ITW Simco-Ion Conveyostat User manual

5100577 Rev L
CONVEYOSTAT IN-LINE IONIZER
Conveyostat®In-Line Ionizer
For Pneumatic Conveyors
INSTALLATION AND OPERATING INSTRUCTIONS

i5100577 Rev L
CONVEYOSTAT IN-LINE IONIZER
TABLE OF CONTENTS
1. SAFETY WARNINGS............................................................................................. 1
2. DESCRIPTION..................................................................................................... 2
Features ...................................................................................................... 2
Receipt of Equipment................................................................................. 2
Return Shipments....................................................................................... 2
3. SPECIFICATIONS ................................................................................................ 3
4. INSTALLATION ................................................................................................... 4
Ground Connections.................................................................................. 6
High Voltage Connections.......................................................................... 7
5. OPERATION ....................................................................................................... 9
BPS-C Indicators/Operators ....................................................................... 9
Dual Phase+ Indicators/Operators ............................................................ 10
6. MAINTENANCE ................................................................................................ 11
Inspecting and Cleaning the Static Bars.................................................... 11
Calibration (BPS-C only) ......................................................................... 12
7. TROUBLESHOOTING.......................................................................................... 13
Conveyostat with BPS-C .......................................................................... 13
Conveyostat with Dual Phase+ ................................................................. 14
8. PARTS AND ACCESSORIES .................................................................................. 15
9. WARRANTY AND SERVICE.................................................................................. 16

15100577 Rev L
CONVEYOSTAT IN-LINE IONIZER
1. SAFETY WARNINGS
PLEASE READ THE INSTRUCTIONS COMPLETELY BEFORE
STARTING THE INSTALLATION.
ALL INSTALLATION AND TROUBLESHOOTING OPERATIONS
MUST BE PERFORMED BY QUALIFIED TECHNICAL PERSONNEL.
This instruction the manual uses symbols to identify dangerous situations as
follows:
NOTE – Statements identified with a NOTE indicate precautions
necessary to avoid potential equipment failure.
CAUTION – Statements identified with a 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 operate system in close proximity to flammable liquids.
CAUTION – Electrical Shock Hazard
Do not touch emitter pins when power supply is energized.
CAUTION – Electrical Shock Hazard
Disconnect input power to high voltage power supply before
connecting or disconnecting static neutralizing bars or performing any
maintenance to the system.
WARNING – Fire Hazard
Do not install or operate Conveyostat in close proximity to any
flammable liquids or solvents.

25100577 Rev L
CONVEYOSTAT IN-LINE IONIZER
2. DESCRIPTION
Simco-Ion’s Conveyostat Systems are designed to provide in-line static
elimination for neutralizing static charges on materials in pneumatic conveying
systems. In-line ionization eliminates clogs caused by static charge buildup
within the conveying system. Once the charges are neutralized, products flow
freely and productivity increases.
Conveyostat’s are typically mounted at the input to a cyclone or collection
vessel so that trim or other conveyed materials are neutralized as they pass
through the unit.
Features
• Ionization prevents pneumatic conveying systems from becoming
jammed
• Dual-phase ion generation ensures high neutralization rates
• Stainless steel construction
• Available flangeless, flanged, or QF bead connection
• Available in standard and custom sizes
Receipt of Equipment
Carefully remove the equipment from the carton.
Inspect contents for damage that may have occurred during shipment. If any
damage has occurred during shipment, the local carrier should be notified at
once. A report should be forwarded to Simco-Ion, 2257 North Penn Road,
Hatfield PA 19440 (215-822-6401).
Empty the carton to ensure that small parts are not discarded.
Return Shipments
Prior to returning goods, contact a Simco-Ion Customer Service representative
(215-822-6401) for a Return Authorization Number. This number should
be included on the packing list. All correspondence should also reference the
Return Authorization Number. Any item being returned should be shipped
prepaid and packed to provide adequate protection.

35100577 Rev L
CONVEYOSTAT IN-LINE IONIZER
3. SPECIFICATIONS
System Components Ionizer housing tube and power supply
Enclosure Stainless Steel
Lengths Standard, 24”, 36”, 48”(other lengths available)
Diameters Standard , 2-12”(larger diameters available)
HV Connection BPS-C: IQ Power connector and IQ Power extension cable
Power Supply Simco-Ion BPS-C or Dual Phase+ (legacy installations)

45100577 Rev L
CONVEYOSTAT IN-LINE IONIZER
4. INSTALLATION
1. Locate the Conveyostat In-line Ionizer as close as possible to the inlet of
receiver vessels (such as dropout boxes, cyclones, fabric filters, etc.). In
these chambers, the speed of particles is lower, and the detrimental effects
of static electricity can be easily observed as clogs and material sticking.
2. The Conveyostat must be installed in the line with the flow direction of
the material being from the cable end side of the static bars thru to the
dead-end side of the static bars.
3. See power supply manual for maximum loading characteristics.
Figure 1. Conveyostat with BPS-C Power Supply

