MKS, Ion Industrial

1000 Old County Circle

Unit 116
Windsor Locks, CT 06096
Phone: (860) 292-6847
MKS, Ion Industrial Europe
Marie-Curie-Strasse 8
D-79539 Loerrach, Germany
Tel. ++ 49 (0) 7621 - 5500 355
Fax ++ 49 (0) 7621 - 5500 360
MKS, Ion Systems
Alameda, California
USA ION POWER
Fax: (860) 292-6807
Email: industrial@ion.com
Email: indeuro@ion.com Intelligent Static Neutralizer
Web: www.mksinst.com/ion-industrial
with Master Controller
Ion Systems’ logo is a trademark of Ion Systems,
©1998 Ion Systems. Printed in the U.S.A.
INSTALLATION AND OPERATING INSTRUCTIONS

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TABLE OF CONTENTS
1. Safety Warnings..................................................................................................1
2. List of Components............................................................................................3
3. Description..........................................................................................................4
System description ........................................................................................4
System installation planning ........................................................................4
Determining locations for neutralizing bars ................................................5
Model 8001KDT static neutralizing bar ......................................................6
Mounting 8001KDT neutralizing bars ..........................................................7
8154 POWER MODULE – high voltage power supply ..............................8
Mounting 8154 POWER MODULE ..........................................................10
8200 MANAGER– master controller..........................................................11
8310 CONNECTOR – serial communication switch ................................13
24VDC power..............................................................................................14
Wiring a multi-station ION POWER system ..............................................14
8154 output wiring ......................................................................................17
Connecting several 8001KDT bars to one 8154 POWER MODULE ........18
8154 POWER MODULE grounding connection ......................................19
Complete system wiring..............................................................................19
8154 POWER MODULE input connections ..............................................22
Remote system output activation and alarms..............................................25
4. Setup and Operation........................................................................................26
8200 Functionality ......................................................................................26
8200 keys ....................................................................................................27
8200 Programming Functions ....................................................................28
8200 Command Functions ..........................................................................31
8200 Display Functions ..............................................................................32
Neutralizing system setup ..........................................................................34
Clean Bar alarm setup ................................................................................37
Neutralizing current display ........................................................................38
Operation and operation check....................................................................41
Fail-safe operation mode ............................................................................42
Alarms ........................................................................................................42
Conductive residue accumulation on the bar surface ................................45
Loss of communications..............................................................................45
8154 POWER MODULE stand-alone operation ........................................46
5. Performance Verification ................................................................................47
6. Maintenance ....................................................................................................48
7. Troubleshooting................................................................................................48
Troubleshooting Chart ................................................................................49
Equipment Service Life ..............................................................................51
Equipment Repairability..............................................................................51
8. Specifications....................................................................................................52
9. Warranty and Service......................................................................................55
10. Appendix A. ......................................................................................................56
Expected values of Ion Output and Neutralizing Current ..........................56
8200-8154 Manual Version 3.0
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1. SAFETY WARNINGS
PLEASE READ INSTRUCTIONS COMPLETELY BEFORE STARTING
INSTALLATION
ALL INSTALLATION AND TROUBLESHOOTING OPERATIONS
MUST BE PERFORMED BY QUALIFIED TECHNICAL PERSONNEL
The ION POWER Virtual AC static neutralizers were developed according to the latest
safety requirements for industrial applications and have successfully passed the relevant
safety and life tests before delivery.
However, operators may be exposed to potentially dangerous situations if the installation
and use are not done in accordance with the Ion Industrial instruction manual.
This instruction manual uses symbols to identify dangerous situations as follows:
WARNING! This warning symbol means danger. You are in a situation that
could cause bodily injury.
CAUTION! This caution symbol means reader be careful. You are capable of
doing something that might result in equipment damage.
1.1 During normal operation
WARNING! Even though the neutralizing bar is of a shockless design and the
current is limited, touching the electrodes of the operating bar is strongly
discouraged.
WARNING! Do not disconnect any wiring of the ION POWER system while
the machinery is running regardless of whether the system is operational or not.
WARNING! Do not disconnect high voltage wires from the 8154 when the
machine where the Neutralizers are installed is running regardless of whether the
ION POWER component is operational or not. Connect to ground the bar wires
when the bar is not connected to the 8154.
WARNING! Disable the high voltage output of the 8100 when processing webs
with a metal foil or metallized film as part of their construction. Electrical
neutralizers are not useful under those conditions, and could create a safety
hazard in some circumstances.
CAUTION! Do not spill liquid or apply mist to the connectors of the
neutralizing bars or high voltage power supply – equipment damage may result.
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 1.5 In problem situations
CAUTION! The system alarms may not function properly if the total high
voltage cable length connected to the 8154 POWER MODULE exceeds the WARNING! If the bar or high voltage cable have been accidentally damaged,
maximum specified length. and the integrity of any of those components has been compromised, disable the
8154 output immediately. Stop the machine and disconnect the power from the
CAUTION! The HV- output should be energized only when is required by the neutralizer. Correct the problem or dismantle the bar before restarting the
application (see the Remote Activation Setup section). machine.

