ITW SIMCO ION D Series User manual

R50 Blue Bar 5101171 Rev. L
R50 Blue Bar and
Power Supplies
(D, N & TRUEAC)
INSTALLATION AND OPERATING INSTRUCTIONS

TABLE OF CONTENTS
1. SAFETY WARNINGS.................................................................................................1
2. INTRODUCTION ......................................................................................................2
R50 Blue Bar...........................................................................................................2
“N” Power Supplies.................................................................................................2
“D” Power Supplies.................................................................................................3
TrueAC Monitoring Power Supplies........................................................................3
Receipt of Equipment .............................................................................................4
Return Shipments ...................................................................................................4
3. SPECIFICATIONS .....................................................................................................5
4. INSTALLATION.........................................................................................................8
R50 Blue Bar...........................................................................................................8
“N” Power Supply ...................................................................................................8
“D” and TrueAC Power Supply.............................................................................10
5. OPERATION .......................................................................................................... 17
Startup for “N” Power Supplies.............................................................................17
True AC Function Indicators.................................................................................17
Calibration Instructions for the TrueAC Monitoring Power Supply ......................17
Calibration Procedures ..........................................................................................17
6. TROUBLESHOOTING ............................................................................................ 21
Troubleshooting for “D” Power Supply .................................................................21
Operating Condition Solutions.............................................................................21
Indicator Light Solutions.......................................................................................21
7. MAINTENANCE..................................................................................................... 23
R50 Blue Bar.........................................................................................................23
Functionality Check of “N” Power Supplies..........................................................23
8. REPLACEMENT PARTS ......................................................................................... 24
9. WARRANTY........................................................................................................... 25

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R50 Blue Bar 5101171 Rev. L
1. SAFETY WARNINGS
NOTE! – Statements identified with a NOTE indicate precautions necessary to avoid
potential equipment failure.
CAUTION! – Statements identified with a CAUTION indicate minor or moderate
injury is possible.
WARNING! – Statements identified with a WARNING indicate serious injury is
possible.
NOTE! – This equipment must be correctly installed and maintained. Adhere
to the following notes for safe installation and operation.
1. Read instruction manual before operating or installing device.
2. Qualified service personnel must do installation and repairs.
3. Ground the frame of the machine on which the power supply and neutralizing bars
are mounted.
4. Disconnect supply voltage to power supply before connecting neutralizing bar to the
high voltage terminal strip.
CAUTION! – Electrical Shock Hazard
1. Do not touch bar when power supply is energized.
2. Disconnect supply voltage to power supply before connecting bar or
performing any maintenance to the system.
WARNING! – Fire Hazard
Do not install or operate equipment in close proximity to any flammable
solvents or flammable materials.

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R50 Blue Bar 5101171 Rev. L
2. INTRODUCTION
Simco-Ion’s N167, N257, N267, D167Q, D257Q, and TrueAC power supplies are
designed as a power source for the static neutralizing R50 Blue Bar. The R50 Blue Bar
is used to eliminate or significantly reduce static charges that disrupt manufacturing
processes. The high voltage from the power supply causes the ionizing pins of the static
neutralizing bar to generate both positive and negative ions from the surrounding air
molecules. The static charge on the material being processed will attract and combine
with the oppositely charged ions, causing the material to be neutralized. The excess ions
either recombine in air or dissipate to ground.
R50 Blue Bar
The R50 Blue Bar is current limited shockless bars with resistors in series between each
emitter pin and the high voltage source. The Blue Bars incorporate an encapsulated
internal ground reference. The current-limited design provides an added safety feature to
prevent hazardous electrical shocks if there is contact with the ionizing pins. This safety
feature does not compromise the static bar’s performance.
Features
• Current limited to prevent electrical shock from contact with ionizing pins.
• Built-in ground reference inside bar for maximizing ion generation.
• Flexible shield high voltage cable to limit EMI and RFI.
• Continuous mounting slot to allow installation flexibility.
“N” Power Supplies
The Simco-Ion Type N Power Supply provides multiple high voltage outputs for
powering various types of static eliminating equipment. Although there are various
models, they are basically the same with respect to mounting, connection, and operation.
Each power supply operates on a specific line voltage and frequency and provides a
specific high voltage output. The voltage of the power supply needed depends upon the
type of static eliminating device it is to power. Therefore, the power supply must be used
only with the device for which it was originally supplied. Do not add any device to the
power supply without first consulting Simco-Ion.
If it should become necessary to contact Simco-Ion regarding the power supply, please be
sure to reference the power supply model number and unit number. These numbers are
listed on the label affixed to the power supply. Line voltage and frequency requirements
as well as output ratings are listed on the nameplate.
The Simco-Ion Type N Power Supplies are UL and CSA listed. These power supplies
also carry CE approval.

