Plasmabrush PB3 Hochleistung in Plasma durch Pulsed Atmospheric Arc Technology – Basissystem – Mehrfachsystem

PlasmaBrush PB3

High-performance atmospheric plasma system

The PlasmaBrush PB3 is our high-performance plasma system for all inline processes in industrial and high-speed applications. The PlasmaBrush PB3 is widely used in the automotive, packaging and printing sectors. The focus here is primarily on plasma cleaning and surface activation. This is primarily used to prepare the products for further downstream processes such as bonding, painting or printing.

The PlasmaBrush PB3 is a combination of a particularly compact and long-term stable plasma generator in nozzle form, a unipolar pulsed high-voltage source and a vortex flow in the nozzle. The perfectly matched components in a robust industrial design are perfect for easy integration into any system.

PlasmaBrush PB3 – High-performance atmospheric plasma
PlasmaBrush PB3 – High-performance atmospheric plasma

Application technology

Field of application

  • Automotive sector
  • Printers and printing industry
  • Packaging industry


  • Ultrafine cleaning
  • Reduction of oxide layers
  • Surface functionalization
  • Pre-activation for bonding, sealing, casting or printing
  • Coating, laminating and sealing
  • Germ reduction and sterilization
  • Print pre-treatment

The table below shows the surface energy of different plastics. In each case, the surface energy is shown after treatment with the PiezoBrush PZ3, the PlasmaBrush PB3 (plasma high-performance system) and without prior plasma treatment.


  • Very compact design, also suitable for narrow grooves and hard-to-reach areas
  • Easy integration even in small robots (
  • Suitable for compressed air, nitrogen and other gases
  • Variable Power
  • High start-stop dynamics
  • Maximum operating reliability
Surface energy of plastics before and after plasma treatment

Customer references

Experimental set-up for grounding of conductive substrates

Grounding of conductive substrates

When using PAA® technology, the ignited plasma bridge can be used for electrical grounding of conductive substrates.

Nickel-plated nozzles A250, A350 and A450

Product change for nozzle improvement

The A250, A350 and A450 nozzles used in conjunction with the plasmabrush® PB3 have undergone a material change. As a minor product change for nozzle improvement, the copper nozzles will be nickel-plated from February 2022.

The shapes of the activation area visualized by the 58 mN/m test ink on the HDPE substrate for configurations A, C and G. The sizes of the substrates seen in pictures for A and C are 50 mm × 50 mm. The treatment times are 100 ms, 3 s, 10 s, 1 s and 20 s for A1, A2, C1, C2, and G1−3 respectively.

Visualization of Activated Area on Polymers

A visualization of activated area on polymers is done with test ink to evaluate atmospheric pressure plasma jets (APPJ). The shrinkage characteristics of the test ink are collected using activation image recording (AIR).

A250 Düsen Lebensdauer

Nozzle lifetime A250

In the following report the service life of the plasmabrush® PB3 A250 nozzle was examined. Flame pattern and temperature hardly change.

Atmosphärendruckplasma zur Prozessverbesserung Drahtbonden

Atmospheric pressure plasma for process improvement in wire bonding

Atmospheric pressure plasma is used to improve the wire bonding process and leads to significant improvements in ball and wedge bonding.

PlasmaBrush PB3 in our Online Shop

Technical Data

  • Flow range: 25 to 80 l/min
  • Cable length: 10 m
  • Weight plasma generator: 680 g
  • Diameter plasma generator: 32 mm
  • Gas connector: 6 mm
  • Treatment speed: 0,1 – 2 m/s
  • Typical treatment distance: 10 – 25 mm
  • Typical treatment width: 15 – 25 mm

Nozzles PlasmaBrush PB3

There are three different nozzles for the PlasmaBrush PB3 atmospheric pressure plasma generator. All nozzles are high performance nozzles which are operated with a Pulsed Atmospheric Arc (PAA®) Plasma Generator (PG31) and pulsed high voltage power supply (PS2000).

