ELTEX R55 User manual

Operating Instructions
R55 Ion Blower Head
PR55 Ion Blower Pistol
for AC Operation
BA-en-2015-1910
F01036y

2BA-en-2015-1910_R55

BA-en-2015-1910_R55 3
List of contents
1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Identification of risks and hazards . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Work and operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 Contact protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 Inspection of the protective resistors - contact protection . . . . . . . . 13
2.6 Technical advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Installation and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Connecting the high voltage cable to the blower head . . . . . . . . . . 14
3.3 Connecting the high voltage cable to the power supply
of series ES5x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Routing the high voltage cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5 Connecting compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.6 Routing the air hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.7 Compressed air properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.8 Distance setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.9 Height setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.10Impact of heat radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.11Balancer (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Operating voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3 Function control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1 Cleaning the nozzle inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Filter / Filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.3 Inspection of the protective resistors - contact protection . . . . . . . . 20
6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9 Dimensions and brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10 Spare parts and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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A Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
A.1 Inspection Instruction Ion Blower Head R55. . . . . . . . . . . . . . .30
A.1.1 Electrical Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
A.1.2 Mechanical and visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
A.2 Inspection Instruction Ion Blower Pistol PR55 . . . . . . . . . . . . .32
A.2.1 Electrical Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
A.2.2 Mechanical and visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

BA-en-2015-1910_R55 5
Dear customer,
Electrostatic charges occurring during production processes often cause
severe disruptions, reducing production speed and product quality.
The R55 Ion Blower Head and the PR55 Ion Blower Pistol are both com-
ponents of the established Eltex discharging system with outstanding
range and depth effect.
The powerful decoupling effect of neutralizing charge particles supported
by the blown air results in a high degree of efficiency in discharging, even
at larger distances from the product.
The air exit profile is tuned to the discharging and/or ionization gap such
that the transition from pile to shingle stream is possible even at high cycle
rates. In reverse order, i.e. when going from shingles to copies, the ion
blower head allows straight-edged stacking at high process speeds. Also,
shingle stream separation is greatly improved.
Charged surfaces binding dirt particles can be efficiently discharged both
with the blower pistol and with the blower head, removing dust effectively
before print finishing.
The air flow exiting from the hole-type nozzles is turbulent. Due to its opti-
mized flow geometry, the fishtail nozzle delivers a target-specific spot air
flow for long ranges.
The compact design of the new ion blower head and its high efficiency
allow a wide variety of applications.
Please read these instructions carefully before starting the unit. This will
help you prevent personal injuries and damage to property.
Simply give us a call if you have any suggestions, proposals or ideas for
improvements. We greatly appreciate the feedback from the users of our
appliances.

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1. Overview
1 High voltage cable 5 Blower head housing
2 Flexible tube 6 Hole-type nozzle
3 Cable gland, high voltage cable 7 Emission tips two rows
4a Air connection for air hose DN8 8 Fishtail nozzle
threaded connection in the 9 Filter (for PR55/F)
blower head M12 x 1.5 10 Cable fixing
4b Air connection for air hose DN10 high voltage cable
threaded connection in the
pistol G 1/4"
(air supply not included in the delivery)
Fig. 1:
Outline drawing
R55 ion blower
head and
PR55 ion blower
pistol
Z-116124ay + Z-116131b_1y



B


"#$








C
C



BA-en-2015-1910_R55 7
A axial design, high voltage cable with flexible tube
B radial design, high voltage cable with flexible tube
C radial design, high voltage cable without flexible tube
1 High voltage cable
2PlugX
3 Cable gland (non-detachable)
4 Air connection
5 Ion blower housing
6 Hole-type or fishtail nozzle
7 Emission tips, two-row
8 Balancer
9 Adjusting wheel of the balancer
Fig. 2:
Ion blower pistol
PR55 with
balancer and
duo spiral tube
with air supply and
cable routing R55
Z-116875y