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R50 Blue Bar 5101171 Rev. L
“D” Power Supplies
The D167Q and D257Q power supplies are neither equipped with a monitoring circuit
nor have provisions for remote monitoring. The D167Q and D257Q power supplies
consist of a ferroresonant type transformer rated at 7,000 volts, 3 mA with short circuit
current limit of 5.0 mA. These potted power supplies are equipped with output outlets
to facilitate up to two static neutralizing bars.
Features
• High impedance transformer design with short circuit current limited to 5.0
mA maximum.
• Outlets to accommodate up to two neutralizing bars.
• Potted transformer in metallic enclosure.
TrueAC Monitoring Power Supplies
The TrueAC power supply is equipped with a monitoring circuit with provisions for
remote On/Off control and remote monitoring. The units are designed to operate with
the R50 Blue Bar to provide monitored static control performance on stationary objects
or on materials traveling at speeds up to 2,500 feet per minute. The power supplies
consist of the monitoring circuit and a ferroresonant type transformer rated at 7,000
volts, 3 mA, with a short circuit current limit of 5 mA. The units are equipped with
output outlets to facilitate up to two static neutralizing bars.
Features
• Bar ON indicator
• Bar OFF indicator
• Remote display capabilities for CLEAN BAR*, FAULT*, and SERVICE*
• CLEAN BAR Indicator – factory set at 40% of maximum bar efficiency, or can
be set by user in the field
• FAULT indicator
• BAR PERFORMANCE RANGE Indicator
• Arc Detection circuit
* Dry contacts available via remote connector included with the unit.

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R50 Blue Bar 5101171 Rev. L
Receipt of Equipment
1. Carefully remove the equipment from the carton.
2. 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 and [phone].
3. Empty the carton to insure that small parts are not discarded.
Return Shipments
Prior to returning goods, contact a Simco-Ion Customer Service representative 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.

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R50 Blue Bar 5101171 Rev. L
3. SPECIFICATIONS
R50 Blue Bar
Operating Voltage R50-8,000 VAC max, 50/60 Hz
Ionizing Pin Current R50-48 mA with 7200 VAC applied voltage, short circuit
Operating Temperature 176°F (80°C) max
Humidity 70% RH max, no dewing permissible
Dimensions 5/8”W x 1 1/4”H x Overall Length (OL) (see Figure 1)
Weight 0.5 lb/ft
Enclosure Glass-fiber-reinforced plastic (GRP)
Encapsulation Material Polyurethane, UL-94 V-O
Installation Hardware Plastic slider and nylon bolts
“D” Power Supply
Part Number 4000074 (D167Q) 4000075 (D257Q)
Input Power Rating 120 VAC 60 Hz 230 VAC 50/60 Hz
Output Voltage 7 kV AC
Output Current 3.0 mA max, 5.0 mA short circuit
Temperature 105˚F (40˚C) max, ambient
Dimensions 5.8”L x 4.0”W x 3.4”H
Weight 7 lbs
High Voltage Connector Two screw-in type connectors
“N”Power Supply
Part Number 4002321 (N167) 4002337 (N257) 4002322 (N267)
Input Power Rating 120 VAC 60 Hz 230 VAC 50 Hz 230 VAC 60 Hz
Output Voltage 7 kV AC
Output Current 3.0 mA max, 5.0 mA short circuit
Temperature 105˚F (40˚C) max, ambient
Dimensions 8.6”L x 4.9”W x 4.5”H
Weight 7 lbs
High Voltage Connector Four terminal block connections

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R50 Blue Bar 5101171 Rev. L
TrueAC Power Supply
Part Number 4010442 4010443 4010604 4010605
Input Power Rating 120 VAC 60 Hz 230 VAC 50 Hz 120 VAC
50/60 Hz
230 VAC 50/60
Hz
Output Voltage 7 kV AC
Output Current 3.0 mA max, 5.0 mA short circuit
Temperature 105˚F (40˚C) max, ambient
Dimensions 5.5”L x 3.9”W x 4.5”H 8.6”L x 4.9”W x 4.5”H
Weight 6 lbs 6 lbs
High Voltage Connector Two screw-in type connectors Four screw-in type connectors
Figure 1. R50 Blue Bar Overview and Dimensional Drawing

