Desco Chargebuster 60473 Installation and operating instructions

DESCO WEST - 3651 Walnut Avenue, Chino, CA 91710 • [phone]
DESCO EAST - One Colgate Way, Canton, MA 02021-1407 • [phone] • Website: Desco.com
TB-3031 Page 1 of 8 © 2014 DESCO INDUSTRIES, INC.
Employee Owned
Chargebuster® Overhead Ionizer
Installation, Operation and Maintenance
Description
The Desco Chargebuster® Overhead Ionizers are steady
state DC ionizers designed to cover 2 foot by 5 foot (60473)
or 2 foot by 4 foot (60640) for use in ESD sensitive work.
The specially designed 3-speed fan modules create better
coverage, consistent offset voltage (±10 Volts) and superior
discharge times (< 3 seconds) tested per ANSI/ESD STM
3.1. The Chargebuster® Overhead Ionizer is equipped with
an Auto-Feedback system that continuously optimizes the
performance and will automatically shut down and alarm
should the supply voltage drop.
“Necessary non-conductors in the environment cannot lose
their electrostatic charge by attachment to ground.
Ionization systems provide neutralization of charges on
these necessary non-conductive items (circuit board
materials and some device packages are examples of
necessary non-conductors). Assessment of the ESD
hazard created by electrostatic charges on the necessary
nonconductors in the work place is required to ensure that
appropriate actions are implemented, commensurate with
risk to ESDS [ESD sensitive] items”. (ANSI/ESD S20.20
Foreword)
“In order to mitigate field-induced CDM [Charged Device
Model] damage, the ESD program shall include a plan for
the handling of process-required insulators. If the field
exceeds 2,000 volts/inch, steps shall be taken to either: A)
Separate the insulator from the ESD-sensitive device by a
distance of 30 cm (12 inches); or B) Use ionization or other
charge mitigating techniques to neutralize the charge.”
(ANSI/ESD S20.20 section 8.3)
“The primary method of static charge control is direct
connection to ground for conductors, static dissipative
materials, and personnel. A complete static control program
must also deal with isolated conductors that cannot be
grounded, insulating materials (e.g., most common plastics),
and moving personnel who cannot use wrist or heel straps
or ESD control flooring and footwear.
November 2014
Air ionization is not a replacement for grounding methods.
It is one component of a complete static control program.
Ionizers are used when it is not possible to properly ground
everything and as backup to other static control methods.
In clean rooms, air ionization may be one of the few
methods of static control available.” (ESD Handbook ESD
TR20.20 Ionization, section 5.3.6.1)
“All ionization devices will require periodic maintenance for
proper operation. Maintenance intervals for ionizers vary
widely depending on the type of ionization equipment and
use environment. Critical clean room uses will generally
require more frequent attention. It is important to set-up a
routine schedule for ionizer service. Routine service is
typically required to meet quality audit requirements.” (ESD
Handbook ESD TR20.20 section 5.3.6.7 Maintenance /
Cleaning)
The Chargebuster® Overhead Ionizer is available in two
models:
Item Fans Input Voltage Power Cord
60473 3120 VAC North America
60640 2 120 VAC North America
Packaging
1 Chargebuster® Overhead Ionizer
1 Hanging Kit
1 Power Cord, North American Plug
3 Emitter Point Cleaners (60473)
2 Emitter Point Cleaners (60640)
1 Certificate of Calibration
Installation
Place the unit at a desired location where that the airflow will
not be restricted. Be sure that the ON/OFF switch located
on the rear of the unit is in the OFF position. Plug the power
cord into the unit and then into the appropriate AC power
source.
Operation
1. Set the fan speed switch to the LOW, MED, or HI
position. Higher airflow will result in faster neutralization
rates.
2. Position the ionizer so that maximum airflow is directed
towards the items or area to be neutralized.
3. Turn the unit ON. When the unit is first turned on, it
conducts a self-test. The audible alarm will sound and
the LED will cycle through the colors red, yellow and
green. The LED will remain green during normal
operation.
Made in the
United States of America
TECHNICAL BULLETIN TB-3031
Figure 1. Desco 60473 Chargebuster® Overhead Ionizer
Figure 2. Desco 60640 Chargebuster® Overhead Ionizer

