ELTEX IONSTAR RX3 User manual

Operating Instructions
IONSTAR RX3 Discharging Bar
for 24 V DC
BA-en-2058-1808
RX3_re

2BA-en-2058-1808_IONSTAR RX3

BA-en-2058-1808_IONSTAR RX3 3
List of contents
1 Outline of appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Identification of risks and hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Contact protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Inspection of the protective resistors - contact protection . . . . . . . . . 8
2.4 Technical advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.6 Work and operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Installation and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Assembling the discharging bar . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Connecting supply voltage and connector . . . . . . . . . . . . . . . . . . . 13
3.3 Ground connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4 Connecting socket for function and fault signals . . . . . . . . . . . . . . . 14
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Function monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Function control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8 Technical specifications IONSTAR RX3 . . . . . . . . . . . . . . . . . . . 19
9 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
10 Spare parts and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4BA-en-2058-1808_IONSTAR RX3

BA-en-2058-1808_IONSTAR RX3 5
Dear customer,
The high performance discharging bar IONSTAR RX3 are used mainly in
cases where disruptive static charges need to be eliminated over great
distances.
The advantages of the IONSTAR RX3 discharging bars:
• integrated high voltage generation
• high output voltage for ultimate discharge range
• non-wearing emission tips
• shockless - no danger of electrical shock to personnel
• robust design
• function and fault monitoring with floating signal contacts
• automatic distance measurement with discharge optimization
(depending on the version)
Please read the operating instructions carefully before operating the unit.
This will help you prevent personal injuries and damage to property.
Please give us a call if you have any suggestions, proposals or ideas for
improvements. We greatly appreciate the feedback from the users of our
appliances.

6BA-en-2058-1808_IONSTAR RX3

BA-en-2058-1808_IONSTAR RX3 7
1. Outline of appliance
Fig. 1:
Overview of the
IONSTAR RX3
discharging bar
Z-109988d_1
distance measurement
(depending on the
version)
operating display LED
connector
supply voltage
connector
function and fault
signals
connection for
application ground








 


 
 
 
Fig. 2:
IONSTAR RX3
discharging bar
Z-109988c_2
GL
> 200
AB
B
A
AB = working width A = first tip
GL = total length B = last tip
winding surface

8BA-en-2058-1808_IONSTAR RX3
2. Safety
The units have been designed, built and tested using state-of-the-art engi-
neering, and have left the factory in a technically and operationally safe
condition. If used improperly, the units may nevertheless be hazardous to
personnel and may cause injury or damage. Read the operating instruc-
tions carefully and observe the safety instructions.
2.1 Identification of risks and hazards
Possible risks and hazards resulting from the use of the units are referred
to in these operating instructions by the following symbols:
Warning!
This symbol appearing in the operating instructions refers to operations
which, if carried out improperly, may result in serious personal injuries.
Caution!
This symbol appearing in the operating instructions refers to operations
which, if carried out improperly, may result in damage to property.
Ex Warning!
For units with EX approval only.
This symbol denotes the special conditions which must be observed when
operating the system in explosion hazard areas as specified in the EX
approvals.
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).
Contact protection devices made of conductive material must be
grounded.
2.3 Inspection of the protective resistors - contact protection
The function and the appearance of the protective resistors must be
inspected at regular intervals. The inspection intervals are specified in the
accident prevention regulations, as amended (e.g. in Germany DGUV
V3). Eltex recommend inspection intervals of 6 months.
The function of the series resistors must be checked using a suitable
measuring device. The test voltage must be 1,000V. The measured resis-
tance between two emission tips of the same tip row must not fall below
240 MOhm and not exceed 360 MOhm.
Ex!

