ITW SIMCO ION MCM 30 User manual

MCM 30 Electrostatic Charging Generator 5201088 Rev. C
INSTALLATION AND OPERATING INSTRUCTIONS
MCM 30
Electrostatic Charging
Generator

A2 5201088 Rev. C
MCM 30 Electrostatic Charging Generator
TABLE OF CONTENTS
1. Notes and Cautions ............................................................................ 1
2. Introduction...................................................................................... 2
3. Specifications ................................................................................... 4
4. Installation ...................................................................................... 5
5. Operation ........................................................................................ 9
6. Maintenance ...................................................................................11
7. Troubleshooting................................................................................12
8. Accessories and Parts ........................................................................13
9. Warranty ........................................................................................13

15201088 Rev. C
MCM 30 Electrostatic Charging Generator
1. NOTES AND CAUTIONS
NOTE – Statements identified with a NOTE indicate precautions necessary to avoid
potential equipment failure.
CAUTION! - Statements identified with a CAUTION indicate potential safety
hazards.
NOTE - This equipment must be correctly installed and maintained. Adhere to the
following cautions for safe installation and operation:
1. Read the complete Operation / Maintenance Manual before operating. Failure to
follow instructions may result in damage to the power unit, MCM 30 Electrostatic
Charging Generator and/or personal injury.
2. The AC power adapter is supplied with a 3-prong inlet plug, which must be inserted
into an appropriate, properly wired and grounded receptacle outlet.
3. A factory qualified service technician must perform component service and repairs.
Please contact Simco-Ion Customer Service for information.
WARNING! – Keep the unit dry. Do not operate the unit in flammable or
explosive atmospheres.
Do not make electrical connections to the unit while high voltage is present.

25201088 Rev. C
MCM 30 Electrostatic Charging Generator
2. INTRODUCTION
The MCM 30 is an adjustable output, DC electrostatic charging generator designed for use
with a variety of Simco-Ion charging bars and charging applicators. Using the principles
of static charge attraction, the units’ high voltage, fixed polarity output provides a method
to temporarily pin or bond a variety of materials together. Example uses are stacking,
packing, converting, printing plastics, in-mold decoration and other various manufacturing
operations.
The compact size of the MCM 30 charging generator makes it well suited for production
environments where operating clearances are limited. Because of its low weight and
small size, it can be mounted directly to a gantry or robot arm in automated stack pinning
processes. The front panel of the power supply features an LED array to provide a
continuous indication of the unit’s operating condition and level of the adjustable output.
The MCM 30 is powered from 24VDC input. The input voltage is supplied from the
provided AC power adapter which is plugged into the terminal block in the end of the unit.
The Simco-Ion AC power adapter also supplies the required electrical (machine) ground
connection. The input voltage may alternately be supplied to the terminal block from
a machine 24VDC power bus located in the parent machinery, however, user supplied
24VDC must provide electrical (machine) ground on the return (negative) side.
The units’ terminal block also includes; relay contact connections for indication of when
a fault condition has occurred, remote control of output level and remote control of unit
on-off.
Features
 •Compactsizeandlightweight.
 •Easyinstallationandoperation.
 •Adjustableoutputwithvisual10LED“bargraph”display.
 •Modeindicatortoindicatevoltageorcurrentoutputdisplay.
 •Status indicators to indicate overload, fault, remote program operation,
HV output on/off, and power on/off condition.