DESCO WEST - 3651 Walnut Avenue, Chino, CA 91710 • [phone]
DESCO EAST - One Colgate Way, Canton, MA 02021-1407 • [phone] • Website: Desco.com
TB-3031 Page 2 of 8 © 2014 DESCO INDUSTRIES, INC.
Employee Owned
Maintenance
“All ionization devices will require periodic maintenance for
proper operation. Maintenance intervals for ionizers vary
widely depending on the type of ionization equipment and
use environment. Critical clean room uses will generally
require more frequent attention. It is important to set-up
a routine schedule for ionizer service. Routine service is
typically required to meet quality audit requirements.” (ESD
Handbook TR20.20 section 5.3.6.7 Maintenance / Cleaning)
EIA-625, recommends checking ionizers every 6 months, but
this may not be suitable for many programs particularly since
an out-of-balance may exist for months before it is checked
again. ANSI/ESD S20.20 section 6.1.3.1 Compliance
Verification Plan Requirement states: “Test equipment shall
be selected to make measurements of appropriate properties
of the technical requirements that are incorporated into the
ESD program plan.”
CLEANING THE EMITTER POINTS
Under normal conditions, the ionizer will attract dirt and dust
(especially on the emitter points). To maintain optimum
neutralization efficiency and operation, cleaning should be
performed on a regular basis.
In the event of circuit failure, the unit will enter shutdown
mode.
When the unit enters shutdown mode, ionization will be
stopped, the LED on the front of the unit will illuminate a
constant red, and the audible alarm will continuously sound.
The user must then reset the unit by turning it OFF and back
ON.
The emitter points should be cleaned using the included
Emitter Point Cleaners or a swab dampened with Isopropyl
alcohol.
1. Turn the unit OFF and unplug the power cord.
2. Open the top screen by
loosening the screw and
swinging the grill to one
side.
3. Clean the emitter points
using the included Emitter
Point Cleaners or a swab
dampened with Isopropyl
alcohol.
4. Reattach the top screen.
5. Plug in the power cord
and turn the unit ON.
6. Verify the performance of
the ionizer by using a
charged plate monitor, or
ionization test kit.
With normal handling, the emitter points should not require
replacement during the life of the unit. If necessary,
item 60507 Replacement Emitter Points are available for
purchase.
Adjustments and Compliance Verification
BALANCE OFFSET VOLTAGE ADJUSTMENT
The Chargebuster® Overhead Ionizer is an auto-balancing
unit. However, tuning or manual adjustment can be
accomplished by inserting a small screwdriver or trimmer
adjustment tool into the balance adjustment hole. To
increase the output in a positive direction, turn the
potentiometer clockwise. To increase the output in a
negative direction, turn the potentiometer counter-clockwise.
INPUT VOLTAGE CONFIGURATION
WARNING - Risk of electric shock
These servicing instructions are for use by qualified
personnel only. Do not perform any servicing of internal
parts unless you are qualified to do so.
NOTE: The AC power cord MUST always be disconnected
before the unit is disassembled.
The input voltage may be verified or reset by opening the
ionizer’s enclosure. This can be accomplished by removing
the 10 screws that secure the cover to the base.
The ionizer’s input voltage can be configured to 120 VAC or
220 VAC using the JH1 jumpers located on its PCB. See
Figures 3 and 4 for these configurations.
Figure 3. 120 VAC jumper
setting
Figure 4. 220 VAC jumper
setting
If the supply voltage drops from 110 Volts to below 85 Volts
or from 200 Volts to below 170 Volts, the unit will shut down,
the audible alarm will beep and the LED will blink red. The
unit will automatically reset when the minimum voltage is
restored.
Auto-balancing closed-loop feedback technology can save
money and extend the maintenance interval of the ionizer.
What the sensor detects is that the offset voltage (balance)
has shifted and the circuits will attempt to compensate. In
the case of corona ionizers, one of the reasons for a shift in
offset voltage is frequently the particle buildup, commonly
called a “fuzz ball”, observed on the emitter points.
Compliance Verification should be per ESD TR53. Offset
voltage (balance) and both polarity’s discharge time should
be checked on every ionizer periodically using an Ionization
Test Kit or a Charged Plate Analyzer. Measure offset
voltage (balance) and both polarity’s discharge times. Clean
the emitter points (with electrical power off), adjust offset
voltage (balance) to zero and then re-test for offset voltage
(balance) and discharge times recording the measurements.

