ITW Simco-Ion IQ Power, Installation And Operating Instructions Manual

Page 1: ...IQ Power BPS 5201197 Rev D IQ Power Static Neutralizing System with BPS Power Supply INSTALLATION AND OPERATING INSTRUCTIONS ...

Page 2: ...e Communication Module optional 14 Electrical Connections 14 6 OPERATION 22 Power Supply Indicators 22 Power Supply Operators 22 System Start up 23 Power Supply Number Address 24 Power Supply Number Table 24 Static Bar Operation 25 Communication Module Operation optional 25 Control Station Operation optional 26 7 MAINTENANCE AND TROUBLESHOOTING 27 Cleaning the Static Bar 27 Troubleshooting 28 8 PA...

Page 3: ...irs 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 system in close proximity to flammable liquids 6 Do not use standard Ethernet cables with IQ PowerTM Systems CAUTION This product is intended...

Page 4: ... 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 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 somew...

Page 5: ... 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 se...

Page 6: ... Length 301 to 3961 mm Overall Length 11 8 to 156 210 to 3870 mm Effective Length 8 27 to 152 Profile Dimensions 26W x 49H mm 1 00 W x 1 93 H Weight 1 8 g mm 0 10 lb in Operating Temp 80 C 176 F max Humidity 70 RH max no dewing permissible Enclosure Glass fiber reinforced polyester HV Conduit Flexible non metallic black Emitter Material Proprietary alloy specially selected to extend life Emitter S...

Page 7: ...ication Module Anybus CompactCom see Replacement Parts Additional Items section for protocols available units with Anybus Dimensions 202L x 123W x 55H mm 7 95 L x 4 85 W x 2 15 H Weight 0 77 kg 1 70 lb Operating Temp 43 C 110 F max Enclosure Aluminum blue polyester powder coated Control Station Input Power 100 240V 50 60Hz 4A max IEC 320 inlet Output Voltage 24 VDC IQ Power connectors 5 thru 10 AU...

Page 8: ... 5 INSTALLATION Static Bar High Voltage Cable Perforated Strip Mounting Bracket Mounting Hardware Figure 1 IQ Power Static Bar Installation Set Screws Hex Key Wrench Mounting Bracket Static Bar Figure 2 IQ Power Static Bar Bracket ...

Page 9: ...ltage Connectors Bar Type Sense Pin to IQ Power Static Bar Captive Screws Figure 3 IQ Power High Voltage Connector IQ Power Static Bar IQ Power BPS High Voltage Cable High Voltage Connector AC Adapter Power In Connector Ground Connection Line Cord 24 VDC Figure 4 IQ Power Connections Bar and Power Supply ...

Page 10: ...damage by using only Simco Ion modular cables Refer to Section 8 Accessories and Parts TOP VIEW SIDE VIEW 6 5 4 2 3 1 WIRING DIAGRAM 8 7 6 5 4 2 3 1 8 7 1 1 Figure 5a IQ Power Crossover Modular Cable 6 5 4 2 3 1 WIRING DIAGRAM 8 7 6 5 4 2 3 1 8 7 TOP VIEW SIDE VIEW 1 1 Figure 5b IQ Power Straight through Modular Cable ...

Page 11: ...tions Bar Power Supply and Communication Module IQ Power Static Bar IQ Power BPS Ground Lead Line Cord AC Adapter PS COMM 2 Web Speed Encoder and Wheel Kit P N 5051766 20 Cable with kit Figure 7 IQ Power Connections Bar Power Supply and Web Speed Encoder ...

Page 12: ... and Wheel Cable P N 5051696 IQ Power Communication Module to CM COMM 2 Connection to PS COMM 2 Connection Figure 8 IQ Power Connections Power Supply to Power Supply to CS 5 thru 10 POWER COMM Comm Data black 1 Ground Lead IQ Power BPS without AC Adapter static bar not shown to PS COMM 1 Connection to CS 1 thru 4 COMM ONLY Comm Data Cable Construction 1 Crossover Wired DO NOT USE standard Ethernet...

Page 13: ...y 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 24 VDC 5 Bar On Relay normal closed 25 Power in 24 VDC 18 Bar On Relay normally open 30V 1A Rating on Contacts 1 6A Rating Connect pins 12 24 in parallel and 13 25 in paralle...

Page 14: ...stallation starts with mounting of the static neutralizing bar Static bars are typically installed just ahead of where problems due to static are occurring The power supply is installed in a convenient location within reach of the static bar high voltage cable and visible to the machine operator Communication modules where used may be installed at any convenient location and connected to the syste...

Page 15: ...ere the web path is variable Hybrid bars can be identified by an ion emitter to emitter spacing of 90 mm 3 54 inches Distance bars emitter point spacing 180 mm are mounted at a greater distance to the target surface 300 to 760 millimeters 12 to 30 inches and must be installed in areas free of obstructions Operating at a greater range of distances makes distance bars best suited for areas such as m...

