Q_START MANUAL

DAT210/213

Digital Auto Tuning

Version V1c

Plasma Technics Inc. 1900 William St. Racine, WI 53404-1875 Phone : (262) 637-7180 Fax : (262) 637-7157
Web Page : http://www.plasmatechnics.com E-Mail : [email protected] Page 1
 MOUNTING
This manual covers a programmed DAT 210 (single phase mains) or DAT 213 (3 phase mains) inverter.
The inverter is usually set up for a specific application and requires only installation wiring to operate
correctly at startup. If the application is changed or flexible, refer to the section on tuning the inverter
in this or the complete standard manual.

DAT means Digital Automatic Tuning that allows the inverter to maintain constant power into an ozone
system load over changing gas pressures and flow rates. It does this by:

Automatically changing the frequency to seek resonance at the programmed power

Automatically changes the output voltage to compensate for mains voltage changes

Mechanical Installation

Do not mount the inverter in a cabinet and then start drilling holes in the cabinet. Metal chips
on the circuit board can destroy it.

Check that there is adequate clearance in front of the fan for adequate cooling.

The ambient air temperature should not exceed 40oC (104oF)

Hole pattern:

Plasma Technics Inc. 1900 William St. Racine, WI 53404-1875 Phone : (262) 637-7180 Fax : (262) 637-7157
Web Page : http://www.plasmatechnics.com E-Mail : [email protected] Page 2
 ELECTRICAL INSTALLATION

Observe all wiring codes. Install wiring separating the control and low power wires from the high
power mains or any high voltage wiring.

190 to 240 VAC operating voltage. DO NOT apply 480 VAC to this inverter.

Mains wiring
Power ratings (208 – 240 VAC):

Less than 2 KVA use a soft start relay circuit

The single phase effective power factor will be 0.6

Greater than 2 KVA use 3 phase power – Use a soft start and link choke on the DC after
the mains rectifier.
The three phase effective power factor will be 0.9

The soft start prevents high inrush currents due to filter capacitor charging when power is
applied. The link choke reduces the ripple current in the filter capacitors (and mains 3rd
harmonic) and improves the power factor from 0.6 to 0.9.

The inverter is capable of 25 Amps RMS 1.0 power factor mains current continuous. This means
at 240 VAC mains, 6 KW is available with the voltage potentiometer turned full clockwise
maximum. Take care so your equipment is not over powered.

For greater detail to help with system design and configuration refer to the complete manual.

Plasma Technics Inc. 1900 William St. Racine, WI 53404-1875 Phone : (262) 637-7180 Fax : (262) 637-7157
Web Page : http://www.plasmatechnics.com E-Mail : [email protected] Page 3
 DAT210

TRANSFORMER
CONNECTION MAINS POWER
208 TO 240 VAC

CONFIGURATION
SWITCHES

STATUS
LEDS

PlasmaView
SERIAL
CONNECTOR

MANUAL ADJUSTMENTS
FLASH PROCESSOR
TO LOAD POWER
AND FREQUENCY LOW VOLTAGE CONTROL I/O
FOR NEW PRESSURE
AND FLOW CONDITIONS

Plasma Technics Inc. 1900 William St. Racine, WI 53404-1875 Phone : (262) 637-7180 Fax : (262) 637-7157
Web Page : http://www.plasmatechnics.com E-Mail : [email protected] Page 4
 LOW POWER CONNECTIONS

Input / Output Connections ( Con12 )

Basic control connection for PDM, ON/OFF, Frequency, Voltage, Enable out, +15vdc, +5vdc are the
same as all other Plasma Block® products that have utilized the DAT210 control board. Note below
that many new outputs are available and the enunciation outputs have been changed from 0-5v logic
level types to open collector for easier interface to a wider variety of PLC’s. The open collector outputs
are all active low [Active low means that the terminal output is at 0V (Pin 3) when the alarm or other
condition is present]. Terminal current is positive source only and is limited to 100 ma.

