Download IQ POWER HL Static Bar

IQ POWER HL
Static Bar
INSTALLATION AND OPERATING INSTRUCTIONS
IQ POW E R H L
5201051 Rev. F
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IQ POW E R H L
5201051 Rev. F
TABLE OF CONTENTS
1. SAFETY............................................................................................ 1
2. INTRODUCTION.................................................................................. 2
3. SPECIFICATIONS................................................................................. 3
4. INSTALLATION................................................................................... 4
Mounting the Static Neutralizing Bar...................................................................................4
‘Y’ Sealing Fitting Installation..............................................................................................6
Conduit Requirements...........................................................................................................8
5. MAINTENANCE..................................................................................10
Cleaning the Static Bar........................................................................................................10
6. WARRANTY......................................................................................11
IQ POW E R H L
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5201051 Rev. F
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IQ POW E R H L
5201051 Rev. F
1. SAFETY WARNINGS
For use in Hazardous Locations, Intrinsically Safe for use in:
Class I, Division I, Group D
Class II, Division I, Groups F and G
Class III, Division I
Temperature Code T4
imco-Ion recommends that these instructions be read completely before
S
installation or operation is attempted. Failure to do so could result in personal
injury and/or damage to the equipment.
OTE! – Statements identified with NOTE indicate precautions necessary to
N
avoid potential equipment failure.
AUTION! – Statements identified with CAUTION indicate potential safety
C
hazards.
OTE! – This equipment must be correctly installed and properly maintained.
N
Adhere to the following notes for safe installation and operation:
1. Read instruction manual before installing or operating equipment.
2. Only qualified service personnel are to perform installation and repairs.
3. All equipment must be properly grounded, including the machine frame to which the
equipment is mounted.
4. Disconnect input power to the Power Supply before connecting or disconnecting
static neutralizing bar or performing any maintenance to the system.
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2. INTRODUCTION
The IQ POWER HL static bar is tailored to the application. Speed bars are optimized
to operate on high speed webs at distances 2” to 9” [50 mm to 230 mm]. Hybrid bars
are optimized to operate at 6” to 18” [150 to 460 mm] on webs where the web path is
somewhat variable.
The static neutralizing bar features current limiting at each individual ion emitting pin to
minimize the risk of hazardous electrical shock if the bar is touched while in operation or
to eliminate the risk of explosion in specific classified areas. This safety feature does not
compromise the IQ POWER HL bars ability to neutralize static charges.
The emitter pins are made of a special alloy to extend the longevity and sharpness of the
points, providing optimal performance of the static bar.
The IQ POWER HL static bar is listed through ETL (Intertek) for both use in the United
States and Canada, and is listed for intrinsically safe use in Class I, Division I, Group
D, Class II, Division I, Groups F & G and Class III, Division I hazardous (classified)
locations.
The IQ POWER HL static bar is designed to operate with a power supply having a
maximum output of 10 kVPEAK positive and 10 kVPEAK negative. Refer to Section 4 for
the proper mounting of the static bar. Refer to Figure 1 for static bar dimensional outline.
Emitter Spacing
Bar Type
Emitter Spacing
Minimum
Maximum
Speed
30 mm
8
130
Hybrid
90 mm
8
44
Bars always have an even number of emitters.
Effective Length = (Number of Emitters -1) X Emitter Spacing
Figure 1. IQ POWER HL Static Bar
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3. SPECIFICATIONS
Operating Voltage
±9.5 kVPEAK, max
Nominal Bar Length (Overall Length)
Speed Bar: 301-3961 mm [11.85-55.95”]; Hybrid Bar:
721-961 mm [28.38-155.95”]
Dimensions
26 mm W x 49 mm H [1.00”W x 1.93”H]
Weight
1.8g/mm [0.11 lb/in]
Operating Temperature
T4/Ta 0-80°C [32-176°F]
Humidity
80% RH max, no dewing permissible
Enclosure
Glass-fiber-reinforced polyester
Connection
½” NPT male thread at end of bar for metal conduit
High Voltage Cable
3m [10’] standard / 27.43m [90’] maximum
Emitter Material
Proprietary alloy specially selected to extend pin life
Emitter Current
50 mA per emitter, max
Emitter Spacing
Speed Bar: 30 mm [1.18”]; Hybrid Bar: 90 mm [3.54”]
Operating Distance
Speed Bar: 50 mm to 230 mm [2” to 9”]; Hybrid Bar: 150
mm to 460 mm [6” to 18”]
Installation Hardware
Plastic mounting brackets, metal perforated strips and
stainless steel hardware (screws, nuts and washers).
Approval
CE
CAUTION! – Intrinsically Safe, Sècuritè Intrinséque for use in the following
Hazardous Locations. (Class I, Division I, Group D, Class II, Division I, Groups F
and G, Class III, Division I)
Typical Loading Capacity of a + 9.5 kV and -9.5 kV Power Supply
Total Effective Length of Bars
Millimeters [inches]
Maximum Total Conduit
Length per Power Supply
Meters [feet]
Up to 1270 [50]
27.43 [90]
1295 [51] to 2540 [100]
24.38 [80]
2565 [101] to 3175 [125]
22.86 [75]
3200 [126] to 3810 [150]
21.33 [70]
3835 [151] to 5080 [200]
18.29 [60]
5105 [201] to 6350 [250]
15.24 [50]
6375 [251] to 6985 [275]
13.72 [45]
7010 [276] to 7924 [312]
12.19 [40]
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4. INSTALLATION
The static bar is supplied with a mounting kit which contains “Blue” plastic mounting
brackets, perforated strips, hardware, and set screws (Figures 2 and 3).
Figure 2 – Static Bar Mounting Kit
Mounting the Static Neutralizing Bar
1. Determine the best location to mount the static neutralizing bar. The static bar will
typically be located just ahead of where problems due to static are occurring. A static
audit by a Simco-Ion representative can determine the best location of the static bar.
2. The appropriate operating distance. “R” (Figure 3) for the static bar is in part
determined by the application:
a. Speed Bars (emitter point spacing 30 mm) are mounted closer to the web, 2”
to 9” [50 mm to 230 mm] and may be installed in more congested areas of the
machine; however the web path should be fixed for the speed bar. Optimum
mounting distance for high speed webs is 4” [100 mm]. Speed bars can be
identified by an ion emitter spacing of 1.18” [30 mm].
b. Hybrid Bars (emitter point spacing 90 mm) are mounted at a distance to the
web, 6” to 18” [150 mm to 460 mm] and are usually installed where the web
path is relatively free of obstructions. The benefit of Hybrid bars is that they
allow mounting where the web path may be variable. Hybrid bars can be
identified by an ion emitter spacing of 3.54” [90 mm].
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Figure 3. Static Bar Mounting Location
NOTE! – IQ POWER HL bars should NOT be installed or operated at distances
less than the minimum distance specified for the particular bar. (Speed 2” [50 mm]
or Hybrid 6” [150 mm])
NOTE! – The “free area” between the static bar and the web should have
approximately equal height and width.
NOTE! – There should be NO grounded metal such as an idler roller immediately
behind the web on the far side from the static bar. The area behind the static bar
should be as free as possible from grounded metal. Refer to Figure 4.
The effectiveness of the IQ POWER HL static bars is determined by the distance to the
web and the speed that the web is moving. If the static bar is not performing adequately
at a given distance, it may be necessary to reduce or increase the operating distance
accordingly. DO NOT exceed the minimum operating distance of the particular bar
though.
3. Install the bar to the conduit and carefully feed the high voltage cable through the
conduit, making sure not the overly twist the high voltage cable and nick the cable
insulation.
4. Locate the “Blue” plastic mounting brackets and slide them onto the “T” channel on
the back of the static bar. Refer to Figure 2.
5. The perforated mounting strip may be installed on the mounting bracket at a right
angle or parallel to the static bar. The perforated strip may be bent or twisted to suit
the application and will hold its shape as installed.
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6. Once the static bar is loosely installed, tighten all the remaining hardware.
7. Locate the set screws and the hex key wrench and install two (2) set screws into the
holes in the side of the mounting bracket. The set screws engage the “T” slot on the
back of the bar securing it in place (Figure 4).