The nozzle achieves the following functions:

  • focussing of the plasma flame
  • acting as a grounded cathode to confine the highpower electric arc
  • forming of the cavity to excite the process gas

Nickel-plated nozzles

Nozzle A 250

Nickel-plated nozzle A250

Field of application:

  • Surface cleaning
  • Surface activation
  • Optimized for electric potential-free processes

Nozzle A 350

Nozzle A 350

Field of application:

  • Surface cleaning
  • Surface activation
  • Thermal treatment and reactive coating
  • Optimized for sensitive materials

Nozzle A 450

Nozzle A 450

Field of application:

  • Surface cleaning
  • Surface activation
  • Thermal treatment and reactive coating
  • Optimized for high process speeds

Although the copper nozzles originally used have very good properties in terms of burning behavior, there were customer requests to improve the oxidation resistance on the outside. This is essentially only an optical effect without any influence on the burning behavior, but it was nevertheless not possible to ensure that no oxide particles would detach from the nozzle and thus contaminate the workpiece. As a result, relyon plasma tested the copper nozzles again in a large-scale series of tests in order, among other things, to prevent the copper oxide from forming on the surface. For this purpose, very good results were achieved by nickel-plating the nozzles, which also prevents the formation of the surface oxides and the associated problems in the long term. In the tests it was shown that the coating does not lead to any impairment of the burning properties and the operating parameters. In the future, relyon plasma will therefore offer nickel-plated copper nozzles as a fully-fledged replacement for the copper nozzles offered to date.

Nozzles in our Online Shop

Carbide nozzles

The most commonly used nozzles in the PlasmaBrush PB3 so far are the copper nozzles. In processes where the arc is transferred to the substrates, e.g. when cleaning or reducing metal surfaces, the copper nozzles have a very long lifetime*. When polymers are surface activated, however, the arcs dock to the lip of the nozzle, resulting in a shortened service life due to erosion.

In order to extend the lifetime of the nozzles in this popular operating mode, relyon plasma has now developed the special nozzles with a carbide core.

Due to the material properties of carbide, the carbide nozzles are much more resistant to oxidation and erosion than the standard copper nozzles. Thus, even in the treatment of polymers, a 4-fold higher nozzle lifetime could be achieved than with the copper nozzles. Due to the significantly longer service life of the nozzles, the process now requires less maintenance, is more sustainable and more stable.

Another field of application for carbide nozzles is in the semiconductor industry, where the copper abrasion of standard nozzles is often problematic. This can also be prevented by using carbide nozzles.

*At this point we expressly refrain from publishing diagrams or tables of the life expectancy of nozzles determined under laboratory conditions. These data were misleading for the consumer, because different process influences as not calculable factors strongly impair the life span.

Nozzle A 350

Düse A350

Field of application:

  • Surface cleaning
  • Surface activation
  • Thermal treatment and reactive coating
  • Optimized for sensitive materials

Nozzle A 450

Düse A450

Field of application:

  • Surface cleaning
  • Surface activation
  • Thermal treatment and reactive coating
  • Optimized for high process speeds


Wide range of applications: High-performance plasma system
Wide range of applications: High-performance plasma system

Our PlasmaBrush can be adapted to fit process requirements spot-on through a wide variety of accessories. Thus, the quality of your processes and products can be optimized at minimal cost. You only use the components you really need. All components are coordinated perfectly and have been through extensive stress tests. This simplifies maintenance and servicing, and availability is ensured on the shortest possible time scale.

We have consciously adapted our high voltage power supply PS2000 to the independent industrial standard of CanOpen, which makes exceedingly reliable communication possible even under the more severe circumstances an industrial environment can bring about.

A great number of sensors or mass flow controllers operate using the same standard. Every prevalent industrial control worldwide provides a suitable interface. Up to 127 devices can be addressed via CAN node. Every PS2000 high power source can be controlled with a simple DIP switch in the address space of 0 to 99.

PS2000 High voltage source

The PS2000 High voltage source optimised for Pulsed Atmospheric Arc Technology (PAA Technology®). Due to the use of a unipolar pulsed high voltage, the arc is prevented from stabilising at “hot spots” in the nozzle. The latest IGBT switching technology and the use of high quality high voltage components ensure that the source is extremely reliable and efficient. Overloading is also not possible in continuous 24/7 operation. In the event of cable damage or short circuiting during critical operations the control unit intercepts all power fluctuations safely.

The capability of the PS2000 is particularly reflected in the fact that it can operate with variable loads and can effectively pump loads within a large potential range of up to > 12 kV. This special feature ensures continuous ignition performance across a wide power range and for different process gases. The high voltage source is switchable in a range of milliseconds at full load and therefore optimised for timed processes where highly precise timing is beneficial.

All communication is based on the reliable and fast CAN bus. Even in the event of a fault, the communication remains active. Integration into each automated production plant is simple and standardised, even in the case of several high voltage sources.

