock Open fault displayed. Press and it
will switch to , the Air Interlock Open message
will disappear and the Start pushbutton will
become active (Figure 30).
Figure 30 Figure 33
With no faults displayed, pressing the Start When displayed from power up, the Home screen
pushbutton will start the system (Figure 31). will show each head DISABLED and the Air
Interlock Open fault for each head. Press
and they will switch to , the Air Interlock Open
messages will disappear and the Start
pushbuttons will become active (Figures 34 & 35).
Figure 31
The word RUNNING will be displayed in place of the
ENABLED pushbutton, the background of the
screen will be green, and the Start and Settings
pushbuttons will be inactive. Figure 34
When the system is running, pressing the Stop
pushbutton will stop the discharge head. The
ENABLED pushbutton will be displayed, the
background will revert back to white, and the Start
and Settings pushbuttons will be active.
Dual Head Local Control Mode
On a dual head system with Local Start/Stop Figure 35
selected, the Home screen will display separate
16
Linked Heads
If the heads are linked and both ENABLED with
no faults displayed, pressing the Start
pushbutton will start both discharge heads (Figure
36).
Figure 38
When a head is running, the ENABLED
pushbutton will be replaced with RUNNING, the
background of the running head will be green, and
the Start pushbutton will be inactive.
The background of the idle head will be white, the
Figure 36 ENABLED pushbutton will still be displayed,
The word RUNNING will be displayed in place of the and the Start pushbutton will remain active.
ENABLED pushbuttons, the background of When either head is running the Settings
each head will be green, and the Start and pushbutton will be inactive.
Settings pushbuttons will be inactive. When running, pressing the associated Stop
When linked with only one head ENABLED, only pushbutton will stop that discharge head. That
the enabled discharge head will start and run. head’s ENABLED pushbutton will be
displayed, the background is white, and the Start
When running, the ENABLED pushbutton will pushbutton will become active.
be replaced with RUNNING, the background of the
running head will be green while the background of If both heads were running the other head will
the idle head will remain white (Figure 37). continue to run until its Stop pushbutton is
pressed.
The Settings pushbutton will only be active
when both heads are idle.
REMOTE CONTROL MODE
When Remote is the selected Start/Stop Mode,
will be displayed
at the top of the Home screen.
Figure 37
In Remote Control Mode you will be able to
If you enable the disabled head while the other head remotely Start/Stop the Discharge Head(s), Enable
is running, the Start pushbutton will become the Discharge Head(s), and Reset System Faults
active and pressing it will start the idle head. The using the External Control Cable and Normally
running head will not be affected unless Stop is Open (N.O.) dry contacts.
pressed. On a Single Head system you will only be required to
connect the cable to a N.O. contact for Head #1, but
Regardless of which heads are running, pressing the on a Dual Head system you will need to connect the
Stop pushbutton will stop the discharge heads. cable to a N.O. contact for both Head #1 and Head
Running will be replaced by the ENABLED #2 (Figure 39).
pushbutton, both backgrounds will be white, and the External Control Cable Connector
(Rear View of Connector)
Start and Settings pushbuttons will become Green
active. Blue Green/Black #1 Remote
Remote #1 #2 Reset
Blue/Black Black/Red
Unlinked Heads Start/Stop #2
1 2
Red
If the heads are unlinked and ENABLED, with Orange
3 4 5 6
no faults displayed, pressing a discharge head’s Remote #1 Orange/Black

7
12
8
13
9
14
10
15
11
Enable
associated Start pushbutton will start that #2
Red/Green 16 17 18
discharge head (Figure 38).

Figure 39
17
Once all of the Remote functions are connected to
N.O. dry contacts, run the cable to the rear of the
power supply and connect to the External Control
connector (Figure 40).
Figure 42
The Start and Stop pushbuttons the Settings
pushbutton will be inactive.
If the head is disabled upon power up, either close
the Remote Enable contact across pins 7 & 9, or
press the DISABLED pushbutton on the screen
and the ENABLED pushbutton and Waiting
For Remote Start will be displayed.
NOTE:
Figure 40 To remotely disable the head when it has been
NOTE: enabled using the pushbutton, you will need to close
In Remote Control Mode, the discharge heads will the Remote Enable contact and then open it.
always be unlinked on dual head systems and the If no faults are displayed, closing the Remote
Start and Stop pushbuttons will be inactive on Start/Stop contact across pins 1 & 3 will start the
both single and dual head systems. system (Figure 43).
Single Head Remote Control Mode