Figure 4. Securing the Static Bar
‘Y’ Sealing Fitting Installation
The IQ POWER HL static bar requires the use of a “Y” conduit sealing fitting between the
static bar and the physical boundary of the classified area. The high voltage wiring from
the IQ POWER HL static bar must be properly prepared to ensure the sealing at the “Y”
fitting(s). Refer to Figure 9 for a typical location.
1. Determine the location of the “Y” sealing fitting.
2. The high voltage wire from the IQ POWER HL static bar should be located in the
conduit as it will be installed. This will prevent unnecessary twisting of the cable
when the static bar is screwed to the conduit which could cause a failure of the cable.
3. Strip 1¾” (1.75” [45 mm]) length of the black PVC jacket to expose the two high
voltage cables. Be careful not to nick the white plastic insulation on the high voltage
cables.
NOTE! – It is recommended to practice stripping off the jacket on the waste end
of the high voltage cable prior to preparing the cable. This will minimize the risk
of nicking or cutting the white high voltage insulation.
4. Separate the high voltage wires as shown in Figure 7.
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Figure 5
Figure 6
5. Install the “Y” sealing fitting onto the conduit and tighten.
NOTE! – The “Y” sealing fitting must be secured to the conduit with a minimum
of 5 full turns.
6. Install the packing fiber generally following the “Y” sealing fitting manufactures;
instructions while maintaining the high voltage wire separation. Refer to Figures 7
and 8.
7. Continue assembling the “Y” sealing fitting using the fitting manufacturers’
instructions regarding the sealing compound preparation, installation and curing.
8. Install the close-up plug and tighten completely.
NOTE! – The “Close-Up” plug must be secured to the “Y” sealing fitting with a
minimum of 5 full turns.
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Figure 7
Figure 8
Recommended “Y” Sealing Fitting
Fitting
Adalet XY-2, 25% Fill, ½” NPT Female Threads
Packing Fiber
Adalet ADACO XAF-6
Sealing Cement
Adalet ADACO No. 1
Conduit Requirements
NOTE! – It is the customer’s responsibility to provide approved conduit material
installed in accordance with the National Electrical Code, (NEC) or any
government, state, providence or local regulations.
1. All conduit and fittings must be approved for use in Class I, Division I, Group D,
Class II, Division I, Groups F & G and Class III, Division I hazardous, (classified)
locations.
2. The high voltage cable for the static bar must be installed in conduit. Each static bar
has a ½” -14 NPT threaded fitting at the cable end of the bar.
3. A “Y” sealing fitting is required between the static bar and the boundary, (physical
separation between the Class 1 location and the non-hazardous or unclassified area).
Refer to Section 4 for the proper installation of the “Y” sealing fitting. Refer to
Figure 9 for the typical location.
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Figure 9. Conduit Requirements
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5. MAINTENANCE
NOTE! – Only qualified service personnel are to perform maintenance tasks.
CAUTION! – Electrical Shock Hazard. Turn off Power Supply before cleaning
bar or performing any maintenance on the system.
The accumulation of contamination on the ionization emitter points and static bar
surfaces will reduce neutralizing efficiency of the bar, therefore it is recommended that
maintenance of the system be performed when the Clean Bar indicator on the display
module illuminates or every three weeks, whichever comes first. Dirty environments may
require more frequent cleaning. Maintenance should be performed by qualified service
personnel only.
Cleaning the Static Bar
A clean brush with nylon bristles should be used to keep the ionization emitter points of
the static bar clean. Periodic use of the brush will prevent deposits from accumulating on
the points. The emitter points must remain sharp for optimum operation.
NOTE! – Do not scrape points with any hard or sharp object that may damage
points.
A.
B.
C.
D.
Turn off power supply.
Remove dirt particles deposited on the static bar with a dry, stiff nylon bristle brush.
Blow off the static bar with clean, dry compressed air.
Remove resistant coatings deposited on static bar by wiping with isopropyl alcohol
or mineral spirits applied to a clean cloth. Apply isopropyl alcohol or mineral spirits
to a stiff nylon bristle brush and thoroughly scrub the ionization emitter channels of
the bar.
E. Blow static bar dry with clean, dry compressed air and ensure the bar is completely
dry before re-applying power to the bar.
NOTE! – Do not soak static bar or related components in alcohol or mineral
spirits. Do not use harsh solvents such as lacquer thinner, naphtha or acetone.
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6. WARRANTY
This product has been carefully tested at the factory and is warranted to be free from
any defects in materials or workmanship. Simco-Ion will, under this warranty, repair
or replace any equipment that proves, upon our examination, to have become defective
within one year from the date of purchase.
The equipment being returned under warranty should be shipped by the purchaser to
Simco-Ion, 2257 North Penn Road, Hatfield PA 19440, transportation prepaid and insured
for its replacement cost. Prior to returning any goods for any reason, contact Simco-Ion
Customer Service at (215) 822-6401 for a Return Authorization Number. This number
must accompany all returned items.
This warranty does not apply when the equipment has been tampered with, misused,
improperly installed, altered, has received damage through abuse, carelessness, accident,
connected to improper line voltage, or has been serviced anyone other than an authorized
factory representative.
The warranty does not apply when Simco-Ion parts and equipment have been energized
by other than the appropriate Simco-Ion power supply or generator, or when a SimcoIon power supply or generator has been used to energize other than Simco-Ion parts
and equipment. Simco-Ion makes no warranty, expressed or implied, nor accepts any
obligation, liabilities, or responsibility in connection with the use of this product other than
the repair or replacement of parts stated herein.
IQ POW E R H L
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Simco-Ion
2257 North Penn Road
Hatfield, PA 19440
(215) 822-6401
(800) 203-3419
www.simco-ion.com
[email protected]
© 2012 Simco-Ion Printed in the U.S.A.
IQ POW E R H L
5201051 Rev. F
IQ Power™ HL
Power Supply
INSTALLATION AND OPERATING INSTRUCTIONS
IQ Po w e r ™ H L
5201201 Rev. C
TABLE OF CONTENTS
1. DESCRIPTION....................................................................................................... 3
2. SAFETY................................................................................................................ 3
3. FEATURES............................................................................................................ 4
4. SPECIFICATIONS.................................................................................................. 5
5. INSTALLATION..................................................................................................... 6
6. OPERATION........................................................................................................ 13
7. MAINTENANCE................................................................................................... 18
8. TROUBLESHOOTING........................................................................................... 19
9. REPLACEMENT PARTS....................................................................................... 20
10. WARRANTY........................................................................................................ 21
IQ Po w e r ™ H L
5201201 Rev. C
1. DESCRIPTION
IQ Power™ HL Power Supply:
Associated Equipment for the IQ Power™ HL Static Bar
Appareillage Connexe
For use in Non-Hazaradous (Unclassified) locations only
Simco-Ion’s IQ Power™ HL Power Supply provides microprocessor controlled
high voltage DC output to the static bar. The high voltage causes the ionizing pins
on the static bar to generate positive and negative ions. The electric field from the
static charge on the material being processed will attract opposite polarity ions
from the static bar causing the material to be neutralized. The excess ions will
either recombine in air or dissipate to ground.
The IQ Power™ HL Power Supply only supports operation of speed and hybrid
type static bars.
The IQ Power™ HL static bar is tailored to the application. Speed bars are
optimized to operate on high speed webs at distances of 50 to 230 millimeters [2
to 9 inches]. Hybrid bars operate at distances of 150 to 460 millimeters [6 to 18
inches] on webs where the web path is somewhat variable.
The IQ Power™ HL static bar has a plug-in style high voltage connector for fast
and easy installation. The connector features a pin that “tells” the IQ Power™ HL
Power Supply what type IQ Power™ HL bar is installed and optimizes the power
supply output for that type of bar.
2. SAFETY
Simco-Ion recommends that these instructions be read completely before
installation or operation is attempted. Failure to do so could result in personal
injury and/or damage to the equipment.
NOTE – Statements identified with NOTE indicate precautions necessary to
avoid potential equipment failure.
CAUTION – Statements identified with CAUTION indicate potential safety
hazards.
NOTE – This equipment must be correctly installed and properly maintained.