55100577 Rev L
CONVEYOSTAT IN-LINE IONIZER
Figure 2. Conveyostat to BPS-C with AC Adapter Power Supply Retrot

65100577 Rev L
CONVEYOSTAT IN-LINE IONIZER
Figure 3. Conveyostat with Dual Phase+ Power Supply
CAUTION – Electrical Shock Hazard
Before placing the Conveyostat in operation, be sure that all grounds
and connections have been made as described in the following section.
Ground Connections
The Conveyostat is provided with a ground braid assembly. The ground braid
is typically terminated with ring terminals. Grounding is important to ensure
safety and proper operation of the Conveyostat.
1. One end of the ground braid terminates at a ground stud on the
Conveyostat.
2. Terminate the other end of the ground braid to the ground stud on the
power supply or machine frame ground.
3. The Conveyostat and power supply must be grounded to machine frame
ground. This connection may be made through the ground braid.

75100577 Rev L
CONVEYOSTAT IN-LINE IONIZER
CAUTION – Electrical Shock Hazard
Disconnect input voltage to power supply while making high voltage
connections.
High Voltage Connections
1. Connect Conveyostat to BPS-C power supply using an IQ Power
Extension Cable. The Conveyostat must be equipped with a two-prong
HV connector assembly. The connector assembly at the Conveyostat plugs
into the receptacle end of the HV extension cable. Secure connection
with (2) captive screws on connector, DO NOT over-tighten screws. HV
extension cables may be chained together to a maximum of 100 feet per
Conveyostat. The plug-end of HV extension cable plugs into HV1 or
HV2 on the BPS-C. Secure connection with (2) captive screws on plug,
DO NOT over-tighten screws. See BPS-C instruction manual.
NOTE – Failure to fully seat the high voltage connectors into the
power supply connectors may result in permanent damage to the bar,
cable, or power supply.
2. Retrofit Conveyostat to BPS-C power supply by disconnecting and
removing the Dual Phase+ power supply. Prepare the existing HV wiring
by installing spring loaded cable connectors (SLCC). Follow instructions
included in the adapter kit to install the SLCC connectors. Attach the
SLCC connectors to the BPS-C to SLCC Adapter. Plug adapter into HV1
or HV2 on the BPS-C. Secure connection with (2) captive screws on plug,
DO NOT over-tighten screws. See BPS-C instruction manual.
NOTE – When retrofitting note that the BPS-C is designed to work
with resistively coupled static eliminators. Conveyostat in-line ionizers
with serial numbers beginning with “16” or greater have resistively
coupled static bars. If the Conveyostat serial number begins with “15”
or less, the static bars should be replaced.
3. Connect Conveyostat to Dual Phase+ power supply Dual Phase+ power
supply using a HV Cable Assembly. HV Cable Assemblies are available
in various lengths up to 100 feet. The HV cable assembly connects to
the Conveyostat inside an insulated junction tube. There the HV cable
ring terminals are connected with a screw / nut. Once connected, the
multi HV wire connector tube is slid into place over the connection and
secured with a nylon screw. The high voltage cables must be kept isolated
from each other and from ground. When utilizing conduit, it must be

85100577 Rev L
CONVEYOSTAT IN-LINE IONIZER
non-metallic and the HV cable from alternate phases cannot be combined
in the same conduit. Failure to do so may result in poor performance,
cable insulation failure, and/or power supply nuisance tripping. See Dual
Phase+ instruction manual.
4. Route cables from Conveyostat to power supply. Keep cables clear of
frames and machinery that could abrade and/or damage the cable.
NOTE – Failure to follow the above guidelines may result in poor
system performance, exhibited by nuisance alarms, power supply
tripping and/or cable insulation failure.

