AtmosAir 500 Series Technical Document

500 Series
Installation, Operation
and Maintenance Guide
OUR MISSION
To improve health and wellness by actively restoring indoor air
to its pure, natural state where no pollution or contaminants
exist, while reducing energy use and emissions in the process.
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Installation, Operation & Maintenance Guide 500 Series 2
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Trademarks
Any brand names and product names included in this document are trademarks, registered trademarks, or trade names of their
respective holders.
To the Holder of this Document
The contents of this document are current as of the date of publication. AtmosAir® reserves the right to change the contents
without prior notice.
In no event will AtmosAir be liable for any special, incidental, or consequential damages or for commercial losses even if AtmosAir
has been advised thereof as a result of issue of this document.
WARNING
Failure to follow this warning could result in personal injury or death.
For installation you MUST:
■ Always disconnect all electrical power to the unit before handling any of the components, to the air handler before removing access
panels, or to perform any maintenance activities.
■ Do NOT connect to the power before the installation is complete and personnel are aware of the imminent operation – secondary
voltage to the ionization tube can be as high as 3,000 VAC.
■ Installation of AtmosAir equipment is not to be performed in areas with extreme conditions such as extreme heat or cold, or where
water or condensing moisture can impact the system.
■ Carefully read this instruction booklet before beginning the installation.
■ Follow each installation or repair step exactly as shown and explained in this guide.
■ Observe all local, state, national, and international electrical codes.
■ Pay close attention to all warnings and caution notices given in this guide.
1. Before installing or servicing system, always turn off main power to system.
Note: There may be more than one disconnect switch.
2. AtmosAir equipment must be installed with a proper ground. The electrical cable enclosed with your AtmosAir unit must be
used as it has a special plug which provides a ground circuit for the equipment.
3. Always replace fuse with the same rating and type of fuse.
4. Failure to follow this caution may result in personal injury or product and/or property damage.
5. Although special care has been taken to minimize sharp edges in the construction of your unit, be extremely careful when
handling parts or reaching into the unit.
6. Do NOT block or obstruct the air flow over or around the ionizing tubes.
7. Do NOT touch ionizing tubes when power is on.
8. Tube cleaning should be performed only when the power is disconnected.
9. The tubes require minimal cleaning with routine operation and maintenance.
Longer operating cycles and reduced ionizing efficiency may indicate the need for
cleaning or replacing tubes by your AtmosAir dealer or qualified installer.
Commissioning Statement
Do not commission new airhandlers after installation. All duct cleaning must be performed before the unit is installed.

Installation, Operation & Maintenance Guide 500 Series 3
Disclaimer: The air purification technologies provided by Clean Air Group are intended to improve indoor air quality. They are
not intended as a replacement for reasonable precautions aimed at preventing the transmission of contaminants, airborne or
otherwise. All persons having access to the serviced premises should comply with applicable public health laws and guidelines
issued by federal, state and local governments and health authorities such as the Centers for Disease Control and Prevention
(CDC). Clean Air Group does not maintain that its products will protect people from all modes of transmission of bacteria, viruses or
other contaminants, and excludes liability for loss or damage arising from any such claims or the consequences arising out of the
application, use or misuse of its products.
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Installation, Operation & Maintenance Guide 500 Series 4
Table of Contents
01 PRODUCT OVERVIEW 5
Control Panel Diagram 5
02 INSTALLATION 6
Mechanical Installation 6
Mechanical Installation — Mounting 7
Mechanical Installation — Mounting Continued 8
Electrical Installation 8
03 FIELD WIRING DIAGRAMS 9
04 OPERATION 11
05 MAINTENANCE REQUIREMENTS 11
06 TROUBLESHOOTING 12
07 EXPLANATION OF TECHNOLOGY 13
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Installation, Operation & Maintenance Guide 500 Series 5
01 PRODUCT OVERVIEW
The AtmosAir 500 series, models 500EC, 500FC and 508FC,
ionization generators are industrial quality units intended for
installation in air conditioning systems or in custom-designed
air distribution systems in commercial and industrial facilities.
AtmosAir equipment is effective in reducing odors and
harmful pollutants through the introduction of positive and
negative ions into the air stream to be treated. The number
and size of the ionization tubes used is dependent upon
the airflow, size of the space, and severity of the pollution
and odors. The AtmosAir 500 series equipment is designed
for minimal maintenance efforts. The 500 series has two
components that require inspection and maintenance:
1. AtmosAir 500 series ionization generator
2. Ionization tubes
Because there are no moving parts, the systems have very
low failure rates and minimal maintenance requirements.