Adhere to the following notes for safe installation and operation:
1.Read instruction manual before installing or operating equipment.
IQ Po w e r ™ H L
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5201201 Rev. C
2. Only qualified service personnel are to perform installation and repairs.
3. All equipment must be properly grounded, including the machine frame
to which the equipment is mounted.
4. Disconnect input power to power supply before connecting or
disconnecting static neutralizing bars to the high voltage power supply.
5. Do not operate the power supply in close proximity to flammable
liquids.
CAUTION – This product is intended to be supplied by a Listed AC Adapter
or Power Unit marked “Class 2” or “LPS” and rated output 24V
DC, 3.75A.
CAUTION – Electrical Shock Hazard
Disconnect input power to the power supply before connecting or
disconnecting static neutralizing bar or performing any maintenance to
the system. Avoid touching static neutralizing bar when power supply is
energized.
CAUTION – Fire Hazard
Do not install or operate the power supply in close proximity to any
flammable liquids or solvents.
WARNING – Substitution of components may impair intrinsic safety. (refer to
Figure-5.1)
AVERTISSEMENT – La substitution de composants peut compromettre la securite
intrinseque. (referez-vous au schema 5.1)
3. FEATURES
• Single momentary push-button calibration simplifies set-up.
• Bar graph display indicates ionizing performance of system.
• Indicators display status of neutralizing system, power, service required and
detection of system faults.
• Relay contact output “echoes” indicators for remote sensing and alarm.
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4. SPECIFICATION
IQ Power™ HL Power Supply
Input Power:
24V
Output Voltage:
+/-7kV “Speed Bar”
+/-8kV “Hybrid Bar”
DC, 1.5A from AC adapter
Dimensions:
202mmL x 123mmW x 106mmH
[7.95”L x 4.85”W x 4.17”H]
Weight:
1.94 kg [4.28 lb]
Max. Operating Temp:
43°C [110°F]
Housing:
Aluminum, blue polyester powder coated
High Voltage Connectors:
2 proprietary IQ Power™ HL plug-in outlets
AC Adapter
Type
“Universal” desktop
Input Power:
100–240V
AC 50/60Hz input
(IEC 320 inlet)
Output:
24V
Dimensions:
132mmL x 60mmW x 34mmH
5.19”L x 2.36”W x 1.34”H]
Weight:
0.45 kg [1.0 lb]
Housing:
Thermoplastic, black
IQ Po w e r ™ H L
DC, 3.75A maximum
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5201201 Rev. C
5. INSTALLATION
Figure 5.1 IQ Power™ HL Control Drawing
5.1 Mounting the Power Supply
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A. Locate at a convenient place within reach of the static bar high voltage
cable. Power for the AC adapter and an electrical ground connection must
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be available.
B. Secure to the mounting surface (commonly a machine frame) using M5 or M4
[#10 or #8] hardware (not supplied).
NOTE - Do not apply line voltage to the AC adapter until installation is complete.
Also ensure that all input power switches are in the OFF (0) position.
CAUTION - Do not install the power supply within hazardous (classified) locations.
Install in non-hazardous (unclassified) locations only (refer to Figure 5.1)
5.2 Electrical Connections
A. Ground power supply by connecting a ground lead between the ground
terminal on the flange of the power supply and a good electrical machine
ground.
B. Connect static bar by cutting the high voltage cable to length,
terminating the leads, and connecting to the power supply: (Refer to
Figure 5.2)
1.
Cut HV cable to length, leaving an extra 3¼” for the connector.
2.
Strip black plastic jacket back 2½”, being careful not to nick the
insulation of the HV wires.
3.
Strip insulation of HV wires back ¾”, being careful not to nick the
conductor of the HV wire.
4.
Straighten conductors and insert into HV connector until conductor
protrudes out from the tip of the connector.
5.
Solder conductor to tip of connector by applying solder to exposed
conductor. Ensure that that solder does not overflow and fill neck area
of tip.
6.
Trim off excess conductor protruding from tip of connector.
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Solder
& Trim
Figure 5.2 High Voltage Cable Terminations
7.
Place HV Connectors into the HV plug bottom. The black plastic jacket
should be fully engaged in the strain relief section of the HV plug. Flex
conduit (where used) should be fully engaged in the hub section of the
HV plug.
8.
Install the HV plug top onto bottom making sure the plug comes
together properly with no binding or gapping. Hold together firmly.
9.
Insert nylon screws through holes in plug bottom and tighten to secure
plug together (do not over tighten screws).
10. Then plug in high voltage connector on static bar to HV1 or HV2 on
power supply. Secure high voltage connector with the (2) captive
screws on the sides of the connector. Do not over-tighten.
CAUTION – Shock Hazard
Do not connect static neutralizing bar with power supply energized.
Disconnect input power or switch power off before connecting static bar.
NOTE – Failure to fully seat the high voltage connectors into the power
supply connectors may result in permanent damage to the bar, cable or
power supply.
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C. Connect power supply alarm output (if used). The power supply “Alarm
Output” is a standard DB25 pin connector located on the end of the IQ
Power™ HL Power Supply. A maximum distance of 3 meters [10 feet] or
less is recommended.
Pin
1
14
Description
Remote on/off optocoupler (-)
Remote on/off optocoupler (+)
Pin
10
6
19
Description
No connection
No connection
No connection
2
3
16
Clean Bar Relay (common)*
Clean Bar Relay (norm close)*
Clean Bar Relay (norm open)*
11
7
20
Power Relay (common)*
Power Relay (normal closed)*
Power Relay (normally open)*
8
4
17
Fault Relay (common)*
Fault Relay (normally closed)*
Fault Relay (normally open)*
12
24
Power in (ground)**
Power in (ground)**
9
5
18
Bar On Relay (common)*
Bar On Relay (normal closed)*
Bar On Relay (normally open)*
13
25
Power in (+24V
Power in (+)**
DC)**
*30V 1A Rating on Contacts
**1.6A Rating, Connect pins 12 & 24 in parallel and 13 & 25 in parallel
24V
D
C
Figure 5.3 Alarm Output Connections
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5201201 Rev. C
The power supply alarm output provides a variety of relay contact outputs that
echo the status of the power supply indicator lights. The relay contacts are
rated for a maximum of 1A at 30V
DC. The alarm output connector also
provides a means of remote power in. (Refer to Figure 5.3)
D. Remote On/Off Control (if used). The power supply “Alarm Output”
connector also provides for remote on/off control of the power supply.
Remote on/off control is configured with a jumper on a pin header on the
main power supply circuit board. The default configuration is with the remote
control disabled. The remote control can be configured “normally off” or
“normally on” by the jumper setting (refer to Figure 5.4). To access the
jumper the cover will have to be removed from the power supply. Disconnect
all input power from the power supply then remove the six screws securing
the cover and slowly and carefully remove the cover.
Main PC Board
Remote On/Off
Disabled
Normally Off
Opto High = Unit ON
Opto Low = Unit OFF
Normally On
Opto High = Unit OFF
Opto Low = Unit ON
Figure 5.4 Jumper Position at J3 for Remote Control Operation
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There is a ribbon cable connecting the face label on the cover to the main
circuit board. Use care not to disconnect this cable. If the cable becomes
disconnected, lift the latches on the sides of the ribbon cable connector, insert
the ribbon cable fully into the connector and press the latches back down.
Reposition the jumper to enable the remote control either “normally on” or
“normally off”, as desired (refer to Figure 5.4). Then replace the cover and
secure with the six screws.
When operating a power supply using the remote control circuit, power may
be applied through the “Alarm Output” connector or the “Power In” connector
on the end panel. If the “Power In” connector on the end panel is used, the
“Power” switch must be set to the ON (1) position.
Remote control is established by applying 24V
DC to the “Alarm
Output” connector pins as specified in Figure 5.3. The user-applied 24V
DC drives a low current optoisolator on the IQ Power™ HL Power Supply
main circuit board, turning the power supply on or off, depending on the
configuration of jumper J3.
