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ELTEX POWER CHARGER PC Operating Instructions Manual
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ELTEX POWER CHARGER PC Operating Instructions Manual

High voltage generator
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Operating Instructions
High voltage generator
POWER CHARGER PC
BA-en-3041-2008

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Summary of Contents for ELTEX POWER CHARGER PC

  • Page 1 Operating Instructions High voltage generator POWER CHARGER PC BA-en-3041-2008...
  • Page 2 BA-en-3041-2008_PC...
  • Page 3 3.10.2 Analog interface Discharging ......30 3.11 Use of the Eltex signal cable CS and mains cable KN ..31 Operation .
  • Page 4 4.4.2.3 Preset..........59 4.4.2.4 Eltex DEBUG overview / Message overview ....60 4.4.2.5 Parameter .
  • Page 5 Dear customer, The POWER CHARGER PC high voltage generator is a universal high voltage supply unit for controlled charging and use of electrostatic effects. The following bars may be connected: Charge: System variants PCSC, PCTL, PCRT und PCRM: • R130A3 / R130A6 •...
  • Page 6 All generators of the POWER CHARGER PC family offer the following features: • Up to 50% higher charging power than comparable Eltex charging generators • Parallel control of charging voltage, charging current and charging capacity • Temperature-controlled power limitation • Robust, compact design •...
  • Page 7 1. Outline of Appliance Fig. 1: High voltage generator POWER CHARGER with field bus Fig. 2: High voltage generator POWER CHARGER with discharge BA-en-3041-2008_PC...
  • Page 8 Fig. 3: HIgh voltage generator POWER CHARGER with charging bars suitable for connection 1 Operating switch ON/OFF 2 System input 90 - 264 V AC 3 System input 24 V DC 4 Ground terminal 5 Analog interface Charge 6 Interface 1 Field bus 7 Service interface 8 Interface 2 Field bus 9 High voltage output: Connection of the charging bar...
  • Page 9 1.1 Variants The high voltage generators of the POWER CHARGER PC family are available in different variants. They can be combined depending on the output voltage, polarity, output power and interfaces etc. Reference code with the individual variables: Article-No. Version...
  • Page 10 1.2 High voltage setting range Depending on the selected variant, you can set different maximum values for the output voltage, output current and output power. Fig. 4: Diagram Depandance Current / Voltage U [%] Output voltage / - current for use in combination with charging bars EXR130A3 / EXR130A3L / R170A3 Variant Umin...
  • Page 11 Depandance current / voltage Supply / Variable output voltage Variable output voltage output power 30 kV 60 kV L = 24 V DC, 75 W 3.75 mA at 20 kV 1.875 mA at 40 kV S = 90/264 V AC, 75 W 2.5 mA at 30 kV 1.25 mA at 60 kV 7.5 mA at 20 kV...
  • Page 12 2.2 Contact protection The site of installation and/or use of the units is outside the control of Eltex, contact protection against inadvertent contact of the bars and of live components by personnel as specified by the employer’s liability insu- rance association may have to be provided (e.g. DGUV V3 in Germany).
  • Page 13 The POWER CHARGER PC high voltage generator has been approved as operating voltage generator for the appropriate Eltex charging bars. It must be operated only with the appropriate Eltex bars (see chapter Instal- lation and Assembly for bar models). If the unit is used in any other high voltage application, the manufacturer´s warranty covers the safe use in terms of technical safety.
  • Page 14 Chapter 3.10.2 "Analog interface Dis- charging”, page 30). • When using the optional Eltex signal cable CS or the mains cable KN, the colour markings and the bending radii should be observed when connecting the individual leads (see Chapter 3.11 "Use of the Eltex sig- nal cable CS and mains cable KN”, page...
  • Page 15 • Check the high voltage generator, all connected units, the electrical wiring and the high voltage cables at regular intervals for any damage. Any damaged components must be repaired or replaced before conti- nuing to operate the unit, or the appropriate units must be disabled. •...
