ITW Simco Ion IQ Power Fantom HL User manual

IQ Power Fantom HL 5201305 Rev A
IQ Power™ Fantom HL Blower
for Hazardous Locations
INSTALLATION AND OPERATING INSTRUCTIONS

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IQ Power Fantom HL 5201305 Rev A
TABLE OF CONTENTS
1. SAFETY WARNINGS ........................................................................... 1
2. DESCRIPTION .................................................................................. 2
3. SPECIFICATIONS ............................................................................... 3
4. INSTALLATION .................................................................................. 4
Position and Mounting..........................................................................................................4
Placement of the IQ Power Fantom HL Blower...................................................................4
Blower Motor Wiring............................................................................................................5
Equipment Grounding Requirements ..................................................................................6
Conduit Requirements .........................................................................................................6
System Wiring .....................................................................................................................7
System Set-Up (without Control Station) ..........................................................................18
System Set-Up (with Control Station) ...............................................................................18
5. OPERATION ....................................................................................21
HL Power Supply Indicators...............................................................................................21
HL Power Supply Operators...............................................................................................21
System Operation (with IQ Power Control Station) ..........................................................23
6. MAINTENANCE .................................................................................24
Cleaning the Static Bar.......................................................................................................24
Air Intake Filter ..................................................................................................................24
Ion Balance .........................................................................................................................25
7. TROUBLESHOOTING ..........................................................................26
Operational Check ..............................................................................................................26
8. PARTS AND ACCESSORIES...................................................................28
9. WARRANTY AND SERVICE ...................................................................29

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IQ Power Fantom HL 5201305 Rev A
1. SAFETY WARNINGS
PLEASE READ INSTRUCTIONS COMPLETELY BEFORE STARTING
INSTALLATION.
ALL INSTALLATION AND TROUBLESHOOTING OPERATIONS MUST
BE PERFORMED BY QUALIFIED TECHNICAL PERSONNEL.
This instruction manual uses symbols to identify dangerous situations as follows:
NOTE – Statements identified with NOTE indicate precautions necessary
to avoid potential equipment failure.
CAUTION – Statements identified with CAUTION indicate potential
safety hazards.
WARNING – Statements identified with WARNING indicate potential
serious injury hazards.
NOTE – This equipment must be correctly installed and properly
maintained. Adhere to the following notes for safe installation and
operation:
1. Read instruction manual before installing or operating equipment.
2. Only qualified service personnel are to perform installation and repairs.
3. All equipment must be properly grounded, including the machine frame to
which the equipment is mounted.
4. Turn off input power to unit before connecting or disconnecting other
equipment.
5. Do not use standard Ethernet cables with IQ Power Systems.
NOTE – Do not attempt to operate at voltages other than those specified.
NOTE – Do not allow dust, dirt or debris to block or obstruct air flow
inlets or outlets.
WARNING – Electrical Shock Hazard
Electrical installation and repairs must be performed by a skilled electrical
engineer according to the applicable national and local regulations. The
equipment must be properly grounded. Grounding is required to ensure
safe and proper operation and to prevent electrical shocks upon contact.

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IQ Power Fantom HL 5201305 Rev A
2. DESCRIPTION
Simco-Ion’s IQ Power Fantom HL blower is a highly reliable, focused ionizing air
blower designed for static elimination in many industrial applications including
hazardous locations. It is ETL approved for use in Class I, Division 1 and 2, Group
D hazardous locations. Its high-power fan covers the target area with balanced
ionization for rapid static neutralization. The output of the blower can be controlled
using the damper blades located over the blower intake. The Fantom HL blower is
a two-part system that includes the blower with the IQ Power HL static neutralizing
bar and the IQ Power HL or HLC power supplies. When coupled with the IQ
Power Control Station, detailed monitoring and communications are available.
In addition to the Control Station, when used with the HL Sensor, closed-loop
feedback is available for optimal ion output and ion balance control. Cables for
interconnection with a Control Station are available by calling Simco-Ion customer
service [phone] (refer to Section 8, Parts and Accessories). Service and
maintenance are simplified with the IQ Power Fantom HL blower. A modular
design makes for easy servicing. The outward facing static neutralizing bar makes
cleaning and maintenance easy. The removable air filter on the side of the blower
can easily be swapped out when the filter has become too dirty.

