Fraser IONFIX COMPACT User manual

IONFIXCOMPACT
WITHCONSTANT-POWEROPERATION
OPERATING
INSTRUCTIONS

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IONFIX_CompactGEN_OI_Iss.1
Page
1.Introduction 4
2.Safety 5
3.Use andOperation 7
4.Installation 9
5.Commissioning andOperation 12
6.Remote interface 18
7.TechnicalSpecifications 27
8.Troubleshooting 30
9.Maintenance andRepair 31
10.Disposal 31
11.Spare Parts 31
Contents

4© FraserAnti-StaticTechniques Ltd2016
Thismanual appliesto theFraserIONFIXCompact Generatorproductrange:
• IONFIXCompact, 24V DCinput, 30kV DCoutput, positiveornegativeoutputpolarity.
• IONFIXCompact, 85-264V ACinput,30 kVDC output,positiveornegativeoutput polarity.
Itis essentialthat youreadandunderstandthecompletemanualbeforeinstallingandusingthis
equipment.This isimportant forboth safetyand warrantycover.
Wherethe word‘generator’is usedwithin thismanual, itrefers exclusivelytotheFraserIONFIX
CompactGenerator.
Explanation of Symbols
Throughoutthis manualthe followingsymbols areused todrawattention toimportant information.
Warning:This symbolrefers tooperationswhich, ifcarried outimproperly,mayresultin
seriouspersonal injuries.
Caution: Thissymbol refersto operationswhich,ifcarriedoutimproperly, mayresultin
damageto property.
Information: Thissymbol refersto informationwhich relatesto obtainingthe best
performanceand operatinglifefrom theproduct.
1. Introduction

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IONFIX_CompactGEN_OI_Iss.1
2. Safety
Safety Concepts
TheFraserIONFIXCompact isa high-voltageswitched-modepowersupply. Ithas beendesigned
inaccordance withthe safetyrequirements ofEN 62368-1:2014(Audio/video,information and
communicationtechnology equipment,Part1: Safetyrequirements). Thisstandard isharmonised under
theEU LowVoltageDirectiveand recognisedbyUL.
Thehigh-voltageoutputofthegeneratorisaClass2electricalenergysource,asdefinedinEN62368
1:2014.This meansthat itis capableof causingpain ifcontact ismade witha bodypart, butis notlikely
tocause aninjury requiringmedical attention.
Thedimensions ofthe industry-standardhigh-voltageoutputconnectorsaresuchthattheymaynot be
consideredto provideinsulationbetweenabodypartandtheoutersurfaceoftheconnector.
Thegeneratormust thereforebe usedonly byinstructedpersons,asdefinedinEN62368-1:2014.An
instructedperson issomeone whois instructedor supervisedbyaskilledpersonwithregardtohazards
posedbyelectricalenergysources.
Ifthe generatoristo beoperatedbyordinarypersons, itmust beinstalled insuch amanner thatthe high
voltageoutputconnectorsarenotaccessibleinnormaloperation,forexamplebymountingwithinan
enclosureor providingappropriateguards.
AC-powered generator variant
Theuser-accessible remoteinterfacing circuitsof thegeneratorare isolatedfrom mainsvoltagesbyan
AC-DCpowersupplyunitconformingtotherequirementsofEN60950.
Warning:TheAC-poweredvariantoftheIONFIXCompactcontainspotentiallylethal
voltages.Disconnectthemainssupplyandwait5minutesallowedforstoredenergywithin
themains powersupply unitto beautomatically discharged.
DC-powered generator variant
Warning:The negativepoleof the24 VDC supplyprovidedtothegeneratormustbe
permanentlyearthed.
Safety Warnings
• Installationand maintenancework onthe generatormustonly becarried outbysuitably
qualifiedpersonnel.
• Theprotectiveearthing(PE)terminalofthegeneratormustbepermanentlyconnected
tothe mainearthing terminalof theelectrical installationbyaconductorofatleast
1.5mm2cross-sectional area.
• Disconnectthe powersupply beforeperforming anyinstallationandmaintenancework
onthe generatororelectrodes.
• Connectonly approvedchargingaccessories tothe highvoltageoutputsofthegenerator.