E. Connect other power supplies (if used). IQ Power™ HL Power Supplies
can be connected together via a “data buss”. The data buss allows one IQ
Power™ HL Communication Module to serve multiple IQ Power™ HL
Power Supplies and feed the data from all power supplies into the network. A
total of 10 power supplies may be chained together on one data buss. Special
cables for the data buss must be 8-conductor modular cables with RJ-45
connectors wired “straight through” (reference color: white).
If multiple IQ Power BPS power supplies are connected together, each power
supply must be given a unique address. This is necessary to enable reliable
digital communication. The power supplies should each be given a unique
address prior to connection with the “data buss” (the chaining together of
power supplies). See section 6.3 Power Supply Number (address) for details
on re-addressing the power supplies.
The modular cable plugs into either “PS COMM 1” connector on a power
supply and chains to the next power supply where it again plugs into either
“PS COMM 1” connector.
F. Connect AC Adapter (make sure “POWER” switch on power supply is in the
“OFF” (0) position). Route low voltage wire clear of moving machine parts
and protect it from abrasion. Secure using nylon wire ties (not supplied). Do
not over tighten. Insert barrel connector into “POWER IN” connector on the
power supply. Hand tighten barrel connector nut to secure.
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Connect line voltage to input side of AC adapter. The AC adapter is a
universal input type that accepts line voltage from 100 to 240 V
AC
50/60Hz. The AC adapter line voltage connector accepts a line cord with an
IEC 320 connector (supplied). The line cord also provides electrical ground
to the AC adapter. Check electrical ground integrity in the line voltage
receptacle used for the AC adapter. This ground must not be defeated.
G. Connect user supplied power (if used). In cases where the user does not
want to use the AC adapter but wants to supply 24V
DC power to the IQ
Power™ HL Power Supply, user supplied 24V
DC power may be applied
two ways.
The “Power In” connector on the end panel of the IQ Power™ HL Power
Supply may be used to supply power to the system. This connector requires
the use of a Switchcraft 760K barrel type power plug. The plug should be
wired +24V
DC to center and common (ground) to outer barrel. The
common must be bonded to electrical ground. Wired in this fashion, the
“Power” switch on the end panel of the power supply is in circuit.
Alternatively, the “Alarm Output” connector on the end panel of the IQ
Power™ HL Power Supply may be used to supply power to the system. This
connector requires the use of a standard DB25 connector. The connector
should be wired:
• +24V
DC to pins 13 & 25
• Common (ground) to pins 12 & 24
To ensure current carrying capacity, two pins are used for each connection.
The common must be bonded to ground. Wired in this fashion, the “Power”
switch on the end panel of the power supply is bypassed. (refer to Figure 5.3)
Power supplied in the above fashion must have adequate current available to
power all components on the system (maximum 4A). Input power should be
appropriately fused for safety purposes.
IQ Po w e r ™ H L
13
5201201 Rev. C
6. OPERATION
NOTE – Before switching on power supply; ensure that units are properly
grounded and that static bar & probes are properly installed.
6.1 Power Supply Indicators
Power: Lights (green) to indicate power is on and the IQ Power™ HL Power
Supply is ready to operate.
Comm: Lights (green) to indicate digital communication is established with
an IQ Power™ Communication Module or Control Station. The Comm light
will flicker to indicate communication activity.
Bar On: Lights (green) to indicate when the static neutralizing bar is active.
Fault: Lights (red) to indicate faulty condition of static bar, power supply
or high voltage connections. Power will have to be turned off to clear the
fault. When fault is cleared and power is restored, the fault light will be
extinguished.
Clean Bar: Lights (yellow) to indicate need to clean static bar. Clean Bar
indicator may light with low ion output (dirt build-up on ion emitters) or high
output current (conductive contamination on face of bar).
Mode: The indicator next to the type of bar connected will light (green).
“Speed” or “Hybrid” will be indicated. In cases where two different types
of bars are connected, the system will set for the safer of the two operating
voltages and light the corresponding Mode indicator.
The Output indicators (along with the Mode indicators) also indicate the
power supply number during start-up of the power supply.
Output: The output indicators range from “Low” to “High” in 10 steps
(2-red, 3-yellow, 5-green) and light to indicate the system relative ion output.
The output will normally be in the high range. Low output generally indicates
the need to clean the static bar.
6.2 Power Supply Operators
Calibrate: Is a momentary push button switch located on the face label.
Pressing the face label firmly on “Calibrate” initiates the calibration sequence
and sets the relative nominal ion output for the system.
IQ Po w e r ™ H L
14
5201201 Rev. C
The Calibrate button is also used to change the power supply number.
This number is used in software to identify the power supply in systems that
contain multiple power supplies and include an optional Communication
Module.
System Start-up:
A. Apply line voltage to the AC adapter.
B. Move the power supply “Power” switch to the “On” (1) position.
C. The power supply indicators will briefly self-test during which all will
light.
D. Immediately after the self-test, the power supply number (default: 01)
will be briefly displayed. (see 6.3 Power Supply Number)
E. After the power supply number displays, the power supply indicators
will settle to display the system status.
On new systems the output indicator will settle to display low output, initial
calibration must be performed.
NOTE – Calibration should be performed when the system is first installed
and may be performed after the static bar has been cleaned and the system
verified as operating correctly.
F. If the system is new, perform an initial calibration. The initial calibration
sets the relative nominal ion output for the system. The calibration
should only be performed on IQ Power™ HL systems that are new or
just cleaned and known to be in proper working order.
During calibration the target to be neutralized (web, film, etc.) may remain
in place, but MUST NOT BE MOVING. If the web is moving past the
static bar (e.g. the machine is in operation) the calibration may be faulty.
The system should be “on” and in the operating mode (not in start-up
self-test or power supply number display modes). Press the face label on
the power supply firmly on the word “Calibrate”. This will initiate the
calibration sequence and set the relative nominal ion output for the system.
During calibration the system output will be cycled and the three mode lights
will illuminate. At completion of the calibration the speed and distance lights
will flicker. The indicated ion output will be high. The calibration sequence
takes less than one minute.
The calibration data is stored in non-volatile memory and used on
subsequent power ups.
IQ Po w e r ™ H L
15
5201201 Rev. C
6.3 Power Supply Number (Address)
Each IQ Power™ HL PS has two numbers associated with it. These numbers
serve to identify the power supply in digital communications. One number
is the IQ Power™ / Performax IQ HL PS address, which can be a number
of 1 through 10 (the default is “1”). The other number is the IQ Power™
Station number, which can be a number of 1 through 30 (the default is “30”).
When the IQ Power™ HL PS is first turned on it will illuminate all LED
indicators as a self test. Then it will briefly display first the IQ Power™ /
Performax IQ address in steadily lit indicators and then it will display the
Ion Power station number in flashing indicators. See the following table for
interpreting the address numbers.
Power Supply Number Table
IQ Power/
Performax IQ
HL PS address
1 (default)
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
1
IQ Po w e r ™ H L
Ion Power
Station
number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30 (default)
OUTPUT
LED
illuminated
LOW (1)
2
3
4
5
6
7
8
9
(none)
LOW (1)
2
3
4
5
6
7
8
9
(none)
LOW (1)
2
3
4
5
6
7
8
9
(none)
16
SPEED
MODE
LED
On
On
On
On
On
On
On
On
On
On
On
On
On
On
On
On
On
On
On
On
On
HYBRID
MODE
LED
On
On
On
On
On
On
On
On
On
On
On
DISTANCE
MODE
LED
On
5201201 Rev. C
Adjusting the power supply number is only necessary in systems with multiple power
supplies daisy chained to a Communication Module or monitoring device. Having
multiple power supplies with the same numbers connected to a Communication Module
or monitoring device is not permitted.
To adjust the power supply number, turn the unit on and wait for the LED self-test to
complete. The COMM light will briefly stay lit and the power supply number may
be adjusted at this time. Press and hold the Initial Calibration button until the power
supply number increments by one (5 second window). Subsequent presses of the Initial
Calibration button will increment the power supply numbers (5 second window). The
Ion Power station number will be displayed and the IQ Power™ / Performax IQ HL PS
address will “map” as shown on the Power Supply Number Table. The incrementing
“wraps around”. Stop pressing the Initial Calibration button when the desired power
supply numbers have been reached. Wait 5 seconds, the COMM light will go out and the
Speed and Distance LEDs will flicker, indicating the power supply numbers have been
saved.