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IQ Power Fantom HL 5201305 Rev A
3. SPECIFICATIONS
Blower
Input 115 VAC, 60 Hz, 1.9A (10A during startup)
Operating Temperature 32-104°F (0-40°C)
Operating Humidity 70% RH max, non-condensing (dewing) permissible
Air Volume 285 cfm [8m3/min] max
Air Filter 5.8” [147 mm] diameter polyurethane foam 25 ppi
Air Speed 1200 fpm @ 4’[6 m/s @ 1.2m] on centerline (fan speed high)
Noise Level 68 dB @ 2’[0.6 m] (fan speed high)
Typical Discharge Time
(1000V to 100V)
Distance Positive (+) Decay Negative (-) Decay
1 ft. [0.3m] 0.5 sec 0.5 sec
2 ft. [0.6m] 1.0 sec 1.0 sec
3 ft. [0.9m] 1.5 sec 1.8 sec
4 ft. [1.2m] 2.0 sec 2.5 sec
5 ft. [1.5m] 3.0 sec 4.0 sec
6 ft. [1.8m] 4.0 sec 5.2 sec
8 ft. [2.4m] 6.5 sec 8.2 sec
10 ft. [3.0m] 9.0 sec 12.5 sec
Enclosure Steel, blue epoxy powder coated
Connection ½”NPT male thread for metal conduit
Dimensions 18.25”L x 21.30”W x 7.50”H [437 x 541 x 191 mm]
Weight 27 lb [12.25 kg]
Bar
Operating Voltage ±7 kV from IQ Power HL/HLC Power supply
Enclosure Glass-fiber-reinforced polyester
Connection ½”NPT male thread at end of bar for metal conduit
Dimensions 21.30”L x 1.00”W x 1.93”H [541 x 26 x 49 mm]

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IQ Power Fantom HL 5201305 Rev A
4. INSTALLATION
Position and Mounting
CAUTION – The installation, operation and maintenance of equipment
for use in hazardous locations shall be performed by qualified personnel.
Refer to the following publications for guidelines:
• ANSI/NFPA70: National Electric Code, Hazardous (Classified) Locations –
Article 500, and Class 2 locations – Article 501.
• NFPA77: Static Electricity
• NFPA 497M: Classifications of Gases, Vapors and Dusts for Electrical
Equipment in Hazardous (Classified) Locations.
Available from: National Fire Protection Association, Batterymarch Park, Quincy,
Massachusetts 02169-7471
For maximum effectiveness, follow the steps below.
Placement of the IQ Power Fantom HL Blower
1. Mount the blower so that its airflow is directed at the material to be neutralized.
CAUTION – Spark Hazard. Do not mount blower with motor
shaft vertically. Only mount the blower with the shaft in a
horizontal orientation.
2. The material to be neutralized should have a background of free air and not
be in contact with another material. Static charges are difficult to neutralize
between two surfaces that are in intimate contact.
3. Mount the blower at the problem site for materials that are stationary. Mount
the blower just before the problem area for materials that are in motion.
4. Mount the blower as close as 1” to 2” or as far away as several feet from the
materials to be neutralized.
5. If an object has deep cavities, it may be necessary to mount the blower close to
the object so that ionized air reaches remote areas.
6. If an object is light in weight, mount the blower far enough away to prevent the
object from being blown out of position. Final adjustment to air flow can be
made with the damper blades.