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Design variants
R55 ion blower head
Ion blower housings (axial and radial design) and two different nozzle
inserts are available:
• hole-type nozzles (turbulent air flow)
axial: R55/AL, radial: R55/RL
• fishtail nozzles (optimized flow geometry for maximum reach)
axial: R55/AB, radial: R55/RB
R55E ion blower head
Combination bar body, nozzle and permanently connected high voltage
cable
PR55 ion blower pistol
Ion blower pistols available:
- with and without filter
- with and without flexible tube (only with balancer)
- with top air connection (with and without balancer) or
with bottom air connection
- two different ion blower housings
• hole-type nozzle
without filter, top air connection, with balancer: PR55/PL
without filter, top air connection: PR55/OL
without filter, bottom air connection: PR55/NL
with filter, top air connection, with balancer: PR55/HL
with filter, top air connection: PR55/GL
with filter, bottom air connection: PR55/FL
• fishtail nozzle
without filter, top air connection, with balancer: PR55/PB
without filter, top air connection: PR55/OB
without filter, bottom air connection: PR55/NB
with filter, top air connection, with balancer: PR55/HB
with filter, top air connection: PR55/GB
with filter, bottom air connection: PR55/FB
To protect the blower heads from damage, the heads are fitted with pro-
tective rubber edging.
Brackets:
• Standard bracket with steel angle pieces
• Universal bracket (rods)
The different design versions can be freely combined in any configuration.

BA-en-2015-1910_R55 9
To prevent damaging, we advise the use of a balancer together with an ion
blower pistol. The cable routing is made parallel to the air routing in a spi-
ral tube (see Fig. 2). A balancer without air and cable routing is available
as optional equipment under article no. 111569.
A design with grease filter is available for ultra-clean blowing air. The
grease filter solely serves to eliminate grease and fat particles from the
piston gear of the blower pistol. Cleaned apparatuses air must be used as
compressed air.

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2. Safety
The units have been designed, built and tested using state-of-the-art engi-
neering, and have left the factory in a technically and operationally safe
condition. If used improperly, the units may nevertheless be hazardous to
personnel and may cause injury or damage. Read the operating instruc-
tions carefully and observe the safety instructions.
2.1 Proper Use
The ion blower head R55 and the ion blower pistol PR55 must be used
only for discharging static surfaces, for separating stacked or wound
sheets, and for cleaning dusty surfaces.
The ion blower heads R55 and the ion blower pistol PR55 must be opera-
ted only together with the 5 or 6 kV AC Eltex power supplies which ensure
an optimum match with the required operating conditions. Other uses are
not permitted.
The manufacturers will not assume any liability and warranty if the units
are used improperly or used outside the intended purpose.
Modifications or changes made to the devices are not permitted.
Use only original Eltex spare parts and equipment.
2.2 Identification of risks and hazards
Possible risks and hazards resulting from the use of the units are referred
to in these operating instructions by the following symbols:
Warning!
This symbol appearing in the operating instructions refers to operations
which, if carried out improperly, may result in serious personal injuries.
Caution!
This symbol appearing in the operating instructions refers to operations
which, if carried out improperly, may result in damage to property.

BA-en-2015-1910_R55 11
2.3 Work and operational safety
Warning!
Carefully observe the following notes and the complete chapter 2 "Safety”,
page 10!
• Before carrying out repairs, cleaning or maintenance work and before
resetting after malfunctions, switch off the power supply and disconnect
the mains supply voltage (see chapter 5 "Maintenance”, page 19, chap-
ter 6 "Troubleshooting”, page 21).
• Before carrying out any work involving the units, the machine which has
the units fitted mut not be in operation (see chapter 5 "Maintenance”,
page 19, chapter 6 "Troubleshooting”, page 21).
• Any work involving the units must be carried out by qualified electri-
cians (see chapter 5 "Maintenance”, page 19, chapter 6 "Troubleshoot-
ing”, page 21).
• Connect or disconnect the high voltage cable only with the power sup-
ply switched off (see chapter 3.4 "Routing the high voltage cable”,
page 15, chapter 3.5 "Connecting compressed air”, page 15).
• The bars passively absorb energy from the moving substrate web. The
high voltage cable must be plugged in or grounded to the power supply.
If the high voltage cable is disconnected, the plug is live (high voltage)
and applies with full power on the plug; this may cause a spark dis-
charge and may lead to a risk of injury. Disconnected high voltage plugs
are not permitted or have to be grounded (see chapter 5 "Mainte-
nance”, page 19).
• Check the units and the high voltage cables at regular intervals and
before startup for any damage. Any damaged components must be
repaired or replaced before continuing to operate the unit, or the units
must be disabled.
•Warning!
The cable is permanently fixed to the PR55 ion blower pistol and the
R55E ion blower head and must on no account be changed. In the
event of defects, please notify Eltex Service or return the unit for repair.
• The high voltage cable must be routed to make sure that it does not
make contact with moving machine parts. Avoid mechanical deforma-
tions and bending radii smaller than 60 mm. Do not route the high volt-
age cable along the floor because the cable should be trodden on. The
high voltage cable installed should not be exposed to tensile stress
(see chapter 3.6 "Routing the air hose”, page 15).
• The air hose must be routed to make sure that it does not make contact
with moving machine parts. Avoid mechanical deformation and exces-
sively small bending radii (see manufacturer´s specifications), see
chapter 3.6 "Routing the air hose”, page 15).