35201088 Rev. C
MCM 30 Electrostatic Charging Generator
MCM 30 Face View
MCM 30 End View

45201088 Rev. C
MCM 30 Electrostatic Charging Generator
3. SPECIFICATIONS
Input power 24 VDC, 3 A, 75 W (max.)
Output Voltage range 3 to 30 kVDC (negative / positive, depending on unit)
Output Current range 0.1 mA to 1 mA (single output)
Output Connector SLCC CC-25 (mating plug: Simco-Ion P.N. 4100286)
Charge Applicator Available from Simco-Ion
Operating Temperature 32°F (0°C) to 104°F (40°C)
ON/OFF Control Power switch provided on front panel or remote
control at terminal block
Output Control Rotary knob provided on front panel or remote control
at terminal block
Indicators OUTPUT
10 green LED “bar graph”
(multi-function, output current and output voltage)
MODE:
Voltage: green LED
Current: green LED
STATUS:
Overload: red LED
Fault: red LED
Remote Program: green LED
Status: yellow LED
HV Output: green LED
Power: green LED
Interface Connections (12) Position terminal block provided at end panel for
standard / auxiliary power input, fault alarm output
connections and remote control.
(Mating plug supplied with unit.)
(Reference: mating plug is Phoenix Contact, P.N.
1803675)
Enclosure ABS plastic (UL94V-0), Color: black
Overall Dimensions 7.75” L x 3.00” W x 2.62” D
(197mm L x 76mm W x 67mm D)
Weight 1.7 lb (0.77 kg)
Mounting Four 0.180” (4.57mm) diameter mounting holes in
flanges
AC Adapter (universal) 100-240 VAC, 50-60 Hz input / 24 VDC, 3.75 A
output

55201088 Rev. C
MCM 30 Electrostatic Charging Generator
4. INSTALLATION
Unpacking
Carefully remove the equipment from the carton and inspect the contents.
NOTE - If any damage has occurred during shipment, notify the local carrier at
once. A report should also be forwarded to Simco-Ion, 2257 North Penn Road,
Hatfield, PA 19440. See Section 9 (Warranty) for Return Shipment information.
Mounting
The MCM 30 charging generator is intended for fixed mounting onto a flat and rigid
surface. Holes in the flanges of the unit enclosure are provided for screw mounting to the
selected surface. The charging generator enclosure may be used as a template to mark
the hole locations onto the surface. The use of #8 or M4 screws, flat washers and nuts
are suggested for the final mounting. Because of the many possible mounting situations,
screw and nut hardware is not included with the power supply. It is recommended that the
unit be positioned so the wiring and charging device cabling exits in a downward direction.
This positioning is preferred to minimize stresses that could kink or pinch the wire and
cable insulation. Allow for wire and cable flex and support wiring if the installation will
be subject to repetitive motion.
Electrical Connections
Connect the charge applicator to the high voltage outlet port using the SLCC (spring
loaded cable connector) on the charge applicator. Hand-tighten connector only.
NOTE – Keep high voltage wiring and low voltage wiring separated. DO NOT
route high voltage wiring along with low voltage wiring. Intermixing high voltage
wiring with low voltage wiring increases the risk of inductively coupled EMI and
machine malfunction.
NOTE – Keep high voltage wiring away from sharp edges. Sharp (metal) edges
increase risk of high voltage insulation damage due to electric field concentration.
Sharp edges may also cause insulation cuts and damage leading to insulation burn-
out. Route high voltage wiring away from sharp edges.
Secure the AC adapter in a location suitable for connection to AC line voltage.
Insert the 24 VDC output (+ wire) of the AC adapter or auxiliary power bus into position
#1 of the Interface Terminal Block plug and tighten the clamping screw. Insert the Ground
(return wire) of the adapter or power bus into position #2 of the Interface Terminal Block
plug and tighten the clamping screw. The return wire of the AC adapter is supplied by
Simco-Ion is connected to the AC input line ground and this connection must be connected
to the local electrical machine ground. Where a machine 24VDC power buss is used, the
return wire on Pin 2 must be connected to a local electrical machine ground.

