Haug Air Series User manual

Air Line
Operating instructions
Air-assisted ionizing unit DA TR
Ident number: 04.73XX.XXX
Keep for future use!
GB

Table of contents
1Operator instructions .................................................4
1.1 Symbols used in operating instructions ............................ 4
1.2 Symbols on the ionizing unit ............................................. 5
2Safety ..........................................................................6
2.1 Intended use ..................................................................... 9
3Product overview......................................................10
4Install ........................................................................11
5Maintenance .............................................................14
5.1 Cleaning interval.............................................................. 14
5.2 Dry cleaning .................................................................... 15
5.3 Wet cleaning.................................................................... 16
6Troubleshooting .......................................................17
7Accessories/spare parts ..........................................19
8Technical data ..........................................................20
8.1 Supply voltage ................................................................ 20
8.2 Compressed air supply ................................................... 20
8.3 Ambient conditions ......................................................... 21
8.4 Dimensions ..................................................................... 21
9Taking the unit out of service ..................................22
9.1 Storing............................................................................. 22
9.2 Disposing ........................................................................ 22

1Operator instructions
4
1Operator instructions
Before installation and commissioning read these operating
instruction in full. Always observe the safety instructions.
These operating instruction is a part of the product; make sure you
retain them for later use or subsequent owners.
The product is an air-assisted ionization unit and will be referred to in
this Operating Instruction only as “ionizing unit”.
The ionizing unit is operationally safe when used as intended.
The term “high voltage” is abbreviated HV in these operating
instructions (e.g. HV plug).
The illustrations in this document are a simplified representation of
the product. They render only the technical facts and provide
support for the text. Departures from the actual product may be
noticeable. However, these deviations neither reduce the proper
function nor mitigate the specifications of the product.
1.1 Symbols used in operating instructions
Always observe this safety instruction to avoid critical or fatal injuries.
Always observe this safety instruction to avoid slight injuries.
Always observe this safety instruction to avoid damage to property.

1Operator instructions
5
NOTE:
Important notes and additional information.
Never dispose of with household garbage.
Not for use by persons with pacemaker!
Ozone warning!
Device produces ozone!
Caution, danger due to electrical current!
Caution, danger spot warning!
1.2 Symbols on the ionizing unit
WARNING!
High voltage

2Safety
6
2Safety
Only persons authorised by the operating firm are permitted to
proceed with tasks on the ionisation unit.
The installer must be an electrician and must be knowledgeable in
the field of mechanical engineering. He must be an expert in
handling and installing compressed air equipment and must wear
personal protective equipment. The installer must read the operating
manual in its entirety.
The operating and maintenance personnel must be instructed in the
handling of compressed air equipment and the resulting dangers.
Personnel must wear personal protective equipment and completely
read the operating manual.
When working on the ionisation unit, switch off the voltage and
compressed air supply and secure the unit to prevent unintentional
restart. Depressurise the compressed air system.
Dangers due to compressed air equipment
Ruptured or broken
compressed air hoses can move erratically and
can injure persons or lead to consequential accidents. Compressed
air can enter the bloodstream through the broken skin, resulting in
an embolism that can lead to death.
•
Always comply with the safety regulations provided by the
operating company.
•
Before proceeding with maintenance and/or installation tasks,
ensure the entire system is de-pressurised.
•
Never direct the jet of compressed air at people or yourself (for
example, to blow dirt off clothes).
•
Never run a compressed air hose across passageways (tripping
hazard).
•
Never use compressed air equipment without pressure reducer
and compressed air filter.
•
Never exceed the permissible operating pressure.
•
Always use filtered (< 20 μm), dry and oil-free compressed air.
•
Always use suitable hose clamps to secure compressed air
hoses.
•
Wearing personal protective equipment for compressed air-
operated products is mandatory (e.g., safety goggles, ear
protection, dust mask, etc.).

2Safety
7
Interference with pacemaker
The high voltage in the ionizing unit
generates an alternating electric
field with 50 Hz. This may influence the function of pacemakers
which may lead to ventricular fibrillation or cardiac arrest.
•
Persons wearing heart pacemakers must maintain a safety
distance of more than 50 cm from the ionizing unit!
•
The operator must mark the danger zone around the ionizing unit
by means of a warning sign.
•
The accident prevention regulations according to BGV A8 must
be observed.
•
An expert study concerning the impact of an ionization system
on implanted pacemakers is available from HAUG
GmbH & Co. KG.
Hazards caused by manipulated or faulty ionizing unit
Unauthorized modifications,
moisture or damage to the ionizing unit
may result in electric shocks or fire hazards due to sparking.
•
In the event of visible damage or suspected electrical defects,
take the ionizing unit out of operation immediately and secure
against inadvertent reuse.
•
Protect the ionizing unit from moisture. Clean any wetness off the
ionizing unit carefully and allow to dry.
•
Never pull the HV cable.
•
Never carry out any unauthorized repairs to the ionizing unit.
•
Always switch off the discharging power pack when the ionizing
unit is out of use.
•
Never keep any inflammable materials in the vicinity of the
discharging power pack or its components.