1.2 During installation and removal
WARNING! The enclosure of the 8154 POWER MODULE is not a junction
box but a finished high-voltage device – do not change the conduit fitting to
metal fitting, do not drill additional holes in the enclosure, and follow the wiring
instruction precisely to avoid equipment damage.
WARNING! Do not install or remove ION POWER equipment while the
machinery is running.
WARNING! If liquid has been spilled on the bar, disable the 8154 output
immediately. Stop the machine and disable 24VDC power. Correct the problem
or dismantle the bar before restarting the machine..
WARNING! Do not use the ION POWER static neutralizers in flammable or
explosive environments.
CAUTION! The ION POWER static neutralizers are designed for indoor use
only.

WARNING! If you need to take the 8154 unit out of service, you must
electrically ground the neutralizing bar wires.

WARNING! Always disable the 8154 output and the 24VDC power when doing 2. LIST OF COMPONENTS
installation or removal of the Virtual AC equipment.

Item Part Qty included

1.3 During static bar cleaning No. Number Description with this order
WARNING! Always disable the 8154 output when cleaning the
1 91-8154 8154 POWER MODULE _
neutralizing bar.
2 91-8200 8200 MANAGER _
3 91-8310 8310 CONNECTOR _
1.4 Grounding 4 91-8001KDT-____ Neutralizing Bar, Model 8001KDT _
WARNING! The 8154 POWER MODULE must be electrically grounded. 5 32-7421 Plastic mounting brackets,
8001KD bar _
6 32-8088 Stainless steel mounting brackets,
8001KD bar _
7 See SPECIFICATIONS 24VDC Power supply _

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3. DESCRIPTION Determining locations for neutralizing bars
1. Locate the static bar in the desired position, as shown in Fig. 2, for neutralization of
web spans and other applications where the distance between the bar and the material does
System Description
not vary. In cases of unwind and rewind, the bar should be installed to clear the largest roll
Each individual station in the master controller system consists of an 8154 POWER (see Fig. 3), and away from other metal objects on the sides of the bar.
MODULE and 8310 CONNECTOR module connected to the 8200 MANAGER, as well
as high-efficiency 8001KDT static neutralizing bars, as shown in Fig. 1.
A single 8200 MANAGER in the master controller system can monitor and control up to
nine stations in a Master-Slave network over a two wire RS-485 multi-drop bus.

3-6" (75-150 mm)

Static Neutralizing Bar
(side view)

4-6"
(100-150 mm)

Figure 2. Typical installation of the Virtual AC neutralizing bar at the open span of a
web.
Note: The bar should not be closer than 4” – 6” (100-150 mm) to the roller.

END OF THE ROLL

Figure 1. ION POWER Master Controller System.

START OF A NEW ROLL

System installation planning

1. Carefully choose locations for all components of the Virtual AC system.
2. Plan to install the 8154 POWER MODULES within the length of the high voltage
cables from to the bar. Keep high voltage cables as short as possible.
Neutralizing Bar
3. Plan to install the 8200 MANAGER at eye level on a vertical panel or wall near or at
the control panel of the machine. Mounting dimensions can be found in Fig. 9. Provide
open space at the bottom of the module to allow access to the connectors. Figure 3. Typical Installation of the Virtual AC neutralizing bar on a rewinder.
4. The 8310 CONNECTORS should be placed where they can be conveniently accessed
for wiring, preferably inside a control panel. Mounting dimensions can be found in
Fig. 11.