65201088 Rev. C
MCM 30 Electrostatic Charging Generator
Interface Terminal Block power connections
Position 1 2 3 4 5 6 7 8 9 10 11 12
Function +24
VDC
GND K1
(NC)
K1
(COM)
K1
(NO)
REMOTE
PRG
(0-5V)
REMOTE
PRG
ENABLE
ENABLE
HV
(on/off)
COMM
A
COMM
B
GND
(aux)
+24
VDC
(aux)
Interface Terminal Block power connections for remote (PLC) operation
Position 1 2 3 4 5 6 7 8 9 10 11 12
Function +24
VDC
GND K1
(NC)
K1
(COM)
K1
(NO)
REMOTE
PRG
(0-5V)
REMOTE
PRG
ENABLE
ENABLE
HV
(on/off)
COMM
A
COMM
B
GND
(aux)
+24
VDC
(aux)
24VDC
Adapter
24VDC
Adapter
Open collector
from PLC to remotely
control unit ON / OFF.
Note that position #8 must be grounded to enable use of on/off switch on face of unit.
Optional Electrical Connections
Interface Terminal Block power connections
Position 1 2 3 4 5 6 7 8 9 10 11 12
Function +24
VDC
GND K1
(NC)
K1
(COM)
K1
(NO)
REMOTE
PRG
(0-5V)
REMOTE
PRG
ENABLE
ENABLE
HV
(on/off)
COMM
A
COMM
B
GND
(aux)
+24
VDC
(aux)
Interface Terminal Block power connections for remote (PLC) operation
Position 1 2 3 4 5 6 7 8 9 10 11 12
Function +24
VDC
GND K1
(NC)
K1
(COM)
K1
(NO)
REMOTE
PRG
(0-5V)
REMOTE
PRG
ENABLE
ENABLE
HV
(on/off)
COMM
A
COMM
B
GND
(aux)
+24
VDC
(aux)
24VDC
Adapter
24VDC
Adapter
Open collector
from PLC to remotely
control unit ON / OFF.
Note that the MCM 30 power switch must be set to “ON” to allow remote control of high voltage
output on / off.
Interface Terminal Block position assignments
Position 1 2 3 4 5 6 7 8 9 10 11 12
Function +24
VDC
GND K1
(NC)
K1
(COM)
K1
(NO)
REMOTE
PRG
(0-5V)
REMOTE
PRG
ENABLE
ENABLE
HV
(on/off)
COMM
A
COMM
B
GND
(aux)
+24
VDC
(aux)
Position 1 +24 VDC supply must be connected to this position.
Position 2 GROUND (return) from the +24VDC supply and local electrical machine
ground must be connected to this position.
Position 3 Fault Relay K1 (NC) normally closed, dry contact
Position 4 Fault Relay K1 (COM) common, dry contact
Position 5 Fault Relay K1 (NO) normally open, dry contact. The above is with the
unit in Fault alarm or with power off. Refer to operation section of this
manual for actual function and operation of these contacts.

75201088 Rev. C
MCM 30 Electrostatic Charging Generator
Position 6 REMOTE PRG, apply 0 TO +5 VDC to program HV Output in Voltage
Mode between 3 kVDC and 30 kVDC.
The range of voltage to apply may be increased to 0 TO +24 VDC by adding an
62 kΩ(kilohm) ¼ W (watt) resistor in series with the connection to position 6.
Position 7 REMOTE PRG ENABLE, ground this pin to Pin 11 to program HV Output
level using REMOTE PRG input (Pin 6). This pin can be grounded by a PLC
with a dry contact switch, an open collector (as shown) or by a FET output.
The switching component must be rated for 24VDC @ 10mA. Grounding
position 7 will override the programmed mode and set-point. The MCM 30
will switch to Voltage Mode and allow real-time remote adjustment of the
HV Output level. Leave position 7 ungrounded, i.e. floating, to adjust the HV
Output set-point using front panel rotary Output knob.
Position 8 Enable HV, ground this pin to Pin 11 to turn on MCM 30 internal power
supply, creating HV. Leaving the pin float, i.e. ungrounded, turns off
the MCM 30 internal HV power supply. This pin can be grounded by a
PLC with a dry contact switch, an open collector (as shown) or by a FET
output. The switching component must be rated for 24VDC @ 10mA.
NotethattheMCM30powerswitchmustbesetto“ON”toallowremote
control of high voltage output on / off.
Position 9 COMM A, RJ485 communication port. (TX/RX)
Position 10 COMM B, RJ485 communication port. (TX/RX) Consult Simco-Ion
customer service for more information on this option.
Position 11 GRD (aux) provides a local source of ground for control functions of Pin
6, Pin 7, and Pin 8. GND (aux) also provides a return for Pin 12 (+24VDC
(aux)) for external indicator lights, audible alarms, etc.
Position 12 +24 VDC (aux), supplies a source of power for user convenience to
operate low power devices such as indicator lights, audible alarms, etc.
Maximum allowable current is 250 mA and should be externally fused to
protect the MCM 30.
(RELAY K1) (RELAY K1) The fault alarm relay in the MCM 30 is energized under the
no-alarm conditions. If there is a power loss to the MCM 30, a fault alarm
signal will be generated. The Fault alarm (NO / Pin 5) and (COM / Pin
4) terminals provide contact closure during normal operating conditions;
(NC / Pin 3) and (COM / Pin 4) provides contact closure if there is a loss
of power to the system or if a fault condition exists, which is indicated
by illuminating the Fault LED on the front panel and can be caused by
excessive current, overload or a short circuit condition.
Position 3 K1 Normally Closed (NC) (dry contact)
Position 4 K1 Common (COM)
Position 5 K1 Normally Open (No) (dry contact)