display the control and monitoring layout for a single
discharge head, and if the remote enable contact is
open, the head will be DISABLED (Figure 41).
Figure 43
NOTE:
The Remote Start/Stop contact must transition from
Open to Closed for the system to start, if the contact
was closed before enabling the head you will need to
open the contact and then close it.
The word RUNNING will be displayed in place of
ENABLED , the screen background will be
green.
When the system is running, opening the Remote
Figure 41 Start/Stop contact will stop the discharge head. The
background will revert back to white, the ENABLED
When the input voltage is applied, the condition of
the Remote Enable contact will determine what is pushbutton and Waiting For Remote Start will
displayed on the Home screen, pins 7 & 9. be displayed.
If the Remote Enable contact is open the head Dual Head Remote Control Mode
On a dual head system the Home screen will display
DISABLED pushbutton, Air Interlock Open separate control and monitoring layouts for two
fault are displayed and the Settings pushbutton unlinked discharge heads (See Figure 44).
will be active.
If the Remote Enable contact is closed the head the Remote Enable Contacts will determine what is
ENABLED pushbutton, Waiting For Remote displayed on the Home screen. Head 1 – pins 7 & 9,
Start will be displayed (Figure 42). Head 2 – pins 8 & 9.
18
Figure 46
Figure 44
The Start and Stop pushbuttons will always be
inactive for both heads and the heads will always be
unlinked in Remote Control Mode. Figure 47
If a Remote Enable contact is open the head The word RUNNING will be displayed in place of
DISABLED pushbutton and the Air Interlock ENABLED and the screen background will be
green for the running head(s).
Open fault are displayed, and the Settings
pushbutton will be active. When the system is running, opening the Remote
Start/Stop contact for the appropriate head will stop
If a Remote Enable contact is closed the head that discharge head. In the display area for the head
ENABLED pushbutton and Waiting For that has been stopped, the ENABLED
Remote Start will be displayed, and the Settings pushbutton and Waiting For Remote Start will be
pushbutton will be inactive. displayed and the background will revert back to
If a head is disabled upon power up, either close the white.
appropriate Remote Enable contact across pins 7 & 9 NOTE:
or 8 & 9 (Refer to Figure 39), or press the DISABLED If a system fault occurs while running in Remote
pushbutton on the screen. The ENABLED Control Mode, you will be able to reset the fault using
pushbutton and Waiting For Remote Start will the Remote Reset circuit. Closing a contact across
be displayed. pins 4 & 6 will reset the fault on a single head system
or for Head 1 on a dual head system, and closing the
NOTE: contact across pins 5 & 6 will reset Head 2.
To remotely disable a head when it has been
enabled using the pushbutton, you will need to close NETWORK CONTROL MODE
the appropriate Remote Enable contact and then When Network is the selected Start/Stop Mode,
open it. will be displayed
NOTE:
You will be able to run one head even with the The Blown-ion™ Pro Series Treating System allows
second head still disabled. you to use either Ethernet or Serial network
commands to control and monitor the system.
If no faults are displayed, closing the Remote
Start/Stop contact across pins 1 & 3 for Head 1 or If a network configuration (Ethernet or Serial) was
pins 2 & 3 for Head 2 will start that head (Figures not specified when the system was ordered, the
45, 46 & 47). system will ship with the internal Ethernet cable
connected to the control board in the Ethernet
Network configuration. You will need to change the
location of the internal Ethernet cable if you require
the Serial Network configuration.
Remove the right side and top covers (facing unit) of
the power supply. The control board is located on the
right hand side of the unit. Verify which port the
Figure 45 internal cable is connected to and swap the
connector as needed (See Figure 48).
19
Ethernet Network
Serial Network Cable Connector
Cable Connector (Default Connection)
Control Board
USB
J16
REMOTE RS485
ENET PORT
J15
J18
Figure 48
Figure 50
Ethernet Network Control – J15 - ENET PORT
On Ethernet Page 1, you will be able to set the Local
Serial Network – J18 - REMOTE RS485
IP, Sub. Mask and Remote IP addresses. Press the
If required, disconnect the cable and reconnect it to address value that you wish to update and the IP
the proper connector for your network requirements. Byte data entry keypad will be displayed (Figure
Network Control Mode will require use of either an 51).
Ethernet or Serial cable that must be connected to
the RJ45 connector on the rear of the power supply
(Figure 49).
Figure 49
Figure 51
Network Control Mode Setup
You will need to setup Network Control before you Enter the required byte value using the keypad and
will be able to control or monitor the system using press to accept the new value and return to
your network. The setup may include physically the Network Configuration screen, or press
swapping the internal Ethernet cable to the correct return to the Network Configuration screen without
connector for the network configuration your network making any changes.
requires. Continue entering the byte values until all 3
Press Settings on the navigation bar to display addresses are correct. Then press the Go to Page 2
the Settings screen, and press Network to pushbutton, and the second Ethernet
display the active Network Configuration screen. Network Configuration screen will be displayed
You will be able to choose between using a Serial (See Figure 52).
Network or an Ethernet Network to control and NOTE:
monitor the system. Go to the appropriate The factory set address information on Page 2 of the
configuration description for type of network you will Ethernet Network Configuration screen will be
be using. sufficient for the majority of installations. Only
change the Page 2 address information if absolutely
Ethernet Network Configuration
Ethernet is the system’s default network necessary.
configuration, and Page 1 of the Ethernet Network On Page 2 of the Ethernet Network Configuration
Configuration screens will be displayed after screens, you will be able to set the Gateway, DNS
pressing Network (Figure 50). and Remote 2 addresses. Press the address value
that you wish to update and the IP Byte data entry
If Ethernet is not the active network configuration,
Keypad will again be displayed.
press the Ethernet check box to enable the
Ethernet network configuration.
20
network configuration. The screen will switch to the
Serial Network Configuration screen (Figure 54).
Figure 52
Enter the required byte value using the keypad and
press to accept the new value and return to Figure 54
the Network Configuration screen, or press
return to the Network Configuration screen without On the Serial Network Configuration screen, you
making any changes. Again, continue entering the will be able to set the Slave ID, Baud Rate, Parity,
byte values until all 3 addresses are correct. and Stop Bits by pressing the associated ribbon for
each parameter.
Pressing Go to Page 1 will return you to Page
Press the Slave ID ribbon and the Slave ID data
1 of the Ethernet Network Configuration screens.
entry keypad will be displayed (Figure 55).
Once all addresses have been properly configured,
press to accept the new configuration and return
to the Settings screen, or press to return to the
Settings screen without making any changes.
If you changed the Ethernet Network configuration,
you will need to cycle the input voltage Off and On
before the changes will take effect.
Serial Network Configuration (RS-485)
If you select the Serial Network configuration, you
will need to provide a custom serial cable. The pin
outs for the cable should be as follows (Figure 53).
1 Rear View Figure 55
8
of
Connector
Enter the required Slave ID address using the
keypad and press to accept the new address
and return to the Network Configuration screen, or
87 press return to the Network Configuration
65 21
43 screen without making any changes.
The Baud Rate, Parity, and Stop Bits can be
Figure 53 changed by pressing the associated ribbon and the
Pin# Description value displayed will scroll through the available
1 No Connection settings:
2 Common Baud Rate: 4600, 9600, 19200, 38400, 57600
3 No Connection Parity: None, Odd, Even
4 TX / RX ( – ) Stop Bits: 1 or 2
5 TX / RX ( + )
6 No Connection Once all addresses and settings have been properly
7 No Connection configured, press to accept the new configuration
8 Common
and return to the Settings screen, or press to
On the Ethernet Network Configuration screen, return to the Settings screen without making any
press the Serial check box to enable the Serial changes.
21
Modbus Data Map
The Blown-ion™ Pro Series Treating System acts as To read the registers the Master device should use
the Slave/Server device. It will respond to Modbus Modbus Code 3 (Read Holding Registers). To write
commands from a Master/Client device. to writable registers, the Master device should use
Modbus Code 16 (Write Multiple Registers).
Blown-ion™ / Blown-arc™ Pro Network Address Map

Read-Only Registers (The Remote Master Device may read these values at any time)
1 Head #1 Nominal Power Level Watts
5 - 14 Reserved for Future Use
15 Head #1 Actual Power Level Watts
19 Head #1 Actual Output Current .01 Amps
23 Head #1 Actual DC Bus Voltage Volts
27 Head #1 Actual Output Frequency .01 kHz
31 Head #1 Heat Sink Temperature .1 °C
System Fault Register - Zero if no system wide faults are present. Greater than zero if a system wide
39
fault is present. Check local screen for further fault details.
Network Enable Register - Bit 15 is set when the system is ready to be controlled over the network
40
(Register value greater than or equal to 32768)
41 Network Information Register - See Table A
44 Head #1 Status Register - See Table B
Head #1 Fault Register - Zero if no head faults are present. Greater than zero if a head fault is
48
present. Check local screen for further fault details.
49
50
51
22
Writeable Registers (The Remote Master Device may write these registers when it is controlling the system)
52 System Commands - See Table C
53 Head #1 Commands - See Table D
Table A
Network Information Register Table
Bit # Description
0 On when the local display is controlling the system
1 On when the system serial port is controlling the system
2 On when the main Ethernet port is controlling the system
3 On when the secondary Ethernet port is controlling the system
4 - 14 Unused
15 On when the system Ethernet port is enabled; off if the serial port is enabled (Only one can be used at a time)
Table B
Head Status Register
Bit # Description
0 On if this head is currently installed and configured
1 On if the head has been requested to run
2-4 Unused
5 On when the head is not running; Off if the head is running normally
6 On when the head is waiting for an external remote start contact
7 On when the head external interlock is not satisfied
8 On when the head air pressure interlock is not satisfied
9 On if the head cannot start because it is receiving a reset command
10 On if the head is ready to be started
11 - 14 Unused
15 On when the head is enabled
Table C
System Command Register
Bit # Description
0 System Reset Request - Set momentarily to reset any system wide faults
1-4 Unused
5 Network Control Request - Set high momentarily to initiate control from the network
6 - 15 Unused
Table D
Head Command Register
Bit # Description
0 Head Run Request - Set high to run this head; Set low to stop this head
1 Unused
2 Head Reset Request - Set high momentarily to reset any faults on this head
3 - 14 Unused
15 Head Enable Request - Set high to enable this head; Set low to disable this head
23
Single Head Network Control Mode
display the control and monitoring layout for a single
discharge head (Figure 56).
Figure 58
When the system is running, setting the Head Run
Request bit low will stop the discharge head. The
background will revert back to white, the ENABLED
pushbutton will be displayed and the Settings
pushbutton will be active.
Dual Head Network Control Mode
Figure 56 On a dual head system the Home screen will display
When the input voltage is applied, the condition of separate control and monitoring layouts for two
the Head Enable Request bit (Reg. 53 / Bit 15) will unlinked discharge heads (Figure 59).
determine what is displayed on the Home screen.
If the Head Enable Request bit is set low, the head
DISABLED pushbutton and the Air Interlock
Open fault are displayed.
If the Head Enable Request bit is set high, the head
ENABLED pushbutton will be displayed
(Figure 57).
Figure 59
the Head Enable Request bits (Reg. 53 / Bit 15 –
Head 1 and Reg. 54 / Bit 15 – Head 2) will determine
Figure 57 what is displayed on the Home screen.
If the head is disabled upon power up, set the Head If the Head Enable Request bit is set low, that
Enable Request bit high to enable the head. heads DISABLED pushbutton and Air
NOTE: Interlock Open fault will be displayed.
The Start and Stop pushbuttons will always If the Head Enable Request bit is set high, that
be inactive in Network Control Mode. If the Stop heads ENABLED pushbutton will be
pushbutton is active, either the network cable is displayed.
unplugged or the network signal has been lost. If a head is disabled upon power up, set the
Check the cable and the status of your network. appropriate Head Enable Request bit high to enable
If no faults are displayed, setting the Head Run the head. You will be able to run one head even with
Request bit high (Reg. 53 / Bit 0) will start the the second head still disabled.
system (Figure 58). NOTE:
The word RUNNING will be displayed in place of The Start and Stop pushbuttons will always
ENABLED , the screen background will be be inactive in Network Control Mode. If the Stop
pushbutton is active, either the network cable is
green, and the Settings pushbutton will be unplugged or the network signal has been lost.
inactive. Check the cable and the status of your network.
24
If no faults are displayed, setting the Head Run When using a customer provided N.O. dry contact on
Request high (Reg. 53 / Bit 0 – Head 1 and Reg. 54 a Single Head system you will only be required to
/ Bit 0 – Head 2) for a specific head will start that provide a contact for Head #1. On a Dual Head
head (Figures 60, 61 & 62). system you will need to provide a contact for both
Head #1 and Head #2, or a single contact paralleled
across both heads (Figure 63).
Auto Control Cable (Rear View of Connector)
White White
Head #1
Black Red
1 5
6
1 5
Red Green
2 4
6
Head #2 3
2 4
Green Black
Figure 60 3
Series Contact For Parallel Contact For

