Related Manuals for Gema iONcharge 4.0
Summary of Contents for Gema iONcharge 4.0
- Page 1 V02/20 Installation and Operating Instructions Electrostatic charging system iONcharge 20 kV Translation of the original operating instructions...
- Page 2 To the best of our knowledge and belief, the information contained in this publication was correct and valid on the date of publication. Gema Switzerland GmbH makes no representations or warranties with respect to the contents or use of this publication, and reserves the right to revise this publication and make changes to its content without prior notice.
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Page 3: Table Of Contents
Overview of local multi-function LED: Functions ..........29 Description of LED functions ................. 29 Network Operation ....................31 Application information Basic layouts for charging applications ..............34 Example: Attaching to wrap ..............34 Table of contents • 3 iONcharge 4.0... - Page 4 Ambient conditions ....................38 Optical display/ device status/ error ..............38 Technical Service ....................39 APPENDIX Drawing ................... iONcharge 4.0: 20 kV Drawing ..............iONnet DIN Rail Distributor plate Connection diagram ................Stand-alone Connection diagram ............... Supply network 24 V Connection diagram ............
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Page 5: Introduction
A single charging applicator or a combination of positive negative applicators can be used for “pinning” or “tacking” together sheets and webs of film or paper. Introduction • 5 iONcharge 4.0... -
Page 6: Versions
The ATEX certified version of the iONcharge-4.0 system guarantees the highest safety levels for usage in potentially explosive environments – refer to version table. 6 • Introduction iONcharge 4.0... -
Page 7: Advantages
Control of compound solutions via Can-Bus and iONcontrol Touch Panel – The emitter pins are decoupled from the high voltage using resistors – All electrical connections are fail safe, vibration-proof plugs in housing protection type IP 54. Introduction • 7 iONcharge 4.0... -
Page 9: Safety Instructions
Any use not described this manual as well as changes to the hardware are not permitted. ► Only original spare parts delivered by Gema Switzerland GmbH may be used for maintenance and repair of the systems! Installation and commissioning of the system need to fulfill all local safety standards and instructions for safe use. -
Page 10: Safety Symbols (Pictograms)
V02/20 Safety symbols (pictograms) The following contains a list of warnings with their meanings found in the Gema operating instructions. Apart from the regulations in the relevant operating instructions, the general safety precautions must also be followed . DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury. -
Page 11: During Normal Operation
Technology. An application engineer is available to assist in the assessment of whether the use of electrostatic charging equipment is suitable. High voltage operation (green LED lights up permanently) should only be active when it is required for the application. Safety Instructions • 11 iONcharge 4.0... -
Page 12: During Installation And Removal
WARNING Danger of electric shock ► Keep charging bars wired to ground at all times while the system is operational regardless of whether the 24 VDC power supply is operational or not. 12 • Safety Instructions iONcharge 4.0... -
Page 13: During Charging Bar Cleaning
It is not possible to specify a common figure of the ozone concentration during usage. – If the ozone concentration becomes an issue at a specific workstation, on-site measurement has to be taken and adequate ventilation must be provided. Safety Instructions • 13 iONcharge 4.0... -
Page 15: User Duties
► All installation and repair work must be performed by qualified technicians! Authorized and trained personal ► Assembly, commissioning and maintenance of the iONcharge system may only be performed by trained and qualified personnel User Duties • 15 iONcharge 4.0... - Page 16 ► If the iONcharge system needs to be removed from the point of use, switch off the power supply. ► If the power plug needs to be removed, ensure safe grounding of the system on the ground terminal next to the bus system. 16 • User Duties iONcharge 4.0...
