SCHNIER HER 02/01 User manual

1
Item no.:
810353
120 kV
2 mA
Operating manual
HV supply HER02/02

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Contents
1. PRODUCT AND MANUFACTURER ..................................................................................3
1.1. PRODUCT IDENTIFICATION ............................................................................................3
1.2. DESIGNATION...................................................................................................................3
1.3. WARRANTY.......................................................................................................................3
1.4. MANUFACTURER .............................................................................................................3
2. GUIDE TO THIS OPERATING MANUAL...........................................................................4
2.1. TARGET GROUP...............................................................................................................4
2.2. ACCESSIBILITY TO THE OPERATING MANUAL / STORING ........................................4
2.1. PICTOGRAMS / SYMBOLS USED....................................................................................4
3. INTENDED USE..................................................................................................................5
3.1. USE....................................................................................................................................5
3.2. FURTHER REQUIREMENTS FOR THE SURROUNDING SYSTEM ................................6
4. INSTALLATION INSTRUCTIONS......................................................................................7
4.1. STRUCTURE......................................................................................................................7
4.2. MOUNTING........................................................................................................................8
4.3. FASTENING DIMENSION SHEET.....................................................................................9
4.4. ELECTRICAL INSTALLATION / PIN ASSIGNMENTS.................................................... 10
5. NORMAL OPERATION ....................................................................................................13
5.1. SAFE SWITCHING OFF OF THE HIGH-VOLTAGE BEFORE ACCESS ........................13
6. MAINTENANCE AND REPAIR.........................................................................................14
7. STRUCTURE AND FUNCTION DESCRIPTION...............................................................15
7.1. GENERAL INFORMATION..............................................................................................15
7.2. SAFETY CONCEPT.........................................................................................................15
7.3. DESCRIPTION OF THE SAFETY FEEDBACK............................................................... 16
7.4. BLOCK DIAGRAM...........................................................................................................20
7.5. TECHNICAL DATA..........................................................................................................20
8. START UP OF THE CANOPEN INTERFACE..................................................................21
8.1. FIRST SETTING OF THE NODE ID AND BAUD RATE..................................................21
8.2. CHANGING THE NODE ID AND/OR BAUD RATE.........................................................24
9. DESCRIPTION OF THE CANOPEN INTERFACE ...........................................................24
9.1. THE CONTROL WORD ...................................................................................................24
9.2. THE STATUS WORD.......................................................................................................25
9.3. OUTPUT FROM MESSAGES AND WARNINGS.............................................................26
9.4. ACKNOWLEDGING A MESSAGE ..................................................................................27
9.5. DESCRIPTION OF THE CONTROL BITS .......................................................................28
9.6. DESCRIPTION OF THE STATUS BITS...........................................................................29
9.7. SETTINGS VIA SDOS......................................................................................................32
9.8. ELECTRONIC DESCRIPTION OF THE INTERFACE .....................................................33
9.9. OVERVIEW OF CONTROL AND STATUS WORD .........................................................34
9.10. OBJECT DIRECTORY...................................................................................................35
10. DECLARATION OF CONFORMITY .................................................................................36

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1. Product and Manufacturer
1.1. Product identification
This operating manual is part of the device:
Device name: High-voltage generator
Type: HER 02/01 and HER 02/02
Item number: 810353
1.2. Designation
1.3. Warranty
All warranties are void if the device is opened, modified, if parts are not replaced with
the original parts or if this operating manual is not observed.
1.4. Manufacturer
SCHNIER Elektrostatik GmbH
Bayernstr. 13
72768 Reutlingen
Germany
Tel: [phone]
Fax: [phone]
www.schnier-elektrostatik.de
[e-mail]
Headquarters: Reutlingen HBR 354 531
VAT ID No.: DE 146 481 986
Managing director: Olav Schnier

