Gema iONstream 4.0 6 kV User manual

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Translation of the original operating instructions
Installation and Operating Instructions
Electrostatic discharge
system
iONstream 4.0 6 kV/12 kV/18 kV

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iONstream 4.0
Documentation iONstream 4.0
© Copyright 2016 Gema Switzerland GmbH
All rights reserved.
This publication is protected by copyright. Unauthorized copying is
prohibited by law. No part of this publication may be reproduced,
photocopied, translated, stored on a retrieval system or transmitted in any
form or by any means for any purpose, neither as a whole nor partially,
without the express written consent of Gema Switzerland GmbH.
AUTODC Technology, TRUEDC Sensor Technology, MagicCompact,
MagicCylinder, MagicPlus, MagicControl, OptiFlex, OptiControl, OptiGun,
OptiSelect, OptiStar and SuperCorona are registered trademarks of
Gema Switzerland GmbH.
OptiFlow, OptiCenter, OptiMove, OptiSpeeder, OptiFeed, OptiSpray,
OptiSieve, OptiAir, OptiPlus, OptiMaster, MultiTronic, EquiFlow, Precise
Charge Control (PCC), Smart Inline Technology (SIT) and Digital Valve
Control (DVC) are trademarks of Gema Switzerland GmbH.
All other product names are trademarks or registered trademarks of their
respective holders.
Reference is made in this manual to different trademarks or registered
trademarks. Such references do not mean that the manufacturers
concerned approve of or are bound in any form by this manual. We have
endeavored to retain the preferred spelling of the trademarks, and
registered trademarks of the copyright holders.
To the best of our knowledge and belief, the information contained in this
publication was correct and valid on the date of publication. Gema
Switzerland GmbH makes no representations or warranties with respect
to the contents or use of this publication, and reserves the right to revise
this publication and make changes to its content without prior notice.
The latest information on Gema products can be found under
www.gemapowdercoating.com or www.hildebrand-technology.com.
For information regarding patents, visit
www.gemapowdercoating.com/patents or
www.gemapowdercoating.us/patents.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
[e-mail]

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iONstream 4.0 Table of contents • 3
Table of contents
Introduction 5
General ................................................................................................................... 5
Versions .................................................................................................................. 6
Application ............................................................................................................... 6
Advantages ............................................................................................................. 7
Safety Instructions 9
Applications / Scope of Use .................................................................................... 9
Safety symbols (pictograms) ................................................................................. 10
During normal operation .......................................................................... 11
During installation and removal................................................................ 12
During neutralizing bar cleaning .............................................................. 13
Grounding ................................................................................................ 13
In problem situations ................................................................................ 13
Ozone generation .................................................................................... 13
User Duties 15
General ................................................................................................................. 15
Safety instructions .................................................................................... 15
Storage, Transport and Packaging/Unpacking ..................................................... 17
User and working safety prior to commissioning .................................................. 17
Installation and commissioning ............................................................................. 18
Neutralizing bar contamination and cleaning ........................................................ 18
Mechanical Installation 19
Determining Locations for Neutralizing Bars ........................................................ 19
Avoiding loss of efficiency ..................................................................................... 21
Setting the NodeID ................................................................................................ 21
Mounting options ................................................................................................... 23
Dimensions 25
Electrical Connection 27
Connector specification ......................................................................................... 27
Description of the Connections ................................................................ 28
Explanation of pin functions ..................................................................... 28
Use in standalone operation ................................................................................. 29
Factory settings ........................................................................................ 29
Use of PIN1 output: for clean bar or system error ................................................ 30
Overview of local multi-function LED: Functions .................................................. 31
Description of LED functions ................................................................................. 31
Network Operation ................................................................................................ 33
Technical Data 35
Electrical data ........................................................................................................ 35

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4 • Table of contents iONstream 4.0
Input ......................................................................................................... 35
Output ...................................................................................................... 35
General .................................................................................................... 36
Mechanical data ................................................................................................... 36
Ambient conditions ............................................................................................... 36
Optical display/ device status/ error ..................................................................... 37
Technical Service ................................................................................................. 37
APPENDIX
Drawing ....................................................................... iONstream 4.0: 6 / 12 / 18 kV
Drawing ................................................................. iONnet DIN Rail Distributor plate
Connection diagram .............................................................................. Stand-alone
Connection diagram ............................................................... Supply network 24 V
Connection diagram .................................................... Supply network with iONnet
Connection diagram ................................................. BUS Network with iONmaster
Connection diagram ...................................................... BUS Network with iONgate
Connection diagram ....................................................... BUS Network with iONlink