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IQ Power Fantom HL 5201305 Rev A
Blower Motor Wiring
The Fantom HL blower requires 115 VAC 60 Hz. Connect the line cord as shown
in Fig. 1.
Figure 1. Motor Schematic and Wiring Diagram
NOTE – Do not attempt to operate at voltages other than those specified.
NOTE – Starting current for blower motor is approximately 5x the motor
nameplate running current. The blower motor power source, including
step-down transformer if used, must be capable of supplying starting
current without excessive voltage drop for proper blower motor operation.
If available starting current is insufficient, blower motor will operate
continuously at greatly reduced RPM, drawing excessive current and
overheating. This may result in damage to the blower motor.
WARNING – Electrical Shock Hazard
Electrical installation and repairs must be performed by a skilled electrical
engineer according to the applicable national and local regulations. The
equipment must be properly grounded. Grounding is required to ensure
safe and proper operation and to prevent electrical shocks upon contact.
WARNING – All regulatory listings and approvals do not apply when the
motor is operated on VFD (Variable Frequency Drive) power.
• Connect motor’s BLACK
and YELLOW leads
together to 115V HOT
(typically black wire)
• Connect motor’s PURPLE
lead to 115V NEUTRAL
(typically white wire)
• Connect motor’s BLUE
and RED leads together
• Connect motor’s GREEN
lead to GROUND
(typically green, green-
yellow, or bare wire)
10A typ.
1.9A typ.

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IQ Power Fantom HL 5201305 Rev A
Equipment Grounding Requirements
CAUTION – Power supply enclosures, blower motor, and conduit systems
must be grounded for safe operation.
1. The HLC power supply enclosure must be grounded for safe operation. The
HL power supply must be grounded by using the ground lug on the mounting
flange of the unit. The Control Station (if used) is grounded through the AC
power cord. Proper grounding can be achieved by connecting the appropriate
ground terminal on the power supply to an appropriate ground source, such as
exposed bare metal on a machine frame, or through a properly grounded AC
outlet.
2. The blower motor is grounded by means of the ground lead coming from the
motor. The ground lead should be run through the conduit and connected to
an appropriate ground terminal.
3. Ground the conduit to the machine frame or some other source of earth
ground.
Conduit Requirements
NOTE – It is the customer’s responsibility to provide approved conduit
material and install the conduit in accordance with the National Electrical
Code and any state, province and local regulations.
1. All conduit fittings must be approved for use in Class I, Division 1 and 2,
Group D hazardous locations.
2. The IQ Power HL bar’s high voltage cable must be installed in rigid conduit to
its threaded fitting.
3. The primary wiring for the blower motor must be installed in rigid conduit.
4. All unused openings located on the IQ Power HLC enclosure must remain
plugged. Do not remove plugs in openings that will not be used during the
installation and use of the equipment.
5. Conduit must be sealed within 18 inches of the power supply enclosure for the
IQ Power HLC or outside the hazardous area for the IQ Power HL. Approved
conduit seal fitting, sealing cement and packing fiber are supplied by Simco-
Ion.

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IQ Power Fantom HL 5201305 Rev A
Figure 2. Conduit Seal on 8 Conductor Modular and HV Cables
System Wiring
Termination of HV Cable
Connect static bar by cutting high voltage cable to length, terminating leads, and
connecting to power supply: (see Figure 3)
1. Cut HV cable to length, leaving an extra 3¼” for connector.
2. Strip black plastic jacket back 2½”, being careful not to nick insulation of HV
wires. (Practice stripping jacket on waste length of HV cable.)
3. Strip insulation of HV wires back 1”, being careful not to nick conductor of HV
wire.
4. Straighten conductors and insert into HV connector until conductor protrudes
out from the tip of connector.
5. Solder conductor to tip of connector by applying solder to exposed conductor.
Ensure that the solder does not overflow and fill neck area of tip.
6. Trim off excess conductor protruding from tip of connector. If using the HLC
power supply, the HV cable is now ready to use. If using the HL power supply,
continue to step 7.

