MKS, Ion Industrial

1000 Old County Circle

Unit 116
Windsor Locks, CT 06096
Phone: (860) 292-6847
MKS, Ion Industrial Europe
Marie-Curie-Strasse 8
D-79539 Loerrach, Germany
Tel. ++ 49 (0) 7621 - 5500 355
Fax ++ 49 (0) 7621 - 5500 360
MKS, Ion Systems
Alameda, California
USA ION POWER
Fax: (860) 292-6807
Email: industrial@ion.com
Email: indeuro@ion.com Intelligent Static Neutralizer
Web: www.mksinst.com/ion-industrial
with Master Controller
Ion Systems’ logo is a trademark of Ion Systems,
©1998 Ion Systems. Printed in the U.S.A.
INSTALLATION AND OPERATING INSTRUCTIONS

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TABLE OF CONTENTS
1. Safety Warnings..................................................................................................1
2. List of Components............................................................................................3
3. Description..........................................................................................................4
System description ........................................................................................4
System installation planning ........................................................................4
Determining locations for neutralizing bars ................................................5
Model 8001KDT static neutralizing bar ......................................................6
Mounting 8001KDT neutralizing bars ..........................................................7
8154 POWER MODULE – high voltage power supply ..............................8
Mounting 8154 POWER MODULE ..........................................................10
8200 MANAGER– master controller..........................................................11
8310 CONNECTOR – serial communication switch ................................13
24VDC power..............................................................................................14
Wiring a multi-station ION POWER system ..............................................14
8154 output wiring ......................................................................................17
Connecting several 8001KDT bars to one 8154 POWER MODULE ........18
8154 POWER MODULE grounding connection ......................................19
Complete system wiring..............................................................................19
8154 POWER MODULE input connections ..............................................22
Remote system output activation and alarms..............................................25
4. Setup and Operation........................................................................................26
8200 Functionality ......................................................................................26
8200 keys ....................................................................................................27
8200 Programming Functions ....................................................................28
8200 Command Functions ..........................................................................31
8200 Display Functions ..............................................................................32
Neutralizing system setup ..........................................................................34
Clean Bar alarm setup ................................................................................37
Neutralizing current display ........................................................................38
Operation and operation check....................................................................41
Fail-safe operation mode ............................................................................42
Alarms ........................................................................................................42
Conductive residue accumulation on the bar surface ................................45
Loss of communications..............................................................................45
8154 POWER MODULE stand-alone operation ........................................46
5. Performance Verification ................................................................................47
6. Maintenance ....................................................................................................48
7. Troubleshooting................................................................................................48
Troubleshooting Chart ................................................................................49
Equipment Service Life ..............................................................................51
Equipment Repairability..............................................................................51
8. Specifications....................................................................................................52
9. Warranty and Service......................................................................................55
10. Appendix A. ......................................................................................................56
Expected values of Ion Output and Neutralizing Current ..........................56
8200-8154 Manual Version 3.0
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1. SAFETY WARNINGS
PLEASE READ INSTRUCTIONS COMPLETELY BEFORE STARTING
INSTALLATION
ALL INSTALLATION AND TROUBLESHOOTING OPERATIONS
MUST BE PERFORMED BY QUALIFIED TECHNICAL PERSONNEL
The ION POWER Virtual AC static neutralizers were developed according to the latest
safety requirements for industrial applications and have successfully passed the relevant
safety and life tests before delivery.
However, operators may be exposed to potentially dangerous situations if the installation
and use are not done in accordance with the Ion Industrial instruction manual.
This instruction manual uses symbols to identify dangerous situations as follows:
WARNING! This warning symbol means danger. You are in a situation that
could cause bodily injury.
CAUTION! This caution symbol means reader be careful. You are capable of
doing something that might result in equipment damage.
1.1 During normal operation
WARNING! Even though the neutralizing bar is of a shockless design and the
current is limited, touching the electrodes of the operating bar is strongly
discouraged.
WARNING! Do not disconnect any wiring of the ION POWER system while
the machinery is running regardless of whether the system is operational or not.
WARNING! Do not disconnect high voltage wires from the 8154 when the
machine where the Neutralizers are installed is running regardless of whether the
ION POWER component is operational or not. Connect to ground the bar wires
when the bar is not connected to the 8154.
WARNING! Disable the high voltage output of the 8100 when processing webs
with a metal foil or metallized film as part of their construction. Electrical
neutralizers are not useful under those conditions, and could create a safety
hazard in some circumstances.
CAUTION! Do not spill liquid or apply mist to the connectors of the
neutralizing bars or high voltage power supply – equipment damage may result.
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 1.5 In problem situations
CAUTION! The system alarms may not function properly if the total high
voltage cable length connected to the 8154 POWER MODULE exceeds the WARNING! If the bar or high voltage cable have been accidentally damaged,
maximum specified length. and the integrity of any of those components has been compromised, disable the
8154 output immediately. Stop the machine and disconnect the power from the
CAUTION! The HV- output should be energized only when is required by the neutralizer. Correct the problem or dismantle the bar before restarting the
application (see the Remote Activation Setup section). machine.

1.2 During installation and removal
WARNING! The enclosure of the 8154 POWER MODULE is not a junction
box but a finished high-voltage device – do not change the conduit fitting to
metal fitting, do not drill additional holes in the enclosure, and follow the wiring
instruction precisely to avoid equipment damage.
WARNING! Do not install or remove ION POWER equipment while the
machinery is running.
WARNING! If liquid has been spilled on the bar, disable the 8154 output
immediately. Stop the machine and disable 24VDC power. Correct the problem
or dismantle the bar before restarting the machine..
WARNING! Do not use the ION POWER static neutralizers in flammable or
explosive environments.
CAUTION! The ION POWER static neutralizers are designed for indoor use
only.

WARNING! If you need to take the 8154 unit out of service, you must
electrically ground the neutralizing bar wires.

WARNING! Always disable the 8154 output and the 24VDC power when doing 2. LIST OF COMPONENTS
installation or removal of the Virtual AC equipment.

Item Part Qty included

1.3 During static bar cleaning No. Number Description with this order
WARNING! Always disable the 8154 output when cleaning the
1 91-8154 8154 POWER MODULE _
neutralizing bar.
2 91-8200 8200 MANAGER _
3 91-8310 8310 CONNECTOR _
1.4 Grounding 4 91-8001KDT-____ Neutralizing Bar, Model 8001KDT _
WARNING! The 8154 POWER MODULE must be electrically grounded. 5 32-7421 Plastic mounting brackets,
8001KD bar _
6 32-8088 Stainless steel mounting brackets,
8001KD bar _
7 See SPECIFICATIONS 24VDC Power supply _

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3. DESCRIPTION Determining locations for neutralizing bars
1. Locate the static bar in the desired position, as shown in Fig. 2, for neutralization of
web spans and other applications where the distance between the bar and the material does
System Description
not vary. In cases of unwind and rewind, the bar should be installed to clear the largest roll
Each individual station in the master controller system consists of an 8154 POWER (see Fig. 3), and away from other metal objects on the sides of the bar.
MODULE and 8310 CONNECTOR module connected to the 8200 MANAGER, as well
as high-efficiency 8001KDT static neutralizing bars, as shown in Fig. 1.
A single 8200 MANAGER in the master controller system can monitor and control up to
nine stations in a Master-Slave network over a two wire RS-485 multi-drop bus.

3-6" (75-150 mm)

Static Neutralizing Bar
(side view)

4-6"
(100-150 mm)

Figure 2. Typical installation of the Virtual AC neutralizing bar at the open span of a
web.
Note: The bar should not be closer than 4” – 6” (100-150 mm) to the roller.

END OF THE ROLL

Figure 1. ION POWER Master Controller System.

START OF A NEW ROLL

System installation planning

1. Carefully choose locations for all components of the Virtual AC system.
2. Plan to install the 8154 POWER MODULES within the length of the high voltage
cables from to the bar. Keep high voltage cables as short as possible.
Neutralizing Bar
3. Plan to install the 8200 MANAGER at eye level on a vertical panel or wall near or at
the control panel of the machine. Mounting dimensions can be found in Fig. 9. Provide
open space at the bottom of the module to allow access to the connectors. Figure 3. Typical Installation of the Virtual AC neutralizing bar on a rewinder.
4. The 8310 CONNECTORS should be placed where they can be conveniently accessed
for wiring, preferably inside a control panel. Mounting dimensions can be found in
Fig. 11.