TERMINAL
1. +15, aux use limit = 1 Amp maximum.
2. Frequency Adjust (optional) external control, selected by jumper J10. Use 5k Ω pot, 0-10vdc
only (10v= 100%). 10 volts can be derived with a 2.0 K resistor in series with the pot to +15 (Pin
1).
3. Signal Common, tied to #9 internally.
4. Flooded cell detector. (Current production inverter)
5. +5vdc, aux use limit = 3 Amps The 5V can be used to drive a 5 V coil relay for input current
pre-charge and for PLC use for low voltage power supply status. There is a 1 – 2 second delay
before +5 V after application of mains voltage.
6. PDM input (optional), selected by jumper J11, use 5kΩ pot, 0-10vdc (10v= 100%). 10 volts can
be derived with a 2.0 K resistor in series with the pot to +15 (Pin 1). 0 – 10 volt control or 4 – 20
& 0 – 20 ma is selected with J12. All voltages/currents are with respect to Pin 3 (0V).
7. Inverter Start, output pulls low via open collector ( MMBT4401 ) when inverter is engaged.
Follows Inv_ON LED. 10k Ω pull-up to +5. 100Ω in series with the transistor for current limit.
8. Inverter OFF when pulled low to terminal 9 via momentary or continuous. 10kΩ pull-up to +5v.
9. Logic Common for # 8 and 10.
10. Inverter ON when pulled low to terminal 9 via momentary or continuous. 10kΩ pull-up to +5v.
11. FAULT OUT pulls low via open collector ( MMBT4401 ) when inverter faults due to: Operating
cell current is above or below customer programmed set point. Over temp cell, over temp
electronics, sustained instantaneous over current. 100Ω on board. (See jumper J4)
12. System LOCKED. Digital auto-tune feature has found and confirmed the proper operating point.
If pressure changes cause significant re-tuning the LOCKED LED will flash. The locked LED will
also flash during the initial tuning acquisition, which lasts for a few seconds.
13. Analog 0 – 5vdc, follows average DC bus current out. Direct op amp (MC33272AD) thru 100Ω
resistor.
14. Analog 0 – 5vdc, follows DC bus voltage. Direct op amp (MC33272AD). 10kΩ series resistor.
15. Voltage Adjust input (optional), selected by jumper J9, use 5kΩ pot, 0-10vdc only (10v= 100%),
impedance 10k Ω.

Plasma Technics Inc. 1900 William St. Racine, WI 53404-1875 Phone : (262) 637-7180 Fax : (262) 637-7157
Web Page : http://www.plasmatechnics.com E-Mail : [email protected] Page 5
 16. Clock Freq out (1x). Output pulls low via open collector ( MMBT4401 ). 10kΩ pull-up to +5.
100Ω series protection resistor.

Plasma Technics Inc. 1900 William St. Racine, WI 53404-1875 Phone : (262) 637-7180 Fax : (262) 637-7157
Web Page : http://www.plasmatechnics.com E-Mail : [email protected] Page 6
 DAT 210 JUMPER CHART
SWITCH
SW1 SWITCH POSITION NAME FUNCTION IF INSTALLED
S1 ON PDM Enable If PDM is remotely commanded, remove to test 100% output
level. This is especially useful if the unit is hard wired to a PLC or
ORP controller.
S2 OFF LOW PDM Lower PDM period than 30 Hz
S3 OFF Not implemented
S4 ON HIGH/LOW current fault A window of normal operating current. This will cause a fault if
either the LOW or HIGH value is exceeded.
S5 OFF Soft fault Produces a wink in fault line #11 if one or more operational
windows are exceeded beyond the factory limit. Will not shut
down the inverter like a hard fault but attention is needed. The
fault is being managed by the inverter processor.
S6 OFF PDM Ramp Default – 5 sec. for inverter to ramp from 0 – 100% power.
Switch ON is immediate ramp to 100% inverter power.
S7 OFF Spare
S8 OFF 4/20 ma. Configuration for 4 - 20 ma. control 0 - 100% ozone output. At 2
ma the INV_ON LED will flash. At 3 ma. The output is reinabled.
If the jumper is removed, 0 - 10 (0 - 100%) volts controls the
ozone output. If the command is for zero ozone, the inverter will
be in standby.

