WellAir Plasma Air PLASMA BAR Series Instruction manual

INSTALLATION, OPERATION
& MAINTENANCE MANUAL
PLASMA BAR SERIES
MODELS: PB-18, PB-24, PB-30, PB-36, PB-42, PB-48, PB-54, PB-60,
PB-66, PB-72, PB-78, PB-84, PB-90, PB-96
www.plasma-air.com
Needlepoint Ionizer
REV 07/202 3

INTRODUCTION
The Plasma BAR is a commercial quality, remote mounted needle point ion generator intended for installation in
air handling units (AHU) and rooftop units (RTU). The Plasma BAR was designed to be mounted on the entering air
side of a cooling coil inside of an AHU or RTU. The Plasma BAR is available in lengths of 18 inches up to 96 inches in 6
inch increments to suit a wide variety of AHU or RTU size applications.
This ionization equipment is effective in reducing harmful pollutants and odors and airborne pathogens (viruses,
bacteria, and mold spores) by introducing positive and negative ions into the system airflow which is then
delivered to the space. The length and quantity of the Plasma BAR ionization units are dependent on the internal
cross sectional dimensions of the applicable AHU or RTU coil and the severity of the indoor air pollutants. The
Plasma BAR ionization assembly is powered and monitored with a remote Plasma BAR Control Panel. One control
panel can power up to two (2) Plasma BARs.
The Plasma BAR utilizes a feedback functionality that provides an electronic signal only when the ionizers are
operating properly, i.e. when the ionizer is creating ions. The products use this signal to power an LED and initiate a
relay that closes dry contacts.
MECHANICAL INSTALLATION INSTRUCTIONS
GENERAL MOUNTING CRITERIA:
CAUTION: The Plasma BAR product should not be installed downstream of a humidifier or exposed to any
source of moisture.
CAUTION: This product is intended for mounting into metallic construction only. Installation must be such
that the structural integrity or function of any heat transfer coil is not compromised. Do not fasten the
Plasma BAR directly onto the fins or tubes of a coil.
1. Mount control panel to allow access to the ionization unit power switch and connections. This product shall not
be installed behind an inaccessible suspended floor/ceiling or a structural wall, ceiling, or floor. A minimum of
3/4" of clearance from metal surfaces for the ionization needles is recommended to prevent shorting.
2. The preferred mounting location for the Plasma BAR is on the entering face of the cooling coil inside of an Air
Handling Unit (see Figure 1a). The mounting brackets provided shall be secured to the structural frame of the
coil without damaging the coil's fins or tubes. Vertical uni-strut provided by the installer may be utilized to aid
in mounting of the Plasma BAR if necessary. (See Figure 1b). The BAR can also be mounted downstream of the
cooling coil as long as moisture carryover on the BAR is avoided.
3. Once the Plasma BAR is securely fastened inside the Air Handling Unit, mount the Plasma BAR Control Panel at
a nearby location to allow connection of the Plasma BAR wiring harness to the control panel (Figure 1a or Figure
1b).
4. Connect the power to the control panel in the correct location and turn the switch to the "ON" position. (See
Electrical Installation section of this IOM).
5. Install Plasma BAR such that ionization needles are pointed down toward the floor of the AHU.
6. Do not mount the BAR before the system filter.
FIGURE 1a FIGURE 1b
PLASMA BAR LOW VOLTAGE WIRING HARNESS
WITH CONNECTOR. RUN HARNESS TO
PLASMA BAR CONTROL PANEL AND CONNECT.
PLASMA BAR
IONIZATION
ASSEMBLY
PLASMA BAR CONTROL
PANEL. MOUNT IN
LOCATION TO SUIT
LENGTH OF WIRE HARNESS.
AIRFLOW AIRFLOW
COOLING COIL
INSIDE OF AHU
FASTEN THE PLASMA BAR
MOUNTING BRACKETS TO
THE COIL STRUCTURAL FRAME.
DO NOT FASTEN MOUNTING
BRACKETS TO COIL, FINS OR TUBES.
