ITW Simco-Ion IQ Easy Sensor Bar User manual

5201226 Rev. F
IQ Easy Sensor Bar
IQ Easy Sensor Bar
INSTALLATION AND OPERATING INSTRUCTIONS

i5201226 Rev. F
IQ Easy Sensor Bar
TABLE OF CONTENTS
1. SAFETY WARNINGS ........................................................................................... 1
2. DESCRIPTION.................................................................................................... 2
3. SPECIFICATIONS ................................................................................................ 4
4. INSTALLATION................................................................................................... 5
Unpacking ............................................................................................................5
Mechanical Installation ........................................................................................5
Electrical Connections ..........................................................................................8
Purge Gas (recommended) ..................................................................................14
Set Up .................................................................................................................14
5. OPERATION..................................................................................................... 17
Indicator Lights...................................................................................................17
6. MAINTENANCE ................................................................................................ 18
Cleaning..............................................................................................................18
Calibration ..........................................................................................................18
7. TROUBLESHOOTING......................................................................................... 19
8. PARTS AND ACCESSORIES ................................................................................. 20
9. WARRANTY AND SERVICE................................................................................. 21

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IQ Easy Sensor Bar
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.
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.
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. Do not operate equipment in close proximity to flammable liquids.
NOTE – SENSITIVE ELECTRONICS : Risk of equipment damage.
1. Do not electrically discharge to bar. Bar must be connected to power supply in
presence of charged materials.
2. Avoid sharp blows to bar. Dropping bar may cause damage to sensors.
CAUTION – FIRE HAZARD
Do not install or operate static sensing bar in close proximity to any
flammable liquids or solvents.

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IQ Easy Sensor Bar
2. DESCRIPTION
The IQ Easy Sensor Bar is an electrostatic field measuring device packaged with a
form-factor similar to a typical static neutralizing bar. This makes the IQ Easy Sensor
Bar suitable for use in plastic film and web processing applications. It can monitor
processed materials for the presence, polarity and degree of electrostatic charges.
This allows for detection of undesirable conditions of excess static electricity.
The IQ Easy Sensor Bar may be integrated with an IQ Easy or IQ Power™ Static
Neutralizing Bar or Fantom Blower to provide closed-loop feedback control of static
elimination. This provides for better neutralization of static charges. Closed-loop
control will minimize troublesome under-compensation and over-compensation
often found in simple (open loop) static neutralizing applications. Sensing charge
on the processed material also has a benefit of monitoring the static neutralizer’s
performance. If static charge on the processed material becomes excessive, it could
be an indication of service needed at the static neutralizing bar.
The IQ Easy Sensor Bar may also be used in conjunction with electrostatic charging
systems. In these applications, the sensor bar assures that desired levels of static
charge are being maintained. The sensor bar offers two user-settable levels of static
detection; a warning level to alert the user that less than optimum levels of static
charge are being generated and an alarm level to alert of drastic or complete loss of
static charge generation.
Static charge may not be readily apparent on processed materials, but often makes
itself noticed in static shocks to machine operators, misfed materials, jammed
operation and the attraction of dust and dirt. The IQ Easy Sensor Bar makes the
intangible tangible, by providing hard data about electrostatic charges on processed
materials. This data can easily be correlated to machine operation or mis-operation.
Being aware of static charges can even make process troubleshooting easier, for
example, understanding coating irregularities as they relate to level of static charge.
Figure 1: IQ Easy Sensor Bar Connector End

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IQ Easy Sensor Bar
Static sensors are typically located at regular intervals along the length of the bar.
With this multi-segment static sensor arraignment, the IQ Easy Sensor Bar provides
a resolution in static measurement previously unavailable. The sensors themselves
use field chopping technology to provide accurate and long term stability of static
field measurement. A further benefit of this technology is freedom from zero drift
in the measurement.

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IQ Easy Sensor Bar
3. SPECIFICATIONS
Power Supply IQ Power Control Station
Input Voltage 24 VDC
Input Current 0.05A +0.022A/sensor
Input Connection 5-pin M12 (A-coded) female receptacle
Input Purge Gas
1 to 2.5 psi (7 to 17 kPa) nominal operating pressure
5 psi (35 kPa) max operating pressure
0.14 scfm (4 NL/min) per sensor at 1 psi (5 kPA)
0.22 scfm (6 NL/min) per sensor at 2.5 psi (20 kPa)
Clean, dry, oil-free compressed air or nitrogen
Gas Input Connection ¼”OD Tubing, Quick Disconnect
Operating Temperature 122˚F [50˚C] max
Operating Humidity 70% RH, no dewing permissible (max)
Operating Distance*/
Voltage
2”(50 mm) 20 kV max
3”(75 mm) 25 kV max
4”(100 mm) 30 kV max (factory default setting)
6”(150 mm) 40 kV max
8”(200 mm) 50 kV max
10”(250 mm) 60 kV max
Length 13.14”(334 mm) to 157.23”(3994 mm)
Width 1.19”(30 mm)
Height 1.71”(44 mm)
Weight 0.9 lb/ft (1.3 kg/m)
Mounting Hardware Polyamide bracket, zinc plated metal perforated strip, stainless steel
hardware
Enclosure Glass fiber reinforced polyester, conductive polyamide
Compliance RoHS
*Note: the operating distance set for the bar in the Control Station must be the same as the mounting
distance bar to web. This is critical for accurate calibration.