JUMPER INSTALLED
DEFAULT
J101 OUT ON with power up ON-OFF command change. The inverter will turn ON 5 seconds
after power is applied and turned OFF when power is removed.
This is not recommended because it eliminates gas purge.
J1, J2 Alternate methods of inverter startup. See Pages 17 – 19.
J3 OUT SEMI-AUTO Tune J5 out, voltage pot active to set maximum power. Frequency
control is automatic.
J4 OUT Manual fan Fan goes on when power is applied and off when removed.
J5 IN Full AUTO-TUNE Voltage and frequency pots are not active. These parameters
are controlled automatically. In SEMI-AUTO mode, the voltage
pot controls total power but frequency control is automatic.
J9 IN Voltage control pot 1 - 2 jumper = internal control. 2 - 3 = external
J10 IN Frequency control pot 1 - 2 jumper = internal control. 2 - 3 = external
J11 IN PDM control pot 1 - 2 jumper = internal control. 2 - 3 = external
J12 *Stow Installed = 4/20 ma. Or
Adds 500 ohm resistor to control input. If two or more DAT 210s
0/20 ma.
are to be controlled via one current loop, wire all Connector
OUT = 0 - 10 VDC
CON12 term. 3 together and all term. 6 together and install J12
on one DAT 210 inverter. Usually S8 ON and J12 jumper are used
together.
*Jumpers that are available for customer needs are stored on one pin.

Plasma Technics Inc. 1900 William St. Racine, WI 53404-1875 Phone : (262) 637-7180 Fax : (262) 637-7157
Web Page : http://www.plasmatechnics.com E-Mail : [email protected] Page 7
 TUNING THE INVERTER
Safety Considerations
DANGEROUS VOLTAGES ARE ON THIS CIRCUIT BOARD
To avoid injury to personnel and/or damage to equipment only qualified personnel should
perform the procedures outlined in this chapter. This person must understand both the electrical
and mechanical components associated with the application.
Thoroughly read and understand the following procedures before beginning the start-up process.
The following specific safety procedures must be observed when performing any maintenance or
adjustments on the amplifier.
Always turn off and lock out AC power at the main machine disconnects switch. Do this before
touching any electrical or mechanical components.
High voltage may be present even with all electrical power supplies disconnected.
Use an appropriate meter to verify that all DC bus capacitor banks have been discharged before
working on any equipment. Do not rely exclusively on high voltage RED LED indicator for bus
voltage, as dangerous voltage levels may remain even when the indicator is off.
Follow industry recognized safety procedures. Use only one hand to hold test equipment probes,
wear approved eye protection, etc. Before energizing the inverter, make sure that device(s)
connected to the output of the inverter will not result in injury or damage to equipment. Keep
unnecessary personnel out of the immediate work area. Never leave an inverter cabinet open
and unattended.

Start-up Checklist
To ensure a complete checkout and test, check off each step as it is completed. If the proper event does not
occur while performing this start-up procedure, do not continue. Take the appropriate action to correct the
malfunction before proceeding.
• Ensure the main disconnect switch is locked off. High voltage may be present even with all electrical
power supplies are disconnected. Use an appropriate meter to verify that all DC bus capacitor banks have
been discharged before working on any equipment. Do not rely exclusively on RED LED indicator of bus
voltage, as dangerous voltage levels may remain even when indicator is off.
• Verify that the inverter mounting has been performed in accordance with the guidelines listed in
• Chapter 2.
• Inspect the inverter to verify that all optional modules have been selected and installed according to the
system drawings and documentation.
• Verify that all wiring has been installed according to the wiring plan produced by the design engineer and
according to the guidelines listed in Chapter 3 for proper connection, grounding, wire size, labeling,
routing and applicable codes. The DAT 210 does not have internal fusing. Install input and output
(optional) fusing per suggestions Page 23.
• Verify that all electrical terminals, screws, nuts, and bolts are securely fastened.
• Apply high voltage DC or single-phase AC power to the inverter as specified.
• Check to make sure that the RED Bus voltage LED is on, indicating bus voltage.

Plasma Technics Inc. 1900 William St. Racine, WI 53404-1875 Phone : (262) 637-7180 Fax : (262) 637-7157
Web Page : http://www.plasmatechnics.com E-Mail : [email protected] Page 8
 PROGRAMMING AND TROUBLESHOOTING

The DAT210 board on all Plasma Block® products contains 10 LED’s which are used to indicate status during normal
operation, board programming and troubleshooting of the unit.