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Model 8001KDT static neutralizing bar Mounting 8001KDT neutralizing bars
The body of the 8001KDT neutralizing bar shown in Fig. 4 is made of a fiber-reinforced The 8001KDT neutralizing bars are mounted using special plastic or stainless steel
polyester resin for extra rigidity. Ionizing electrodes in the 8001KDT neutralizing bar are brackets that engage in the grooves and can slide along the entire length of the bar. For
spaced about 1” (25.4 mm) apart and converge into a single row from each side of the bar. each 18-24” (450-600 mm) of bar length an additional mounting bracket is required.
Ionizing electrodes are connected to the high voltage power supply through resistors to 1. Make sure to position the bar so that its end with the cable at the side of the machine
ensure low current at the electrodes for safety. A fixed high voltage cable exits the bar at frame where the HVPS is installed.
one end. A Universal V.AC cable plug is attached to the end of the cable. Two grooves, one
2. Slide all the provided mounting brackets on the end of the bar and space them along
on each side of the bar body, extend for the length of the bar.
the bar length (see Fig. 5 and 6).
3. After placing the brackets in the desirable positions, secure the brackets by tightening
1 the screws (pos. 3 in Fig. 5 and 6).
2 ) The tab of the mounting bracket can be bent (pos. 4 in Fig. 6) to adapt to the orientation
9 mm
" (8 of the mounting surface.
3.5
L + EL
=E 0.7" 4. Use screws (and nut) to attach the mounting brackets to the mounting surface.
OL (18 mm) 0.8"
0.8" (20 mm)
(20 mm)
CAUTION! Any metal mounting surfaces where the bar is installed must be
electrically grounded.
2 holes
1.3" 0.200" dia
(34 mm)
(5 mm)
4A 1
3

1.73”
4B (44 mm)

Figure 4. Model 8001KDT static neutralizing bar.

1 – bar body; 2 – cable plug; 3 – high voltage wires in a protective conduit; 4A – plastic 3
1.75"
mounting brackets; 4B – optional stainless steel mounting brackets. (44.5 mm)
2.15"
(54.5 mm)

The 8001KDT neutralizing bars are mounted using special plastic or stainless steel Figure 5. Mounting 8001KDT bar using the plastic mounting brackets.
brackets that slide along two slots which extend on each side of the bar profile the entire
1 –bar body; 2 – sliding bracket; 4 –6-32x3/8” screw for fixing the mounting bracket in
length of the bar. Several mounting brackets are provided with each bar.
place.

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 The power supply is installed inside an IP-54 rated polycarbonate enclosure, as shown in
Fig. 8 Four mounting holes are exposed when the cover is removed.
All wiring is done inside the enclosure. Two conduit fittings at the input end of the
1
1.57" enclosure are provided for electrical power, safety ground and communication wires.
2 (37 mm)
Up to four 8001KDT neutralizing bars can be connected to the 8154 POWER MODULE
3 using conduit fittings at the output end of the enclosure. The high voltage wires from the
0.8” (20mm) 10-32 or M4 bolt
4 neutralizing bars connect to high voltage outputs terminals inside the enclosure.
A panel-mount HV Output switch is located on the input side of the enclosure. The LED
Figure 6. Mounting 8001KDT bar using the stainless steel mounting brackets. indicator inside the enclosure can be easily observed through the clear enclosure cover to
see if the high voltage output is enabled.
1 – grooves on each side of the bar body; 2 – sliding bracket with mounting tab;
3 – set screw to fix the mounting bracket in place; 4 –bracket can be modified by
bending the tab.

6" (150 mm) 6" (150 mm)

2
Figure 7. Recommended metal-free envelope around a Virtual AC neutralizing bar.

6 1

8154 POWER MODULE – high voltage power supply

Figure 8. 8154 Power Module high voltage power supply.
IMPORTANT! The ION POWER devices are not compatible with the Virtual
1 – enclosure bottom; 2 – clear cover; 3 - output conduit fittings with protective conduit;
AC 8011-series power supplies and 8004/8005 control modules, 8003 computer
4 - power supply board; 5 – input conduit fittings; 6 – HV Output switch.
or Fieldbus interface modules.

The 8154 POWER MODULE is a microprocessor-controlled solid-state high voltage Note: Model 8154 high voltage power supply has four output conduit fittings for
power supply based on the patented Virtual AC technology. The 8154 POWER MODULE connecting up to four neutralizing bars; the unused holes can be plugged in with special
is capable of powering up to 400” (10 m) of 8001-series neutralizing bars with a total up plugs.
to 32 ft (10 m) of high voltage cables.
The 8154 contains circuitry for monitoring the neutralizing bars, malfunction sensor
circuit, and circuitry for remote power activation using a digital signal from a PLC master.
The status LED indicator stays green when everything is okay, or changes to a flashing red
in case of a malfunction. The 8154 uses 24VDC power.

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 Mounting 8154 POWER MODULE 8200 MANAGER– master controller
1. Plan to install the 8154 high voltage power supply outside the hazardous area but The 8200 MANAGER shown in Fig. 10 can control up to nine 8154 neutralizing stations,
within 30 ft. from the bar. The size of its footprint is shown in Fig. 9. displaying the performance parameters and diagnostics for every station in the mini-
Note: A label on the enclosure identifies the output end. network.
2. Remove the cover from the enclosure to expose four mounting holes inside deep wells The 8200 uses 24VDC power which can be connected directly through the dedicated DC
in the corners of the enclosure. power jack, through the RJ11-6 combined communication and power receptacle, or hard-
wired to the terminal blocks on the circuit board accessed through the cutout in the bottom
3. Secure the 8154 to the mounting surface using four 8-32 or M4 size screws.
of the enclosure.
4. Leave the enclosure opened for access to the input/output terminals and grounding
The 8200 MANAGER has two mounting flanges for wall or panel mount installation (see
terminals.
A. Fig. 10).
7.362" IMPORTANT! When installing 8200 MANAGER, leave four-inch (100 mm)
(187 mm)
space at the bottom of the enclosure.
2

5.51 "
3.425" 3 (140 mm)
(87 mm)
6
= 0.16" (4.2 mm) x 4 1

4 10 " 4
5
(254 mm) 3 2 1
4.34 "
4.7" 7.87" (110 mm)
(120 mm) (200 mm)
0.19 " diameter
(Ø 4.8 mm)

3.56 "
(90 mm)

6.10 "
B. C. D. (155 mm)
6.60 "
(168 mm)

Figure 9. 8154 POWER MODULE footprint and mounting dimensions.

ALARM
ALARM

CLEAN
FAULT

BAR
GND

OFF EXT

ON EXT
RESET
A – top view with the cover removed exposing mounting holes; B – view from the input

COM

NO
NC

NO
NC
1.84 "

1
1 2 3 4 5 6 7 8
(47 mm)
end; C – side view; D - view from the output end.
1 – enclosure bottom; 2 – clear cover; 3 - output conduit fittings; 4 - HV
Output switch; 5 – input conduit fittings; 6 –mounting holes (4).
5 6 7 8 9 10

Figure 10. 8200 MANAGER.

1 – Neutralizing Current display; 2 – station address display; 3 – Ion Output display;
4 – control and programming keys; 5 – DC power jack (J2); 6 – RJ11-6communication
port (J1); 7 – reset push-button switch; 8 – remote connector header (J5); 9 – aperture
with grommet for hardwiring the 8200; 10 – matching connector plug.

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 • “Ion Output” display shows the bar ionizing efficiency level. The Ion Output value 8310 CONNECTOR – Serial communication switch
depends primarily on the length of the neutralizing bar or bars connected to the The 8310 CONNECTOR unit shown in Fig. 11 is a simple communications passthrough
specific 8154 and the condition of the ionizing electrodes. See Appendix A for the switch for MODBUS RTU serial communications between the 8154 POWER MODULE
expected values of the Ion Output. The Ion Output display doubles up as a fault and units and the 8200 MANAGER module, or a host computer. It allows multiple 8154
alarm display. POWER MODULES to be connected in the network.
• “Station #” display shows the station address from “1” to “9”, with the “0” reserved
for the Master – 8200 MANAGER.
1
• “Neutralizing Current” display shows how much ion current is flowing to the
charged material to neutralize it. The higher the charge on the material, the more ions
flow to it, and higher the current value. The polarity of the neutralizing current is 1.52 "
(39 mm)
opposite to the polarity of the charge on the material. In the programming mode, the
2
Neutralizing Current display serves for Clean Bar function setup. 5.63 "
4 (143 mm)
3

Displaying the Neutralizing Current values must be disabled under certain conditions
explained later in the manual. When disabled, the display shows “– – –”.
• Control and programming keys.
3.25 "
• The following connectors and terminals are accessible through a cutout in the bottom (83 mm)
panel of the enclosure.
• DC power input connector and terminals.
• Communications connector and terminals.
• Terminals for remote alarm signals 4 8
7 7 4.63 "
• Terminals for remote HVPS activation. (117.5 mm)

• Reset switch
6
4.25" 3.75 "
(108 mm) (95 mm)
The 8200 MANAGER displays the following information for each of the stations 5
connected to it.
4 mounting holes, 0.140" 4.13 "
• Station’s ON/OFF state diameter (3.5mm) (104.8 mm)

• Ion Output in microamperes

• Neutralizing Current in microamperes
• Alarm Status including Short Circuit, Hardware Malfunction and Clean Bar
indication. Figure 11. 8310 CONNECTOR – serial communications switch.
• Clean Bar alarm threshold 1 – bypass switch; 2 – dedicated 24VDC power jack (J15); 3 – DIN rail clips;
• 8154 and 8200 Firmware versions and the serial numbers of the 8154 POWER 4 – RJ11-6 serial communication connectors (J4 and J6); 5 – aperture for hard wiring;
MODULES connected to the 8200. 6 – RJ11-6 combined power & communication connector for 8154 (J5); 7 –apertures for
hard wiring power and serial communication between 8310 CONNECTORS in the
network; 8 – alternative mounting with wall bracket.