Each Head Both Heads
Figure 63
Once the Auto Control Cable is connected to a
sensor, PLC or foot switch, you will then need to run
the cable to the power supply and connect it to the
Auto Control connector (Figure 64).
Figure 61
Auto Control Cable
Foot Switch
Figure 62
The word RUNNING will be displayed in place of Figure 64
ENABLED and the screen background will be
NOTE:
green for the running head(s). The Settings In Auto Start/Stop Control Mode, the discharge
pushbutton will be inactive. heads will always be unlinked on dual head systems
When the system is running, setting the Head Run and the Start and Stop pushbuttons will be
Request low for a specific head will stop that inactive on both single and dual head systems.
discharge head. In the display area for the head that When Auto Start/Stop is selected, press the Go To
has been stopped, the ENABLED pushbutton pushbutton in the Auto Start/Stop ribbon to
will be displayed and the background will revert back display the Auto Mode Setup screen (Figure 65).
to white. The Settings pushbutton will be
active.
AUTO START/STOP CONTROL MODE (Optional)
When Auto Start/Stop is selected the standard
start/stop control mode, either Local or Remote, will
remain selected and the auto start/stop control title
will be displayed
NOTE:
If Network is selected, Auto Start/Stop mode
cannot be selected.
In Auto Start/Stop Control Mode you will be able to Figure 65
automatically Start and Stop the Discharge Head(s)
using a Normally Open (N.O.) dry contact(s) and the On the Auto Mode Setup screen, you will be able to
On Delay and Off Delay settings. select either Standard Mode or Edge Mode.
25
Standard Mode
In Auto Start/Stop control mode, the Standard stop and the system will remain idle until the auto
Mode of operation allows you to automatically Start start/stop signal(s) is reapplied.
and Stop the Discharge Head(s) using a customer In this mode it does not matter if the auto start/stop
supplied Normally Open (N.O.) dry contact(s) and signal(s) is removed before the end of the On Delay
the On Delay and Off Delay set points. cycle is complete, or if the signal(s) is held beyond
This mode is designed for used on a production line the end of Off Delay cycle. The discharge head(s)
that has a fairly constant stream of product passing will start and stop as the On Delay and Off Delay
beneath the discharge head(s). A sensor(s) can be cycles are programmed and the auto start/stop
used to detect your product and either supply the signal(s) will need to be opened and closed to initiate
auto start/stop signal(s) itself or trigger a PLC to the next treat cycle.
apply the signal(s). In either scenario, the auto On and Off Delays
start/stop signal(s) must be applied using a N.O. dry While still on the Auto Mode Setup screen, you will
contact. also need to set the On Delay and Off Delay
The auto start/stop signal(s) must be applied to start parameters. Press the On Delay or Off
the On Delay countdown, which should end before Delay ribbon and the appropriate data entry
the first product passes beneath the discharge screen will be displayed (Figure 66).
head(s). The auto start/stop signal(s) should be held
on as long as product is passing beneath the
sensor(s) and discharge head(s).
When no product is being seen by the sensor the
auto start/stop signal should be removed from the
head(s), the Off Delay countdown will begin and the
discharge head(s) will stop once the countdown is
complete.
If the auto start/stop signal(s) is removed during the
On Delay the discharge head(s) will not start and the
delay will start over when the signal(s) is reapplied. If
the auto start/stop signal(s) is reapplied during the
Off Delay the delay will stop and will begin from 0 Figure 66
when the signal(s) is next removed. Enter the desired set point using the keypad and
Edge Mode press to accept the new value and return to the
In Auto Start/Stop control mode, Edge Mode allows Auto Mode Setup screen, or press return to
you to Start and Stop the Discharge Head(s) using a the Auto Mode Setup screen without making any
customer supplied Normally Open (N.O.) dry changes. Repeat this for the remaining delay set
contact(s) and the On Delay and Off Delay set point.
points. Setting the On Delay
This mode is designed for used on a production line The On Delay set point is the amount of time
where there the product does not flow beneath the between the triggering of the auto start/stop signal(s)
discharge head(s), but instead is placed beneath the and the starting of the discharge head(s). The On
head(s). A sensor(s) can still be used when the Delay set point will also determine if your system is
placement of the product is handled by your running in the Auto Air mode or not.
equipment, or the operator can trigger the start If the On Delay is set at 0.0, your system will not run
signal using a mechanical switch, such as a foot in the Auto Air mode and you will be required to
switch, when the product is placed beneath the enable your discharge head(s) by pressing the
discharge head(s) by hand. In either scenario, the appropriate DISABLED pushbutton on the
auto start/stop signal(s) must be applied using a touch screen or by closing a Remote Enable
N.O. dry contact. contact(s).
When the auto start signal(s) is applied the On Delay If the On Delay is set at 0.1 or higher, your system
countdown begins and once the countdown is will automatically switch into Auto Air mode. In Auto
complete the discharge head(s) will start and the Off Air mode the system enables the discharge head(s)
Delay countdown will begin. When the Off delay when the auto start/stop signal(s) is applied.
countdown is complete the discharge head(s) will
26
The On Delay can be set between 0.0 and 10.0 Dual Head
seconds in 0.1 second increments.
Setting Off Delay
The Off Delay value is the amount of time between
the starting and stopping of the discharge head(s).
The Off Delay can be set between 0.1 and 60.0
seconds in 0.1 second increments.
Once the Auto Mode has been selected and the on
and off delay parameter have been set, press on
the Auto Mode Setup screen to accept the changes
and return to the Start/Stop Control screen. Press
on the Start/Stop Control screen to accept the
Auto Start/Stop control mode and return to the Figure 68
Settings screen. On the Settings screen press The following information covers each combination
to return to the Home screen. or variables that you will be able to select when
setting up your Blown-ion™ Pro Series Treating
On the Home screen verify that the appropriate
System.
information for the selected modes is displayed in
the top ribbon . Local Auto Control - Standard Mode - Auto Air
This information displayed in the ribbon will depend In this mode, will
on the selections you have made while setting up the be displayed at the top of the Home screen. This is
Auto Start/Stop Control mode. the Auto Start/Stop mode when Local, Auto
Start/Stop, and Standard Mode are selected,
RUNNING IN AUTO START/STOP CONTROL MODE
and the On Delay is set at 0.1 seconds or longer.
display the control and monitoring layout for a single The DISABLED and ENABLED
discharge head, while on a dual head system it will pushbuttons are for display purposes only in this
display the for 2 discharge heads. The heads will be mode and will not change state if pressed. The Air
DISABLED upon powering up the system (Figures Interlock Open message is displayed until the auto
67 & 68). start/stop signal(s) is triggered and the Start and
On the Home screen, the DISABLED Stop pushbuttons will be inactive (Figures 69 &
pushbutton(s) will be displayed along with the Air 70).
Interlock Open message(s). The title displayed at
Single Head
the top of the screen will depend on the standard
control and auto modes you have selected and the
set point of the On Delay. The manner, timing and
duration that the discharge head will start and run
will also depend on the auto start/stop variables you
have selected.
Single Head
Figure 69
Dual Head
Figure 70
When the auto start/stop signal(s) is applied to a
Figure 67 head, several things occur at the same time. The
27
discharge head(s) will be automatically ENABLED Once the Off Delay cycle is complete, the system
, the air pressure will be applied to the head, will revert back to its disabled state while waiting for
the on delay cycle will begin, and On Delay Time the next auto start/stop signal(s).
Remaining: x sec will be displayed and count down Single Head
the remaining time (Figure 71 & 72). On the Home
screen, Settings will be inactive.
Single Head
Figure 75
Dual Head
Figure 71
Dual Head
Figure 76
Remote Auto Control - Standard Mode - Auto Air
In this mode, will
Figure 72 be displayed at the top of the Home screen. This is the
Auto Start/Stop mode when Remote, Auto
Once the On Delay cycle is complete the discharge
Start/Stop, and Standard Mode are selected and
head(s) will start and the touch screen background
the On Delay is set at 0.1 seconds or longer.
will change to green, displaying RUNNING and Auto
Signal On (Figures 73 & 74). In this mode, the Blown-ion™ Pro Series Treating