85201088 Rev. C
MCM 30 Electrostatic Charging Generator
NOTE - Fault Relay K1 is of the electro-mechanical type having a DC coil which
pulls down an armature which switches the contacts. Contact rating on the relay
is 24 VDC, 2 amps. See the following schematic diagram.
Position 3
Normally Closed (NC)
Positon 5
Normally Open (NO)
Position 4
Common (COM)
K1
SPST
Relay
Dry Contacts
MCM 30 in
Fault Alarm
or
Power Off
K1
SPST
Relay
Dry Contacts
MCM 30 in
Normal Operation
with
Power On
Position 3
Normally Closed (NC)
Positon 5
Normally Open (NO)
Position 4
Common (COM)
Fault Relay Schematic: example relay operation K1 inside MCM 30
NOTE - Verify that the mounting and connections of the MCM 30 charging
generator and charging devices are properly installed prior to turning on the
equipment.

95201088 Rev. C
MCM 30 Electrostatic Charging Generator
5. OPERATION
ON / OFF SWITCH - Switch turns the MCM 30 charging generator on or off. Note that
position #8 on the Interface Terminal Block must be grounded (i.e. connected to position
#11) to energize the unit using the on/off switch on the face of the unit.
SETTINGS KNOB - Knob controls the output of the High Voltage supply. In the Voltage
Mode it provides for output adjustment between 3 and 30 kVDC. In the Current Mode it
provides for output adjustment between 0.1 and 1 mA. The Settings knob is also used in
conjunction to the MODE/SETUP switch to select voltage or current mode of operation
along with the unit address function.
MODE / SETUP – Is a push button tactile switch located on the front panel which toggles
the Mode of operation when pressed or is used to enter the Setup sub menus. Pressing this
button causes the Status LED to light.
Voltage Mode Function - In Voltage Mode operation, (the Voltage Mode LED will be
lit),theMCM30willdisplaytheoutputvoltageonthe“bargraph”.PressingtheMode/
SetupbuttonwillcausetheCurrentModeLEDtolightandtheoutputLED“bargraph”
will display the output current. After approximately five (5), the unit will revert to
displaying the output voltage.
Current Mode Function - In Current Mode operation, (the Current Mode LED will be
lit),theMCM30willdisplaytheoutputcurrentonthe“bargraph”.PressingtheMode/
SetupbuttonwillcausetheVoltageModeLEDtolightandtheoutputLED“bargraph”
will display the output voltage. After approximately five (5), the unit will revert to
displaying the output current.
Setup Function – To enter the Setup function the MCM 30 needs to be de-energized
(Green Power LED is OFF). Then energize the MCM 30, (Green Power LED is lit) and
within five (5) seconds press the MODE / SETUP button twice (2) the Status LED will
flash each tome the button id pressed. Once the MCM 30 is in setup mode either the
Voltage or Current LED will be flashing. The Settings knob will be used to select between
Voltage or Current Mode control.
NOTE - The MCM 30 will operate in voltage control mode OR current control
mode (not both at the same time). In voltage control mode, the unit will adjust
output current as needed to maintain the output voltage set-point. In current
control mode, the unit will adjust output voltage as needed to maintain the output
current set point. If the unit is unable to meet the desired set-point, it will trigger
an overload light.

