Quite simply the GEN4 Ion Air Cannon is based on the mechanics of the 2″ diameter Super Air Amplifier that has static reduction capabilities and as its name implies it amplifies the supply air up to 25 times!
This highly engineered product is very effective at cleaning product and reducing static at distances of up to 15′ away.
The GEN4 Ion Air Cannon comes in a handy stand/mounting unit for easy installation in a wide variety of applications. It can be mounted to machine frames, mounted out of the way from a process, or placed on a bench top.
The GEN4 Ion Air Cannon is used in many applications such as bottling, manufacturing of solar panels and preparing new automobile car bodies to be painted – to name a few. Wherever static reduction and/or cleaning is required the Ion Air Cannon can contribute.
EXAIR published a whitepaper, Basics of Static Electricity, explaining what causes static electricity, how it is generated, and steps to eliminate it. Download it now by clicking the link, and begin to eliminate the static problems on your plant or process.
In this blog, I would like to expand on the subject about how static can be generated. On a molecular scale, the outer electrons that are orbiting the nucleus can be “stripped” and redistributed from one atom to another. This will cause an electrical charge imbalance called static. An additional electron will create negatively charged static while atoms losing an electron will create a positively charged static. With non-conductive materials like plastic, paper, rubber, glass, etc, the electrons cannot move back to the original atom. There are three common methods of static generation that will cause this phenomenon to occur. I will explain each one in brief detail below:
Contact – Whenever objects hit each other, electrons can be passed to or received from the surface of another object. The number of electrons being transferred is based on the type of triboelectric material. But, with plastic bottles or trays bumping into each other on conveyor belts, static is being generated.
Detachment – when one material is being separated from another material by peeling, electrons may not able to return back to the original molecule. Adhesive tape and protective films are prevalent in generating static charges by detachment because of the larger surface areas. As an example; when the backing material is being removed from labels, the static will cause the labels to be misaligned.
Frictional – This is one of the most common reasons for generating large static forces. It is caused by two non-conductive surfaces being rubbed together. The amount of force being applied to the material as it slides back and forth will create higher static charges. It is definitely noticed when you rub a balloon on your hair. The more times that you rub the balloon against your hair, the stronger the static forces, allowing the balloon to “stick” to the wall. It is also noticed as sheets of material are stacked or running over rollers.
Static tends to propagate. The more contact, detachment, and friction that occurs; the higher the static charges. Even when the static is removed from the surface, static charges can still regenerate by the mechanisms above. So, controlling the static can be determined by the treatment process as well as the location.
Another variable that affects the static generation is humidity. Most process problems are noticed during the winter seasons as the ambient air is drier. With a lower relative humidity, the development of static is enhanced; making it easier to produce static as well as creating a higher static force. We always refer to winter as static season.
Production problems with static can occur like dirty surfaces, tearing, alignment, jamming and shock to personnel. EXAIR has a number of Static Eliminators to remove these process snags and down time that will cost your company money. You can contact an Application Engineer at EXAIR to discuss any static issues that are being generated.
EXAIR’sGen4 Ion Air Jet is a compact ionizer that is capable of delivering a concentrated ionized airflow that will cover a precise spot without disturbing the rest of the process. The quiet, focused air stream can quickly eliminate the static charge on surfaces. At a pressure of 80 psig the Ion Air Jet is capable of dissipating a 5kV charge in .18 seconds!
In addition to providing rapid static decay, the Ion Air Jet also helps to minimize compressed air use while maximizing the ionizing airflow. Utilizing a specially designed shim, the Ion Air Jet entrains ambient air at a rate of 5:1. The Ion Air Jet can be adjusted from a “blast” to a “breeze” simply by increasing or decreasing the inlet pressure to the ionizer.