For more information, read the AtmosAir 500 series
submittal documents.
Control Panel Diagram
AtmosAir 500 Series Control Panel Layout:
Unit Size Flowrate
(CMH)
Drag – mm / inch WG
(Pascals)
500FC 17,000 259.1mm / 0.0102 (2.55)
508FC 25,500 754.4mm / 0.0297 (7.40)
Pressure Drop @ 20°C, Density of Air = 1.225 kg/m3 & 120V @ 50/60 Hz
Pressure Drop Chart
A. Fuse
B. 5-Step Power Adjustment Switch
C. Monitoring DB-9 Output Connection
D. Power Socket / Quick Disconnect
E. Power Switch
F. Green System Power Light
G. Red Ionization Power Light
A
F
E
BG
C
Overall Dimensions Chart
Product Length Height Width
500FC 704.85mm 209.55mm 273.05mm
508FC 704.85mm 241.30mm 273.05mm
D
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Installation, Operation & Maintenance Guide 500 Series 6
500
Series
Inside
500
Series
Inside
500
Series
Inside
500
Series
Inside
02 INSTALLATION
The AtmosAir 500 series equipment can be mounted on the
side of a duct or air handler wall, using the integral mounting
flange and a weather-strip gasket, or inside an air handler
using a custom mounting rack with an optional wall mount
bracket. In an air handler, the units operate best when located
after the filters. Ideally, the tubes lie parallel to the direction of
airflow with the end of the tubes pointing upstream.
When installed on the side of a duct or air handler wall, the
outer box and faceplate should not be exposed to direct
sunlight or moisture. If installing outside, a weatherproof
enclosure with an access panel for servicing should be
installed over the AtmosAir Ion Generator (which can be
provided by AtmosAir).
The 500 series operates on 110/120 VAC, 50/60 Hz or 220/240
VAC, 50/60 Hz is available upon request. If using the integral
remote monitoring panel, the connection is made using a
supplied 9-pin (DB-9) connector. The tubes and electrode
contacts should not come into contact with any conductive
surface. A minimum 101.6mm clearance around the tubes is
recommended.
Mechanical Installation
1. Carefully remove the equipment from its shipping
container. Inspect the box, components, and tubes for
damage. Verify that the unit’s voltage rating is the same as
the available voltage, either 110/120 VAC, 50/60 Hz or
220/240 VAC, 50/60 Hz.
2. If they have been packaged separately, install the ionization
tubes using the supplied friction nuts and clamp screws.
Gently tighten the tube grounding clamps to ensure solid
contact with the tube’s outer mesh. Do not over-tighten
either connection. In most cases, units come with tubes
pre-installed.
3. Orientation: Install the unit with tubes parallel to
the airflow and the nosecones normal to the airflow,
whenever possible; otherwise, perpendicular orientation is
acceptable. If multiple units are installed in the same duct,
stagger the units, if possible, in the airflow so they are not
in the same airflow path.
4. For in-duct installation: Verify the flange gasket are in
place and in good shape to ensure the unit seals properly.
Make a cut-out in the duct sized per the illustration and
table on the following page. Use the unit as a template for
the mounting screw locations. Affix the unit securely in the
duct using self-tapping screws. Do not over-tighten, this
may strip the screw-hole. The unit is self-sealing to the
duct, so no further sealing is needed.
5. For in-plenum/AHU installation: Mounting varies with
rack-style. Follow mounting instructions provided with
rack. Typically, racks require 101.6mm of clearance from
walls.
6. Units should be installed to allow easy access for
maintenance. Install units so that the power switch and
5-step power adjustment knob are accessible. When
oriented vertically, control panel should be upwards.
Types of Insulated Duct Walls
A B
C D
A. Single Wall, No Insulation
B. Single Wall, Internal Insulation
C. Single Wall, External Insulation
D. Double Wall, Internal Insulation
Duct Wall Duct Wall
Duct WallDuct Wall
Fiberglass
Insulation
Fiberglass
Insulation
Cut Away
Double Wall
External
Insulation
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Installation, Operation & Maintenance Guide - 500 Series
A
i
r
F
l
o
w
A
i
r
F
l
o
w
Typical HVAC Duct
Single Unit Installation
Top View
Side/Top View
Min. Distance
25.4mm
Min. Distance
152.5mm
Min. Distance
152.5mm
Min. Distance
101.6mm
for staggered
Installation
Min. Distance
101.6mm
for Continuous Installation
Min. Distance
152.5mm
Typical
500 Series
Footprint
NOTE: Watch for support
structures.