System will function identical to Local Auto Control
Single Head - Standard Mode - Auto Air due to the fact that the
Auto Air function does not allow the head(s) to be
enabled either locally or remotely.
Refer to Local Auto Control - Standard Mode -
Auto Air for Operation Details.
Local Auto Control - Edge Mode - Auto Air
In this mode, will
Figure 73 be displayed at the top of the Home screen. This is
the Auto Start/Stop mode when Local, Auto
Dual Head
Start/Stop, and Edge Mode are selected, and the
On Delay is set at 0.1 seconds or longer.
The DISABLED and ENABLED
pushbuttons are for display purposes only in this
mode and will not change state if pressed. The Air
Interlock Open message is displayed until the auto
start/stop signal(s) is triggered and the Start and
Figure 74 Stop pushbuttons will be inactive.
The screen will display Auto Signal On until the auto When the auto start/stop signal(s) is applied to a
start/stop signal(s) is removed and the Off Delay head it will be automatically ENABLED and
cycle begins and the text display will change to Run the air pressure will be applied to the head. The On
Time Remaining: (Figures 75 & 76). Delay Time Remaining: x sec will be displayed and
28
count down the remaining time. On the Home Dual Head
screen, Settings will be inactive.
Once the On Delay cycle is complete the discharge
head(s) will start and the touch screen background
will change to green and display RUNNING and Run
Time Remaining.
Once the Off Delay cycle is complete, the system will
revert back to its disabled state while waiting for the Figure 78
next auto start/stop signal(s).
To enable a discharge head, press DISABLED
The auto start/stop command can be released and it will change to ENABLED . The air pressure
immediately or held throughout the treat cycle will be applied to the head and Waiting For Auto Start
without changing the cycle duration, but the system will be displayed (Figures 79 & 80). On the Home
will not restart until the auto start/stop signal(s) has screen, Settings will be inactive.
been removed and then reapplied.
Single Head
It is strongly recommended that you use a momentary
contact closure for the Auto Start/Stop signal(s) to
prevent possible timing issues.
Remote Auto Control - Edge Mode - Auto Air
In this mode, will
be displayed at the top of the Home screen. This is the
Auto Start/Stop mode when Remote, Auto Figure 79
Start/Stop, and Edge Mode are selected and the Dual Head
On Delay is set at 0.1 seconds or longer.
In this mode, the Blown-ion™ Pro Series Treating
System will function identical to Local Auto Control
- Edge Mode - Auto Air due to the fact that the Auto
Air function does not allow the head(s) to be enabled
either locally or remotely.
Refer to Local Auto Control - Edge Mode - Auto Figure 80
Air for Operation Details. With no faults displayed, close the auto start contact
Local Auto Control - Standard Mode and the discharge head(s) will start. The touch
In this mode, will screen background will change to green and display
be displayed at the top of the Home screen. This is RUNNING and Auto Signal On (Figures 81 & 82).
the Auto Start/Stop mode when Local, Auto Single Head
Start/Stop, and Standard Mode are selected,
and the On Delay is set at 0.0 seconds.
The DISABLED pushbutton(s) will be displayed
with the Air Interlock Open message displayed and
the Start and Stop pushbuttons will be
inactive (Figures 77 & 78).
Single Head Figure 81
Dual Head
Figure 77
Figure 82
29
The screen will display Auto Signal On until the auto Start/Stop, and Edge Mode are selected, and the
start/stop signal(s) is removed and the Off Delay On Delay is set at 0.0 seconds.
cycle begins. The discharge head(s) will continue to
run and the background will remain green, but the The DISABLED pushbutton(s) will be displayed
text displayed will change to Run Time Remaining: with the Air Interlock Open message displayed and
x sec (Figures 83 & 84). the Start and Stop pushbuttons will be
inactive.
Single Head
To enable a discharge head, press DISABLED
and it will change to ENABLED . The air pressure
will be applied to the head and Waiting For Auto Start
will be displayed. On the Home screen, Settings
will be inactive.
With no faults displayed, close the auto start contact
and the discharge head(s) will start. The touch
Figure 83
screen background will change to green and display
Dual Head
RUNNING and Run Time Remaining: x sec.
Once the Off Delay cycle is complete, the system will
revert back to its disabled state while waiting for the
next auto start/stop signal(s).
The auto start/stop command can be released
immediately or held throughout the treat cycle
without changing the cycle duration, but the system
Figure 84 will not restart until the auto start/stop signal(s) has
When the Off Delay expires, the discharge head will been removed and then reapplied.
stop and the Home screen will revert back to white,
It is strongly recommended that you use a momentary
the ENABLED pushbutton and Waiting For contact closure for the Auto Start/Stop signal(s) to
Auto Start will again be displayed. prevent possible timing issues.
NOTE:
In Standard Mode, if the auto start contact is Remote Auto Control - Edge Mode
reclosed before the Off Delay cycle is complete the In this mode, will
discharge head(s) will continue to run and Auto be displayed at the top of the Home screen. This is the
Signal On will again be displayed. Auto Start/Stop mode when Remote, Auto
Start/Stop, and Edge Mode are selected and the
Remote Auto Control - Standard Mode On Delay is set at 0.1 seconds or longer.
In this mode, will In this mode, the Blown-ion™ Pro Series Treating
be displayed at the top of the Home screen. This is the System will function identical to Local Auto Control
Auto Start/Stop mode when Remote, Auto - Edge Mode with the addition of the ability to
Start/Stop, and Standard Mode are selected and ENABLE the discharge head(s) remotely by closing
the On Delay is set at 0.0 seconds. a N.O. dry contact across Remote Enable circuit
In this mode, the Blown-ion™ Pro Series Treating (Refer to Figure 39).
System will function identical to Local Auto Control Refer to Local Auto Control - Edge Mode for
- Standard Mode with the addition of the ability to Operation Details.
ENABLE the discharge head(s) remotely by closing
a N.O. dry contact across Remote Enable circuit STATUS CONTROL
(Refer to Figure 39). A STATUS pushbutton will be displayed on the
Refer to Local Auto Control - Standard Mode for Home screen for each head display included with
Operation Details. your system. Pressing the STATUS pushbutton
will take you to the appropriate Head Control screen
Local Auto Control - Edge Mode
for that discharge head. On the displayed screen you
In this mode, will
be displayed at the top of the Home screen. This is will be able to check the current conditions of the
selected head.
the Auto Start/Stop mode when Local, Auto
30
Single Head System Status
To check the discharge head operation status, press active when in Local Control with the head
the STATUS pushbutton and the status screen Enabled and the Stop pushbutton is always
will be displayed (Figure 85). active in Local Control mode.
When the system is in Remote Control or Network
Control mode, the Start and Stop
pushbuttons will be inactive.
In Local Control mode you can start the head by
pressing the Start pushbutton, and stop it by
pressing the Stop pushbutton (Figure 86).
Figure 85
The status screen will display Head #1, the current
control mode and total run time for the discharge
Figure 86
head in the top ribbon. When the head is idle, the
screen will display the discharge head Status, output In Remote Control or Network Control modes, you
Power, output Current, output Frequency, the can start and stop the head by either closing and
Enable check box, and a Graphs opening the remote start/stop contact, or by toggling
pushbutton. When the head is running, the Enabled the network run request bit high or low.
check box will be replaced with the heat sink When the discharge head is running, the background
Temperature. will be green and in Local Control mode the Start
The Power, Current, Frequency, and Temperature pushbutton will become inactive, while it is always
are real time readings from systems monitoring inactive in Remote Control and Network Control
circuits, but Status is the operational condition of the modes.
discharge head.
Dual Head System Status
The head Status will either prevent or allow starting To check the operation status of a discharge head,
of the discharge head. The conditions that can be
press the associated STATUS pushbutton and
listed under Status are listed in the Status
the appropriate status screen will be displayed
Condition Table.
(Figures 87 & 88).
Status Condition Table Heads Linked -
Status Description
Running The head is currently running.
Faulted A Fault Condition stopped the head.
Interlock Air or External Interlock not satisfied.
Waiting In Remote Mode, awaiting Remote Start signal.
Enabled Head is Enabled but not running.
The background will be white when the status is

