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ITW Simco-Ion IQ Power Installation And Operating Instructions Manual

Static neutralizing system with bps power supply
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IQ Power
™
Static Neutralizing System
with BPS Power Supply
INSTALLATION AND OPERATING INSTRUCTIONS
I Q Power™ B PS
5 20 11 97 Re v. D

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Summary of Contents for ITW Simco-Ion IQ Power

  • Page 1 IQ Power ™ Static Neutralizing System with BPS Power Supply INSTALLATION AND OPERATING INSTRUCTIONS I Q Power™ B PS 5 20 11 97 Re v. D...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS 1. SAFETY WARNINGS ................1 2. DESCRIPTION ................... 2 Features ..........................3 4. SPECIFICATIONS ................4 5. INSTALLATION .................. 6 Initial Considerations ......................12 Mounting the Static Neutralizing Bar ................13 Mounting the Power Supply ....................14 Mounting the Communication Module (optional) .............14 Electrical Connections ......................14 6.

  • Page 3: Safety Warnings

    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.

  • Page 4: Description

    2. DESCRIPTION Simco-Ion’s IQ Power™ Static Neutralizing System consists of a high voltage power supply, static neutralizing bar, and optional web speed encoder, optional control station and/or optional computer communication module. The IQ Power™ static bar is available in three different types; tailored for high speed processes, operating at a distance from the material or intermediate (hybrid) applications.

  • Page 5: Features

    Features • Three types of IQ Power™ static neutralizing bars are available to suit the specific application. • Static bar disconnect plug pre-installed on static bar cable for quick and easy installation. Plug also identifies bar type to power supply automating power supply set-up. • Single momentary push-button calibration simplifies set-up. • Ionization emitter points current limited to enhance operator safety. • Ionization emitter points of special alloy to extend operating life of emitter points. • Continuous “T” slot at back of static bar and mounting brackets for easy and flexible installation. • Bar graph display on power supply indicates ionizing performance of system. • Indicators on power supply display status of neutralizing system, power, service required and detection of system faults. • Relay contact output “echoes” indicators on power supply for remote sensing and alarm.

  • Page 6: Specifications

    4. SPECIFICATIONS High Voltage Power Supply Input Power VDC, 1.5A from AC adapter BPS Basic Power Supply +/-7 kV “Speed Bar”; +/-9 kV “Hybrid Bar”; Output Voltage +/-12 kV “Distance Bar” Dimensions 202L x 123W x 106H mm [7.95”L x 4.85”W x 4.17”H] Weight 1.94 kg [4.28 lb] Operating Temp...
  • Page 7 AC Adapter Type “Universal” desktop Input Power 100-240V 50/60Hz input (IEC 320 inlet) Part Number 4108774 4108104 Output , 3.75A maximum , 1.6A maximum 132L x 60W x 34H mm 87L x 51W x 33H mm Dimensions [5.19”L x 2.36”W x 1.34”H] [3.43”L x 2.00”W x 1.30”H] Weight 0.45 kg [1.0 lb]...

  • Page 8: Installation

    5. INSTALLATION Mounting Mounting Hardware Bracket Perforated Strip High Voltage Cable Static Bar Figure 1. IQ Power™ Static Bar Installation Static Mounting Bracket Set Screws Hex Key Wrench Figure 2. IQ Power™ Static Bar Bracket I Q Power™ B PS 5 20 11 97 Re v.
  • Page 9 17.8mm [0.7"] Speed Bar 25.4mm [1.0"] Hybrid Bar 33.0mm [1.3"] Distance Bar Bar Type Sense Pin to IQ Power Static Bar High Voltage Connectors Captive Screws Figure 3. IQ Power™ High Voltage Connector IQ Power BPS IQ Power Static Bar High Voltage Cable Line Cord Power In Connector...
  • Page 10 NOTE – DO NOT USE standard Ethernet cables with IQ Power systems. Avoid permanent equipment damage by using only Simco-Ion modular cables. (Refer to Section 8, Accessories and Parts). TOP VIEW SIDE VIEW WIRING DIAGRAM Figure 5a. IQ Power Crossover Modular Cable TOP VIEW SIDE VIEW WIRING DIAGRAM...
  • Page 11 Figure 6. IQ Power™ Connections (Bar, Power Supply, and Communication Module) IQ Power BPS Web Speed Encoder and Wheel Kit P.N. 5051766 IQ Power Static Bar PS COMM 2 Ground Lead Line Cord AC Adapter Figure 7. IQ Power™ Connections (Bar, Power Supply and Web Speed Encoder) I Q Power™...
  • Page 12 IQ Power BPS IQ Power Static Bar 24 VDC to PS COMM 1 Connection IQ Power IQ Power BPS Communication Module Web Speed Encoder and Wheel IQ Power Static Bar 24 VDC Power In Connector to PS COMM 2 to PS COMM 1 Line Cord Connection Connection...
  • Page 13 Description Description Remote on/off optocoupler (-) No connection Remote on/off optocoupler (+) No connection No connection Clean Bar Relay (common)* Power Relay (common)* Clean Bar Relay (norm close)* Power Relay (normal closed)* Clean Bar Relay (norm open)* Power Relay (normally open)* Fault Relay (common)* Fault Relay (normally closed)* Power in (ground)** Fault Relay (normally open)* Power in (ground)** Bar On Relay (common)* Power in (+24 VDC)** Bar On Relay (normal closed)* Power in (+24 VDC)** 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 10. IQ Power™ Power Supply Alarm Output Connections I Q Power™...

