ITW Simco-Ion Chargemaster Pinner User manual

Chargemaster Pinner 5200710 Rev. H
Chargemaster Pinner,
Pinner-R & Pinner-T
Arc Resistant Charging Bars
INSTALLATION AND OPERATING INSTRUCTIONS

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Chargemaster Pinner 5200710 Rev. H
TABLE OF CONTENTS
1. SAFETY AND WARNINGS...................................................................... 1
2. DESCRIPTION ................................................................................... 2
3. SPECIFICATIONS................................................................................ 3
4. INSTALLATION .................................................................................. 4
Option 1: Charging Bar with a Grounded Surface ..............................................................4
Option 2: Charging Bar with Static Neutralizing Bar..........................................................5
Option 3: Two Charging Bars ...............................................................................................6
Top Mounting .......................................................................................................................7
Side Mounting ......................................................................................................................7
Mounting With 5/16-18 Nylon Bolt .....................................................................................7
Mounting With 1/4” Hardware .............................................................................................8
5. OPERATION ...................................................................................... 9
6. MAINTENANCE .................................................................................10
7. TROUBLESHOOTING ..........................................................................11
8. REPLACEMENT PARTS........................................................................12
9. WARRANTY..................................................................................... 13

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Chargemaster Pinner 5200710 Rev. H
1. SAFETY AND WARNINGS
NOTE – Statements identified with a NOTE indicate precautions necessary
to avoid potential equipment failure.
CAUTION – Statements identified with a CAUTION indicate potential
safety hazards.
NOTE – This equipment must be correctly installed and maintained.
Adhere to the following notes for safe installation and operation:
1. Read instruction manual before installing or operating equipment.
2. Only qualified service personnel are to perform installation and repairs.
3. All equipment must be properly grounded, including the machine frame to
which the equipment is mounted and all metal parts in the vicinity.
CAUTION –ELECTRICAL SHOCK HAZARD
Always disconnect power supply before connecting or disconnecting
charging equipment. Never touch a charging bar when power supply is
energized.
CAUTION – FIRE HAZARD
Do not install or operate equipment in close proximity to any flammable
solvents or flammable materials.

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Chargemaster Pinner 5200710 Rev. H
2. DESCRIPTION
Simco-Ion’s Arc Resistant Charging Bars are part of the Chargemaster
Electrostatic Generating System. These bars are energized with Simco-Ion
Chargemaster VCM, CM20, MCM30 DC power supplies that provide the
necessary high voltage that is current limited for safety. This system is used
to produce electrostatic adhesion for temporarily bonding or pinning materials.
The success of the process depends on the insulating qualities of the material
being charged. Good insulators, such as plastic films, work particularly well
with this process.
The Pinner, Pinner-R and Pinner-T bars are resistor-limited to provide arc-resistant
operation. Arc-resistant operation lowers radiated electrical noise that affects
sensitive equipment in the surrounding area and eliminates physical damage to
materials and equipment.
Simco-Ion’s Pinner, Pinner-R and Pinner-T bars limit the amount of electrical
current that is drawn from the Chargemaster Power Supply. It is this advancement
that prevents hard arcs from occurring resulting in several improvements when
compared to traditional charging equipment.
Features
• Increased voltage consistency and pinning action.
• Reduced EMI/RMI that can disturb sensitive electronic components.
• Limited energy release that could otherwise degrade some plastics and other
materials causing additional damage and failures.

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Chargemaster Pinner 5200710 Rev. H
3. SPECIFICATIONS
Input Voltage ±30 kVDC (±50 kVDC with special mounting & insulation precautions)
Output Current 1.5 mA/ft max
Operating Environment 32°F (0°C) to 200°F (90°C); 70% RH Max, no dewing permissible
Operating Distance 1/2”to 3”(application & voltage dependant)
Weight 2.1 lb per foot
Dimensions 3/4”W x 3-1/4”H x (EL + 2”) L
EL = Effective Length (6”to 144”; 3”mults)
Emitter Material Pinner Bar: 316 stainless steel, permanent, resistor limited
Pinner-R Bar: 316 stainless steel, removable/replaceable, resistor limited
Pinner-T Bar: Tungsten, permanent, resistor limited
Casing Material Glass filled vinylester (rugged, impact resistant, light grey color)
High Voltage Cable Flexible, abrasion-resistant, silicone outer jacket rated to ±50 kV, 10-ft
standard length (1/2”min bend radius)