  • Page 16 Information on performance level applications: • The 24 V DC power supply to be used must be tested according to the EN 60950-1 or EN 62368-1 standard / must meet the applicable PELV (protective extra low voltage) or SELV (safety extra low voltage) requirements (see Chapter 3.8.1 "Connecting the supply voltage 24 V DC”, page...
  • Page 17 3. Installation 3.1 Assembly of the high voltage generator The unit is designed for wall mounting. Attach the unit using the assembly/ mounting brackets supplied with the unit. When mounting the unit make sure that the operating elements and the connector terminals remain accessible and that control of the unit is not impaired.
  • Page 18 A cross section of 2.5 mm is required for cable lengths exceeding 0.5 meters. Eltex recommends using the ground cable supplied with the generator. Ground terminal Insert the ground cable into the side slot of the open terminal until it pro- jects from the opposite side.
  • Page 19 3.3 Installation of the high voltage cables • A minimum bending radius of 10 times the external diameter must be maintained when routing the high voltage cable. • The high voltage cables must not be attached with metal clips. • Do not route the cable over sharp edges (bending radius <5 mm). •...
  • Page 20 3.4 Bars suitable for connection 3.4.1 Charging bars suitable for connection The following charging bars may be connected to the high voltage genera- tor POWER CHARGER PC_ _: System variants PCSC, PCTL, PCRT und PCRM: • R130A3 / R130A6 • R120 voltage limitation, note Operating Instructions R120 •...
  • Page 21 High voltage output: Connection of the charging bar 9.1 High voltage output: Connetion shown with cover cap 10 HIgh voltage cable Fig. 8: Connection of the high voltage cable Example: Current per meter of active bar length: 1 mA Sum of active bar lengths: 3 m =>...
  • Page 22 3.4.2 Discharging bars suitable for connection The following charging bars may be connected to the high voltage genera- tor POWER CHARGER PC_ _: • Variant "A" (not for Performance Level applications) EXR5C • Variant "C" R60L • Variant "P" RG52C 3.5 Connecting the charging bar to the high voltage generator Warning! Electric shock hazard!
  • Page 23 If no charging / discharging bar is connected to the respective plug con- nection of the generator, the connection must be closed with the blind plug provided. Note: The screw connection must be fastened with a torque of 3 Nm. Caution! The high voltage cable must be pushed up to the stop (150 mm) into the cable inlet! The connecting area of the high voltage cable must be kept...
  • Page 24 If no charging / discharging bar is connected to the respective plug con- nection of the generator, the connection must be closed with the blind plug provided. 3.7 Disconnecting the high voltage cable Warning! Electric shock hazard! Work may be carried out only if: •...
  • Page 25 In case of customer’s provision: To prevent an interruption of the power supply due to vibrations or other mechanical influences, Eltex recommends using a plug for power cable, form C13 with integrated locking, see Chapter 10 "Spare parts and accesso- ries”, page...
  • Page 26 4.4 and 4.5). The complete description of the CANopen® protocol for the generator POWER CHARGER PC_ _ and the corresponding EDS file "PC.eds" are available in the download area: www.eltex.com/support/download service. The bus network has to be terminated at both sides.
  • Page 27 A complete description of supported commands and assignment of pro- cess data, parameters etc. in the respective registers is available in the Downloads area at www.eltex.com/support/download service. Caution! The generator must be connected to the network by means of suitable, shielded cables;...
  • Page 28 3.10 Analog Interface 3.10.1 Analog interface Charging The analog interface allows the generator to be integrated into a SPC or into another environment using 0…10 V or 0…20 mA interfaces. A hardware release is required if an analog interface is used. Caution! •...
  • Page 29 Actual value I wire color: gray 0…20 mA (output): 0 mA corresponding to 0 mA output current 20 mA corresponding to 7.5 mA output current Max. load: 500  Analog setpoint wire color: pink for setting the voltage or current setpoint (input); see the table “Setting options”...
  • Page 30 3.10.2 Analog interface Discharging The analog interface allows the generator to be integrated into a SPC or into another environment using 0…10 V or 0…20 mA interfaces. A hardware release is required if an analog interface is used. Caution! • To avoid damaging the generator, make sure that the signals are con- nected correctly.
