ITW SIMCO ION IQ Power HLC User manual

5201259 Rev. D
IQ Power HLC Power Supply
& Control Station
IQ Power™HLC Power Supply &
Control Station with
Sensor Technology
Associated Equipment - Appareillage Connexe for
the IQ Power HL Static Bar
INSTALLATION AND OPERATING INSTRUCTIONS

5201259 Rev. D
IQ Power HLC Power Supply
& Control Station
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i
IQ Power HLC Power Supply
& Control Station
5201259 Rev. D
TABLE OF CONTENTS
1. SAFETY WARNINGS.................................................................................................1
2. DESCRIPTION ..........................................................................................................3
Features ...................................................................................................................3
3. SPECIFICATIONS .....................................................................................................4
4. INSTALLATION.........................................................................................................5
Mounting the Power Supply....................................................................................5
Mounting the Control Station (or Legacy Remote Display Module).......................5
Electrical Connections.............................................................................................5
Modular Cable HV Cable.......................................................................................6
Power Supply Number (Address / Device Number) ..............................................21
Set Up (with IQ Power Control Station) ..............................................................22
5. OPERATION .......................................................................................................... 25
System Start-up.....................................................................................................25
System Operation .................................................................................................26
Legacy Remote Display Module Indicators ...........................................................27
Legacy Remote Display Module Operators ...........................................................27
6. MAINTENANCE..................................................................................................... 28
Cleaning the Static Bar..........................................................................................28
7. TROUBLESHOOTING ............................................................................................ 29
8. PARTS & ACCESSORIES........................................................................................ 30
9. WARRANTY & SERVICE ........................................................................................ 31

1
IQ Power HLC Power Supply
& Control Station
5201259 Rev. D
1. SAFETY WARNINGS
Simco-Ion recommends that these instructions be read completely before installation
or operation is attempted. Failure to do so could result in personal injury and/or
damage to the equipment.
NOTE – Statements identified with NOTE indicate precautions necessary
to avoid potential equipment failure.
CAUTION – Statements identified with CAUTION indicate potential
safety hazards.
ATTENTION – Les déclarations identifiées avec ATTENTION indiquent
des dangers potentiels pour la sécurité.
WARNING – Statements identified with WARNING indicate potential
serious injury hazards.
AVERTISSEMENT – Les déclarations identifiées avec AVERTISSEMENT
indiquent un risque de blessures graves.
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 machine frame to which
the equipment is mounted.
4. Disconnect input power to Power Supply before connecting or disconnecting
static neutralizing bars to high voltage Power Supply.
5. Do not use standard Ethernet cables with IQ Power Systems.
CAUTION – This product is intended to be supplied by a Listed AC
Adapter or Power Unit marked “Class 2” or “LPS” and rated output 24
VDC, 1.6A.
ATTENTION – Ce produit est destiné à être alimenté par un adaptateur
de courant alternatif ou transformateur listé “classe 2” ou “LPS” et avec une
puissance nominale 24 VDC, 1.6A.

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IQ Power HLC Power Supply
& Control Station
5201259 Rev. D
CAUTION – Electrical Shock Hazard
Disconnect input power to the high voltage power supply before connecting
or disconnecting static neutralizing bar or performing any maintenance to
the system. Avoid touching static neutralizing bar when power supply is
energized.
ATTENTION – Risque De Choc Électrique
Couper l’alimentation à l’alimentation électrique de haute tension avant de
brancher ou de débrancher la barre de neutralisation statique ou d’effectuer
un entretien au système. Évitez de toucher la barre de neutralisation statique
lorsque l’alimentation électrique est sous tension.
WARNING – Fire Hazard
Do not install or operate Remote Display Module in close proximity to any
flammable liquids or solvents.
AVERTISSEMENT - Risque d’incendie
Ne pas installer ou d’utiliser le module d’affichage à distance à proximité de
liquides ou de solvants inflammables.
WARNING –Substitution of components may impair intrinsic safety. (See
Figure 3a, 3b and 3c).
AVERTISSEMENT – La substitution de composants peut compromettre
la securite intrinseque. (referez-vous au schema 3a, 3b et 3c)

