INSTRUCTIONS Operation / Maintenance scorpION3™ Ionizing Bar
Contents
1. Typical Discharge Time Reduction 10 30 50 60 65 Table 6 3 scorplON2 with Air Assist Typical Discharge Time Reduction The typical recommended operating pressure for the scorplION3 with Air Assist is 200 kPa 30 psi Pressures less than 50 kPa 7 5 psi may provide an air purge but provide little overall reduction in discharge times Pressures greater than 300 kPa 45 psi increase air consumption without providing significant gains in discharge time reduction Compressed air or nitrogen must be clean dry and oil free SECTION 7 Maintenance The scorplON3 bar is designed to require minimum maintenance cleaning and calibration There are no user serviceable parts within the scorplON3 bar No attempt should be made to disassemble or repair defective products Please contact SIMCO customer service for information concerning repair or replacement Periodic cleaning of system emitters will make a valuable contribution to optimum system performance and emitter life All corona ionization systems form deposits on the emitter tips over time The majority of these deposits are the result of the interaction of moisture vapor with the electric field around the emitter The emitter material has little or no relationship to the formation of these deposits Your process and system performance demands must be considered when determining a suitable interval for emitter cleaning Maintenance frequency also depends on the cleanline2. asSiMCO An Illinois Tool Works Company INSTRUCTIONS Operation Maintenance scorplON3 lonizing Bar System US Patents 6 252 756 and 6 417 581 6 826 030 international patents pending Phone 215 997 0590 Fax 215 997 3450 2257 North Penn Road Hatfield PA 19440 Publication 5200969 Rev A May 2007 The scorplON3 bar system is an ionization solution for work areas and OEM mini environments Intended for cleanroom applications the bar is available with silicon carbide ion emitters for the cleanest ionization available ScorplON3 s flexible design allows independent or dependent operation of multiple bars in a system 24VDC operation allows easy installation in OEM semiconductor and wafer processing tools Set up and adjustment is easy with the two way communication provided by the scorplION3 MMI man machine interface or Cl computer interface The computer interface also offers real time monitoring of ScorplION3 system performance SECTION 1 Description casiasriiiecddtitominuerrueuntaiiminiaioemimanbinns 2 SECTION 2 STe E A wocswccesctocccuduecerercweceweucuaceueeweceweueweceweuwucs 2 SECTION 3 att AU 2 eee ee 3 SECTION 4 SDECIICANONS ce iidacseudisieiniinincmnnhuniennidenmeneihams 4 SECTION 5 Installation seasacteectded ieeaeseda cd picasa css 6 Mounting Considerations cssccsesessseeeeeeees 6 Wiring Considerations ccsccsssseeseeeeeeenees 6
3. pulse time overlap balance fault threshold HV on off w fault fault contact 1 not present if in steady state save local to bar not present if slave save as preset IR DIAGNOSTICS NAVIGATION feedback fault status accumulators bar information serial number reset bar command point MMI amp enter execute ADDRESS TEST searching for address conflicts accept or change address conflicts change desired address HOT KEYS up amp left jump to top of menu up amp right jump to save settings local to bar down amp right _ jump to fault status accumulators down amp left jump to feedback program current drive monitors left amp right jump to balance adjustment Hot Keys are NOT enabled SIMCO Ionization for Electronics Manufacture Publication 5200969 22 Appendix B Fault Status Code Reference Guide Fault Message Possible Causes Potential Actions Number in order of occurrence 0 No Faults N A N A 1 Positive lon Output Emitters need cleaning Clean emitters Too Low Emitter housing or emitter Check emitter housing amp electrode not seated emitter electrode seating HV open circuit Reduce lon Output setting Pos HV supply is faulty Replace emitter electrodes Replace Pos HV supply Replace bar 2 Negative lon Emitters need cleaning Clean emitters Output Too Low Emitter housing or emitter Check emitter housing amp
4. Bar Configuration ccccccssscssseesseeeeeseesseeeeeseees 8 Multi Bar Installations ccssseeeeeseeeeees 8 Air Assist optional c ccccesseeceeesseeeeeeeseees 9 Man Machine Interface MMI ss scee 9 Computer Interface Cl cccsssceeesseeeeeeeeees 15 SECTION 6 Operaatio icsienetsietesctedinsssasetinncacinenssantiasadinncel 16 Setup Recommendations sccceseesseeeeeens 17 SECTION 7 Maintenance ccccccceceeeeeeeeeeeeeeeeeeeeeeeeeeeneeees 18 Cleaning the Emitters c ccssesssesseeeeeeeeees 19 System Calibration cccssccseeeesecssseeeseeeeeeees 19 System DiaQnOstics csccsseeeeeseceeeeeeseeeneeeees 20 SECTION 8 Replacement Parts ccccccessssssseeeeeeeeees 20 SECTION 9 DD GNOIX vicancittscenascatsstsaninadacadadsndssnananasanandens 21 A MMI Navigation Reference Guide 21 B Fault Status Code Reference Guide 23 SECTION 10 Warranty iicinnidanedennintrinnicinianmccinncinvenentamnicieesin 24 SIMCO lonization for Electronics Manufacture Publication 5200969 1 SECTION 1 Description The scorplON3 bar utilizes SIMCO s innovative and effective microcontroller intelligent ionization technology The system provides rapid neutralization of static charges over a localized work area or a mini environment It is the most flexible and efficient system available capable of eliminating electrostatic discharge ESD and preventi
5. bar pulse rate When no master bar is present bars with non zero addresses will operate independently The bar address is used to ensure that operating adjustments are made only to the desired bar during set up and calibration The bar address is also used to identify operating parameters and alarms downloaded from a multi bar system Multi Bar Installations For multi bar installations power is distributed via the RJ 11 connector with 6 conductor modular cable and bars must be chained together via this connection Note that in this configuration adequate current must be available for multiple bars and the maximum SIMCO lonization for Electronics Manufacture Publication 5200969 8 rating on the DC power supply should not be exceeded Bar address numbers should not be duplicated on a given chain Having more than one bar 0 will cause communication conflict on the chain Address 0 designates the bar as the master and other bars if designated as slave attached to the chain will pulse synchronously with the master Where the user supplies appropriate power to the system up to 9 bars may be connected to the master In cases where a combination of steady state and pulse coverage is required with multiple bars a bar or bars within the system can be set to the independent class Air Assist optional If the scorplION3 bar has Air Assist the inlet fitting will be located on the end of the bar with the fault output jack This fitting
