ELTEX ES53 Series User manual

Operating Instructions
IONIZER ES53
Series ES53 and ES53US Power Supplies
for supplying -discharging bars
BA-en-2018-2307
F01061y

2BA-en-2018-2307_ES53

BA-en-2018-2307_ES53 3
List of contents
1 Outline of appliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Identification of risks and hazards . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Work and operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Technical advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Installation and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Assembly the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Ground connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Selecting the discharge bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.4 Connecting the high voltage cable . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5 Maximum active bar length and length of the high voltage cable . 13
3.6 Connecting supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.7 Connection for function and fault signals . . . . . . . . . . . . . . . . . . . . 14
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Function and pollution monitoring (optional) . . . . . . . . . . . . . . . . . 15
5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 Discharging bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6 Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7 Technical specifications ES53 / ES53US . . . . . . . . . . . . . . . . . . 18
8 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9 Spare parts and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
UKCA Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4BA-en-2018-2307_ES53

BA-en-2018-2307_ES53 5
Dear Customer,
The ES53 high voltage power supplies and the EX discharging bars are
designed for the active discharging of disruptive static charges which
develop in production processes in explosion hazard area.
The discharging bars and the power supply are used mainly in cases
where disruptive static charges on fast-moving material webs impair pro-
duction processes and need to be eliminated. The power supply delivers
an alternating voltage of 5 kV at 50...60 Hz.
The ES53 power supply complies with the requirements of the EX dis-
charging bar approval (details in Operating Instructions of discharging bar)
and features the following characteristics:
• 5 plug-type high voltage outputs
• stable 5 kV AC output voltage
• small dimensions
• easy installation
• protection class IP54 design
• function and pollution monitoring of the bars with floating signal
contacts (optional)
• complies with the approval specifications for Eltex EX bars.
Please read the operating instructions carefully before starting the instru-
ment. 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 feedback from the users of our
appliances.

6BA-en-2018-2307_ES53
1. Outline of appliance
1 Power supply lead
2 High voltage terminals (5 terminals)
3 Fuse (type: see name plate)
4 ON/OFF switch (ON = illuminated)
5 Plug for function and fault signals 
(only with function and pollution monitoring, optional)
6 Grounding terminal
7 LED red, fault signal 
(only with function and pollution monitoring, optional)
8 LED green, high voltage active 
(only with function and pollution monitoring, optional)
9 Mounting bracket
Fig. 1: 
ES53 high voltage
power supply for
AC operation
Z00058y
1 2 3 4 5 6 7 8 9
ES53

BA-en-2018-2307_ES53 7
2. Safety
The ES53 Power Supplies have been designed, built and tested using
state-of-the-art engineering, and have left the factory in a technically and
operationally safe condition. If used improperly, the units may neverthe-
less be hazardous to personnel and may cause injury or damage. Read
the operating instructions carefully and observe the safety instructions.
Always observe the rules and regulations applying in your country with
reference to opening and repairing electrical appliances in explosion
hazard area.
The manufacturers will not assume any liability and warranty if the units
are used improperly or outside the intended purpose.
For warranty conditions, please refer to the General Terms and Conditions
(GTC), see www.eltex.de.
2.1 Proper use
The ES53 Power Supplies may be operated only in connection with the
appropriate Eltex discharging bars for AC operation (see Technical Speci-
fications).
Modifications or changes made to the power supplies or discharging bars
are not permitted.
Use only original Eltex spare parts and equipment.
2.2 Identification of risks and hazards
Possible risks and hazards resulting from the use of the power supplies
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 injury.
Caution!
This symbol appearing in the operating instructions refers to operations
which, if carried out improperly, may result in damage to property.
Ex Warning!
This symbol denotes the special conditions which must be observed when
operating the system in explosion hazard areas as specified in the EX
approvals.
Ex!