3
IQ Power HLC Power Supply
& Control Station
5201259 Rev. D
2. DESCRIPTION
Simco-Ion’s IQ Power HLC Power Supply and Control Station provide
microprocessor controlled high voltage DC output to the static bar. High voltage
causes ionizing pins on the static bar to generate positive and negative ions. The
electric field from the static charge on material being processed will attract opposite
polarity ions from the static bar causing the material to be neutralized. Excess ions
will either recombine in air or dissipate to ground.
The IQ Power HL static bar is tailored to the application. Speed bars are optimized
to operate on high speed webs at distances of 50 to 230 millimeters [2 to 9 inches].
Hybrid bars operate at distances of 150 to 460 millimeters [6 to 18 inches] on webs
where the web path is somewhat variable.
The IQ Power HLC Power Supply is agency approved for mounting within
hazardous locations:
• Class I, Division 1, Group D
• Class II, Division 1, Groups F and G
• Class III, Division 1
The Control Station is a convenient hub that provides power and communication
for IQ Power or IQ Easy devices. Two-way digital communication provided by the
Control Station enables monitoring and logging of system performance, and allows
access to enhanced features in the static neutralization system. These enhanced
features include; manual control of ionization balance, Auto-Tune automatic control
of ionization balance and CLFB (Closed-Loop Feedback) providing the ultimate in
static eliminator control (use of the IQ Power HL Static Sensor is required).
All IQ Power optional modules use 8-conductor modular cable and RJ-45
connectors for connection to the IQ Power system. They are typically supplied
with 7 foot cable assemblies but longer lengths are available by calling Simco-Ion
customer service [phone] (refer to Section 8, Parts & Accessories).
Features
• Easy calibration procedure simplifies set-up.
• Relay contact output “echoes” indicators for remote sensing and alarm.
• Control Station provides power and a communication hub for HLC Power
Supply.
• Control Station displays status of neutralizing system, power, service
required and detection of system faults.
• Optional static sensor for gathering web charge data (used in CLFB mode).

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IQ Power HLC Power Supply
& Control Station
5201259 Rev. D
3. SPECIFICATIONS
IQ Power HLC Power Supply
Input Power 24 VDC, 1.5A from AC adapter or Control Station
Output Voltage +/-7 kV“Speed Bar”; +/-8 kV“Hybrid Bar”
Dimensions 388L x 253W x 159H mm [15.25”L x 9.25”W x 6.25”H]
Weight 14.5 kg [32 lb]
Operating Temperature 43°C [110°F] max
Enclosure Cast Aluminum
IQ Power Control Station
Input Power 100-240V~ 50/60 Hz, 4A max (IEC 320 inlet)
Output Voltage 24 VDC (all IQ Power and IQ Easy connectors)
Device Port USB-A
Network Port Ethernet
Interface 10.2”ColorTFT LCD (backlit) with resistive touch screen
Operating Temp 39°C [102°F] max
Mounting Slots M6 or M5 [1/4”or #10] hardware (not included)
Enclosure Steel, blue epoxy powder coated
Dimensions 197L x 314W x 118H mm [7.75”L x 12.38”W x 4.65”H]
Weight 5.2 kg [11.4 lb]

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IQ Power HLC Power Supply
& Control Station
5201259 Rev. D
4. INSTALLATION
Mounting the Power Supply
A. Locate at a convenient place within reach of static bar high voltage cable.
Note the HLC Power Supply is agency listed for mounting within hazardous
(classified) locations (see Figure 3a, 3b and 3c).
B. Secure to mounting surface (commonly a machine frame) using M10 [3/8”]
hardware (not supplied).
NOTE – Do not apply line voltage to AC adapter or Control Station until
installation is complete. Also ensure that all input power switches are in the
OFF (0) position.
Mounting the Control Station (or Legacy Remote Display Module)
A. Locate at a convenient place within reach of power supply cable. Power for
Control Station or AC adapter and an electrical ground connection must be
available.
B. Secure Control Station to mounting surface using M6 or M5 [1/4” or #10]
hardware (not supplied).
C. Secure Remote Display Module (in legacy installations) to mounting surface
(commonly a machine frame) using M5 or M4 [#10 or #8] hardware (not
supplied).
WARNING – Fire Hazard
Do not install Control Station or Remote Display Module within hazardous
(classified) locations. Install in non-hazardous (unclassified) locations only
(see Figure 3a, 3b and 3c).
AVERTISSEMENT – Risque d’incendie
Ne pas installer le station contrôle ou module d’affichage à distance des
emplacements dangereux (classifiés). Installer dans des emplacements non
dangereux (non classifiés) seulement (voir Figure 3a, 3b et 3c).
Electrical Connections
A. Ground Power Supply by connecting a ground lead between metal conduit to
Power Supply and a good electrical machine ground. Note that conduit seals
must be properly installed to prevent the propagation of vapors and flames
through conduit runs (see Figure 1). Outer jacket of modular cables must
be removed (and individual wires separated) before filling conduit seals with
cement.

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IQ Power HLC Power Supply
& Control Station
5201259 Rev. D
Modular Cable HV Cable
Figure 1. Conduit Seal
B. Connect static bar by cutting the high voltage cable to length, terminating the
leads, and connecting to the power supply: (see to Figure 2)
1. Strip black plastic jacket back 3¼” being careful not to nick insulation of
HV wires and strip insulation of HV wires back 1” using a wire stripper
(being careful not to nick conductor of HV wire).
2. Straighten conductors and insert into HV connector until conductor
protrudes out from the tip of connector.
3. 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.
4. Trim off excess conductor protruding from tip of connector.
Figure 2. HighVoltage Cable Termination
5. Plug connectors into sockets labeled HV1 or HV2 on Power Supply.