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The 8310 module provides communication interface using three connections, two COMM 8200
POWER MANAGER

IN/OUT and one for 8154. It allows power, and the MODBUS connections to be connected

GND
DC INPUT
through the 8310 to the 8154.
The MODBUS IN and MODBUS OUT signals are connected together in the 8154. This 8 7 6 5 4 3 2 1 J5 4 3 2 1 J4
NC
6 5 4 3 2
NC
1 J1 2 1 J3 J2
creates the 2 wire bus required for RS485. The additional RJ11 connectors are used to

RJ11-6
N.C. CLEAN
N.O. CLEAN
N.C. FAULT
N.O. FAULT
COM
ON EXT
OFF EXT
GND
B- A- B+ A+

connect the 8310 to additional modules in the network. In addition to the RJ11-6
receptacle for connecting a cable with communication and power wires, terminal blocks
are provided on the 8310 circuit board for using hard-wired connections (see Fig. 15). ALARMS
MATERIAL SAFETY
There are identical terminal blocks on the 8154 POWER MODULE and 8200 MANAGER

MODEL 8001 or 8001KD NEUTRALIZING BAR

MOVEMENT INTERLOCK GND J15
DC INPUT
circuit boards.
J8
The bypass switch allows users to take any 8154 units out of the network and avoid 1
2

rewiring communication connections by simply setting the bypass switch to the ON J3 J9 J10

position. 1
2
1
2
1
2
DC INPUT
J5 J4 RJ11-6
1 3
2 4
3
J11
4
E3 1
5
2
VO+ 6

J4 J12 J6 RJ11-6
SW1
A+ A+
24VDC power E4
1
B+ B+
1
3
4
VO- 2 2
A- A-
Any 24VDC source of power can be used with the ION POWER neutralizers. Ion E1
3
B- B-
3 J13
1
4 4

Industrial offers several models of 24 VDC switch-mode power supplies with universal 2

input. See the SPECIFICATIONS section for the list. 8154

POWER MODULE
8310
CONNECTOR

MODEL 8001 or 8001KD NEUTRALIZING BAR

GND J15
DC INPUT

Wiring a multi-station ION POWER system J8

1
2
The ION POWER Virtual AC Neutralizers with the 8200 MANAGER master controller J3 J9 J10
and 8154 POWER MODULES uses a Master-Slave network with Modbus RTU 1 1 1
2 2 2
communication protocol over a two wire RS-485 multi-drop bus. In a Master-Slave DC INPUT
J5 J4 RJ11-6
protocol, the 8200 MANAGER module communicates with 8154 POWER MODULES 1
2
3
4

connected to the bus using the Modbus RTU communication protocol. 3

J11
4
E3 1
A multi-station ION POWER system can be wired with and without the 8310 VO+
5
6
2

CONNECTOR. The rule of thumb if there are more than 2-3 station in the network, the E4
J4
A+ A+
J12 SW1
J6 RJ11-6
3
1 1
stations are far apart, and you anticipate the need to take some neutralizers out of the VO- 2
B+
A-
B+
A-
2
4

J13
network, you want to use the 8310’s to avoid rewiring communication connections and use E1
3
4
B- B-
3
4 1

the bypass switch to the ON position. The wiring is simpler with the 8310’s. 2

8154 8310
The system wiring diagram with the 8310’s is shown for reference in Fig. 12. and the POWER MODULE CONNECTOR

diagram without the 8310’s is shown in Fig. 13.

TO THE NEXT
8310 CONNECTOR

Figure 12. Wiring diagram for the ION POWER Virtual AC Neutralizer with 8154
POWER MODULES, 8200 MANAGER using 8310 CONNECTORS.

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 8154 output wiring

MODEL 8001 or 8001KD NEUTRALIZING BAR

CAUTION! Before performing any wiring, be sure power to the system is off
J2 GND
and the 24VDC is disconnected.
DC INPUT
1. With the 8001KDT bar or bars mounted in the appropriate position,
J3 DC INPUT J3 2. Expose 4” of the wires at the end of the protective conduit from the bar.
1 1
2 2 3. Unscrew and remove the pressure nut from the output conduit fitting in the 8154
RJ11-6 J1 enclosure.
1 NC
2 4. Feed the ends of the wires and the protective tubing through the pressure nut. Then,
3
4
feed the ends of the wires through the fitting into the enclosure. Press the protective
E3 5 conduit inside the gripping teeth of the fitting until it stops.
VO+ 6 NC
J4 J4 5. Thread the pressure nut onto the cord grip. Tighten the pressure nut to secure the
E4 A+ A+
VO-
1
B+ B+
1 protective tubing and the wires.
2 2
A- A-
3
B- SAFETY B-
3 6. Still inside the 8154 enclosure, cut the two black high voltage wires leaving 4” of each
E1 4 4
INTERLOCK
wire inside the enclosure.
8154 GND
J5 7. Strip 1/4” of insulation from the wires. Crimp a provided ring terminal to each wire.
POWER MODULE 1
Do not provide for any slack in the high voltage wires inside the enclosure.
MOVEMENT
MATERIAL

OFF EXT
2
MODEL 8001 or 8001KD NEUTRALIZING BAR

ON EXT
3 8. Loop the high voltage wires to the output posts, one wire to one post and the second
COM
N.O. FAULT
4
wire to other post, as shown in Fig. 14, and secure the wires to the output posts using
5
provided screws and star washers The outputs are not polarized.
ALARMS

N.C. FAULT
6
N.O. CLEAN
7
N.C. CLEAN
J3 DC INPUT
8 CAUTION! DO NOT LEAVE ANY SLACK IN THE HIGH VOLTAGE
1 8200
POWER MANAGER
WIRES INSIDE THE ENCLOSURE! THE HIGH VOLTAGE WIRES MUST
2
STAY WITHIN THE BOUNDARIES OF THE BLACK SHELL.

4
E3
VO+
2
J4
E4 A+
1
B+
VO- 2
A-
E1
3
B- 4
4

8154
POWER MODULE 1

TO THE NEXT 8154 3

Figure 13. Wiring diagram for the ION POWER Virtual AC Neutralizer with 8154
POWER MODULES and 8200 MANAGER, but without 8310 CONNECTORS.
IMPORTANT: Wiring of the Virtual AC Neutralizer must be done by qualified
personnel in accordance with this manual and with the appropriate national
safety standards.
3
Figure 14. Connecting bar wires to the output of the 8154 POWER MODULE
1 – threaded high voltage output posts; 2 – socket-type high voltage output posts (ARE
NOT USED IN THE 8154); 3 – bar high voltage wires with ring terminals;
4 – protective conduit with bar high voltage wires.