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2. Safety
• Avoidcontactwiththehigh-voltageoutputconnector andthe chargingelectrode(s)
whenenergised.
• Donot insertor removehighvoltageconnectorswhenthegeneratorispoweredorits
outputenergised.
• Anychangestotheequipmentwithoutwrittenconsentofthemanufacturerwill
invalidatethewarrantyand CEcertification.

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IONFIX_CompactGEN_OI_Iss.1
3. Use and Operation
TheFraserIONFIXCompact isa controlledhigh-voltagepowersupplydesignedtopowercharging
electrodesprovidingtemporaryadhesionbetweenmaterialsinindustrialapplications.
TheIONFIX Compacthas simplefront-panel controlsallowing theoutput voltagetobesetprecisely
tomatch theprocess requirements.The outputcurrent iselectronically limited,and thislimit maybe
reducedif necessaryto suitthe particularapplication.
TheIONFIX Compacthas aremote controlinterface, providingremoteswitchingofthehigh-voltage
outputand remotesetting ofthe outputvoltage.Overloadorfault conditionsare alsosignalled onthis
interface,allowing remotemonitoring ofthe generator.
Theunique flexiblepowercontrolfeatureofthegeneratorallows itto provideahigheroutputcurrentat
lowervoltages,maintainingfullchargingpowerovera widerrangeofoutputvoltages.
Overview
Thediagrambelow showsthe mainfeatures ofthe IONFIXCompact generator.
LCDscreen (16x 2character)
HVoutput sockets,remote
interfaceand power
connectionsat rear.
See‘Installation’fordetails.
Powerswitch
Controls

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Accessories
FraserAnti-StaticTechniques manufacturea rangeofcompatible chargingelectrodes tosuit many
temporaryadhesionapplications:
Yourlocal Fraserdistributor canadvise onthe useand installationof theseelectrodes. Alternatively,
pleasevisit ourwebsite (www.fraser-antistatic.com)forfurtherinformationonapplicationsofthese
products.
7081charging Bar 7130charging Bar
7090spot pinningelectrode
7095pinner
7093edge pinner

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IONFIX_CompactGEN_OI_Iss.1
4. Installation
Checking on delivered equipment
Theequipment leavesourfactory insuitable protectivepackaging.Please checkthat itis undamaged
whenit arrives.
Ifthere isvisible damagecontact thesupplier immediately.
Checkthat theparts whichhavebeen deliveredarethe sameas youhaveordered.
Front panel rotation
Thefront paneldisplayandcontrolsofthegeneratormayberotatedby180°in orderto accommodate
differentmounting orientations.
Torotatethe displayfrom‘desktop’to‘wall-mounted’ orientation,follow thesteps below:
1. Ensurethe generatorisswitched offand disconnectedfrom itspower supply(24 Vor mains
connectionisolated andremoved).
a. ACvariant:Allow 5minutes forstored chargeto dissipatebefore openingcover.
2. Removethe8 M4x 8mm screwssecuring thelid ofthe generatorusinga 3mmhexkeyor
driver.Disconnect theearthing connectionfrom thelid.
3. Removethe2 M3screws securingthe frontpanel assemblyto thegeneratorchassis
(underneaththe generator).
4. Undothe 4M3 x15 mmthreaded spacerssecuring thedisplayandcontrolassemblytothe
generatorfrontpanel, usinga 5.5mm spanner.
5. Rotatethe displayandcontrolassemblyby180°. Ensurethat theflexiblecableconnectingthe
displayandcontrolstothemainPCBdoesnotbecometrappedor kinked.
6. Securethe displayandcontrolassemblyinitsneworientation,thenre-fitthefrontpanel
assemblyto thegeneratorchassis.
7. Re-connectthe earthingwire tothe generatorlid,replace thelid andsecure usingthe 8M4
screws.
Mounting
Thegeneratoris providedwithmountingbracketstoallowmountingtoawallorpanel,underatableor
shelf, etc.Use onlythe hardwareprovided(M5 x10 mm)to affixthe mountingbracketstothe generator.
Ifwall-mounted, usefixings suitablefor thewall materialand generatorweightto securethe
generator.Ensure thatthe generatorissecurely mountedand thatall mountingfasteners
havebeentightened beforeuse.

