Operating Manual - SCHNIER Elektrostatik GmbH

1 

Operating Manual 

HV Generator smartPack 310c 

Art.Nr.: 

810364 

100 kV 

300 µA

Contents 

1. Product and Manufacturer 3 

1.1. Product Identification 3 

1.2. Marking 3 

1.3. Warranty 3 

1.4. Manufacturer 3 

2. About this operating manual 4 

2.1. Accessibility of the manual 4 

2.1. Work safety icons and expressions 4 

3. Intended Use 5 

3.1. Further Requirements for the Stationary Equipment 5 

3.2. Particular Notes 6 

4. Installation 7 

4.1. Description 7 

4.2. Dimensional Drawing 9 

4.3. Electrical Installation / Connectors 10 

Grounding 10 

High Voltage Connector 11 

M12 Bus and Power Connector 11 

5. Normal Operation 12 

5.1. Safe shut down of the high voltage before access to live parts 13 

6. Repair and Maintenance 13 

7. Functional Description 14 

7.1. General 14 

7.2. Safety 14 

7.3. Block Diagram 15 

7.4. Specification 15 

8. Description of the CANopen Interface using PDOs 16 

8.1. Description of Control Word 19 

8.2. Description of Status Word 20 

8.3. Additional Parameter Settings using SDOs 22 

8.4. Interface Description File EDS 22 

8.5. Overview Control and Status Word 23 

8.6. Object Dictionary 24 

9. Declaration of Conformity 25 

Operating Instructions 810364_BAL_EN120302 Stand 02.03.2012 Seite 2 von 25

1. Product and Manufacturer 

1.1. Product Identification 

This Operating Manual is part of the device: 

Product: High Voltage Generator 

Type: smartPack 310c 

Part Number: 810364 

1.2. Marking 

1.3. Warranty 

Any warranty is void if the device is opened and/or modified, if parts were replaced by 

others than the original ones or if this operating manual is not observed. 

1.4. Manufacturer 

SCHNIER Elektrostatik GmbH 

Bayernstr. 13 

72768 Reutlingen 

Germany 

Fon: +49 (0) 71 21 / 90 973 -60 

Fax: +49 (0) 71 21 / 90 973 -99 

www.schnier-elektrostatik.de 

mail@schnier-elektrostatik.de 

Headquarters: Reutlingen HBR 354 531 

USt.-IdNr.: DE 146 481 986 

General Manager: Olav Schnier 


2. About this operating manual 

This operating Manual has to be read, understood and observed in all items by all persons 

who are responsible for the devices and the electrostatic plant. Only with the 

knowledge of this operating manual faults can be avoided and a trouble free operations 

be guaranteed. SCHNIER does not assume any liability for damage resulting from the 

non-observance of these operating instructions. Therefore it is important that the Manual 

is known to all people involved. 

This operating instructions are intended for: 

Installation and maintenance personnel (e.g. machine setters, IT professionals, 

electrically qualified people) who have been trained by the manufacturer or operator 

using the manual and the relevant safety regulations. 

Operation personnel (e.g. machine setters, IT professionals, electrically qualified 

people) who have been trained by the manufacturer or operator using the manual and 

the relevant safety regulations. 

2.1. Accessibility of the manual 

This operating manual should be available and within reach to the involved operating, 

maintenance and service personal at all times. 

The operating company has to keep this manual over the whole lifetime of the installation. 

Since it is part of the installation this manual has to be handed over to the new owner in 

case of resale of the installation or the resale of parts of it. 

2.1.Work safety icons and expressions 

Icon Impact 

This icon indicates a warning of a potentially hazardous situation which, if not 

avoided, could result in death or injury. 

This icon indicates a warning of a potentially hazardous electrical shock situa- 

tion which, if not avoided, could result in death or injury. 

Warning of damage to equipment or malfunction 

Efficient Approach 

The expression „live parts“ or “active parts” is used in this operating manual for „parts 

that are at High Voltage potential during normal operation. 


3. Intended Use 

This Product is dedicated for the use in stationary installations which comply with the 

safety requirements of at least one of this harmonized standards: 

EN 50176:2009, 

EN 50177:2009, 

EN 50223:2010 or 

EN 50348 :2010 

This high voltage generator is classified as category 3G and/or 3D equipment for use in 

Zone 2 and/or Zone 22 in potentially explosive atmospheres. 