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2. Guide to this Operating Manual
This operating manual must be read, understood and observed in all points by all per-
sons with responsibility for the devices and electrostatic systems. Only with knowledge
of this operating manual can errors be avoided and safe, malfunction-free operation be
guaranteed. SCHNIER assumes no liability for damage that occurs due to non-
compliance with this operating manual!
2.1. Target group
This operating manual is intended for:
Machine operators (such as machine setters, electricians, IT specialists or fitters),
who have been trained by the manufacturer or operating company based on the oper-
ating manual and relevant safety regulations.
Maintenance specialists (such as machine setters, electricians, IT specialists or fit-
ters), who have been trained by the manufacturer or operating company based on the
operating manual and relevant safety regulations.
2.2. Accessibility to the operating manual / storing
The operating manual must always be available and easily accessible at the unit for the
responsible specialists (operators, service and maintenance personnel).
The operating manual must be kept by the operating company for the entire service life
of the unit. In case of a resale of the unit or of unit parts, the operating manual must be
handed over to the new owner, since it is a part of the system.
2.1. Pictograms / symbols used
Pictogram /
Symbol
Meaning
Warning of a danger zone, that is used to indicate an immediate hazardous
situation, which, if not prevented, can lead to a serious injury or to death.
Warning of dangerous electrical voltage, that is used to indicate an immediate
hazardous situation, which, if not prevented, can lead to a serious injury or to
death.
Warning of damage to the system or operational malfunctions.
Hints for easy, rational proceeding

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3. Intended Use
3.1. Use
This device is intended for use in stationary electrostatic systems which correspond to
the safety requirements of the product standard EN 50348:2010 + Cor.:2010.
CAUTION
Any start up outside of this condition is prohibited.
This device is not a finished part and may only be put into operation after complete
and proper installation and if it is detected that the system into which the device will be
installed completely corresponds to the regulations of EN 50348.
Standard EN 50348 describes the safety requirements for stationary equipment for
electrostatic application equipment for non-flammable liquid coating material. For in-
formation, and in the interests of safety, pay particular attention to the following sec-
tions of the standard EN50348:2010:
Section
EN50348
5.2.3
After switching off the high-voltage all high-voltage carrying
parts must be discharged to a discharge energy of less than
350 mJ before these parts can be reached.
5.3.2
When using walls, covers, signs and labels made of non-
conducting material there is the risk of propagating brush dis-
charges. These can occur if thin plastics have contact with
large surface grounded conductors (e.g., metals). The dielec-
tric strength of the coating must not exceed 4kV.
5.4.
Describes the requirements for the high-voltage power supply
which this generator is a part of.
5.5.
The electrical equipment of the system must comply with the
requirements of EN 60204-1. Especially the protective con-
ductor section 4.2 must comply with this standard.
5.6.1
All conductive system components, e.g., floors, transport
equipment, etc., with the exception of the normal operational
high-voltage carrying parts, must be grounded. The bleeder
resistance may be max. 1 MΩ.

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3.2. Further requirements for the surrounding system
The HV generator must only be used in electrostatic systems within a
temperature range of 15°C to 50°C and with a relative humidity between
10% and 70% (not condensing).
The HV generator is intended for operation in a specific stationary
system in an industrial environment. Due to the occurrence of conduc-
tive or radiated interference, there may be difficulties in ensuring electro-
magnetic compatibility in other environments.
To prevent hazards the entire system must undergo a risk analysis. Es-
pecially the Performance Level required in the above mentioned
EN50348 standard for safety functions can only be met via a safety con-
cept of the entire system.
All poles of the energy supply of the high-voltage generator must be able
to be disconnected from power with a circuit breaker, since the generator
itself has no circuit breaker.
The system must have an emergency stop switch, which also discon-
nects all poles of the power supply of the generator.
The power supply must comply with the Overvoltage category III or bet-
ter. The supply wire of the power supply must be fused with maximum 16
A.