BA-en-2058-1808_IONSTAR RX3 9
2.4 Technical advance
The manufacturer reserves the right to make changes to the technical
specifications without prior notice in order to adapt the units to state-of-
the-art engineering. Eltex will provide the latest information on any
changes or modifications in the operating instructions on request.
2.5 Proper Use
The Series IONSTAR RX3 discharging bars must be used only for dis-
charging static charges from material surfaces. Other uses are not permit-
ted.
Other uses are not permitted. The manufacturers will not assume any lia-
bility and warranty if the units are used improperly or used outside the
intended purpose.
Modifications or changes made to the devices are not permitted.
Use only original Eltex spare parts and equipment.
2.6 Work and operational safety
Warning!
Carefully observe the following notes!
• If a conductive substrate (e.g. composite film material with aluminium
coating) is processed under EX atmosphere in the unit in which the
IONSTAR RX3 is installed or if a conductive coating (e.g. metallic inks)
is applied or printed, the IONSTAR RX3 must be de-energised.
• Before carrying out repairs, cleaning or maintenance work and before
resetting after malfunctions, switch off the unit and disconnect the
mains supply voltage.
• The units must be installed, repaired, serviced and tested by qualified
personnel only.
• The bars passively absorb energy from the moving substrate web. The
high voltage cable must be plugged in or grounded to the power supply.
An unconnected grounding cable may cause a spark discharge and
may lead to a risk of injury.
• Check the units at regular intervals and before startup for any damage.
Any damaged components must be repaired or replaced before contin-
uing to operate the unit, or the units must be disabled.
• Make sure that the units are clean at all times.
Dirt results in malfunctions and in premature wear of the units.
• Do not touch the emission tips - risk of injury.
If the high voltage supply is connected, reflex responses to electrical
irritation can lead to secondary accidents, especially in the vicinity of
unguarded rotating assemblies. The charging bar as such is safe to

10 BA-en-2058-1808_IONSTAR RX3
touch. If contact is made, the energy transferred is so low that there is
no risk of injury.
• Potential risk for wearers of cardiac pacemakers:
Moving the chest closer than 3.5 cm to the emission tips of the
discharging bars or making surface contact with several emission tips
(touching a single tip is not critical) can result in a temporary switchover
of the cardiac pacemaker into the fault mode. Permanent proximity or
contact can therefore cause severe problems.
If it is likely that the chest of such a person comes closer than 3.5 cm to
the emission tips of the discharging bar, or if several emission tips are
touched at the same time, the appropriate warning notices must be dis-
played.
• The operation of the bars can generate ozone. The ozone concentra-
tion levels developing near the bars depend on many different factors
such as site of installation, bar current and voltage, air circulation, etc.,
and can therefore not be specified in general terms.
If the maximum allowable concentration of ozone must be observed at
the site of installation of the bar, the concentration must be measured
on site.
The AGW value (maximum admissible concentration) serves to assess
the ozone concentration at the workplace. The user must make sure
that the appropriate national AGW value is at no times exceeded, e.g.
in Germany the ozone concentration occurring during the operation of
the system must not exceed the recommended value based on interna-
tional limits of 0.06 ml/m³ (0.12 mg/m³).
• Mechanical or electrical modifications of the discharging bars are not
permitted.

BA-en-2058-1808_IONSTAR RX3 11
3. Installation and assembly
3.1 Assembling the discharging bar
Attach the Series IONSTAR RX3 discharging bars to the machine wall.
For easier installation we recommend using the assembly material offered
by Eltex. Fig. 3 shows the installation principle.
The profiled assembly section of the discharging bar is grooved. The slid-
ing nuts pushed into this groove serve as bolt attachments for the dis-
charging bar.
Max. bolt depth 9.5 mm
Torque 14 Nm
Caution!
Evenly space the sliding nuts across the full length.
below 1 meter total length: 2 per bar
below 2 meters total length: 3 per bar
over 2 meters total length: 4 per bar
Warning !
For safety in operation, please note the following:
• The bar must be mounted such that mechanical damage to the bar tips
is ruled out.
• When routing the cable, select the attachment points such that
mechanical damage to the cable (e.g. chafing against rotating machine
parts) is ruled out.
• In applications involving moving bars, the cable must be attached such
that there is no cable movement near the connection zone of the bar.
Fig. 3:
Assembling the
discharging bar
Z-109988c_3
1 2
1 aluminum profile
2 sliding nut M6

12 BA-en-2058-1808_IONSTAR RX3
Locating the discharging bar
The best possible discharging results are achieved if the bar is located in
areas with minimum web capacities. In practical terms this means placing
the bar with maximum distances from the machine environment, i.e. no
discharging against the idler roller.
A rough guideline:
No objects of conductive grounded material must be mounted within a
minimum distance of 260 mm from the tip array (Fig. 4). A cylindrical
space with the radius R of the bar distance to the web ought to be kept
free of any conductive material (Fig. 4).
Distance frontal: min. 60mm!
Fig. 4:
Zone free of con-
ductive grounded
material around
the discharging
bar
Z-109988d_4