6. electrode not seated emitter electrode seating HV open circuit Reduce lon Output setting Neg HV supply is faulty Replace emitter electrodes Replace Neg HV supply Replace bar 3 lon Output Too Unable to drive lon Clean emitters Low Output from either supply Check emitter housing amp as currently set emitter electrode seating Emitters need cleaning Reduce lon Output setting Emitter housing or emitter Replace emitter electrodes electrode not seated Replace HV supplies HV open circuit Replace bar HV supplies faulty 4 lon Output Too Excessive drive levels Clean emitters High Emitters need cleaning Increase lon Output setting Bar located near ground Adjust Balance setting plane or arcing Adjust humidity or airflow HV short circuit Relocate bar or ground plane NV supplies faulty Replace bar 5 Positive lon Output Emitters need cleaning Clean emitters Too High Bar located near ground Adjust Balance setting plane or arcing Increase lon Output setting HV short circuit Adjust humidity or airflow Relocate bar or ground plane Replace bar 6 Negative lon Emitters need cleaning Clean emitters Output Too High Bar located near ground Adjust Balance setting plane or arcing Increase lon Output setting HV short circuit Adjust humidity or airflow Relocate bar or ground plane Replace bar 7 Program Voltage I O board fault Replace I O board Error Replace bar 8 Pos Control Error I O board fault Replace I O bo
7. result in damage to the scorplON3 bar Interconnection between bars should be made only with SIMCO supplied interconnect wiring A factory qualified service technician must perform component service and repairs Please contact SIMCO Customer Service at 215 997 0590 for information SECTION 2 Features scorplON3 Low Voltage Bar Closed loop feedback system monitors operating conditions Individually adjustable via hand held MMI 10 unique addresses are available Replaceable emitters Silicon carbide for ultra clean environments or tungsten standard emitters Easy mounting using included hardware MMI hand held Allows addressable control of up to 10 individual bars Remotely adjusts ionization parameters for calibration Acquires diagnostic information from the system Two way communication enables display of operating status and system monitoring Detects address conflicts on bus allows user to resolve CI computer interface Provides Ethernet connection for networking Remote set up monitoring and control Connection to other scorplON3 computer interfaces Automatically addresses and resolves bar address conflicts SIMCO lonization for Electronics Manufacture Publication 5200969 3 SECTION 3 Specifications scorplION2 3 AC Adapter Input Output scorplION3 Bar Input Power Pulse Rates Pulse Overlap Output Connector LED Indicators Address Control Mode Control Communica
8. 0 adjusting the balance with the up down arrows causes the balance ratio to shift by 0 01 steps Press the Enter button to transmit the new setting to the bar Note Save settings local to bar must be performed after adjustments to balance are made to ensure the changes are stored in the bar memory Hot Key Tip Pressing the left arrow and right arrow at the same time will jump the MMI menu to the balance menu SIMCO Ionization for Electronics Manufacture Publication 5200969 12 Fault Threshold default 20 is the relative number of times the microprocessor must encounter a fault condition before it signals the fault state Using a threshold to trigger a fault state reduces nuisance alarms Increasing the threshold reduces the likelihood of encountering nuisance fault notification HV_on w Fault default yes allows disabling of the ionizer by turning off the high voltage power supplies if a fault state is entered Fault Contacts default N O allows setting of the Fault Output opto isolated transistor as N O normally open or N C normally closed Save settings local to bar default no Saves the changes made to the operating parameters for the bar into the memory of the bar Y must be selected with the down arrow then ENTER pressed to save settings The green indicator lights on the bar and MMI will flicker to confirm saving of settings This operation must be performed to ensure the changes will not be lost Hot Key Tip Pre
9. 40 ome 100 20 sec pulse 1 75 sec 30 40 50 45 sec pulse 2 50 sec 50 50 24 O ae Ee 30 sec pulse 3 00 sec 50 50 50 60 sec pulse 4 00 sec 70 60 Poora 100 40 sec pulse 5 00 sec 60 60 Table 6 2 Typical Setup Recommendations in still air no airflow Not recommended for use at less than 300 mm 12 inches Measures of performance should be made using the test methods described in either your company methods and standard practice or industry standard ESD STM 3 1 IONIZATION Section 6 2 laminar flow hood ionization A Charge Plate Monitor that meets the requirements of ESD STM 3 1 should be used for this purpose SIMCO Ionization for Electronics Manufacture Publication 5200969 17 During normal operation the Positive lon and Negative lon indicators on the scorplION3 face label will glow green If the bar is in the steady state mode the indicators will glow continuously If the bar is in the pulse mode the indicators will flash alternately with both on during overlap indicating ion output If a fault occurs the indicator color will change to red The indicators will typically briefly flicker to show the receipt of IR commands from the MMI The scorplON3 bar with Air Assist will provide reduced discharge times Compressed air will reduce discharge times according to the following table Operating 50 kPa 100 kPa 200 kPa 300 kPa 400 kPa Pressure 7 5 psi 15 psi 30 psi 45 psi 60 psi
10. Network Interface Power Indicator Fault Indicator Dimensions Enclosure Software OS 24VDC 200mA from bar system chain RJ 11 modular connectors or User Interface terminal block RJ 11 modular jack modular wire power amp communication RJ 11 modular jack modular wire full duplex communication Ethernet RJ 45 modular connector Green LED Red LED 84mm x 211mm x 34mm 3 30 x 8 30 x 1 35 Stainless Steel Windows 2000 Wiindows XP SECTION 5 Installation NOTE Inspect packages for visible damage and report damage directly to the carrier ATTENTION Remove the shipping caps yellow or orange plastic from each emitter before placing ionizer in service The caps protect the ion emitter points from damage during shipping but must be removed before use Mounting Considerations Prior to powering up a single or multi bar system the ionizing bar s should be securely mounted using the provided hardware If the scorplON3 bar is mounted using hardware not provided with the unit it is important to keep any grounded hardware away from the emitter tips Introducing a ground near the emitter tips can affect ion balance and discharge times The bar should be installed so no grounded objects are within 300 mm 12 of the emitter face of the bar For applications with no airflow the bar should be positioned centered over the work area or the area where static control is desired For fan filter type applications where a