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IQ Easy Sensor Bar
4. INSTALLATION
Unpacking
Carefully remove all equipment from its carton and inspect the contents:
• Check that the details on the packing slip correspond to the details of the
product received.
• Check that the equipment is free from damage.
• 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 of this manual for Return
Shipment information.
Mechanical Installation
NOTE – Conductive machine parts or a static neutralizing bar in the vicinity
of the static sensor bar have an undesired influence on its operation. For
optimum results, the static sensor bar must be installed as per Figure 4.
1. Downstream of the static neutralizing bar, at a minimum distance of 12” (300
mm) so that any electric fields from the static neutralizing bar will not interfere
with charge measurement.
Downstream of the charging bar (where used in static charge generation
monitoring), at an absolute minimum distance of 12” (300 mm), greater
distances are preferred, as installation allows. So that electric fields from the
static charging bar will not interfere with charge measurement.
2. At an optimum distance from the material to be measured. The mounting
distance is related to the maximum static charge anticipated. The higher the
anticipated charge, the further the sensor bar should be mounted from the
material. The factory default mounting distance of 4” (100 mm) will provide
an operating range of +/-30 kV.
Other operating distances and maximum operating ranges are:
• 2” (50 mm) 20 kV
• 3” (75 mm) 25 kV
• 4” (100 mm) 30 kV (factory default setting)
• 6” (150 mm) 40 kV
• 8” (200 mm) 50 kV
• 10” (250 mm) 60 kV
NOTE – Calibration of the static sensor bar is distance dependent. If a
distance other than the factory default setting is used, the Mounting
Distance setting will need to be changed at the IQ Power Control Station.
3. Sensors must face the material to be measured, perpendicular to surface.
4. DO NOT mount the bar over a roller or where the material to be neutralized is
in contact with any other surface.

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IQ Easy Sensor Bar
Figure 2: IQ Easy Sensor Bar Dimensions

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IQ Easy Sensor Bar
NOTE – SENSITIVE ELECTRONICS : Risk of equipment damage.
Do not install bar with charged materials present. Bar must already be
connected to power supply in presence of charged materials. Avoid sharp
blows to bar. Dropping bar may cause damage to sensor element. Bar should
be mounted on a structure that is free of vibration.
Figure 3: IQ Easy Sensor Bar Mounting
Figure 4: IQ Easy Sensor Bar Positioning for Closed-loop Operation
(minimum 12" downstream of neutralizing bar)
5. Attach the sensor bar using mounting bracket and hardware supplied. See
Figures 3 and 4.
6. Lock the sensor bar in the mounting brackets by manually tightening the set
screws in the brackets.
7. Connect the M12 connector of the power cable to the sensor bar and route the
power cable to the power supply safely.

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IQ Easy Sensor Bar
Electrical Connections
NOTE – Turn line voltage power off at IQ Power Control Station before
connecting / disconnecting any devices. This is to avoid potential equipment
failure and ensure proper digital communication.
The IQ Easy Sensor Bar may be connected directly to the Control Station or the
Sensor Bar may be connected in conjunction with BPS static neutralizing power
supply. When the Sensor Bar is connected to a BPS power supply, the Sensor Bar is
automatically paired with the power supply. This prepares the system for operation
in the CLFB (Closed-Loop Feedback) mode.
Connecting Sensor Bar to Control Station through BPS Power Supply
Cables used to connect IQ Easy Sensor Bars with a BPS power supply are available
in a variety of standard lengths with straight and right angle M12 connectors at the
IQ Easy device end (see Parts & Accessories section).
The IQ Easy end of the cable has an M12 connector. Place the cable connector
against the connector on the IQ Easy Sensor Bar and rotate the connector until
the keyed connection aligns. Press the connectors together and turn the knurled
coupling nut clockwise to thread it on. Finger-tighten the coupling nut until the
connector is fully seated. Route cable away from any moving machine parts and
secure the cable to prevent damage.
When the IQ Easy Sensor Bar is used with a BPS (typically in CLFB - Closed-Loop
Feedback) it is required the sensor bar be plugged into connector “PS COMM 2” of
that BPS power supply. This will automatically associate (pair) the sensor bar with
the BPS for CLFB mode.