Plasma Technics Inc. 1900 William St. Racine, WI 53404-1875 Phone : (262) 637-7180 Fax : (262) 637-7157
Web Page : http://www.plasmatechnics.com E-Mail : [email protected] Page 9
The DAT210 board's 10 LED's are shown below in various patterns with related status/description information.

NORMAL RUNNING LED LIGHT PATTERN.

Under normal running conditions, the LED light pattern will appear as shown here.
The INV ON and +5VOLTS will be solid ; the LOCKED will be flickering.

PERFORMING CALIBRATION MODE – STEP 1

Press the START button and hold briefly until these LED’s show, then release.

Note – Unit must be in Semi-Auto mode (J5 removed).

B Note – Holding any longer will show a different pattern of LEDs.
B
B
S
S
PERFORMING CALIBRATION MODE – STEP 2
F HS Temp LED will flicker, showing that the board is in Calibration Mode.

S
S
PERFORMING CALIBRATION MODE – STEP 3
F This light pattern indicates T1 is set higher than 2% of the original set point. Adjust the T1
voltage pot to a value within the 2% range where the HIGH PWR led turns off. Proceed to
the final step below.
S
B
S
S OR
PERFORMING CALIBRATION MODE – STEP 3A
F This light pattern indicates T1 is set lower than 2% of the original set point. Adjust the T1
voltage pot to a value within the 2% range where the LOW PWR led turns off. Proceed to the
final step below.
S
B
S
S
PERFORMING CALIBRATION MODE – STEP 4

FINAL STEP. Press the start button and hold it briefly until the LED’s light up, release the
start button to exit calibration mode. The unit has now been adjusted to the original
factory set values.
B
B
B
S
S

Plasma Technics Inc. 1900 William St. Racine, WI 53404-1875 Phone : (262) 637-7180 Fax : (262) 637-7157
Web Page : http://www.plasmatechnics.com E-Mail : [email protected] Page 10
The DAT210 board's 10 LED's are shown below in various patterns with related status/description information.

PERFORMING START BUTTON SWEEP – STEP 1

Under normal running conditions, the LED light pattern will appear as shown here.
The INV ON and +5VOLTS will be solid throughout this process; the LOCKED will be
flickering.

F
S
S
PERFORMING START BUTTON SWEEP – STEP 2

Holding the START button down until the LOCKED, LOW_PWR, and HIGH_PWR blink
simultaneously.
B
B
B
S
S
PERFORMING START BUTTON SWEEP – STEP 3

After a second or two the LOAD_FLT and HOT_LOAD will blink simultaneously, along with
B the blinking LEDs in the previous step. When this occurs, release the START button.
B
B
B
B
S
S
PERFORMING START BUTTON SWEEP – STEP 4

Upon release the LOCKED LED will blink rapidly. This indicates the frequency is
sweeping up and down to find optimum value. The LOCKED LED will blink then flicker as
normal after a few seconds completing the process. Verify the power or amperage draw
values are within acceptable range for the model being used.
B
S
S

Plasma Technics Inc. 1900 William St. Racine, WI 53404-1875 Phone : (262) 637-7180 Fax : (262) 637-7157
Web Page : http://www.plasmatechnics.com E-Mail : [email protected] Page 11
The DAT210 board's 10 LED's are shown below in various patterns with related status/description information.

PROGRAMMING A POWER SET POINT – STEP 1

NOTE – the unit must be in semi-auto mode (J5 removed) to program the power setpoint.

When T1 has been turned to the desired set point press and hold the OP_OK button until this
B pattern shows --- then release.
B
S
S
S
PROGRAMMING A POWER SET POINT – STEP 2

Upon release, the HIGH_PWR and LOW_PWR LED's will blink alternately. The unit may
be in a tolerance set point of +/- 40%, +/- 20% or +/- 10%. Pressing the OP_OK button
will cycle/repeat thru these three choices with a varying LED blink time (10% fast, 20%
B medium, 40% slow). To exit this mode or select a tolerance, move to STEP 3.
B