11. ard Replace bar 9 Neg Control Error I O board fault Replace I O board Replace bar 10 Internal Fault Hardware problem Check op amp on I O board Replace I O board Replace bar SIMCO lonization for Electronics Manufacture Publication 5200969 23 11 Pos Feedback 1 O board fault Replace I O board Error Faulty Pos HV supply Replace Pos HV supply Replace bar 12 Neg Feedback I O board fault Replace I O board Error Faulty Neg HV supply Replace Neg HV supply Replace bar 13 Feedback Error O Board fault Replace I O board Replace bar 14 Multiple Fault Must be interpreted by a Replace bar Simco technician 15 Communication Fault in RJ 11 connectors Check connections and Fault or modular cable modular cable SECTION 10 Warranty SIMCO Static Control and Cleanroom Products warrants its products to be free of defects in components workmanship or materials for a period of one year from the date of purchase This warranty does not apply to any physical or electrical damage done to the product through misuse or abuse or negligence such as any modifications made to the unit or service work done by any other than SIMCO authorized technicians Any unit that has had its serial number altered or removed will be ineligible for warranty All products returned must have an RA Return Authorization number regardless of warranty status Call SIMCO for an assigned number SIMCO will not be lia
12. are adjusted at the individual bar or the master bar depending upon configuration The scorplON3 CI Computer Interface provides an interface between the scorplON3 bar system and a personal computer or local computer network With SIMCO s interface software a user may set up monitor or control the scorplION3 bar system from their computer The scorplON3 Cl provides for communication via an Ethernet connection SECTION 2 Safety Warning Do not operate this unit or other system components in a flammable volatile or explosive atmosphere 1 Read the complete Instruction Manual before proceeding with installation or operation Failure to follow instructions may result in damage to the scorplON3 system or user supplied power sources SIMCO lonization for Electronics Manufacture Publication 5200969 2 When this unit is supplied with the AC adapter the adapter must be used with a 3 prong grounding plug The adapter must be connected to a properly wired and grounded receptacle Do not defeat the electrical ground Grounding and proper wiring are required for operation User supplied 24VDC power must conform to the electrical characteristics as outlined in this document Incorrect power connections to the bar can result in damage to the scorplON3 bar and or to user power supply User connections to the fault output must conform to the limitations outlined for the opto isolated transistor Incorrect connections to the fault interface can
13. ations The factory default settings for the scorplION3 are for a typical tool or mini environment installation with the scorplON3 bar installed under the filter fan top of the unit and a target distance of approximately 600 mm 24 The following tables contain recommendations for starting setup points and supply typical performance from the scorplION3 bar Actual performance will vary depending on your particular operating conditions bar length airflow temperature humidity obstructions and other environmental influences specific to your application Offset Discharge Approximate Voltage Time Bar Pulse Time Pulse Output Distance nominal nominal Mode Setting Overlap Level 300 mm 12 15 6 sec SS i 30 10 10 sec SS 40 450 mm 18 30 9 sec pulse 0 50 sec 0 40 60 7 sec pulse 1 00 sec 0 40 10 15 sec SS 50 600 mm 24 30 12 sec pulse 0 75 sec 30 50 60 10 sec pulse 1 25 sec 30 50 10 18 sec SS 60 750 mm 30 30 15 sec pulse 1 00 sec 50 60 60 12 sec pulse 1 50 sec 50 60 Table 6 1 Typical Setup Recommendations in 0 5 m s 90 fpm airflow Offset Discharge Approximate Voltage Time Bar Pulse Time Pulse Output Distance nominal nominal Mode Setting Overlap Level 50 30 sec pulse 0 50 sec 0 30 SOOT 100 15 sec pulse 1 00 sec 0 30 50 30 sec pulse 1 50 sec 30
14. ble for loss or damage due directly or indirectly to an occurrence or use for which the product is not designed or intended In no event shall SIMCO be liable for incidental or consequential damages except where state laws override This warranty extends to the original purchaser and is not transferable No person agent distributor dealer or company is authorized to change modify or amend the terms of this warranty in any manner whatsoever Information in this document is subject to change without notice and does not represent a commitment on the part of SIMCO No part of this manual may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying and recording for any purpose other than the purchaser s personal use without written permission of SIMCO SIMCO An Illinois Tool Works Company 2257 North Penn Road Hatfield PA 19440 Phone 215 822 2171 800 538 0750 Fax 215 997 3450 http www simcolON com e mail simco itw com SIMCO lonization for Electronics Manufacture Publication 5200969 24
15. ce The scorplON3 Cl Computer Interface provides an interface between the scorplON3 bar system and a personal computer or local computer network via Ethernet connection With SIMCO s monitor software a user may set up monitor or control the scorplON3 bar system from their computer The computer interface contains two RJ 11 connectors for direct connection to the scorplON3 bar system two RJ 11 connectors for connection to other Computer Interfaces and an RJ 45 connector for connection to a personal computer or local computer network power indicator fault indicator Faull ScorplON3 Bi 7 TT f 7 ea RJ 45 RJ 11 RJ 11 Ethernet scorplON3 Cl scorplON3 bar Woo o C3 g O O Ar ok ter Interface S terminal block optional power in fault out connector The green LED Power indicator illuminates to indicate power and flickers if an MMI is on the system chain transmitting commands The red LED Fault indicator illuminates if the CI doesn t detect bars on the system chain one of the bars on the system chain is resetting or if any of the bars on the system chain is in a fault condition Where a computer interface is used on the system chain it is necessary that any MMI on the system chain remain turned off during power up of the system chain Once the system chain is powered then the MMI may be turned on to access the system If the MMI is connected to the system chain an