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4. Installation instructions
4.1. Structure
1. Display and keyboard
2. M12 Sensor / actuator plug 5 pin (24V and CAN)
3. POAG pin for ground connection
4. Power connector for power supply + feedback contact
5. Transformer unit
6. Housing lower part with power module
7. Housing upper part with control module
8. Epoxy resin housing with cascade
9. Cable screw fitting for HV connection cable
4
3
2
1
5
9
8
6
7
2
Figure 3. a

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4.2. Mounting
The high-voltage generator is intended for wall mounting. So that the cooling ribs can
fulfill their function the high-voltage generator must be mounted vertically (as illustrat-
ed).
The metal housing is fabricated from seawater resistant aluminum and anodized. The
brown cascade part is cast from a salt resistant epoxy resin.
M6 screws in the appropriate length are to be used for fastening on the wall.
CAUTION
Tightening the screws too tight can lead to cracks in the
epoxy resin and risk of injury from falling
The high-voltage generator contains live parts and must
only be opened by the manufacturer.
To prevent electrostatic charging it is recommended to
screw the generator onto a grounded, conductive base.
Fig. 1

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4.3. Fastening dimension sheet
6.4

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4.4. Electrical installation / pin assignments
4.4.1. Power plug
ILME CQM 04/2 or Harting HAN Q 4/2
Pin
Description
Signal
1
Power supply L1
400 V
2
Power supply L2
400 V
3
Power supply L3
400 V
4
Not used
-
PE
Protective conductor
PE
11
Feedback
Potential-free 24V/1A
12
Feedback
Potential-free 24V/1A
CAUTION
The power supply is done via a 7-pin plug, e.g. HARTING HAN Q 4/2 or
ILMA type CQM 04/2. The plug lock must be locked before start up (see
figure).
The power supply must comply with the Overvoltage category III or better.
The supply wire must be fused with maximum16 A.
Connection PE must be connected on a circuit breaker system which
complies with the safety regulations.
Plug and socket must be in perfect condition.
1
2
3
PE
11
12
4
Ground connection
POAG
Sensor / actuator plug
Power plug
Plug lock

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The plug connection must meet IP54 at least.
The feedback contacts (RM) are designed for 24 V / 1A. They must on-
ly be connected to safety extra low voltage systems.
To improve the immunity in industrial networks the use of a 4% 2A line
choke is recommended in the 400V supply lines. E.g. Block transformer LR3
40-4/2 (14mH)
When using a 2A line choke the supply line must be fused with maximum
2A.
When using several generators these can also be supplied via a common
4% choke. The rated current of the choke must account for 2A per gen-
erator.
Maximum 16A for 8 generators.
4.4.2. Ground connection
The ground connection POAG is used for closing the high-voltage current circuit be-
tween the high-voltage generator and deposition electrode:
CAUTION
The ground connection (Fig. 1/3) must be contacted with a POAG
socket (see Figure) and connected with min. 4 mm2as short as
possible with the operating ground of the ground electrode.
This connection should not be laid parallel to power supplies or
fieldbus lines.
Description: Angle socket for equipotential bonding POAG
crimp connection
Item no.: 260066
CAUTION
The ground connection does not replace the circuit breaker
(PE on power plug)
As short a possible
Ground connection (POAG)
Loading electrode
Deposition electrode
HV generator

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4.4.3. High Voltage Connection
The 4mm high-voltage contact pin of the high-voltage cable must
be completely plugged in and the strain relief screw connection
must be tightened.
CAUTION
If shielded HV cable is used, the shielding must be grounded
4.4.4. M12 Sensor / actuator plug
(safety extra low voltage)
The supply to the controls is done together with the CAN connection via a M12 sensor/
actuator plug.
M12 plug 5-pin
Pin
Description
Signal
1
Shield
GND
2
V+
24 V DC
3
V-
0 V DC / GND
4
CAN_H
CAN High
5
Can_L
CAN Low
Screw connection
Shield
CAUTION
The control line must be shielded.
Operation is only permissible with tightened lock nut of the M12
connector.
At least an IP 54 design must be used for the counter piece.
A CAN bus must be connected at a point in the bus with 120
Ohm. The generator does not have 120 Ohm connection re-
sistance built in, this must then be connected in addition to the
bus.
1
4
3
2
5