PROGRAMMING A POWER SET POINT – STEP 3

S Once desired tolerance band has been selected press and hold OP_OK longer than in the first
S step to attain this LED light pattern and then release.
S
S
S
S
S
S
PROGRAMMING A POWER SET POINT – STEP 4
S
S If successful, this pattern of LED’s will display. The INV_ON will blink once followed by a
S blink of the LOW_PWR LED. This pattern is a response to let the user know that the
S programming of the power setpoint has been successful.
S
B
S
B
S

Plasma Technics Inc. 1900 William St. Racine, WI 53404-1875 Phone : (262) 637-7180 Fax : (262) 637-7157
Web Page : http://www.plasmatechnics.com E-Mail : [email protected] Page 12
TROUBLESHOOTING DAT210 PROBLEMS

HIGH POWER WARNING – PATTERN 1

LEDs indicate the unit’s power is higher than

the tolerance level of the programmed power
point.
B
F
S
S
Step 1 Does unit show a hard fault? (PATTERN 3)
HIGH POWER WARNING – PATTERN 2 Yes – Go to Step 2
No – Go to Step 3.
After a period of 5 – 10 seconds this pattern
will display indicating a warning that the unit
Step 2 Turn unit on.
will hard fault and shut itself off.
S
Step 3 Turn T1 pot counterclockwise.

S Step 4 Did HIGH PWR LED turn off ?

S Yes – No further action needed
S HIGH POWER WARNING – PATTERN 3 No – Repeat Step 3 and 4.

Hard fault indicator of T1 being set higher

than its programmed set point for too long of a
period of time. The unit has now shut itself off
B to prevent possibility of damage.

S
LOW POWER WARNING – PATTERN 1

LEDs indicate the unit’s power is lower than

the tolerance level of the programmed power
point. Also, it may indicate issues in the
system outside the block. Investigate that
B possibility if the steps here do not resolve
F the problem.
S
S
LOW POWER WARNING – PATTERN 2 Step 1 Does unit show a hard fault? (PATTERN 3)
Yes – Go to Step 2.
After a period of 5 – 10 seconds this pattern No – Go to Step 3.
will display indicating a warning that the unit
will hard fault and shut itself off. Step 2 Turn unit on.
S
Step 3 Turn T1 pot clockwise.
S
S Step 4 Did LOW PWR LED light turn off ?
S LOW POWER WARNING – PATTERN 3 Yes – No further action needed.
No – Repeat steps 3 and 4.
Low power hard fault indicates that T1 has
not been adjusted in time and the unit has shut
itself off.
B

Plasma Technics Inc. 1900 William St. Racine, WI 53404-1875 Phone : (262) 637-7180 Fax : (262) 637-7157
Web Page : http://www.plasmatechnics.com E-Mail : [email protected] Page 13
 POWER LIMIT WARNING.

F HS_TEMP and HOT_LOAD lights will flicker Step 1 Turn T1 pot counterclockwise until LED
F rapidly in an alternating pattern. Power level pattern ceases.
is reaching or at a dangerous point; unit will
S not increase wattage past this limit. DAT210 Step 2 Continue decreasing T1 until HIGH PWR
will shut itself off after approximately 20 LED turns off.
F seconds.
S
S
LOAD FAULT - PATTERN 1

Pattern is caused by the DAT210 detecting a Step 1 Does unit display a hard fault? PATTERN 3
problem with Plasma Block cell or the Yes – Go to step 2.
B transformer. After 5 – 10 seconds board will No – Go to step 3.
display pattern 2 shown below.
Step 2 Check for proper connection of transformer
F To PCB and Plasma Block cell.
S
S
LOAD FAULT - PATTERN 2 Step 3 Replace the transformer with a known
Functioning transformer.
After 10 – 15 seconds board will display
pattern 3 shown below. Step 4 Turn unit on.
B Does the light pattern remain ?
(ANY OF THE THREE)
Yes – Turn unit off. Proceed to Step 5.
B No – Transformer has gone bad.
S
Step 5 Using original transformer, swap the cell.
S LOAD FAULT - PATTERN 3
Step 6 Turn unit on.
Hard fault indicated by this LED pattern. The
Does the light pattern remain ?
unit has shut itself off to prevent damage to
S (ANY OF THE THREE)
the cell, transformer, or PCB .
Yes – PCB has malfunctioned, contact PTI.
No – There is a problem with the cell block
or other component.
S
S SOFT CHARGE RELAY FAILURE. Step 1 Check proper connections by referring
to “Single phase soft start” manual
This pattern of lights indicates a soft charge on PTI’s website.
relay failure.
B Step 2 Remove AC from relay.
B Step 3 Remove wires from DAT210
(on 12 terminals 3 & 5).
S
Step 4 Apply 5VDC to those removed wires
and listen for an immediate click sound.
If no CLICK, bad relay.