To reset the unit to its factory default power supply numbers (see Power Supply Number
Table), press and hold the Initial Calibration button while turning the unit on. Continue
holding down the Initial Calibration button while the Output indicators “count-up” and
when the COMM light starts flashing, then release the Initial Calibration button. When
just the Speed and Distance LED flicker, the default power supply numbers (address = ”1”,
station number = ”30”) are saved.
IQ Po w e r ™ H L
17
5201201 Rev. C
7. MAINTENANCE
NOTE – Only qualified service personnel are to perform maintenance tasks.
CAUTION – Electrical Shock Hazard
Turn off power supply before cleaning bar or performing any maintenance
on the system.
The accumulation of contamination on the ionization emitter points and static bar
surfaces will reduce neutralizing efficiency of the bar, therefore it is recommended
that maintenance of the system be performed when the Clean Bar indicator on
the display module illuminates or every three weeks, whichever comes first.
Dirty environments may require more frequent cleaning. Maintenance should be
performed by qualified service personnel only.
Cleaning the Static Bar
A clean brush with nylon bristles should be used to keep the ionization emitter
points of the static bar clean. Periodic use of the brush will prevent deposits from
accumulating on the points. The emitter points must remain sharp for optimum
operation.
NOTE –Do not scrape points with any hard or sharp object that may damage
points.
A. Turn off power supply.
B. Remove dirt particles deposited on the static bar with a dry, stiff nylon
bristle brush.
C. Blow off the static bar with clean, dry compressed air.
D. Remove resistant coatings deposited on static bar by wiping with
isopropyl alcohol or mineral spirits applied to a clean cloth. Apply
isopropyl alcohol or mineral spirits to a stiff nylon bristle brush and
thoroughly scrub the ionization emitter channels of the bar.
E. Blow static bar dry with clean, dry compressed air and ensure the bar is
completely dry before re-applying power to the bar.
NOTE – Do not soak static bar or related components in alcohol or mineral
spirits. Do not use harsh solvents such as lacquer thinner, naphtha or
acetone.
IQ Po w e r ™ H L
18
5201201 Rev. C
8. TROUBLESHOOTING
PROBLEM
CAUSE
Power not on at power supply.
Power indicator NOT
illuminated.
Poor electrical connections.
SOLUTION
Turn on Power switch on end of
power supply case.
Check input power connections,
both 24V
DC and line
voltage.
Defective AC adapter.
Replace AC adapter.
Clean Bar indicator
illuminated.
Process material fouling static
bar ion emitters.
Dirt build-up on ion emitters or
conductive contamination on face
of bar.
No static bar connected.
Bar ON indicator NOT
illuminated.
Static bar high voltage connector
is not connected.
Remove process material from
static bar.
Clean ion emitters and static
bar. See Maintenance section for
details.
Install static bar and connect to
power supply.
Turn off power, reconnect static
bar and secure plug with captive
screws.
Replace static bar high voltage
connector plug.
Separate static bar from grounded
metal.
Fault indicator
illuminated.
IQ Po w e r ™ H L
Static bar high voltage connector
missing bar type sense pin.
Static bar mounted too close to
grounded metal.
Damage to high voltage
connector.
Replace high voltage connector.
Damage to high voltage cable.
Replace static bar.
High voltage module inside
power supply faulty
Replace high voltage module.
19
5201201 Rev. C
9. REPLACEMENT PARTS
IQ Power™ HL Power Supply:
(no AC adapter)
(With AC adapter, 100/120V
AC Jap/ N.Amer. Cord)
(With AC adapter, 230V
AC N.Amer. Cord)
AC Adapter (100-240V
AC input, standard, 1.6A)
AC Adapter (100-240V
AC input, large, 3.75A)
Line Cord, 100/120V
AC Japan/ N. Amer.
Line Cord, North American 230V
AC
Part Number
4012508
4012509
4012510
4108104
4108774
4106272
4106274
Modular Cable (8-conductor, straight through wired, RJ-45) for
use between multiple IQ Power™ HL Power Supplies:
(0.91 meter [3 foot] white)
4520788
(2.13 meter [7 foot] white)
4520789
(4.27 meter [14 foot] white)
4520791
(7.62 meter [25 foot] white)
4520792
HL Junction Block
HL Conduit Seal
IQ Po w e r ™ H L
4012352
4108231
20
5201201 Rev. C
10. WARRANTY
This product has been carefully tested at the factory and is warranted to be free from
any defects in materials or workmanship. Simco-Ion will, under this warranty, repair
or replace any equipment that proves, upon our examination, to have become defective
within one year from the date of purchase.
The equipment being returned under warranty should be shipped by the purchaser to
Simco-Ion, 2257 North Penn Road, Hatfield PA 19440, transportation prepaid and insured
for its replacement cost. Prior to returning any goods for any reason, contact Simco-Ion
Customer Service at (215) 822-6401 for a Return Authorization Number. This number
must accompany all returned items.
This warranty does not apply when the equipment has been tampered with, misused,
improperly installed, altered, has received damage through abuse, carelessness, accident,
connected to improper line voltage, or has been serviced by anyone other than an
authorized factory representative.
The warranty does not apply when Simco-Ion parts and equipment have been energized
by other than the appropriate Simco-Ion power supply or generator, or when a SimcoIon power supply or generator has been used to energize other than Simco-Ion parts
and equipment. Simco-Ion makes no warranty, expressed or implied, nor accepts any
obligation, liabilities, or responsibility in connection with the use of this product other than
the repair or replacement of parts stated herein.
IQ Po w e r ™ H L
21
5201201 Rev. C
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IQ Po w e r ™ H L
22
5201201 Rev. C
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IQ Po w e r ™ H L
23
5201201 Rev. C
Simco-Ion
2257 North Penn Road
Hatfield, PA 19440
(215) 822-6401
(800) 203-3419
www.simco-ion.com
[email protected]
© 2013 Simco-Ion. Printed in the U.S.A.
IQ Po w e r ™ H L
5201201 Rev. C
IQ Power™ IQ HLC Power Supply
and Remote Display Module
Associated Equipment for the IQ Power™ HL
Static Bar
INSTALLATION AND OPERATING INSTRUCTIONS
IQ Power™ HLC Power Supply
and Remote Display Module
5201200 Rev. C
TABLE OF CONTENTS
1. SAFETY WARNINGS............................................................................. 1
2. INTRODUCTION.................................................................................. 2
Features..................................................................................................................................2
3. SPECIFICATIONS................................................................................. 3
4. INSTALLATION................................................................................... 4
Mounting the Power Supply..................................................................................................4
Mounting the Remote Display Module.................................................................................4
Electrical Connections...........................................................................................................5
5. OPERATION.....................................................................................15
Remote Display Module Indicators.....................................................................................15
Remote Display Module Start-Up.......................................................................................15
System Start-up...................................................................................................................16
Power Supply Number (Address)........................................................................................17
6. MAINTENANCE..................................................................................19
Cleaning the Static Bar........................................................................................................19
7. TROUBLESHOOTING ..........................................................................20
8. REPLACEMENT PARTS.........................................................................21
9. WARRANTY......................................................................................22
IQ Power™ HLC Power Supply
and Remote Display Module
i
5201200 Rev. C
1. SAFETY WARNINGS
Simco-Ion recommends that these instructions be read completely before installation or
operation is attempted. Failure to do so could result in personal injury and/or damage to
the equipment.
NOTE! – Statements identified with NOTE indicate precautions necessary to avoid
potential equipment failure.
CAUTION! – Statements identified with CAUTION indicate potential safety hazards.
WARNING! – Statements identified with WARNING indicate potential serious injury
hazards.
NOTE! – This equipment must be correctly installed and properly maintained.
Adhere to the following notes for safe installation and operation:
1. Read instruction manual before installing or operating equipment.
2. Only qualified service personnel are to perform installation and repairs.
3. All equipment must be properly grounded, including the machine frame to which the
equipment is mounted.
4. Disconnect input power to Power Supply before connecting or disconnecting static
neutralizing bars to the high voltage Power Supply.