Enabled, Waiting or Interlock; green when the
status is Running, or red when the status is Faulted.
Whether the head is running or not, you will be able
to view the Plasma Interity Monitor screen by
pressing the pushbutton. Figure 87
When the system is idle, you can enable or
disable the discharge head by pressing the
Enabled check box. The Start pushbutton will be
31
Heads Unlinked - When the system is in Remote Control or Network
Control mode, the Start and Stop
pushbuttons will be inactive.
In Local Control mode you can start the head by
pressing the Start pushbutton, and stop it by
pressing the Stop pushbutton (Figure 89).
Figure 88
NOTE: Figure 89
The status screen that is displayed will depend on
whether the discharge heads are Linked or Unlinked. In Remote Control or Network Control modes, you
Return to the Home screen to change the link can start and stop the head by either closing and
condition. opening the remote start/stop contact, or by toggling
The status screen will display the appropriate Head the network run request bit high or low.
#, the current control mode and total run time for the When the discharge head is running, the background
selected discharge head in the top ribbon. When the will be green and in Local Control mode the Start
heads are idle, the screen will display the selected pushbutton will become inactive, while it is always
discharge head’s Status, output Power, output inactive in Remote Control and Network Control
Current, output Frequency, the Enable check box, modes.
and a Graphs pushbutton. When the head
is running, the Enabled check box will be replaced Unlinked Heads Status Screens
with the heat sink Temperature. When the heads are linked the status screen will
The Power, Current, Frequency, and Temperature only display a Stop pushbutton for each head.
are real time readings from systems monitoring When the system is idle, you can enable or
circuits, but Status is the operational condition of the disable the selected discharge head by pressing
discharge head. the Enabled check box. The Stop pushbuttons
The head Status will either prevent or allow starting will be active when in Local Control, but when the
of the selected discharge. The conditions that can be system is in Remote Control or Network Control
listed under Status are listed in the Status mode, the Stop pushbuttons will be inactive.
Condition Table.
When the discharge heads are unlinked and you are
The background will be white when the status is
in Local Control mode, you will only be able start a
Enabled, Waiting or Interlock; green when the
status is Running, or red when the status is Faulted. heads by pressing the associated Start
pushbutton on the Home screen. You will, however,
Whether the head is running or not, you will be able
to view the Plasma Interity Monitor screen by be able to stop the heads by pressing the Stop
pushbuttons on the Status screen.
pressing the pushbutton.
When one or both heads are running, the
Linked Heads Status Screens background will be green behind the status ribbons,
When the heads are linked the status screen will but only green behind the individual Head stop
display a single Start and Stop pushbutton. pushbuttons the head(s) that are running. The
background behind a head that is idle will remain
When the system is idle, you can enable or
white (See Figures 90, 91 & 92).
disable the selected discharge head by pressing
the Enabled check box. The Start pushbutton will In Remote Control or Network Control modes, you
be active when in Local Control with at least one of can start and stop the head by either closing and
opening the remote start/stop contact, or by toggling
the heads Enabled and the Stop pushbutton
the network run request bit high or low.
is always active in Local Control mode.
32
start command. Once you have finished collecting
data from the Plasma Monitor screen, press
arrow to return to the previous Status screen.
SOFTWARE
The software for the control board and display board
on the Blown-ion™ Pro Series Treating System can
Figure 90 be updated using a USB Flash Drive containing the
software updates. These updates will be delivered by
email from Enercon’s Customer Service Department.
Using an empty USB Flash Drive that is formatted to
FAT 32, copy the software update onto the drive.
Do not change the file names!
NOTE:
When you receive a software update it is strongly
Figure 91 recommended that you also copy the update to a
secure location on your company network. Do not
change the file names!
Plug your USB Flash Drive into the USB port on the
front of the power supply (Figure 94). The system
will detect the flash drive and the software versions
on the drive.
Figure 92
Plasma Integrity Monitor
While on the discharge head Status screen,
pressing the Graphs pushbutton will
display the Plasma Integrity Monitor screen (Figure
93).
Figure 94
Navigate to the Settings Screen (Refer to Figure
15) and press the Software icon and the
Software Update screen will be displayed. While the
system is reading the flash drive the home screen
background will be gray and USB Busy will be
displayed in the status ribbon (Figure 95).
Figure 93
The Plasma Monitoring screen will display the
active data for the selected discharge head. On the
screen you will be able to select the data for the
output Current , output Power , Frequency
, Temperature , and output Voltage . The
screen displays a real time graph of the selected
system parameter, the MIN, MAX, AVG, LIFETIME,
and CURRENT values of the selected parameter
and the run time of the selected head since the last Figure 95
33
NOTE: NOTE:
All screens will display the gray background when While the Display Board Microcontroller software
the system is reading a USB flash drive. is being updated the display may go blank several
If you open the Software Update screen without a times during the update process.
USB flash drive inserted, an error message, No USB Once the update is complete the status ribbon will
device present, will be displayed. Also, if the USB display Update complete – Please Reboot. Since
flash drive does not include updates for the software there is no way to exit from this screen, you will need
you have selected, the No Update File Found error to cycle the circuit breaker to complete the update
will be displayed. process.
On the Software Update screen, the check boxes
Update Errors
will be unselected when initially displayed and you
If compatibilities issues are found with the Software
will need to select the software update you wish to
update and the software on your system, you will get
install (Figure 96).
an error message that will list the action you must
take to successfully update the software. The errors
can include any of the following messages:
Update FPGA First – deselect Control Board
Microcontroller and update Control Board FPGA
before continuing.
Update Micro First – deselect Control Board FPGA
and update Control Board Microcontroller before
continuing.
Cannot Update Both – deselect either Control
Board FPGA or Microcontroller and update the
remaining selection before continuing.
Figure 96
Language Update
The Control Board FPGA and Control Board The software update includes software updates for
Microcontroller software can be updated at the both languages the Blown-ion™ Pro Series Treating
same time, but the Display Board Microcontroller System supports. On the Software Update screen is
software must be updated on its own. a pushbutton that displays either English or
The status ribbon will display one of the following Spanish .
messages when you have selected the software you
want to update: When English is displayed the English
software will be updated, and when Spanish is
Touch to update FPGA software – Control Board
displayed the Spanish software will be updated.
FPGA
Pressing the pushbutton will toggle the software
Touch to update micro software – Control Board
update between the 2 languages.
Microcontroller
Touch to update display software – Display Board LOGGING
Microcontroller The Blown-ion™ Pro Series Treating System has the
Touch to update FPGA/micro – Both the Control ability to log and display up to 32 of the events and
Board FPGA and Microcontroller software. faults that have occurred since the last reset of the
Press the status ribbon to begin the update process logs.
for the selected software and repeat this process
Fault Log
until all desired updates are complete.
On the Settings or Data screens, press the Logging
While the update is in process, the status ribbon will icon and the Fault Log screen will be displayed
display the update status allowing you to monitor the initially (See Figure 97).
progress of the update. Do not interrupt the update
process. The Fault Log screen initially displays the last 6
faults that have occurred on the system, but you can
CAUTION! scroll down though the previous faults on the list
using the down arrow. Once you have begun
Once the update has begun, do not interrupt the scrolling down the list the up arrow will be
process as this will have unpredictable result. displayed.
34
to Figure 94). The system will automatically detect
the flash drive once it is plugged in.
NOTE:
If the system does not detect a flash drive connected
to the USB port, the export pushbutton will not be
displayed on the Fault Log or Event Log screens.
With a flash drive in the USB port, press the export
pushbutton and the contents of both the Fault
and Event logs will be saved to the flash drive as a
text file named Logs.txt.
Figure 97 Clearing The Logs
On the Fault Log screen you will be able to display To clear the contents of either log, you will need to
the Event Log screen with the Event Log press the Clear pushbutton and the fault or
pushbutton, clear the contents of the log with the event list will default to Empty for all 32 faults or
events (Figure 99).
Clear pushbutton, and export the contents to
a USB flash drive with the export pushbutton.
Event Log
To view the events that have occurred to the system
since the last reset, press the Event Log
pushbutton and the Event Log screen will be Figure 99
displayed (Figure 98). NOTE:
The system will only clear the contents of the log you
have currently displayed.
CAUTION!
Once the update has begun, do not interrupt the
process as this will have unpredictable result.
Once you finished viewing, saving or clearing the
logs, press to return to the Settings screen.
CALCULATOR
The Blown-ion™ Pro Series Treating System
includes a basic calculator screen that has been
Figure 98 included for your convenience.
The Event Log screen initially displays the last 6 On the Settings screen, press the Calculator
events that have occurred on the system, but you icon and the Calculator screen will be displayed
can scroll down though the previous events on the (Figure 100).
list using the down arrow. Once you have begun
scrolling down the list the up arrow will be
displayed allowing you to scroll back up the list.
On the Event Log screen you will be able to display
the Fault Log screen with the Fault Log
pushbutton, clear the contents of the log with the
Clear pushbutton, and export the contents to
a USB flash drive with the export pushbutton.
Exporting The Logs
To export the contents of either log, you will need to
plug a USB Flash Drive, formatted to FAT 32, into
the USB port on the front of the power supply (Refer Figure 100
35
Perform the calculations like a standard calculator The Head 1 and Head 2 status screens were
and when you are done press to return to the discussed under STATUS CONTROL.
Settings screen.
Line Monitor
DATA On the Data screen, press the Line Monitor
The Blown-ion™ Pro Series Treating System pushbutton and the Line Voltage Monitor screen
includes a Data screen for access to monitoring and will be displayed (Figure 103).
function screens, including some also found on the
Settings screen.
You will be able to access the Data screen whenever
the navigation bar is displayed. Press Data in
the navigation bar and the Data screen will be
displayed (Figures 101 & 102).
Single Head System
Figure 103
On the Line Voltage Monitor screen, a real time
representation of the current line voltage will be
displayed.
If the line voltage falls between 90 - 95 VAC or 180 -
190 VAC, a system warning indication will be
displayed on the Home screen; a Yellow background
Figure 101
when the head is idle, or Aqua an background when
Dual Head System the head is running (Figures 104, 105 & 106). A
warning condition will not shut off your discharge
head(s).
If the line voltage falls below 90 VAC, or rises above
135 VAC the system will fault and the head(s) will
shut off. A Red background will be displayed.
Single Head System
Figure 102
The Data screen is similar for both single and dual
head systems, with the exception that the Head 2
pushbutton is not displayed on the single head Data Figure 104
screen.
From the Data screen, you will have access to the
Logging and Calculator functions, the Factory,
Line Monitor, Head 1 and Head 2 (Dual Head Only)
status, Help and Electrode screens.
The Factory, Logging and Calculator functions
were discussed earlier in this manual, refer to these
write ups for details.
Figure 105
36
Dual Head System head is idle, or Aqua an background when the head
is running (Refer to Figures 104, 105 & 106). A
warning condition will not shut off your discharge
head(s).
Single Head System
Figure 106
For details on how to address system Faults and
Warnings, see Warnings in SECTION 6.
When you are done on the Line Voltage Monitor
screen, press Data in the navigation bar to
return to the Data screen.
Help
Figure 108
On the Data screen, press the Help pushbutton
and the Help Menu screen will be displayed (Figure Dual Head System
107).
Figure 109
Figure 107 Whenever you replace the electrode on a discharge
head, you will need to return to the Electrode
The Help Menu screen lists Enercon Industries Monitor screen to reset the time count by pressing
contact information and includes pushbuttons that
will allow you to access issue specific tips by the Reset pushbutton.
pressing the pushbuttons. When you are done on the When you are done on the Electrode Monitor
Help Menu press to return to the Data screen. screen, press Data in the navigation bar to
All of the Troubleshooting Information screens are return to the Data screen.
covered in SECTION 6. INFO
Electrode The Blown-ion™ Pro Series Treating System
includes an Information screen where you can find
On the Data screen, press the Electrode
contact information and system information that
pushbutton and the Electrode Monitor screen will
customer service may require to aid you in resolving
be displayed (Figures 108 & 109).
issues with your system.
On the Electrode Monitor screen, a real time count
You will be able to access the Information screen
of each discharge head’s electrode run time is
whenever the navigation bar is displayed. Press Info
displayed.
in the navigation bar and the Information
When the run time for an electrodes reaches 2500 screen will be displayed (See Figure 110).
hours a system warning indication will be displayed
on the Home screen; a Yellow background when the
37
Figure 110
On the Information screen you will find your
system’s Serial Number, Model Number, and the
Software Version your system is currently using.
The main Phone number, service E-Mail and
Enercon’s Website are also listed.
38
SECTION 4 – OPTIONAL EQUIPMENT
GENERAL OPTIONAL FOOT SWITCH