Permitted is only the use in potentially explosive atmospheres which are caused by the 

spray cloud of the processed coating material itself. 

WARNING 

any other or extended use is strictly prohibited and lead to a potentially 

hazardous situation which could result in death or injury 

This device must not be used stand-alone. It has to be fully installed in stationary 

equipment that complies in total with the product standards mentioned above. 

3.1.Further Requirements for the Stationary Equipment 

This HV-generator must be used only in electrostatic units within a temperature 

range of 15 °C to 40 °C and a relative humidity between 10% 

and 70%.(non-condensing) 

This HV-generator is intended for incorporation in a given fixed 

installation in industrial environments. There may be difficulties to ensure 

electromagnetic compability (EMC) in other environments. 

To avoid potentially hazardous situations it is necessary to do a risk analysis 

of the installation in total. Particularly with regard to safety categories 

and/or performance levels stated in the relevant product standards this is 

mandatory* 

* Since the spray system is connected via a high voltage cable to the high voltage generator, 

a performance level cannot be ensured by the high voltage generator alone. For 

this, a second high voltage cable from the spray system returned to a redundant measurement 

path in the high voltage generator would be necessary. 


3.2.Particular Notes 

The hamonized standards mentioned under „intended use“ specify safety requirements 

for stationary electrostatical coating equipment. For safety benefit particular sections 

are listed here for your information: 

Section 

5.2.1 

(5.3.1) 

5.2.3 

5.2.4 

(5.3.3) 

(5.3.4) 

[5.2.3] 

5.4.5 

(5.5.2.3) 

[5.3.2] 

5.5. 

[(5.4)] 

5.6. 

(5.5.2.1) 

[5.5] 

5.7. 

(5.5.2.2) 

[5.6.1] 

The distance between the workpieces and the parts of the 

spraying system under high voltage shall be large enough to 

prevent an electrical discharge during normal operation. 

After switching off the high voltage all active parts shall be 

discharged to a discharge energy of less than 350 mJ before 

these parts can be reached. 

If ignitable liquids are used for cleaning purposes the remaining 

discharge energy has to be less than 0.24 mJ before 

these parts can be reached. 

When using walls, enclosures, signs and labels made of nonconductive 

material the occurence of propagating brush discharges 

shall be prevented. 

Thin sheets of plastic material less than 9mm thick in contact 

with large areas of earthed conductors (e.g. metal) can cause 

brush discharges. The breakdown voltage of such sheets 

shall not exceed 4kV 

Describes all of the requirements for the high voltage supply 

Before any access to live parts the high voltage must be 

switched off and the life parts be discharged to a safe level. 

The electric equipment that is not part of the high voltage 

supply shall comply with EN 60204-1 

All conductive components of the installation like floors, containers 

etc within the spraying area except for parts under 

high voltage for operational reasons shall be connected to 

the grounding system with not more than 1 MΩ 

Section numbers refer to the standards EN50176/EN50177 - (EN50223) - [EN 50348]. 

Note: This extract does not replace the fulfillment of all of the safety requirements in 

these standards. 


4. Installation 

4.1. Description 

1 M12 5-pin-connector (24V and CAN) 

2 Ground connector M4 Screw or POAG (see 4.4.) 

3 Aluminium front panel 

4 Epoxy housing 

5 HV cable 

1 

2 

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3 

4 

5

Abb.1 

Mounting 

This HV generator is designed to be mounted on a plate. 

Use hexagon socket screws M5x16mm. 

WARNING 

Excessive tightening of the screws will possibly cause 

cracks 


4.2. Dimensional Drawing 


4.3. Electrical Installation / Connectors 

Grounding 

Bus and power connector 

With the ground connector the high voltage circuit is closed between the generator and 

the work piece. 

HV-Generator 

HV Ground Screw (M4) 

WARNING 

Ground wiring should be done as short as possible and at least 

with 4 mm 2 (AWG 11) wire. 

Do not place this wiring in parallel to supply or bus lines. 