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iONstream 4.0 Introduction • 5
Introduction
General
The intelligent electrostatic IONstream 4.0 discharge systems are the
most efficient, contactless way to electrostatically neutralize a substrate
surface in web or sheet form. The neutralizing product line from Gema
Switzerland GmbH represents the most advanced and easiest way of
effectively controlling electrostatic charge. The 18 kV version is suitable
for applications with distances greater than 600 mm, 12 kV version is
suitable for applications with distances up to 600 mm, and the 6 kV
version for distances up to 300 mm. All systems are designed for normal
speed applications up to 1000 m/min. For high speed applications, the
iONstream 4.0 with AUTODC® Technology is the most sophisticated
efficient discharging method. In iONstream 4.0, the sensor technology is
integrated in the electrode profile. The multi-function LED for the local
status display is located next to the bus connector. When connected to a
master display, all parameters are visualized on the display. The
neutralizing bars are available in lengths from 320 mm to 4500 mm. Wider
applications are realized by using additional bars.

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6 • Introduction iONstream 4.0
Versions
Type Designation ATEX labeling Zone
IC41 iONstream 4.0
6 kV – –
IC43 iONstream 4.0
12 kV – –
IC45 iONstream 4.0
18 kV – –
Application
Typical applications include the electrostatic neutralization of plastics,
carton, film, foams, non-woven tissue, glass textiles and many other
insulating materials. The ATEX certified version of the iONstream 4.0
system guarantees the highest safety levels for usage in potentially
explosive environments – refer to version table.

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iONstream 4.0 Introduction • 7
Advantages
The high-voltage supply is integrated in the electrode profile and is
designed for demanding industrial applications with outstanding safety
standards.
– Power supply 24 VDC (20-28 VDC)
– extremely compact, stable and glass fiber-reinforced electrode
profile for mounting with mounting clips or T-slot and screws
– completely encapsulated
– housing protection type IP 68
– non-contact Tungsten emitter tips,
– short circuit-proof design, 30 mm pin distance.
– Microprocessor-controlled with local intelligence.
– The emitter pins are decoupled from the high voltage using resistors
– All electrical connections are fail safe, vibration-proof plugs in
housing protection type IP 54.

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iONstream 4.0 Safety Instructions • 9
Safety Instructions
ATTENTION
Damage to the system or components
Please read and understand the instructions fully before installing the
system!
► All installation and repair work must be performed by qualified
technicians!
The iONstream electrostatic discharge systems were developed
according to the latest safety requirements for industrial applications and
have successfully passed the relevant safety and life tests before
delivery. The systems consist of an encapsulated, glass fiber-enforced
plastic electrode profile with integrated HV generator that contains
resistances and emitter pins.
Follow all instructions of this manual to ensure proper function of the
system and to retain your entitlement under the guarantee. Any
installation or commissioning deviating from the instructions in this
manual will lead to the loss of guarantee.
Applications / Scope of Use
The iONstream high performance systems for electrostatic discharge are
designed to neutralize the static charge of surfaces. The technology is the
latest generation of electrostatic discharge systems and is used in a wide
range of applications with moving webs, sheets or 3D parts applications.
ATTENTION
Damage to the system or components
Any use not described this manual as well as changes to the
hardware are not permitted.
► Only original spare parts delivered by Gema Switzerland GmbH
may be used for maintenance and repair of the systems!
Installation and commissioning of the system need to fulfill all local safety
standards and instructions for safe use. Operators may be exposed to
potentially dangerous situations if installation and use are not in
accordance with the instruction manual. Persons coming in contact with
the emitter pins while they are energized can be charged and may suffer
from an electric shock when they come into contact with the ground.
Place guards and "Danger High Voltage" warnings signs around the point
of use of the bar.