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IQ Power Fantom HL 5201305 Rev A
Figure 3. HL/HLC Power Supply High Voltage CableTermination
7. Place HV Connectors into HV plug bottom. The black plastic jacket should be
fully engaged in strain relief section of HV plug.
8. Install HV plug top onto bottom making sure plug comes together properly
with no binding or gapping. Hold together firmly.
9. Insert nylon screws through holes in plug bottom and tighten to secure plug
together (do not over tighten screws).
10. Plug in high voltage connector on static bar to HV1 or HV2 on power supply.
Secure high voltage connector with the (2) captive screws on the sides of
connector. Do not over-tighten.
NOTE – Conduit seals must be properly installed to prevent the
propagation of vapors and flames through conduit runs (see Figure 2).
Outer (black) jacket of HV cables must be removed and (white) insulated
wires separated) before filling conduit seals with cement. Use care not to
nick or cut insulation on HV wires.
CAUTION – Electrical Shock Hazard
Do not connect static neutralizing bar with Power Supply energized.
Disconnect input power or switch power off before connecting static bar.
NOTE – Failure to fully seat high voltage connectors into power supply
connectors may result in permanent damage to bar, cable or power supply.

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IQ Power Fantom HL 5201305 Rev A
Figure 4a. IQ Power Fantom HL and HL Power Supply Control Drawing

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IQ Power Fantom HL 5201305 Rev A
Figure 4b. IQ Power Fantom HL and HLC Power Supply Control Drawing

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IQ Power Fantom HL 5201305 Rev A
Connect AC Adapter (AC adapter not required if power supply is connected to a
Control Station)
Make sure “POWER” switch on power supply is in “OFF” (0) position. Route low
voltage wire clear of moving machine parts and protect it from abrasion. Secure
using nylon wire ties (not supplied). Do not over tighten. Insert barrel connector
into “POWER IN” connector on power supply. Hand tighten barrel connector nut
to secure.
Connect line voltage to input side of AC adapter. The AC adapter is a universal
input type that accepts line voltage from 100 to 240 VAC 50/60 Hz. The AC
adapter line voltage connector accepts a line cord with an IEC 320 connector
(supplied). The line cord also provides electrical ground to the AC adapter. Check
electrical ground integrity in line voltage receptacle used for AC adapter. This
ground must not be defeated.
Figure 5. IQ Power Connections (Fantom HL to HL Power Supply)
Connect Power Supply Alarm Output (if used)
The IQ Power HL/HLC power supply “Alarm Output” is a standard DB25 pin
connector. A maximum distance of 3 meters [10 feet] or less is recommended. The
alarm output provides a variety of relay contact outputs that indicate the status of the
power supply. The relay contacts are rated for a maximum of 1A at 30 VDC. The
alarm output connector also provides a means of remote power in. (see Figure 6).

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IQ Power Fantom HL 5201305 Rev A
Figure 6. IQ Power HL/HLC Power Supply Alarm Output
Pin Description Pin Description
1Remote on/off optocoupler (-) 10 No connection
14 Remote on/off optocoupler (+) 6No connection
2Clean Bar Relay (common)* 19 No connection
3Clean Bar Relay (normally closed)* 11 Power Relay (common)*
16 Clean Bar Relay (normally open)* 7Power Relay (normally closed)*
8Fault Relay (common)* 20 Power Relay (normally open)*
4Fault Relay (normally closed)* 12 Power in (ground)**
17 Fault Relay (normally open)* 24 Power in (ground)**
9Bar On Relay (common)* 13 Power in (+24 VDC)**
5Bar On Relay (normally closed)* 25 Power in (+24 VDC)**
18 Bar On Relay (normally open)*
*30V 1A Rating on contacts.
**1.6A Rating, Connect pins 12 & 24 in parallel and 13 & 25 in parallel.
Remote On/Off Control (if used)
The “Alarm Output” connector also provides for remote on/off control of the Power
Supply. Remote on/off control is configured with a jumper on a pin header on the
main Alarm Output circuit board. The default configuration is with remote control
disabled. The remote control can be configured “normally off ” or “normally on”
by the jumper setting (see Figure 8). To access the jumpers the cover will have to
be removed from the HL/HLC Power Supply. Disconnect all input power, then
remove the six screws securing the cover and slowly and carefully remove the cover.
On the HL power supply, there is a ribbon cable connecting the face label on cover
to the main circuit board. Use care not to disconnect this cable. If cable becomes
disconnected, lift the latches on sides of ribbon cable connector, insert ribbon cable
fully into connector and press latches back down.