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Earthing
The M5protectiveearthing(PE)terminalofthegeneratormustbepermanentlyconnected
tothe mainearthing terminalof theelectrical installationbyaconductorofatleast0.5mm2
cross-sectionalarea (20AWG).
DC variant:the 0V railofthe24VsupplyMUSTbepermanentlyconnectedtoearth.
AC variant:anearthed IEC320 C13cable MUSTbe usedwith thegenerator, andthe socket
outletsupplying thegeneratorMUST beearthed correctly.
Electrical installation
Thissection describesthe electricalinstallation ofthe generator.The electricalconnections are
shownbelow.
Powerinlet
connector Remote interface
connector
Earthingterminal
HVoutput
socketsx4
1. Ensurethat thegeneratoris earthedas describedabove.
2. Connectthe high-voltageelectrode(s)totheHVoutputsocketsat therear ofthe generator.
Notethat the4 socketsareinternallyconnectedinparallel.Ensurethat anyunusedsocketsare
pluggedwith thesupplied blankingplugs (FraserP/N730218)topreventdirtingress.
• Donot routeHV cablesnear tosharp metalcomponents.
• AvoidbendsorkinksintheHVcables.
• RouteHV cablesseparatelyfrom low-voltagecables.
• KeepHVcables asshort aspracticallypossible.
3. Connectthe remoteinterface cableto the25-wayD-typeconnectorattherearofthegenerator.
Fordetails ofthe remoteinterface, see‘Remote Interface’section ofthis manual.

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IONFIX_CompactGEN_OI_Iss.1
4. Connectthe powerinput cableto thegenerator.
a. DCvariant: connect+24 Vto theleft-hand terminalof the‘Combicon’pluggable terminal
block(viewed fromrear ofgenerator),and 0V totheright-handterminalofthe‘Combicon’
pluggableterminal block.It isrecommended tofit bootlaceferrules tothe strippedends
ofthe 24V inputcable. Insertthe terminalblock intothe ‘Combicon’ socketatthe rearof
thegeneratorand tightenthe retainingscrews.
+24V (POSITIVE)
RETAININGSCREW
0V (NEGATIVE)
RETAININGSCREW
b. AC variant:insertthe IEC320 C13plug intothe socketatthe rearof thegenerator,
ensuringit isfully andfirmly seated.
5. Connectthe powerinput cableto thesupply.
a. DC variant:connect the24 Vand 0V linesto the24 VDC supplyof the
machine/control cabinet.
b. AC variant:connectthe plugto anearthed socketoutlet,or intothe ACsupplyof the
machine/control cabinet.

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5. Commissioning and Operation
Foradvice abouttuning thegeneratorsettingstobestsuitaparticularprocess,pleasecontactyourlocal
Fraserrepresentative.
Beforeturning thegeneratoron forthe firsttime, ensurethat:
• Thepower inputand caseare correctlygrounded asdescribed in‘Electrical Installation’.
• Thecharging electrodesare correctlyconnected tothe outputsockets,withnoloose
connections ordamaged cables.
• Anywiringconnectedtotheremoteinterfaceisconfiguredcorrectly. Ifthe remote
interface isconfigured tooverridethe frontpanel controls,ensure thatthe charging
electrodes becomingenergised doesnot posea safetyrisk.
• Thegeneratoris securelymounted.
Generator front panel controls and display
Thediagrambelow showsthe frontpanel controlsand displayofthegenerator.Thefunctionofthe
controlsis describedin briefbelow thediagram.
• Display:Indicatesthesettingsandoutputparametersof thegenerator, andanywarning
messages.
• LED Indicators (HV, Remote, Current Limited):Showtheoperatingstatus ofthe generatorat
atglance.
• RUN/STOP Button: Togglesthehigh voltageoutputofthegeneratoronandoff.
• Voltage +/- Buttons:Allowthehighvoltageoutput levelofthe generatortobe adjusted.
• Current Limit +/- Buttons:Allow theoutput currentlimit levelofthe generatortobe adjusted.

