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Gema HIDEBRAND TECHNOLOGY iONcharge 4.0 20 kV Installation And Operating Instructions Manual

Electrostatic charging system
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Rev. 00
Installation and Operating Instructions
Electrostatic charging
system
iONcharge
4.0
20 kV
in potentially explosive area
Translation of the original operating instructions

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Summary of Contents for Gema HIDEBRAND TECHNOLOGY iONcharge 4.0 20 kV

  • Page 1 Rev. 00 Installation and Operating Instructions Electrostatic charging system iONcharge 20 kV in potentially explosive area 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.
  • Page 3 Rev.00 01/25 Table of contents Einführung Allgemein ........................ 5 Versionen ........................ 6 Anwendung ......................7 Vorteile ........................8 Sicherheitsanweisungen Anwendungen / Einsatzbereiche ................9 Sicherheitssymbole (Piktogramme) ..............10 Im Normalbetrieb ..................11 Während der Installation und der Entfernung .......... 13 Während der Reinigung des Aufladestabs ..........
  • Page 4 Rev.00 01/25 Einstellung der NodeID und der Hochspannung ..........38 Technische Daten Elektrische Daten ....................41 Input ......................41 Output ...................... 41 Allgemein ....................41 Mechanische Daten ....................42 Umgebungsbedingungen ..................42 Optische Anzeige/ Device Status/ Error ............... 42 Technischer Service ..................... 43 APPENDIX Drawing ...................
  • Page 5 Rev.00 01/25 Introduction General Electrostatic charging systems are the most efficient non-contact method of preventing powder transfer on the back of the workpiece to be powder- coated. Hildebrand Technology’s charging applicators are representing the most advanced and easy way of effective handling and controlling high voltage charging applications.
  • Page 6 Rev.00 01/25 Versions Designation ATEX labeling Zone PTB 22 ATEX 5003 X iONcharge 4.0 IC52 20 kV Zone 21 (positive) / 22 II Ex 2D IIIB T85 °C Db PTB 22 ATEX 5003 X iONcharge 4.0 IC54 20 kV Zone 21 (negative) / 22 II Ex 2D IIIB T85 °C Db...
  • Page 7 Rev.00 01/25 The iONcharge 4.0 20 kV charging bars must be connected within the potentially explosive area (zone) with the torque defined by the manufacturer. The connection to the power supply must be made outside the potentially explosive area (zone). The connections must be checked accordingly during maintenance and test intervals.
  • Page 8 Rev.00 01/25 Advantages The high-voltage supply is integrated in the electrode profile and is designed for demanding industrial applications with outstanding safety standards. – Power supply 24 VDC (20-28 VDC) – extremely compact, stable and glass fiber-reinforced electrode profile for mounting with mounting clips or T-slot and screws –...

  • 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)

    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 .

  • Page 11: During Normal Operation

    Rev.00 01/25 During normal operation WARNING Danger of electric shock Even though the charging bar is insulated and the current is limited, touching the electrodes of the emitter pins is strongly discouraged when the bar is in operation. It is possible that persons (depending on the shunt resistance) are charged to a greater or lesser extent and experience an electric shock when they make direct contact with ground.
  • Page 12 Rev.00 01/25 WARNING Danger of electric shock Use prohibited for operators with active body aids, e.g. pacemakers, insulin pumps, etc. High voltage operation (green LED lights up permanently) should only be active when it is required for the application. 12 • Safety Instructions iONcharge 4.0-ATEX...
  • Page 13 Rev.00 01/25 During installation and removal NOTICE Damage to components ► Do not drill holes in the bar housing, and follow the wiring instruction accurately to avoid equipment damage. WARNING Danger of electric shock ► Do not install or remove iONcharge equipment while the machinery and/or application are operational.
  • Page 14 Rev.00 01/25 During charging bar cleaning WARNING Danger of electric shock ► Always disable the 24 VDC power supply when cleaning the charging bars. WARNING Danger of coating powder-air atmosphere ► When working on the iONcharge 4.0 20 kV charging bars, electrostatic spraying equipment for ignitable coating powders must be switched off.

  • Page 15: Ozone Generation

    Rev.00 01/25 Ozone generation Ozone may be generated when the iONcharge is in use. Due to their intended use, the iONcharge 4.0 20 kV charging bars are used together with electrostatic spraying equipment for ignitable coating powders in areas with technical ventilation or under equivalent ventilation conditions.

  • Page 17: User Duties

    ► All installation and repair work must be performed by qualified technicians! Authorized and trained personal ► Installation, commissioning and maintenance of the iONcharge system may only be carried out by trained, qualified personnel authorized by Hildebrand Technology or Gema Switzerland GmbH. User Duties • 17 iONcharge 4.0-ATEX...
  • Page 18 Rev.00 01/25 WARNING High voltage shocks ► Always switch off the 24 VDC power supply before working on the system! ► Use protection equipment against unauthorized restart of the power supply during this period. ► If the iONcharge system needs to be removed from the point of use, switch off the power supply.
  • Page 19 – 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 20: Installation And Commissioning

    Rev.00 01/25 Installation and commissioning The iONcharge system is an electrostatic charging system consisting of a charging bar with integrated high voltage modules and encapsulated microprocessor electronics. The charging bars are in lengths from 320 mm to 4500 mm available. The local status LED is visible on the front side and indicates the system status.
  • Page 21 Rev.00 01/25 NOTICE 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. User Duties • 21 iONcharge 4.0-ATEX...