Page 16: ... mounting surface with alcohol Allow alcohol to dry Secure AC adapter to mounting surface with two self adhesive mounting pads 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 Communication Module optional A Locate communication module at a convenient place within reasonably close distan...

Page 17: ...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 The exposed pin on the connector tells the power supply what type of IQ Power static bar is being connected and automatically sets ...

Page 18: ...nector on the end panel is used the Power switch must be set to the On 1 position Remote control is established by applying 24 volts DC to the Alarm Output connector pins as specified in the Power Supply Alarm Output Connections diagram The user applied 24 VDC drives a low current optoisolator on the IQ Power power supply main circuit board turning the power supply on or off depending on the confi...

Page 19: ...lied Do not over tighten Insert barrel connector into POWER IN connector on the power supply Hand tighten barrel connector nut to secure If a Communication Module is used it requires a separate AC adapter Connect AC adapter make sure POWER switch on communication module is in the OFF 0 position Route low voltage wire clear of moving machine parts and protect it from abrasion Secure using nylon wir...

Page 20: ...plied power if used In cases where the user does not want to use the AC adapter but wants to supply 24 VDC power to the IQ Power system user supplied 24 VDC power may be applied two ways The Power In connector on the end panel of the IQ Power BPS 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 24 VDC to...

Page 21: ...allow connection between an existing Ion Power system and the COMM 1 connector on the IQ Power The required cable is included 5051693 Adapter Block Kit VAC Ion Power to 8115 IQ Power is an enclosed terminal block on a short modular cable that can be used to adapt the existing wiring from an Ion Power system to plug into COMM 1 on the IQ Power It does require user cable preparation to terminate 505...

Page 22: ...able is included 5051693 Adapter Block Kit VAC VAC Ion Power to 8115 IQ Power is an enclosed terminal block on a short modular cable that can be used to adapt the existing wiring from an Ion Power system to plug into COMM 1 on the IQ Power BPS It does require user cable preparation to terminate See drawing 5201175 System Configuration 8115 IQ Power Ion Power for more information on connecting adap...

Page 23: ...on The web speed encoder uses a modular cable to connect to the IQ Power system A 6 10 meter 20 foot cable is available for installation The web speed encoder connects to the PS COMM 2 connector on the power supply If it is necessary to connect a web speed encoder to a remote display module the remote display module has a dedicated connector labeled Web Speed Encoder The modular cable should not b...

Page 24: ...d up on ion emitters or high output current conductive contamination on face of bar See Maintenance section for static bar cleaning details Mode The indicator next to the type of bar connected will light green Speed Hybrid or Distance 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 correspondin...

Page 25: ... 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 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 rem...

Page 26: ...ly 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 BPS Address Ion Power Station number OUTPUT LED Illuminated SPEED MODE LED HYBRID MODE LED DISTANCE MODE LED 1 default 1 LOW 1 2 2 2 3 3...

Page 27: ...n 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 Static Bar Operation A Operation normally requires only occasional checking of the system indicators on the power supply B Antic...

Page 28: ...on 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 D From the home page global settings and adjustments may also be made ...

Page 29: ...ent 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 sh...

Page 30: ... epoxy CAUTION Fire Hazard Do not turn on power supply with any trace of alcohol or mineral spirits on the equipment Allow all alcohol or mineral spirits to evaporate Troubleshooting CAUTION Electrical Shock Hazard Do not troubleshoot high voltage components with power supply energized Disconnect input power or switch power off before troubleshooting Troubleshooting must be performed by a qualifie...

Page 31: ...repair modular cable Power indicator NOT illuminated Power not on at power supply Turn on Power switch on end of power supply case Poor electrical connections Check input power connections both 24 VDC and line voltage Defective AC adapter Replace AC adapter COMM NOT illuminated Power supply operating stand alone Comm indicator only illuminates if other modules are connected Poor electrical connect...

Page 32: ...4 Kit Web Speed Encoder with wheel and 20 cable 5051766 Communication Module w Anybus no AC adapter With AC adapter 100 120 VAC Jpn N Amer Cord With AC adapter 230 VAC N Amer Cord With AC adapter 230 VAC European Cord With AC adapter 230 VAC UK Cord 4011592 4011855 4011856 4012043 4012044 Anybus EtherNet IP IT AB6214 module kit 5051542 Anybus Profibus DPV1 AB6200 module kit 5051543 Anybus Modbus R...

Page 33: ...tween IQ Power control station and communication module CM COMM2 DO NOT USE Standard Ethernet Cables Figure 5b 0 91 meter 3 foot white 2 13 meter 7 foot white 3 05 meter 10 foot white 4 27 meter 14 foot white 7 62 meter 25 foot white 4520788 4520789 4520834 4520791 4520792 IQ Power Bar Mounting Bracket Kit 5051455 Static Bar Cleaning Brush 4670204 Control Station 4015868 ...

Page 34: ... 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 pa...

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Page 36: ...IQ Power BPS 5201197 Rev D 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 ...