  • Page 31 3.11 Use of the Eltex signal cable CS and mains cable KN When using the optional Eltex signal cable CS or the mains cable KN, the following data, the colour markings and the bending radii should be observed when connecting the individual leads.
  • Page 32 • KN/G Mains cable Supply voltage AC KN/GA connection generator: mains plug C13 connection customer: mains safety plug KN/GB connection generator: mains plug C13 connection customer: mains plug Switzerland KN/GD connection generator: mains plug C13 connection customer: open end • KN/H Mains cabel Supply voltage 24 V KN/HD connection generator: straight plug connection customer: open end...
  • Page 33 CS/C Signal cable CANopen ® Signal Core no. Core colour +24 V DC output (optional) black white CAN-H blue CAN-L shield ground potential KN/H Mains cable Supply voltage 24 V DC Signal Core no. Core colour white +24 V DC brown +24 V DC green...
  • Page 34 4. Operation In all generator variants, the operating status of the device is indicated by LEDs. Fig. 18: Operating status indicated by illuminated LED, shown for variant PC_ _/X and PC_ _/P Fig. 19: Operating status indicated by illuminated LED, shown for variant PC_ _/A and PC_ _/C (with...
  • Page 35 4.2 Function monitoring The proper function of the unit is signaled via the LEDs and the fault signal output. • Fault signal output Display of the function State Error / The generator is not ready for operation. 24 V Power supply ON, no error. •...
  • Page 36 • Status LED: Display of the different operating states Status-LED State Red steady light Initializing Red flashing Fault Red 1 x flashing System fault Green steady light Hight voltage ON Green flashing Warning and High voltage ON Green 1 x flashing Generator in standy mode High voltage OFF Green 2 x flashing...
  • Page 37 • LED CHARGE only for variants with integrated active discharge LED CHARGE State High voltage Charge OFF Green steady light High voltage Charge ON • LED DISCHARGE only for variants with integrated active discharge LED DISCHARGE State High voltage Discharge OFF Green steady light High voltage Discharge ON •...
  • Page 38 4.2.1 Variants with CANopen® (optional) Presentation of the LED outputs for the CAN bus specified under CiA 303-3. BUS LED State CANopen® not initialized Green steady light CANopen® Device in OPERATIONAL state Green 1 x flashing CANopen® device in STOPPED state Green slowly flashing (2,5 Hz) CANopen®...
  • Page 39 4.2.2 Variants with ModbusTCP (optional) BUS LED State No IP address assigned Green steady light Modbus messages received correctly Green flashing Waiting for first Modbus message Red steady light Invalid IP address LINK LED State No connection Green steady light 100 Mbit/s connection detected Green flashing 100 Mbit/s data interchange...
  • Page 40 LED Bar kV State Charging current mode Green steady light Charging voltage mode Yellow steady light Voltage limitation active Yellow flashing Indication Sup Menu LED Bar mA State Charging voltage mode Green steady light Charging current mode Yellow steady light Current limitation active Yellow flashing Indication Setup Menu...
  • Page 41 4.3 Releasing the high voltage The release of the high voltage requires two steps: • Hardware release, see Chapter. 3.10 • Software release as described below Software release options • Automatic The software is released automatically once the generator has powered •...
  • Page 42 4.4 Integrated control elements Settings at the high voltage generator are made via the integrated control elements. Error and warning messages can be acknowledged directly at the device. Depending on the generator variant, the operator can use the integrated membrane keyboard or a touchscreen. 4.4.1 Using the membrane keyboard The membrane keyboard is used to set certain parameters and the set-...
  • Page 43 Changing the setpoint The setpoint can be changed with the +/- buttons. Depending on the selected mode, you can change the voltage or current setpoint (voltage constant starting at 1500 V, current constant starting at 50 µA). The buttons can be pressed individually / pressed and held. The setpoint can only be changed once the Setup menu has been closed.
  • Page 44 Acknowledging error / warning messages Error and warning messages can be acknowledged with a common button combination. Press and hold the three buttons Setup, OK and kV / mA until the LEDs flash twice. The message is acknowledged following an internal system check.
