Ion Air Jet Applications

While writing my blog last week on all of the features & benefits of the Gen4 Ion Air Jet, I couldn’t help but think of some of the very interesting and successful uses I’ve seen in my nine years (as of this past Monday) as an Application Engineer at EXAIR Corporation.  In honor of my workaversary, this week’s edition is Russ’ Top 9 Ion Air Jet applications:

  1. A medical device manufacturer uses Ion Air Jets to remove dust from plastic extrusion as it goes through a puller belt.  The small diameter (0.05″ to 0.10″) made the Ion Air Jet a more efficient fit than the Super Ion Air Wipe, which is commonly used for extrusions like this, but is most effective for larger diameters.
  2. A maker of large scale automated machinery has provided Ion Air Jets (as well as other EXAIR quiet, efficient, and safe compressed air products) on machines they’ve been selling their customers for years.  When they started machining their own plastic parts, the Ion Air Jet was their first thought for a solution when plastic chips started sticking to their drill bits.
  3. A commercial printer makes displays, signs, etc. from a variety of static-prone materials such as acrylic, polycarbonate, and styrene.  They use CNC routers to cut them to size & shape, form the edges, and add dimensional detail.  Ion Air Jets blow the dust & shavings away, and keep them away, greatly reducing the prep time between routing and assembly.
  4. A weather sealing/stripping manufacturer uses Ion Air Jets to remove statically charged dust from their rubber & foam product extrusions, allowing for increased line speeds and better cuts for the products they cut for specific seal packages for the residential & commercial door and automotive industries, among others.
  5. A major provider of electrical and electronic contactors uses Ion Air Jets to blow off contact strip as it rolls off large reels to remove protective film and static.
  6. A manufacturer of wire marking machinery installs Ion Air Jets on their machines that are used to print on products with especially static-prone jackets, to ensure clean and crisp markings
  7. A cable manufacturer that caters to the computer & electronic industries uses Ion Air Jets to remove static & dust as foil is applied to PVC coated wire.  This eliminates the static charge that was causing inconsistencies when the adhesive was heated to activate.
  8. A wholesale food equipment distributor uses Ion Air Jets to blow out bottles during the sterilization process, prior to filling.
  9. A maker of specialty polymers uses Ion Air Jets to keep fine powders from accumulating in the entries into their hoppers.
Some applications call for a fixed-in-place solution, like the (above, from left) Super Ion Air Knife, Super Ion Air Wipe, Ion Air Jet, and Ion Air Cannon.) Others are best suited to the hand-held convenience of the Ion Air Gun.  Whatever your static problem is, though, EXAIR has a solution for you!

If you have a problem with static, the Ion Air Jet is just one of the solutions EXAIR Corporation can provide.  If you’d like to find out more about how we can help, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook

Static Eliminators: Ion Air Jet

Static charge causes a variety of problems & challenges in industrial applications:

  • It “zaps” operators who have to handle statically charged materials.
  • It makes sheets and films cling to each other.
  • It can cause tearing or jamming of those sheets and films as well.
  • Objects with high static charges can cause sensors or sensitive electronics to malfunction, and it the charge is high enough, even damage them.
  • It makes dust cling to parts and material that you want to keep clean.
  • It can lead to uneven or spotty coverage if the statically charged piece is to be painted, coated, printed on, etc.

Good news is, static charge is pretty easy to dissipate, and EXAIR Corporation offers a number of solutions that are simple to install and easy to operate.  Among them is the Gen4 Ion Air Jet.

The Gen4 Ion Air Jet generates a concentrated flow of ionized air, which is ideal when you need to focus on a specific spot without disturbing anything in the surrounding area.  They’re quiet, efficient, and OSHA compliant.  They are also available with a number of options to further simply installation & operation:

If you can hard plumb an air pipe directly, the Gen4 Ion Air Jet is ready to go, right out of the box.