  • Page 23: Mechanical Installation

    Rev.00 01/25 Mechanical installation Determining locations for charging bars WARNING Explosion hazard ► If the system is installed in a potentially explosive zone, the position of the charging bar must be selected in such a way that the substrate is charged and does not pose a risk of ignition. Attach the iONcharge 4.0 20 kV charging bar to the desired position, as shown in Fig.
  • Page 24 Rev.00 01/25 Avoiding loss of efficiency NOTICE Ground near emission pins ► Ensure that there is no ground near the pins. > 2xd > 2xd Fig. 3: 24 • Mechanical installation iONcharge 4.0-ATEX...

  • Page 25: Mounting Options

    Rev.00 01/25 Mounting options Option 1: Option 2: Slide on clip M5 screw in T-slot Fig. 4: Grub screw for position Screw set included in scope of fixation delivery (hexagon head screw DIN 4017 M5x25; washer DIN 125 M5; nut DIN 4032 M5 Mechanical installation •...
  • Page 27 Rev.00 01/25 Dimensions Fig. 5: Mounting option at least 2 attachment screws per m + 1 Pro per additional m Mounting option Freely slidable GRP brackets (at least 2 per m + 1 Pro per additional m) GL working width Dimensions •...

  • Page 29: Electrical Connection

    Rev.00 01/25 Electrical Connection Connector specification Bus system connector, M12, 5-pin, easy and flexible adaptation for individual systems via "daisy chain" connection. IP54 protection class: The plugs must be tightened to the torque defined by the manufacturer. This is usually in the range of 0.6...1.5 Nm. Fig.

  • Page 30: Description Of The Connections

    Rev.00 01/25 Description of the Connections Fig. 8: Pin position and number Function Standard Hildebrand cable Error brown 20-28 VDC white blue CAN H black CAN L gray Explanation of pin functions Return signal for clean bar or system error. Pin 1 –...

  • Page 31: Factory Settings

    Rev.00 01/25 Use in standalone operation Standalone operation occurs without the use of a communication interface. For use of an individual charging bar, simply connect the 24 VDC power supply protected by the fuse (for value, refer to “Technical Data”). The system runs according to the factory settings. WARNING Explosion hazard ►...
  • Page 32 Rev.00 01/25 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 32 •...
  • Page 33 Rev.00 01/25 Overview of local multi-function LED: Functions Visual display: Device LED function Status INITIALIZING flickering green 50/50 ms STANDBY blinking green 500/1000 ms ACTIVE constant green CLEAN BAR WARNING blinking green yellow 500/500 ms CLEAN BAR ALARM constant yellow STARTUP blinking green 200/200 ms Visual display:...
  • Page 34 Rev.00 01/25 System efficiency has dropped from originally 100 % to 40 %. This mode displays the emitter pin status. The pin sharpness has Worn tips (wear & reached the set limit value for abrasion of the pins due to wear / age tear) (factory setting = 80 %) The system efficiency has dropped from 100 % to below 80 % without...

  • Page 35: Network Operation

    Rev.00 01/25 Network Operation iONcharge systems are charging systems with integrated high voltage power supply and micro controller technology. This enables the systems to be connected to a master unit such as a PC or a GateWay. Via the internal CANopen bus, the system can communicate and write as well as read parameters.

  • Page 37: Application Information

    Rev.00 01/25 Application information The iONcharge 4.0 20 kV charging bars make it possible to coat the workpiece more effectively when using electrostatic spraying equipment for ignitable coating powders. The use of the iONcharge 4.0 20 kV charging bar as a counter-electrode to the electrostatic spraying equipment prevents unintentional coating of the workpiece.
  • Page 38 Rev.00 01/25 The charging electrode prevents negative paint particles from sticking to the back of the workpiece. Setting the NodeID and the high voltage The setting is made using the T button: CAUTION Danger due to electrostatic charge People not connected to the ground can be electrostatically charged, which could result in an electric shock if they are touching a metal part.
  • Page 39 Rev.00 01/25 Application information • 39 iONcharge 4.0-ATEX...

  • Page 41: Technical Data

    Rev.00 01/25 Technical Data Electrical data Input Value min. Nom. Unit Number of contacts 5 pin/M12 Power supply (pin2(+); 3(GND)) Current consumption 20 kV Output Value min. Nom. Unit Voltage 20 kV ±20 ±20 Current of all emitter tips 20 kV ±500 µA Contact current (1 emitter tip)

  • Page 42: Mechanical Data

    Rev.00 01/25 Mechanical data Value min. Nom. Unit Width Height Working width 20 kV 4460 Weight kg/m Attachment rail M5 T-slot or iONclip (min. 1/m) Ambient conditions Value min. Nom. Unit Temperature TAmb °C Humidity/ non-condensing %rel. F. Protection class acc. to DIN 60529 IP68 (M12 tightened to specified torque) Stand-alone 500 mA T Fuse in primary circuit (provided by the...

  • Page 43: Technical Service

    Rev.00 01/25 Technical Service Gema Switzerland GmbH Sommeraustrasse 5 9200 Gossau 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 • 43 iONcharge 4.0-ATEX...

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