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R50 Blue Bar 5101171 Rev. L
35
30
25
20
15
10
5
0
04 812 16 20 24 28 32 36 40 44 4
8
Eective Bar Length (Feet )
Cable Length (Feet)
R50
Figure 2. Loading Capacity

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R50 Blue Bar 5101171 Rev. L
4. INSTALLATION
R50 Blue Bar
CAUTION – Electrical Shock Hazard
DO NOT use metallic screws. DO NOT omit insulator blocks.
1 Mount bar to machine. Bar should be positioned away from all metal ground
references. In an ideal mounting arrangement, a cylindrical space with radius R
between bar and web should be kept free of any grounded metal structure. In the
event of confined mounting space, the minimum distance that a bar should be
located from a nearby metal ground reference is 1”.
2. Determination of radius R depends on web speed. For varying web speed, radius R
should be 2” from web surface. Refer to Figure 4 for maximum mounting distance
of bar from web surface. In certain applications, the Blue Bar has been found to
work well at distances in excess of 6”.
CAUTION – Mounting the bar directly against a grounded metal support
without sufficient air space or plastic insulation could result in burn-out of the
bar.
3. Insert nylon screws through washers, then metal bracket, insulation block and
finally into the sliding nuts supplied with each Blue Bar (see Figure 4).
4. Hand-tighten screws plus ¼ turn. Do not over-tighten. For permanent mounting,
apply liquid thread-lock to screw prior to assembly (Loctite 243 or equivalent).
CAUTION – Failure to properly ground the power supply may result in an
electrical shock hazard to personnel and inefficient operation of the equipment.
Do not apply line power until all grounds and high voltage connections have
been completed.
“N” Power Supply
Mounting and Grounding the Power Supply
The power supply is designed for flat surface mounting and can be easily mounted using
the mounting flanges at the base of the unit. The ambient temperature of mounting are
of the power supply must not exceed 105˚F (40˚C).
CAUTION – Electrical Shock Hazard
Failure to properly ground a power supply may result in an electrical shock
hazard to personnel and inefficient operation of equipment.

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R50 Blue Bar 5101171 Rev. L
Proper grounding of the power supply enclosure is essential for safe and efficient
operation. Proper grounding can be accomplished by either of the following methods:
1. For power supplies mounted on machinery, connect power supply ground stud with
at least #16 AWG copper wire.
2. All power supplies are equipped with a 3-conductor line cord.
For power supplies with 120 VAC operating voltage, the line cord is fitted with a
standard NEMA 5-15P plug. The line cord must be plugged into a 3-terminal grounded
receptacle.
For power supplies with 230 VAC operating voltage, the line cord is fitted with a
standard NEMA 6-15P plug. The line cord must be plugged into a 3-terminal grounded
receptacle.
For power supplies that are equipped with a plug-less 3-conductor line cord, the ground
wire (green or green/yellow) must be connected to earth ground.
Input Line Voltage Connections
The line cord must be connected to a power source of the correct voltage and frequency
as listed on the nameplate. For power supplies with 120 or 240 VAC operating voltage,
the line cord is fitted with a plug. For power supplies with a plug-less line cord, the
following connections are required:
Wire Colors
North America International Power Connection
Black Brown Live
White Blue Neutral
Green Green/Yellow Ground
If the static eliminating equipment is used ton machinery, it is recommended that the
line cord of the power supply be connected to the machine “RUN” button. This enables
the static eliminating equipment to turn on and off with the machine. Some power
supplies are equipped with an ON/OFF switch with indicator.
CAUTION – Electrical Shock Hazard
Do not apply line voltage to the power supply until all grounds and high voltage
connections are complete and static eliminating equipment has been installed.