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5. Normal operation
The specifications for the intended use according to EN 50348 apply. In addition the
operating manuals of the relevant electrostatic system must be complied with!
Operation of the system must only be carried out by a trained operating team. The per-
sonnel must be informed in reasonable intervals about the accident prevention regula-
tions and about the operation of the system.
CAUTION
The 400 V supply should only be disconnected if the high-voltage
was switched off beforehand.
Exception: Emergency Stop in hazardous situations.
CAUTION
In work in which parts connected with the high-voltage output can
be reached the following must be done:
The high-voltage must be switched off.
All high-voltage carrying parts must be discharged to a discharge
energy of less than 350 mJ
The 400 V supply must be safely disconnected and secured
against being switched on again.
The high-voltage carrying parts grounded with a suitable ground-
ing rod.
The high-voltage cascade and the high-voltage transformer are
enclosed in a housing with cooling ribs. Cooling ribs must be kept
clean so that they do not lose their function. If dirty they must be
cleaned with a suitable cleaning agent.
Fundamentally the regulations for normal operation of the HV generator must be ob-
served during maintenance and repair work of the surrounding system. Electrical sys-
tems under power must not be worked on.
5.1. Safe switching off of the high-voltage before access
To guarantee safety before and during a release of the access to high-voltage carrying
components the following sequence must be complied with and also ensured through
technical actions:
1. Switch off the high-voltage via CAN command
2. Wait until "safely off" is reported via the feedback contact. This should be done
after 60s at the latest. In the interest of safety also this should be monitoring in
order to recognize if, for example, the system capacity changes.
3. Switch off the 400V supply

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4. Secure against switching on again.
5. Though the absence of the 400V supply the generators now again report "un-
safe". This depends on the system and is OK.
6. For further safety after switching off the 400 V a waiting time of 60 seconds
should be implemented up to release of access.
7. Use grounding rod for grounding of the high-voltage carrying parts in operation.
6. Maintenance and Repair
The specifications for the intended use according to EN 50348 apply and the safety
regulations for normal operation. In addition, the operating manuals of the relevant
electrostatic system must be complied with!
The high-voltage generator has no service parts. It can only be repaired by the manu-
facturer.
The following sequence is recommended for disconnecting the lines:
1. Disconnect the power plug
2. Disconnect the sensor/actuator plug
3. Disconnect HV connection
4. Disconnect the ground connection
CAUTION
If a generator is removed from a system, no high-voltage
carrying parts in operation should be touched without
them being previously grounding using a grounding rod.
The ground connection of the generator must be con-
nected during this.
This especially applies to defective generators.
CAUTION
The high-voltage generator contains live parts and must
only be opened by the manufacturer.
All warranties are void if the device is opened, modified
or if parts are not replaced with the original parts.