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Connecting several 8001KDT bars to one 8154 POWER MODULE
Up to four 8001KDT neutralizing bars can be connected to a single 8154 POWER MODULE.
9. Repeat steps 1 through 8 for additional bars connected to the 8154.
IMPORTANT!
• Exercise care when wiring several bars. Use the provided ring terminals. Make sure
the terminals are angled away from the other output terminal to prevent arcing.
• Loop the high voltage wires to the output posts, as shown in Fig. 14A, and secure the
wires to the output posts using provided screws and star washers
• Do not attach more than the maximum specified total length of neutralizing bars to
the 8154 POWER MODULE.
• When more bars are added, the Clean Bar Alarm threshold may need to be reset. See
System Setup and Operation.
• Unless the bars of a multi-bar neutralizer are installed to traverse the same span of a
wide web or on a dual rewinder, disable the 8200 neutralizing current display for a
multi-bar neutralizing station. See System Setup and Operation.
Figure 14A. Wiring four bars to the output of the 8154 POWER MODULE.
10. The 8154 high voltage output wiring is now completed.
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8154 POWER MODULE grounding connection
WARNING! The enclosure of the 8154 POWER MODULE is a finished high-
voltage device not a junction box – do not change the conduit fittings to any
other type, do not drill additional holes in the enclosure, and follow the wiring
instruction precisely to avoid equipment damage.
11. The 8154 unit must be connected to earth ground using the grounding wire attached to
the grounding tab on the 8154 board, shown in Fig. 19.
12. Connect the other end of the grounding wire with the ring terminal to the machine
frame in the vicinity of the input end of the 8154 unit.
CAUTION: The grounding connection must be completed and intact. Damage
to equipment and electrical shock can occur if the power supply is left
ungrounded.
Complete system wiring
Depending on the 24VDC availability, there are several 24VDC wiring choices.
• Single 24VDC power source connected to any of the 8310 units or the 8200
MANAGER.
• Individual 24VDC power sources connected to each 8154 POWER MODULE and
the 8200 MANAGER.
For a single 24VDC power source, the simplest and most straightforward power and
communication wiring, is using a four-wire cable to interconnect the terminal blocks of all
the 8310 units and the 8200 MANAGER.
1. Remove the covers from all the 8310 units to expose the wire terminals.
2. Using four-wire cable, establish the communication and power connections between
the 8310 units in the network.
3. Connect the terminal blocks J11 and J13 of the consecutive 8310’s. Connect “A+” and
“B+” terminals of one 8310 to “A-” and “B-” terminals in the next 8310 (Fig. 15).
4. Connect the terminal blocks J8 and J10 of the consecutive 8310’s. Connect “GND”
and “+24V” terminals in one 8310 to “GND” and “+24V” terminals in the next 8310
(Fig. 15).
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 3 3
2 2
7. Using the other two wires, establish the communication connections between the
terminal block J4 in the 8200 and J11 or J13 in the end 8310. Connect “A+” and “B+”
terminals in the 8200 (pos. 2 in Fig. 17) to “A+” and “B+” terminals in the first 8310 (pos.
2a or 2c in Fig. 17).

GND +24V

GND +24V
A+ B+

A+ B+
A- B-

A- B-
GND +24V

GND +24V
A+ B+ A- B- GND +24V A+ B+ A- B- GND +24V

4 4 1 2
1 1
5 5

Figure 15. Wiring 8310 units together.

1 & 3 – 24VDC power terminal blocks (J8) & (J10); 2 & 4 – serial communication
terminal blocks (J11) & (J13); 5 – communication and power receptacle for connecting GND +24V A+ B+ A- B-

8154’s (J12).

5. Alternatively, four-wire phone-style cables like the one shown in Fig. 16 could be
connected to provide communications between 8310 units, and between the 8200 8200
MANAGER and the first 8310.
8310
5
4
3
3

GND +24V
2

A+ B+

A- B-
GND +24V
1 A+ B+ A- B- GND +24V

4 4
5
Figure 16. Communication cable termination.
6
1 – RJ11-4 plugs; 2 – locking tabs; 3 – 4-wire flat phone-style cable; 4 – terminal #4in
both plugs must have the same-color wire.
Figure 17. Wiring the end 8310 unit to the 8200 MANAGER.
IMPORTANT! CABLE ORIENTATION IN BOTH RJ11 PLUGS IS
IDENTICAL, NOT LIKE IN THE PHONE CABLE. INCORRECT 1 – 24VDC power terminal blocks (J3); 2 – communication terminal blocks (J4);
TERMINATION WILL RESULT IN COMMUNICATION ERRORS. 3 & 5 – 24VDC power terminal blocks (J8) & (J10); 4 & 6 – serial communication
terminal blocks (J11) & (J13).
6. For hardwiring the communication and power between the end 8310 and the 8200 using
four-wire cable, connect the terminal block J3 in the 8200 and J8 or J10 in the end 8310.
Connect “GND” and “+24V” terminals in the 8200 (pos. 1 in Fig. 17) to “GND” and
“+24V” terminals in the first 8310 (pos. 1a or 1c in Fig. 17).

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8154 POWER MODULE input connections The input end of the wired 8154 unit is
8. Prepare wiring for connecting the 8154 POWER MODULES to the 8310 units in the shown in Fig. 19.
network.
9. Using four-wire cables, connect the terminals “GND” and “+24V” in the terminal block 10. Wiring is completed.
J3 in the 8154 with the corresponding terminals in the terminal block J9 in the 8310. Using
the other two wires, establish the communication connections between the terminal block NOTE: For wiring a multi-
J4 in the 8154 and J12 in the 8310. Connect “A+” and “B+” terminals in the 8154 to “A+” station system without using the
and “B+” terminals in the 8310. See Fig. 18. 8310 CONNECTORS, follow the
wiring diagram in Fig. 13 and the 1
general steps described above.
2
8310 8310 11. Replace the 8310 covers and secure
each with four screws. Make sure the
3
grommets fit properly in the grommet 4
apertures.
GND +24V

GND +24V
5
12. Set the bypass switch in the back of
A+ B+

A+ B+
A- B-

A- B-
6
GND +24V

GND +24V
A+ B+ A- B- GND +24V A+ B+ A- B- GND +24V
each 8310 enclosure to the OFF position. 7
13. Connect the 24VDC power to any of 8
the 8310 units or to the 8200 MANAGER, Figure 19. 8154 input power and
either to the DC power jack or the terminal communications connections.
blocks. 1 – communication wires;
8154 8154 14. Close the 8154 cover and secure all 2 – communication terminal blocks;
bolts. 3 – 24VDC power wires; 4 – 24VDC
15. Do not apply 24VDC power just yet. power terminal blocks (J3); 5 – PCB-
mounted output switch (must be set in
A+ B+ A- B- A+ B+ A- B-
WARNING: When the green the OFF position); 6 - LED power
GND GND

indicator; 7 – quick-disconnect
+24V +24V

LED in the 8154 is lit the high

voltage outputs are energized. grounding terminal; 8 – earth ground
wire with a quick disconnect.

When using multiple 24VDC power sources:

Figure 18. Hardwiring 8154 units to 8310’s using the terminal blocks. a. Follow all the previous instructions for wiring serial communications only.
b. Connect the 24VDC power to any of the 8310 units or to the 8200 MANAGER,
either to the DC power jack or the terminal blocks, as shown in Fig. 20.

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 5
Remote system output activation and alarms

1 – connection at the 8200 DC jack; 2, 3, 4 – possible connections at the 8310 DC jacks; 5 – possible hardwiring 24VDC at the last 8310.
Remote Network Activation and Safety Interlock
It is a good practice to automatically activate 8154 output with a signal from the control
system of the machinery where the neutralizers are installed. It is recommended to turn the

TO 8154
GND +24V
GND +24V A- B-

neutralizers on as soon as the web starts to move and turn it off few seconds after the web

A+ B+ A- B-
stops. This ensures that the high voltage output is down when the machine is not running.
That will minimize contamination of the ionizing electrodes and also extend the life of the
equipment by many months.
When remote network activation is used it is necessary to provide the safety interlock for
personnel protection. See the wiring diagrams in Figs. 12 and 13 for interlock connections,

Figure 20. 24VDC power connection options in a multi-station network.

8310
A+ B+ GND +24V

including E-STOP, personnel-access door protection, or others.

8200

When the terminals “EXT ON” is shorted to terminal 1 “GND” on the remote terminal
block of the 8200 MANAGER, the outputs for all the 8154 in the network are enabled.
When the terminals “EXT OFF” is shorted to terminal 1 “GND”, the outputs for all the
3

8154 in the network are disabled.

Use a remote SPDT switch or relay for wiring the Virtual AC Neutralizer to an external
A+ B+ A- B-

activation circuit, as shown in the wiring diagram.

+24V

TO 8154
GND +24V

GND +24V A- B-
1. Remove the provided connector shown in Fig. 10 from the header in the 8200.
GND

A+ B+ A- B-

2. Connect the wires from the external activation circuit to terminals 1, 2 and 3 in the 8200
connector.
3. Plug the connector into the header in the 8200.
The remote HVPS output activation controls the network independently of the state of the
1

A+ B+ GND +24V 8200 ON/OFF key.