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R50 Blue Bar 5101171 Rev. L
High Voltage Connections for Standard Cable
When connecting high voltage cable through the high voltage outlets of the power supply
enclosure, always install the strain relief bushing onto the cutout to insulate cable and
prevent it from arcing to ground. Refer to the installation procedures below:
1. Disconnect line voltage to power supply
2. Remove lid from power supply
3. Remove black insert bushing from cutout of high voltage outlet. Mount strain relief
bushing (P/N 4610634 supplied with power supply) on cutout.
4. Cut a suitable high voltage cable to desired length. Insert cable through strain relief
bushing. Allow additional length for cable to reach high voltage output terminal
block inside power supply.
5. Strip 3/8 inch insulation from end of high voltage cable. Attach cable to one of the
free positions n the high voltage output terminal block.
6. Re-tighten strain relief bushing to fit snug. Pull gently on cable to make certain
connection is secure.
Some static eliminating devices may have a separate insulated ground wire (green)
running along the high voltage cable. This wire must be connected to the ground screw
on the outside of the power supply.
If corona-free shielded cable is used, be sure to connect ground wire to ground terminal
located inside the power supply.
CAUTION – Electrical Shock Hazard
Failure to properly ground shielding may result in electrical shock hazard to
personnel and inefficient operation of equipment.
“D” and TrueAC Power Supply
1. Determine the location for mounting the neutralizing bar and power supply. Refer
to Figure 8 (see Figure 9 for TrueAC cable connections) for correct cable assembly.
Some cable assemblies have SLCC high voltage connector pre-installed.
2. DO NOT PLUG LINE CORD OF POWER SUPPLY INTO THE INPUT
POWER RECEPTACLE UNTIL INSTALLATION IS COMPLETED.
3. Drill four 9/32” diameter clearance holes for mounting the power supply using
¼-20 hardware. Refer to Figure 10 for dimensions between clearance holes.
4. Ensure the mounting location of the power supply will allow the high voltage cables
to be positioned away from moving parts and sharp edges then mount power supply.

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R50 Blue Bar 5101171 Rev. L
5. Connect a ground wire to the ground terminal of the power supply. (See Figure 12
for ground terminal location)
6. Mount the neutralizing bar using the hardware provided with the
shipment. Refer to R50 Blue Bar installation instructions in Section 4 for
details.
7. Proceed to section on attaching high voltage cable to “D” and TrueAC.
8. Plug line cord into receptacle to energize power supply.
SLCC High Voltage Connector Assembly
The equipment you have ordered may be supplied with a spring-loaded connector
installed. If so, keep these instructions for use when ordering a replacement connector.
If the spring-loaded connector is not installed, follow the instructions below, using
Figure 8 as a guide.
1. Slide knurled plug (knurled end first) over the end of the cable that will be inserted
into the power supply.
2. Slide connector body (end without setscrew hole first) over cable.
3. Slide high voltage connector (small metal piece with threaded hole for
setscrew) over gold tip at end of connector wire. Line up setscrew hole in connector
body with hole in high voltage connector.
4. Insert setscrew in connector through the hole in the connector body and
tighten until setscrew is just even with or slightly below the surface of the connector
body.
5. Pull firmly to be sure high voltage connector is tight on conductor wire.
6. Turn contact spring (end with close turns) clockwise, by hand, onto high
voltage connector until spring butts against connector body.
Attaching High Voltage Cable to “D” and TrueAC Power Supply
1. Switch off power supply and unplug line cord from receptacle.
2. Insert SLCC high voltage connector in female port on the power supply and finger-
tighten (see Figure 13 for TrueAC).
3. For “D” connect ground wire to ground terminal of power supply. For TrueAC,
connect shield wire to shield terminal of power supply (see Figures 12 and 13)
Removing High Voltage cable from “D” and TrueAC Power Supplies
1. Switch off power supply and unplug line cord from receptacle.
2. For “D” remove ground wire of cable assembly from ground terminal. For TrueAC,
remove shield wire of cable assembly from shield terminal (see Figure 13).
3. Carefully finger-loosen SLCC connector and remove cable from power
supply.

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R50 Blue Bar 5101171 Rev. L
Mounting Bracket Requirements per Bar:
• Overall length up to 3.25 feet: 2 brackets
• Overall length up to 6.50 feet: 3 brackets
• Overall length up to 8.75 feet: 4 brackets
• Overall length up to 13.0 feet: 5 brackets
Figure 3. Installation of R50 Blue Bar with Distance from Ground Reference
Figure 4. Optimal Mounting Distance of Blue Bar atVarious Web Speeds

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R50 Blue Bar 5101171 Rev. L
Figure 5. Cable Assembly for “N”Power Supplies
Figure 6. Outline Drawings of Type N Power Suplies

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R50 Blue Bar 5101171 Rev. L
Figure 7. HighVoltage Output Connections of “N”Power Supplies
Figure 8. Cable Assembly and Connector Kit for“D”Power Supplies