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7. Structure and function description
7.1. General Information
The high-voltage generator is built in a compact design. The controls, end stage, HV
transformer and the HV cascade are combined in one device. The unit is supplied with
3-phase 400 V 50/60 Hz. The controls are separately supplied with 24 V. The power
output stage has its own µController, which guarantees a precise and very fast control.
The control module takes over all control functions with a separate microcontroller and
establishes communication to the outside using CANopen.
The temperature of the end stage and the aluminum housing is monitored. If there is an
impermissible temperature increase there is first a warning and if it continues to in-
crease there is a shutdown.
7.2.Safety concept
Communication of both µcontrollers is permanently monitored. As soon as the commu-
nication is defective or interrupted, there is a shutdown and an error is reported.
The internal measurement resistance of the cascade, the current measurement and the
internal protection circuit undergo a plausibility test each time the high voltage is
switched on. This test runs at the start of the start up ramp and is completed after ap-
prox. 200 ms. If the test fails there is an immediate shut down and an error is reported.
The actual applied high voltage is continuously measured and monitored. The control
can be preset with the system capacity via CANopen. The factory setting is at 3 nF.
According to the formula:
E= C1/2 X U2
E = Residual energy in joules [J]
C = System capacity in farad [F]
U = Voltage in volts [V]
the µController calculates the dangerous voltage level.
Basics for this are 0.24 mJ. At 3 nF and 0.24 mJ the voltage threshold lies at 400 V. As
soon as the applied high voltage lies above this value "unsafe" is reported, regardless
of whether the high voltage is switched on or not. If the high voltage lies below 400 V
(with setting 3nF) “safe" is reported. The message is output via CANopen and is addi-
tionally available as potential-free relay output. The relay is a safety relay and is con-
tinuously monitored. For additional safety the relay is delayed by 10 seconds after
switching off the high voltage regardless of U actual (see also 4.3).
High voltage-ON is additionally reported via CANopen if the high voltage is switched on
and the output voltage has reached at least 90 % of U target.
The 400 V input voltage is measured on the power module and monitored. With more
that 10% over-voltage there is a shut down and an error is reported. If the 400 V is not
applied an error is also output.

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The software of the power module and the control modules are continually checked
and monitored. For errors there is a shutdown and the error output.
7.3. Description of the safety feedback
The state of the high-voltage generator is transmitted via the bit "Device is safely off" in
the status word (see in document "Explanation of the status word") of a PDO via CAN
interface. As shown in the illustration, the bit "Device is safety off" corresponds to the
condition of the safety relay. The bit is set if the high-voltage generator is in a new state
and the safety relay is closed. The bit is reset if the high-voltage generator is in an un-
safe condition and thus the safety relay is open.
The safety relay is controlled both by the control module and the power module. Only if
the control signals REL1 and REL2 are simultaneously set are the switches SW1 and
SW2 closed and the safety relay is energized. The control conditions are listed in the
following table.
The plausibility of the safety relay is checked by a monitoring function. If the safety re-
lay cannot be controlled by the control signals, "Safety error" is set in the status word.
The plausibility of the safety relay can also be checked through the bit "OPEN safety
contact" in the control word. The safety relay can only be controlled by this bit, if the
high voltage is not switched on (the bit "High voltage ON" equals 0). The state of the
safety relay can be determined by the bit "Safety contact OPEN" in status word. If the
safety relay functions correctly, the bit "Safety contact OPEN" must equal the bit
"OPEN safety contact".

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Control
signal
Condition
Conditions
REL 1
1
safe
1. The bit "High voltage ON" in the control word
equals 0.
2. The bit "OPEN safety contact" in the control
word equals 0.
3. The output voltage is smaller than the safety
level that corresponds to the residual energy.
4. No relevant malfunction is detected from the
CM and PM. (see below).
0
unsafe
One of the above conditions is not met.
REL 2
1
safe
1. No relevant malfunction detected from the PM.
(see below).
2. The 10 second waiting time after HV-OFF (re-
setting the bit "High voltage ON" in the control
word) has elapsed.
0
unsafe
One of the above conditions is not met.
CAUTION
The safety relay should be tested at least once per month by the bit
Open safety contact from the higher-level control system.
For the following malfunctions the safety relay is opened:
Malfunction messages of the control module:
Malfunction
Cause
Remedy
Current measure-
ment*
If the current measurement or
Imess suppressor diode is not OK
in the test phase (shortly after
switching on the HV).
Check by the manufacturer
required.
Udutycycle*
If the output line is not in the
range that corresponds to the
control variable of the controller.
Check the high voltage cir-
cuit for short circuit. If the
error continually occurs:
Check by the manufacturer
required.
ProgrammTest*
If the checksum of the program is
not correct.
Check by the manufacturer
required.