Before installing or operating the optional The optional foot switch is designed for use with
equipment covered in the section, please read this Auto Start/Stop Control and will allow your operator a
section completely. Also, please refer to SECTION 1, convenient way to apply the auto start signal to your
Pages 1 and 2, to become familiar with all safety surface treater system (Figure 112).
requirements and precautions for this equipment.
The Blown-ion™ Pro Series Treating System has
standard options that can be included with your
surface treating system.
Standard Options Include:
Stack Light
Foot Switch Figure 112
OPTIONAL STACK LIGHT
The foot switch includes a Normally Open (N.O.) dry
The optional Stack Light provides a visual indication
contact that closes when the foot switch is
of the operating status of your Blown-ion™ Pro
depressed and open when the switch is released.
Series Treating System. The Stack Light is pole
The optional foot switch can be used to apply the
mounted on a spacer that is to be mounted on an
auto start signal to a single head at a time when
appropriate mounting structure within the range of
wired in series with the head’s auto start circuit, or
the interconnection cable. The Stack Light cable
both heads at once when connected in parallel
connects to the External Indicator connector on the
across the auto start circuit for both heads on dual
back of the Blown-ion™ Pro Series Treating System
head system.
cabinet (Figure 111).
Refer to AUTO START/STOP CONTROL MODE
(Optional) for details on using the optional foot
RED - Discharge
Head is not Running switch on your Blown-ion™ Pro Series Treating
System.
GREEN - Discharge
Head is Running NOTE:
For individual control of the auto start signal on a
dual head system, you will need 2 foot switches
connected in series with each head’s auto start
circuit.
Single Head
Dual Head
Figure 111
The Stack Light uses Green and Red indicator lights
to display the discharge head status. When a
discharge head is running the associated green
indicator is lit, when a discharge head is not running
the Red indicator light will be on indicating that
power is applied, but the head is not running.
39
SECTION 5 – MAINTENANCE
GENERAL
Before performing maintenance on this To help prevent the nozzle from becoming coated,
equipment, please read this section completely. Also, ensure that your compressed air source is clean, and
please refer to SECTION 1, Pages 1 and 2, to become that your filtering components are inspected and
familiar with all safety requirements and precautions for cleaned on a regular basis. Inspect the tip of the
this equipment. nozzle for signs of buildup and if required, remove
The Blown-ion™ Pro Series Treating System is the nozzle to inspect its interior.
designed to require minimal maintenance. However, Clean the nozzle using isopropyl alcohol and a
to insure long-range reliability, it is a good practice to Scotch Brite™ pad or stiff bristle bottle brush.
have a planned maintenance program. This section Extremely heavy buildup can be removed using a
will include recommended preventative and media blaster. If the buildup cannot be completely
corrective maintenance procedures. removed you will need to replace the Nozzle.
PREVENTIVE MAINTENANCE NOTE:
When operated under normal conditions, the Blown- If heavy buildup is found on a regular basis, you may
ion™ Pro Series Treating System will require little or wish to perform this check more frequently.
no service at all. It is important, however, that the
discharge heads are frequently checked to assure QUARTERLY CHECKS
that it is free from any dust or dirt build-up. Any Inspect for loose connections, excessive dust build-
accumulation of dirt in the air passage between up, and evidence of excessive heating. Dry,
blower and electrodes can cause serious arcing and compressed air is convenient for removing dust from
subsequent damage to the assembly and the high the equipment.
voltage bearing wires and parts. ELECTRODE AND AIR VANE
It is recommended that a Preventative Maintenance Each discharge head’s electrode should be replaced
Program is set up and followed to insure proper after 2500 hours of run time (Refer to Electrode).
system operation. The Air Vane should be inspected at that time for
damage or wear and replaced if necessary.
DANGER! CORRECTIVE MAINTENANCE
High voltage is present within the cabinet. FACTORY RESTORE
Only qualified personnel should be allowed to The Blown-ion™ Pro Series Treater System allows
work on the equipment with the cover open. you to restore all of the factory settings using a
“Logs.txt” file on a USB drive without having to
For safety purposes, disconnect power and
update the system software.
verify all capacitors are discharged before
working on the power supply. NOTE:
The DC Bus Capacitors discharge very slowly. Restoring your system back to factory settings
should only be attempted when recommended by
Enercon Customer Service.
DANGER! The “Logs.txt” file can be obtained from Enercon via
Never attempt to perform maintenance on this email or a file-sharing site, or you can update the
equipment unless electrical power is locked settings using the “Logs.txt” that you have previously
out and tagged out. saved from the logging screens.
The “Logs.txt” file must be saved to compatible USB
MONTHLY CHECKS drive and inserted into the USB port on the front of
DISCHARGE HEAD NOZZLE the power supply (Refer to Figure 94). Navigate to
Under heavy use, or when there are contaminates the Settings screen, unit cannot be running, and
present in the compressed air source, the nozzle of press the Restore pushbutton to display the
the Blown-ion™ discharge head may gradually Settings Restore screen (See Figure 113).
become coated and if the coating becomes too
heavy, the plasma discharge can be affected.
40
Figure 113
If a compatible USB drive with the “Logs.txt” file is
detected, the Restore pushbutton will be
displayed and will be displayed as the
status.
If a compatible USB drive is not detected,
will be displayed as the status.
If a compatible USB drive is detected, but the
“Logs.txt” file is not, will be displayed as
the status.
Press to start the process. The pushbutton
will disappear from the screen and will be
displayed as the settings are updated and
will be displayed once the update is complete.
Press to close out the Settings Restore screen
and return to the Settings screen.
41
SECTION 6 – TROUBLESHOOTING
GENERAL
Before performing troubleshooting on this Head Specific Faults
equipment, please read this section completely. Also, When a head is running and a head fault occurs, the
please refer to SECTION 1, Pages 1 and 2, to become background will turn red, the word FAULT will be
familiar with all safety requirements and precautions for displayed with the fault description listed below
this equipment. FAULT, and the Reset pushbutton will be
displayed.
DANGER! How the Home screen will be displayed will depend
Ensure all power is disconnected from the power on the number of heads your system has and
supply before removing the cover for any whether you have a dual head system’s heads linked
maintenance procedures. or unlinked.
Use your company’s approved Lockout and Tag Out Single Head System
procedures.
On a single head system, the head will stop, the
The Blown-ion™ Pro Series Treater System is screen background will turn red, and the Stop
designed for reliable and trouble-free operation. If a pushbutton will be replaced with the Reset
failure should occur, a Fault screen will be displayed pushbutton (Figure 115).
listing the Type of Fault and the Time and Date that
the fault occurred.
FAULTS
On each Fault screen there will be a Reset
pushbutton that will reset the fault and return you to
the Home screen when pressed.
When a system fault occurs, the Date, Time, and
Type of Fault are logged into the Fault Log. You
can access the Fault Log from the Settings screen
by pressing the Logging icon and the Fault Log
screen will be displayed (Figure 114).
Figure 115
Pressing the Reset pushbutton will reset the Home
screen with the head DISABLED. The fault
condition must be corrected before the system can
be ENABLED and started.
Dual Head System – Heads Linked
When the heads are linked, both heads will stop. The
faulted head background will turn red with the Reset
pushbutton displayed and the other head will default
to the Enabled condition (Figure 116).
Figure 114
The Fault Log displays the Date, Time and
Description of the last six faults that have occurred
on the system. Refer to LOGGING for a more
detailed explanation of the Fault Log screen.
The Blown-ion™ Pro Series Treater System is
programmed with several faults that will be displayed
on a Fault screen when general system faults occur
or the Home screen when a discharge head specific
fault occurs. Contact Customer Service with any
questions not covered in this section. Figure 116
42
Pressing the Reset pushbutton will reset the affected
discharge head but it will be DISABLED. The fault
condition must be corrected before the head can be
ENABLED and both heads started.
Dual Head System – Heads Unlinked
When the heads are unlinked, only the affected head
will stop. The faulted head background will turn red
with the Reset pushbutton displayed. The other head