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IQ Power HLC Power Supply
& Control Station
5201259 Rev. D
Note that conduit seals must be properly installed to prevent the propagation of
vapors and flames through conduit runs. 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.
ATTENTION – Risque De Choc Électrique
Ne branchez pas la barre de neutralisation statique avec alimentation sous
tension. Couper l’alimentation ou coupez le courant avant de connecter la
barre statique.
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 HLC Power Supply
& Control Station
5201259 Rev. D
Figure 3a. IQ Power HLC SPEED Control Drawing

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IQ Power HLC Power Supply
& Control Station
5201259 Rev. D
Figure 3b. IQ Power HLC HYBRID Control Drawing

10
IQ Power HLC Power Supply
& Control Station
5201259 Rev. D
”
An ITW Company
OPTIONAL
EQUIPMENT
Figure 3c. IQ Power HLC SPEED with Fantom HL Control Drawing

11
IQ Power HLC Power Supply
& Control Station
5201259 Rev. D
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 & Accessories).
Figure 4. IQ Power Crossover Modular Cable (black)
C. Connect Control Station . The Control Station supplies 24 VDC power for the
IQ Power static eliminator power supplies. Use the 7.62 meter [25 foot] (black)
modular cable supplied with HLC. Longer cables (not supplied) are available.
Cables must be IQ Power 8-conductor modular cables with RJ-45 connectors
wired “crossover” (reference color: black, Figure 4).
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 HLC Power Supply. (see Figure 5)
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).
The IQ Power 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 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.

12
IQ Power HLC Power Supply
& Control Station
5201259 Rev. D
The Control Station can be used to automatically address the power supplies.
The default Power Supply Number for a new unit is “1”. Plug first HLC
(only) into Control Station and turn Control Station on. Allow Control Station
to boot-up and begin operation. Plug second system into Control Station. The
Control Station will re-address the second HLC to “2”. Plug third system into
Control Station. The Control Station will re-address the third HLC to “3”.
Repeat this process until all power supplies (or IQ Power / IQ Easy devices) are
installed. Each power supply or device will be given a unique address (device
number).
IQ Power HLC power supplies may also be manually re-addressed through the
Control Station.
See Power Supply Number (Address / Device Number) section.

13
IQ Power HLC Power Supply
& Control Station
5201259 Rev. D
Figure 5: IQ Power Connections (HLC to Control Station)

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IQ Power HLC Power Supply
& Control Station
5201259 Rev. D
D. Connect Sensor (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.
Use the 7.62 meter [25 foot] (black) modular cable supplied with HLC. Longer
cables (not supplied) are available. Cables for Sensor Interface must be IQ
Power 8-conductor modular cables with RJ-45 connectors wired “crossover”
(reference color: black, Figure 4).
The modular cable plugs into one of the connectors labeled “SI COMM 1” on
Sensor Interface and into the “PS COMM 1” connector on HLC Power Supply.
(see Figure 6)
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.
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.

15
IQ Power HLC Power Supply
& Control Station
5201259 Rev. D
Figure 6: IQ Power Connections (HLC with Sensor Interface to Control Station)

16
IQ Power HLC Power Supply
& Control Station
5201259 Rev. D
Figure 7: IQ Power Connections (HLC-SPEED (only) to Control Station with Fantom HL and Options)

17
IQ Power HLC Power Supply
& Control Station
5201259 Rev. D
E. Connect power supply alarm output (if used). The HLC Power Supply and
(legacy) Remote Display Module “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 7).
Figure 7. IQ Power HLC Power Supply and Remote Display Module Alarm Output
Alarm Output Pin-out
Pin Description Pin Description
1 Remote on/off optocoupler (-) 10 No connection
14 Remote on/off optocoupler (+) 6 No connection
19 No connection
2 Clean Bar Relay (common)* 11 Power Relay (common)*
3 Clean Bar Relay (normally closed)* 7 Power Relay (normally closed)*
16 Clean Bar Relay (normally open)* 20 Power Relay (normally open)*
8 Fault Relay (common)*
4 Fault Relay (normally closed)* 12 Power in (ground)**
17 Fault Relay (normally open)* 24 Power in (ground)**
9 Bar On Relay (common)* 13 Power in (+24V DC)**
5 Bar On Relay (normally closed)* 25 Power in (+24V DC)**
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.
F. 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 7). To access the jumpers the cover will have to be removed from the
HLC Power Supply or (legacy) Remote Display Module. Disconnect all input
power, then remove the six screws securing the cover and slowly and carefully
remove the cover.