FIELD BUILT UNI-STRUT
MOUNTING FRAME
PROVIDED BY INSTALLER.
ANCHOR TO FLOOR OF AHU
COOLING COIL
INSIDE OF AHU
PLASMA BAR LOW VOLTAGE WIRING HARNESS
WITH CONNECTOR. RUN HARNESS TO
PLASMA BAR CONTROL PANEL AND CONNECT.
PLASMA BAR
IONIZATION
ASSEMBLY
NOTE: If using multiple BARs on the same Air Handler, we recommend selecting two BARs of equivalent length in
order to mitigate the possibility of ion agglomeration. One Control Panel can power up to two BARs.

ENTERING FACE
OF COOLING COIL
CONTROL
PANEL
CENTER PLASMA BAR ON ENTERING
FACE OF COOLING COIL
• For installations that have a cooling coil
height of greater than 60" or where one
BAR is insufficient, multiple Plasma
BARs are required.
• Install Plasma BAR equal distance
vertically between BARs as shown by
dimension “X”.
X
X
IF NOT WIRED FROM FACTORY,
PROVIDE FIELD WIRING CONNECTING 2 BARS.
FIGURE 2
FIGURE 3
PLASMA BAR MODEL #PB-XXX 018 024 030 036 042 048 054
AIRFLOW TREATED (CFM) 3,750 5,000 6,250 7,500 8,750 10,000 11,250
LENGTH OF PLASMA BAR (inches) 18 24 30 36 42 48 54
ELECTRICAL CURRENT DRAW (mA) 90 120 150 180 210 240 270
POWER CONSUMPTION (VA) 2.2 2.9 3.6 4.3 5.0 5.8 6.5
WEIGHT (LBS) 1.1 1.5 1.9 2.3 2.6 3.0 3.4
PLASMA BAR MODEL #PB-XXX 060 066 072 078 084 090 096
AIRFLOW TREATED (CFM) 12,500 13,750 15,000 16,250 17,500 18,750 20,000
LENGTH OF PLASMA BAR-X (inches) 60 66 72 78 84 90 96
ELECTRICAL CURRENT DRAW (mA) 300 330 360 390 420 450 480
POWER CONSUMPTION (VA) 7.2 7.9 8.6 9.4 10.1 10.8 11.5
WEIGHT (LBS) 3.8 4.1 4.5 4.9 5.3 5.6 6.0
ELECTRICAL INSTALLATION INSTRUCTIONS
WARNING: Do not connect to power before the installation is complete. Always disconnect power to the
unit before handling any of the unit components.
1. It is recommended that surge protection be installed with this ionizer at the equipment level, building level, or
circuit breaker panel feeding the product.
2. If a step down transformer is used to power the ionizer, the transformer must be grounded.
3. Do not install the ionizer on the same circuit as a UV Lamp or connect to the same transformer as a UV Lamp.
4. It is preferred that a dedicated 24V AC transformer be used to power the Plasma BAR Control Panel. The control
panel may be powered from a shared control transformer if sized sufficiently to handle the additional VA rating
of the Plasma BAR(s). (See Figure 2 for Plasma BAR VA ratings).
5. The control panel draws less than 32 watts maximum. The power source should not be protected by a circuit
breaker exceeding 20 amps.
6. Power may be connected to the ionization unit using either of the following methods:
• OPTION 1: Connect 24V AC directly to the power input terminal block on the control panel where indicated. The
line and neutral wires can be connected to either screw terminal. (See Figure 3 & 4).
• OPTION 2: Use a factory supplied 120V/230V AC to 12V DC power supply. A 12V DC 2.1mm pin connector shall be
inserted into the 12V DC in/out pin located on the control panel. (See Figure 3 & 4). Do not use an extension cord.