  • Page 14: Initial Considerations

    Remote On/Off Normally Off Normally On Disabled Opto High = Unit ON Opto High = Unit OFF Opto Low = Unit OFF Opto Low = Unit ON Figure 11. Jumper Position at J3 for Remote Control Operation Initial Considerations Installation starts with mounting of the static neutralizing bar. Static bars are typically installed just ahead of where problems due to static are occurring.

  • Page 15: Mounting The Static Neutralizing Bar

    Mounting the Static Neutralizing Bar CAUTION – Fire Hazard Do not install or operate static neutralizing bar in close proximity to any flammable liquids or solvents. A. Determine location for mounting the static bar. The static bar will typically be located just ahead of where problems due to static are occurring.

  • Page 16: Mounting The Power Supply

    E. The perforated strip may be installed on the mounting bracket at right angle to the bar or parallel to the bar. The perforated strip may be bent or twisted to suit the application and will hold its shape as installed. Once the static bar is loosely installed, tighten all hardware.
  • Page 17 Connect static bar(s) by plugging 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. See Bar and Power Supply Connections diagram. B. Static bar adapters (if existing Ion Power Bars are used). In cases where an existing Ion Power static bar is used, the HV connector will have to be adapted for connection to the IQ Power™ BPS.
  • Page 18 Remote on/off Control. The “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.
  • Page 19 Connect other Power Supplies (if used with communication module). IQ Power™ BPS power supplies can be connected together via a “data buss”. The data buss allows one computer communication module to serve multiple 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.
  • Page 20 Where the Control Station does not supply 24 VDC power to the BPS, the BPS will require its own AC adapter. In this case, plug the modular cable into one of the four connectors numbered 1 thru 4 and labeled “COMM ONLY” on the Control Station. See diagram for Power Supply and Control Station Connections. The modular cable should not be run parallel with the static bar high voltage cable.
  • Page 21 H. Connect to existing 8200 / 8300 / 8310 Ion Power system (if used). In cases where the unit is being used to replace or expand an existing Ion Ion Power 8115 Power system, 24V power may be received from the (24 VDC) Ion Power system.
  • Page 22 Connect to existing 8003 Virtual AC system (if used). In cases where the unit is being used to replace or expand an existing Virtual AC system, power cannot be received from the (24VAC) Virtual AC system. The connection to the Virtual AC system will provide for digital communication only.
  • Page 23 Direct connection to a personal computer (if used). In cases where direct connection to a computer was made (with Ion Systems cable 33-8100iP), this cable can be replaced with retrofit converter cable, P.N. 5051697. Figure 15. RS-485 Converter Cable T his cable plugs into PS COMM 1 on the IQ Power™ BPS and into the USB port on the personal computer.

  • Page 24: Operation

    6. OPERATION NOTE – Before switching on power supply; ensure units are properly grounded and static bar & probes are properly installed. Power Supply Indicators Power: Lights (green) to indicate power is on and the IQ Power™ system 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.

  • Page 25: System Start-Up

    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 a Communication Module or monitoring device. The Calibrate button is also used to reset the unit to factory default settings. System Start-up: A.

  • Page 26: Power Supply Number (Address)

    Power Supply Number (Address) Each IQ Power™ BPS 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 BPS 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”).

  • Page 27: Static Bar Operation

    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.

  • Page 28: Control Station Operation (Optional)

    Control Station Operation (optional) A. Move the control station module power switch to the ON (I) position. The control station module will include a full instruction manual (5201209). B. The control station will power up and begin running the system software automatically. C. From the home page, individual BPS power supplies can be accessed to check information and make setting adjustments to each power supply.

  • Page 29: Maintenance And Troubleshooting

    7. MAINTENANCE AND TROUBLESHOOTING NOTE – Only qualified service personnel are to perform maintenance tasks. NOTE – Never use hard or sharp objects to scrape ionization emitter points. CAUTION – Electrical Shock Hazard Turn off power supply before cleaning bar or performing any maintenance on the system.

  • Page 30: Troubleshooting

    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. They will damage the bar housing and epoxy. CAUTION – Fire Hazard Do not turn on power supply with any trace of alcohol or mineral spirits on the equipment.
  • Page 31 PROBLEM CAUSE SOLUTION Process material fouling static bar Remove process material from ion emitters. static bar. Clean Bar indicator Dirt build-up on ion emitters or illuminated. Clean ion emitters and static bar. conductive contamination on face See Maintenance section for details. of bar. Power not on at communication Turn on Power switch on end of module.

  • Page 32: Parts And Accessories

    8. PARTS AND ACCESSORIES Part Description Part Number BPS Power Supply (no AC adapter) 4011725 (With AC adapter, 100/120 VAC Jpn. / N. Amer. Cord) 4011726 (With AC adapter, 230 VAC N. Amer. Cord) 4011727 (With AC adapter, 230 VAC European Cord) 4012041 (With AC adapter, 230 VAC UK Cord) 4012042 AC Adapter (100-240 VAC input, standard, 1.6A) 4108104...
  • Page 33 Modular Cable (IQ Power 8-conductor, straight through wired, RJ-45) for use between IQ Power™ power supply and IQ Power™ power supply or for use between IQ Power™ control station and communication module “CM COMM2” DO NOT USE Standard Ethernet Cables (Figure 5b) 4520788 0.91 meter [3 foot] white 4520789...

  • Page 34: Warranty

    9. 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.
  • Page 35 (This page intentionally left blank.) I Q Power™ B PS 5 20 11 97 Re v. D...
  • Page 36 Simco-Ion 2257 North Penn Road Hatfield, PA 19440 (215) 822-6401 (800) 203-3419 www.simco-ion.com customerservice@simco-ion.com © 2014 Simco-Ion. Printed in the U.S.A. I Q Power™ B PS 5 20 11 97 Re v. D...

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