  • Page 45 The currently selected item of the Setup menu is indicated by an illumina- ted LED in the right part of the LED bar. The left part indicates the current setting with an illuminated LED. Fig. 21: Image detail: "Start setup menu " with illuminated mA and kV LED Fig.
  • Page 46 • Selecting the Discharge mode only for variants with integrated active discharge The 10th LED from the left on the bar lights up. Use the + and - buttons to select “passive discharge” or “active discharge”. The passive discharge mode is indicated by the first LED on the left, the active discharge mode by the LED to the right of it.
  • Page 47 • Selecting the Charge mode The 11th LED from the left on the bar lights up. Use the + and - buttons to select “voltage-constant” or “current-constant” charging. The voltage- constant mode is indicated by the first LED on the left, the current- constant mode by the LED to the right of it.
  • Page 48 • Selecting the Release options The 12th LED of the bar indicates the selection of the release option. The currently selected option is shown on the left. The selection can be chan- ged with the + and - keys. Only one release option can be selected at any time.
  • Page 49 • Defining the analog setpoint Select the mode for defining the analog setpoint. The 13th LED of the bar lights up. Use the + and - buttons to select the analog setpoint. Press the OK button to confirm your selection. In devices with an integrated CANopen®...
  • Page 50 • Setting the CANopen® node address Setting the CANopen® node address is a two-step process: first you set the tens for the address 0 –12, then the units of the address 0–9. These settings define the address as follows: Node address = (tens position * 10) + units position The 14th LED of the bar shows that the address is being set.
  • Page 51 • Setting the CANopen® transmission rate The 15th LED of the bar lights up for the setting of the transmission rate. The left part of the bar shows the currently selected setting. The setting can be changed with the + and - buttons. Confirm your selection with the OK button.
  • Page 52 • Concluding the Setup Press the OK button to close the Setup menu. Following an internal check, all parameters are set to their respective minimum and maximum values. Then the entire parameter set is saved. The LED bar returns to showing the actual value.
  • Page 53 3 Presetting Saving and loading of the presettings for generator parameterization 4 Main screen Navigation to the main screen 5 Eltex DEBUG / message overview Display of current error / warning messages 6 Status Display of generator status information 7 Parameters...
  • Page 54 4.4.2.1 Release Press the "Release" button. Slide the button in the lower left corner to the appropriate position to disable or release the high voltage. If there is a password prompt, enter the correct password. 4.4.2.2 Configuration Pres the "Configuration" button. Fig.
  • Page 55 4.4.2.2.1 ECC User Press the "ECC user" button. Screen for changing passwords and user log-on / log-off. Fig. 37: Password To change your password, enter the current password in the field “Current password”, then the new password in the field “New password” and again in the field “Confirm new password”;...
  • Page 56 4.4.2.2.2 Access Management Press the "Access Management" button. Screen for setting and configuring parameters for the respective user level. Fig. 38: Access Management Select the access level from the selection list of the respective parameter and confirm with OK. Press "Cancel" to cancel the changes and preserve the old settings.
  • Page 57 4.4.2.2.3 Settings Press the "Settings" button. Screen for setting and configuring parameters for the respective user level. Fig. 39: Settings Select the desired language from the selection list and confirm with OK. Press "Cancel" to cancel the changes and preserve the old settings. With the setting of the standard access level, the access level can be con- figured, which is active when the ECC visualization system is started and when the user logs off.
  • Page 58 4.4.2.2.4 Highlight Values Press the "Highlight Values" button. Screen for configuring the "Parameters / Status". Fig. 40: Highlight Values Adjustable actual values are displayed based on the user’s access autho- rization. Select the parameters and confirm with OK. Press “Cancel” to cancel the changes and preserve the old settings.
  • Page 59 4.4.2.3 Preset Press the "Preset" button. Screen for loading, saving, editing and deleting preset parameter sets for a quick adjustment of values to the respective operation. The left part of the screen shows the current preset parameters, the right side the editing options. Fig.