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Model 8001KDT static neutralizing bar Mounting 8001KDT neutralizing bars
The body of the 8001KDT neutralizing bar shown in Fig. 4 is made of a fiber-reinforced The 8001KDT neutralizing bars are mounted using special plastic or stainless steel
polyester resin for extra rigidity. Ionizing electrodes in the 8001KDT neutralizing bar are brackets that engage in the grooves and can slide along the entire length of the bar. For
spaced about 1” (25.4 mm) apart and converge into a single row from each side of the bar. each 18-24” (450-600 mm) of bar length an additional mounting bracket is required.
Ionizing electrodes are connected to the high voltage power supply through resistors to 1. Make sure to position the bar so that its end with the cable at the side of the machine
ensure low current at the electrodes for safety. A fixed high voltage cable exits the bar at frame where the HVPS is installed.
one end. A Universal V.AC cable plug is attached to the end of the cable. Two grooves, one
2. Slide all the provided mounting brackets on the end of the bar and space them along
on each side of the bar body, extend for the length of the bar.
the bar length (see Fig. 5 and 6).
3. After placing the brackets in the desirable positions, secure the brackets by tightening
1 the screws (pos. 3 in Fig. 5 and 6).
2 ) The tab of the mounting bracket can be bent (pos. 4 in Fig. 6) to adapt to the orientation
9 mm
" (8 of the mounting surface.
3.5
L + EL
=E 0.7" 4. Use screws (and nut) to attach the mounting brackets to the mounting surface.
OL (18 mm) 0.8"
0.8" (20 mm)
(20 mm)
CAUTION! Any metal mounting surfaces where the bar is installed must be
electrically grounded.
2 holes
1.3" 0.200" dia
(34 mm)
(5 mm)
4A 1
3

1.73”
4B (44 mm)

Figure 4. Model 8001KDT static neutralizing bar.

1 – bar body; 2 – cable plug; 3 – high voltage wires in a protective conduit; 4A – plastic 3
1.75"
mounting brackets; 4B – optional stainless steel mounting brackets. (44.5 mm)
2.15"
(54.5 mm)

The 8001KDT neutralizing bars are mounted using special plastic or stainless steel Figure 5. Mounting 8001KDT bar using the plastic mounting brackets.
brackets that slide along two slots which extend on each side of the bar profile the entire
1 –bar body; 2 – sliding bracket; 4 –6-32x3/8” screw for fixing the mounting bracket in
length of the bar. Several mounting brackets are provided with each bar.
place.

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 The power supply is installed inside an IP-54 rated polycarbonate enclosure, as shown in
Fig. 8 Four mounting holes are exposed when the cover is removed.
All wiring is done inside the enclosure. Two conduit fittings at the input end of the
1
1.57" enclosure are provided for electrical power, safety ground and communication wires.
2 (37 mm)
Up to four 8001KDT neutralizing bars can be connected to the 8154 POWER MODULE
3 using conduit fittings at the output end of the enclosure. The high voltage wires from the
0.8” (20mm) 10-32 or M4 bolt
4 neutralizing bars connect to high voltage outputs terminals inside the enclosure.
A panel-mount HV Output switch is located on the input side of the enclosure. The LED
Figure 6. Mounting 8001KDT bar using the stainless steel mounting brackets. indicator inside the enclosure can be easily observed through the clear enclosure cover to
see if the high voltage output is enabled.
1 – grooves on each side of the bar body; 2 – sliding bracket with mounting tab;
3 – set screw to fix the mounting bracket in place; 4 –bracket can be modified by
bending the tab.

6" (150 mm) 6" (150 mm)

2
Figure 7. Recommended metal-free envelope around a Virtual AC neutralizing bar.

6 1

8154 POWER MODULE – high voltage power supply

Figure 8. 8154 Power Module high voltage power supply.
IMPORTANT! The ION POWER devices are not compatible with the Virtual
1 – enclosure bottom; 2 – clear cover; 3 - output conduit fittings with protective conduit;
AC 8011-series power supplies and 8004/8005 control modules, 8003 computer
4 - power supply board; 5 – input conduit fittings; 6 – HV Output switch.
or Fieldbus interface modules.

The 8154 POWER MODULE is a microprocessor-controlled solid-state high voltage Note: Model 8154 high voltage power supply has four output conduit fittings for
power supply based on the patented Virtual AC technology. The 8154 POWER MODULE connecting up to four neutralizing bars; the unused holes can be plugged in with special
is capable of powering up to 400” (10 m) of 8001-series neutralizing bars with a total up plugs.
to 32 ft (10 m) of high voltage cables.
The 8154 contains circuitry for monitoring the neutralizing bars, malfunction sensor
circuit, and circuitry for remote power activation using a digital signal from a PLC master.
The status LED indicator stays green when everything is okay, or changes to a flashing red
in case of a malfunction. The 8154 uses 24VDC power.