Turning Vanes
Acceptable
Unacceptable
Preferred
Air Flow
Air Flow
Duct
Section
View
Multiple Unit
Installation
Multiple Unit
Installation
Installation, Operation & Maintenance Guide 500 Series 7
Mechanical Installation — Mounting
Continue on Next page
DUCT
SECTION
VIEW
TOP VIEW
SIDETOP VIEW
TYPICAL HVAC DUCT
SINGLE UNIT INSTALLATION
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Installation, Operation & Maintenance Guide 500 Series 8
Mechanical Installation — Mounting Continued
Installation Orientation
Cut-Out Dimensions (mm/in)
Model A B
500FC 660.4mm 228.6mm
508FC 660.4mm 228.6mm
Electrical Installation
AtmosAir 500 series systems require an average of 50
watts per unit. A replaceable fuse protects the unit. Note:
It is required to order the proper fuse per 110/120 V or
220/240 V unit.
Follow proper electrical procedures, guidelines, and codes
for providing power supplies to the systems, including
requirements for conduit, sufficient ampacity, phase
balancing, etc. Electrical installation should be performed by a
qualified electrician.
1. Field-install a junction box within 2.44 meters of the
unit(s). Each 500 series unit is typically shipped with a 10-
foot power lead in a flexible metallic conduit with a quick-
!!!WARNING!!!
The secondary voltage to the ionization tubes can be as high as 3000 volts AC. Do NOT connect to power before the installation is complete and all
personnel are aware of imminent operation. Always disconnect power to the unit before handling any of the components.
connect power plug on one end and bare wires on the other.
2. The unit is equipped with a normally open relay that closes
on ionization start-up and opens on loss of power. This relay
can initiate a local alarm or be tied into a building automation
system. Connection is via a DB-9 connector. Pins 1 and 5,
starting from the top left, are the active pins. There is no
electrical power across the terminals.
Preferred
Airflow
DB-9 Connector
Inactive Pins
Active Pins
Duct Wall
Acceptable
A
B
As of August 2021, all 500 Series units are equipped with a power conditioning attenuator and thermistor. A
fuse rating of 315mA Glass 5mm x 20mm Fast Blow (FSF) for 110/120V and fuse rating of 200mA Glass 5mm x
20mm Fast Blow (FSF) for 220/240V must be used. No other substitutions will be advised on these units.
To source the proper fuse, it is recommended to contact an authorized AtmosAir Representative or to only
purchase the specific part by the brand Bussmann.
315mA Part #: GMA-315MA-R 200mA Part#: GMA-200MA
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Installation, Operation & Maintenance Guide 500 Series 9
BLACK (HOT) WIRE TO N/O
NORMALLY OPEN AND COM
WHITE (NEUTRAL)
AIRFLOW SAMPLING TUBE
INSERT 152.4mm INTO AHU OR
DUCT AFTER FAN, AIRFLOW INTO
TUBE END. SILICONE IN PLACE
LEAVE OPEN TO
AMBIENT AIR
LID IS REMOVABLE
6.35mm
POLYETHYLENE TUBING
X 914.4mm PROVIDED
MOUNT ON DUCT OR AHU
BLACK (HOT) WIRE TO N/O
NORMALLY OPEN AND COM
BLACK=HOT
WHITE=NEUTRAL
GREEN=GROUND
GREEN=GROUND
ARMORFLEX
SHIELDED CABLE
3M LONG 3
WIRE INTERNAL
LO
HI
ALL 110VAC TO 250VAC
50/60Hz
COMMON
NORM
OPEN
AFS 262
WIRING
500'S/AFS262
DO NOT SCALE DRAWING
FIELD
WIRING DIAGRAM
500 SERIES TO AFS-262
AIRSWITCH
SHEET 1 OF 1
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:3
REV.
B
DWG. NO.
A
SIZE
TITLE:
NAME
DATE
COMMENTS: FIELD WIRING DIAGRAM
FOR CONNECTING 500 SERIES TO AFS-
262 AIR SWITCH TO LINE VOLTAGE
Q.A.
REV B SB 2-22-21
ENG APPR. TA 2-21-19
2/21/19
DRAWN HRG 2-21-19
FINISH
MATERIAL
INTERPRET GEOMETRIC
TOLERANCING PER:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL
.010
ANGULAR: MACH
BEND
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL
APPLICATION
USED ON
NEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
ATMOSAIR SOLUTIONS. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
ATMOSAIR SOLUTIONS IS PROHIBITED.