If a POAG Connector is built in instead of a M4 Screw the 

following connector is needed: 

Designation: Winkelbuchse für 

Potenzialausgleich POAG 

Crimp connector 

SCHNIER Part.-No.: 260066 

Ground connector 

Spraying System Workpiece 

As short as possible 


High Voltage Connector 

The 4mm HV Pin of the HV cable has to be inserted completely in 

the HV jack inside the generator. The cable gland has to be tightened 

properly 

ATTENTION 

If shielded HV cable is used the shield has to be grounded 

ATTENTION 

To avoid the appearance of ozone and oxidation it is recommended 

to grease the contact pin. 

If High voltage cable is used which contains inner conductors 

made of plastic the cable must not be greased. 

M12 Bus and Power Connector 

Power supply and bus interface is done in this connector 

Pin Description Signal 

1 Shield GND 

2 V+ 24 V DC 

3 V- 0 V DC / GND 

4 CAN_H CAN High 

5 Can_L CAN Low 

Screw Shield 

ATTENTION 

The connected cable has to be shielded 

Screw has to be tightened for operation. 

ATTENTION 

Connection of CAN_H and/or CAN_L to other signals than CAN 

bus may damage the unit. Don’t connect the CAN-Bus to 24V ! 

A IP 54 protected female connector has to be used 

Operating Instructions 810364_BAL_EN120302 Stand 02.03.2012 Seite 11 von 25 

4 

5 

3 2 

1

5. Normal Operation 

The terms for the intended use as specified above are mandatory. Furthermore the 

operating instructions of the surrounding installation have to be observed. 

The operation of the installation has to be performed by a trained service team. The 

staff must be informed at reasonable intervals about accident prevention regulations 

and operation instructions. 

ATTENTION 

High voltage has to be switched off prior to disconnecting the 24V 

Power Line. Exception: emergency situations 

WARNING 

At working situations where active HV parts can be reached it is 

mandatory that: 

High Voltage is switched off ! 

The active parts have to be discharged to less than 350 mJ 

If ignitable liquids are used for cleaning purposes the active 

parts havde to be discharged to less than 0.24 mJ 

24V power line is safely disconnected and secured against 

reconnecting. 

The active parts are grounded with a suitable earth rod 

The housing of the high voltage generator is also used for cooling. 

For this purpose the housing should be kept clean. 

Never operate a broken or opened device. 

During repair and maintenance of the surrounding installation the terms for the normal 

use of this HV generator apply. Do NOT work at installations under high tension 


5.1. Safe shut down of the high voltage before access to live parts 

In order to ensure the safety it is mandatory to follow the steps 1-5 mentioned below 

before and during a release of access to live electrical components. This has also to be 

ensured by technical means: 

1. Switch off high voltage via CAN bus command 

2. Wait until generator sets the bit „High voltage is off safely“. This should occur after 

10 to 60 seconds. For safety reasons this duration should be observed over 

life time to recognize changes of the electical capacity of the installation. 

3. Switch off 24V supply (safe) 

4. Take measures to secure 24V supply against reconnecting 

5. Ground active parts with earth stick 

6. Repair and Maintenance 

The terms for the normal use as specified above apply also during repair and maintenance 

situations. Furthermore the operating instructions of the surrounding installation 

have to be observed. 

This HV generator does not contain any user repairable parts. It can only be repaired 

by the manufacturer. 

If the generator has to be uninstalled for repair the following order of disconnecting the 

Signals is recommended: 

1. Check if parts carrying HV during normal operation are grounded 

2. Remove M12 connector 

3. Unplug HV connector 

4. Remove ground 

WARNING 

If a HV generator is uninstalled avoid to touch metallic parts, 

that are active during operation without grounding them with an 

earth stick BEFORE the ground connector of the HV generator 

is disconnected ! 

Observe this in particular when a generator is defect ! 

Any warranty is void if the HV generator is opened and/or 

modified, if parts were replaced by others than the original 

ones. 


7. Functional Description 

7.1. General 

The high voltage generator is built as a compact design. The control, power amplifier, 

the transformer and the HV multiplier are combined in one device. Supply Voltage is 

24 V DC. The built-in microcontroller provides a very accurate and fast control of the 

HV output. 

