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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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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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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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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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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Figure 2: IQ Easy Sensor Bar Dimensions

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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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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.

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Figure 5: IQ Power Connections (Sensor Bar to Control Station through BPS Power Supply)

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Connecting Sensor Bar to Control Station (standalone or with other devices)
Cables used to connect the IQ Easy Sensor Bar to the Control Station have M12
connectors on both ends. Cables are available in a variety of lengths with straight or
right angle connectors at the IQ Easy device end (see Parts & Accessories section).
Connection is made at the Control Station to one of the six connectors labeled
DEV1 thru DEV6.
Place the appropriate M12 cable connector against the connector on the device or
control station 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.
Alternate cables to connect the IQ Easy Neutralizer Bar to the Control Station are
available. These cables are available with a straight or right angle connector at the
IQ Easy device end and an RJ-45 connector at the Control Station end (see Parts
& Accessories section). Connection is made at the Control Station to one of the ten
connectors labeled 1 thru 10 POWER & COMM.
Figure 6: IQ Power Connections (Sensor Bar to Control Station)

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Figure 7: IQ Power Connections (Sensor Bar and IQ Easy Static Bar to Control Station)

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Figure 8: IQ Power Connections (Sensor Bar and MPS Power Supply to Control Station)

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Figure 9: IQ Power Connections (Sensor Bar and Fantom to Control Station)

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Purge Gas (recommended)
NOTE – Purge gas or compressed air used with this device MUST be clean
and dry. Dirt, water or oil in the purge gas will damage the sensors.
In dirty or dusty environments low pressure purge gas may be used to prevent the
sensors from becoming fouled with debris. The purge system is designed to provide
a gentle flow of purge gas at each sensor aperture, where the electrostatic field is
measured.
The purge gas must be prepared with filtration and pressure regulation to ensure a
low pressure flow of clean, dry, oil-free air. The operation of the purge system calls
for purge gas at 1 to 2.5 psi (7 to 17 kPa). Connection to the sensor bar is made with
a ¼”outside diameter tubing quick disconnect. The tubing must be clean and may
include typically used tubing materials such as nylon, polyethylene or polyurethane.
To connect the sensor bar, make sure the tubing is cut cleanly and not at an angle,
then simply push the tubing into the fitting on the end of the bar.
NOTE – Do not apply more than 10 psi (70 kPa) to the purge gas fitting or
equipment damage may result.
Route the tubing away from any moving machine parts and secure the tubing to
prevent damage
Set Up
A variety of information can be checked, and operating parameters set, for the IQ
Easy Sensor Bar through the IQ Power Control Station via the sensor page/tab. Tap
on the device icon for the sensor bar to access these pages.
To edit or select an operating parameter, tap on the pencil icon to the right of the
parameter description.
Device Name: A user editable name to identify the specific sensor bar (17 character).
Device Type: A fixed description for the device type (IQ Easy Sensor).
Sensor Quantity : The number of sensor modules found on the sensor bar.
Overall Average : The numeric average of voltages from all sensor modules on the
sensor bar.
Feedback Average : The numeric average of voltages from Sensors for Feedback. This
value is used during closed-loop feedback (CLFB) control for the static neutralizing
bar.
Sensors for Feedback : The sensor modules selected to provide feedback for closed-
loop feedback (CLFB) control. The default setting for this is to use all sensors on
the bar for feedback control.