The Ion Air Jet can be used in both fixed, permanent solutions as well as those that will require frequent re-positioning. For applications requiring a fixed position of the ionizer, the compact Gen4 Ion Air Jet is an ideal solution. It’s lightweight and easy to install with the 1/8 NPT male inlet. For applications where the positioning of the ionizer may need to be adjusted, look to the flexible Gen4 Stay Set Ion Air Jet. Utilizing a Stay Set Hose, The Gen4 Stay Set Ion Air Jet can be frequently adjusted to focus the air stream at a specific area. The hose will maintain rigidity and will not creep or bend, making it an ideal solution when accommodating different parts. The Gen4 Stay Set Ion Air Jet comes with a strong magnetic base that allows for easy mounting and portability. The 8910 Instant Blowoff Station is another option that includes the Gen4 Stay Set Ion Air Jet, power supply, foot pedal, and compressed air hoses for applications that can benefit from hands free operation.
Cold weather is still upon us. With colder temperatures come lower levels of humidity, with lower humidity comes an increase in static problems. Don’t let static hold you down. Whether it’s cleaning glass jars, removing dust from plastic medical components in a clean-room operation, or keeping a laser lens clean to eliminate false readings, EXAIR has the solution to keep you running smoothly.
Within industrial processes, static electricity can lead to a variety of problems like printing errors, harmful shock, damaged product or shorted life for electrical components. EXAIR offers a wide range of static eliminating products that can help control this nuisance and restore material to an electrically balanced state.
When it comes to a static causing problems with a manual operation, our Gen4 Ion Air Gun is the preferred choice. The Gen4 Ion Air Gun incorporates a thumb trigger air gun with an ionizer attached to deliver a bulk of positive and negative ions to quickly eliminate the surface charge of a material, up to 5kV in only 0.18 seconds, when operated at 80 PSIG.
The Model # 8193 Gen4 Ion Air Gun is shipped from stock with a 10′ flexible armored and electromagnetic shielded cable to protect against potential damage in an industrial setting. (special length cables up to 50′ are available if needed). The cable assembly can also be easily removed for cleaning or replacing of the stainless steel emitter point, allowing for worry free, proper operation.
Here is a short video showing how to change the emitter point:
The Gen4 Ion Air Gun is UL recognized for the US and Canada and CE compliant, meeting the product requirements for items being sold in European markets. It also meets 2 important OSHA directives relating to the safe use of compressed air. The first being OSHA Standards 29 CFR 1910.242(b), requiring that the outlet pressure of an open pipe, nozzle, air gun, etc., when used for cleaning purposes, must remain below 30 PSI when dead-ended. The second being Standard 29 CFR 1910.95(a), protecting workers from potential injury related to dangerous sound levels of 90 dBA or higher. Additionally, the Gen4 Ion Air Gun is RoHS compliant as well.
They are designed to be used with our Gen4 Power Supplies, Model # 7960 with 2 outlets or the Model # 7961 with 4 outlets for powering multiple ionizers. The Gen4 Power Supplies are selectable voltage, 115VAC or 230VAC, and feature a 6′ modular power cord and lighted power switch.
To discuss how the Gen4 Ion Air Gun or any of our other products can help solve your process needs, give me a call at 800-903-9247.
Here in the Northern Hemisphere, we are in the middle of winter and that means extremely dry air, and frequent shocks when reaching for a door knob after walking across a carpeted surface. While a shock is mildly uncomfortable and can be annoying to us, the presence of static electricity in an industrial manufacturing process can be much more problematic.
Problems that static cause range from operator discomfort to increased downtime to quality issues. Dust can cling to product, product can cling to itself, rollers, frames, or conveyors. Materials may tear, jam, curl and sheet fed items can stick and mis-feed. Hazardous sparks and shocks can occur, possibly damaging sensitive electronics.
EXAIR has put together a useful tool, the Basics of Static Electricity white paper with Interactive Regions to help a person learn more about static.