  • Page 60 4.4.2.4 Eltex DEBUG overview / Message overview Press the "Eltex DEBUG" button. View of current error and warning messages Fig. 42: Overview Eltex DEBUG Pressing the "Error history" button will open a chronological list of all mes- sages. Click on an entry to see additional information on the cause of the message and the remedy.
  • Page 61 4.4.2.5 Parameters Press the "Parameters" button. Fig. 44: Overview of parameters Change the parameter value using either the slide switch or the selection list, then confirm with OK. If you do not have the required access authori- zation, you will have to enter a password. Select “Change all” to set all parameters that can be changed with the current access authorization;...
  • Page 62 4.4.2.6 General Parameters Fig. 45: Overview of general parameters For a better overview, the individual parameters are organized in several tabs. For example, the mode for high voltage release can be changed via the "General" tab. With this parameter it is possible to activate or deac- tivate the options for setting or blocking the high voltage release.
  • Page 63 5. Maintenance Warning! Electric shock hazard! • Do not carry out any maintenance or repair work without first discon- necting the supply voltage of the units. • The machine which has the units fitted must not be in operation. • Repairs and maintenance work must be carried out by qualified person- nel only.
  • Page 64 6. Troubleshooting Warning! Electric shock hazard! • Do not carry out any maintenance or repair work without first switching off the high voltage and disconnecting the supply voltage. • The machine which has the units fitted must not be in operation. •...
  • Page 65 Error Error Cause Measure number clearable • Interrupt the supply voltage. Invalid warning num- • If this error occurs again, send in the device for repairs. Invalid warning status • Interrupt the supply voltage. • If this error occurs again, send in the device for repairs.
  • Page 66 Error Error Cause Measure number clearable • Check the 24 V DC supply. 24 V DC Supply faulty • Interrupt the supply voltage. • If this error occurs again, send in the device for repairs. • Check the 24 V DC supply. Overcurrent supply voltage •...
  • Page 67 Error Error Cause Measure number clearable • Clean the bar. Pollution bar charging • Check the mounting position. • Reduce the setpoint value. • Clear the error. • If this error occurs again, send in the device for repairs. • Clear the error. General memory •...
  • Page 68 Error Error Cause Measure number clearable • Clear the error. Range PID controller • If this error occurs again, send in the device for repairs. Setpoint ramp • Clear the error. • If this error occurs again, send in the device for repairs.
  • Page 69 Error Error Cause Measure number clearable • Clean the bar. Short circuit high voltage • Check the mounting position. charging • Reduce the setpoint value. • Clear the error. • If this error occurs again, send in the device for repairs. •...
  • Page 70 Error Error Cause Measure number clearable • Interrupt the supply voltage. Diagnostic error: error in the error • If this error occurs again, send in the device management of the for repairs. diagnosis • Interrupt the supply voltage. Diagnostic error: invalid state of the •...
  • Page 71 Error Error Cause Measure number clearable • Interrupt the supply voltage. Diagnostic error: hardware release • Check the release switching. channel 2 • If this error occurs again, send in the device charging for repairs. • Interrupt the supply voltage. Diagnostic error: software release •...
  • Page 72 Error Error Cause Measure number clearable • Interrupt the supply voltage. Nein Diagnostic error: hardware release • Check the release switching.. channel 2 • If this error occurs again, send in the device discharging for repairs. • Interrupt the supply voltage. Nein Diagnostic error: software release...
  • Page 73 Warning Cause Measure number • Change the integrated battery; see discription Battery Chap. 11. voltage too low • Change must be carried out by qualified per- sonnel. • Clean the bar. Flash count of hard flashes, limit exceeded • Check the mounting position. •...
  • Page 74 Warning Cause Measure number • Check bus cabling. communication error • Check baud rate. • Clear the warning. • If this warning occurs again, send in the device for repairs. • Check bus cabling. General CANopen® • Check CANopen® - transmission. communication error •...
  • Page 75 Warning Cause Measure number • Check node monitoring of the CANopen® CANopen® master. node monitoring error • Clear the warning. • If this warning occurs again, send in the device for repairs. • Check bus cabling. Error during re-connection • Check baud rate. •...