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400V supply volt-
age.
If the 400V supply voltage is miss-
ing or the communication between
the power module and control
module is interrupted.
Check supply voltage. If the
error continually occurs:
Check by the manufacturer
required.
Safety*
If the plausibility test of the safety
relay failed
Check by the manufacturer
required.
Self-test*
If the output voltage of 2.8 KV is
not reached within 200 ms then
the HV generator has failed the
self test.
Check the high voltage cir-
cuit for short circuit.
Otherwise: Check by the
manufacturer required.
Malfunction of the power module:
Shutdown-LM
If the output voltage is larger than
approx. 140 kV.
Acknowledge error if the
error occurs continually:
check by the manufacturer
required.
Internal communi-
cation
If the communication between the
control module and power module
is distorted by the SPI interface.
Acknowledge error.
Check supply voltages.
The malfunctions marked with * (current measurement, Udutycy-
cle, ProgramTest, Safety, Self test) indicates continuous error of
the device. These errors can possibly falsify the function of the feed-
back "safe off". Therefore, these should not be acknowledged with-
out taking suitable actions to eliminate any hazard.
(For this refer to the instructions under Maintenance and Repair).

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The following malfunction messages are not device-related, but rather operation-
related and do not lead to the feedback "unsafe".
Malfunction messages of the control module (CM)
Malfunction
Cause
Remedy
Umin
If the output voltage during I-mode
is smaller than the threshold value
in the object directory.
Check parameters and if
necessary adapt to the op-
erating conditions. Check
the high voltage circuit for
short circuit / leakage cur-
rents.
Acknowledge error.
Imax
If the output current during U-
mode is larger than the threshold
value in the object directory.
Check parameters and if
necessary adapt to the op-
erating conditions. Check
the high voltage circuit for
short circuit / leakage cur-
rents.
Acknowledge error
Over-temperature
cascade
If the temperature of the cascade
is above 65 °C.
Check ambient temperature
(max. 50°C).
Check fan:
Check cooling ribs (see 4.1)
Over-temperature
power module
If the temperature of the power
module is above 75 °C.
Check ambient temperature
(max. 50°C).
Check by the manufacturer
required.
Invalid parameter
If any parameter in the object di-
rectory is set with an invalid value.
Check parameters.
Node guarding
If the generator has not received
any node guarding object within
its lifetime. (The communication is
interrupted via the CAN-Bus).
Check CAN connection.
Check system software.
Malfunction of the power module (PM).
Over-voltage
If 400V supply voltage is over 10
percent too high.
Check supply voltage.
Acknowledge error.

Operating manual 810353-BALDE-150220 Version 20.02.2015 Page 20 of 36
Power part
with µControl-
ler, controller
and end stage
High voltage
transformer
Control module
with µController
Protective
resistance
High voltage
cascade
HV
output
L1
L3
L2
PE
Measure-
ment
resistance
24 VDC
CANopen
SP
I
Voltage measurement
Current measure-
ment
Front module w/
display, LED*s
and buttons
7.4. Block diagram
7.5. Technical data
Power supply voltage
400 V 50/60 Hz 3 phases max. 1 A (power part)
24 V DC max. 250 mA (control)
Output voltage
10-120 kV
Output current
2 mA
Ambient conditions
+5°C to 50°C or* 55°C, max. 70% r.H.
Storage temperatures
-20°C - +70°C
Dimensions
Approx. 400 x 200 X 200
Weight
Approx. 14 kg
Protection class
IP 65
HV connection
Anode tube with 4 mm jack
Bus connection
CANopen
Operating modes
Current and voltage constant
Safety
Feedback contact "safely discharge"
Display + buttons
Single row 16 characters, 2 buttons 3 LED’s For setting
the bus address and display of current and voltage in run-
ning operation
* Operation up to 55°C. The temperature optimized version of the generator (recognizable
by the cooling ribs of the electronic housing) allows operation above 50 degrees to 55 de-
grees. The internal temperature of the device is monitored and if necessary a warning is
output.