Performance features:

  • Input voltage: 220 – 240 V AC, 50-60 Hz
  • Max. input current: 6A
  • Weight: 18 kg
  • Power: 0 – 1,000 Watt (variable)
  • Open circuit voltage: up to 20 kV

PlasmaBrush PB3 systems

Our PlasmaBrush PB3 system can be operated as a basic system with one plasma source and high voltage source as well as a multiple system with several plasma and high voltage sources – according to your individual requirements:

PlasmaBrush Basic System

More information Basic Plasma System

Start the plasma process reliably and easily by the simple push of a button with preset operating parameters. All you need is a dry compressed air supply with adjustable system pressure.

PlasmaBrush Basic System


  1. PS2000 high voltage supply
  2. PB3 plasma generator equipped with fixed choke
  3. Air supply with constant pressure setting
  4. Optional gas supply package

Information: Simplified functional scheme

Connect your PS2000 to the main supply. Then adapt the air flow via your system pressure. A constant flow will be provided when using a throttle valve dependent on the system pressure. Ignite the plasma flame by pressing the button at a preset value of frequency and power.

PlasmaBrush Multiple System

More information about Multiple Plasma System

In a modern production environment, several plasma channels can be integrated intelligently and connected to any control solution you choose. We have developed flexible solutions for Siemens, Allen-Bradley/Rockwell, Beckhoff and equivalent control systems. Each of these manufacturers offers a CAN module. Simply download our driver (universal EDS file) and thus gain full process control in your system environment. Your system can be connected to easily, no matter the SPS manufacturer.

Multiple PB3 Plasma System / Mehrfahc PB3 Plasma System


  1. PS2000 high power supply
  2. PB3 plasma generator
  3. Adjusted air supply
  4. Host controller
  5. CAN bus for PLC

Information: Simplified functional scheme

All processes are controlled via CAN bus by addressing up to 127 channels simultaneously. Thus, air pressure or gas supplies can be integrated without any difficulty. This system makes it very easy to monitor mass flow of air or any process gas mixtures. The entire system intelligence is implemented into the central control.

Communication Systems

For our PlasmaBrush PB3 plasma system you can add different communication packages:

USB Communication System

More information about USB Communication System

In this system configuration, all plasma operating parameters can be controlled as well as displayed on a PC, which also makes it ideal as a test environment for technical service and customer service. Our program with its clear layout lets you comfortably connect to the PS2000 CAN bus via USB. All you need is a dry compressed air supply with adjustable system pressure, a Windows PC with USB port and our USB/CAN converter.

USB Communication PB3 Plasma System


  1. PS 2000 high power supply
  2. PB3 plasma system supplied with fixed throttle
  3. Air supply with constant pressure adjustment
  4. PC with control and visualization adjustment
  5. USB interface for PC
  6. Optional gas supply package

Information: Simplified functional scheme

The first step is to set the inlet pressure at the air supply. The fixed throttle valve on the PB3 plasma generator is used to set a constant flow rate in accordance with the fixed characteristic curve. The “plasma control” software is installed and started on the PC for process control and visualization. The “plasma control” software uses a hardware interface to establish communication via USB to the CAN bus and enables the performance parameters of the PS2000 to be set on the PC. In the operating window of the software, the current data are displayed in x-ton format and can be saved in the common .csv format.

CAN Communication System

More information about CAN Communication System

In this system configuration, all plasma operating parameters can be controlled and displayed on a PLC, which also makes it ideal as a test environment for technical and customer service or for use with different lots in in-line production.

CAN Communication System PlasmaBrush PB3


  1. PS2000 High Power Supply
  2. PB3 plasma generator with fixed throttle
  3. Air supply with constant pressure adjustment and preset valve
  4. Superior PLC
  5. CAN Interface for PLC

Information: Simplified functional scheme

First, the system pressure is set at the air supply. About a permanently set throttle valve on the plasma generator PB3 is set according to the solid curve a constant flowrate. For process control, different PLCs can be used which have a CAN-Bus interface or a CAN-Bus expansion card. The integration is supplied by the customer.

ProfiNet Communication System

More information about ProfiNet Communication System

All you need is a connection for dry compressed air with adjustable inlet pressure and our ProfiNet communication package. You use it to control the system via the already existing ProfiNet network. The solution works for up to 125 plasma systems.

ProfiNet Kommunikationspaket


  1. PS2000 High Power Supply
  2. PB3 plasma generator with fixed throttle
  3. Air supply with constant pressure adjustment and preset valve
  4. ProfiNet communication system
  5. Existing ProfiNet network

Information: Simplified functional scheme

The first step is to set the inlet pressure at the air supply. This can be done, for example, via a simple solenoid valve. Via the fixed throttle valve on the PlasmaBrush PB3 plasma generator, a constant flow rate is set according to the fixed characteristic curve. The performance parameters of the PS2000 high-voltage source are transmitted to the higher-level control system via the ProfiNet system. An adjustment of the parameters is thus possible, as well as the output of error messages and the resetting of the system.