7.2. Safety 

The voltage (U) at the HV connector is measured permanently even after switching off 

the high voltage. With a given capacity (C) one can calculate the discharging energy 

(E) that remains in the spraying system and the high voltage supply system: 

E=1/2C* U 2 

E: remaining discharging energy after switch off in Joule 

C: total capacity of the whole HV supply system in Farad 

U: Voltage level in Volt 

Factory preset for the calculation by the HV generator is 3nF. This value can be 

changed via CAN bus to the actual capacity of the installation (not yet implemented). 

Based on the limit of 0.24mJ (EN 50176,50177,50223) for the discharge energy to be 

safe the hv generator sets the bit “high voltage is off safely” in the status word if E is 

below this limit. Otherwise the bit is reset. For 3nF and 0.24mJ the voltage limit is about 

400V. 

WARNING 

If a Generator has to be removed for repair – 

especially after the occurence of failures of selftests – 

Observe Section 6 of this manual. 


7.3. Block Diagram 

24 VDC 

CANopen 

Power 

Stagel 

7.4. Specification 

Micro 

Controller 

Transformer 

I-Measurement 

U-Measurement 

HV Multiplier Protection HS- 

Resistor Ausgang 

Measurement 

Resistor 

Supply Voltage 24 V DC max. 2A 

Output Voltage 10-100 kV negative 

Output Current 300uA 

Max. installation capacity 2 nF 

Environment +15°C bis 40°C max. 70% rel . humidity non condensing. 

Storage Temperature -20°C - +70°C 

Dimensions see 4.3. 

Weight Max 3,5 kg 

Protection IP 65 

HV Connector Anode tube with 4mm hv connector 

Bus Interface Based on CAN Open 

Operation Modes Constant U (Voltage) and Constant I (current) 


8. Description of the CANopen Interface using PDOs 

ATTENTION: 

Node Guarding has to be activated. This is needed to 

recognize a communication loss between the HV unit 

and the master control unit to switch off HV ! 

Node Guarding has to be activated using the 

CANopen objects 0x100C and 0x100D. 

1. This high voltage generator is controlled via the CAN interface, which uses a protocol 

based on CAN Open with default baud rate 250 kbit/s and default node-ID 02. The 

baud rates 50 kbits/s and 125 kbit/s are also available. The baud rate and the node- 

ID can be set by SDO. But the new settings will take effect only after a reset. After 

power on, a boot up message will be sent over the CAN interface when the high voltage 

generator is ready to operate. 

The high voltage generator is controlled by the receive-PDO „RXPDO1“ with the 

COB-ID „0x200+Node-ID“. The state of the high voltage generator is saved in the 

Send-PDO „TXPDO1“ with the COB-ID „0x180+NODE-ID“ and can be requested by 

SYN-Objekt. 

The content of the RXPDO1 consists of three objects from the object dictionary. The 

three objects are arranged fixed. (See figure 8.1.) 

Figure 8.1 The content of RXPDO1 

The content of the TXPDO1 consists of three objects defined in the object dictionary. 

The three objects are also arranged fixed. (See figure 8.2.) 

Figure 8.2 The content of TXPDO1 

2. If the high voltage generator is not in the state of failure, it can be switched on for 

example 10 kV in U-mode by RXPDO1. (See figure 8.3.) The set value of voltage 

must be higher than 10 kV, otherwise the high voltage will not be generated. In Umode 

a constant output voltage (U-set) is wanted, while the value of I-set is used to 

limit the voltage. The set value of current „I set“ is in this example given by 100 uA. If 

the output voltage reaches 10 kV and the output current lower than 100 uA, the out- 


put voltage will be hold constantly. If e.g. the output current is over 100 uA before the 

output voltage reaches 10 kV, the output voltage will be limited in the actual level. 

(The high voltage generator behaves like in I-mode). To reach 10 kV in this case the 

current could be set by a higher value. 