CAUTION! – This product is intended to be supplied by a Listed AC Adapter or
Power Unit marked “Class 2” or “LPS” and rated output 24V , 3.75A.
CAUTION! – Electrical Shock Hazard
Disconnect input power to the Power Supply before connecting or disconnecting static
neutralizing bar or performing any maintenance to the system. Avoid touching static
neutralizing bar when power supply is energized.
WARNING! – Fire Hazard
Do not install or operate the Remote Display Module in close proximity to any flammable
liquids or solvents.
WARNING! – Substitution of components may impair intrinsic safety. (See
Figure 3a & 3b)
IQ Power™ HLC Power Supply
and Remote Display Module
1
5201200 Rev. C
2. INTRODUCTION
Simco-Ion’s IQ Power™ HLC Power Supply and Remote Display Module provide
microprocessor controlled high voltage DC output to the static bar. The high voltage
causes the ionizing pins on the static bar to generate positive and negative ions. The
electric field from the static charge on the material being processed will attract opposite
polarity ions from the static bar causing the material to be neutralized. The excess ions
will either recombine in air or dissipate to ground.
The IQ Power™ HL static bar is tailored to the application. Speed bars are optimized to
operate on high speed webs at distances of 50 to 230 millimeters [2 to 9 inches]. Hybrid
bars operate at distances of 150 to 460 millimeters [6 to 18 inches] on webs where the web
path is somewhat variable.
The IQ Power™ HLC Power Supply is agency approved for mounting within hazardous
locations:
• Class I, Division 1, Group D
• Class II, Division 1, Groups F and G
• Class III, Division 1
Features
• Single momentary push-button calibration simplifies set-up.
• Bar graph display indicates ionizing performance of system.
• Indicators display status of neutralizing system, power, service required and
detection of system faults.
• Relay contact output “echoes” indicators for remote sensing and alarm.
IQ Power™ HLC Power Supply
and Remote Display Module
2
5201200 Rev. C
3. SPECIFICATIONS
IQ Power™ HLC Power Supply
Input Power:
24V
DC, 1.5A from AC adapter
Output Voltage:
+/-7kV
+/-8kV
Dimensions:
388mmL x 235mmW x 159mmH
[15.25”L x 9.25”W x 6.25”H]
Weight:
14.5 kg [32 lb]
Max. Operating Temp:
43°C [110°F] maximum
Housing:
Cast Aluminum
“Speed Bar”
“Hybrid Bar”
IQ Power™ Remote Display Module
Input Power:
24V
, 2.0A (maximum system current)
Dimensions:
202L x 123W x 58H mm
[7.95”L x 4.85”W x 2.28”H]
Weight:
0.7 kg [1.5 lb]
Operating Temp:
43°C [110°F] maximum
Enclosure:
Aluminum, blue polyester powder coated
AC Adapter
Type
“Universal” desktop
Input Power:
100–240V
AC 50/60Hz input
(IEC 320 inlet)
Output:
24V
Dimensions:
132mmL x 60mmW x 34mmH
5.19”L x 2.36”W x 1.34”H]
Weight:
0.45 kg [1.0 lb]
Housing:
Thermoplastic, black
IQ Power™ HLC Power Supply
and Remote Display Module
DC, 3.75A maximum
3
5201200 Rev. C
4. INSTALLATION
Mounting the Power Supply
A. Locate at a convenient place within reach of the static bar high voltage cable.
Note the Power Supply is agency listed for mounting within hazardous (classified)
locations (see Figure 3a & 3b).
B. Secure to the mounting surface (commonly a machine frame) using M10 [3/8”]
hardware (not supplied).
NOTE! – Do not apply line voltage to the AC adapter until installation is
complete. Also ensure that all input power switches are in the OFF (0) position.
Mounting the Remote Display Module
A. Locate at a convenient place within reach of the power supply cable. Power for the
AC adapter and an electrical ground connection must be available.
B. Secure to the mounting surface (commonly a machine frame) using M5 or M4 [#10
or #8] hardware (not supplied).
WARNING! – Do not install The Remote Display Module within hazardous
(classified) locations. Install in non-hazardous (unclassified) locations only (see
Figure 3a & 3b).
IQ Power™ HLC Power Supply
and Remote Display Module
4
5201200 Rev. C
Electrical Connections
A. Ground the Power Supply by connecting a ground
lead between the metal conduit to the Power Supply
and a good electrical machine ground. Note that
conduit seals must be properly installed to prevent
the propagation of vapors and flames through conduit
runs (see Figure 1). Outer jacket of modular cables
must be removed (and individual wires separated)
before filling conduit seals with cement.
B. Connect static bar by cutting the high voltage cable
to length, terminating the leads, and connecting to the
Power Supply: (See Figure 2)
1. Strip black plastic jacket back 3¼” (being careful
Figure 1. Conduit Seal
not to nick the insulation of the HV wires) and
strip insulation of HV wires back 1” using a wire
stripper (being careful not to nick the conductor of the HV wire).
2. Straighten conductors and insert into HV connector until conductor protrudes
out from the tip of the connector.
3. Solder conductor to tip of connector by applying solder to exposed conductor.
Ensure that solder does not overflow and fill neck area of tip.
4. Trim off excess conductor protruding from tip of connector.
Figure 2. High Voltage Cable Terminations
5. Plug connectors into sockets labeled HV1 or HV2 on the Power Supply.
CAUTION! – Shock Hazard
Do not connect static neutralizing bar with Power Supply energized. Disconnect input
power or switch power off before connecting static bar.
IQ Power™ HLC Power Supply
and Remote Display Module
5
5201200 Rev. C
Figure 3a. IQ Power™ HLC-SPEED Control Drawing
IQ Power™ HLC Power Supply
and Remote Display Module
6
5201200 Rev. C
IQ Power™ HLC Power Supply
and Remote Display Module
7
5201200 Rev. C
IQ Power™ HLC Power Supply
and Remote Display Module
8
5201200 Rev. C
Figure 3b. IQ Power™ HLC-HYBRID Control Drawing
IQ Power™ HLC Power Supply
and Remote Display Module
9
5201200 Rev. C
NOTE! – Failure to fully seat the high voltage connectors into the Power Supply
connectors may result in permanent damage to the bar, cable or Power Supply.
C. Connect Remote Display Module. Plug one end of modular cable into one of the
Power Supply “PS COMM1” jacks. Run the cable through rigid metal conduit (see
Figure 3) to the Remote Display Module. Plug the other end of the cable into the
“RDM COMM2” jack.
D. Connect Power Supply alarm output (if used). The Remote Display Module
“Alarm Output” is a standard DB25 pin connector. A maximum distance of 3 meters
[10 feet] or less is recommended. The Remote Display Module alarm output provides
a variety of dry relay contact outputs that indicate the status of the power supply. The
relay contacts are rated for a maximum of 1A at 30V . The alarm output connector
also provides a means of remote power in. (See Figure 5)
E. Remote On/Off Control (if used). The Remote Display Module “Alarm Output”
connector also provides for remote on/off control of the Power Supply. Remote on/
off control is configured with a jumper on a pin header on the main Remote Display
Module circuit board. The default configuration is with the remote control disabled.
The remote control can be configured “normally off” or “normally on” by the jumper
setting (see Figure 6). To access the jumper the cover will have to be removed from
the Remote Display Module. Disconnect all input power, then remove the six screws
securing the cover and slowly and carefully remove the cover.
There is a ribbon cable connecting the face label on the cover to the main circuit
board. Use care not to disconnect this cable. If the cable becomes disconnected, lift
the latches on the sides of the ribbon cable connector, insert the ribbon cable fully
into the connector and press the latches back down.
Reposition the jumper to enable the remote control either “normally on” or “normally
off”, as desired (see Figure 6). Then replace the cover and secure with the six screws.
When operating a Power Supply using the remote control circuit, power may be
applied through the “Alarm Output” connector or the “Power In” connector on the
end panel. If the “Power In” connector on the end panel is used, the “Power” switch
must be set to the ON (1) position. Remote control is established by applying 24V
to the “Alarm Output” connector pins as specified in Figure 6. The user-applied
24V
drives a low current optoisolator on the main circuit board, turning the Power
Supply on or off, depending on the configuration of jumper J3.