8BA-en-2018-2307_ES53
2.3 Work and operational safety
Warning!
Carefully observe the following notes and the complete chapter 2 "Safety”,
page 7!
• Before carrying out repairs, cleaning or maintenance work involving the
power supplies and the discharging bars, switch off the power supply
and disconnect the mains power supply (see chapter 5 "Maintenance”,
page 16, chapter 6 "Trouble-shooting”, page 17).
•Before carrying out any work involving the units, the machine which has
the units fitted must not be in operation (see chapter 5 "Maintenance”,
page 16, chapter 6 "Trouble-shooting”, page 17).
• Any work involving the units must be carried out by qualified electrici-
ans (see chapter 5 "Maintenance”, page 16, chapter 6 "Trouble-shoot-
ing”, page 17).
• The unit may only be used by qualified personnel trained for explosion
hazard areas.
• The power supply must be installed outside the explosion hazard area
(see chapter 3.1 "Assembly the power supply”, page 11).
• Before starting the unit make sure that the appliance is permanently
grounded via the grounding terminal (6, Fig. 1). The ground cable
should have a minimum cross section of 1.5 mm2 (see chapter 3.2
"Ground connection”, page 11).
• Check the power supplies and the discharging bars at regular intervals
for any damage to the electrical wiring and the high voltage cables. Any
damaged components must be repaired or replaced before continuing
to operate the units.
• If the housing cover is removed and the supply voltage is switched on
at the same time, contact protection is no longer effective. Always dis-
connect the power before opening the power supply units.
•The protection class IP54 only applies if the housing cover is closed
and the cable connections are shrouded.
• Connect/disconnect the discharging bars only if the power supply unit is
switched off (see chapter 3.4 "Connecting the high voltage cable”,
page 12).
• In applications involving moving bars (e.g. film draw strips), the high
voltage cable must be attached such that there is no cable movement
near the connection zone of the power supply unit (see chapter 3.4
"Connecting the high voltage cable”, page 12).
• Both the lengths of the high voltage cable and of the active bars are 
limited, observe maximum lengths (see chapter 3.5 "Maximum active
bar length and length of the high voltage cable”, page 13).

BA-en-2018-2307_ES53 9
• An overcurrent protection device with a nominal current rating  16 A
and breaking capacity  4 kA must be installed in the mains power sup-
ply circuit. To ensure that no voltage is supplied to the bars when the
material web is at rest, enabling the supply voltage to the power supply
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 (see chapter 3.6 "Connecting supply voltage”, page 13).
•Before starting up the power supply the user must make sure that the
power supply and the bars have been installed and assembled cor-
rectly. The supply voltage can then be switched on (see chapter 4.1
"Startup”, page 15).
• The power supply must be checked regularly to ensure its proper func-
tioning. The connections of the high voltage cables must be free of dirt
and other foreign matter (see chapter 5.1 "Power supply”, page 16).
• Make sure that the bars are clean at all times. Dirt results in malfunc-
tions and in premature wear of the units.
• When cleaning do not soak the bars and the high voltage cable in sol-
vent and do not damage the emission tips; allow the solvent to evapo-
rate completely before restarting the unit (see chapter 5.2 "Discharging
bars”, page 16, chapter 6 "Trouble-shooting”, page 17).
•Ex-Warning:
Only fuses specified in the spare parts list and complying with Standard
IEC 60127-2/5 may be used; failure to observe this specification will
void the Ex approval (see chapter 6 "Trouble-shooting”, page 17).
• 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
displayed.
• 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
Ex!

10 BA-en-2018-2307_ES53
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).
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.

BA-en-2018-2307_ES53 11
3. Installation and assembly
3.1 Assembly the power supply
The power supply must be installed outside the explosion hazard area.
The power supply is designed for wall mounting. Attach using the brackets
provided (installation dimensions, see Fig. 2). The operating elements of
the power supply and the terminals must be freely accessible at all times
and the display LEDs must be visible.
3.2 Ground connection
A permanent ground connection must be made via the grounding terminal
(6, Fig. 1). The ground cable should have a minimum cross section of
1.5 mm2.
Fig. 2: 
Installation 
dimensions ES53
Z00040y
40
Ø
5,5
98
230
>100
145
160
140
112
7
15
180
148
89
Ø
6,5
10

12 BA-en-2018-2307_ES53
3.3 Selecting the discharging bar
Only Eltex discharging bars for AC operation can be connected to the
ES53 power supplies.
3.4 Connecting the high voltage cable
Warning!
Electric shock hazard!
Always disable the supply voltage to the high voltage generator before
disconnecting or connecting the high voltage cables.
Connect the bars via the prefabricated high voltage cable. Push the high
voltage cables up to the stop into the connecting socket. Then secure the
adapter in the socket with the clip provided (see Fig. 3). Cables without
adapter carry a coloured marking on the flexible tubing. This marking must
lie flush with the outside edge of the coupling. Cables without flexible tube
and cables with plug-type adapters are plugged in flush and secured with
the clip.
Warning!
In applications involving moving bars (e.g. film draw strips), the high vol-
tage cable must be attached such that there is no cable movement near
the connection zone of the power supply unit.
Fig. 3: 
Connecting the
high voltage cable
Z00004y