Ion Air Jet

The Gen4 Stay Set Ion Air Jet includes a Magnetic Base and 12″ Stay Set Hose, for quick setup and easy aiming of the ionized air flow, exactly where you want it.

The Magnetic Base and Stay Set Hose make it a breeze to mount & aim your Ion Air Jet.

The Gen4 Instant Static Elimination Station adds a foot pedal and two 10ft compressed air hoses, perfect for hands-free on/off operation.

For a total hands-free solution, look no further than the Model 8910 Instant Static Elimination Station.

The Gen4 Deluxe Stay Set Ion Air Jet Kit adds an Automatic Drain Filter Separator and Pressure Regulator so you can keep your air supply clean & moisture free, and dial in the flow & force of the ionized air stream, from a breeze to a blast, or anywhere in between, depending on the needs of your application.

The Model 8495-9362 Deluxe Stay Set Ion Air Jet Kit has everything you need, right out of the box.

We offer two Power Supply options: the Model 7960 has two ports, which will operate any two EXAIR Static Eliminator Products, and the Model 7961 has four ports, to operate up to four Static Eliminators.  They’re switchable for operation with either 115VAC or 230VAC, and come with both cables for your convenience.

Model 7960 Gen4 Power Supply (top) has two ports; Model 7961 (bottom) has four, depending on how many Static Eliminators you wish to operate from the same Power Supply

The Gen4 Ion Air Jet is just one of EXAIR Corporation’s eight distinct lines of Static Eliminator Products.  If you’ve got a problem with static charge, we can help.  Give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook

Static Eliminators, Gen4 Ionizing Points: Overview

Gen4 Ionizing Points

EXAIR has an extensive static control product line called the Gen4 Static Eliminators. In this blog, I will cover our smallest unit, Model 8199 Gen4 Ionizing Point™. They are a low-cost solution for point-of-use targeting. They are UL Component Recognized as well as CE compliant in safety and electromagnetic compatibility. EXAIR was also able to keep compliant with RoHS and REACH with our updated product design.

Static is all around us. It is caused by non-conductive materials having their electrons move from one atom to another. When parts get bumped, rubbed, or peeled; static can be generated. Process problems will start to appear like jamming, alignment, debris clinging and hazardous shock to personnel. The Gen4 Ionizing Point is a single point ionizer and is a great solution to remove static chstatic discharge, static arges within in small compact areas. And they can be used in air duct systems that already have their own air supply to blow ionized air.

The Gen4 Static Eliminators are specifically made for rugged industrial use. And the Gen4 Ionizing Point falls into that same group. It may be small, but it is durable. The high voltage cable has a robust construction; made from a PVC coated, stainless steel armored cable to withstand many common hazards and abrasions. The ionization is created by a stainless steel emitter point which is removable and replaceable. This helps to insure continuous problem-free operations. And once the emitter point wears from use, it can be replaced very simply and economically. The Gen4 Ionizing Point comes standard with a 5-foot (1.5 meter) cable; but, other cable lengths up to 50 feet (15 meter) can be made upon request. This shockless design has an integrated ground to connect the Gen4 Ionizing Point to the Gen4 Power Supply. Thus, no separate ground connections are required.

Model 8299
Ionizing Point

The ionizers are powered by a 5,000 Vac Gen4 Power Supply. The input voltage is selectable for either 115Vac or 230Vac in both 50/60 hz; and, the alternating current will create both negative and positive ions. So, no matter what type of static charge is on the surface, the Gen4 Ionizing Point will be able to remove it. The Gen4 Power Supplies come in either a 2-port or 4-port design; so, you can power multiple ionizers with one power supply. Together, they can eliminate static very quickly; even at 2” (51mm) from the surface.

Model 7905 Digital Static Meter

Some industrial areas that could use the Gen4 Ionizing Point would be slitting, trimming, hemming, winding, labeling, or for neutralizing duct air. Static is an invisible force that can cause many issues and problems. To find if static is a problem in your application, EXAIR does offer a Digital Static Meter, model 7905, to measure the amount of static in kilovolts. It is a great tool for finding problem areas in your process as well as determining the effectiveness of the treatment.