95100577 Rev L
CONVEYOSTAT IN-LINE IONIZER
5. OPERATION
NOTE – Before operating equipment, ensure that units are properly
grounded and that the Conveyostat has been properly installed.
To begin operating the equipment, simply apply input power to the Power
Supply and switch power supply on. The Green Power light indicates power
to the unit. In the case of the BPS-C a green Bar On light indicates the static
bars are energized.
In the case of a Clean Bar/Warning or Fault light, see Troubleshooting section.
See power supply instruction manual for details on power supply operation.
BPS-C Indicators/Operators
Power: Lights (green) to indicate power is on at the power supply and it is
ready to operate.
Bar On: Lights (green) to indicate when static neutralizing is active.
Fault: Lights (red) to indicate faulty condition of static neutralizer, power
supply or high voltage connections. Power will have to be turned off to clear
the fault. When the fault is cleared and power is restored, the fault light will
be extinguished.
Clean Bar: Lights (yellow) to indicate need to clean static bars. Clean Bar
indicator may light with low ion output (dirt build-up on ion emitters) or high
output current (conductive contamination on face of bar).
Output: The output indicators range Low, Medium, or High to indicate the
system relative ion output. The output will normally be in the high range.
Low output generally indicates the need to clean the static bar.
Locked: Lights to indicate calibration at the BPS-C is locked out. This occurs
automatically when a Control Station is connected, where calibration is
performed through the Control Station.
Calibrate: Is a momentary push-button switch located on the face label.
Pressing the face label firmly on “Calibrate” initiates calibration sequence and
sets relative nominal ion output for the system.
New installations will need to be calibrated for the Output indicators and the
Clean Bar indicators to work properly.
See BPS-C instruction manual for more details.

10 5100577 Rev L
CONVEYOSTAT IN-LINE IONIZER
Dual Phase+ Indicators/Operators
Power: Lights (green) to indicate power is on at the power supply and it is
ready to operate.
Fault and Warning: Light (yellow and red) indicators on power supply. Loss
of high voltage, or a short circuit within the attached static neutralizing device
or its cables, will disable the Power Supply’s high voltage output and cause the
indicator to flash.
Reset: Push-button to reset a fault condition and extinguish the flashing
indicator. First the cause of the fault must be remedied. Then press and hold
the Reset button until normal operation is resumed.
See Dual Phase+ instruction manual for more details.

11 5100577 Rev L
CONVEYOSTAT IN-LINE IONIZER
6. MAINTENANCE
NOTE – Only qualified service personnel are to perform maintenance
tasks.
CAUTION – Electrical Shock Hazard
Turn off power supply before cleaning bar or performing any
maintenance on the system.
Occasionally check to make certain that all ground and electrical connections
are clean and secure. Periodically inspect all cables to ensure that there are
no cuts, abrasions, or damage that can lead to operator shock or equipment
damage.
The accumulation of contamination on the ionization emitter points and static
bar surfaces will reduce neutralizing efficiency of the Conveyostat, therefore it
is recommended that maintenance of the system be performed when the Clean
Bar (BPS-C) or Warning (Dual Phase+) indicator on the display illuminates.
Dirty environments may require more frequent cleaning. Maintenance should
be performed by qualified service personnel only.
Inspecting and Cleaning the Static Bars
Periodically inspect the static bars for physical damage such as missing pins
and cracked (or broken) housings. Such damage may occur from foreign
particles traveling through the unit. Abrasive wear on the exposed surfaces of
the static bar is to be expected in normal operations. Wear depends on the
materials being conveyed.
A clean brush with nylon bristles should be used to keep the ionization emitter
points of the static bar clean. Periodic use of the brush will prevent deposits
from accumulating on the points. The emitter points must remain sharp for
optimum operation.
NOTE – Do not scrape points with any hard or sharp object that may
damage points.
1. Turn off power supply.
2. Remove dirt particles deposited on the static bars with a dry, stiff nylon
bristle brush.
3. Blow off the static bars with clean, dry compressed air.

12 5100577 Rev L
CONVEYOSTAT IN-LINE IONIZER
4. Remove resistant coatings deposited on static bars by wiping with isopropyl
alcohol or mineral spirits applied to a clean cloth. Apply isopropyl alcohol
or mineral spirits to a stiff nylon bristle brush and thoroughly scrub the
ionization emitter channels of the bar.
5. Blow static bars dry with clean, dry compressed air and ensure the bars are
completely dry before re-applying power to the bar.
NOTE – Do not soak static bar or related components in alcohol or
mineral spirits. Do not use harsh solvents such as lacquer thinner,
naphtha or acetone.
WARNING – Fire Hazard
Do not turn on power supply with any trace of alcohol or mineral
spirits on the equipment. Allow all alcohol or mineral spirits to
evaporate.
Calibration (BPS-C only)
NOTE – Calibration should be performed when the system is first
installed and may be performed after the static bar has been cleaned and
the system verified as operating correctly.
If the system is new, perform an initial calibration. The initial calibration sets
relative nominal ion output for the system. The calibration should only be
performed on systems that are new or just cleaned and known to be in proper
working order.
During calibration the Conveyostat must be clear of material, i.e. no material
is to be flowing through the Conveyostat. If material is flowing in the
Conveyostat (e.g., the machine is in operation) the calibration may be faulty.
The system should be “on” and in the operating mode (not in start-up
mode). On units NOT connected to a Control Station: press the face label
on power supply firmly on the word “Calibrate”. This will initiate the
calibration sequence and set relative nominal ion output for the system. On
units connected to a Control station, tap on the device icon, neutralizer tab.
The Device Calibrate button may be found on page 2. Tapping on Device
Calibration initiates the calibration sequence.
During calibration, the system output will be cycled. At completion of
calibration the indicator lights will flicker. The indicated ion output will be
high. The calibration sequence takes less than one minute.
The calibration data is stored in non-volatile memory and used on subsequent
power ups.