BA-en-2058-1808_IONSTAR RX3 13
Alignment of the discharging bar
Depending on application, the distance between discharging bar and sub-
strate ought to be 200...800 mm.
The discharging bar must be aligned such that it is mounted centered in
relation to the reel core or - depending on the type of mounting - perpen-
dicular to the material web.
3.2 Connecting supply voltage and connector
The operation of the discharging bar IONSTAR RX3 requires a 24V DC
supply designed for a maximum current of 3 A.
The supply voltage is to be supplied by the customer and is connected via
the connector plug supplied. Alternatively, the optional power supply unit
may be used.
To ensure that no voltage is supplied to the bars when the material web is
at rest, enabling the supply voltage to the unit via machine contact is
recommended. If the material web is at rest, or if the machine is not in
operation, no high voltage is supplied to the bars in this case.
3.3 Ground connection
A permanent ground connection must be made via the grounding terminal
over the shortest possible distance to the conductive machine contact
(6, Fig. 1). A grounding cable with a conductor cross-section of 10 mm²
and a maximum length of 1 meter is required for trouble-free operation.
Fig. 5:
Cylindrical zone
free of conductive
material at a
distance R
ZZ-109988d_5

14 BA-en-2058-1808_IONSTAR RX3
3.4 Connecting socket for function and fault signals
A 4-pin connector for the supply voltage (Fig. 6) and a 6-pin connector for
the function and fault signals (Fig. 7) are available.
The supply voltage of of 24 V DC has to be connected to the supply con-
nector at the contact 2 (24 V) and the contact 3 (ground) resp. to the opti-
onal power supply.
If required, the following floating signals (max. contact load 24V / 0.5 AC/
DC) may be taken off the connector for function and fault signals:
•Warning:
Contact 1 to contact 2 (COM) open
(no Warning: contact closed)
•Malfunction:
Contact 3 to contact 2 (COM) open
(no malfunction: contact closed)
•No line voltage:
(both contacts open.
•Caution!
Contact 4, 5 and 6 are assigned internally and must not be used!
Caution!
The connector for function and fault signals must be attached even if the
connector has not been connected.
Fig. 6:
Connector
supply voltage
Z-109988c_6
1 3
4 2
PIN 1: do not connect
PIN 2: +24 V DC
PIN 3: Ground
PIN 4: do not connect
Fig. 7:
Assignment of the
connector for func-
tion and fault sig-
nals (contacts at
rest)
Z-109988c_7+8
5 4
3
6
1 2
1
2
3
PIN 1: Warning
PIN 2: COM
PIN 3: Error
PIN 4: do not connect
PIN 5: do not connect
PIN 6: do not connect

BA-en-2058-1808_IONSTAR RX3 15
4. Operation
The discharging bars must be operated with a 24 V DC power supply.
4.1 Startup
Once all the connections have been correctly made, the system is opera-
tional and the supply voltage can be switched on.
4.2 Function monitoring
The proper function of the unit is signaled via the LEDs in the connection
zone.
• During startup, all three LEDs (green, yellow, red) of the discharging
bar must light up briefly.
• The green LED lights up as soon as the discharging bar is operational.
• Brief disruptions (1/2 second) of the green LED at 10 second intervals
are possible; the discharging bar otherwise operates continuously.
• The yellow LED signals warning messages:
- LED off: optimum working range
- LED flashing in 1/2 second cycles:
Distance current working range < 350 mm
- LED flashing in 3 second cycles:
Distance current working range > 700 mm
The discharging bar continues ot operate without disruption;
the desired discharging power may not be reached.
• The red LED lights up or flashes as soon as a malfunction is detected.
Note!
Malfunctions are not saved. The disruption of the supply voltage
automatically cancels the malfunction message.
4.3 Function control
Use the Eltex Volt Stick or a glow-lamp voltage tester to check the proper
function of the emission points. Quote Article No. 109136 when ordering
the Volt Stick from Eltex.