16. d isopropyl alcohol These items may be obtained from local cleanroom product suppliers 3 The TX726 CrushTube swab is shipped with a protective sleeve covering the white foam swab end Remove the protective sleeve to expose the swab end Discard the protective sleeve The CrushTube swab has an inner glass vial of alcohol inside of a plastic tube Crush the inner glass vial by squeezing the plastic tube then tilt the foam swab end down to allow the alcohol to wet the swab Carefully insert the wetted swab onto the emitter point slowly rotate the tube and withdraw Repeat until all deposited material has been removed Each CrushTube swab may be used to clean from 5 to 8 emitter tips depending on the amount of material on each tip When the swab fails to remove the material a new swab should be used Clean all the emitter electrode points 4 The bar housing can be cleaned using a cleanroom wiper or soft cloth as appropriate 5 Allow all alcohol to evaporate before applying power to the bar 6 It is recommended practice to develop a regular cleaning schedule that meets your requirements and operating conditions System Calibration System calibration is a complete analysis of performance and includes any adjustments that may be necessary to restore the system This should be performed after maintenance and cleaning of the emitters has been completed Adjustment to output level first and ion balance settings second should be made only a
17. d turned on during power up of the system communication with the computer interface may be impaired SIMCO lonization for Electronics Manufacture Publication 5200969 15 The computer interface normally draws power from the scorpION3 bar system via the RJ 11 connectors However the computer interface may serve as the source of power for the bar system When using the computer interface to power the bar system the user must supply 24 VDC via the plug type terminal block labeled user interface Connect pin 1 to ground return pin 1 ground pin 5 NO and pin 2 to 24 VDC Users connecting to the pin 2 24VDC pin 4 COM scorplION3 in this way should be ready to pin 3 NC supply 200mA per bar connected plus 200mA for the computer interface The user interface terminal block on the computer interface also provides relay contact output for the fault alarm Pin 4 is Common Pin 3 is Normally Closed Pin 5 is Normally Open The relay contacts are rated for a maximum of 1 A at 30 VDC resistive with a maximum switching voltage of 220 VDC The Computer Interface will automatically resolve bar address conflicts where more than one bar on a system chain has the same address number This feature is required to make the software function properly In the event of duplicate bar addresses on a system chain the Cl will assign the next available address to the newest bar on the chain Bars that have been on the chain and have establish
18. e provides a comprehensive listing of menus available through the MMI IR mode is automatically enabled when the MMI is turned on and not connected to a bar system chain The first menu allows selection of adjusting a Bar or Preset If Bar is selected the MMI will prompt the user to point the MMI at the bar and press enter The MMI and scorpION3 bar feature narrow angle IR transceivers to minimize undesired IR cross talk It will be necessary to align the MMI and bar IR transceivers to ensure communication Pressing the Enter button establishes communication with the bar The green lights on the bar and the MMI will flicker indicating successful communication of the operating parameters The MMI will display the bar address and serial number while requesting confirmation that this is the desired bar Confirming the bar address in the IR mode will enable the MMI to enter Setting or Diagnostic mode The operation of these modes is virtually identical for both the IR mode and the Wired mode Wired mode is automatically enabled when the MMI is turned on and connected to a bar system chain The MMI will offer the option of running Adr Test an address test mode Adr Test address test is typically used during the initial set up of multi bar systems address test is also used when new bars are added to an existing bar system Address test evaluates the system for bar address conflicts where more than one bar has the same address number and guides the
19. e up down arrow buttons The bar address number in the system will appear on the MMI display and the indicator lights on the selected bar will flicker to confirm which bar in the system is selected Pressing the right arrow button when the desired bar is displayed will enter a series of options for that bar NOTE the following bar parameters are temporarily stored in the MMI The parameters in the MMI will appear as NEW The parameters operating in the bar will appear as SET To transmit the NEW parameters press the Enter button The green lights on the bar and the MMI will flicker indicating successful communication of the data and the SET will update to the new setting Changed parameters are held in a temporary memory until the command save settings local to bar is performed When this command is performed the parameters in the bar are synchronized to the parameters in the MMI and stored in a flash memory in the bar If save settings local to bar is not performed and power is removed from the bar the changes will be lost Change Address allows changing of the address number for the bar O thru 9 are possible bar addresses active bar addresses will not be offered The desired address is selected by up down arrow button Settings enters a series of menus that use two way communication with the bar for adjustment and set up purposes The setting mode may be entered from the Change Address menu Following are selections fro