How could this get any better for our U.S. and Canadian customers? EXAIR is offering a free promotional item, an AC Sensor, with a purchase of any of the Gen4 Static Eliminators until February 29th, 2020. This is a $58.00 value which you will get for free. This sensor provides a non-contact way to verify if voltage is present. A red light at the tip will glow, and an audible tone will sound when voltage is detected. The model 7929 AC Sensor is an ideal tool to quickly verify that power is going to your ionizer. This instrument will also work for finding power in receptacles, junction boxes, switches and breaks inside power cords. Batteries are included, so you can start using it right after purchasing a robust Gen4 Static Eliminator, including the Gen4 Ionizing Point.

If you find that static is creating process difficulties, wasting time, and costing you money, EXAIR has a large line of Gen4 Static Eliminators that can help you. We stock product from 108” (2743mm) wide down to the Gen4 Ionizing Point. If you would like to discuss further, you can contact an Application Engineer at EXAIR for help in selecting the correct model for your static problems.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

The 3 Types of Static Generation

Static electricity is something that we talk about often here at EXAIR, particularly during the colder winter months. When an atom gains or loses an electron from its outer shell, it becomes electrically imbalanced. A material’s propensity to either gain or lose an electron is “ranked” on a list known as the Triboelectric Series. So how does static actually generate, or what causes these atoms to either gain or lose an electron? There are three types of static generation: contact, detachment, and frictional static build up.

Contact static build up is one of the simplest methods of static generation. In this type of static generation, a charge is generated simply from two objects contacting one another and separating. This often results in an instantaneous static charge as the electrons are transferred from one object to another in accordance with the Triboelectric Series.

redplasticbox_peel
As a layer of material is peeled off, electrons are transferred from one sheet to another.

The second type of static generation is known as detachment static buildup. The principle behind the type of static electricity is the same as contact static buildup, but the materials are already in contact with one another and the charge is generated as the surfaces are separated. During the separation, not all of the electrons are able to get back to their original molecule. The amount of static generated in detachment static buildup is generally far greater than contact static buildup due to the large surface area.

BOSE 2

The last type of static generation is frictional static buildup. When two objects have friction between one another, electrons in the outer valences of the molecules can easily pass from one atom to another. If the force pressing the objects together increases, even more molecules come into contact with each other and increase the charge that is generated. Just as detachment static buildup, frictional static buildup generally produces higher charges than contact static buildup.

Gen4 Static
Gen4 Static Eliminators

Regardless of the type of static generation occurring in your process, EXAIR has a Static Eliminator that is suitable for neutralizing that charge and mitigating any issues that you’re having as a result. With a team of Application Engineers standing by to help and our unconditional 30 day guarantee, there’s no reason to not give us a call and try one out!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

Super Ion Air Wipes – Eliminate Static on Wire, Cable, Extrusions

Gen4 Super Ion Air Wipe

As the colder dryer months are upon us, static electricity will be more frequent and will become a real nuisance.  Machines will start jamming, alignments will be difficult, dirt will collect to surfaces, and hazardous sparks can shock personnel.  EXAIR manufactures a line of Gen4 Static Eliminators to remove this nuisance.

EXAIR manufactures eight different product lines in two different styles within our Gen4 Static Eliminators.  In this blog, I will be covering the Super Ion Air Wipe.  This product blows ionized air in a 360-degree pattern.  They are engineered to remove static and debris from the outside of hoses, plastic pipe, extrusions, and coated wires.  With a split design, the Gen4 Super Ion Air Wipe can easily mount around the product without having to re-thread.  EXAIR stocks two different sizes with a 2” (51mm) and 4” (102mm) inside diameter. The Super Ion Air Wipes give a fast static-decay, a shockless and non-radioactive design, variable flow and force, low air consumption and no moving parts.