Figure 8.3 RXPDO1 for 10 kV and 100 uA in U-mode 

Figure 8.4 RXPDO1 for 20 kV and 100 uA in I-mode 

In I-mode a constant output current (I-set) is wanted, while the value of U-set is used 

to limit the current. If the high voltage generator is switched on e.g. for 100 uA und 20 

kV in I-mode, the output current will rise to 100 uA and hold constantly, as long as the 

output voltage is lower than 20 kV (See figure 8.4.). If the output voltage reaches 20 

kV, the output current will be limited or reduced. (The high voltage generator behaves 

like in U-mode.) 

3. If the high voltage generator detects a failure during the operation, the high voltage will 

be switched off and a corresponding bit in the statusword will be set. The bit „Centralized 

failure“ will be set too, if any failure appears. The high voltage generator enters 

the state of failure. The states of the high voltage generator can be determined from 

the TXPDO1 by SYN-Object. Figure 8.5 shows the TXPDO1, as the high voltage is 

switched off e.g. due to exceeding of Imax in U-mode. 

Figure 8.5 TXPDO1 for Imax switch off in U-mode 

The output voltage and current will fall back to zero in ideal case. The falling speed is 

dependent on capacitance of the plant. 

4. The high voltage generator can come out of the state of failure, only if the failure is 

quitted and the high voltage is switched off. After that the high voltage can be 

switched on again. The failure should be quitted by RXPDO1 e.g. showed in figure 

8.6. 


Figure 8.6 RXPDO1 for quitting failure. 

If the failure is quitted and the high voltage is switched off and the output voltage is 

lower than the safety level, the bit „Device is off safely“ will be set as showed in figure 

8.7. 

Figure 8.7 TXPDO1 shows the state of safety in I-mode 

If the high voltage is switched off, but the output voltage is higher than the safety 

level, the TXPDO1 could show like figure 8.8 (output voltage is 10 kV). That means, 

the high voltage generator is unsafe although the high voltage is already switched off. 

Figure 8.8 TXPDO1 shows unsafe status 


8.1.Description of Control Word 

Byte Bit Statusbit Description 

0 0 Highvoltage on 1: turn on the Highvoltage 

0: turn off the Highvoltage 

1 Reset Fault 1: acknowledge failure 

0: no action 

2 Reserve 

3 Reserve 

4 Reserve 

5 Reserve 

6 Reserve 

7 Reserve 

1 0 Operation Mode 1: constant U mode: 

Output Voltage is regulated to the value 

defined in “Voltage set value”. Current is 

limited to the value defined in “Current set 

value” 

0: constant I mode: 

Output is regulated to the value defined in 

“Current set value”.Voltage is limited hereby 

to the value defined in “Voltage set value”. 

1 Reserve 

2 Reserve 

3 Reserve 

4 Reserve 

5 Reserve 

6 Reserve 

7 Reserve 

2 0 Reserve 

1 Reserve 

2 Reserve 

3 Reserve 

4 Reserve 

5 Reserve 

6 Reserve 

7 Reserve 

3 0 Reserve 

1 Reserve 

2 Reserve 

3 Reserve 

4 Reserve 

5 Reserve 

6 Reserve 

7 Reserve 


8.2. Description of Status Word 

Byte Bit Statusbit Description 

0 0 Highvoltage is on 1: If the bit „Highvoltage on“ 

in controlword is set and the 

voltage set value is higher 

than 10 kV. 

0: If the bit „Highvoltage on“ 

in controlword is cleared 

and the internal regulator 

output is zero 

1 Centralized Fault 1: If any failure appears. 

0: No failure. 

2 Centralized Warning 1: If any warning appears. 

0: No warning 

3 High Voltage is off 

safely 

4 Reserve 

5 Reserve 

6 Reserve 

7 Reserve 

1 0 Operation Mode 1: U-mode. 

0: I-mode. 

1 Reserve 

2 Reserve 

3 Reserve 

4 Reserve 

5 Reserve 

6 Reserve 

7 Reserve 

2 0 Reserve 

1 Umax warning in I- 

Mode 

2 Umin switchoff in I- 

Mode 

1: If the highvoltage is 

switched off and the output 

voltage is lower than 300 V 

and no failure exists. 

0: If the highvoltage is 

switched on or the output 

voltage is higher than 400 V 

or any failure exists. 

1: If the output voltage in Imode 

is higher than the 

threshold value in object - 

dictionary. 

0: If this warning does not 

exist or is quitted. 