Plasma Technics Inc. 1900 William St. Racine, WI 53404-1875 Phone : (262) 637-7180 Fax : (262) 637-7157
Web Page : http://www.plasmatechnics.com E-Mail : [email protected] Page 14
 START-UP PROCEDURE POWER ADJUSTMENT

1. For PlasmaBlocks®

Reasons for changing the factory setup:

By altering the ‘Voltage’ setting, you can easily modify the full power operational point if need be. Remember
that the purpose of the PDM control is to provide a turndown from the 100% power set-point established by the
VOLTAGE pot. The goals are 1) Maximum power and 2) Current High/Low limits. Adjustment is very easy.

If it is determined that the Plasma Block® has much more ozone output than the application requires. You
would know this if, for example, if the closed loop control from an ORP unit always had the PDM adjusted to a
very low value of current, like 6-10ma.
OR
A PlasmaBlock® is going to be applied at pressure and flow range that is different from the factory setup.
OR
If the inverter was purchased to be used with a PTI resonating inductor and transformer set to drive a new cell
or changed cell configuration, the inverter would have to be tuned.

REMOVE POWER FROM THE INVERTER FOR SET UP

1. Install a true RMS current clamp-on meter to one of the mains AC power wires. A power meter could
also be used.
Note: An inexpensive and surprisingly accurate power meter can be purchased for $25-$35: UPM
model EM100 or Kill-A-Watt from P3 International.
2. PDM should be set at 100%. Another method of turning the PDM to full ON if it is more convenient is to
turn Switch S1 OFF. This forces the PDM at 100%.
3. Verify Switch S4 and S5 OFF: fault enable. This will prevent any faults, current exceeding the High/Low
limits for example, from shutting down the unit while it’s being adjusted.
Note: Maximum power safety is now OFF. It is possible to damage the ozone cell.
4. Pull jumper J5 AUTO, which will select the Semi-Auto mode and allow the VOLTAGE pot
(potentiometer) to be manual active. The frequency will still be automatically adjusted for resonance.
5. Turn the VOLTAGE pot counterclockwise (CCW) until clicking sound indicates minimum.

APPLY POWER TO THE INVERTER – TURN THE INVERTER ON

6. Adjust the VOLTAGE pot CW to the desired maximum current (power) level permissible. Ozone levels
alone can also be used to establish maximum power if satisfactory at a lower current (power). The
processor continues to optimize other aspects of the tuning process as indicated by the occasional
‘wink’ of the LOCKED (resonant frequency found) LED. If the VOLTAGE control is increased excessively
(pot CW), and a safety limit is reached, the pair of Red LEDs will flash rapidly in an alternating manor.
This will not damage the ozone cell. Simply reduce (CCW) the voltage control to an acceptable level of
current (power) and the LEDs will extinguish.
7. Set the High/Low power limits.
Push the OP_OK push switch once (1 to 5 seconds). Two Yellow LEDS will come on and blink slowly.
This is the +/- 40% power fault tolerance limits.
Push OP_OK once again. The Yellow LEDS will flash faster. This is the +/- 20% limit.
Push OP_OK once again. The Yellow LED will flash even faster. This is the +/- 10% limit.
Keep pushing OP_OK and the cycle repeats.
The normal factory recommended limit is +/- 20% (40% total).