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Chargemaster Pinner 5200710 Rev. H
4. INSTALLATION
Unpacking
Carefully remove equipment from the carton and inspect the contents.
NOTE – If any damage has occurred during shipment, notify the local
carrier at once. A report should also be forwarded to Simco-Ion, 2257 North
Penn Road, Hatfield PA 19440. See Section 9 (Warranty) for Return
Shipment information.
Determining Pinner Bar Location
Although Simco-Ion’s Pinner, Pinner-R and Pinner-T bars prevent hard arcs from
occurring, the bars do exhibit a soft arcing that can be both useful in setting up the
application and useful in keeping the system operational. As the distance between the
Pinner Bar and ground reference is decreased, the first signs of electrical stress will be
observed. The pins will start to display a purple glow and, in quiet surroundings, a
slight sizzling buzz may also be heard as air molecules become stressed. Continuous
operation in this condition will cause premature aging of the bar. Once the power
supply is in position and operational, ensure that there is no purple glow at the
emitter points. It is this purple glow that indicates the overstressed condition and
that the bar is not providing its maximum possible pinning voltage.
CAUTION – FIRE HAZARD
Do not install or operate equipment in close proximity to any flammable
solvents or flammable materials.
Option 1: Charging Bar with a Grounded Surface
In Figure 1, the charging bar faces an empty core in
a roll-to-roll changeover application. The empty core
is mounted on a grounded metal shaft and a plastic
film travels between the charging bar and the empty
core. The negative ions created by the charging bar are
driven toward the grounded metal shaft by an electric
field formed between them. The film blocks ion travel
through the field and becomes electrostatically charged,
resulting in adhesion between the film and roll.
Figure 1

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Chargemaster Pinner 5200710 Rev. H
In Figure 2, the charging bar faces a production
fixture that moves beneath the charging bar
(alternatively the bar could move over the fixture)
in an interleaving application where paper or film
is pinned to metal prior to cutting and stacking.
After the materials to be pinned together are
positioned on the fixture, it moves beneath the
charging bar. The negative ions created by the
bar are driven toward the grounded metal fixture
by an electric field formed between them. The
top material blocks ion travel through the field
and becomes electrostatically charged, resulting
in adhesion between the two materials and the
fixture.
Option 2: Charging Bar with Static
Neutralizing Bar
In Figure 3, the charging bar faces an insulative
film while a static neutralizing bar faces an
insulative sheet of material on the opposite side
(glass, plastic, light particle-board, etc.). As the
two materials to be pinned together pass between
the bars, the negative ions created by the charging
bar charge the film, while the static neutralizing
bar attempts to eliminate the apparent charge on
the sheet. This deposits a positive charge on the
lower sheet. The use of the static neutralizing bar
dramatically improves the electrostatic pinning
adhesion between the two materials.
Figure 2
Figure 3

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Chargemaster Pinner 5200710 Rev. H
Option 3: Two Charging Bars
In Figure 4, one charging bar faces another
of opposite polarity in an application where
decorative sheets are pinned to both sides of
heavy particle board prior to laminating. As
the materials move between the charging bars,
the opposite polarity ions created by each bar
are driven toward each other by an electric field
formed between them. The decorative sheets
block ion travel through the field and become
electrostatically charged, resulting in adhesion
between the two sheets and the particleboard.
With this arrangement, the voltage differential
between the charging bars can be substantial. The
sizeable voltages cause higher levels of charge to be
deposited on the decorative sheets, which results
in the highest level of electrostatic adhesion. This
method of charging materials is generally used
in the most difficult pinning applications. Dual
polarity BP-Series power supplies are designed for
applications like this.
Mounting Charging Bars
CAUTION – FIRE HAZARD
Do not install or operate equipment in close proximity to any flammable
solvents or flammable materials.
CAUTION –ELECTRICAL SHOCK HAZARD
Only qualified service personnel are to perform installation tasks.
CAUTION –ELECTRICAL SHOCK HAZARD
It is essential that the machine frame, and all metal parts in the vicinity,
be grounded either through well-grounded electrical conduit or by heavy
copper wire connecting the frame to a water pipe.
NOTE – Pinner Bars are shipped from the factory with a 50 kV connector
installed on the cable. A 30 kV connector is also supplied and must be
installed for use on all Simco-Ion Chargemaster power supplies with ratings
of 30 kV and lower.
Determine the best location for the for guidance.
Figure 4

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Chargemaster Pinner 5200710 Rev. H
Multi-Function Bracket
Top Mounting
1. Drill a clearance hole in each side of the machine frame to accommodate a 5/16-
18 bolt. Bars exceeding 48” in length require additional support centered on
the bar.
2. Slide bracket into the mounting channel molded into the rear of the charging
bar (see Figure 5) then lock bracket in place using provided set screws.
3. Secure the charging bar to the machine
frame. Tighten 5/16-18 bolt hand-
tight plus ¼-turn only. DO NOT
OVER TIGHTEN MOUNTING
BOLTS.
Side Mounting
NOTE – Side mounting is only
recommended for applications up
to 30 kV)
1. Drill a clearance hole in each side of
the machine frame to accommodate a
1/4” bolt.
2. Drill a clearance hole through bracket
using the pilot holes molded into
bracket to accommodate a 1/4” bolt.
3. Slide bracket into the mounting channel molded into the rear of the charging
bar (see Figure 5) then lock bracket in place using provided set screws.
4. Secure the charging bar to the machine frame using 1/4” bolt and nut. DO
NOT OVER TIGHTEN MOUNTING HARDWARE.
Low Profile Bracket
NOTE – This bracket should only
be used in well maintained
environments and up to 30 kV use)
Mounting With 5/16-18 Nylon Bolt
1. Drill a clearance hole in each side of
the machine frame to accommodate a
5/16-18 nylon bolt.
2. Run 5/16-18 nylon bolt through
bracket. Hex head will sit in hex-
shaped pocket in “T” mounting rib in
bracket.