  • Page 76 The warranty applies only if the operating and assembly instructions spe- cified by Eltex have been observed. The warranty period begins on the date of delivery. In the event of defects occurring during the warranty period, the units or defective components will be repaired at Eltex.
  • Page 77 Technical Specifications POWER CHARGER PC_ _ Power ratings Supply Voltage PC_ _/_ _ _L: 24 V DC ±15%, 100 W PC_ _/_ _ _S: 90 - 264 V AC, 47 - 63 Hz, 100 W PC_ _/_ _ _H: 90 - 264 V AC, 47 - 63 Hz, 200 W The voltage at the input plugs of the 24 V DC supply voltage, the analog interfaces for charging and discharging and the field bus interfaces must not exceed 60 V DC.
  • Page 78 Connections, interfaces High voltage output 2 high voltage connections for the direct connection of two consumers Analog interface Floating input for external high voltage release (24 V DC) Input setpoint: 0…10 V resp. 0 - 20 mA Output actual value: 0…20 mA Fault signal contact: max.
  • Page 79 Guaranteed safety characteristics for generator variants with performance level d PC_ _ / _ _ _ __ _ _ P und PC_ _ / _ _ _ __ _ _ D High voltage generator POWER CHARGER Safety-related parameters according EN ISO 13849 SF1 + SF2 (Charging) (Discharging)
  • Page 80 9. Dimensions Fig. 46: Dimensions High voltage gene- rator with fixing positions Assembly with 4 x hexagon screws M5 (alternatively M6) including flat washer BA-en-3041-2008_PC...
  • Page 81 10. Spare parts and accessories Article Article No. Mains cable 24 V DC (specify customer-side connection and cable length) KN/H_ _ _ _ _ Mains cable Standard with plug for power cable, form C13, with integrated locking (specify customer-side connection and cable length) KN/G_ _ _ _ _ Mains calbe Standard (shockproof plug), cable length 2 m...
  • Page 82 Article Article No. Protective cap M12 socket 108449 Protective cap M16 plug ELM01115 Terminating plug CANopen® 114855 Terminating box CANopen® 117550 Fine wire fuse AC version ELM00201 Plug "Y" Set for prefabricating the high voltage cable with flexible tube for 30 kV charging bars resp. modification set for charging pluy Y, high voltage cable Hivolt, Bedea 117077 Modification set for charging plug Y,...
  • Page 83 11. Battery change / Decommissioning Follow the instructions below to dispose of the generator: Caution! All work must be carried out by qualified personnel only. Warning! Electric shock hazard! Before opening the generator, switch it off and disconnect all plug connec- tors and cables.
  • Page 84 A. Assembly of the plugs A.1 Plug M16 for 24 V DC supply voltage straight version, version with shield clamping ring Fig. 47: Plug M16 for 24 V DC supply voltage 1. Bead pressing screw, pinch ring, seal, distance shell and first shield clamping ring on cable.
  • Page 85 A.2 Plug for power cable for AC supply voltage TDIXBS[ /S  PEFS CSBVO CMBDL OP  PS CSPXO HFMCHS¯O ;VHFOUMBTUVOH NVTT HFTDIMPTTFO TFJO ZFMMPXHSFFO DBCMF SFMJFG OFFET TDIXBS[ /S  PEFS CMBV UP CF DMPTFE CMBDL OP  PS CMVF Fig.
  • Page 86 A.3 Plug M12, 8-pin for analog interface Charging A = 5 mm Fig. 49: Plug M12, 8-pin for analog inter- face Charging Plug M12, 5-pin for analog interface Discharging A = 5 mm Fig. 50: Plug M12, 5-pin for analog inter- face Discharging BA-en-3041-2008_PC...
  • Page 88 Eltex offices and agencies The addresses of all Eltex agencies can be found on our website at www.eltex.de Eltex-Elektrostatik-Gesellschaft mbH Blauenstraße 67-69 79576 Weil am Rhein | Germany Phone +49 (0) 7621 7905-422 eMail info@eltex.de Internet www.eltex.de...