5
4
3
2
1
ATMOSAIR SOLUTIONS
ALL 500 SEIES
SERIES TO
AFS-262
CONNECTIONS
03 FIELD WIRING DIAGRAMS
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Installation, Operation & Maintenance Guide 500 Series 10
DB-9 CONNECTOR
'FOR CENTRAL MONITORING'
FIELD WIRING QUICK RELEASE
CONNECTOR 120VAC/60HZ
3 WIRE=BLACK/WHITE/GREEN
MAIN SWITCH ON/OFF
ION INTENSITY
SELECTOR DIAL
20%>100%
500mA
FUSE
FEMALE DB-9
CONNECTOR
PIN#1
FOR BMS
PIN#5
FOR BMS
CENTRAL
MONITORING
PORT. MALE
ON CASEWORK
0-10 VDC
FEMALE
CONNECTOR
508BMS-001
DO NOT SCALE DRAWING
508 FC BMS
CONNECTION
SHEET 1 OF 1
7/28/21
SB
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:20
WEIGHT:
REV.
B
DWG. NO.
A
SIZE
TITLE:
NAME
DATE
COMMENTS: 2 PIN CONNECTOR FOR
BMS MONITORING STATUS ONLY
Q.A.
Rev B
ENG APPR. TA 11/10/17
CHECKED
DRAWN HRG 11/10/17
FINISH
MATERIAL
INTERPRET GEOMETRIC
TOLERANCING PER:
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL
.010
ANGULAR: MACH
BEND
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL
APPLICATION
USED ON
NEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
ATMOSAIR SOLUTIONS. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
ATMOSAIR SOLUTIONS IS PROHIBITED.
5
4
3
2
1
500FC
508FC
ATMOSAIR SOLUTIONS
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Installation, Operation & Maintenance Guide 500 Series 11
04 OPERATION
Once the system is properly installed and all personnel are
clear of the high voltage tubes, the system can be turned on:
1. Ensure the ionization power knob is turned all the way
counterclockwise in the ‘off’ position.
2. Flip the power switch up to the ‘on’ position. The green
embedded LED light above the power switch should light
up to indicate that the power is on and running to the
system.
3. Set the ionization power knob to the appropriate setting
(1-5, with 1 being low and 5 being high). The red embedded
LED above the power knob should light up to indicate that
ionization has been activated and high voltage is being
sent to the tubes’ electrodes. An initial ion level setting of
#3 is recommended.
05 MAINTENANCE
REQUIREMENTS
■ The maintenance requirements on an AtmosAir system are
mainly site-dependent; a heavily contaminated environment
may require more frequent inspection & maintenance. In
general, a semi-annual inspection is recommended along
with a bi- annual tube replacement.
■ The local AtmosAir dealer can provide you with an annual
service contract.
Inspection:
■ Visually check the performance of the system by checking the
red and green lights on the individual units. If both lights are on,
and you can hear the ‘buzz’ of the tubes, then unit is functioning
properly. If not, proceed to the troubleshooting section for repair.
Maintain a physical distance between all personnel and the
tubes while system is operating or turned on.
!!!WARNING!!!
A non-functioning LED light may improperly indicate that the system
is not functioning. Be sure to disconnect from the mains power before
performing maintenance or troubleshooting the system.
■Optional: Check performance using a high voltage probe
(minimum of 5000 V, Contact AtmosAir for additional minimum
probe specifications) paired with a multimeter. Follow proper
procedures for dealing with high voltages. If you are uncertain,
do NOT perform any maintenance with the power on and,
instead, proceed to the next step.
■ Disconnect the system from the mains power before
performing any maintenance steps.
■ Inspect the unit box, plastic tube caps, and tube-mounting
plate. Remove any stains, dirt or debris using ordinary
household cleaner from mounting plate, and thoroughly wipe
clean any tracks or grooves that may have developed in the
plate or caps.
■ Inspect connections: tightness of all nuts and screws; remove
deposits on the connections using sandpaper or wire brush - it
may be necessary to remove the tubes for this step.
■ It may be beneficial to clean the tubes to improve performance.
The tubes can be cleaned using an air compressor for a quick
clean, or more thoroughly with cleaning solutions. Do not
immerse the tubes in water. Ensure that the tubes and mesh
and all components are completely dry before re-installing.
■ When replacing tubes, be sure not to over-tighten the loop
connector. Do not use a power driver, please only use a hand
Phillips head screwdriver to tighten the loop connector and
be sure not to over tighten. For the retaining nut on the back
end of tube, only use a hand held nut driver, and tighten this nut
snugly.