Topics covered include Electron Theory, Causes of Static Electricity, Triboelectric Series chart, and Types of Static Generation. Also, the white paper covers the areas of How to Control Static Charge Buildup, Determining the Source of the Static Buildup, Eliminating or Minimizing the Source Causing the Buildup, and Treating Static Buildup.
The Treating Static Buildup is a comprehensive review of the EXAIR Static Elimination products and how each technology is best applied to different processes and applications.
To receive your copy of the Basics of Static Electricity white paper, click the photo above or the link here.
If you would like to talk about static electricity or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.
One of the best ways, in industry, to generate a static charge is to roll or unroll non-conductive materials such as polymer films, plastic sheet, etc. It’s common to see static charges well in excess of 10,000 volts in such operations, like the one I discussed with a customer recently.
One of the best ways, in industry, to dissipate a static charge is to use ionized air. There are different methods of doing this; one of the most popular is to effect a Corona discharge, via a high voltage, low amperage electric current. This is precisely what EXAIR’s Static Eliminators provide: a Corona discharge produces a bulk of both (+) and (-) ions in the enormous volume of high velocity air flow generated. When these (+) and (-) ions flow onto a surface charged with (-) and (+) ions, they cancel each other out, leaving a net neutral charge. Static, eliminated!
By combining an Ionizing Bar with a Super Air Knife, as Super Ion Air Knife provides rapid static elimination AND blow off of any dust, chips, or debris that was being statically held. The laminar curtain of ionized air not only maximizes the rate of static dissipation, but is also ideal for stripping/sweeping away any debris, leaving a clean, static-free surface. No more jamming, tearing, nuisance shocks to operators, dust attraction, or any of the other host of problems associated with static electricity.
The ionized air flow can be precisely regulated to whatever level it takes to get the job done. At 100psig, the powerful, high velocity blast will dissipate 5,000 volts of static charge in 0.18 seconds. If the material is fragile, or if that kind of air flow might disrupt the process, it’s not a big deal…even at 5psig supply pressure, that same 5,000 volts is dissipated in 0.40 seconds. That’s how it works on the plastic roll above – with just a whisper of ionized air flow from a Super Ion Air Knife, they consistently reduce the resultant static charge to less than 400 volts…far below the threshold for the nuisance shocks they wanted to avoid.
They’re on the shelf in lengths from 3 inches to 9 feet long, and we can make custom lengths in three days after receipt of an order. The 115/230VAC GEN4 Power Supplies are available with 2 or 4 outlets, to energize any 2 or 4 EXAIR GEN4 Static Eliminators.
Versatile. Efficient. Effective. Quiet. Safe. And, readily available. If you’d like to discuss a static problem, give me a call.
A honey producer sells their product in specialty glass jars. They pay a premium for these jars, as they enhance the appearance of their product, so the “visual” is obviously very important to them. So much so, that they’re willing to go to great lengths to make sure that the jars are sparkly clean and pristine before filling them with honey.
It’s a given that the inside needs to be clean…it’s a food product, so, of course, there’s a thorough cleaning process for that. The outsides of the jars, though, would sometimes have a little dust or debris left over in the ‘nooks and crannies’ which took away from the crystal clear appearance of the rest of the jar.
They got a Model 8494 GEN4 Ion Air Jet Kit, which they use to remove all of this dust & debris from the outside of the bottle, and then they got another Model 8194 GEN4 Ion Air Jet (which uses the same Power Supply, Filter Separator, and Pressure Regulator from the 8494 Kit) to blow an “insurance” blast of ionized air inside the bottle…just in case. “You can’t be too careful” is a popular mantra for folks who make food products, it seems!
Ionized air is extremely effective for ensuring the cleanliness of glass surfaces. Window makers love our Super Ion Air Knives. Some big name sunglasses manufacturers use our Ion Air Jets to ensure the highest quality and consistency of their products. Ion Air Jets and Ion Air Cannons are commonly used to keep optics clean & clear in critical vision inspection systems. If you’d like to find out more about improving “visuals” with ionized air, give me a call.