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10 • Safety Instructions iONstream 4.0
Safety symbols (pictograms)
The following contains a list of warnings with their meanings found in the
Gema operating instructions. Apart from the regulations in the relevant
operating instructions, the general safety precautions must also be
followed.
DANGER
Indicates a hazardous situation which,
if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation which,
if not avoided, could result in death or serious injury.
Caution!
Indicates a potentially hazardous situation which,
if not avoided, could result in minor or moderate injury.
ATTENTION
Indicates a potentially harmful situation which,
if not avoided, the equipment or something in its surrounding may be
damaged.
ENVIRONMENT
Indicates a potentially harmful situation which,
if not avoided, may have harmful consequences for the environment.
MANDATORY NOTE
Information which must be observed.
Note
Useful information, tips, etc.

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iONstream 4.0 Safety Instructions • 11
During normal operation
WARNING
Danger of electric shock
Even though the neutralizing bar is insulated and the current is limited,
touching the electrodes of the emitter pins is strongly discouraged when
the bar is in operation. It is possible that persons (depending on the
shunt resistance) are charged to a greater or lesser extent and
experience an electric shock when they make direct contact with
ground.
WARNING
Danger of electric shock
Do not disconnect any wiring of the iONstream system while the
24 VDC power supply is operational regardless of whether the
application is operational.
WARNING
Danger of electric shock
Keep neutralizing bars wired to ground at all times while the system is
operational regardless of whether the 24 VDC power supply is
operational or not.
WARNING
Danger of electric shock
Disable the 24 VDC supply voltage input when processing webs that
contain a metal foil or metallized film. Under certain circumstances,
metallized areas, strips or webs can store charges or conduct them
along the material web and can therefore represent safety risks. If
metallized products are processed, please contact Hildebrand
Technology. An application engineer is available to assist in the
assessment of whether the use of electrostatic neutralizing equipment is
suitable.
High voltage operation (green LED lights up permanently) should
only be active when it is required for the application.

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12 • Safety Instructions iONstream 4.0
During installation and removal
ATTENTION
Damage to components
► Do not drill holes in the bar housing, and follow the wiring
instruction accurately to avoid equipment damage.
WARNING
Danger of electric shock
► Do not install or remove iONstream equipment while the
machinery and/or application are operational.
WARNING
Danger of electric shock
► Always disable the 24 VDC power supply when installing or
removing the iONstream system.
WARNING
Danger of electric shock
Persons with a pacemaker must not touch the emitter pins!
► Pacemakers may no longer function correctly when the distance
between emitter pins and chest is < 3.5 cm.
► Touching the emitter pins, especially with a large surface area
such as the palm of your hand, can temporarily switch a
pacemaker into error mode and may result in major health risk.
WARNING
Danger of electric shock
► Keep neutralizing bars wired to ground at all times while the
system is operational regardless of whether the 24 VDC power
supply is operational or not.

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iONstream 4.0 Safety Instructions • 13
During neutralizing bar cleaning
WARNING
Danger of electric shock
► Always disable the 24 VDC power supply when cleaning the
neutralizing bars.
Caution!
Sharp pins
Grounding
WARNING
Danger of electric shock
► The iONstream neutralizing systems MUST be grounded.
In problem situations
ATTENTION
If liquid has been spilled on the bar, disable 24 VDC power immediately.
Correct the problem before restarting the machine.
WARNING
Danger when using uncertified systems
Never use iONstream neutralizing systems in explosive environments if
they are not Ex-Certified.
► also refer to version table
► Ex-Certified bars have an ATEX Ex label attached to the bar
profile.
Ozone generation
Ozone may be generated when the iONstream is in use.
This phenomenon and its concentration depend on several
parameters. It is not possible to specify a common figure of the ozone
concentration during usage.
– If the ozone concentration becomes an issue at a specific
workstation, on-site measurement has to be taken and
adequate ventilation must be provided.

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iONstream 4.0 User Duties • 15
User Duties
General
This manual must be available at all times to personal/operators using
this equipment.
Safety instructions
The iONstream system may only be installed and operated in accordance
with this manual. Always follow local regulations and standards
concerning repair and grounding according to relevant European
regulations such as the Low Voltage and EMC directives.
ATTENTION
Damage during transport and installation
► During transportation, the iONstream system must be protected
against damage and bending.
ATTENTION
Damage to the system or components
Please read and understand the instructions fully before installing the
system!
► All installation and repair work must be performed by qualified
technicians!
Authorized and trained personal
► Assembly, commissioning and maintenance of the iONstream
system may only be performed by trained and qualified
personnel

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16 • User Duties iONstream 4.0
WARNING
High voltage shocks
► Always switch off the 24 VDC power supply before working on the
system!
► Use protection equipment against unauthorized restart of the
power supply during this period.
► If the iONstream system needs to be removed from the point of
use, switch off the power supply.
► If the power plug needs to be removed, ensure safe grounding
of the system on the ground terminal next to the bus system.