2Safety
8
Danger of injury from ionizing pins
The ionizing pins are sharp, pointed and carry a high voltage when
in operation. Contact can result i
n puncture or tear wounds, and the
high voltage will also cause a tingling sensation. These factors can
produce a shock reaction which could lead to accidents.
•
Never touch the ionizing pins.
•
During maintenance / repair work, disconnect the discharging
power pack and wear protective gloves (EN 388 3122).
Physical complaints due to an excess of ozone
During operation, small amoun
ts of ozone are created through the
corona at the ionizing pins. A very high ozone concentration and
prolonged continuous exposure times may result in headache,
irritation to the eyes, circulatory problems etc.
•
Always ensure adequate ventilation during
operation in order not
to exceed the statutory admissible ozone concentration limits at
the workplace.
•
An expert study concerning ozone emissions from a ionization
system is available from HAUG GmbH & Co. KG.

2Safety
9
2.1 Intended use
Risk of explosion!
The ionizing unit may generate sparks which ignite
gases, dust or
similar substances.
•
Never install or use the ionizing unit in areas with potentially
explosive atmospheres.
A power pack from HAUG is required for the HV supply of the
ionisation unit. A compressed air supply must be available.
The ionisation unit is used for contactless surface cleaning in
industrial production processes. It removes electrostatic charges as
well as dust and similar particles.
Due to its design, the ionisation unit is ideally suited for separating
single sheets from stacks of paper and film.
Compliance with the installation and operating conditions specified
in this operating manual is mandatory.
A guarantee can only be provided for equipment and accessories
supplied by HAUG GmbH & Co. KG.

3Product overview
10
3Product overview
A Counter electrode
B Mounting thread M6
C HV plug
D HV cable
E Compressed air connection
F Insulation profile
G Ionisation tips
H Nozzles

4Install
11
4Install
Risk of explosion!
The ionizing unit may generate sparks which ignite gases, dust or
similar substances.
•
Never install or use the ionizing unit in areas with potentially
explosive atmospheres.
Damage to equipment!
Kinking or bending may damage the HV cable and
insulation. This
may result in a short
-circuit.
•
Never kink the HV cable.
•
Never pull the HV cable.
•
When routing around bends, the bending radius not be smaller
than 50 mm.
• Check the HV cable for kinks, cuts etc.
1. Checking whether the ionizing unit corresponds to the ordering
data. In the event of any damage to the ionizing unit, contact
HAUG GmbH & Co. KG.

4Install
12
2. During installation, it must
be ensured that the
ionisation units have a
limited effective range. The
effective range is formed
approximately as shown in
the illustration on the right-
hand side. The width (x) of
the effective range depends
on the distance (a) and can
be approximated.
x = a * 1.8
3. Prepare the selected mounting location in the production process
with regard to the following parameters.
The most ideal distance (A)
between the ionisation unit and
the ionising material is approx.
20 - 300 mm. The limits of the
ionisation effect are min.
10 mm and max. 500 mm.
The clearance between the
ionisation unit and an earthed
machine part (B) must be
greater than the distance to the
ionising material (A).

4Install
13
Earthed machine parts behind
the material to be ionised are
not permitted.
To improve surface cleaning,
aim the air jet approx. 10 - 30°
(A) against the direction of
travel of the product that must
be ionised.
4. Connect the compressed air connection to the compressed air
supply.
• Use compressed air hose Ø 6 x 4 mm.
5. Lay the HV cable in curves (r = > 50 mm) as far as the
discharging power pack. Observe the operating instructions of
the discharging power pack.
6. Connect the ionizing unit to
the HV terminal of the
discharging power pack.
• Insert the ionizing unit’s
HV plug in the HV
terminal of the
discharging power pack
and press the HV cable
until it reaches the stop.
• Screw the screw cap
onto the HV terminal and tighten by hand.
7. The ionizing unit is ready to operate.