8462 Super Ion Air Wipe Kit

The Gen4 Super Ion Air Wipe can be purchased as a kit which will include the power supply (required for ionization), a filter separator (to clean contamination from the compressed air), and a pressure regulator (to control the blowing force).  The filter and regulator are properly sized to avoid any air flow restrictions or loss of performance which can occur when using components which are not suited for the application.

Static

Generally speaking, static is generated from non-conductive surfaces being “rubbed”.  This could be from going over rollers on a conveyor, stacking product onto each other, sheet feeding, and even peeling away a backing material.  When non-conductive surfaces, or insulators, are moved or separated, electrons are “stripped” and redistribute on to different areas of the surface.  Static charges are typically measured in kilovolts (kV), or 1,000 volts, and they can be either positive or negative.  The higher the charge, the stronger the static force.  In reference, at 10 kilovolts, a spark can jump one inch (25 mm) from the surface.   EXAIR offers a Digital Static Meter, model 7905, to measure the amount of static voltage on a surface.  It is a great tool for finding problem areas in your process as well as determining the effectiveness of the treatment.

All EXAIR Gen4 Static Eliminators use one of two Power Supplies – your choice of the 2-port Model 7960, or the 4-port Model 7961.

These ionizers are powered by a 5,000V AC power supply.  The alternating current, AC, will create both negative ions and positive ions.  So, no matter the polarity of charge on the surface, the Gen4 Static Eliminators will be able to remove it.  The power supplies come in either a 2 port or 4 port design so you can power multiple Gen4 Static Eliminators with one power supply.  The input power is selectable from either 115VAC or 230VAC in both 50/60 Hz.   Two armored and electromagnetic shielded cables connect the Super Ion Air Wipe to the power supply. This will help to protect the cable from abrasions, cuts and splits which can be common in rugged industrial areas.

Static can be a real nuisance with shocking operators, “sticking” debris, and jamming processes.  If you run into these issues in your application, no matter the shape, EXAIR has a Gen4 Static Eliminator for you.  Even if you have cylindrical objects like tubes, pipes, hoses and extrusions; EXAIR can provide the Gen4 Super Ion Air Wipes in stock.  For more information, you can contact one of our Application Engineers at EXAIR.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Static Electricity: What Is It And The Products To Solve Industrial Process Problems

The lower relative humidity associated with the cold, dry air of winter results in a significant increase in customers  with problems related to static. Luckily, EXAIR has a wide-range of Static Eliminators that are designed specifically to address static issues in a wide variety of industries. So, what exactly is static and how is it generated? Let’s take a quick trip down memory lane to elementary school science class….

An atom consists of three basic particles: protons, neutrons, and electrons. The protons (positively charged) and neutrons (neutral charge) form the nucleus. Outside of the nucleus, electrons (negatively charged) are quickly zipping around in orbits at specific distances from the nucleus. These electrons are bound to the nucleus due to electromagnetic force. Opposite charges attract. Since the protons in the nucleus carry a positive charge this acts on the negative charge of the electrons and keeps them in orbit. The closer the electron to the nucleus, the stronger the bond and the more energy required to break that electron from its original orbit.

When an atom gains or loses an electron, it affects the balance that occurs within an atom. If an atom gains an electron, it now has more electrons than protons. This results in a negatively charged atom. The opposite can be said if an atom loses an electron, it now carries a positive charge. This charge imbalance is where static electricity comes from. Both positive and negative charges will remain static until contacted by or in close proximity to a conductive or grounded surface. Materials such as paper, plastic, or textiles will normally contain an equal number of both positive and negative ions. When subjected to friction, this balance can be disturbed if the atoms gain or lose an electron.

The static charge will then exert a force on nearby charged objects or grounded conductors (including personnel). These issues can also manifest in the form of dust clinging to product, product clinging to itself, rollers, machine beds or frames, materials jamming, and sheet feeding problems.

To eliminate these charges, EXAIR’s Static Eliminators produce an equal amount of both positive and negatively charged ions. This allows us to neutralize either charge quickly and effectively.