8310
2

TO 8154
GND +24V

GND +24V A- B-
A+ B+ A- B-

A+ B+ GND +24V
8310

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Remote alarm connections
The remote alarm terminals are located in the same terminal block as the remote activation
terminals and are accessible from the bottom of the 8200 enclosure (Figs. 10).
The connector header has separate sets of relay contacts for the Fault and Clean Bar alarm
signals, normally closed (NC), normally open (NO) and common (COM). The Clean Bar
alarm NO and COM terminals provide contact closure during an alarm condition; the NC
and RTN connections terminals provide contact closure during normal operating conditions.
The Fault alarm relay in the 8200 is energized under the no-alarm conditions. The Fault
alarm NO and COM terminals provide contact closure during normal operating
conditions; NC and COM terminals provide contact closure during an alarm condition or
if there is a loss of power to the system.
1. Remove the connector from the header in the 8200.
2. Connect the wires from the remote alarm indicator to the appropriate connector
terminals according to Figs. 10 and 12.
3. Plug the connector into the header in the 8200.
4. SETUP AND OPERATION
IMPORTANT! Initial setup must be performed when the line is not running and
there is no charged material in the vicinity of the bar.
8200 Functionality
The 8154 and 8200 are designed for 8154 to maintain or resume its operation during or
after communication glitches or power disruptions.
• After an individual 8154 is disconnected from the network (both power and
communications, or just communications), and then is connected back, when an
8154 starts to communicate with the 8200, it gets set to the last state prior to the loss
of communications.
• After a power cycle or a communications glitch for any individual 8154, the 8154
would always come back to the state it was before the glitch.
• When the 8154 RESET button is pressed, the 8154 would always come back to the
state it was before resetting.
• Pressing the 8200 RESET button does not change the state of the 8154's in the network.
• After recycling network power for any period of time, the 8154's always come back
to the state they were before the power recycle.
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IMPORTANT! It is recommended that prior to removing the network power for
any extended period the high voltage output for all the 8154’s in the network are
disabled using the 8200 On/Off key. See Table 1 in the Instruction Manual for
ENABLE/DISABLE HV OUTPUTS FOR ALL STATIONS function.
• If the 8200 loses communications with some or all units in the network, the 8154’s will
continue to operate and keep the output state existing before communication was lost, as
indicated by the LED in the 8154. When the 8200 starts to communicate with the 8154’s
again, all affected 8154’s will get set to the last state prior to the loss of communications.
• For most 8200 failures, including loss of functionality or power disruption, the 8154
will continue to operate and keep the output state existing before the 8200 problem,
as indicated by the LED in the 8154.
• Any 8154 units with address “30” are always turned off when added to a multi-station
network or directly to the 8200. The 8200 will turn off an 8154 with address 30.
• When the 8200 assigns an address to a 8154, it is always set to off. If the manual
switch on the 8154 is then turned on the LED will turn on green for a brief moment,
but then turn off again, as the 8200 will immediately turn it back off.
• If the 8200 has an 8154 set to off and the manual switch in that 8154 is turned off
and then on, the LED will turn on green for a brief moment and then turn off again.
• The BYPASS switch in the 8310 must be in the OFF position when an 8154 is
connected to the 8310 and in the ON position when the 8154 is disconnected.
8200 Keys
The 8200 can operate in one of three modes, Station View, Scan Stations and
Programming.
Many display functions require pressing a single key. The programming functions require
pressing a combination of two keys.
When a key is pressed, the station # display changes and illuminates a single segment
indicating that pressing a key is recognized. If two keys are pressed at the same time, then
two segments are illuminated accordingly. The functions corresponding to a specific key
or key combination are not processed until the keys are released. After pressing a key, or
keys, see in the display that they are recognized, and then release the keys to perform the
desired operation.
No segments are illuminated when up or down keys are pressed for adjusting the clean bar
alarm threshold in the clean bar setup mode.
See summary of all 8200 key functions on the following page.
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8200 Programming Functions STATION CLEAN BAR FUNCTION TOGGLE
Puts the 8200 in the “Set Clean Bar”
PRESS & RELEASE
mode for the displayed station; the
SET ADDRESS Neutralizing Current display will flash
Sets any 8154 POWER MODULE with “Cb”. Repeat pressing of the keys while
PRESS & RELEASE
initial address “30” to an open address in the “Set Clean Bar” mode, puts the
between 1 and 9. 8200 back in the “Station View” mode.
The 8200 will show several dashes (-) in
the display whenever there is an 8154
connected to the network at address “30”.

SET DEFAULT ADDRESS

Resets the address of a connected 8154 to PRESS & RELEASE
“30”; only one 8154 could be connected.

Appearance of the 8200 display for setting up the Clean Bar alarm.

INCREMENT CLEAN BAR ALARM THRESHOLD

In the “Set Clean Bar” mode,
PRESS & HOLD
increments the value of the clean bar ion or
output threshold. PRESS & RELEASE

8200 display appearance after the 8154’s address has changed to 30.
DECREMENT CLEAN BAR ALARM THRESHOLD
In the “Set Clean Bar” mode, PRESS & HOLD
decrements the value of the clean or
bar ion output threshold. PRESS & RELEASE

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ENABLE/DISABLE NEUTRALIZING CURRENT DISPLAY 8200 Command Functions
In the “Set Clean Bar” mode,
PRESS & RELEASE
disables or enables the neutralizing
current display ENABLE/DISABLE STATION HV OUTPUT
In “Station View” mode, will toggle PRESS & RELEASE
8154 POWER MODULE output of
The flashing “Cb” will be replaced
the selected station on and off.
with “OFF” flashing for 5 seconds,
as shown below.

ENABLE/DISABLE HV OUTPUTS FOR ALL STATIONS

In “Station View” mode and at
PRESS & RELEASE
station “0”, will toggle output of all
8154 POWER MODULES in the
network on and off. The Ion Output
display will show “Enb” or “OFF”.
Appearance of the 8200 display when disabling the Neutralizing Current display.
To enable a previously disabled Neutralizing Current display, pressing the On/Off key
when in the Set Clean Bar mode. The flashing “Cb” will be replaced with “On” flashing
for 5 seconds, as shown below. ENABLE/DISABLE HV OUTPUTS FOR ALL STATIONS
In “Scan Stations” mode, will toggle
PRESS & RELEASE
output of all 8154 POWER
MODULES in the network on and
off. The Ion Output display will
show “Enb” or “OFF” when station
“0” is scanned.

Appearance of the 8200 display when enabling a previously disabled Neutralizing

Current display. RESET FAULT ALARMS
Resets the station(s) F1 and F2 alarm(s).
PRESS & RELEASE

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8200 Display Functions DISPLAY 8154 FIRMWARE VERSION AND S/N
In “Station View” mode, will display the PRESS & HOLD
8154 firmware version in the Neutralizing
SCAN ALL STATIONS Current display and its serial number in the
Sets the 8200 to “Scan Stations” mode to PRESS & RELEASE Ion Output display
sequentially display the neutralizing
current and ion output values, and the
status of all the neutralizing stations in the
network, including station “0” as the
network view.

ADVANCE STATIONS SCAN

In “Scan Stations” mode, advances the PRESS & RELEASE
display to the next neutralizing station and
continues scanning from that point
8200 display appearance with the 8154’s firmware version and unit’s serial number.
forward, including station “0” as the
network view.

VIEW SELECTED STATION

Sets the 8200 to “Station View”
PRESS & RELEASE
mode for the neutralizing station
which address is displayed,
including station “0” as the network
view.

VIEW NEXT STATION

In “Station View” mode, advances
PRESS & RELEASE
the display to view the next
neutralizing station, including
station “0” as the network view.

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Neutralizing system setup

IMPORTANT!

• Make sure that prior to addressing all 8154 POWER MODULES designated to
operate in the network are set to address “30”, and are not connected to the network.
• Only one 8154 at a time can be added to the network to set its address.
• Initial setup must be performed when the line is not running and there is no charged
material in the vicinity of the bar. Figure 22. 8200 display appearance after the first 8154 with the default address “30” has
• If you need to take one 8154 out, put the BYPASS switch in the corresponding 8310 been connected to the network.
(see Fig. 11) to the ON position prior to disconnecting the 8154.
1. Set manual ON/OFF switches in the 8154’s to the OFF (0) position. 5. Press simultaneously ON/OFF and View Station keys.
2. Apply 24-volt power to the network of 8200 and 8310 units, or individually to the PRESS & RELEASE
components.
3. The 8200 displays will go through the initialization routine culminating with the display
of the 8200 firmware version in the Ion Output display, following by the display shown in
Fig. 21.

When keys are pressed, two vertical segments will appear in the STATION # display.
Release the keys and the STATION # display will show number “1” which will blink five
times. The output of the 8154 will remain disabled after addressing. After that, the blinking
will stop and the 8200 will go into the View Station mode and remain in that mode
displaying that station’s parameters. The 8200 displays will have the appearance in Fig. 23.

Figure 21. 8200 display appearance after it is powered up with no

8154 units connected to it.

IMPORTANT! When the system/network output is enabled, “Enb” shows in the

ION OUTPUT display. When the system/network output is disabled, “OFF”
shows in the ION OUTPUT display and the output of individual stations can not Figure 23. 8200 display appearance after a station has been assigned an address.
be turned on.