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IQ Power Fantom HL 5201305 Rev A
Reposition jumper to enable remote control either “normally on” or “normally off ”,
as desired (see Figure 8). Then replace cover and secure with six screws.
When operating a Power Supply using the remote control circuit, power may be
applied through the “Alarm Output” connector or the “Power In” connector on end
panel. If the “Power In” connector on end panel is used, the “Power” switch must
be set to ON (1) position.
Remote control is established by applying 24 VDC to the “Alarm Output”
connector pins as specified in Figure 8. User-applied 24 VDC drives a low current
optoisolator on the main circuit board, turning Power Supply on or off, depending
on configuration of jumper J3.
Figure 7. Remote Control Optocoupler Schematic
Figure 8. Jumper Position at J3 for Remote Control Operation

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IQ Power Fantom HL 5201305 Rev A
Connect User Supplied Power (if used)
In cases where the user does not want to use the AC adapter but wants to supply 24
VDC power to the IQ Power HL/HLC Power Supply, user supplied 24 VDC power
may be applied two ways.
The “Power In” connector on end panel of IQ Power HL power supply may be used
to supply power to the system. This connector requires the use of a Switchcraft 760K
barrel type power plug. The plug should be wired +24 VDC to center and common
(ground) to outer barrel. The common must be bonded to electrical ground. Wired
in this fashion, the “Power” switch on end panel of HL power supply is in-circuit.
Alternatively, the “Alarm Output” connector on the end panel of IQ Power HL/
HLC power supply may be used to supply power to the system. This connector
requires the use of a standard DB25 connector. The connector should be wired:
• +24 VDC to pins 13 & 25
• Common (ground) to pins 12 & 24
To ensure current carrying capacity, two pins are used for each connection. The
common must be bonded to ground. Wired in this fashion, the “Power” switch on
end panel of the HL power supply is bypassed.
Power supplied in above fashion must have adequate current available to power all
components on system (maximum 1.6A). Input power should be appropriately fused
for safety purposes.
Connection to the IQ Power Control Station
Connection with a Control Station allows two-way digital communication with the
IQ Power HL/HLC power supplies. The Control Station is able to display a variety
of operating parameters and settings. The Control Station supplies 24 VDC power
for the IQ Power HL/HLC power supplies. Cables must be IQ Power 8-conductor
modular cables with RJ-45 connectors wired “crossover” (reference color: black,
Figure 9). Three communication ports are available on the IQ Power HL/HLC,
labeled COMM1 and COMM2. The COMM1 ports allow connection to an IQ
Power Control Station. The COMM2 port on the HL power supply allows for
the pairing of the HL Sensor Interface with HL Sensors for Closed-Loop Feedback
operation. These ports are not interchangeable. Cables of various lengths are
available, see Section 8, Parts and Accessories.
The modular cable plugs into one of the connectors labeled “POWER & COMM”
on the Control Station and into either “PS COMM 1” connector on the HL/HLC
power supply.
Route the modular cable clear of moving machine parts and protect it from abrasion.
Secure using nylon wire ties (not supplied). Do not over-tighten wire tie.
If there is an excess of modular cable, if possible, cut modular cable to length and
re-terminate using an RJ-45 connector installed with the same “polarization” as
connector removed (note rib / wire color code to modular connector).