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iONstream 4.0 User Duties • 17
Storage, Transport and Packaging/Unpacking
The iONstream system must be packed in the original packaging and
protected against breakage, ingress of water and humidity. Establish the
ambient conditions in accordance with the technical data in this manual.
Caution!
Sharp pins
The emissions pins of the neutralizing bars are extremely sharp and can
cause injury when touched. Check carefully for possible transport
damage. Inform the transporting company immediately about transport
damage. Also inform Gema Switzerland GmbH immediately.
Check the following carefully when unpacking:
– Quantity delivered
– Type and model according to label
– Accessories
– Correct manual
In case of incorrect deliveries or questions, please contact your local
representative or Gema Switzerland GmbH. Follow local instructions for
package material disposal.
User and working safety prior to commissioning
WARNING
Danger of electric shock
► Always ground by using the ground stud!
Prior to commissioning, ensure that the device ground is connected to the
ground stud as shown in figure 1. The ground wire must have a minimum
cross-section of 2.5 mm² (AWG 13).
fig. 1: Connection to machine or plant mass / ground
The iONstream systems for electrostatic neutralizing must be regularly
checked for mechanical damage as well as for bar contamination. Any
errors must be eliminated prior to switching on the system.

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18 • User Duties iONstream 4.0
Installation and commissioning
The iONstream system is an electrostatic neutralizing system consisting
of a neutralizing bar with integrated high voltage modules and
encapsulated microprocessor electronics. The neutralizing bars are
available in lengths from 320 mm to 4500 mm. The local status LED is
visible on the front side and indicates the system status.
WARNING
Danger of electric shock
Only connect or disconnect when the power supply is OFF!
► Ensure that the 24 VDC supply is disconnected before connecting
or disconnecting the main plug.
► The device ground must always be connected.
Neutralizing bar contamination and cleaning
Contamination of the emitter pins will occur. The emitter tips of the
ionizers must be kept clear of contamination and cleaned regularly.
WARNING
Explosion hazard
The tips of the ionizers must be kept clear of contamination and cleaned
regularly.
► Only use IPA alcohol or a suitable solvent.
► Unless the operational and local conditions specify a shorter
cleaning interval, we recommend cleaning the emitter tips on a
weekly basis.
ATTENTION
Damage to components
Use a brass brush for cleaning in order to avoid damage and scratches.
► This should preferably have a curved handle in order to avoid
injuries to the hand from the emitter pins.

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iONstream 4.0 Mechanical Installation • 19
Mechanical Installation
Determining Locations for Neutralizing Bars
WARNING
Explosion hazard
► If the system is installed in a potentially explosive zone, the
position of the neutralizing bar must be selected in such a way
that the substrate is discharged and does not pose a risk of
ignition.
Attach the neutralizing bar to 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 not vary.
fig. 2
A: Distance to roller must be greater than 1x diameter of the roller.
* Dimensions in this image are based on experience and may differ
from case to case. Adequate ionization efficiency must be
demonstrated for the particular application by measurement.
The bar should not be closer than 80 - 300 mm (6 kV), 300 - 600
mm (12 kV) or 600 - 1000 mm (18 kV) to the roller.
A: > 1 x d d
iONstream
6 kV: 80 ~ 300 mm*
12 kV: 300 ~ 600 mm*
18 kV: 600 ~ 1000 mm*
6 k
V
12 kV
18 kV

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20 • Mechanical Installation iONstream 4.0
For reels, the neutralizing bar should be installed so that it neutralizes the
roll after the last separating point (contact roller) (see Fig. 3) and is not
near metal objects on the sides of the bar.
fig. 3
* Dimensions in this image are based on experience and may differ
from case to case. Adequate ionization efficiency must be
demonstrated for the particular application by measurement.
Blue is an alternative position for the reel but only for the rotary
direction shown.
Start of new roll End of roll
iONstream
6 kV: to 600 mm*
12 kV: to 1500 mm*
18 kV: to 2000 mm*