12 BA-en-2015-1910_R55
• Cleaned apparatuses air must be used as compressed air (see chapter
3.7 "Compressed air properties”, page 16).
• To ensure that the permissible operating temperature is not exceeded,
the ion blower head resp. the ion blower pistol must not be exposed to
direct heat radiation (see chapter 3.10 "Impact of heat radiation”,
page 16).
• Do not open the balancer! It holds a set of springs which may result in
personal injury if used improperly (see chapter 3.11 "Balancer
(optional)”, page 17).
• Attach the ion blower head via the bracket (bracket types see chap. 9
Dimensions and brackets) on the air nozzle provided. Keep a minimum
distance from metallic parts of 10 mm (see chapter 3.1 "Assembly”,
page 14).
• To avoid severe damage, keep other objects from hitting against the ion
blower head (see chapter 4 "Operation”, page 18).
• Make sure that the units are clean at all times.
Dirt results in malfunctions and in premature wear of the units.
• When cleaning the bars do not soak the bars and the high voltage cable
in solvent and do not damage the emission tips; allow the solvent to
evaporate completely before restarting the unit (see chapter 5 "Mainte-
nance”, page 19, chapter 6 "Troubleshooting”, page 21).
• Do not touch the emission tips - risk of injury.
If the high voltage supply is connected, reflex responses to electrical
irritation can lead to secondary accidents; the charging bar as such is
safe to touch. If contact is made (single touch), the energy transferred
is so low that there is no risk of injury.
• Potential risk for wearers of cardiac pacemakers:
Moving the chest closer than 3.5 cm to the emission tips of the
discharging bars or making surface contact with several emission tips
(touching a single tip is not critical) can result in a temporary switchover
of the cardiac pacemaker into the fault mode. Permanent proximity or
contact can therefore cause severe problems.
If it is likely that the chest of such a person comes closer than 3.5 cm to
the emission tips of the discharging bar, or if several emission tips are
touched at the same time, the appropriate warning notices must be dis-
played.
• The operation of the bars can generate ozone. The ozone concentra-
tion levels developing near the bars depend on many different factors
such as site of installation, bar current and voltage, air circulation, etc.,
and can therefore not be specified in general terms.
If the maximum allowable concentration of ozone must be observed at
the site of installation of the bar, the concentration must be measured
on site.

BA-en-2015-1910_R55 13
The AGW value (maximum admissible concentration) serves to assess
the ozone concentration at the workplace. The user must make sure
that the appropriate national AGW value is at no times exceeded, e.g.
in Germany the ozone concentration occurring during the operation of
the system must not exceed the recommended value based on interna-
tional limits of 0.06 ml/m³ (0.12 mg/m³)
2.4 Contact protection
The site of installation and/or use of the units is outside the control of
Eltex, contact protection against inadvertent contact of the bars and of live
components by personnel as specified by the employer’s liability insu-
rance association may have to be provided (e.g. DGUV V3 in Germany).
Contact protection devices made of conductive material must be
grounded.
2.5 Inspection of the protective resistors - contact protection
The function and the appearance of the protective resistors must be
inspected at regular intervals. The inspection intervals are specified in the
accident prevention regulations, as amended (e.g. in Germany DGUV
V3). Eltex recommend inspection intervals of 6 months.
The function of the series resistors must be checked using a suitable
measuring device. The test voltage must be 1,000V. The measured resis-
tance between the high-voltage connection and the individual emission tip
must not fall below 104 MOhm and not exceed 156 MOhm.
Please note that only one of the two emission tip rows is connected to the
high voltage connection and the other to the shield connection.
2.6 Technical advance
The manufacturer reserves the right to make changes to the technical
specifications without prior notice in order to adapt the units to state-of-
the-art engineering. Eltex will provide the latest information on any
changes or modifications in the operating instructions on request.