4. Connect the first 8154 to the network. The STATION # display will change as shown in 6. Turn the ON/OFF switch on the 8154 unit ON.
Fig. 22. The 8154 output will be disabled. The LED will turn on green for a brief moment, but then turn off again.

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7. Press the ON/OFF key to enable the 8154 output.
PRESS & RELEASE
The ION OUTPUT and NEUTRALIZING CURRENT displays will show the values for
both currents as shown in Fig. 24. The green LED on the 8154 will light up.
Figure 24. Normal appearance of the 8200 display with the output of the 8154 POWER
MODULE on and the Neutralizing Current display enabled.
Make a note of the Ion Output initial value; it should serve as a benchmark for the Clean
Bar alarm threshold.
Notes:
a. You may see a reading in the range from 30-50 microamperes for a 12” (300 mm)
neutralizing bar to over 500 microamperes for bars with a total length of 400” (10
meters). See Appendix A for the expected values of the Ion Output.
b. It is common for the ion output of all static bars to drop 5-10% during first hours of
operation. That is the nature of ion generation where sharp points of new electrodes
lose their initial sharpness, dropping the initial level of ion production.
c. After the initial drop, a user can expect a gradual decline of the ion output over the
life of the bar, totaling about 50% in 3-5 years depending on the neutralizer’s duty
cycle and ambient environment.
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Clean Bar alarm setup
The “Clean Bar” indicator is activated when the ion output drops below a predetermined
level. Follow the steps below to set the Clean Bar alarm threshold for each station in the
system.
9. Press simultaneously the two Clean Bar Set keys.
PRESS & RELEASE
Two vertical segments will appear in the STATION # display. Release the keys. “Cb”
flashes in the neutralizing current display to indicate clean bar threshold is being set.
Clean Bar threshold value will be shown in the Ion Output display. See Fig. 25.
Figure 25. Appearance of the 8200 display for setting up the Clean Bar alarm.
10. While in the Set Clean Bar mode, press the up arrow or down arrow keys multiple
times to set the Clean Bar threshold to the desired value.
Advice: 20-35% of the initial Ion Output value is a recommended range. For instance, if
the initial Ion Output is 112 uA, a 40 uA threshold would be appropriate.
PRESS & HOLD
or
PRESS & RELEASE
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 11. For the neutralizing applications matching the descriptions above, disable the
Neutralizing Current display by pressing the On/Off key when in the Set Clean Bar mode.
The flashing “Cb” will be replaced with “OFF” flashing for 5 seconds, as shown in
Fig. 27.

Figure 26. Appearance of the 8200 display after dialing up the Clean Bar alarm
threshold value.

Neutralizing current display

This is a good time to determine if the Neutralizing Current display need to be disabled, Figure 27. Appearance of the 8200 display when disabling the Neutralizing Current
as it is done when the station is in the Set Clean Bar mode. display.

IMPORTANT! Determine if you need to disable the Neutralizing Current To enable a previously disabled Neutralizing Current display, pressing the On/Off key
display. when in the Set Clean Bar mode. The flashing “Cb” will be replaced with “On” flashing
for 5 seconds, as shown in Fig. 28.
There are three types of applications when neutralizing current is not measured and
its displaying should be disabled.
• First, with the Multi-Bar Neutralizer systems in applications where some of the
bars in the system may be neutralizing static charges of one polarity and other
bars neutralizing static charges of the opposite polarity. The bars will be sending
both positive and negative ions to the material.
• The second application is neutralization of webs that carry charges of both
polarities, such as some printed webs. In these applications, the portions of the
web with print may carry charges of a different polarity than the portions without
print. Thus, a bar will send both positive and negative ions to the material. Under Figure 28. Appearance of the 8200 display when enabling a previously disabled
these two conditions the neutralizing current display would not be informative, Neutralizing Current display.
and could even be confusing.
• The third type of application involve slow-moving webs (approx. 50 fpm and
slower) or stationary or slow-moving molded parts. In these cases the
neutralizing current required to neutralize the charge is too low to register on the
display.
Disable the Neutralizing Current display if appropriate at this point. Proceed with
step 11 below. If the Neutralizing Current display should remain enabled, skip step 11
and proceed with step 12.

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12. To leave the Set Clean Bar mode, press simultaneously the two Set Clean Bar keys.
PRESS & RELEASE
Two vertical segments will appear in the STATION # display. “Cb” flashing in the
Neutralizing Current display will extinguish. The displays will return to the View Station
mode.
If the Neutralizing Current display has been disabled, the 8200 will look as shown in
Fig. 29. If the Neutralizing Current display was left enabled, the 8200 will look as shown
in Fig. 24.
Figure 29. Normal appearance of the 8200 display with the output of the 8154 POWER
MODULE on and the Neutralizing Current display disabled.
13. If the Neutralizing Current display is used, check the value of the neutralizing current.
If the neutralizing bar was installed correctly, and there are no machine frame components
or rollers within the area shown in Fig. 7, the Neutralizing Current reading will be low
(under 2 microamperes), as shown in Fig. 24. However, if there are machine frame
components or rollers, or other metal objects too close to the neutralizing bar, the
Neutralizing Current value will be higher. The value of the “background “current will be
equal to the amount of ion current flowing to the metal components. The polarity of that
offset is usually negative.
It is recommended to reposition the neutralizing bar to eliminate the loss of ions to ground.
Contact Ion Industrial for guidance.
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The setup of the first neutralizing station is now completed.
14. Connect the next 8154 POWER MODULE to the network.
15. The 8200 stays in the View Station mode and switches to show the new station with
address “30”. See Fig. 22.
16. Repeat steps 5 through 13 above for each additional 8154 in the network. The 8200 will
assign the consecutive address numbers to each 8154.
17. When all neutralizing stations have been addressed, press the “Scan Stations” key. The
8200 MANAGER will start scanning all stations switching from station to station every 7
seconds. The station address will be identified in the “STATION #” display.
Operation and operation check
WARNING! Disable the Virtual AC neutralizers when processing webs with a
metal foil or metallized film as part of their construction. Electrical neutralizers
are not useful under those conditions, and could create a safety hazard in some
circumstances.
1. Leave the 8154 running. From time to time, review the system status on the 8200
MANAGER.
You can review every individual station in the network by pressing Scan Stations key.
1. “Ion Output” indicates the bar ionizing efficiency level. As the efficiency goes down
when ionizing electrodes accumulate residue, the ion output value will go down too.
Note: You may notice a drop in the ion output during first day of operation. That is the
nature of ion generation with new sharp electrodes where points normally lose their initial
sharpness, reducing the initial level of ion production.
3. “Neutralizing Current” indicates the ion current flowing to the charged material. The
higher the charge on the material and the faster the material speed, the more ions flow to
it and the higher the neutralizing current value. The neutralizing current value also depends
on the width of the web. The polarity of the neutralizing current is opposite to the polarity
of the charge on the material. If the material is neutral, the neutralizing current value is
close to zero.
4. Verify that there are no “F1”, “F2”, “bar” or “Cb” fault messages in the 8200 display. If,
at any time a fault message appears, check the Troubleshooting section of this manual.
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Fail-safe ionization mode Clean Bar indicator is activated when the ion output drops to a predetermined level.
The Virtual AC Neutralizer is designed to provide a fail-safe ionization mode under certain See Fig. 31.
conditions. This means that, even when power is not applied to the high voltage power
supply or if it is not functional, the bar will continue neutralizing static charges. The fail-
safe ionization mode is operable when the bar is installed within 3” (75mm) of the moving
charged material, and it kicks in when the material charge reaches high levels (above 20
kV). The efficiency of the neutralization in the fail-safe ionization mode is, in most cases,
enough to knock down the charges from dangerously high levels.
In the fail-safe ionization mode, “OFF” will be shown in the Ion Output display and the
current value will appear in the Neutralizing Current display. As with the normal ionization
mode, the value of the neutralizing current display will reflect the ion current flowing to
the charged material. Figure 31. Appearance of the 8200 display during the Clean Bar alarm.

Bar Disconnected/ Inactive Station alarm warns a user that the neutralizing bar(s) are
Alarms disconnected and/or there no ion output from the bars. See Fig. 32.
8154 Output Fault Alarm and Short Circuit Alarm indicate electrical malfunction or failure
of the neutralization equipment. The output of the 8154 POWER MODULE will be
automatically disabled in case of either alarm. The 8200 will display the information about
the alarm condition as shown below.

Figure 32. Appearance of the 8200 display during the Bar Disconnected/Inactive Station
alarm.

Figure 30. Appearance of the 8200 display after 8100 output fault (top “F1”) and Short
Circuit alarm (bottom “F2”).