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IONFIX_CompactGEN_OI_Iss.1
Operating the generator
Switching the generator on
Topowerup thegenerator, putthe mainpower switchon thefront panelinto the‘ON’position.
TheLCDbacklightwillilluminateandthefollowingtextwillbe displayedonthe screenas thegenerator
initialisesand performsself-checks:
Ifanyofthegeneratorremote interfacefunctions areenabled the‘Remote’LEDindicator
willilluminate. Notethat inthis case,the HVoutput ofthe generatormaybeenabled
remotelyat anytime.
Ifthe remoteon/offfunctionisnotenabled,thegeneratorHVoutputwillalwaysbeOFF
whenthe generatorispowered up.If itis necessaryfor thegeneratortopowerupwiththe
HVoutput enabled,use theremote on/off functionto achievethis.
Setting output voltage
Whenthe HVoutput isnot enabled,the generatorvoltageandcurrentsetpointvaluesareshownonthe
display,along with‘SP’ toindicate thatthese aresetpoint values.
Bydefault, thegeneratoroutput voltageisinitiallysetto0.0kV.Thesetpoint valueis storedin non-
volatilememoryanddoesnotneedtobere-seteverytimethegeneratorispoweredon.
Toadjustthe generatoroutputvoltagesetpoint,use the‘Voltage+’ and‘Voltage–‘buttons.Forexample,
ifthe voltagesetpointwasincreasedto12.5kV, thefollowing wouldbe displayed:
TheLCDwillthenswitchtothenormaloperatingdisplay(positivegeneratorshown):

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Pressthe appropriatebutton onceto increaseor decreasethe voltagein0.1kVsteps.Pressandholdthe
appropriatebutton tomakelargeradjustments.
Onnegativepolaritygenerators,the‘Voltage+’ buttonincreases themagnitude ofthe
voltagesetpoint,makingitmorenegative.This correspondsto agreater pinningeffect atthe
generatorelectrode.
Ifthe voltagesetpointisadjustedwhilsttheHVoutputisenabled,thesetpointvalue
followedby‘SP’willbeshownbrieflyonthedisplay.
Setting current limit
Theoutput currentof thegeneratoris electronicallylimited toprotect thegeneratorandminimise
electrodewear.The currentlimit levelcanbe adjustedusing thefront-panel controls.By default,the
generatorcurrentlimit isset toits maximumvalue of1 mA.
Whenthe currentlimit isactive,the‘CurrentLimited’LEDindicatorwillilluminate.
Ifthe voltagesetpointisgreaterthan20kV, theactual currentlimit willbe reducedaccordingly to
maintaina maximumoutput powerof 20W.At 30kV,amaximumof0.66mAisavailable.
Thecurrent limitvalue canbe setto 1mA independentlyof voltagesetpoint,howeverthe
full1 mAis onlyavailableat20kVorless.
Forexample,if thevoltagesetpointis30kVandthecurrentlimitis0.8mA,thefollowingsequence
describesthe behaviourofthegeneratorastheloadisincreased(numbersrefertothediagrambelow):
1. Outputvoltage 30kV,current increasingfrom0 to0.66 mA.Output power<20 W.
2. Outputvoltage reducingfrom30 kV,currentincreasing from0.66 mAtowards 0.8mA.
Outputpower =20 W.
3. Outputvoltage 25kV,output current0.8mA. Outputpower =20 W.
4. Outputvoltage reducingbelow25 kV,outputcurrent limitedto 0.8mA. Outputpower< 20W.
0
0.2
0.4
0.6
0.8
1
1.2
10 150 5 20 25 30 35
OutputVoltage(kV)
MaximumAvailable OutputCurrent (mA)
FraserIONFIXCompactGenerator CompetingGenerators
1
2
3
4