Plasma Technics Inc. 1900 William St. Racine, WI 53404-1875 Phone : (262) 637-7180 Fax : (262) 637-7157
Web Page : http://www.plasmatechnics.com E-Mail : [email protected] Page 15
 8. Lock in the new operating point by pushing and hold the ‘Op_OK’ button until the Red LEDs come ON.
Then release it. Then ALL the LEDs will come ON (except FAULT) momentarily to acknowledge your input
and the inverter will turn OFF. This action permanently stores the new parameters in the processors
memory and causes a reboot of the unit.
9. Set Switches S1, S4 and S5 to ON. Reinstall J5 (AUTO_Tune). Re-enable by cycling the inverter OFF and
ON.
10. Now observe the inverter gradually increase power to the new programmed level automatically at 100%
PDM. Frequency control is automatic and the LOCKED LED will cycle indicating frequency lock. The
inverter PDM can now control power from 1% to the 100% new programmed value.

You should now observe that the PDM level (power control) being commanded from the ORP unit is much
greater, for example, hence making the control loop more stable.
OR
The inverter is now properly configured for the new ozone cell components
OR
The inverter is now properly configured for new pressure or flow ranges.

2. For other manufacturer’s generator cells or other applications

Make sure the inverter has the correct code for the frequency range of interest. Either the factory has or will set
this up before shipment or you will need a PC in terminal mode connected via USB to RS-232 to the inverter
board. Call the factory for the correct codes and instructions.

Monitor the line current with a true RMS ammeter. The following assumes power factor correcting components
are installed. See the 700250 inverter assembly.

It will be necessary to configure the inverter for a manual mode of operation.

S1 OFF Forces PDM to 100% maximum for tuning purposes
S5 OFF Disables alarms and power limits. It is possible to apply too much power
Jumper J3 IN Enables Manual operation of frequency and voltage
Jumper J5 OUT Disables full Auto-Tune
Turn the FREQUENCY pot full clockwise until clicking sound is heard
Turn the Voltage pot full counterclockwise (minimum) until clicking sound is heard then CW 3 turns

Procedure:
1. Observe the current or power meter and reduce the frequency by turning the Frequency pot CCW.
The power will peak at a lower power because the Voltage pot is turned down.
If the frequency is lowered too far (CCW) the power will reduce. You want the peak.
2. Increase the voltage at the current (power) peak until ½ of the maximum desired current per leg
(power) is reached.
3. Readjust the frequency slightly to find the current peak.
4. Increase the voltage until the current reaches 90% of the expected maximum power.
5. Verify the frequency is still at peak with the frequency pot.
6. Increase the voltage pot CW to reach 100% expected power.
7. Set the High/Low power limits.

Plasma Technics Inc. 1900 William St. Racine, WI 53404-1875 Phone : (262) 637-7180 Fax : (262) 637-7157
Web Page : http://www.plasmatechnics.com E-Mail : [email protected] Page 16
 Push the OP_OK push switch once (1 to 5 seconds). Two Yellow LEDS will come on and blink slowly.
This is the +/- 40% power fault tolerance limits.
Push OP_OK once again. The Yellow LEDS will flash faster. This is the +/- 20% limit.
Push OP_OK once again. The Yellow LED will flash even faster. This is the +/- 10% limit.
Keep pushing OP_OK and the cycle repeats.
The normal factory recommended limit is +/- 20% (40% total).
8. Lock in the new operating point by pushing and hold the ‘Op_OK’ button until the Red LEDs come
ON. Then release it. Then ALL the LEDs will come ON (except FAULT) momentarily to acknowledge your
input and the inverter will turn OFF. This action permanently stores the new parameters in the
processors memory and causes a reboot of the unit.
9. Set Switches S1, S4 and S5 to ON. Reinstall J5 (AUTO_Tune). Re-enable by cycling the inverter OFF and
ON.
10. Now observe the inverter gradually increase power to the new programmed level automatically at
100% PDM. Frequency control is automatic and the LOCKED LED will cycle indicating frequency lock. The
inverter PDM can now control power from 1% to the 100% new programmed value.

If during the manual portion of the tuning effort it is not possible to reach the current peak, then call the factory
to help diagnose the reason. It may be that the load is very insensitive to the frequency and that Auto-Tune is
not feasible. In that case, expect the inverter to be left in the manual mode.