For applications that allow you to install close (generally within 2”) to the surface of the material, we offer our Ionizing Bar in lengths ranging from 3”-108”. If a wide area of coverage is necessary, but you can’t get close to it, the same Ionizing Bar is installed on the Super Ion Air Knife to help deliver those ions over a greater distance.

gen4 super ion air knife
Gen4 SIAK

The Ionizing Point is another product that can be used without the need for compressed air. A compact, single point ionizer, this product is ideal for winding, rewinding or slitting operations. It can also be mounted through a duct to neutralize static charges due to moving air or materials.

ionpointCUTCARDS_350x
Gen4 Ionizing Point

The Ion Air Gun combines incredibly fast static decay rates with low compressed air consumption. With a 10’ flexible armored cable and ergonomic handle, the Ion Air Gun is best for applications where an operator will perform the blowoff process.

72G4Iagions_800x

If the airflow pattern from the Ion Air Gun is conducive to your application, but you’d prefer to automate the blowoff or maintain a continuous usage, both the Ion Air Jet and the Stay Set Ion Air Jet provide an identical airflow pattern. The Stay Set Ion Air Jet comes with a magnetic base and Stay Set Hose, allowing you to precisely position the static eliminating ions in your process.

staysetiaj_559x

The Ion Air Cannon delivers a quit, efficient, and concentrated flow of ionized air. It is ideal for hard to reach spaces or confined areas that necessitate a solution to static problems. Designed with a sturdy stand, the pre-drilled holes can be wall, bench, or machine mounted. It incorporates a swivel adjustment for directing the airflow.

Our Gen4 Static Eliminators have all undergone independent laboratory tests to certify that they meet the rigorous safety, health, and environmental standards of the USA, European Union and Canada that are required to attain the CE and UL marks. If there’s a process in your facility that could benefit from a solution to static problems, please give us a call. Any of our Application Engineers will be happy to help select the best option for your process.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

The Impact of Cold Temperatures and Lower Humidity on Static Electricity

This time of the year it is not uncommon to feel a slight shock after walking across a carpeted surface and touching a door knob. This little “jolt” is a result of fast-moving electrons leaping from your body to the door knob, or vice versa. As your feet shuffle across the surface of a rug or carpet, your body will either gain or lose electrons. Touching a conductive surface then causes these electrons to leap from one place to another. This is known as static electricity.

2843109634_8982d7710c_o

If you notice, this happens to occur much more often during colder winter months (if you’re one of those fortunate people to live outside of this sensation we call “cold” please don’t rub it in!). The reason that you experience static shocks more frequently during winter is due to the relative humidity. At colder temperatures, air does not hold as much moisture as it does when it’s warm and moisture helps to conduct electrical charges. Even though you’re heating your house to a similar temperature, the air that is being drawn into your home and heated is still the dry cold air containing less moisture.

The amount of moisture in the air is expressed as relative humidity. This value is given as a percentage of water vapor in the air, compared to how much it could hold at that temperature. In conditions of lower relative humidity, static charges build up much easier. When the relative humidity is high, there’s a higher concentration of water molecules present in the air. These water molecules “coat” the surface of the material, allowing electrons to move more freely and form a layer over the material. This layer of water molecules acts like a lubricant, reducing the forces that cause static to generate. This is why static is much more noticeable during the winter months.

Gen4 Static
Gen4 Static Eliminators

There are many applications that static only appears when the seasonal climate changes. Issues can manifest in the form of nuisance shocks to operators, materials jamming, tearing or curling, product sticking to itself and to rollers, dust clinging to product, and many more. If static is causing problems in your processes, we have a wide variety of Static Eliminators available from stock. Don’t just deal with the problems until humid conditions return, get a permanent solution in place that’ll neutralize the static and eliminate a troublesome application. Contact an EXAIR Application Engineer today and we’ll help to diagnose the root cause of the problem and recommend the best solution.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

 

Photo courtesy of Ken Bosma via Flickr Creative Commons License