20. ed addresses will not have their addresses changed The process of testing and correcting duplicate bar addresses may take several minutes therefore when adding a bar to an existing system that has a Computer Interface allow the system to run for approximately two minutes undisturbed The personal computer software available with the Computer Interface provides continuous monitoring of the bar system set up and operating parameters the ability to adjust parameters and display of diagnostic information Detailed information on the Computer Interface and software is available in publication 5200968 scorplON3 Monitor Software user manual SECTION 6 Operation Measures of system performance vary according to environmental factors including airflow velocity air turoulence presence of large grounded objects and the distance from the emitter to the test instrument Operating parameters can be adjusted to compensate for much of the variation common to the workspace or mini environment Increasing output current and or lengthening the pulse time can reduce discharge times but will also affect the relative level of space charge and emitter life expectancy Increasing overlap can reduce space charge in pulsed mode Balance adjustment should be made after setting output current pulse time and overlap Adjustments must be saved using save settings local to bar SIMCO Ionization for Electronics Manufacture Publication 5200969 16 Setup Recommend
21. fter the emitters have been cleaned and after every emitter cleaning or replacement Adjustments must be saved using save settings local to bar or they will be lost when power is removed from the bar Standard system tests include charge discharge time and offset voltage Test data should include temperature humidity and air velocity Tests of the system are made in accordance with ESD STM 3 1 IONIZATION Section 6 2 laminar flow hood ionization Contact SIMCO for information concerning test instruments and services SIMCO Ionization for Electronics Manufacture Publication 5200969 19 System Diagnostics System diagnostics are available through the Man Machine Interface MMI and the Computer Interface Cl Diagnostic information available includes the operating parameters the bar has been set to the value the bar is operating at and if any fault status exists a fault status is typically when the operating value is consistently unable to achieve set operating parameter The system diagnostics can be accessed through the MMI by wired or IR communication with the scorpION3 bar When the diagnostic menus are entered the MMI downloads settings and operating data from the bar This information is displayed in a series of menus on the MMI A further description of this information is available in the MMI section of this instruction manual and in the appendix System diagnostics are also available through the Computer Interface The compute
22. ght arrow at the same time will jump the MMI menu to the Fault Code Status Screen Bar Info Screen shows the bar Software Version number bar serial number the Up Hours total run time for the bar and Time a reset able timer for maintenance Bar Reset Screen shows the bar address and first four last four digits of the bar serial number to confirm bar and allows resetting rebooting of the bar software Settings not saved local to bar will be lost Settings saved local to bar will remain Bar Reset will reset the Time the reset able timer to zero From Select Bar Preset or System Monitor review and adjustment of any of the 14 P1 through P14 preset operating parameters may be selected The menus under the Preset selection are the same as under the bar set up selection but may be saved as a one of fourteen convenient preset set up for downloading into scorplION3 bars At the SIMCO lonization for Electronics Manufacture Publication 5200969 14 end of setting the preset the preset number P1 through P14 may be assigned and the preset saved From Select Bar Preset or System Monitor the system may be monitored by selecting SYS This will activate a screen that shows the number of bars in the system This screen automatically scrolls through all bars in the system at a rate of approximately One per second The system address of a bar will appear along with its operating status and fault code if present CI Computer Interfa
23. irflow is present location relative to the target is less critical but for best result the bar should also be centered over the target area Wiring Considerations The scorplON3 may be configured for independent operation or configured for multiple bar installations In multiple bar installations one bar may be designated as the master and serve as the system controller by assigning it to address 0 zero SIMCO lonization for Electronics Manufacture Publication 5200969 6 For installations of up to 3 bars Simco s AC adapter power supply 1 8 3 5mm can be utilized Install all bars and mono interconnect wiring before applying 4 power Plug the adapter power cord phone jack into a grounded electrical outlet of 100 to 240 VAC 50 or 60 HZ Connect the adapter to one of the scorplON3 bars with a modular RJ 11 cable The power will automatically connector be distributed to the other bars in the chain The scorplON3 bar has no on off switch so application of the 24VDC to the unit will turn it on and 1 4 tubing ionization will begin The power mene supply and wiring can be located as QC fitting desired by the user air assist only FAULT OUTPUT Note A bar that is powered this way will provide power to other bars connected to it via the RJ 11 modular connector In this configuration the SIMCO AC adapter power supply can power a maximum
24. is a 4 quick connect suitable for typical plastic tubing 1 4 OD polyethylene polyurethane nylon etc To make connection with the fitting insert the tubing until it stops To remove tubing from the fitting depress the collar on the fitting and pull the tubing out of the fitting Compressed air or nitrogen may be used however it must be clean dry and oil free While the maximum allowable input pressure is 700 kPa 100 psi the recommended nominal operating pressure is 200 kPa 30 psi MMI Man Machine Interface IR transceiver Adjustments to ion balance and ion output can be i made to the scorplON3 bar system by using the hand held MMI The MMI features a 4 line LCD display for setting the bar parameters and monitoring its operation The MMI uses an infrared transceiver for two way communication with the bar in IR Mode The MMI also has RJ 11 connectors that enable it to be connected inline with the bar system chain for two way communication by hardwired RS 485 in Wired o Mode Infrared communication is established by pointing the MMI at the IR transceiver on the bar The IR transceivers must be aligned to communicate the transmission reception cone is 15 Communication can typically take place at up to 3 meters 10 feet Successful two way communication is indicated by flashing green indicators on the bar and MMI If the MMI indicator flashes red the MMI was unable to Bn J establish two way communicatio