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Page 17: Storage, Transport And Packaging/Unpacking
– Accessories – Correct manual In case of incorrect deliveries or questions, please contact your local representative or Gema Switzerland GmbH. Follow local instructions for package material disposal. User and working safety prior to commissioning WARNING Danger of electric shock ►... -
Page 18: Installation And Commissioning
Damage to components Use a brass brush for cleaning in order to avoid damage and scratches. ► This should preferably have a curved handle in order to avoid injuries to the hand from the emitter pins. 18 • User Duties iONcharge 4.0... -
Page 19: Mechanical Installation
Ensure that there is no ground nearby pins beside the ground needed for the charging application. Mounting bars and parts must be behind the electrode and minimum 2 x the distance from pin to substrate as shown in Fig. 2. fig. 2 Mechanical Installation • 19 iONcharge 4.0... -
Page 20: Avoiding Loss Of Efficiency
V02/20 Avoiding loss of efficiency ATTENTION Ground near emission pins ► Ensure that there is no ground near the pins. > 2xd > 2xd fig. 3: 20 • Mechanical Installation iONcharge 4.0... -
Page 21: Mounting Options
Slide on clip M5 screw in T-slot fig. 4: Grub screw for position Screw set is part of delivery fixation (hexagon head screw DIN 4017 M5x25; plain washer DIN 125 M5; screw nut DIN 4032 M5) Mechanical Installation • 21 iONcharge 4.0... -
Page 23: Dimensions
Mounting option 1 at least 2 attachment screws per m + 1 Pro per additional m Mounting option 2 Freely slidable GRP brackets (at least 2 per m + 1 Pro per additional m) GL working width Dimensions • 23 iONcharge 4.0... -
Page 25: Electrical Connection
V02/20 Electrical Connection Connector specification Bus system connector, M12, 5-pin, easy and flexible adaptation for individual systems via "daisy chain" connection. fig. 6: Standard version fig. 7: 90 degree version: Option Electrical Connection • 25 iONcharge 4.0... -
Page 26: Description Of The Connections
(20 kV < 500 mA) Pin 3 CAN High Pin 4 CAN low Pin 5 WARNING Danger of electric shock ► Always ground using the ground stud! fig. 9: Connection to machine or plant mass / ground 26 • Electrical Connection iONcharge 4.0... -
Page 27: Use In Standalone Operation
= 24 VDC OFF Factory settings HV frequency range to 100 Hz max. output voltage 20 kV Operating mode AUTO Clean Bar Warning at 40% efficiency loss Clean Bar Alarm at 60% efficiency loss Electrical Connection • 27 iONcharge 4.0... -
Page 28: Use Of Pin1 Output: For Clean Bar Or System Error
In order to use the error output, PIN 1 must be connected via a 680-Ohm resistor to the 24 V power supply. R = 680 Ohm / 2 W 24 V = System OK 0 V = System fault 28 • Electrical Connection iONcharge 4.0... -
Page 29: Overview Of Local Multi-Function Led: Functions
(contamination) System efficiency has dropped from originally 100 % to 60 %. This mode shows that the contamination of the bar has reached the ALARM set alarm value. (Factory setting = 60 %) (contamination) Electrical Connection • 29 iONcharge 4.0... - Page 30 CAN "hard-beat". If there is no BUS available, the system automatically switches to the initialization state and activates the charge. This mode shows that the charge electrode has been installed to close Check Installation to a ground / machine ground. 30 • Electrical Connection iONcharge 4.0...
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Page 31: Network Operation
T-connector to T-connector. – See network layout drawings. 5 m maximum. For detailed information on the wiring of the individual options, please refer to the drawings attached to this manual. Electrical Connection • 31 iONcharge 4.0... -
Page 33: Application Information
V02/20 Application information With the iONcharge 4.0 charging system, it is possible to automate and control a wide range of industrial processes through targeted charging. This includes fully automatic roll changes without gluing, blocking and adhesion of materials, improvement of print quality, targeted application of aerosols and coatings, fixation of web materials and much more. -
Page 34: Basic Layouts For Charging Applications
Example: Cooling roll adhesion The charging bar is located opposite the grounded cooling roller. As a result of the electric field, the material band will stick to the grounded roller. 34 • Application information iONcharge 4.0... -
Page 35: Example: Strand Adhesion
In order for the newly set NodeID to be updated, the supply must be interrupted for 3 seconds. Application information • 35 iONcharge 4.0... - Page 36 V02/20 36 • Application information iONcharge 4.0...
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Page 37: Technical Data
Open collector (OR-circuit) max. 28 V 100 mA General Value Min. Nom. Unit Communication CAN Open Bus clock kbit/s Termination (external and on both sides) Ω term. Ground connection terminal with M5 screw and nuts at machine ground Technical Data • 37 iONcharge 4.0... -
Page 38: Mechanical Data
PIN AGED flickering red 50/50 ms active TIMEOUT triple flash red active FAILURE constant Red active UNCONFIGURATED blinking Red 200/200 ms active STARTUP blinking green 200/200 ms Check Installation flickering red yellow 50/50 ms active 38 • Technical Data iONcharge 4.0... -
Page 39: Technical Service
V02/20 Technical Service Gema Switzerland GmbH Mövenstrasse 17 9015 St.Gallen Switzerland Phone: +41-71-313 83 00 Fax: +41-71-313 83 83 info@hildebrand-technology.com Global sales and service network www.gemapowdercoating.com www.hildebrand-technology.com Technical Data • 39 iONcharge 4.0...
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