If you’re having problems with static build up on small and/or lightweight materials where even the smallest amount of airflow can disturb the product, EXAIR has the perfect solution, the EXAIR Gen4 Ionizing Point. The Gen4 Ionizing Point is a single point ionizer that lends itself naturally to winding, rewinding, slitting or a myriad of other applications. It can even be mounted through the wall of a duct to neutralize static charges in an existing air or conveyance duct.
The Gen4 Ionizing Point is very powerful and robust solution that can dissipate 5,000 volts in .24 seconds from 2″ (51mm) away! The Gen4 Ionizing Point features an electromagnetically shielded high-voltage cable that is armored to protect against abrasion and cuts and its integrated ground design does not require a separate ground connection. For even more convenience the Gen4 Ionizing Point is replaceable if the point should ever become dull or bent.
Its smaller footprint naturally lends itself to installation into the limited space normally associated with smaller applications. The stainless steel, and replaceable, emitter point is mounted in a saddle that is 1.77″ (45mm) long by 1″ (26mm) wide and includes two .20″ (5mm) mounting holes that are 1.44″ (37mm) apart for easy mounting.
Gen4 Ionizing Points are supplied power by either the model 7960 power supply which can operate up to two ionizing products or the 7961 that can operate up to four ionizing products. Both models feature selectable voltage to run on either 115 VAC or 230 VAC.
Static electricity can cause jamming of machines, misalignment, collection of dirt and debris, and shock hazards to personnel. EXAIR manufactures a variety of Static Eliminators to remove this common nuisance. In this blog, I will examine our most versatile product within the Static Eliminators; the Gen4 Ion Air Jets.
The Gen4 Ion Air Jets are a modification to the EXAIR Air Jets. The Air Jets create a high velocity air stream along an engineered Coanda profile. This profile will create a low pressure at the entrance of the Air Jet to draw in ambient air. This makes the Air Jet very efficient as it utilizes more ambient air than compressed air at a ratio of 5:1. Also, with the engineered design, we are able to create a laminar air stream to carry ions to the target.
The ions are generated at the exit of the Air Jet by an ionizing point. This ionizer can create a large amount of positive and negative ions. This allows for two things to occur. They are able to eliminate any type of static charge, and they can establish a fast decay rate in removing the static charges. The replaceable emitter point inside the Gen4 Ion Air Jet allows for an easy, cost-effective way to recondition the unit for years of life.
What operates the Gen4 Ion Air Jet is the power supply. It is the “engine” behind the ion generation. EXAIR offers two types; the model 7960 which has two output ports and the model 7961 which has four output ports. They are very useful to operate multiple units with just one power supply. They have a selectable input voltage to operate between 115Vac and 230Vac. The transmission line that connects the Gen4 Power Supply to the Gen4 Ion Air Jet is our high voltage cable. This cable has an armored coating to resist cuts and wear. It also has an integrated ground and is electromagnetically shielded. Together with the Gen4 Ion Air Jet, you get a compact powerful unit that can remove static quickly for spot blowing and cleaning.
Overall, the operation of the Gen4 Ion Air Jet is similar to the Gen4 Ion Air Gun; but, with the Ion Air Jet, it is mainly used for “hands-free” operations. With a small amount of compressed air, the unit can “shoot” the ions onto a small surface up to 15 feet (4.5 meters) away. They are very quiet, and they meet the OSHA requirements for dead-end pressure and noise allowance. They are very easy to control with a regulator to adjust the flow from a breeze to a blast. The design of the ionizing point is shockless and does not use any radioactive materials. The applications would include neutralizing static and cleaning objects for three-dimensional parts, screen printing, glass lenses, shrink bands and much more.
The Gen4 Ion Air Jet is the most versatile product in our Static Eliminator line. It can be permanently mounted or attached to a Stay Set Hose for flexible adjustments and maneuverability. EXAIR packages the Gen4 Ion Air Jets with other products to make it easy to set-up, control, and operate. Here are the packages that EXAIR stocks for quick delivery.