16 BA-en-2058-1808_IONSTAR RX3
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.
• The bars passively absorb energy from the moving substrate web. The
high voltage cable must be plugged in or grounded to the power supply.
An unconnected grounding cable may cause a spark discharge and
may lead to a risk of injury.
• Repairs and maintenance work must be carried out by qualified person-
nel only.
To ensure the trouble-free function of the discharging bars, clean the bars
at least once a week with compressed air free of oil and water (max.6 bar
and standard compressed air pistol) and a brush with soft plastic bristles.
Clean grease, ink, glue, paper dust, etc. off the discharging bar and the
distance detection using a suitable solvent (benzine). Do not soak the
bars and the high voltage cable in solvent!
Caution!
Do not damage the emission tips when cleaning. Brush only in longitudinal
direction.
Warning!
Risk of deflagration!
Allow the solvent to evaporate completely before restarting the unit.
Inspection of the protective resistors
The function and the appearance of the protective resistors must be
inspected at regular intervals. The inspection intervals are specified in the
accident prevention regulations, as amended (e.g. in Germany DGUV
V3). Eltex recommend inspection intervals of 6 months.
The function of the series resistors must be checked using a suitable
measuring device. The test voltage must be 1,000V. The measured resis-
tance between two emission tips of the same tip row must not fall below
240 MOhm and not exceed 360 MOhm.

BA-en-2058-1808_IONSTAR RX3 17
6. Troubleshooting
Warning!
Electric shock hazard!
• Do not carry out any maintenance or repair work without first discon-
necting the supply voltage.
• 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.
Malfunction Cause Measure
red LED flashing • Dirty bar.
• Sparking aganist metallic
machine parts.
• Serious source of EMC
interference in the vicinity
of bar or power supply units
• Clean bar
(see chapter Maintenance).
• Check installation situation.
• Loctate and rectify the source of interfe-
rance, if necessary take measures to
suppress interference
red LED on • Internal error. • Acknowledge the malfunction; disconnect
the supply voltage and restart the unit.
• If the malfunction recurs, send the unit for
repair.
No LED on • Supply voltage not enabled
or not connected.
• Defective internal fuse.
• Defective LED.
• Check supply voltage, connections and
connected cables.
• Acknowledge the malfunction; disconnect
the supply voltage and restart the unit.
• If the malfunction recurs, send the unit for
repair.

18 BA-en-2058-1808_IONSTAR RX3
7. Warranty
The units are warranted for a period of 12 months provided that the opera-
ting conditions have been maintained, that the units have not been tam-
pered with and that the units show no mechanical damage.
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. Defective components will
be replaced and installed free of charge.
If repairs are required at the customer's premises, the costs for sending a
technician (travel, travel time, expenses) will be charged to the customer.

BA-en-2058-1808_IONSTAR RX3 19
8. Technical specifications IONSTAR RX3
Discharging bar IONSTAR RX3
Supply voltage 24 V DC ±10%
Input current max. 3 A
Power input max. 55 W
Output voltage ±40 kV
Operating distance 200 - 800 mm
Measuring range
ultrasonic sensor
350 - 700 mm
optional: version with factory-set distance
Operating
ambient temperature +5...+40 °C (+41...+104° F)
Ambient humidity max. 70% RH, non-dewing
Bar element glass-fibre-reinforced plastic GRP
Encapsulation material polyurethane
Emission tips tungsten
Installation material sliding nuts M6
Short-circuit current/tip max. 0.45 mA
Function and fault
monitoring signals
2 floating contacts, max. 24 V / 0,5 A DC/AC
LED in the connecting plate:
green LED: high voltage active
red LED: malfunction
yellow LED: warning
Contact protection according to EN 61140
Application ground grounding terminal at the housing
Protection class
housing IP 40 according to EN 60529
Dimensions 108.5 mm x 58 mm x total length
Weight see chapter dimensions

20 BA-en-2058-1808_IONSTAR RX3
9. Dimensions
Available lengths of the bar IONSTAR RX3
Fig. 8:
IONSTAR RX3
discharging bar
Z00062y
GL
> 200
AB
B
A
AB = working width A = frist tip
GL = total length B = last tip
winding surface
reference code total length max. working
width
weight
IONSTAR RX3/S000848 848 mm 920 mm 5.6 kg
IONSTAR RX3/S001088 1088 mm 1160 mm 6.8 kg
IONSTAR RX3/S001328 1328 mm 1400 mm 8.0 kg
IONSTAR RX3/S001568 1568 mm 1640 mm 9.2 kg
IONSTAR RX3/S001808 1808 mm 1880 mm 10.4 kg
IONSTAR RX3/S002048 2048 mm 2120 mm 11.6 kg
IONSTAR RX3/S002288 2288 mm 2360 mm 12.8 kg
IONSTAR RX3/S002528 2528 mm 2600 mm 14.0 kg
IONSTAR RX3/S002768 2768 mm 2840 mm 15.2 kg
IONSTAR RX3/S003008 3008 mm 3080 mm 16.4 kg