IQ Power™ HLC Power Supply
and Remote Display Module
10
5201200 Rev. C
Figure 4. Interconnection Block Diagram
IQ Power™ HLC Power Supply
and Remote Display Module
11
5201200 Rev. C
Pin
Description
1
Remote on/off optocoupler (-)
14
Remote on/off optocoupler (+)
Pin
Description
10
No connection
6
No connection
19
No connection
2
Clean Bar Relay (common)*
11
Power Relay (common)*
3
Clean Bar Relay (norm close)*
7
Power Relay (normal closed)*
16
Clean Bar Relay (norm open)*
20
Power Relay (normally open)*
8
Fault Relay (common)*
4
Fault Relay (normally closed)*
12
Power in (ground)**
17
Fault Relay (normally open)*
24
Power in (ground)**
9
Bar On Relay (common)*
13
Power in (+24V
5
Bar On Relay (normal closed)*
25
Power in (+)**
18
Bar On Relay (normally open)*
)**
*30V 1A Rating on Contacts
**1.6A Rating, Connect pins 12 & 24 in parallel and 13 & 25 in parallel
Figure 5. Alarm Output Connections
IQ Power™ HLC Power Supply
and Remote Display Module
12
5201200 Rev. C
Figure 6. Jumper Position at J3 for Remote Control Operation
F. Connect other Power Supplies (if used). IQ Power™ HLC Power Supplies can
be connected together via a “data buss”. The data buss allows one IQ Power™
Communication Module to serve multiple IQ Power™ HLC Power Supplies and
feed the data from all Power Supplies into the network. A total of 10 Power Supplies
may be chained together on one data buss. Special cables for the data buss must
be 8-conductor modular cables with RJ-45 connectors wired “straight through”
(reference color: white).
If multiple 1Q Power BPS power supplies are connected together, each power
supply must be given a unique address. This is necessary to enable reliable digital
communication. The power supplies should each be given a unique address prior
to connection with the “data buss” (the chaining together of power supplies). See
section 6.3 Power Supply Number (address) for details on re-addressing the power
supplies.
Note that each Power Supply requires its own Remote Display Module. The modular
cable plugs into either “RDM COMM 1” connector on a Remote Display Module
and chains to the next Remote Display Module where it again plugs into either “PS
COMM 1” connector. Each Remote Display Module then connects to one, and only
one, Power Supply.
IQ Power™ HLC Power Supply
and Remote Display Module
13
5201200 Rev. C
G. Connect AC Adapter (make sure “POWER” switch on Remote Display Module is in
the “OFF” (0) position). Route low voltage wire clear of moving machine parts and
protect it from abrasion. Secure using nylon wire ties (not supplied). Do not over
tighten. Insert barrel connector into “POWER IN” connector on the Remote Display
Module. Hand tighten barrel connector nut to secure.
Connect line voltage to input side of AC adapter. The AC adapter is a universal input
type that accepts line voltage from 100 to 240V
50/60 Hz. The AC adapter line
voltage connector accepts a line cord with an IEC 320 connector (supplied). The
line cord also provides electrical ground to the AC adapter. Check electrical ground
integrity in the line voltage receptacle used for the AC adapter. This ground must not
be defeated.
H. Connect user supplied power (if used). In cases where the user does not want to use
the AC adapter but wants to supply 24V
power to the IQ Power™ HLC Power
Supply, user supplied 24V
power may be applied two ways.
The “Power In” connector on the end panel of the IQ Power™ Remote Display
Module may be used to supply power to the system. This connector requires the
use of a Switchcraft 760K barrel type power plug. The plug should be wired +24V
to center and common (ground) to outer barrel. The common must be bonded to
electrical ground. Wired in this fashion, the “Power” switch on the end panel of the
Remote Display Module is in circuit.
Alternatively, the “Alarm Output” connector on the end panel of the IQ Power™
Remote Display Module may be used to supply power to the system. This connector
requires the use of a standard DB25 connector. The connector should be wired:
• +24V
to pins 13 & 25
• Common (ground) to pins 12 & 24
To ensure current carrying capacity, two pins are used for each connection. The
common must be bonded to ground. Wired in this fashion, the “Power” switch on the
end panel of the Remote Display Module is bypassed (see Figure 5).
Power supplied in the above fashion must have adequate current available to power
all components on the system (maximum 4A). Input power should be appropriately
fused for safety purposes.
IQ Power™ HLC Power Supply
and Remote Display Module
14
5201200 Rev. C
5. OPERATION
NOTE! – Before switching on Power Supply; ensure that units are properly
grounded and that static bar & probes are properly installed.
Remote Display Module Indicators
Power: Lights (green) to indicate power is on and the IQ Power™ HLC Power Supply is
ready to operate.
Comm: Lights (green) to indicate digital communication is established with an
IQ Power™ Communication Module or Control Station. The COMM light will
flicker to indicate communication activity.
Bar On: Lights (green) to indicate when the static neutralizing bar is active.
Fault: Lights (red) to indicate faulty condition of static bar, power supply or high voltage
connections. Power will have to be turned off to clear the fault. When fault is cleared and
power is restored, the fault light will be extinguished.
Clean Bar: Lights (yellow) to indicate need to clean static bar. Clean Bar indicator may
light with low ion output (dirt build-up on ion emitters) or high output current (conductive
contamination on face of bar).
Mode: The indicator next to the type of power supply connected will light (green).
“Speed” or “Hybrid” will be indicated.
The Output indicators (along with the Mode indicators) also indicate the RDM Address
during start-up of the power supply.
Output: The output indicators range from “Low” to “High” in 10 steps (2-red, 3-yellow,
5-green) and light to indicate the system relative ion output. The output will normally be
in the high range. Low output generally indicates the need to clean the static bar.
Remote Display Module Start-Up
Calibrate: Is a momentary push button switch located on the face label. Pressing the face
label firmly on “Calibrate” initiates the calibration sequence and sets the relative nominal
ion output for the system.
The Calibrate button is also used to change the RDM number. This number is used in
software to identify the Remote Display Module and Power Supply in systems that contain
multiple Power Supplies and include an optional Communication Module or monitoring
device. The Calibrate button is also used to reset the unit to factory default settings.
IQ Power™ HLC Power Supply
and Remote Display Module
15
5201200 Rev. C
System Start-up
A. Apply line voltage to the AC adapter.
B. Move the Remote Display Module “Power” switch to the “On” (1) position.
C. The Remote Display Module indicators will briefly self-test during which all will
light.
D. Immediately after the self-test, the RDM numbers will be briefly displayed. (see 6.3
Power Supply Number)
E. After the RDM Address displays, the Remote Display Module indicators will settle
to display the system status.
On new systems the output indicator will settle to display low output, initial calibration
must be performed.
NOTE! – Calibration should be performed when the system is first installed and
may be performed after the static bar has been cleaned and the system verified as
operating correctly.
F. If the system is new, perform an initial calibration. The initial calibration sets the
relative nominal ion output for the system. Calibration should only be performed on
IQ Power™ HLC systems that are new or just cleaned and known to be in proper
working order.
During calibration the target to be neutralized (web, film, etc.) may remain in place, but
MUST NOT BE MOVING. If the web is moving past the static bar (e.g. the machine is
in operation) the calibration may be faulty.
Press the face label on the Remote Display Module firmly on the word “Calibrate”. This
will initiate the calibration sequence and set the relative nominal ion output for the system.
During calibration the system output will be cycled and the three mode lights
will illuminate. At completion of calibration the speed and distance lights will
flicker. The indicated ion output will be high. The calibration sequence takes less than
one minute.
The calibration data is stored in non-volatile memory and used on subsequent power ups.
IQ Power™ HLC Power Supply
and Remote Display Module
16
5201200 Rev. C
6.3 Power Supply Number (Address)
Each IQ Power™ RDM has two numbers associated with it. These numbers
serve to identify RDM and power supply pair in digital communications. One
number is the IQ Power™ / Performax IQ RDM address, which can be a number
of 1 through 10 (the default is “1”). The other number is the Ion Power Station
number, which can be a number of 1 through 30 (the default is “30”).
