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

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

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Connecting several 8001KDT bars to one 8154 POWER MODULE 8154 POWER MODULE grounding connection
Up to four 8001KDT neutralizing bars can be connected to a single 8154 POWER MODULE. WARNING! The enclosure of the 8154 POWER MODULE is a finished high-
9. Repeat steps 1 through 8 for additional bars connected to the 8154. 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.
IMPORTANT!
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.
• 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. 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.
• 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 CAUTION: The grounding connection must be completed and intact. Damage
• Do not attach more than the maximum specified total length of neutralizing bars to to equipment and electrical shock can occur if the power supply is left
the 8154 POWER MODULE. ungrounded.
• 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. 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).

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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 3 3
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+”
2 2 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
IMPORTANT! It is recommended that prior to removing the network power for
The remote alarm terminals are located in the same terminal block as the remote activation any extended period the high voltage output for all the 8154’s in the network are
terminals and are accessible from the bottom of the 8200 enclosure (Figs. 10). disabled using the 8200 On/Off key. See Table 1 in the Instruction Manual for
The connector header has separate sets of relay contacts for the Fault and Clean Bar alarm ENABLE/DISABLE HV OUTPUTS FOR ALL STATIONS function.
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 • If the 8200 loses communications with some or all units in the network, the 8154’s will
and RTN connections terminals provide contact closure during normal operating conditions. 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
The Fault alarm relay in the 8200 is energized under the no-alarm conditions. The Fault
again, all affected 8154’s will get set to the last state prior to the loss of communications.
alarm NO and COM terminals provide contact closure during normal operating
conditions; NC and COM terminals provide contact closure during an alarm condition or • For most 8200 failures, including loss of functionality or power disruption, the 8154
if there is a loss of power to the system. will continue to operate and keep the output state existing before the 8200 problem,
as indicated by the LED in the 8154.
1. Remove the connector from the header in the 8200.
• Any 8154 units with address “30” are always turned off when added to a multi-station
2. Connect the wires from the remote alarm indicator to the appropriate connector
network or directly to the 8200. The 8200 will turn off an 8154 with address 30.
terminals according to Figs. 10 and 12.
• When the 8200 assigns an address to a 8154, it is always set to off. If the manual
3. Plug the connector into the header in the 8200.
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.
4. SETUP AND OPERATION • 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.
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 8200 Keys
after communication glitches or power disruptions. The 8200 can operate in one of three modes, Station View, Scan Stations and
• After an individual 8154 is disconnected from the network (both power and Programming.
communications, or just communications), and then is connected back, when an Many display functions require pressing a single key. The programming functions require
8154 starts to communicate with the 8200, it gets set to the last state prior to the loss pressing a combination of two keys.
of communications. When a key is pressed, the station # display changes and illuminates a single segment
• After a power cycle or a communications glitch for any individual 8154, the 8154 indicating that pressing a key is recognized. If two keys are pressed at the same time, then
would always come back to the state it was before the glitch. two segments are illuminated accordingly. The functions corresponding to a specific key
• When the 8154 RESET button is pressed, the 8154 would always come back to the or key combination are not processed until the keys are released. After pressing a key, or
state it was before resetting. keys, see in the display that they are recognized, and then release the keys to perform the
desired operation.
• Pressing the 8200 RESET button does not change the state of the 8154's in the network.
No segments are illuminated when up or down keys are pressed for adjusting the clean bar
• After recycling network power for any period of time, the 8154's always come back alarm threshold in the clean bar setup mode.
to the state they were before the power recycle.
See summary of all 8200 key functions on the following page.

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