DESCO WEST - 3651 Walnut Avenue, Chino, CA 91710 • [phone]
DESCO EAST - One Colgate Way, Canton, MA 02021-1407 • [phone] • Website: Desco.com
TB-3031 Page 3 of 8 © 2014 DESCO INDUSTRIES, INC.
Employee Owned
Calibration
When an alarm sounds, most users will clean emitter pins
(see Maintenance / Alarms section) and calibrate the ionizer.
Per ESD TR 53 section 5.3.6.7.1 “The best practice is to
measure the offset voltage and discharge times, clean the
unit, including emitter points and air filters if present, offset
voltage to zero (if adjustable), and then repeat offset voltage
and discharge time testing. If the unit does not meet offset
voltage specifications or minimum established discharge
time limits, further service is indicated. Manufacturers should
provide details on service procedures and typical service
intervals.”
Most companies will assign a number or otherwise
identify each ionizer and setup a compliance Verification /
Maintenance / Calibration schedule. If the ionizers all test
good, the data can justify lengthening the calibration period.
If ionizers require adjustment the calibration period should
be shortened. Although ESD TR53 does not advise a test
frequency, JESDD625-A (Revision of EIA-625) recommends
ionizers be tested semiannually, noting to use “S3.1 except
the number of measurement points and locations may be
selected based on the application.”
NOTE: A charged plate analyzer or monitor should be used
in order to properly calibrate the Chargebuster® Overhead
Ionizer. The EMIT 50571 Charged Plate Analyzer can be
used to calibrate the Chargebuster® Overhead Ionizer.
1. Properly setup the ionizer as described in the Installation
procedure on page 1.
2. Turn the unit ON and set the FAN SPEED to HIGH.
3. Position the charged plate analyzer 18 inches
underneath one of the fans of the ionizer.
4. Push and hold the ALARM RESET button on the ionizer
until the STATUS LED turns red. Release the button and
the LED should switch back to green. This allows the
user to calibrate the balance (offset voltage) of the
ionizer without setting off the alarm.
5. The balance (offset voltage) of each fan should be within
0 and ±10 volts. The required limit per ANSI/ESD S20.20
is less than ± 50 volts. To increase the output in a
positive direction, turn the BALANCE ADJUST
potentiometer in a clockwise direction. To increase the
output in a negative direction, turn the BALANCE
ADJUST potentiometer in a counter-clockwise direction.
6. Test the neutralization (discharge) time by applying
a ±1,000 volt on the charged plate. The neutralization
(discharge) time should be less than 3 seconds when
charged plate analyzer is directly under a fan. See
the “Neutralization (Discharge) Times” section for typical
discharge times. The required limit per ANSI/ESD
S20.20 is “user defined”.
7. Submit the balance (offset voltage) to the ionizer’s
control circuit by quickly pressing the ALARM RESET
button. The STATUS LED should turn off and then
illuminate green to verify that the control circuit was
successfully programmed.
8. Test each fan’s alarm by shorting its two grills located on
the bottom side of the ionizer. The alarm should sound
and the STATUS LED should illuminate red.
Figure 5. Calibration controls Figure 6. Shorting the ionizer’s two fan grills