Which materials can be processed?
All Materials can be processed. Basically, all materials can be treated with the PlasmaBrush PB3. Conductive materials can be treated particularly effectively due to the transfer of the arc.
What is the temperature of the generated plasma?
The temperature distribution within the plasma flame is between 200 degrees and goes up to 1000 degrees, this differs greatly according to the particular nozzle types.
What is the optimum working distance?
For surface treatment, the optimum distance is typically between 6-25 mm.
How fast should I move the PlasmaBrush PB3 over the surface?
The optimum processing speed is very material-dependent, and can be calculated as a first approximation. Consult our application engineers.
What are the operating modes for the PlasmaBrush PB3?
For ordinary surface activation or fine cleaning to increase the wettability of a surface, the diffuse mode of operation is suitable, in which the plasma interacts with the substrate surface without any further measures. If one wants to remove an organic layer on the substrate, a so-called cathodic cleaning by means of a transferred arc is suitable. By grounding the substrate, the nozzle no longer acts as the cathode, but the substrate itself. Due to the greatly increased intensity of the treatment, thin layers of paint, for example, can be removed.
How long does the surface activation last?
The surface energy will decrease after the treatment on a timeframe of minutes to days. However the surface energy will allways remain higher than the initial value.
How can I make the activation effect visible?
In the simplest case, you will achieve good water wettability (72mN/m), which you can test with a simple water ink. Of course, there are also special test inks for a more precise analysis.
Can I overtreat a component?
Yes, you can cause thermal damage or the surface energy will decrease if the component is overtreated.
Can the PlasmaBrush clean components?
Yes, the PlasmaBrush is ideally suited for cleaning components. With suitable selection of the process parameters, oils, emulsions and release agents are removed.
Is a gas supply necessary?
Yes, operation is possible with industrial compressed air or nitrogen via a standardized Festo hose connection. The operator only has to ensure the appropriate gas flow in the range between 30-70 slm. A Festo MFM (Mass Flow Meter) can be used for this purpose, for example.
What power supply does the device require?
The PlasmaBrush can be operated via a standard household power socket.
How often should the nozzle and the electrode be exchanged?
In normal operation with air, a nozzle change is recommended every 500h. The electrode lasts approx. 1,000h.
Is the offered system ESD proof?
Yes, the A250 nozzle of our PlasmaBrush PB3 system is specifically designed for the treatment of ESD sensitive parts.
Can multiple plasma heads be used on one generator or does each head require a separate control unit?
Each PlasmaBrush PB3 system consists of the high voltage source PS2000 (compact design for integration in 19″ racks), 9 m of high voltage cable (suitable for robots and drag chains) and the plasma generator PG31 (very compact, weighing less than 1 kg).
How many different recipes/parameter settings are possible?
The PlasmaBrush PB3 allows for power as well as frequency setting at the high voltage source. Other important parameter include the choice of nozzle, the choice of process gas (CDA, nitrogen, forming gas, etc.) and the gas flow (35-80 slm).
If several recipes/parameter settings can be used: What is the concept to import, load and use different internally stored recipes?
Since the most important process parameters are speed and nozzle-susbtrate distance we determine these in close coordination with the process owner. If changes have to be made to the parameters of the high voltage source these can simply be accessed via the communication interface.
Can recipes/parameter settings be imported via MES or the SPS of the production cell?
Yes, the PlasmaBrush PB3 system can communicate via CANopen (Standard), EtherCat, Profinet, Profibus, etc.
Are different nozzles / different nozzle designs available?
Three different standard noozle designs are available: A250 for ESD sensitive substrates, A350 for temperature sensitive materials and A450 for high-speed processes. We also offer long-life versions of our standard nozzles.
What's the concept on how to exchange the nozzles?
Nozzles can be exchanged without tools by instructed personnel.
What's the range of the possible treatment area / width?
The treatment width of the PlasmaBrush PB3 system ranges between 15 and 25 mm for one pass. Larger widths can either be achieved by the use of additional plasmagenerators or by meandering which is easily possbile due to high process speed and lightweight plasma head.
What's the available power range?
The plasma jet output ranges from 480 – 770 W.
Which process parameters are controlled / monitored / tracked?
The PlasmaBrush PB3 system allows the control of power and frequency. Via the communication interface of the high voltage source PS2000 power, current and voltage of the plasma jet can be monitored in real time.
How is the PlasmaBrush PB3 controlled?
The standard communication is via CANopen. However, control via USB interface is also possible. We would be pleased to support you with the integration into your plant, e.g. with the control via Profi-Net, Profi-BUS, EtherCAT.
Which data can be sent through this interface? Which data formats are available?
The CANopen project directory is listed in the manual (see page 16-20) and includes object types (VAR, ARRAY, RECORD, etc.) and data types (VISIBLE_STRING, UNSIGNED8, etc.). The .eds-file is included in the scope of delivery.
Which process exhaust gases occur during the plasma process?
The PlasmaBrush PB3 system generates exhaust gases typical for high power jet plasma systems, like NOx and ozone. The quantities are dependent on the process gas. Detailed analysis are available.
Was the electromagnetical radiation measured for your system?
The PlasmaBrush PB3 system is CE certified and complies with all relevant regulations. Both certification and analysis are available.
How can the PlasmaBrush be mounted?
The compact and lightweight (approx. 0.5kg) plasma generator can be integrated into an existing system by means of a simple bracket. We will gladly send you the drawing files for this purpose.
What's the typical size, weight etc. of the plasma system?
The PlasmaBrush PB3 is a modular system consisting of: high voltage source PS2000 for 19 inch rack (448x343x177,18 kg), high voltage cable suitable for robot and drag chain (9 m) and plasmagenerator PG31 (1 m cable length, 32 mm diameter, 680 g). Please find all relevant data in the manuals attached.
How safe is it to work with the PlasmaBrush?
Do not reach into the plasma flame during operation. The system can easily be integrated into the emergency stop circuit. The resulting emissions must be extracted, for this we recommend a volume flow of about 30m³ per hour.
Does the PlasmaBrush PB3 emit UV light?
Yes, but the UV emission using air is of low intensity and harmless at normal working distances of >200mm.
Does the PlasmaBrush PB3 emit dangerous gases?
Depending on process conditions the PB3 can emit ozone or nitroxides. We recommend to use an active filter or to exhaust the gas load into a hood.
Can the PlasmaBrush PB3 cause skin burns?
Also after swich off the nozzle can still be very hot.
Can the PlasmaBrush PB3 cause dangerous electric shock?
No, the amount of charge and the current are too low to be dangerous.