13 5100577 Rev L
CONVEYOSTAT IN-LINE IONIZER
7. TROUBLESHOOTING
NOTE – Only qualified service personnel are to perform troubleshooting
tasks.
CAUTION – Electrical Shock Hazard
Do not troubleshoot high voltage components with power supply
energized.
Disconnect input power or switch power off before troubleshooting
Conveyostat with BPS-C
PROBLEM CAUSE SOLUTION
Power indicator
NOT illuminated
Power not on at power supply Turn on Power switch on end of power supply case
Poor electrical connections
Check input power connections, both 24 VDC and
line voltage; check modular cable if used with a
Control Station
Defective AC adapter Replace AC adapter
Blown device fuse in Control Station Try another modular connector on Control Station
Clean Bar indicator
illuminated
Process material fouling static bar ion emitters Remove process material from static bar
Dirt build-up on ion emitters or conductive
contamination on face of bar
Clean ion emitters and static bar
See Maintenance section for details
Bar ON indicator
NOT illuminated
No static bar connected Install static bar and connect to power supply
High voltage connector is not connected Turn off power, reconnect high voltage cable and
secure plug with captive screws
High voltage connector missing bar type sense
pin at BPS-C Replace high voltage connector plug at BPS-C
Bar power off at Control Station Turn bar power on through device page on Control
Station
Fault indicator
illuminated
Static bar shorted to grounded metal Clear debris shorting static bar to grounded metal
Damage to high voltage connector Replace high voltage connector
Damage to high voltage cable Replace defective cable
High voltage module inside power supply faulty Replace high voltage module
Locked indicator
NOT illuminated
Power supply operating stand-alone Locked indicator only illuminates if Control Station
connected
Poor electrical connection Check connections of modular cable at power supply
and Control Station

14 5100577 Rev L
CONVEYOSTAT IN-LINE IONIZER
NOTE – Device power input is protected by an internal fuse identified
as F1 that is replaceable only by qualified service personnel. Use
cartridge-type slow blow 0.25 x 1.25” fuses rated 250V, 5A only (such
as Little Fuse 0313005.HXP or equivalent).
Conveyostat with Dual Phase+
PROBLEM CAUSE SOLUTION
Power indicator
NOT illuminated
Power not on at power supply Turn on Power switch on power supply
Poor electrical connections Check input power connections and voltage
Warning indicator
illuminated
Process material fouling static bar ion
emitters Remove process material from static bar
Dirt build-up on ion emitters or conductive
contamination on face of bar
Clean ion emitters and static bar. See
Maintenance section for details
Fault indicator
illuminated
Static bar shorted to grounded metal Clear debris shorting static bar to grounded
metal
Damage to high voltage connector Replace high voltage connector
Damage to high voltage cable Replace defective cable
High voltage transformer inside power
supply faulty Replace high voltage transformer

15 5100577 Rev L
CONVEYOSTAT IN-LINE IONIZER
8. PARTS AND ACCESSORIES
Part Description Part Number
Connector Assembly, Conveyostat to IQ Power 4110893
Adapter Kit, BPS-C to SLCC (for retrotting legacy systems) 5052096
IQ Power Extension HV Cable (for use with BPS-C)
10 foot [3.05 meter]
30 foot [9.14 meter]
50 foot [15.24 meter]
4017051
4017052
4017053
Ground Cable (braid) 10 foot [3.05 meter] 4104236
Multi HV Wire Connector Tube with Nylon Screw 4100442
Static Bar Cleaning Brush 4670204

16 5100577 Rev L
CONVEYOSTAT IN-LINE IONIZER
9. WARRANTY AND SERVICE
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 which 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
215-822-6401 for a Return Authorization Number (RMA). 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, connection to improper line voltage, or has been
serviced by 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 power supply or generator,
or when a Simco-Ion power supply 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.
Information in this publication supersedes that in all previous published
material. Specifications are subject to change without notice.

5100577 Rev L
CONVEYOSTAT IN-LINE IONIZER
Simco-Ion
2257 North Penn Road
Hatfield, PA 19440
[phone]
[phone]
www.simco-ion.com
[email protected]
© 2022 Simco-Ion. Printed in the U.S.A.