10 5201088 Rev. C
MCM 30 Electrostatic Charging Generator
Changing the MODE To change the Mode rotate the knob fully counter clockwise,
(CCW) and observe the Mode LEDs, (if you need to change the Mode again rotate the
Settings knob clockwise, (CW) at least 45° then fully CCW again.) Once the operating
mode is set, (Voltage or Current Mode), then rotate the Settings knob clockwise to set
the desired output level on the LED “bar graph” display, (In Voltage Mode the bar
graph display represents 3KVDC to 30KVDC and in current mode the bar graph display
represents 0.1mA to 1.0mA). To save this setting press the MODE / SETUP button once
(the Status LED will flash).
Setting the ADDRESS– ObservetheOutput LED“bar graph”displayand oneof the
LEDs will be flashing, then rotate the Settings knob fully counter clockwise (CCW)so
that the bottom LED, (1.0mA / 3KV), is flashing this is address #1. To change the address
rotate the knob CW until the desired Address is set, (1.0mA / 3KV = #1 and 1.0mA /
30KV = #10), each LED represents an address from 1 to 10. To save this setting press the
MODE / SETUP button once (the Status LED will flash along with both Mode LED’s and
bar graph LEDs lighting indicating that the values have been store in the flash memory).
NOTE – If the MCM 30 is turned off while in setup state, any adjustment to the
set-points will be lost. The unit must be placed into the operating state from the
setup state for adjustments to the set-points to be recorded.
MODE LEDS - Green LEDs indicate the Mode of operation set on the MCM 30.
Voltage Mode – Where the voltage is fixed to a predefined level and the MCM 30 adjusts
the output current automatically.
Current Mode - Where the current is fixed to a predefined level and the MCM 30 adjusts
the output voltage automatically until the maximum output voltage of 30KV is reached. If
the LED is FLASHING in normal operation this indicated that the MCM 30 is unable to
reach the desired current set point and the output voltage is at the MCM 30’s maximum
level. This could indicate that the charging applicator requires service or the current level
has not been properly set for the charging requirements of the material.
OUTPUT DISPLAY -10greenLED“bargraph”thatindicatesvoltageorcurrentoutputin
the operating state and voltage or current set-points or Address value in the Setup state.
OVERLOAD - The Red LED illuminates when the output current exceed the maximum
current capability of the MCM 30. This is typically due to a short circuit on the HV output,
or when the charging applicator exceeds the output current capability of the MCM 30. The
Overload LED is a non-latching condition that does not shut off the High Voltage output.
FAULT – Red LED that illuminates when there is a persistent Overload (typically greater
than 10 seconds). Fault is a latching condition that shuts off the HV output. To clear a
Fault, power (ether power switch or power input) must be cycled off then on.
REMOTE PROGRAM – Green LED that illuminates when Remote Program is Enabled (i.e.
position 7 is connected to position 11 on the terminal block.)