5Maintenance
14
5Maintenance
Risk of injury!
The ionizing pins are sharp and
pointed. During cleaning of the
ionizing unit, there is a risk of injuries to the hand due to needle
-
pricks, tears or cuts.
•
Always wear protective gloves (EN 388 3122) when carrying out
maintenance and cleaning work on the ionizing unit.
Damage to equipment!
The ionizing unit can be damage
d by using unsuitable brushes and
cleaning agents.
•
We recommend using our cleaning accessories. Refer page 19.
•
Use a brass wire brush (corrugated Ø 0.15 mm) or plastic fibre
brush (hardness level soft).
•
Use pharmaceutical alcohol.
•
Never use a high-pressure cleaner.
•
Never use aggressive cleaning agents (e.g. acetone, cellulose
thinner, toluene, xylene etc.).
Always switch off the ionisation unit prior to maintenance and
cleaning work and de-pressurise the system.
5.1 Cleaning interval
Contamination reduces the ionizing effect of the ionizing units. It can
be improved by cleaning.
• Clean the ionizing pins of the ionizing units at least every 14
days.
• The higher the degree of ambient contamination, the shorter the
cleaning intervals.
• The duration of cleaning depends on the type and degree of
contamination.

5Maintenance
15
5.2 Dry cleaning
1. Switch off the power pack and secure it to prevent unintentional
restart.
2. Disconnect the ionisation unit from the discharging power pack
and the compressed air supply line.
3. Brush off the ionisation tips with a suitable brush.
4. Vacuum the ionisation unit or blow off with clean compressed air
(max. 6 bar).
Damage to property and risk of fire!
Dirt in the HV connection and HV plug can cause short circuits. Short
circuits cause malfunctions in the power pack and the HV plug.
Neglecting these instructions would damage the ionisation unit or
the power pack and a fire could occur.
•
Check and ensure the HV connections and plugs are clean.
•
The HV connections and plugs must be clean, dry and free of
grease.
5. Reconnect the ionisation unit to the power pack and the
compressed air supply line.
NOTE:
If the result of the dry cleaning is not satisfactory, continue with a
wet cleaning.

5Maintenance
16
5.3 Wet cleaning
1. Switch off the power pack and secure it to prevent unintentional
restart.
2. Disconnect the ionisation unit from the discharging power pack
and the compressed air supply line.
3. Moisten a suitable brush with a suitable cleaning agent. As an
optional, use the RS2 special cleaning system for cleaning.
4. Use a brush to clean the ionisation tips.
5. Use compressed air (max. 6 bar) to clean the ionisation unit, and
then let it dry.
Damage to property and risk of fire!
Dirt in the HV connection and HV plug can cause short circuits. Short
circuits cause malfunctions in the power pack and the HV plug.
Neglecting these instructions would damage the ionisation unit or
the po
wer pack and a fire could occur.
•
Check and ensure the HV connections and plugs are clean.
•
The HV connections and plugs must be clean, dry and free of
grease.
6. Reconnect the ionisation unit to the power pack and the
compressed air supply line.

6Troubleshooting
17
6Troubleshooting
Electric shock hazard!
The ionizing unit is operated with high electric voltage. In the event of
any faults, there is a risk of
an electric shock.
•
Faults may only be eliminated by a trained and qualified
electrician.
NOTE:
If the defect cannot be eliminated in this way, return the ionizing unit
to HAUG GmbH & Co. KG for checking (see back cover for
address).
Fault
Cause
Troubleshooting
Ionisation not
available
The ionisation unit is
contaminated.
Clean the ionisation unit.
No high-voltage
Inspect the power pack.
The ionisation unit is
malfunctioning.
Use the “Combicheck” to
inspect the ionisation unit.
No
compressed
air
Malfunction in the
compressed air
supply.
Check compressed air
supply (hoses, lines,
connections, compressor,
etc.).

6Troubleshooting
18
Fault
Cause
Troubleshooting
Flashover
The ionisation unit is
malfunctioning.
Shut down the ionisation
unit and replace it.
The ionisation tips are
too close to an
electrically conductive
material.
Increase the gap to
object(s) that may cause the
fault.
The ionisation unit is
tainted with electrically
conductive impurity.
Clean the ionisation unit.

7Accessories/spare parts
19
7Accessories/spare parts
Accessories and spare parts can be sourced from your authorized
sales partner or directly from HAUG GmbH & Co. KG (the address is
provided on the back of the envelope).
Item Images
Order
number
HAUG power pack
—
Upon request
Special cleaning
agent SRM1
10.7220.000
Brass special
cleaning brush RB1
10.7218.000
Special cleaning
system RS2
10.7218.004
Disc brush for
special cleaning
system
X – 5677
Plastic fibre cleaning
brush RB3
10.7218.003
Combicheck 12.7231.000
Compressed air
service unit
— 11.7210.001
Compressed air hose
Ø 6 x 4 mm
— X – 6619

8Technical data
20
8Technical data
8.1 Supply voltage
Supply voltage through HAUG
discharging power pack
6,7 ±1 kV~
8.2 Compressed air supply
Compressed air
Filtered (< 20 μm), dry and oil-free
Maximum pressure
5 bar
Operating pressure
1 - 5 bar
Compressed air
consumption in
Nl/min
p = bar