Plasma Technics Inc. 1900 William St. Racine, WI 53404-1875 Phone : (262) 637-7180 Fax : (262) 637-7157
Web Page : http://www.plasmatechnics.com E-Mail : [email protected] Page 17
 TROUBLESHOOTING

PROBLEM STEP VERIFY NEXT STEP

ON - OFF switch/PLC 1 Is there power to the inverter? No - troubleshoot elsewhere.
control - nothing happens Yes - Get a voltmeter and do Step 2
2 Was there 5 seconds between applying power No - increase the timing between
and the ON command? application of power and the ON
command. See Section 6 p.18 & 19.
Yes - Step 3
3 +5 VDC between Terminals 5(+) and 3 on CON12 No - Check connector seating,
and +5 green LED ON? broken wires to the small power
supply inside the generator toward
the rear. Replace supply if
necessary.
Yes - There is power to the inverter.
Step 4.
4 Is the "INV ON" light on? Measure voltage No - Step 5
terminals 3 & 5 on Connector 12. Verify if the Yes - Increase the ozone output
external command output power setting is at control voltage/current.
zero?
Verify 4/20 or 0 - 10 VDC control as set by Switch
8 on the inverter board.
5 If you have gone through steps 1 - 4 without Replace the inverter circuit board.
results, it is possible that the inverter board has Refer to the instruction sent with
failed. the replacement to ensure reliable
operation.

FAULT indicators on the circuit board are illuminated.

ALL LEDS flashing 1 Low voltage power supply cycling on and off Problem with a broken wire, mis-
wiring or shorted circuits in the
inverter electronics. Look for metal
drilling chips caused by contractor
drilling. If there, vacuum the
electronics thoroughly and retry.
If this is not the problem, go to 2.
2 If there are no other shorts in the system or the Replace the low voltage power
system is mis-wired, the low voltage power supply.
supply may be defective.
FAULTED light - Flashing = 1 Caused by: High or Low cell current, high Usually this fault is a result of
soft fault temporary instantaneous current in power section, over improper tuning of the inverter
condition temperature in the electronics or cell. beyond factory limits. Go to Step 2
2 Is the ambient temperature greater than 40 C Yes - Improve ambient air flow.
(104 F)? Inverter will eventually compensate
by running at reduced power.
No - Go to Step 3
3 Retune the inverter using the procedure in This should solve the problem if
Section 7. Review Section 4. flashing. Flashing is a "call for
service" with reduced ozone output.
FAULTED light - On solid = 1 Look at other fault lights to diagnose the Go to step 2.
Hard fault condition and problem. Ozone production is turned OFF.
the inverter is locked OFF

Plasma Technics Inc. 1900 William St. Racine, WI 53404-1875 Phone : (262) 637-7180 Fax : (262) 637-7157
Web Page : http://www.plasmatechnics.com E-Mail : [email protected] Page 18
 IGBT FAULTED 2 Is IGBT faulted light ON? Yes - There is a short in the inverter
output section that has exceeded
the allowable event limit. Look for
damaged or loose wires, metal
chips, water corrosion or anything
that could cause a short.
No - Go to step 3
HS TEMP 3 Is HS TEMP faulted light ON? Yes - Review Status LED description
for detail
No - Go to Step 4
HOT LOAD 4 Is HOT LOAD faulted light ON Yes - Review Status LED description
Section 6 for detail.
No - Go to Step 5
LOAD FAULT 5 Is LOAD FAULT light ON? Yes - Possible water flooded cell due
to the process entering the cell. If
the process water is clean, empty
the water out of the cell and flush
with DI water or 91% alcohol.
EMPTY FLUSH WATER FROM CELL!
Then dry with very dry oil free air or
oxygen for several minutes. Try to
operate again. Do not disassemble
the cell. Call the factory.
No - Go to Step 6.
HIGH POWER 6 Is HIGH POWER light ON? Yes - Review Status LED description
Section 6 for detail.
LOW POWER 1 Is LOW POWER flashing? Yes - This is non-critical indication
that the power is less than the
programmed window.
No - Go to Step 2
2 Is LOW POWER ON steady? Yes - Output current is too low than
the programmed window. If this
condition remains for more than 32
seconds, a hard fault will shut off
ozone and turn on the fault LEDs for
diagnostics. Review Status LED
description in Section 7 for more
detail.

Plasma Technics Inc. 1900 William St. Racine, WI 53404-1875 Phone : (262) 637-7180 Fax : (262) 637-7157
Web Page : http://www.plasmatechnics.com E-Mail : [email protected] Page 19