11 5201088 Rev. C
MCM 30 Electrostatic Charging Generator
STATUS – Yellow LED indicates when the MCM 30 is in setup mode or indicates when
the MODE / SETUP button is pressed.
HV OUTPUT – Green LED that illuminates when there is high voltage present on the HV
connector.
POWER – Green LED that illuminates when the power switch is on and 24 VDC is applied.
BASIC OPERATION – make all connection per section 4, (Installation) of this manual.
1. Install and mount the charging applicator to the MCM 30.
2. Refer to section 5 (Operation) MODE / SETUP of this manual to select the
operating mode and output level.
3. Set the operating Mode, (Voltage or Current), while using the Settings knob adjust
the output of the MCM 30 until the desired pinning is achieved.
4. Save this setting to the flash memory per the MODE / SETUP procedure in this
manual.
5. The MCM 30 is now ready for service.
NOTE - In setting the output in Current Mode the pinning applicator should be
adjusted so as to limit the output voltage to approximately 24KV. This will allow
the MCM 30 to automatically adjust the output voltage, (up to 30KV), to
compensate for atmospheric changes and contamination.
6. MAINTENANCE
Cleaning
CAUTION! Disconnect the electrostatic charging generator before attempting any
cleaning operation.
The exterior surface of the MCM 30 charging generator can be cleaned with a soft cloth
moistened with common window cleaning solution. Alcohols or solvent-based cleaners
must not be used.
NOTE - The charging generator enclosure is not liquid tight and must not be
subjected to aerosol sprays or condensation, as damage to the internal circuitry
may occur.

12 5201088 Rev. C
MCM 30 Electrostatic Charging Generator
7. TROUBLESHOOTING
This information provides a quick troubleshooting reference for the MCM 30 charging generator.
Should any of these possible solutions not solve the problem, please contact Simco-Ion Customer
Service.
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION
MCM 30 FAILS TO OPERATE
(GREEN INDICATOR OFF)
AC ADAPTER NOT
CONNECTED
CHECK ALL ELECTRICAL
CONNECTIONS
REPLACE AC ADAPTER
AC ADAPTER DEFECTIVE
MCM 30 FAILS TO OPERATE
CHARGING DEVICE
(GREEN INDICATOR ON)
CHARGING DEVICE
CONNECTIONS LOOSE
TIGHTEN CHARGING DEVICE
CONNECTORS INTO POWER
SUPPLY
MCM 30 INDICATES FAULT
(RED INDICATOR ON)
CHARGING DEVICE DIRTY OR
DEFECTIVE
CLEAN OR REPLACE
CHARGING DEVICE
CHECK CHARGING DEVICE
CLEARANCES
CHARGING DEVICE SHORTED

13 5201088 Rev. C
MCM 30 Electrostatic Charging Generator
8. ACCESSORIES AND PARTS
Item Part Number Part Number
(Negative) (Positive)
MCM 30 Unit No AC adapter....................... 4015426 4015427
MCM 30 Unit ............................................... 4015435 4015438
North America / Japan
MCM 30 Unit ............................................... 4015436 4015439
Continental Europe
MCM 30 Unit ............................................... 4015437 4015440
United Kingdom
Item Part Number
AC Adapter .................................................... 4110321
Output connector............................................ 4100286
9. WARRANTY
This product has been carefully tested at the factory and is warranted to be free from any
defects in materials or workmanship. Simco-Ion will, under this warranty, repair or replace
any equipment that proves, upon our examination, to have become defective within one year
from the date of purchase.
The equipment being returned under warranty should be shipped by the purchaser to Simco-
Ion, 2257 North Penn Road, Hatfield PA 19440, transportation prepaid and insured for its
replacement cost. Prior to returning any goods for any reason, contact Simco-Ion Customer
Service at [phone] for a Return Authorization Number. This number must accompany
all returned items.
This warranty does not apply when the equipment has been tampered with, misused,
improperly installed, altered, has received damage through abuse, carelessness, accident,
connected to improper line voltage, or has been serviced anyone other than an authorized
factory representative.
The warranty does not apply when Simco-Ion parts and equipment have been energized by
other than the appropriate Simco-Ion electrostatic charging generator or generator, or when a
Simco-Ion electrostatic charging generator or generator has been used to energize other than
Simco-Ion parts and equipment. Simco-Ion makes no warranty, expressed or implied, nor
accepts any obligation, liabilities, or responsibility in connection with the use of this product
other than the repair or replacement of parts stated herein.

MCM 30 Electrostatic Charging Generator 5201088 Rev. C
Simco-Ion
2257 North Penn Road
Hatfield, PA 19440
[phone]
[phone]
www.Simco-Ion.com
[email protected]
© 2011 Simco-Ion. Printed in the U.S.A.