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IONFIX_CompactGEN_OI_Iss.1
Withavoltagesetpointgreater than20kV,the‘CurrentLimited’LEDindicatorwillilluminate
ifthe 20W powerlimit isreached, evenifthe programmedcurrentlimit isnot reached.
Toadjustthe currentlimit, usethe ‘Current–’and ‘Current+’to changethe setpointvalue. Forexample,if
thecurrent setpointwas reducedto 0.5mA, thefollowing wouldbe displayed:
Ifthe currentlimit isadjusted whilstthe HVoutput isenabled, thesetpoint valuefollowed by
‘SP’will beshown brieflyon thedisplay.
Switching high voltage on/off
Toenablethe highvoltageoutputofthegenerator,pressthe‘RUN/STOP’button. The‘HV’ indicatorLED
willilluminate tosignal thatthe HighVoltageoutputisactive,and‘SP’willbereplacedwith‘OP’onthe
LCD.Thisindicates thatthe displayedvaluesarethecurrentmeasuredoutputs.
Ifthe remoteon/offfunctionisnotenabled,theRUN/STOP buttontoggles thehigh voltageoutputon
andoff.
Ifthe remoteon/offfunctionisenabled,buttheHVoutputisnotturnedonviatheremoteinterface,
theRUN/STOPbutton canbe usedto temporarilyoverridetheremote on/off inputfor testingor
commissioningpurposes. Ifthe HVoutput isalready turnedon viathe remoteinterface, theRUN/STOP
buttonwill havenoeffect.

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Operation with remote interface active
Thissection describesthe operationofthe frontpanel displayandcontrolswhentheremoteinterfaceis
inuse. Fordetails ofthe remoteinterface, seethe ‘RemoteInterface’sectionofthismanual.
‘REMOTE’ LED indicator
Ifany oftheremotecontrolfunctions(remoteon/off,remotevoltagesetpoint, remote
currentlimit) areenabled viatheremoteinterfaceconnector,the‘REMOTE’LED indicatoron
thegeneratorfront panelwill illuminate.
If theremote on/off functionis enabled,the HVoutput ofthe generatorcouldbe enabledat
anytimeviaaremotesignal.
Remote on/off input
Ifthe remoteon/offinputisenabled,the‘REMOTE’ LEDindicator willilluminate asdescribed above.
Whenthe HVoutput isenabled usingthe remoteon/offinput,the‘HV’indicatorwillilluminate.
Remote voltage setpoint
Ifthe remotevoltagesetpointfunctionisenabled,an‘R’willbeaddedtothe‘SP’or‘OP’afterthevoltage
readouton thegeneratordisplay.
Forexample,with HVoff andremote voltagesetpointenabled:
WithHV onand remotevoltagesetpointenabled:
Ifthe frontpanel voltageadjustmentbuttonsarepressedinthisstate,thefollowingerrormessagewillbe
shown:

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IONFIX_CompactGEN_OI_Iss.1
Remote current limit
Ifthe remotecurrent limitfunction isenabled, an‘R’ willbe addedto the‘SP’ or‘OP’after thecurrent
readouton thegeneratordisplay.
Forexample,with HVoff and remotecurrent limitenabled:
WithHV onand remotecurrent limitenabled:
Ifthe frontpanel currentlimit adjustmentbuttons arepressed inthis state,the followingerror message
willbe shown:
Ifboth theremote voltagesetpointandremotecurrentlimitareenabled,thefollowingwillbeshown
(HVoff):
HVon:

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6. Remote interface
Thegeneratoris equippedwith aremote controland monitoringinterface permittingremote settingand
operationofthe generator.
Thefollowing functionsare provided:
• Remote on/off enable: enablesoperationoftheremoteon/offinput.
• Remote on/off input: permitsthe HVoutput ofthe generatortobeswitchedonoroffusinga
voltagesignal.
• External voltage setpoint enable:enablesoperationofthe externalvoltagesetpointinput,
overridingthevalue setusing thefront panelcontrols.
• External voltage setpoint input:permitstheHVoutputofthegeneratorto becontrolled from
0-100%according toan analoguevoltagesignal,e.g.fromaPLC output.
• External current setpoint enable:enablesoperationoftheexternalcurrentsetpointinput,
overridingthevalue setusing thefront panelcontrols.
• External current setpoint input:permitstheoutputcurrentlimitofthegeneratortobecon-
trolledfrom 0-100%according toan analoguevoltagesignal.
• Operating signal output:signalswhenthegeneratorisoperatingnormally.
• Overload/limit signal output:signalswhenthegeneratormaximumoutputcurrentisreached,
orwhen anarc oroverloadcondition occursat thegeneratoroutput.
Pin assignment
Theremote interfaceelectrical connectionsare providedbya 25-pinsubminiature D-typesocketatthe
rearof thegenerator. Thepins arenumbered asshown below(viewed looking into socket on rear of
generator):
Thecorresponding 25-wayD-typeplugisAmphenolL717DB25Porequivalent.Anystandard25-way
D-typeconnector,cable orbreakoutboardcanbeusedtomakeconnections tothe remoteinterface.

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IONFIX_CompactGEN_OI_Iss.1
Pin No. Function Pin No. Function
1Remoteon/offinput+ve 14 Remoteon/offinput -ve
2Externalcurrent setpointinput 15 GND (0V)
3Externalvoltagesetpointinput 16 GND(0V)
4Remotevoltagemonitoroutput 17 GND(0V)
5Remotecurrent monitoroutput 18 External voltagesetpointenable
6+24V referenceoutput 19 GND (0V)
7+12V referenceoutput 20 GND (0V)
8Reserved 21 Reserved
9Overloadopencollector 22 Overloadopenemitter
10 Operatingopencollector 23 Operatingopenemitter
11 Externalcurrent setpointenable 24 GND (0V)
12 Notconnected 25 Remote on/off enable
13 Notconnected
Theinterface connectionsare asfollows:
Pins whichare identifiedas ‘reserved’shouldbeleftdisconnectedandnot‘tied’toanypo-
tential(e.g.ground,24V, etc.)These pinsare usedfor productiontesting andare connected
tointernal circuitrywithin thegenerator.
Pins whichare identifiedas ‘notconnected’ canbe connectedto groundpotential without
damagingthe generator.

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Electrical and functional characteristics
Theremote interfacefunctions andthe electricalcharacteristicsof theinterface aredescribed indetail
below.Thepinsoftheinterfacearegroupedaccordingtothefunctiontheyprovide.
Theremote controlfunctions (HVon/off, remotevoltagesetpoint,remotecurrentlimit)may
beused inanycombination.Theremotemonitoringfunctionsarealwaysactive.
Remote on/off input (pins 1, 14, 24, 25)
Theremote on/off inputallows thehigh voltageoutputofthegeneratortobeturnedonoroffbya
voltagesignal.
Tousethe remoteon/offfunction,itmustfirstbeenabledbyconnectingpin 25 (remote on/offenable)to
pin 24 (GND).
Toturnthe highvoltageoutputon,asignallevelof 10-30V mustbe appliedbetween pin 1 andpin 14
(pin 1 positivewithrespecttopin 14).Thisisalowimpedanceinput,andwilldrawapproximately8mA
fromthe signalsource at10 Vrising to35 mAat 30V.
Thewiring examplebelowshowshowtoconnectanexternalHV on/offswitchtothegeneratorusingthe
internal12 Vsupply toprovidethesignalvoltage.
Thefront panel‘RUN/STOP’button maybeused tomomentarily over-ridetheremote on/off inputfor
testing/commissioning purposes.The HVoutput ofthe generatorwillbe enabledwhilst the‘RUN/STOP’
buttonremains pressed.It isnot possibleto turnthe HVoff usingthe ‘RUN/STOP’buttonifitisenabled
viathe remoteon/offinput.