Model: 8194 – The Gen4 Ion Air Jet only. It comes with a 5 foot (1.5 meter) armored and electromagnetically shielded cable. They are typically used for permanent mounts with a 1/8” NPT male connection, and are generally purchased with the other packages below.
Model: 8294 – The Gen4 Ion Air Jet with a model 7960 Gen4 Power Supply. This unit is the basic requirement for a permanent mount application. The Gen4 Power Supply has two outputs, so it can support another Gen4 Ion Air Jet.
Model: 8494 – Gen4 Ion Air Jet Kit. This kit includes the Gen4 Ion Air Jet, Gen4 Power Supply, a filter separator and a pressure regulator with coupling kit. This kit allows for cleaning the compressed air before entering the Gen4 Ion Air Jet as well as controlling the air requirements. So, you will be able to maximize the efficiency of these units.
Model: 8194-9362 – Gen4 Stay Set Ion Air Jet. We attach the Ion Air Jet to a 12” Stay Set Hose and a magnetic base with shut-off valve. The magnetic base will hold the Gen4 Ion Air Jet to a steel surface while the 12” Stay Set Hose gives flexibility to direct the ionized air at a specific point. This product works great if the Ion Air Jet need to be moved into different locations. (This does not include the Gen4 Power Supply)
Model: 8294-9362 – This is the Gen4 Stay Set Ion Air Jet (as described in the package above) with a model 7960 Gen4 Power Supply.
Model: 8494-9362 – This is the Gen4 Stay Set Ion Air Jet Kit. Like with the standard units, this package will add a filter separator and a pressure regulator to the model 8294-9362.
Model: 8495-9362 – Gen4 Deluxe Stay Set Ion Air Jet Kit. The Deluxe Kit includes additional items to the model 8494-9362 package. It will include a foot pedal and 10 feet (3 meters) of a compressed air hose. The foot pedal gives this system that “hands-free” operation to turn on/off the air flow to the Gen4 Ion Air Jet to blow air only when you need it.
Model: 8910 – Gen4 Instant Static Elimination Station. This is a slight modification to the 8495-9362 Deluxe Kit. The filter separator and pressure regulator are replaced with an additional 10 foot (3 meter) compressed air line. Now you can connect from the compressed air source to the foot pedal to the magnetic base. Once you attach the Gen4 Ion Air Jet to the supplied Gen4 Power Supply, you have a station ready to operate.
Static creates process problems, reduces productivity, and costs you money. EXAIR manufactures a large line of Static Eliminators that can help you. If you need a compact, low-cost ionizer to blow off and clean small targets, then the Gen4 Ion Air Jet would be a great option. You can contact an Application Engineer at EXAIR to see which package would work best for you to remove that static nuisance.
When the weather gets dry and cool, static can be generated very easily, and it can become a real nuisance. For the printing industry, static forces can pull or push the ink droplets which can create poor print quality like “ghost” images. Static can also cause contamination to “stick” to the surface of the sheets affecting the printing process. This can slow production, generate high scrap rates, and allow for poor quality. In this blog, I will share the details about a printing company having static problems and a simple solution with a Gen4 Static Eliminator.
For this printing company, static was causing issues in print quality on their polypropylene sheets. Polypropylene is a non-conductive material which can generate high amounts of static that can cause many issues. Their manual operation of moving, sliding, and picking up of the polypropylene sheets was generating the static. Now that we found the cause, I had to determine a solution.
They sent pictures to describe the process in more detail. An operator would pick up a sheet with the dimensions of 3 feet wide by 5 feet long (0.9 meters by 1.5 meters) from a bin. He or she would load three polypropylene sheets onto a wide vacuum table next to the printing machine. The table had an indicating bar which used yellow/green lights to align each sheet. Once the indicator lights turned green, this meant that the sheet was aligned properly, and the operator would then hit a switch.