14 BA-en-2015-1910_R55
3. Installation and assembly
3.1 Assembly
Attach the ion blower head via the bracket (bracket types see chap. 9
Dimensions and brackets) on the air nozzle provided. Keep a minimum
distance from metallic parts of 10 mm.
To prevent damaging the blower heads, we advise the use of a balancer
together with an ion blower pistol. The cable routing is made parallel to the
air routing in a spiral tube (see Fig. 2 ). A balancer without air and cable
routing is available as optional equipment under article no. 111569.
3.2 Connecting the high voltage cable to the blower head
Depending on the unit version, e.g. PR55 or R55E with a fixed high vol-
tage cable, the high voltage cable is permanently fixed to the blower head.
Unit version with detachable cable connection:
Warning!
Connect or disconnect the high voltage cable only with the power supply
switched off.
Connect the ion blower head to the power supply using the prefabricated
high voltage cable. Push the high voltage cables into the sockets up to the
stop. Then the cable gland is screwed in up to the stop.
3.3 Connecting the high voltage cable to the power supply of
series ES5x
Warning!
Connect or disconnect the high voltage cable only with the power supply
switched off .
Connect the ion blower head to the power supply using the prefabricated
high voltage cable. Push the high voltage cables into the sockets up to the
stop. Then secure the adapter in the socket with the clip provided (see
Fig. 3).

BA-en-2015-1910_R55 15
Warning!
In applications involving moving ion blower heads, the high voltage cable
must be attached such that there is no cable movement near the connec-
tion zone of the ion blower head and the power supply unit. Use suitable
clamps to attach the high voltage cables.
3.4 Routing the high voltage cable
The high voltage cable must be routed to make sure that it does not make
contact with moving machine parts. Avoid mechanical deformations and
bending radii smaller than 60 mm. Do not route the high voltage cable
along the floor because the cable should be trodden on. The high voltage
cable installed should not be exposed to tensile stress.
In applications using movable bars (e.g. film draw strips), attach the high
voltage cables such that there is no cable movement near the connection
point to the power supply.
3.5 Connecting compressed air
The ion blower head R55 is supplied with an air nipple DN8 and the ion
blower pistol PR55 with an air nipple DN10 or a 10 mm plug-in connection
(variant with balancer). Attach the hose for the air supply to the air nipple
(4, Fig. 1). Secure the air hose with a hose clip or a cable binder. The hose
must have an internal diameter of 8 mm.
3.6 Routing the air hose
The air hose must be routed to make sure that it does not make contact
with moving machine parts. Avoid mechanical deformation and exces-
sively small bending radii (see manufacturer´s specifications).
Abb. 3:
Anschluss der
Hochspannungs-
kabel
Z00178y

16 BA-en-2015-1910_R55
3.7 Compressed air properties
The compressed air must be free from oil, water and dust. If the air supply
hoses are very long, a water separator must be fitted immediately
upstream from the ion blower. Maximum rated air pressure is 6.0 bar.
Cleaned apparatuses air must be used as compressed air.
3.8 Distance setting
The ion blower heads used for separating piles to feed into a shingle
stream must be mounted at a distance of approx. 3...20 mm from the edge
of the pile (see Fig. 4). In other applications the distance ought to be
between 10 and 50 mm.
The distance setting is also selected depending on the air pressure set-
ting.
3.9 Height setting
A certain height setting of the ion blower head is required for optimum
sheet separation from pile to shingle stream. The ionized air flow must be
able to penetrate the top paper sheets. Adjust the height of the ion blower
head via the attachment bracket.
3.10 Impact of heat radiation
To ensure that the permissible operating temperature is not exceeded, the
ion blower head resp. the ion blower pistol must not be exposed to direct
heat radiation.
In the event of heat radiation caused by hot moulds or blowing tools, a
sheet metal guard (3 mm gauge) or a special plastic guard must be pro-
vided. A sheet metal guard must not be allowed to make direct contact
with the ionization head and must always be grounded.
The ion blower head may also be operated with pulsed compressed air to
prevent tools from cooling down, for instance. The compressed air will
only be switched on when the tool opens to eject a moulded part.
Fig. 4:
Distance setting
Z00131y
3...20 mm