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IQ Power Fantom HL 5201305 Rev A
Figure 9. IQ Power Crossover Modular Cable (black)
The IQ Power HL/HLC will report to the Control Station using the Power Supply
Number (address / device number). It will appear on the Control Station as a single
device. If an IQ Power HL Sensor Interface is paired with the HL/HLC, it will
appear as a tab on the device page.
If multiple IQ Power supplies are connected to the Control Station, each power
supply must have a unique Power Supply Number (address / device number). This
is necessary to enable reliable digital communication.
The Control Station can be used to automatically address the power supplies. The
default Power Supply Number for a new unit is “1”. Plug the first power supply into
the Control Station and turn Control Station on. Allow the Control Station to boot-
up and begin operation. Plug the second power supply into the Control Station.
The Control Station will re-address the second power supply to “2”. Plug the third
system into the Control Station. The Control Station will re-address the third power
supply to “3”. Repeat this process until all power supplies are installed. Each power
supply or device will be given a unique address (device number).
IQ Power HL/HLC power supplies may also be manually re-addressed through the
Control Station.
NOTE – DO NOT USE standard Ethernet cables with IQ Power systems.
Avoid permanent equipment damage by using only Simco-Ion modular
cables. (Refer to Section 8, Parts and Accessories).

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IQ Power Fantom HL 5201305 Rev A
Figure 10. IQ Power Connections (Fantom HL to HL Power Supply and Control Station with Options)

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IQ Power Fantom HL 5201305 Rev A
Figure 11. IQ Power Connections (Fantom HL to HLC Power Supply and Control Station with Options)

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IQ Power Fantom HL 5201305 Rev A
Connect the HL Sensor Interface (if used)
An IQ Power HL Sensor may be integrated into the IQ Power system to provide
feedback on static eliminating performance and is used for the CLFB (Closed-
Loop Feedback) static eliminating mode. Cables for the Sensor Interface must be
IQ Power 8-conductor modular cables with RJ-45 connectors wired “crossover”
(reference color: black, Figure 9).
When using the IQ Power HL power supply, the modular cable plugs into one of the
connectors labeled “SI COMM 1” on the Sensor Interface and into the “PS COMM
2” connector on the HL power supply (see Figure 10). The second modular cable
plugs into one of the “PS COMM 1” connectors on the power supply and into one
of the connectors labeled “POWER & COMM” on the Control Station. The Sensor
Interface will now automatically pair with the IQ Power HL power supply.
When using the IQ Power HLC power supply, the modular cable plugs into one
of the connectors labeled “SI COMM 1” on the Sensor Interface and into the “PS
COMM 1” connector on the HLC power supply. (see Figure 11). The second
modular cable plugs into the other connector labeled “SI COMM 1” on Sensor
Interface and into one of the connectors labeled “POWER & COMM” on the
Control Station. The Sensor Interface must be manually addressed to the same
address of the HLC power supply in order to be paired.
Route modular cable clear of moving machine parts and protect it from abrasion.
Secure using nylon wire ties (not supplied). Do not over-tighten wire tie.
If there is an excess of modular cable, if possible, cut modular cable to length and
re-terminate using an RJ-45 connector installed with the same “polarization” as
connector removed (note rib / wire color code to modular connector).
See instructions included with IQ Power HL Sensor for sensor installation.
System Set-Up (without Control Station)
If the Fantom HL Blower is operating free standing (without connection to a
Control Station) set up is simply adjusting the air flow on target and adjusting the
blower output with the damper blades as necessary. Balance is factory calibrated.
System Set-Up (with Control Station)
A variety of information can be checked, and operating parameters set, for the IQ
Power HL/HLC power supply through the IQ Power Control Station via the device
page. Tap on device icon for the power supply and static bar to access these pages.
A summary tab will appear offering important information. Tabs for the neutralizer
and sensor (if installed) will also appear. Tapping on a neutralizer tab or sensor
tab opens a page where operating parameters may be edited or selected. Typical
parameters are listed below.
Device Name: A user editable name to identify specific device (14 character).