A dual rail with vacuum cups would come over and “grab” the three sheets. The vacuum rail would pull the new sheets onto a sliding platform at the same time removing the printed sheets into a stacking area. With the new sheets, this sliding platform would travel into the print machine where the print head would create the images.
Once the printing was completed, the sliding platform would come back to the original position where the process would repeat itself. With all the handling and moving of the polypropylene sheets, static was being generated. To improve their printing process by removing the static, we had to target an area where we would not have to worry about static regenerating.
EXAIR is a leading manufacturer of Static Eliminators, and we had a good discussion in solving his issue. Ideally, we want to place the Static Eliminator just before the printing process. In this application. I recommended to them to locate a Gen4 Ionizing Bar just behind the indicating bar. This would remove any static as the sheets were going onto the sliding platform. Since the sheets were 3 feet (0.9 meters) wide, we needed to cover a span of 9 feet (2.7 meters) total. Believe it or not, EXAIR manufactures and stocks an Ionizing Bar this long!!!
For this customer, they would not have to worry about any stop gaps in coverage with a single length product. Also, the profile for the Gen4 Ionizing Bar is very thin and would not interfere with the vacuum rail system. So, when the vacuum rail picks up the polypropylene sheets, the Gen4 Ionizing Bar will be able to remove the static from the printable surface.
I recommended the model 80108 Gen4 Ionizing Bar with the model 7960 Gen4 Power Supply. This model can emit ions that can cover a span of 108 inches (2.73 meters). The Gen4 Power Supply, which generates a 5,000 Volt signal, connects to the Gen4 Ionizing Bar with an electromagnetically shielded durable cable. The alternating current generated by the Power Supply allows for the creation of both positive and negative ions from each point. This will ensure neutralization of any type of static.
The Ionizing Bar can be positioned between 0.5” (13mm) to 2” (51mm) from the sheet surface to optimize decay rates. After they mounted and started using the Ionization Bar, the static was removed quickly, and the printing issues were eliminated. With a quick and simple set up of the Gen4 Ionizing Bar, they were able to get back on track with great quality and fast productivity.
If you have static issues with your printing process, you can contact an Application Engineer at EXAIR. We will be happy to make your static issues disappear and your vibrant images reappear.
EXAIR’sGen4 Super Ion Air Knife and Ionizing Bars are a great way to relieve static charges in your products and/or processes. They are a very powerful, efficient design that will eliminate static charges and require only minimal maintenance to keep them performing at peak efficiency.
Check out the video below to see just how easy it is!
When you are looking for expert advice on your static relief application or any of our safe, quiet and efficient point of use compressed air products give us a call. We would enjoy hearing from you!
The lower relative humidity associated with the cold, dry air of winter results in a significant increase in calls related to static problems. Luckily, EXAIR has a wide-range of Static Eliminators that are designed specifically to address static issues in a variety of industries. 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. This gaining/losing of an electron causes the atom to be electrically imbalanced.
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. Our Gen4 Static Eliminators have 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.
One of these such products is the Gen4 Ion Air Cannon. EXAIR’s Gen4 Ion Air Cannon neutralizes static charges at distances up to 15 feet without any moving parts. Utilizing EXAIR’s 2” Super Air Amplifier, the Ion Air Cannon will maximize ionized airflow while minimizing compressed air consumption. The strong, concentrated, quiet, and efficient ionized air is capable of eliminating a 5kV charge in as little as .37 seconds.
With a wide variety of Static Eliminating products available from stock, don’t wait for your static problems to subside when humidity levels come back up in the spring. Get yourself a Gen4 Static Eliminator from EXAIR and make sure you’re able to operate, static-free, for the rest of this winter and in the subsequent seasons to come!