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When there is an alarm at any of the stations in the network, the appearance of the 8200
display at station “0” is shown in Fig. 33. The 8200 will always display the station numbers
with “F1” output fault alarm or “F2” short circuit alarm. The other two alarms, Clean Bar
“Cb” and Bar Disconnected/inactive Station “bar” will be displayed only when the outputs
of the alarming stations are enabled.
Figure 33. Appearance of the 8200 display at station “0” with alarming station “9”.
When there are no alarms at any of the stations in the network, the appearance of the 8200
display at station “0” is shown in Fig. 34.
Figure 34. Appearance of the 8200 display at station “0” with the outputs of all the
8154’s enabled and no alarms of any kinds.
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When the outputs of all the 8154’s are disabled with a global OFF command from the 8200
or with a remote control, the appearance of the 8200 display at station “0” is shown
in Fig. 35.
Figure 35. Appearance of the 8200 display at station “0” with the high voltage outputs of
all the 8154’s disabled and no “F1” or “F2” alarms.
Conductive residue accumulation on the bar surface
Short Circuit alarm (“F2”) is activated when there is a short circuit anywhere in the high
voltage side of the system.
Among the causes for the short circuit alarm is accumulation of an electrically conductive
residue on the surface of the bar. Such conductive residue can develop from the chemicals
or substances used in production processes around the neutralizer.
The conductive residue causes a leakage current along the encapsulated surface between
the ionizing electrodes of the bar. The more conductive is the residue, the higher the
leakage current. The leakage current manifests itself as a rising ion output value. When the
leakage current exceeds the alarm level, the Short Circuit alarm (“F2”) goes off and the
output of the 8154 will be disabled. See the Troubleshooting section for recommendations.
Loss of communications
The 8154 POWER MODULE is specially designed to maintain their state that existed prior
to communication loss. If the 8154 output was enabled, it would stay enabled. If it was
disabled, it would stay disabled. Maintaining its state is inherent in the design of the
embedded firmware. If communications is reestablished the state will be updated to the
current requested state of the 8200. See the section on the 8200 Functionality.
When there is loss of communications for the station, the 8200 display will appear as
shown below. When there is a problem with communications with a station or stations, it
is not exchanging information with the network and is not controlled by the network host.
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 5. PERFORMANCE VERIFICATION

Figure 36. 8200 display appearance if communication with the 8154’s in the network
was lost.
Top image – when the outputs of the network stations are enabled with the global “ON”
command; bottom image – when the network stations are disabled with the global “OFF”
command.
8154 POWER MODULE stand-alone operation
The 8154 POWER MODULE can operate without being connected to the 8200 network.
After applying 24VDC power to the 8154, use the manual ON/OFF switch for enabling
and disabling the high voltage output.
The “Neutralizing Current” display indicates the ion current flowing to the charged
material. In other words, this display shows how much charge on the material is being
neutralized.
In most cases, especially when the neutralizing bar is installed within 4” from the material,
and its ion output is no less than half of its maximum value, the bar will neutralize over
90% of the charge on the material. At longer distances, the percent of neutralizing
efficiency will depend on the speed of the material and its charge.
In order to translate the neutralizing current information into a value of residual charge on
the material the following steps need to be employed:
1. Record the parameters of each production situation which requires verification
- material and its gauge, material size (width for webs, width and length for sheets,
diameter of the finished roll for rewinders), material speed (fpm for webs, sheets per
minute for sheets), ambient temperature and humidity, and other pertinent information
of the process engineer’s choice.
2. Record the Ion Output value displayed by the 8200 MANAGER.
3. Record the polarity and value of the Neutralizing Current.
This will generally be constant when the material speed and the distance between the bar
and material, do not vary. In cases of unwind and rewind, the neutralizing current is
inversely proportional to the distance, and therefore the number of lit segments will be
changing throughout the run. In rewind applications, the user may choose to perform the
verification at the end of the roll.
4. Using Ion Systems Industrial’s electrostatic fieldmeter Model M770 determine the
electrostatic potential of the material before and after the bar, or with the bar on and off.
Record the polarities and values of the electrostatic potential. An example of the
verification record is shown in Table 3.
Table 3. Verification record format.

Date Ambient Neutralizer Material Material Roll dia. Material Ion Neutr. Static Potential
conditions location /gauge width if applic. speed Output, Current,
µA µA Without With
bar bar
1/15/08 Dry cold Coater PP/2mil 60" N/A 600 fpm 80.0 -8.0 +30 kV +2 kV
day head exit

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5. Repeat this procedure several times to verify that the “Neutralizing Current” display Troubleshooting Chart
corresponds to the reduction of the electrostatic potential on the material.
6. Subsequent to the initial establishment of the verification parameters, the verification Symptom Check Action
can be done regularly but infrequently. In the Scan Stations None Press the View Station key in the
mode, 8200 displays 8200 when the scan goes through
“Alr” when the scan the alarming station
goes through address
6. MAINTENANCE “0”, and indicates
station address in the
Neutralizing Current
WARNING! Before carrying out any maintenance or display
service work on the neutralizing bars switch off the
power supply. 8200 displays “F1” Go to the 8154 of the alarming Press and release Reset Alarm
or “F2” alarm, 8154 station and check the status of key in the 8200
When the “Cb” clean bar indicator appears in the 8200 high voltage output the Status LED to confirm it’s
display, it’s time to clean the ionizing electrodes in the bar. has automatically flashing red
turned off
Choose a moment when the line is down; turn off the
8154. The Ion Output display in the View The 8154 turns on If the LED stays green, it If the “F1” Fault indicator comes
Station will show “OFF” and the LED in and the LED turns could have been false alarm; if on again and the HVPS shuts off,
green; after a couple after a couple of seconds the the 8154 has failed. Contact Ion
the 8154 will go out. of seconds the LED LED starts blinking red, the Industrial.
Using a brush with stainless steel or brass starts blinking red problem is legitimate; check
bristles, clean the pins of the bar as again. the 8200 display for the type of If the “F2” Fault indicator comes
Figure 37. the alarm indicator “F1” or on again and the HVPS shuts off,
shown in Fig. 37. Cleaning the ionizing “F2”. examine all high voltage wiring,
Enable the output. Verify that the “Cb” electrodes of the cable plugs, power strip and
indicator is no longer appears and the “Ion bar with a brush. other connectors for signs of
Output” value is up to the level at the beginning of the high voltage breakdown. Contact
Ion Industrial.
previous maintenance cycle.
The Neutralizing 1. Check the green LED in the
CAUTION! Deposits on electrodes and bar surface, such as grease, ink, glue, Current display 8154 unit in the alarming
paper dust, etc., can be removed using swabs dipped in isopropyl alcohol. Allow shows the word station – it should be lit
alcohol to evaporate before putting the bar back in operation. Do not soak the bar “Bar”
and cable in any other solvents! 2. Check that the bar or bars If necessary, restore the proper
are securely connected to the wiring and connections.
output of the 8154 and
extension cables and/or VAC
Power Strip.
7. TROUBLESHOOTING If the alarm remains, thoroughly
clean the ionizing electrodes of
Troubleshooting Chart the neutralizing bars.

If, after the cleaning, the alarm

CAUTION! The Fault alarm may not function properly if the total high voltage
message remains, contact Ion
cable length connected to the 8154 power supply exceeds the maximum Industrial.
specified length.

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Troubleshooting Chart (continued) Equipment Service Life
Electrical static charge neutralizers are designed to operate at high voltages which
Symptom Check Action inherently expose them to high electrical tension. Such conditions put certain physical
8200 is not 1. Check communication and Restore wiring if is not done limits to the life of these products.
displaying one or power wiring. correctly and recycle network All components of the Virtual AC Neutralizers are designed for maximum reliability and
several stations power. If no change, proceed the longest possible life expectancy. Users should expect up to 5 years of trouble-free
with check step 2.
service for 8154 POWER MODULES, 5-7 years for the neutralizing bars and over 10
2. Check the positions of the Set all BYPASS switches to OFF years for the 8200 MANAGER.
BYPASS switches in the 8310 for the 8310’s with 8154’s This information should be used as a general guideline and the individual service life for
units. connected to them, and to ON components will vary. The actual component service life depends on many variables,
for the 8310’s without 8154’s
connected to them. Recycle the including the ambient operating conditions where the components are installed and the
network power. If no change, ratio of high voltage time on and time off. Specifically, utilizing system-provided features
proceed with check step 3. for the remote power supply activation and applying the high voltage only during actual
production time will extend service life of power supplies and neutralizing bars.
3. Some of the 8154’s must At the 8310’s, disconnect the Performing regular maintenance on the bars, keeping them clean and in good repair will
have duplicate addresses. communications wires coming
from the 8154’s. Reconnect each also extend their useful lives.
8154 individually to determine It is also recommended to evaluate the static neutralizing bars for replacement after five
their addresses. years of service in light-duty environments and after three years of heavy-duty service.
When that time comes, contact Ion Industrial to help you evaluate your options.
WARNING! If you need to take the 8154 out of service you must connect the
connector pins of the neutralizing bar or bar cable to electrical ground.
Equipment Repairability
Note: If you suspect that accumulation of conductive residue on the surface of the bar
The design of the Virtual AC equipment often allows for component repair, and users
causes the Fault alarm, try washing the encapsulated surface between the ionizing
should contact Ion Industrial for potential repair before discarding a failed component.
electrodes with isopropyl alcohol. If this cures the problem, determine the source of the
Virtual AC 8154 POWER MODULES are repairable for most circuit malfunctions and
residue. If it can not be avoided, establish a regular maintenance schedule.
failures, extending their useful life by many years. Some other bar failures can also
potentially be repaired, and users should contact Ion Industrial to evaluate their options.