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 Mounting 8154 POWER MODULE 8200 MANAGER– master controller
1. Plan to install the 8154 high voltage power supply outside the hazardous area but The 8200 MANAGER shown in Fig. 10 can control up to nine 8154 neutralizing stations,
within 30 ft. from the bar. The size of its footprint is shown in Fig. 9. displaying the performance parameters and diagnostics for every station in the mini-
Note: A label on the enclosure identifies the output end. network.
2. Remove the cover from the enclosure to expose four mounting holes inside deep wells The 8200 uses 24VDC power which can be connected directly through the dedicated DC
in the corners of the enclosure. power jack, through the RJ11-6 combined communication and power receptacle, or hard-
wired to the terminal blocks on the circuit board accessed through the cutout in the bottom
3. Secure the 8154 to the mounting surface using four 8-32 or M4 size screws.
of the enclosure.
4. Leave the enclosure opened for access to the input/output terminals and grounding
The 8200 MANAGER has two mounting flanges for wall or panel mount installation (see
terminals.
A. Fig. 10).
7.362" IMPORTANT! When installing 8200 MANAGER, leave four-inch (100 mm)
(187 mm)
space at the bottom of the enclosure.
2

5.51 "
3.425" 3 (140 mm)
(87 mm)
6
= 0.16" (4.2 mm) x 4 1

4 10 " 4
5
(254 mm) 3 2 1
4.34 "
4.7" 7.87" (110 mm)
(120 mm) (200 mm)
0.19 " diameter
(Ø 4.8 mm)

3.56 "
(90 mm)

6.10 "
B. C. D. (155 mm)
6.60 "
(168 mm)

Figure 9. 8154 POWER MODULE footprint and mounting dimensions.

ALARM
ALARM

CLEAN
FAULT

BAR
GND

OFF EXT

ON EXT
RESET
A – top view with the cover removed exposing mounting holes; B – view from the input

COM

NO
NC

NO
NC
1.84 "

1
1 2 3 4 5 6 7 8
(47 mm)
end; C – side view; D - view from the output end.
1 – enclosure bottom; 2 – clear cover; 3 - output conduit fittings; 4 - HV
Output switch; 5 – input conduit fittings; 6 –mounting holes (4).
5 6 7 8 9 10

Figure 10. 8200 MANAGER.

1 – Neutralizing Current display; 2 – station address display; 3 – Ion Output display;
4 – control and programming keys; 5 – DC power jack (J2); 6 – RJ11-6communication
port (J1); 7 – reset push-button switch; 8 – remote connector header (J5); 9 – aperture
with grommet for hardwiring the 8200; 10 – matching connector plug.

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 • “Ion Output” display shows the bar ionizing efficiency level. The Ion Output value 8310 CONNECTOR – Serial communication switch
depends primarily on the length of the neutralizing bar or bars connected to the The 8310 CONNECTOR unit shown in Fig. 11 is a simple communications passthrough
specific 8154 and the condition of the ionizing electrodes. See Appendix A for the switch for MODBUS RTU serial communications between the 8154 POWER MODULE
expected values of the Ion Output. The Ion Output display doubles up as a fault and units and the 8200 MANAGER module, or a host computer. It allows multiple 8154
alarm display. POWER MODULES to be connected in the network.
• “Station #” display shows the station address from “1” to “9”, with the “0” reserved
for the Master – 8200 MANAGER.
1
• “Neutralizing Current” display shows how much ion current is flowing to the
charged material to neutralize it. The higher the charge on the material, the more ions
flow to it, and higher the current value. The polarity of the neutralizing current is 1.52 "
(39 mm)
opposite to the polarity of the charge on the material. In the programming mode, the
2
Neutralizing Current display serves for Clean Bar function setup. 5.63 "
4 (143 mm)
3

Displaying the Neutralizing Current values must be disabled under certain conditions
explained later in the manual. When disabled, the display shows “– – –”.
• Control and programming keys.
3.25 "
• The following connectors and terminals are accessible through a cutout in the bottom (83 mm)
panel of the enclosure.
• DC power input connector and terminals.
• Communications connector and terminals.
• Terminals for remote alarm signals 4 8
7 7 4.63 "
• Terminals for remote HVPS activation. (117.5 mm)

• Reset switch
6
4.25" 3.75 "
(108 mm) (95 mm)
The 8200 MANAGER displays the following information for each of the stations 5
connected to it.
4 mounting holes, 0.140" 4.13 "
• Station’s ON/OFF state diameter (3.5mm) (104.8 mm)

• Ion Output in microamperes

• Neutralizing Current in microamperes
• Alarm Status including Short Circuit, Hardware Malfunction and Clean Bar
indication. Figure 11. 8310 CONNECTOR – serial communications switch.
• Clean Bar alarm threshold 1 – bypass switch; 2 – dedicated 24VDC power jack (J15); 3 – DIN rail clips;
• 8154 and 8200 Firmware versions and the serial numbers of the 8154 POWER 4 – RJ11-6 serial communication connectors (J4 and J6); 5 – aperture for hard wiring;
MODULES connected to the 8200. 6 – RJ11-6 combined power & communication connector for 8154 (J5); 7 –apertures for
hard wiring power and serial communication between 8310 CONNECTORS in the
network; 8 – alternative mounting with wall bracket.

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