DESCO WEST - 3651 Walnut Avenue, Chino, CA 91710 • [phone]
DESCO EAST - One Colgate Way, Canton, MA 02021-1407 • [phone] • Website: Desco.com
TB-3031 Page 4 of 8 © 2014 DESCO INDUSTRIES, INC.
Employee Owned
Neutralization (Discharge) Times
All data was taken with the fan speed set to high. All time measurements are in seconds. The distance between the
overhead ionizer and charged plate is 18" per ANSI/ESD STM 3.1.
NOTE: Discharge times in seconds are representative only and are not a guarantee. Discharge times are actual
measurements recorded in a factory ambient environment.
Per ANSI/ESD S20.20, the test method for Product Qualification test is ANSI/ESD STM3.1, and for Compliance Verification
is ESD TR53 which advises “Measurements should be made at the location where ESD sensitive items are to be ionized.”
A larger area may require additional ionizers. Per S20.20 the required limit for ionizer discharge time is user defined. Use
Table to determine the number of ionizers to achieve ionization of area to be neutralized to meet your company’s ESD control
plan specified discharge times.
TP1
+10.4
-11.8
16" 16"
12"
12"
Charged Plate
16"
Figure 7. 60473 Neutralization (Discharge) Times at 100VAC, 50Hz input
TP4
+3.4
-3.7
TP7
+3.3
-3.6
TP10
+9.1
-9.7
TP2
+4.1
-4.8
TP5
+2.0
-2.3
TP8
+2.2
-2.7
TP11
+3.4
-3.9
TP3
+7.5
-8.4
TP6
+2.6
-3.2
TP9
+3.0
-3.9
TP12
+7.0
-9.1

DESCO WEST - 3651 Walnut Avenue, Chino, CA 91710 • [phone]
DESCO EAST - One Colgate Way, Canton, MA 02021-1407 • [phone] • Website: Desco.com
TB-3031 Page 5 of 8 © 2014 DESCO INDUSTRIES, INC.
Employee Owned
TP1
+8.2
-9.5
16" 16"
12"
12"
Charged Plate
16"
Figure 8. 60473 Neutralization (Discharge) Times at 120VAC, 60Hz input
TP4
+2.2
-2.9
TP7
+2.2
-2.8
TP10
+5.5
-6.7
TP2
+2.5
-3.4
TP5
+1.4
-1.9
TP8
+1.9
-2.3
TP11
+2.3
-2.8
TP3
+5.2
-6.8
TP6
+2.1
-2.8
TP9
+2.4
-2.8
TP12
+5.8
-7.6
TP1
+10.1
-10.8
16" 16"
12"
12"
Charged Plate
16"
Figure 9. 60473 Neutralization (Discharge) Times at 220VAC, 50Hz input
TP4
+3.2
-3.4
TP7
+2.7
-3.0
TP10
+7.5
-8.4
TP2
+3.1
-3.2
TP5
+2.0
-2.1
TP8
+1.9
-2.0
TP11
+3.4
-4.2
TP3
+5.2
-5.4
TP6
+2.4
-2.6
TP9
+2.6
-3.0
TP12
+6.7
-7.5

DESCO WEST - 3651 Walnut Avenue, Chino, CA 91710 • [phone]
DESCO EAST - One Colgate Way, Canton, MA 02021-1407 • [phone] • Website: Desco.com
TB-3031 Page 6 of 8 © 2014 DESCO INDUSTRIES, INC.
Employee Owned
TP1
+9.9
-11.9
16" 16"
12"
12"
Charged Plate
16"
Figure 10. 60640 Neutralization (Discharge) Times at 100VAC, 50Hz input
TP4
+2.7
-3.6
TP7
+3.3
-4.0
TP10
+15.6
-22.8
TP2
+9.1
-11.8
TP5
+1.7
-2.1
TP8
+1.8
-2.2
TP11
+9.6
-12.8
TP3
+13.5
-17.5
TP6
+3.9
-4.7
TP9
+3.8
-5.4
TP12
+14.8
-22.9
TP1
+7.1
-9.3
16" 16"
12"
12"
Charged Plate
16"
Figure 11. 60640 Neutralization (Discharge) Times at 120VAC, 60Hz input
TP4
+2.0
-2.8
TP7
+2.5
-3.0
TP10
+10.3
-11.1
TP2
+6.1
-7.0
TP5
+1.4
-1.7
TP8
+1.9
-2.2
TP11
+8.5
-9.5
TP3
+9.8
-11.1
TP6
+3.0
-3.9
TP9
+3.7
-5.2
TP12
+10.7
-14.6