will continue to run (Figure 117).
Figure 118
System Fault List
Local Comm Fault – Loss of communication
between the control board and the display board,
detected by the display board.
Communication Fault – Loss of communication
between the control board and the display board,
detected by the control board.
Control Board Fault – An internal problem has
Figure 117
occurred on the control board.
Pressing the Reset pushbutton will reset the affected Voltage Doubler Trip – Failed Triac device or
discharge head but it will be DISABLED. The fault incorrect system setup.
condition must be corrected before the head can be
ENABLED and started. Line Voltage Fault – The line voltage has dropped
below 90 VAC or is between 135 and 180 VAC.
Head Specific Fault List
Air Pressure Trip – Low Air Pressure Interlock Troubleshooting with the help menu
opened while running. The Help Menu includes several pushbuttons that
Intelock Trip – An External Interlock opened while will take you to Troubleshooting Information
running. screens to aid you in troubleshooting issues you may
Temperature Trip – Heat Sink overheated while encounter with your system.
running.
Under Power Trip – Discharge Head, HV To navigate to the Help Menu press Data on
Transformer or IGBT device failed while running. the navigation bar, then the Help on the Data
Min. Freq. Trip – Discharge Head, HV Transformer screen to display the Help Menu screen (Refer to
or IGBT device failed while running. Figure 107).
Over Current Trip – Discharge Head, HV Currently there are 6 ribbons displayed on the Help
Transformer or HV wiring failed while running. Menu screen. Pressing one of the troubleshooting
ribbons will open the Troubleshooting Information
System Faults
screen for the described Fault.
When a head is running and a system fault occurs, a
Fault screen will be displayed listing the fault name, This screen may be updated in the future and any
the time and date that the fault occurred, and the changes to these screens will be addressed when
Reset pushbutton. software updates are made available.
How the Home screen will be displayed will depend To access the Troubleshooting Information
on the number of heads your system has and screens press the ribbon that represents the issue
whether you have a dual head systems heads linked you are troubleshooting and that information screen
or unlinked (Figure 118). will be displayed.
Pressing the Reset pushbutton will reset the screen When you are finished, press to return to the
to the home screen with all of the system heads
Help Menu. Press on the Help Menu to return
DISABLED. You will need to correct the issue before
to the Data screen.
the system heads can be ENABLED and started.
43
Air Interlock No Start
External Interlock No Discharge
Over Current Trip
Min. Freq. Trip
44
INVERTER OHM CHECK PROCEDURE
 Any “Zero” ohm reading will constitute a bad
Semi-Conductor.
 Meter Required: Standard Analog VOM-OR-
DVOM with Diode Test.
DANGER!
Ensure all power is disconnected and locked out
from unit before performing ohm check procedures.
CAUTION!
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.
FACTORY ASSISTANCE
If the steps in this section have failed to determine
the problem, the factory should be contacted for
assistance.
Enercon Customer Service Department
Phone Number: (262) 255-6070
Fax Number: (262) 255-7784
E-Mail Address: service@enerconmail.com
Website: www.enerconind.com
24hr Customer Service is available.
45
SECTION 7 – PART BREAKDOWNS
GENERAL SHIPPING INSTRUCTIONS FOR RETURNS
This Section of your manual contains illustrated part Enercon has 2 facilities that perform repairs and
breakdowns of the various components that make up process credits. Before shipping parts or equipment
the Blown-ion™ Pro Series Treater System. If back, contact Enercon’s Customer Service
standard options are offered with your system they Department for a Return Material Authorization
will be represented with parts breakdown illustrations (RMA) number, the proper shipping address, and
as well, but special order options typically will not. any special shipping instructions.
The illustrations, and their associated part tables, are If possible, use the original packaging material the
primarily provided for replacement part identification, parts or equipment were shipped with. If that is not
but can also be useful in locating items that are available, use a fiberboard box and adequate
identified as being required for operation, or requiring packing materials to support the items weight and
maintenance or adjustment. prevent movement during shipping.
HOW TO USE THE PART LISTS Ensure both the shipper and receiver addresses are
1. Refer to the illustrated part breakdowns to identify clearly printed on top of package along with the RMA
the desired breakdown illustration. number.
2. Visually locate the desired part in the breakdown Parts must be sent Prepaid.
illustration to find the Item #.
3. Refer to the part table to find the Item # and note
the Enercon Part # and Description before
contacting the parts department.
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 1 on Page 3 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) 255-7784
E-Mail Address: parts@enerconmail.com
46
Single Head Blown-ion™ Pro Part Breakdown
19 14
5
4
9 13
22
18
10
11
20 17
8
3
7
21
11
16
2 15
1 12
6
Figure 119
Item # Part # Description Qty.
1 EM0412 Touch Screen Module 1
2 LM5697-03 Touch Screen Display Board 1
3 LM5823-01 Control Board 1
4 LM5834-03 Power Board Assembly 1
5 LM5824-01 IO Board 1
6 CB0350 15 Amp, 2 Pole Circuit Breaker 1
7 TF0400-04 High Voltage Transformer 1
8 LM5837-SHP-02 Single Head PRO Blown Arc/Ion Air Sub-Assembly 1
9 SW0621 Pressure Switch 1
10 CA1201 RJ45 Panel Mount Cable Assembly 1
11 CA1200 USB Panel Mount Cable Assembly 1
12 CA0758-UA RJ45 to RJ45 Patch Cable 1
13 CA1105 40 Pin Ribbon Cable, 4" Long 1
14 LM5842-BIxx-xx Discharge Head (See Figure 121) 1
15 EM0346 Battery 1
16 EM0347 SD Card 1
17 IN0012-07 Glazed Alumina Post 2
18 FD3265-1075 HV Standoff Connections Barrier 1
19 CA0074 14 AWG 3 Wire Power Cord 1
20 TB7100 Terminal Block 4
21 TB7103 Ground Terminal Block 2
22 TU7090 Polyethylene Tube - Black Length Varies
NOTE: To insure the correct parts are supplied please have the model and serial number of the system available.
47
Dual Head Blown-ion™ Pro Part Breakdown
20 15
4
5
4
8
23 14
10
19
11
9
21 18 19 18
3
7
7
22
9 23 12
17
10 2 16
1 13
6
Figure 120
1 EM0412 Touch Screen 1
2 LM5697-03 Touch Screen Display Control Board 1
3 LM5823-01 Control Board 1
4 LM5834-03 Power Board Assembly 2
5 LM5824-01 IO Board 1
6 CB0350 15 Amp, 2 Pole Circuit Breaker 1
7 TF0400-04 High Voltage Transformer 2
8 LF0200 Line Reactor (1 Hidden) 2
9 LM5837-DHP-02 Dual Head PRO Blown Arc/Ion Air Sub-Assembly 1
10 SW0621 Pressure Switch 2
11 CA1201 RJ45 Panel Mount Cable Assembly 1
12 CA1200 USB Panel Mount Cable Assembly 1
13 CA0758-UA RJ45 to RJ45 Patch Cable 1
14 CA1105 40 Pin Ribbon Cable, 4" Long 1
15 LM5842-BIxx-xx Discharge Head (See Figure 121) 2
16 EM0346 Battery 1
17 EM0347 SD Card 1
18 IN0012-07 Glazed Alumina Post (2 hidden beneath Item 17) 4
19 FD3265-1075 HV Standoff Connections Barrier 2
20 CA0074 14 AWG 3 Wire Power Cord 1
21 TB7100 Terminal Block 8
22 TB7103 Ground Terminal Block 2
23 TU7090 Polyethylene Tube – Black Lengths Vary
48
Discharge Head Part Breakdown
12
10
9 11
16
19
20 15
6 7 8
4
5 14
2 3
1
15
20 17
18
20
13
Figure 121
1 FD6679-07 Nozzle Mounting Disc 1
2 FD6679-08 Nozzle 1
3 RN2079 Silicone O-Ring 1" ID 1
4 HW5018 Electrode Tip 1
5 FD6679-14 Air Vane 1
6 FD6679-18 Housing Disc 1
7 FD6679-09 Teflon Body B 1
8 RN2120 Silicone O-Ring 3/4" ID 1
9 FD6679-15 Teflon Body A 1
10 RN2080 Silicone O-Ring 1 1/8" ID 1
11 FD6679-17 Grounding Ring 1
12 FD6679-19 Housing Shield 1
13 FD6679-16 Housing Base 1
14 LM5839-BI-XX-XX Discharge Head Cable Assembly 6 ft / 12 ft
15 CD0542 Cord Grip w/Strain Relief 3/4" NPT 2
16 CO1521 3/4" Conduit Lock Nut 1
17 MM040-070P080S-0 Stainless Steel Socket Head Cap Screw M4 X .7P X 80mm LG 3
18 MM040-070P010S-0 Stainless Steel Socket Head Cap Screw M4 X .7P X 10mm LG 3
19 MM040-070P020S-0 Phillips Head Stainless Steel Screw M4 x .7P x 20 1
20 WA1545 Stainless Steel Lock Washer 7
49
Optional Stack Light and Foot Switch Part Breakdown
4
9 9
9
2 2
17 15
16 4
5 1 1
Optional Foot
Switch 9 9
3 3
11
8 1 1
10
8
7 6
14 Optional Stack
Light
13
12
Figure 122
Qty.
Item # Part # Description
Single Head Dual Head
1 LT0151 Stack Lite 24V Bulb 2 4
2 LT0150 Stack Light Red 1 2
3 LT0144 Stack Light Green 1 2
4 LT0145 Stack Light Base and Cover 1 1
5 LT0216 Stack Light Tube and Mounting Tulip - 400mm 1 1
6 FD5447-01 Spacer, Stack Light 1 1
7 LM5846-20 Blown Arc/Ion Stack Light Cable Assembly – 20 Ft 1 1
8 CD0512 Plastic Cord Grip and Nut 1 1
9 -- Gasket – Included w/Items 2, 3 & 5 3 5
10 -- Gasket – Included w/Item 6 1 1
11 MM050-080S050S-0 SS Socket Head Screw M5 x 0.8P x 50 4 4
12 NU0021 SS Nut M5 x 0.8P 4 4
13 WA1550 SS Lock Washer 4 4
14 WA4050 SS Flat Washer 4 4
15 SW0088 Foot Switch 1 1
16 LM5878-20 Blown Arc/Ion Foot Switch Cable Assembly – 20 Ft 1 1
17 CD0501 Plastic Cord Grip 1 1
50
SECTION 8 – 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
51
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
52
NOTES
53
NOTES
54