BA-en-2018-2307_ES53 13
3.5 Maximum active bar length and length of the high voltage cable
Both the lengths of the high voltage cable and the active bars are limited.
The shielded high voltage cables cause a capacitive load on the trans-
former inside the power supply. The maximum loading capacity is a result
of the function of the total active bar length and the total length of all high
voltage cables. Fig. 4 demonstrates this principle for EXR50 / EXR5C bars.
Example: The maximum permissible total cable length with a 3 meter
active bar length is 32 meters.
3.6 Connecting supply voltage
Depending on the design of the power supply, connect the supply voltage
via the power supply lead (1, Fig. 1) using an earthing pin plug (depending
on device version); overvoltage category II.
Caution!
An overcurrent protection device with a nominal current rating  16 A and
breaking capacity  4 kA must be installed in the mains power supply cir-
cuit. To ensure that no voltage is supplied to the bars when the material
web is at rest, enabling the supply voltage to the power supply 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.
For external security of the power supply the following circuit breaker is
recommended: Tripping Characteristic 2A/K according to DIN EN 60947-2.
Fig. 4: 
Loading capacity
of the power sup-
ply as factor of bar
length and length
of high voltage
cable.
Z00041e
Σlengths of h.v. cable [m]
Σlengths of active bars [m]
15
10
5
10 20 30 40 50
permissible
range

14 BA-en-2018-2307_ES53
3.7 Connection for function and fault signals
The 5-pin connecting plug (Fig. 5) is only provided in units equipped with
function and pollution monitoring. Depending on requirements, the follow-
ing signals can be picked up at this plug:
• Output voltage active: contact 1, 2, 5
(contact 1 and 5 closed)
• fault/pollution: contact 3, 4, 5 
(contact 3 and 5 closed).
Cables prefabricated at one end are available for connection to this plug
(see spare parts).
Wire colours: 
1 = white, 2 = brown, 3 = green, 4 = yellow, 5 = grey
Fig. 5: 
Assignment of the 
plug for function 
and fault signals
(contacts at rest)
z00009y
12
3
4
5
2
1
5
4
3
Fig. 6: 
Connecting cable
interface, fault 
signal contact
Z00010y
1
2
3
4
5
KS/C Schirm/shield/ecran

BA-en-2018-2307_ES53 15
4. Operation
4.1 Startup
Before starting up the power supply the user must make sure that the
ES53 power supply and the bars have been installed and assembled
correctly. The supply voltage can then be switched on.
Use the toggle switch (4, Fig. 1) to switch on the power supply. In the ON
position the switch lights up green. High voltage is now supplied to the dis-
charging bars.
The output voltage is now a constant 5 kV AC.
If the fuse is defective, the switch will not light up.
4.2 Function and pollution monitoring (optional)
In general, proper operation is indicated by the illuminated switch in all
units.
The optional function and pollution monitoring analyses the high voltage
signal at the output.
• High voltage is indicated by a green LED in the front panel (active). A
floating changeover contact is available for transmitting this signal.
• If a defect or fault is detected (e.g. sparking, dirt or arcing at defective
cable), the fault signal will be activated and displayed via a red LED in
the front panel (fault). The signal is available at a second floating
changeover contact.
Note!
The fault will not be stored. Once the cause of the fault has been reme-
died, the fault signal goes off.
Dirt beginning to settle on a discharging bar is initially indicated by an
irregular response of the fault signal. This must be kept in mind when
processing the fault signal further.

16 BA-en-2018-2307_ES53
5. Maintenance
Warning!
Electric shock hazard!
• Switch the power supply off and disconnect the supply voltage before
carrying out any maintenance or repair work.
• The machine in which the discharging bars are installed must not be in
operation.
• Maintenance work must be carried out by qualified electricians.
5.1 Power supply
The power supply must be checked regularly to ensure its proper func-
tioning. The connections of the high voltage cables must be free of dirt
and other foreign matter. The intervals for the check depend on the appli-
cation and must hence be defined by the user according to the operating
conditions. The power supply itself does not require any maintenance.
Check for correct ground connection!
5.2 Discharging bars
To ensure the trouble-free function of the discharging bars, clean the bars
regularly depening on pollution with compressed air free of oil and water
(max. 6 x 105 Pa and standard compressed air pistol) and a brush with
soft plastic bristles (see chapter 9 "Spare parts and accessories”, page 21.
Refer to the operating instructions for the bar used.
Dirt deposits settling on the bars (e.g. grease) must be cleaned off using a
suitable solvent (benzine). Do not soak the bars and the high voltage
cable in solvent!
Caution!
Risk of deflagration!
Allow the solvent to evaporate completely before restarting the unit.
Do not damage the emission tips of the bars.