25. m the Settings menus Settings Advancing from this menu allows the selection of Settings or Diagnostics Following are selections from the Settings menus Hot Key Tip Pressing the up arrow and left arrow at the same time will jump the MMI menu to Settings Power default on may be turned on off up down arrows for an individual bar in a system SIMCO lonization for Electronics Manufacture Publication 5200969 11 Output default 50 may be adjusted for the bar Using the up down arrows adjusts the bar output setting Output level sets the ionization output from the ionizer This value should be set to the lowest level possible to achieve the desired discharge time Higher values of output will result in more ion generation which can reduce discharge time but may result in more frequent ionizer maintenance The system will limit maximum output in cases of long pulse time Pulse Steady default pulse allows selection of Pulse mode ionization or SSDC steady state DC ionization In pulse mode the positive and negative ionization will be energized in alternating sequence This provides quicker discharge times for still air but creates a mildly alternating peak offset voltage Steady state DC mode maintains constant output for both the positive and negative ionization This is more typically used where there is airflow to carry the ions to the target Slave Independent default independent allows for selection of the bar as a Sla
26. n and realignment RJ 11 connectors of the IR transceivers may be required a power switch SIMCO lonization for Electronics Manufacture Publication 5200969 9 The green indicator on the MMI is also used to indicate if the selected bar is operating normally with no fault alarms If the red indicator on the MMI is lit the selected bar is in fault alarm Hardwired communication is established by using 6 conductor modular cable with RJ 11 connectors to insert the MMI at any point in the chain Hardwired communication would typically be used where access to the IR transceiver on the bar was limited or difficult Used in this fashion the MMI taps into the RS 485 communication lines on the chain and provides feed thru for the 24 VDC power To enable the hardwired communication it is necessary to turn the MMI power switch off connect the MMI to the active bar chain and then turn the MMI power switch on The MMI will sense the power on the chain and activate the hardwired communication Turning the power switch off then on at any time will clear any temporary information entered into the MMI and return the display to the main menu In general navigating through the system menus is done with the left right arrow buttons The right arrow generally advances to the next menu and the left arrow generally backs up to the previous menu An MMI Navigation Reference Guide is located in the appendix the navigation guid
27. ng electrostatic attraction ESA of particles to surfaces The scorplON3 s design allows multiple bars to be connected together into a system that operates synchronously without the added expense and installation of a dedicated controller adding cost effectiveness to its features The scorplON3 bar incorporates integrated total communication capability This allows one bar to operate as both an ionization source and as a controller for additional scorplION3 bars The scorplON3 is designed to monitor and maintain critical operating parameters through the use of its microcontroller active self monitoring and automatic system correction A scorplON3 bar may be designated as a master it will then talk to the other bars connected to it via integrated RS 485 communication The master maintains contact with each bar to synchronize system operations Individual bars connected in a system monitor and store their own operating parameters If a problem should occur each bar has the capability to visually indicate a fault condition and also provide an output that can be integrated into system control hardware Adjustment of ion output and balance can be made to individual scorplION3 bars via the hand held MMI module Man Machine Interface which features two way communication with the bars via wireless infrared or hardwired RS 485 on a modular cable Individual bar addressing ensures adjustment of only the desired bar Operating mode and pulse frequency
28. no phone jack 1 E me or ee LED ScomiONs Bar Internal O tip IL tip Opto isolated transistor relay buzzer m sleeve v sleeve Config ued for N O or N C The fault output transistor may be used to provide switching in order to drive a variety of low current devices such as LEDs or buzzers relays may be used to switch power to higher power devices Fault Output Bar Configuration The scorplON3 bar has two ionization indicators and a window for receiving and transmitting commands via IR with the MMI they are incorporated into the scorplON3 face label on the front of the bar The indicators have multiple functions The main function of the indicator is to illuminate when the high voltage power supply is activated A green indicator shows that the bar is operating normally and no faults are present A red indicator shows that a fault is present The indicators will typically briefly flicker rapidly to show the receipt of IR commands from the MMI indicators IR transceiver SIMCO An Illinois Tool Works Company LV Bar ionizer Each scorplON2 bar can be assigned a unique address Addresses are numbers 0 9 and in multi bar systems each bar must have a unique address Address 0 designates a master bar and allows the master to send messages to other connected bars for pulse mode synchronization in multiple bar systems Note that any bar set to a non zero address and set to slave class will follow the master
29. ns Simco software version display test indicator LED test WIRED MODE select mode wired or address test wired searching select bar preset or sysmon bar scroll list LEDs on selected bar flash bar change address select settings or diagnostics WIRED SETTINGS NAVIGATION power output pulse steady state slave independent pulse time overlap balance fault threshold HV on off w fault fault contact 1 not present if in steady state save local to bar not present if slave save as preset DIAGNOSTIC NAVIGATION feedback fault status accumulators bar information reset bar command PRESET NAVIGATION select preset number P01 P02 P14 power output pulse steady state slave independent pulse time overlap balance fault threshold HV on off w fault fault contact 1 not present if in steady state save as preset not present if slave upload to bar Hot Keys are NOT enabled SIMCO Ionization for Electronics Manufacture Publication 5200969 21 UPLOAD PRESET NAVIGATION select bar enter execute transmit preset settings to bar SYSTEM MONITOR MMI screens rotation showing fault status code for each bar MMI LED s indicate bar fault status IR MODE NAVIGATION select bar or preset IR ACQUISITION 1 READBACK Point MMI at bar amp press enter accept bar address select settings or diagnostics IR SETTINGS NAVIGATION power output pulse steady state slave independent