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8. SPECIFICATIONS 8200 MANAGER master controller
(U.S. Patent 5,930,105; 6,088,211; 6,130,815; 6,259,591; others pending)
High Voltage Power Supply Model 8154 Input Voltage: 24 volts dc at 0.2A max
(U.S. Patent 5,930,105; 6,088,211; 6,130,815; 6,259,591; others pending) Displays:
Input voltage: 24VDC Ion Output 3-digit LED
Input current: 0.4A max Neutralizing Current 3-1/2-digit LED
Output voltage: 10 kV peak nominal Station Address 1-digit LED
Output power: 10 watts each output Keys: On/Off, Alarm Reset, Scan Stations, View Station,
Output current: 1.5 mA max (short-circuit protected) Set Clean Bar
Ion Output range: 900 µA Maximum number of stations: 9
Neutralizing Current range: ±500 µA Power & communication
Ambient operating temperature: 0°C to +50°C (32°F to 122°F) connections: RJ11-6 and WAGO-type terminal blocks
Communications: Modbus RTU over RS485 Dedicated power connector: 2.1 mm DC socket
Maximum load (bar length): Up to 400 inches (10 meters) of 8001KDT bars Remote connector:
with up to 32 ft. (10 meters) of high voltage cable Clean bar signal NO/NC/COM
High voltage connections: Terminals with 6-32 threaded holes Fault signal NO/NC/COM; the relay energized under no-alarm
Power & communication condition
connections: WAGO terminals HVPS activation ON EXT/OFF EXT/GND
Dimensions: 10” x 4.72” x 3.56” (254 x 120 x 90 mm) Relay contacts rating: 1A @ 24 volts dc and 0.5A @ 120 volts ac
Weight: 2 lb 3 oz (1 kG) Weight: 12 oz (0.34 kG)
Enclosure IP rating: IP 54 Certifications: CE
Mounting: Wall-mount
Certification: CE 8310 CONNECTOR serial communication switch
Power & communication
connections: RJ11-6 or WAGO-type terminal blocks
Dedicated power connector: 2.1 mm DC socket
Ambient operating temperature: 0˚C to +50˚C (32˚F to 122˚F)
Enclosure IP rating: IP 20
Certifications: CE

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Neutralizing Bar Model 8001KDT
(U.S. Patent 5,930,105, 6,330,146; and European Patent 0 871 267)
Type:
Ionizing electrode material:
Ionizing pin spacing:
Maximum material speed:
Maximum operating distance:
Cable
Housing material:
Ambient operating temperature: 0˚C to +50˚C (32˚F to 122˚F)
Standard bar lengths
(effective length):
Certifications:
8200-8154 Manual
19-8154-8200-M
Shockless, nominal pin short-circuit current
80 mA RMS
Tungsten
1” (25.4 mm)
Neutralizes charged webs traveling over 2500 fpm
(800 m/min)
Starts neutralizing rewind rolls from 20” (500 mm)
(efficiency depends on roll charge)
Integral cable, 6-ft. (1.8 m) standard in a protective
plastic conduit with a Universal V.AC cable plug;
axial cable exit, cable bend radius 2” (50 mm)
Fiberglass-reinforced polyester, UL flammability
rating V-0
3” (75 mm) min. to 119” (3000 mm) max. with
2” (51 mm) length increments
CE
54 Version 3.0
24VDC Power Supplies
Part No. Description
14-1147 Power Supply, Switching, 24VDC, 1.1A, 25W, 3.8” X 3.87”, panel mount
14-1148 Power Supply, Switching, 24VDC, 1.8A, 40W, 3.8” X 5.07”, panel mount
14-1149 Power Supply, Switching, 24VDC, 2.5A, 60W, 3.8” X 6.25”, panel mount
14-1150 Power Supply, Switching, 24VDC, 4.5A, 100W, 3.8” X 6.26”, panel mount
14-1151 Power Supply, Switching, 24VDC, 6.5A, 150W, 3.8” X 7.5”, panel mount
14-21182 Power Supply, Switching, 24VDC, 2.5A, 60W, 2.1mm,
130 X 60 X 32mm, desk top
14-1130 Power Supply, Switching, 24VDC, 2A, 45W, 3.07” X 3.66”, DIN rail
14-1132 Power Supply, Switching, 24VDC, 2.5A, 60W, 3.07” X 3.66”, DIN rail
14-1134 Power Supply, Switching, 24VDC, 5A, 120W, 3.93” X 4.93”, DIN rail
9. WARRANTY AND SERVICE
New Products Warranty
New Virtual AC Neutralizers are guaranteed to be free from defects in material or
workmanship for a period of twelve (12) months from one week after the date of initial
shipment.
MKS Ion Industrial’s liability under its new product warranty is limited to servicing
(evaluating, repairing, or replacing) any unit, free of charge, that has not been subjected to
misuse, neglect, lack of routine maintenance, repair, alteration, or accident. In no event
shall MKS Ion Industrial be liable for collateral or consequential damages.
Serviced Products Warranty
All products serviced by a certified MKS Ion Industrial technician are guaranteed to be
free from defects in new materials or workmanship for the longer of ninety (90) days from
date of service or the remaining New Product Warranty period for the product being
serviced.
MKS Ion Industrial’s liability under its service products warranty is limited to reservicing
any unit, free of charge, that has not been subjected to misuse, neglect, lack of routine
maintenance, repair, alteration, or accident. In no event shall MKS Ion Industrial be liable
for collateral or consequential damages.
Call MKS Ion Industrial for service information.
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10. APPENDIX A. Neutralizing Current
a. If the neutralizing bar was installed correctly, the Neutralizing Current reading will be
between 0 and 0.5 microamperes when there is no charged material in the vicinity of the
Expected values of Ion Output and Neutralizing Current
neutralizing bar. However, if there are machine frame components or rollers, or other metal
The system constantly monitors two parameters for each neutralizer, Neutralizing Current objects too close to the neutralizing bar, the Neutralizing Current value will be higher. The
and Ion Output. value of the current is equal to the amount of ion current flowing to the metal components.
The polarity of that offset is usually negative.
Ion Output b. Neutralizing Current indicates the ions going to the charged material. The polarity of the
The Ion Output value depends primarily on the length of the neutralizing bar or bars Neutralizing Current is opposite to the polarity of the charge on the material. There is no
connected to the same high voltage power supply. way of predicting the value of the Neutralizing Current. The higher the charge on the
a. For a brand-new bar, you may see readings in the range from 30-50 microamperes for a material, and the faster the material speed, the more ions go to the material and the higher
12-inch (300mm) neutralizing bar to over 400 microamperes for bars with a total length the Neutralizing Current values. You may see anything in the range from 1 microampere
of 200 inches (5 m). See the table below for the average expected Ion Output values for for neutralization of slow webs with low charge or at start of roll on a winder, to over 100
8001iP and 8001KDT bars of different effective lengths. The actual values may vary microamperes for a fast moving, highly charged web. The neutralizing current value also
±25% off the average value in the table. depends on the width of the web. If the material is neutral, the Neutralizing Current should
be close to zero.
EL, inch 20 40 80 120 160 200
c. The Neutralizing Current value will generally be stable when the material speed and the
IO, microamperes 81 127 198 257 309 357 distance between the bar and material do not vary. In cases of unwind and rewind where
b. It is common for the ion output of all static bars to drop 5-10% during first days of the bar is installed at a fixed distance to the core, the neutralizing current is inversely
operation. That is the nature of ion generation where sharp points of new electrodes lose proportional to the distance, and therefore, the ion current value will be changing
their initial sharpness, dropping the initial level of ion production. throughout the roll cycle.
c. After the initial drop, a user can expect a gradual decline of the ion output over the life
of the bar, totaling about 50% in 2-5 years depending on the neutralizer’s duty cycle and
ambient environment.

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