WIRE HARNESS
TO PLASMA BAR
24V AC POWER
12V DC AVAILABLE TO
POWER (OPTIONAL) DUCT ION SENSOR
DRY CONTRACTS FOR
BAS MONITORING (OPTIONAL)
CONTROL
PANEL
FIGURE 1c Plasma BAR Installation for Air Handlers Requiring Multiple BARs
12V DC POWER WIRE HARNESS
TO PLASMA BAR
120/230V AC AVAILABLE TO
DRY CONTACTS FOR
BAS MONITORING
CONTROL
PANEL
POWER
SUPPLY
WIRING PROVIDED BY PLASMA AIR WIRING PROVIDED BY CONTRACTOR

FIGURE 5 Bottom view of PB-CP control panel
FIGURE 4 Left view of PB-CP control panel
DUAL BAR SYSTEM WIRING INSTRUCTIONS
For applications where two linked BARs are required, follow the wiring instructions listed below. Accessories
Required: 3 x Ring Terminals per (2) BAR system.
Remove the white cover plate with the Plasma Air logo from BAR #1 exposing its ring terminals.
1. Snip the control panel connector off the end of the wiring from BAR #2 and attach the new ring terminals to the
loose wire ends.
2. Lay the new ring terminals from BAR #2 on
top of the exposed ring terminals on BAR #1.
3. Reattach the cover plate on BAR #1. Connect
BAR #1 to the Control Panel using the
standard factory connector.
OPERATION
1. When power is supplied to the Plasma BAR
Control Panel and the switch is in the "on"
position, the Plasma BAR ionization assembly
will be activated with the supply fan.
2. The Plasma BAR ionization unit is self
balancing and does not require any type of
adjustment.
3. The benefit of the Plasma BAR ionization
system is realized only when the supply fan
is running. Therefore, to achieve improved
air quality, interlock the Plasma BAR Control
Panel to be activated with the supply fan.
MONITORING CIRCUIT
The Plasma BAR Control Panel includes a
monitoring circuit to verify operation status. The
circuit consists of a relay with isolated normally
open contacts. The contacts remain open
whenever the ionization system is not powered
or if there is a fault in the equipment. Whenever
the ionizer is energized and producing ions, the
normally open contacts close and the green
ion indicator light will illuminate. Connect
the monitoring control wires of the Building
Automation System (BAS) to the dry contacts on
the unit. (See Figure 4 & 5).
TROUBLESHOOTING & MAINTENANCE
The Plasma BAR ionizer should be inspected annually to ensure optimal performance. If any dust has built up on
the tip of the ionizing needles, this can be removed using a simple cotton swab or compressed air. The control
panel requires no maintenance of any kind.
1. If the Plasma BAR ionization unit is not working, check that: The control panel power switch is in the "on"
position, the supply fan is running and the green ion indicator light is illuminated.
2. The power input connections to the control panel are properly connected. Verify all connections are correct
and securely tightened. Reconnect any loose wires.
3. Test the BAS alarm dry contacts using a multimeter set to continuity mode (Ohms symbol). If the multimeter
buzzes the circuit is continuous and operation is normal. If it does not buzz the circuit is broken. Verify other
steps and contact support if needed.
4. If the control panel internal fuse is blown, wait 2 minutes to allow the unit to automatically reset the fuse. Turn
on the power to the control panel. If the fuse blows again, return the control panel to the factory for service.
SEQUENCE OF OPERATION
1. For units that are interlocked with the supply fan control, the BAS controls the start/stop of the air conditioning
unit supply fan.
2. After a one minute time delay on a call for supply fan operation, the BAS monitors the ionization system via the
control panel.
3. Open contacts indicate a fault; closed contacts indicate normal operation.
3540 Toringdon Way Suite 200, Charlotte, NC 28277
phone [phone] www.plasma-air.com [e-mail]
200080-C
© 2023 All rights reserved
GREEN LED
IONIZATION
LIGHT
(MAY APPEAR
SLIGHTLY DIFFERENT
THAN PICTURED)
ON/OFF
SWITCH
12 VOLT DC
IN/OUT PIN
(2.1mm pin)
DRY CONTACTS
FOR BAS
MONITORING
24 VOLT AC
POWER INPUT
CONNECTION