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Blown-ion™ Pro Series

OWNERS REFERENCE MANUAL

MAILING ADDRESS: SHIPPING ADDRESS:

Phone: (262) 255-6070 ● Fax: (262) 255-7784 ● Web Site: www.enerconind.com

SECTION 1 – INTRODUCTION ........................................................................................................................................................... 1

DO NOT OPERATE THIS EQUIPMENT IN A HAZARDOUS ENVIRONMENT!

SAFETY AND WARNINGS

Ø 2" Ø 2" Figure 3

Orange/Black - N.O. Red/Green - N.O.

HV Xfrmr 1 Power Board

Press to enable the selected mode and return to

Enabling/Disabling Lockout When Operator Lockout is enabled, the icons on the

no faults displayed, pressing a discharge head’s Remote #1 Orange/Black

discharge head (Figure 38).

Single Head Remote Control Mode

Blown-ion™ / Blown-arc™ Pro Network Address Map

Series Contact For Parallel Contact For

Auto Control Cable

The background will be white when the status is

GENERAL OPTIONAL FOOT SWITCH

External Interlock No Discharge

Over Current Trip

Min. Freq. Trip

Meter Lead VOM DVOM

Enercon Parts Department

Date Issues Found Corrective Actions Required Verified By

Date Issues Found Corrective Actions Required Verified By

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