When the IQ Power™ RDM is first turned on it will illuminate all LED indicators
as a self test. Then it will briefly display first the IQ Power™ / Performax IQ
address in steadily lit indicators and then it will display the Ion Power station
number in flashing indicators. See the following table for interpreting the
address numbers.
Power Supply Number Table
IQ Power/
Performax IQ
RDM address
1 (default)
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
1
Ion Power
Station
number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30 (default)
IQ Power™ HLC Power Supply
and Remote Display Module
OUTPUT
LED
illuminated
LOW (1)
2
3
4
5
6
7
8
9
(none)
LOW (1)
2
3
4
5
6
7
8
9
(none)
LOW (1)
2
3
4
5
6
7
8
9
(none)
17
SPEED
MODE
LED
On
On
On
On
On
On
On
On
On
On
On
On
On
On
On
On
On
On
On
On
On
HYBRID
MODE
LED
On
On
On
On
On
On
On
On
On
On
On
DISTANCE
MODE
LED
On
5201200 Rev. C
Adjusting the power supply number is only necessary in systems with multiple power
supplies daisy chained to a Communication Module or monitoring device. Having
multiple power supplies with the same numbers connected to a Communication Module
or monitoring device is not permitted.
To adjust the power supply number, turn the unit on and wait for the LED self-test to
complete. The COMM light will briefly stay lit and the power supply number may be
adjusted at this time. Press and hold the Calibrate button until the power supply number
increments by one (5 second window). Subsequent presses of the Calibrate button will
increment the power supply numbers (5 second window). The Ion Power station number
will be displayed and the IQ Power™ / Performax IQ HL PS address will “map” as shown
on the Power Supply Number Table. The incrementing “wraps around”. Stop pressing
the Calibrate button when the desired power supply numbers have been reached. Wait
5 seconds, the COMM light will go out and the Speed and Distance LEDs will flicker,
indicating the power supply numbers have been saved.
To reset the unit to its factory default power supply numbers (see Power Supply Number
Table), press and hold the Calibrate button while turning the unit on. Continue holding
down the Calibrate button while the Output indicators “count-up” and when the COMM
light starts flashing, then release the Calibrate button. When just the Speed and Distance
LED flicker, the default power supply numbers (address = ”1”, station number = ”30”)
are saved.
IQ Power™ HLC Power Supply
and Remote Display Module
18
5201200 Rev. C
6. MAINTENANCE
NOTE! – Only qualified service personnel are to perform maintenance tasks.
CAUTION! – Electrical Shock Hazard. Turn off Power Supply before
cleaning bar or performing any maintenance on the system.
The accumulation of contamination on the ionization emitter points and static bar
surfaces will reduce neutralizing efficiency of the bar, therefore it is recommended that
maintenance of the system be performed when the Clean Bar indicator on the display
module illuminates or every three weeks, whichever comes first. Dirty environments may
require more frequent cleaning. Maintenance should be performed by qualified service
personnel only.
Cleaning the Static Bar
A clean brush with nylon bristles should be used to keep the ionization emitter points of
the static bar clean. Periodic use of the brush will prevent deposits from accumulating on
the points. The emitter points must remain sharp for optimum operation.
NOTE! – Do not scrape points with any hard or sharp object that may damage
points.
A.
B.
C.
D.
Turn off power supply.
Remove dirt particles deposited on the static bar with a dry, stiff nylon bristle brush.
Blow off the static bar with clean, dry compressed air.
Remove resistant coatings deposited on static bar by wiping with isopropyl alcohol
or mineral spirits applied to a clean cloth. Apply isopropyl alcohol or mineral spirits
to a stiff nylon bristle brush and thoroughly scrub the ionization emitter channels of
the bar.
E. Blow static bar dry with clean, dry compressed air and ensure the bar is completely
dry before re-applying power to the bar.
NOTE! – Do not soak static bar or related components in alcohol or mineral
spirits. Do not use harsh solvents such as lacquer thinner, naphtha or acetone.
IQ Power™ HLC Power Supply
and Remote Display Module
19
5201200 Rev. C
7. TROUBLESHOOTING
Problem
Power indicator
NOT illuminated
Clean Bar
indicator
illuminated
Bar ON indicator
NOT illuminated
Fault indicator
illuminated
Cause
Solution
Power not on at remote display
module
Turn on Power switch on end of
remote display module case
Poor electrical connections
Check input power connections,
both 24V
and line voltage
Defective AC adapter
Replace AC adapter
Process material fouling static
bar ion emitters
Remove process material from
static bar
Dirt build-up on ion emitters or
conductive contamination on
face of bar
Clean ion emitters and static
bar. See Maintenance section
for details
No static bar connected
Install static bar and connect to
power supply
Static bar high voltage connector
is not connected
Turn off power and reconnect
static bar
Static bar mounted too close to
grounded metal
Separate static bar from
grounded metal
Damage to high voltage
connector
Replace high voltage connector
Damage to high voltage cable
Replace static bar
High voltage module inside
power supply faulty
Replace high voltage module
IQ Power™ HLC Power Supply
and Remote Display Module
20
5201200 Rev. C
8. REPLACEMENT PARTS
Description
Part Number
IQ Power™ HLC Replacement Power Supplies
SPEED (for use with HL Speed Bars only)
4110350
HYBRID (for use with HL Hybrid Bars only)
4110351
IQ Power™ Remote Display Module (no AC adapter)
4011593
AC Adapter (100-240V
input, standard 1.6A)
4108104
AC Adapter (100-240V
input, large 3.75A)
4108774
, Japan/North America)
4106272
Line Cord (100/120V
Line Cord (230V
4106274
, North America)
Modular Cable (8-conductor, cross-over wired, RJ-45) for use between
IQ Power™ Remote Display Module and IQ Power™ HLC Power Supply
0.91m [3 ft] black
4520785
2.13m [7 ft] black
4520786
4.27m [14 ft] black
4520787
7.62m [25 ft] black
4520784
Modular Cable (8-conductor, straight through wired, RJ-45) for use
between multiple IQ Power™ Remote Display Modules
0.91m [3 ft] white
4520788
2.13m [7 ft] white
4520789
4.27m [14 ft] white
4520791
7.62m [25 ft] white
4520792
HL Junction Block
4012352
HL Conduit Seal
4108231
IQ Power™ HLC Power Supply
and Remote Display Module
21
5201200 Rev. C
9. WARRANTY
Simco-Ion equipment has been carefully tested and inspected at the factory and is warranted
to be free of defects in material, workmanship. Simco-Ion will, under this warranty, repair
or replace any equipment which proves, upon our examination, to have become defective
within the Warranty period from the date of purchase. A one-year Warranty applies to all
Simco-Ion equipment. A six-month Warranty applies to Eltex equipment. Equipment is to
be returned by the purchaser to Simco-Ion, 2257 North Penn Road, Hatfield, Pennsylvania,
19440, transportation pre-paid and insured for its full purchase price. Prior to returning
goods for any reason, contact Simco-Ion for an Authorized Return Number. This number
must accompany all returns. The Warranty does not apply when the equipment has been
tampered with, misused, improperly installed, altered, been damaged through abuse,
carelessness, accident, connected to improper line voltage, or has been serviced by anyone
other than an authorized factory representative.
The Warranty does not apply when Simco-Ion parts and equipment have been energized
by other than the appropriate Simco-Ion power supply or generator, or when Simco-Ion
power supplies or generators have been used to energize other than Simco-Ion parts and
equipment.
Simco-Ion makes no warranty, expressed or implied, not accepts any obligation, liabilities
or responsibility in connection with the use of these products other than the repair or
replacement of parts as stated herein.
IQ Power™ HLC Power Supply
and Remote Display Module
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5201200 Rev. C
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IQ Power™ HLC Power Supply
and Remote Display Module
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and Remote Display Module
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IQ Power™ HLC Power Supply
and Remote Display Module
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5201200 Rev. C
Simco-Ion
2257 North Penn Road
Hatfield, PA 19440
(215) 822-6401
(800) 203-3419
www.simco-ion.com
[email protected]
© 2013 Simco-Ion Printed in the U.S.A.
IQ Power™ HLC Power Supply
and Remote Display Module
5201200 Rev. C