DESCO WEST - 3651 Walnut Avenue, Chino, CA 91710 • [phone]
DESCO EAST - One Colgate Way, Canton, MA 02021-1407 • [phone] • Website: Desco.com
TB-3031 Page 7 of 8 © 2014 DESCO INDUSTRIES, INC.
Employee Owned
TP1
+8.9
-11.8
16" 16"
12"
12"
Charged Plate
16"
Figure 12. 60640 Neutralization (Discharge) Times at 220VAC, 50Hz input
TP4
+3.2
-3.5
TP7
+2.2
-3.2
TP10
+12.3
-14.9
TP2
+8.1
-9.2
TP5
+1.6
-2.1
TP8
+1.3
-1.8
TP11
+10.3
-14.4
TP3
+10.7
-11.3
TP6
+3.1
-3.6
TP9
+3.1
-4.3
TP12
+10.8
-12.8

DESCO WEST - 3651 Walnut Avenue, Chino, CA 91710 • [phone]
DESCO EAST - One Colgate Way, Canton, MA 02021-1407 • [phone] • Website: Desco.com
TB-3031 Page 8 of 8 © 2014 DESCO INDUSTRIES, INC.
Employee Owned
Specifications
The comparative efficiency of overhead ionizers is
determined by a standard test published by the ESD
Association: ANSI/ESD STM 3.1. Typical positive and
negative discharge times (1000V - 100V) measured using
this standard are shown in the “Neutralization (Discharge)
Times” section. The performance of the ionizer was
measured with the unit positioned as shown, with the fan
speed on high and without a filter.
Air Flow
60473 - Three speed fan (150 cfm - 300 cfm)
60640 - Three speed fan (100 cfm - 200 cfm)
Balance (offset voltage)
±10 Volts Typical
±20 Volts Maximum
(Temperature Range: 65°F - 80°F, RH: 15% - 65%)
Chassis
Powder coated steel
Dimensions
60473 - 3.9" H x 6.6" W x 37.3" L
(9.9cm H x 16.8cm W x 94.7 cm L)
60640 - 3.9" H x 6.6" W x 22.3" L
(9.9cm H x 16.8cm W x 56.6 cm L)
Emitter Points
.050" diameter
Made of pure tungsten for improved mechanical strength and
ionization stability.
Fuse
400mA slow blow
High Voltage Power Supply
5.5kV DC nominal
Input Power
AC line power
Internally selectable for 100/120 VAC - 50/60Hz or
220/230 VAC - 50/60Hz
Ion Emission
Steady-state DC with sense feedback
Mounting
May be rigid-mounted or suspended from ceiling
Ozone
< 0.05 ppm
Weight
60473 - 10 lbs (4.5 kg)
60640 - 7 lbs (3.2 kg)
Limited Warranty, Warranty Exclusions, Limit of
Liability and RMA Request Instructions
See Desco Terms and Conditions
Health
There are no known health risks associated with our devices.
The emitters work at about 4-6 kV and can create ozone,
but there have been no significant measurement of ozone
from our emitter sets, as all our existing units test well below
the OSHA limit of 0.05 ppm ozone. For additional safety
information, see “Dispelling an Old Myth” written by William
Metz of Hewlett-Packard published in Evaluation Engineering
Magazine, September 2001.

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