1: If the output voltage in Imode 

is lower than the 


dictionary. 

0: If this failure does not 


If high voltage has 

been switched off by 

a fault (i.e. Imax, 

Umin) the fault has 

to be acknowledged 

before this bit will 

return to zero. 

See 7.2 


3 Imax switchoff in Umode 

1: If the output current in Umode 

is higher than the 


dictionary. 



4 Sparkover switchoff 1: If a sparkover happens. 



5 Reserve 

6 Reserve 

7 Node Guarding Failure 

1: If Nodeguarding signal is 

broken. 



3 0 Invalid Parameter 1: If any Parameter in the 

Object dictionary is set by 

an invalid value. 



1 U Measurement 

Failure 

2 I Measurement 

Failure 

3 Internal Power 

Failure 

4 Reserve 

5 Reserve 

6 Reserve 

7 Reserve 

1: If the voltage measurement 

circuit is defect. 



1: If the current measurement 

circuit is defect. 



1: If intern power controlling 

does not funktion. 



Check why CAN 

master does not 

send Nodeguard 

periodically as defined 

in the object 

0x100C 

Check value range 

of parameters sent 

to the HV controller 

Has to be checked 

by manufacturer if 

failure persists 








8.3. Additional Parameter Settings using SDOs 

The following parameters are set using SDOs: 

Threshold of Umin-switchoff 

HV generator is switched off if, during 

constant-I-mode, output voltage drops 

below this value 

Threshold of Umax-warning During constant-I-mode the output 

voltage is limited to this value. A warning 

wil be issued if Umax is reached. 

Threshold of Imax-switchoff HV generator is switched off if, during 

constant-U-mode, output current reaches 

this value 

Sensitivity of sparkover detection This value defines the sensitivity of spark 

detection. Do not change! 

Voltage run up ramp Output voltage ramp up speed after HV 

is switched on 

8.4. Interface Description File EDS 

EDS files are simple text files used by network configuration tools to help you identify 

products and easily commission them on a network. 

SCHNIER provides a eds-File with all parameter and format information of the HV generator. 


8.5. Overview Control and Status Word 


8.6. Object Dictionary 


9. Declaration of Conformity 

Hersteller: 

SCHNIER Elektrostatik GmbH 

Bayernstrasse 13 

D-72768 Reutlingen 

Product: High Voltage Generator 

Type / SCHNIER Art.-Nr.: smartPACK310c / 810364 

Marking: II 3G/D T6 X 

We declare that the product named above is in conformity with the following EU directives: 

Applied harmonized standards: 

Directive 94/9/EG (ATEX) 

Directive 2006/42/EG (Machinery) 

Directive 2004/108/EG (EMC) 

The Directive 2006/95/EG (Low Voltage) is observed 

regarding their safety objectives (s. Appendix I Nr 1.5.1 

Directive 2006/42/EG) 

EN 50176:2009 Stationary electrostatic application equipment for ignitable liquid coating material - Safety requirements 

EN 50177:2009 Stationary electrostatic application equipment for ignitable coating powders - Safety requirements 

EN 50223:2010 Stationary electrostatic application equipment for ignitable flock material - Safety requirements 

EN 50348:2010 Stationary electrostatic application equipment for non-ignitable liquid coating material - Safety 

requirements 

EN ISO 12100-1:2003/A1:2009 Safety of machinery - General principles for design - 

Part 1: Basic terminology, methodology (ISO 12100-1:2003) + Amendment 1 

EN ISO 12100-2:2003/A1:2009 Safety of machinery - General principles for design – 

Part 2: Technical principles - (ISO 12100-2:2003)+ Amendment 1 

EN 60204-1:2006/A1:2009 Safety of machinery - Electrical equipment of machines - 

Part 1: General requirements (IEC 60204-1:2005, modified + Amendment 1 

EN 61000-6-2:2005 Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity for industrial 

environments 

EN 61000-6-4:2007 Electromagnetic compatibility (EMC) – Part 6-4: Generic standards - Emission standard 

for industrial environments 

Rommelsbach 20.05.2011 

Olav Schnier (Geschäftsführer)

Operating Manual - SCHNIER Elektrostatik GmbH

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