Tube Replacements:
Bi-annual tube inspections are recommended, in addition to
tube replacements once every two years as the production
efficiency slowly declines over time due to the stress caused
by plasma and (lack of) cleanliness of the electrodes. Old
or excessively dirty tubes can also put undue stress on the
transformer causing premature failure.
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Installation, Operation & Maintenance Guide 500 Series 12
06 TROUBLESHOOTING
In the event that the system is not functioning, follow these
steps IN ORDER:
1. Check that the main power supply is sending the correct
power to the unit.
2. Power off unit using the Off / On switch. Check the fuse.
If it is blown, replace it with only the exact sized and
branded fast blow glass 5 mm × 20 mm fuse rated at for
110/120 V or 220/240 V and power on. If it fails to power
on, continue to the next step.
3. If the system is controlled by an air pressure switch, and/or
a door switch, check that these are not preventing power
from being sent to the system.
4. If power is reaching the unit and it was necessary to
replace the fuse, and on powering up, the new fuse blows,
the next step is to determine whether there is a fault in the
system or a tube. First, to check that the system’s power is
functioning, set the ionization power knob and the power
switch both to the ‘off’ position. Make sure all personnel
are clear of the high voltage tubes, then re-connect the
power supply. Flip the power switch to ‘on’ and observe
the green light. If the light does not turn on, there is still a
problem with delivering power to the system. If all external
sources of failure are eliminated, the system should be
serviced by a qualified AtmosAir technician. Please see
contact information at the bottom of this page.
The next step is to determine the cause of the failure, or
blown fuse. Typically, failures are caused by short circuiting
between the inner and outer electrodes, or between
one electrode and ground. This often occurs because of
damaged tubes or dirty and/or wet conditions that have
allowed carbon tracking to temporarily connect two
electrodes and/or a grounding point electrically.
5. Inspect the mounting plate for tracking evidence.
6. Inspect the tubes for cracks, pitting, or other degeneration
of the tube material that may cause the tube to become
breached and fail and short circuiting to occur.
7. If physical inspection has not revealed the cause of
failure, one may carefully observe the tubes as the
ionization system is turned on to determine whether
short circuiting is occurring at a particular tube. The
fuse will usually blow, again, but for a short time, one
may observe the cause of the power surge in the form of
a visual or audio cue. Usually, a failing tube can be
determined in a darkened room by looking for a flash or
arc from the failing tube. In some cases, the correctly
operating tubes may be in the way of the failing tube’s
visual indication. It ispermissible and recommended
to remove the top row of tubes temporarily to assist
in the visual diagnosis. The device uses a bus-bar
technology allowing the servicing technician to
remove any number of tubes needed to diagnose and/
or temporarily run the device whilst waiting for
replacement tubes.
8. It may be necessary to remove all the tubes to ensure
that the transformer is working properly in the absence
of tubes. If the fuse still blows, then there is an internal
short circuit, and the system should be serviced by a
qualified AtmosAir technician.
9. It is recommended to also check the voltage levels of the
system when a fuse has blown and been replaced, in
order to ensure that the transformer has not been
irreparably damaged. Output voltage to the tubes are as
follows, Setting 1 = 2,200 VAC, Setting 2 = 2,400 VAC,
Setting 3= 2,600 VAC, Setting 4= 2,800 VAC and Setting
5= 3,000 VAC. If the voltages are lower than expected,
also check that all the connections are secure and rust-
free; also check that the input voltage is approximately
110/120 VAC or 220/240 VAC.
10. If the fuse blows, then the system should be serviced by a
qualified AtmosAir Technician. You can contact repair
services at [email protected].
11. Otherwise, replace the damaged tube(s), clean and
smooth any mounting plate or end cap carbon tracking,
and return the system to service.
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Installation, Operation & Maintenance Guide 500 Series 13
AtmosAir Solutions’ ™ mission is to bring and restore every indoor environment the same clean and pure quality air that is typically
found at higher mountain elevations.
AtmosAir’s unique and proven air purification process significantly reduces mold, controls the spread of bacteria and airborne
viruses, and reduces airborne particles that evade normal filtration solutions.
AtmosAir equipment uses non-thermal plasma technologies to generate bi-polar Ionization that attacks and breaks down odors
and contaminants.
07 EXPLANATION OF TECHNOLOGY07 EXPLANATION OF TECHNOLOGY07 EXPLANATION OF TECHNOLOGY
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