Plasma generator PB31

Plasma Generator PG31 ManualDEManual
Plasma Generator PG31 ManualENManual
Plasma Generator PG31 ManualESManual
Plasma Generator PG31 ManualFRManual
Plasma Generator Nozzle ChangeDENozzle Change
Plasma Generator Nozzle ChangeENNozzle Change
PlasmaBrush PB3 FlyerENFlyer
PlasmaBrush PB3 PaperENPaper

Plasma source PS2000

PS2000 ManualENManual
PS2000 ManualDEManual
PS2000 ManualESManual
PS2000 ManuelFRManuel
PS2000 Quick Start GuideENQuick Start Guide
PS2000 Quick Start GuideDEQuick Start Guide
PS2000 FlyerENFlyer
PS2000 Software (eds)ENPS2000 Software (eds)

Communication packages

Manual Communication Package CANDEManual Communication PackageCAN
Manual Communication Package CANENManual Communication Package CAN
Manual Communication Package CANESManual Communication Package CAN
Manual Communication Package CANFRManual Communication Package CAN
Manual Communication Package USBDEManual Communication Package USB
Manual Communication Package USBENManual Communication Package USB
Manual Communication Package USBESManual Communication Package USB
Manual Communication Package USBFRManual Communication Package USB
Software Communication Package USBENPlasma control V2.6
Manual Communication Package ProfiNetDEManual Communication Package ProfiNet
Manual Communication Package ProfiNetENManual Communication Package ProfiNet
Software Communication Package ProfiNetENSoftware Communication Package ProfiNet


Data Sheet Nozzle A250DEData Sheet A250
Data Sheet Nozzle A250ENData Sheet A250
Data Sheet Nozzle A350DEData Sheet A350
Data Sheet Nozzle A350ENData Sheet A350
Data Sheet Nozzle A450DEData Sheet A450
Data Sheet Nozzle A450ENData Sheet A450

HVC Cable Extension

Cable Extension ManualDECable Extension Manual
Cable Extension ManualENCable Extension Manual
Cable Extension ManualESCable Extension Manual
Cable Extension ManualFRCable Extension Manual
Cable Extension ManualJPCable Extension Manual
Cable Extension ManualITCable Extension Manual
Cable Extension ManualPTCable Extension Manual
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