BA-en-2015-1910_R55 17
3.11 Balancer (optional)
Suspend the balancer from a suitable attachment point. You may also use
an appripriate tripod or stand.
Adjust the desired spring force.
To avoid unnecessary wear and tear, make sure that the balancer moves
freely.
Adjusting the spring force
• Make sure that the ropes moves freely over its entire length.
• Hang the ion blower pistol onto the lower hook and secure it against
inadvertently falling off.
• Check the condition of the rope at regular intervals. If damaged, the
balancer must be replaced at once for safety reasons.
• Do not use the balancer above its maximum load of 1.0 kg.
Warning!
Do not open the balancer! It holds a set of springs which may result in per-
sonal injury if used improperly.
+To increase the spring force, turn the rotary button
anticlockwise.
-To decrease the spring force, turn the rotary button clockwise.

18 BA-en-2015-1910_R55
4. Operation
4.1 Startup
Once all the connections have been made correctly, the system is opera-
tional and the supply voltage can be switched on at the power supply. The
ion blower head and the ion blower pistol are also operational now.
4.2 Operating voltage
The blower head and the blower pistol are supplied via the high voltage
supply unit. The appliances are operated with an optimum operating volt-
age of 5 resp. 6 kV.
4.3 Function control
Use the Eltex Volt Stick or a glow-lamp voltage tester to check the proper
function of the emission tips. Quote Article No. 109136 when ordering the
Volt Stick from Eltex.
Caution!
To avoid severe damage, keep other objects from hitting against the ion
blower head!

BA-en-2015-1910_R55 19
5. Maintenance
Warning!
Electric shock hazard!
• Switch off the power supply unit and disconnect the supply voltage
before carrying out any maintenance or repair work.
• The bars passively absorb energy from the moving substrate web. The
high voltage cable must be plugged in or grounded to the power supply.
If the high voltage cable is disconnected, the plug is live (high voltage)
and applies with full power on the plug; this may cause a spark dis-
charge and may lead to a risk of injury. Disconnected high voltage plugs
are not permitted or have to be grounded.
• The machine which has the units fitted must not be in operation.
• Repairs and maintenance work must be carried out by qualified
electricians.
5.1 Cleaning the nozzle inserts
To ensure the trouble-free function of the ion blower heads, the surface
from which the emission tips and the compressed air exit must be clean
and dry at all times. Dirty blower heads must be cleaned with a suitable
solvent (cleaning gasoline) and a brush with soft plactic bristles. To pre-
vent the air exit holes from clogging up with dirt during cleaning, the com-
pressed air (0.3...0.5 bar) must be switched on during cleaning.
Warning!
Risk of deflagration!
Allow the solvent to evaporate completely before restarting the unit.
Caution!
Do not damage the emission tips when cleaning.
5.2 Filter / Filter change
Inspect and, if necessary, exchange the filter for dirt deposits at regular
intervals.
Hold filter casing tight, loosen and pull off the union nut.
Exchange the filter and turn back in reverse order. Finally, check the
proper assembly.

20 BA-en-2015-1910_R55
5.3 Inspection of the protective resistors - contact protection
The function and the appearance of the protective resistors must be
inspected at regular intervals. The inspection intervals are specified in the
accident prevention regulations, as amended (e.g. in Germany DGUV
V3). Eltex recommend inspection intervals of 6 months.
The function of the series resistors must be checked using a suitable
measuring device. The test voltage must be 1,000V. The measured resis-
tance between the high-voltage connection and the individual emission tip
must not fall below 104 MOhm and not exceed 156 MOhm.
Please note that only one of the two emission tip rows is connected to the
high voltage connection and the other to the shield connection.