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Paired Bar : The specific static neutralizing bar used with a sensor bar in closed-loop
feedback (CLFB) mode. The static neutralizing bar MUST be upstream (before)
the sensor bar.
Pairing is controlled by connection to “PS COMM 2” on a BPS power supply or
by matching the sensor bar address to an IQ Easy static neutralizing bar or Fantom
ionizing blower. In either case, the sensor will appear as a tab on the neutralizer
device page on the Control Station Display.
Mounting Distance : A user entered dimension, the spacing between the face of the
sensor bar and web (surface being measured). The factory default mounting distance
is 4” (100 mm).
NOTE – This information (Mounting Distance) MUST be correct. It is
used by the sensor bar for calibration. If this information is not correct, the
sensor bar calibration will be incorrect.
Voltage Range : The voltage range is the maximum (both positive and negative)
that the sensor bar is capable of measuring. The voltage range is determined by
the mounting distance. As the mounting distances increase, the voltage range also
increases.
Sensor Mode: Two sensor modes are available, Neutralizing and Charging.
The Neutralizing Mode triggers the Warning and Alarm on rising voltage, indicating
excess static electricity. This indicates a static neutralizing bar is not effectively
neutralizing static electricity.
The Charging Mode triggers the Warning and Alarm on falling voltage, indicating
a lack of static electricity. This indicates static charging equipment is not effectively
electrostatically charging material.
The default Sensor Mode setting is Neutralizing.
Warning Setpoint : The web voltage level at which the sensor bar will set a “Warning”
and illuminate the yellow indicator light on the end of the bar. In the Neutralizing
(default) Sensor Mode, the Warning triggers on rising voltage (indicated by “>”),
i.e., the Warning triggers when voltage rises above the Warning Setpoint. In the
Charging Sensor Mode, the Warning triggers on falling voltage (indicated by “<”),
i.e., the Warning triggers when voltage falls below the Warning Setpoint. The
factory default value is 5 kV, however this value may be user adjusted.
Alarm Setpoint : The web voltage level at which the sensor bar will set an “Alarm”
and illuminate the red indicator light on the end of the bar. In the Neutralizing
(default) Sensor Mode, the Alarm triggers on rising voltage (indicated by “>”), i.e.,
the Alarm triggers when voltage rises above the Alarm setpoint. In the Charging
Sensor Mode, the Alarm triggers on falling voltage (indicated by “<”), i.e., the Alarm
triggers when voltage falls below the Alarm Setpoint. The factory default value is
20 kV, however this value may be user adjusted.

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Data Logging : Available, must be turned on.
Firmware Version Main : The firmware revision in the gateway (main) circuit board.
Web Voltage Sensor 1,2,3... : The voltage level reported by a given sensor module.
Firmware Version Sensor 1,2,3… : The firmware revision in the sensor module circuit
board.
The IQ Easy Sensor Bar can be used as part of a closed-loop feedback system to
control an IQ Easy or IQ Power Static Bar or Fantom Blower. In this configuration
the ion output from the static bar or blower is optimized to provide the best possible
web neutralization. Enabling the CLFB Mode (closed-loop feedback) is performed
on the IQ Power Control Station under the neutralizer device pages.
NOTE – CLFB with a neutralizer is not possible when the sensor bar is
configured in the charging mode. Ensure Sensor Mode is set to “Neutralizing”
for CLFB applications.

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5. OPERATION
The operation of the sensor bar is controlled through the IQ Power Control Station.
In operation, a device icon appears on the IQ Power Control Station, a tab appears
on the neutralizer page when the sensor is paired with the neutralizer. Tapping on
the device icon / tab for the sensor bar enters a series of pages containing information
about that sensor bar. This includes descriptive information such as the device name,
quantity of sensor segments, and firmware revision levels. User inputs such as the
sensor bar mounting distance (critical for correct calibration), device name, selection
of sensor modules for CLFB, warning and alarm setpoints are available. Output
information includes average voltage for all sensors and voltage for individual sensor
modules. Warning and alarm outputs are also included in these pages. Additional
features may be available.
Indicator Lights
Three indicator lights are located on the connector end of the sensor bar: green,
yellow and red.
Green
• A steady green light indicates the sensor bar is powered and active.
• A rapidly flashing green indicator light indicates the bar has received a
command. The rapid flashing only lasts for several seconds.
Yellow
• A steady yellow light indicates the user adjustable web voltage warning
setpoint is being exceeded. This is a non-latching feature; the indicator
light will go out when web voltage resumes acceptable levels.
Red
• A steady red light indicates the user adjustable web voltage alarm setpoint
is being exceeded. This is a non-latching feature; the indicator light will go
out when web voltage resumes acceptable levels.
• A blinking red indicator light indicates an internal failure of the sensor bar.
Sensor Mode
Selection of the Sensor Mode is available through the IQ Power Control Station.
The default Sensor Mode setting is “Neutralizing” for applications where the sensor
bar is use in typical static eliminating applications.
For applications where the sensor bar is being used with electrostatic charging
equipment, it will be necessary to manually set the Sensor Mode, through the
Control Station, to “Charging”.
This adjustment is required to obtain the proper function of the Warning and Alarm
indicators & outputs.

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6. MAINTENANCE
NOTE – Turn off power to sensor bar before performing any maintenance.
Do not disconnect sensor bar if charged materials are present.
Cleaning
Clean the sensor bar using a lint-free wiper moistened (but not saturated) with
isopropyl alcohol. Use caution around the sensor modules and avoid contact with
the sensor aperture. Allow the sensor bar to dry completely before applying power.
Calibration
Sensor modules should be calibrated to ensure accurate measurement. Calibration
is performed at the factory or authorized service center. Recommended calibration
interval is one year.