If you’re a regular reader of EXAIR Application Engineering blogs, you’ll likely recognize the words “easy to do business with.” And if you’re an EXAIR customer, you’ve likely found that to be true – from customer service, to technical support, to shipping your order – and, of course, the product itself. We get calls, from time to time, asking about what kind of “engineering system design” services we offer…and the simple answer is, it’s already been included in the product itself. Most of the time, installation of an EXAIR Intelligent Compressed Air Product requires basic hand tools, and a compressed air supply.
One exception to this is our Static Eliminators product line: they also require electricity. Good news is, the “engineering system design” is included for these products as well, in the Power Supply. Gen4 Static Eliminator Power Supplies are energized by either 115VAC or 230VAC. Cables for both are provided; the 115VAC three-prong grounded plug being the most common…just plug it in to any grounded wall outlet, and you’re in business.
Connecting EXAIR Gen4 Static Eliminators to the Power Supply is just as easy. All of our Gen4 Static Eliminator Products have a 5ft (1.52m) cable (except the Ion Air Gun…it’s got a 10ft, or 3.04m cable) with a bayonet end for easy, safe, and reliable connection to the Power Supply. The Model 7960 Gen4 Power Supply has two ports, which can accommodate any two Gen4 Static Eliminators. This is often quite convenient…for example, Super Ion Air Knives are commonly used in pairs, to eliminate static on both sides of a sheet or film.
Occasionally, a Static Eliminator needs to be installed in such a way that its 5ft (1.52m) cable cannot reach the desired location of the Power Supply, or an Ion Air Gun needs a longer cable to get everywhere in the space it’s being used in. Or sometimes, a 5ft cable is simply too long. To meet those needs, our shop can make custom length cables, precisely to any length you require, up to 50ft (15.2m) in length, for any Static Eliminator. The only limitation, “engineering system design”-wise is 100ft (30.4m) of total cable length from any one Power Supply.
Static electricity is responsible for a multitude of problems from dust clinging to material, to material clinging to itself, to jamming, misfeeding, tearing & curling of product, and last but certainly not least, painful shocks. If you’ve got a static problem you want to get rid of in a hurry, give me a call. We’ve got a solution for you, ready to go, right out of the box.
***Order any qualifying EXAIR Static Eliminator by February 28, 2019, and we will include a FREE AC Sensor. Click here for details.***
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We’ve all been shocked before. And no, I’m not talking about the feeling we all here in Cincinnati felt when the Cincinnati Bengals finally fired Marvin Lewis… I’m referring to the discharge you’ve likely felt on a cold winter day after walking across a carpeted surface and touching a door knob. This electrostatic discharge is a result of static electricity. To understand how this static electricity is generated, let’s first go back to basic chemistry class and talk about the atomic structure of an atom.
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.
The strength of this charge will depend on a few different factors: the types of materials, surface area, environmental conditions, etc. will all play a role in the generation of a static charge. The triboelectric series is a scale, listing various different materials and their tendency to become positive or negative. Those at the far end of the spectrum have an increased propensity to gain or lose an electron, while those in the center are more likely to remain balanced. When two materials on opposite ends of the spectrum come into contact with one another, it poses the greatest risk of generating high levels of static electricity. The chart below shows some common materials and where they fall on the tribolectric series.
When materials carry a static charge, a variety of problems can ensue during manufacturing. These can manifest in the form of painful shocks to operators, materials jamming or tearing, sheet feeding problems, discharges causing imperfections in the material appearance, etc. To remove the charge, we need to introduce static eliminating ions to balance it out. EXAIR’s full line of Static Eliminators create an equal number of both positive and negative ions to saturate the surface of the material and neutralize any charge present.
With a wide range of different solutions all available from stock, EXAIR has the solution to your static problems this winter. Give us a call and we’ll be happy to discuss the application and help to identify the best method to mitigating any static issues in your processes. Take advantage of EXAIR’s current promotion (now through the end of March) and receive a free AC Sensor with your Static Eliminator purchase!