30. of 3 bars For other installations 24 VDC power can be supplied via the RJ 11 modular connector Connect pins 1 amp 6 to the 24 volt supply voltage and connect pins 3 amp 4 to ground ground serving as the return for the supply voltage see table below Users connecting to the scorpION3 in this way should be ready to supply 200mA per bar connected Note The scorplON3 is internally fused to protect the user s power supply during this type of setup 1 6 RJ 11 MODULAR CONNECTOR N C No Connection Permitted PIN NUMBER 1 2 3 4 5 6 CONNECTION 24VDC N C GND GND N C 24VDC Ls Table 5 1 RJ 11 modular connector user connections RJ 11 Caution Connections or grounding of pins 2 amp 5 on the modular connector connector is not permitted and may result in malfunction or damage to the system The fault alarm may be remotely monitored using the fault output jack on the end of the bar The output jack is a 3 5mm 1 8 mono phone jack connected to an opto isolated transistor inside the bar The tip of the phone jack is positive collector and the sleeve of the phone jack is negative emitter The opto isolated transistor may be set normally open N O or normally closed N C by changing the Fault Contact setting with the MMI or through configuration software using the Cl SIMCO lonization for Electronics Manufacture Publication 5200969 7 aVt 3 5 mm 1 8 R s mo
31. orplON2 is available in the following sizes 457 mm 0 8 kg 18 1 8 Ib 610mm 1 0kg 24 2 1 Ib 914 mm 1 3 kg 36 2 8 Ib 1118mm 1 5kg 44 3 2 lb 1626 mm 2 0kg 64 4 3 lb 1880 mm 2 2kg 74 4 9 lb 21384mm 2 5kg 84 5 5 1b Bar Enclosure Reinforced Polycarbonate Mounting Brackets Stainless steel universal adjustable mounting centers Clamping thumbscrew Integrated 8 32 mounting nut scorplION3 Bar with Air Assist Air Inlet V4 QC Tube Fitting Input Pressure 200 kPa 30 psi recommended nominal 700 kPa 100 psi maximum clean dry air Air Consumption 5 1 Nm3 h at 200 kPa 3 scfm at 30 psi 8 5 Nm3 h at 400kPa 5 scfm at 60 psi 13 6 Nm3 h at 700 kPa 8 scfm at 100 psi Noise Level 76 GB at 200 kPa 30 psi 82 dB at 400 kPa 60 psi 88 dB at 700 kPa 100 psi Measured 600 mm 24 from bar MMI Module Output IR infrared and hardwired RS 485 Controls Up Arrow Down Arrow Left Arrow Right Arrow Enter Power on off Slide Switch Indicators LCD menu driven user interface Green red LEDs indicate transmit receive fault status Power Type 1604 standard 9 volt alkaline battery or from bar system chain when hardwired RJ 11 modular connectors Dimensions 110mm x 196mm x 32mm 4 40 x7 70 x1 25 Enclosure Impact resistant ABS SIMCO lonization for Electronics Manufacture Publication 5200969 5 CI Module Input Power Bar Connection Computer Interface Connection
32. r interface offers continuous monitoring of the bar system and display of diagnostic information This information is available on various screens presented via the host personal computer A further description of this information is available in the Computer Interface section of this instruction manual and in the appendix SECTION 8 Replacement Parts Part Number Description 4370971 Silicon Carbide Electrode 4370760 Tungsten Emitter Electrode 4107829 Emitter Housing without Air Assist 4108039 Emitter Housing with Air Assist 5051195 Modular Interconnect Cable 152 mm 6 5051168 Modular Interconnect Cable 406 mm 16 5051196 Modular Interconnect Cable 610 mm 24 5051183 Modular Interconnect Cable 914 mm 36 5051331 Modular Interconnect Cable 2 13 m 84 5051197 Modular Interconnect Cable 3 05 m 120 5051328 scorplON2 3 AC Adapter 24VDC Out 100 240VAC Universal Input with North American NEMA5 15P Japan Line Cord 5051329 scorplON2 3 AC Adapter 24VDC Out 100 240VAC Universal Input with European CEE7 Line Cord 5051330 scorplON2 3 AC Adapter 24VDC Out 100 240VAC Universal Input with United Kingdom BS 1363 Line Cord 4107405 Mounting Bracket with integrated 8 32 nut 4107878 Mounting Bracket with clearance hole for M4 or M5 8 or 10 screw SIMCO Ionization for Electronics Manufacture Publication 5200969 20 SECTION 9 Appendix Appendix A MMI Navigation Reference Guide START splash scree
33. ss and relative humidity of the environment In most cleanroom environments cleaning should be scheduled on a quarterly basis SIMCO recommends cleaning the system after 90 days After initial cleaning you may decide to adjust the cleaning schedule Emitter cleaning frequency is determined through observation Cleaning does not harm the emitters and regular cleaning of emitters removes deposits that can reduce emitter life and affect system performance ScorplON3 operation calibration should be checked whenever the emitters are cleaned SIMCO Ionization for Electronics Manufacture Publication 5200969 18 Cleaning the Emitters SIMCO emitters have a serviceable life of three or more years in a typical cleanroom environment when operated in conjunction with a regular maintenance program Evaluation of emitter condition should be considered when cleaning the emitters Worn emitter replacement can be performed as part of a scheduled cleaning and calibration Note Prior to any cleaning power to the ionizer bar must be turned off This can be achieved using the MMI or by simply disconnecting the bar 1 Visually inspect each emitter electrode for signs of deposited material Typical deposits appear as a white coating on the pointed tip region 2 SIMCO recommends using the ITW TEXWIPE model TX726 CrushTube swab for cleaning the emitter electrodes A substitute method consists of a cleanroom swab saturated with a solution of de ionized water an