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R50 Blue Bar 5101171 Rev. L
Figure 9. Cable Assembly and Connector Kit TrueAC Power Supplies
Figure 10. Mounting Holes for“D”Power Supply
Figure 11. Mounting Holes for TrueAC Power Supplies

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R50 Blue Bar 5101171 Rev. L
Figure 12. Installation of High Voltage Cable Assembly to “D” Power Supplies
Figure 13. Installation of High Voltage Cable Assembly to TrueAC Power Supplies

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R50 Blue Bar 5101171 Rev. L
5. OPERATION
Before switching on power supply, ensure that power supply is properly grounded and
static bar properly assembled and installed.
Startup for “N”Power Supplies
To operate the static eliminating equipment, apply line voltage to the power supply. For
power supply equipped with an ON/OFF switch, place the switch in the ON position.
True AC Function Indicators
1. BAR ON – High voltage is present on the static bar
2. BAR OFF – No high voltage on the static bar or cable
3. CLEAN BAR – Tells the machine operator when it is time to clean a dirty static bar.
Also has a remote dry contact output.
4. FAULT – The Arc Detection portion of the circuit turns the power supply off if the
high voltage is shorted to earth ground to alarm that there is a system failure and
protect the transformer. Also has a remote dry contact output.
5. SERVICE – Illuminates when an insulator covers the static bar emitter pins and ion
production has stopped. Also has a remote dry contact output.
6. BAR PERFORMANCE – Bar graph displaying the ionization output performance
of the static bar.
Calibration Instructions for the TrueAC Monitoring Power Supply
Calibrating the TrueAC Monitoring Power Supply is a simple process using the two
calibration pots located on the face of the power supply. The “Clean Bar” light is
preset at the factory to illuminate when the ionization output from the static bar is at
approximately 40% of maximum output potential, however, it can also be re-calibrated
in the field to either increase or decrease the sensitivity of the monitoring system,
depending on the users requirement. Normally the monitor will require calibration only
at the initial set-up. Recalibration may be required several days later as a result of changes
that may occur during the burn-in period experienced by new bars.
Calibration Procedures
Initial Set-up
Since the clean bar light is pre-set at the factory, the “Bar Monitor Set-Up” is the only
calibration requirement. Calibrate the light as follows:

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R50 Blue Bar 5101171 Rev. L
1. Mount the static bar(s) in its permanent location directed toward a web or a roll of
material. The production line should be stopped during the calibration procedure.
2. Connect the bar(s) to the power supply. Attach the pigtail lead at the connector end
of the static bar cable to the metal stud located above the female connector ports on
the power supply.
NOTE – Please note that this connection point is part of the monitoring
circuitry, and IS NOT a ground connection. Any ground connection at this
point will cause the SERVICE circuit to activate.
3. Turn on the power. The BAR ON and SERVICE lights will illuminate, and there
will be no lights illuminated on the “Bar Performance” grid display.
4. Locate the pot marked “Bar Monitor Set-Up” that is located above the service light.
5. Use a very thin bladed screwdriver to adjust the pot, either left or right, until the
light on the “Bar Performance” grid illuminates. Continue to turn the pot until the
SERVICE light extinguishes, then continue for 1/8 turn.
6. The calibration is complete.
Calibrate the Clean Bar Set-up
The “Clean Bar” light is preset at the factory, however, it can be re-calibrated in the
field to change the sensitivity of the monitoring system. Calibrate the display as follows:
1. Mount the static bar(s) in its permanent location directed toward a web or a roll of
material. The production line should be stopped during the calibration procedure.
2. Connect the bar(s) to the power supply. Attach the ground lead at the connector
end of the static bar cable to the metal stud located above the female connector ports
on the power supply.
NOTE – Please note that this connection point is part of the monitoring
circuitry, and IS NOT a ground connection. Any ground connection at this
point will cause the fault circuit to activate.
3. Turn on the power.
4. Locate the pot marked “Bar Monitor Set-Up”, just above the SERVICE light.
5. Use a very thin bladed screwdriver to adjust the pot, either left or right, to move the
“Bar Performance” indicator light to the desired level on the performance grid where
the clean bar light would activate.
6. Once the desired alarm level has been reached, move to the “Clean Bar Set-Up” pot
located above the clean bar light. Slowly turn the pot, left or right, until the “Clean
Bar” light illuminates.