BA-en-2018-2307_ES53 17
6. Trouble-shooting
Warning!
Electric shock hazard!
• Switch the power supply off and disconnect the supply voltage before
carrying out any maintenance or repair work.
•Any work involving the units must be carried out by qualified electrici-
ans.
(* F + V = Function and pollution monitoring)
Ex-Warning:
Only fuses specified in the spare parts list and complying with Standard
IEC 60127-2/5 may be used; failure to observe this specification will void
the Ex approval.
Fault with F + V* Cause Measure
red LED (fault) 
lights up
• Dirty bars.
• Sparking on cables
and bars.
• Defective plug
connection.
• Serious source of EMC
interference in the
vicinity of the bar or the
power supply units
•Clean bars 
(see Maintenance).
• Replace defective cables
and bars.
• Insert plug properly.
• Locate and rectify the
source of interference. If
this is not possible, take
measures to suppress
interference.
green LED (active) 
fails to light up, 
no high voltage
• Lamp in mains power
switch lit: defective
transformer.
• Lamp in mains power
switch fails to light:
supply voltage not
enabled or not
connected.
• Defective fuse.
• Inform Eltex Service.

• Check supply voltage
and connections. 
Check connected
cables, cable connec-
tions and bars.
• Replace fuse.
no high voltage • Lamp in mains power
switch lit: transformer
defective.
• Lamp in mains power
switch fails to light: 
enabled or not
connected.
• Defective fuse.
• Inform Eltex Service.

• Check supply voltage
and connections. Check
connected cables, cable
connections and bars.
• Replace fuse.
Ex!

18 BA-en-2018-2307_ES53
7. Technical specifications ES53 / ES53US
Input
Supply voltage 115 or 230 V AC, 50/60 Hz
Power input max. 80 VA
Fuse (primary circuit) see name plate
Recommended 
protection
Tripping Characteristic 2A/K 
according to DIN EN 60947-2
Overvoltage category II according to IEC standard 60664-1
Mains power cable depending on the unit variant, either with groun-
ding contact plug (approx. 2.5 m) or with free
end (cable length max. 99 m)
Connectivity
Operation illuminated ON / OFF switch
Interfaces optional
Output
Voltage 5 kV AC
Current max. 6,2 mA at 5 kV
Frequency 50/60 Hz
pluggable connections 5
Load capacity depending on bar type and length and 
high voltage cable length (see chapter 3.5)
Features
Ion balance with and without parameter diode
Function monitoring and
fault signals (optional)
2 floating contacts, max 250 V AC /1 A
or 24 V DC / 0.5 A loading capacity
green (high voltage active) resp. red (fault) 
LED in the front panel
passive operating mode with the power supply unit switched off

BA-en-2018-2307_ES53 19
Key date
Housing type sheet metal steel with wall bracket
Ground link grounding terminal on housing
Operating ambient 
temperature
ES53: 0 °C...+60 °C (+32 °F...+140 °F)
ES53US: 0 °C...+40 °C (+32 °F...+104 °F)
Storage temperature -20...+80 °C (-4... +176 °F)
Ambient humidity max. 80 % r.h., non-dewing
Protection class IP54 according to EN 60529
Housing dimensions 230 x 180 x 82 mm [HxWxD], see Fig. 7
Weight approx. 4 kg
Ex Approval complying with the requirements of the power
supplies for Ex discharging bar approval EXR50 /
EXR5C: BAS98ATEX2179X and for the Protec-
tive resistor EXRV55 for the Ion Blower Head
EXR55 and for the Ion Blower Pistol EXPR55:
PTB00ATEX2071X
complying with the requirements of the power
supplies for Ex discharging bar approval EXR5N:
TÜV10ATEX7872X / TÜV10ATEX7937X in con-
nection with the ES53/G..., ES53/H... resp. ES53/
I... power supplies and the ion power pistol
EXPR50: TÜV10ATEX7873X
UL Approval ES51US: File No. E227156
as shown on
appliance
marking:

20 BA-en-2018-2307_ES53
8. Dimensions
Fig. 7: 
Dimensions, 
ES53 
power supply
Z00040y+Z00042y
82
183
40
Ø
5,5
98
230
>100
145
160
140
112
7
15
180
148
89
Ø
6,5
10