34. ssing the up arrow and right arrow at the same time will jump the MMI menu to Save settings local to bar Save as preset default no This is the option to saving the changes local to bar It allows selection of the desired preset number P1 through P14 and saving the parameters under this preset for later downloading into a bar Upload Settings to Bar default no Uploads the active preset to a bar The up down arrows select the target bar address Pressing ENTER uploads the preset to the bar but does not save the settings local to bar In IR mode the MMI will prompt the user to point the MMI at the bar and press ENTER Diagnostic enters a series of menus that use two way communication with the bar for diagnostic purposes The diagnostic mode may be entered from the Change Address menu Following are selections from the Diagnostic menus Feedback is data transmitted back from the bar to the MMI Hot Key Tip Pressing the down arrow and left arrow at the same time will jump the MMI menu to the Feedback screen PRG Metered feedback Program is the input value to the ion regulating circuitry as established by the microprocessor There is a Program value for the positive and negative high voltage supplies The range for this feedback value is from 0 to 1024 CUR Metered feedback Current is a measure of the output ion current of the high voltage supply During normal operation this value should be within approximatel
35. tions Fault Interface SIMCO lonization for Electronics Manufacture Universal 100 240VAC 47 63Hz line voltage input IEC320 Provides power to a maximum of 3 bars any length RJ 11 adapter and modular cable included 24VDC 200mA per bar power provided through the RJ 11 modular jack 0 125 to 6 seconds adjustable in 0 025 second increments Steady state operation is also available 0 to 100 adjustable in 0 25 increments 6 pin RJ 11 modular jacks provide both power and communications interconnections 2 bicolor LEDs provide information on positive and negative high voltage power supplies and feedback condition Green indicates the high voltage is functioning normally Red indicates a fault condition Each bar can be set to one of 10 unique addresses ScorplON3 bars can be set to independent or slave mode Independent bars can be set to steady state or a pulse rate independent of the system Slave bars will follow the pulse timing of the master bar RS 485 3 5 mm 1 8 phone jack opto isolated transistor that can be set to normally off or normally on this transistor NEC PS2502 1 is toggled during a fault condition Phone jack connections Tip positive collector Sleeve negative emitter Fault Interface Maximum Ratings Vceo collector emitter voltage 40 VDC max Veco emitter to collector voltage 6 VDC max Ic collector current 5OmA max Publication 5200969 4 Lengths Weight The sc
36. user to resolving the address conflicts by assigning new address numbers to the appropriate bars Address conflicts may take place in new systems because the factory default bar address is 1 In multi bar systems this necessitates the assigning of address numbers to avoid duplicate addresses on a system chain An exception to this is systems that have a Computer SIMCO Ionization for Electronics Manufacture Publication 5200969 10 Interface Cl on the system chain If a Cl is on the system chain it will automatically detect duplicate bar addresses and assign new address numbers as required Advancing into the Wired mode will cause the MMI to search the scorplION3 system and determine the number of bars present the number of bars in the system will be displayed When the MMI has searched the system and determined the proper number of bars in the system pressing the right arrow button will advance to the next menu Select Bar Preset or System Monitor provides for review and adjustment of individual bar operating parameters review and adjustment of any of the 14 P1 through P14 preset operating parameters or monitoring of the system for operating status and fault codes The up down arrows are used to scroll through bar system monitor or the preset numbers and the selection is activated by pressing the right arrow button Select Bar enters a menu where the bar address can be selected by scrolling through the bars on the system with th
37. ve non O address only or Independent Slave bars must be in pulse mode and will synchronize their pulse cycles with the Master bar 0 address on the system it generally takes several minutes for the synchronization to occur Pulse Time default 0 75 seconds must be set when pulse mode ionization is selected The Pulse Time is the duration a power supply is energized two pulse times compromise a full cycle of positive and negative ionization Using the up down arrow adjusts the pulse time in terms of seconds Generally longer pulse times are used in still air where there is relatively longer distance to the target area However the longer pulse times can create a greater peak offset voltage If a bar is a Slave the Pulse Time can only be set through the Master bar Pulse time is ignored when the ionizer is placed in the steady state mode Overlap default 30 sets the overlap of positive and negative ionization in pulse mode The system will switch the power supplies according to the pulse time the cycle time of positive and negative ionization does not change however overlap will cause the power supply to extend its run time determined by the percentage setting Overlap is beneficial to reduce the peak offset voltage when operating in the pulse ionization mode The system will set a mandatory minimum overlap in cases of long pulse time Overlap is not available when the ionizer is placed in the steady state mode Balance default 50 5
38. y 10 of the Program set point established by the microprocessor There is a Current value for the positive and negative high voltage supplies The range for this feedback value is from 0 to 1024 SIMCO Ionization for Electronics Manufacture Publication 5200969 13 DRV Metered feedback Drive indicates the input drive level into the high voltage supply required to achieve the programmed level There is a Drive value for the positive and negative high voltage supplies The range for this value is from 0 to 1024 Typically this value should be between approximately 100 and 924 Fault Code Status Screen appears as follows N 0 64 C8 R 000 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 N indicates a normal status W would indicate a warning status and F would indicate a fault status 0 indicates no faults above the threshold If an accumulator accumulates faults above the threshold this position will display the fault code with most significant accumulation 64 C8 indicates warning threshold first two digits and fault threshold second two digits The threshold values are in hexadecimal R 000 provides a snapshot of which accumulators are above threshold value 00 indicates accumulated fault codes in this case no accumulation The accumulator bins indicate fault codes as follows 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Hot Key Tip Pressing the down arrow and ri
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