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Chargemaster Pinner 5200710 Rev. H
3. Slide bracket into the mounting channel molded into the rear of the charging
bar (see Figure 5) then lock bracket in place using provided set screws.
4. Secure the charging bar to the machine frame. Tighten nylon nut hand-tight
plus ¼-turn only. DO NOT OVER TIGHTEN MOUNTING NUTS.
Mounting With 1/4” Hardware
1. Determine how many of the mounting
holes will be used (note: it is not
required to use all six) in mounting.
2. Drill clearance holes in each side of the
machine frame to accommodate 1/4”
hardware.
3. Slide bracket into the mounting
channel molded into the rear of the
charging bar (see Figure 5) then lock
bracket in place using provided set
screws.
4. Secure the charging bar to the machine
frame using 1/4” hardware. DO NOT
OVER TIGHTEN MOUNTING
HARDWARE.
Installing High Voltage Cables
CAUTION –ELECTRICAL SHOCK HAZARD
Turn off power supply before connecting high voltage cable.
1. Route the high voltage cables attached to each charging bar along the machine
frame or wall to the power supply.
2. Cable supports are used to guide the cables back to the power supply. All cables
must be kept a minimum of 1/4” away from machine frame and parts, walls
and ceilings. If this is not possible, encase cables in plastic insulating tubing
(available from Simco-Ion).
3. Ensure that the power supply is de-energized, and then remove the protective
plastic plug from the power supply high voltage connection by gently prying
with an insulted screwdriver.
4. Install spring loaded cable connectors on the free end of each cable, as described
on the enclosed SL instruction sheet.
5. Insert the cable (with spring loaded connector attached) into the power supply
high voltage connection. Screw in the knurled plug to secure the cable.
NOTE – FINGER TIGHTEN ONLY.
Figure 5

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Chargemaster Pinner 5200710 Rev. H
5. OPERATION
CAUTION –ELECTRICAL SHOCK HAZARD
Do not touch Charging Bar during operation.
CAUTION – FIRE HAZARD
Do not operate equipment in close proximity to any flammable solvents or
flammable materials.
1. Before energizing any power supply:
• Ensure that all power supplies are properly grounded.
• Ensure that all charging bars have been properly located, positioned and
installed.
• Ensure all requirements printed in the applicable power supply instructions
have been fully complied with.
2. After the above checks have been performed, simply energize each power supply
to operate the charging bars.
3. Setting Strength of Pinning:
• If charging bar is operating in electrical stress condition (evident by purple
glow on pins and slight sizzling noise), slowly decrease operating voltage of
the power supply.
• If adhesion or pinning strength is not adequate, slowly increase operating
voltage of the power supply.
4. Always turn the power supply OFF when the system is not in use. For safety
and ease of operation, it is recommended to connect the power supply line cord
to the electrical system of the machine in such a manner that the power supply
is only energized when the machine is in operation.
NOTE – Sustained operation in electrical stress will likely interfere with
operation of the charging system. Electrical stress reduces output voltage
from the power supply and suppresses the charging process. Sustained
stressed operation may also damage the bar and power supply.

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Chargemaster Pinner 5200710 Rev. H
6. MAINTENANCE
NOTE – Only qualified service personnel are to perform maintenance tasks.
CAUTION –ELECTRICAL SHOCK HAZARD
De-energize all power supplies before performing any maintenance tasks.
Cleaning Emitter Pins
Dust or dirt around the emitter pins will reduce the effectiveness of the Pinner Bar.
The bar must be cleaned periodically to prevent deposits from accumulating:
1. De-energize all power supplies before performing any maintenance tasks.
2. The cleaning brush supplied with the bar should be used periodically to keep
the emitter pins clean and prevent deposits form accumulating.
NOTE – Never use hard or sharp objects to scrape emitter pins. Pins must
remain sharp for optimal performance.

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Chargemaster Pinner 5200710 Rev. H
7. TROUBLESHOOTING
Troubleshooting Electrical Stress
• Electrical stress can occur between the bar and a ground reference beneath
the target material. This stress typically occurs at edges of material being
charged and comes from the ion emitter points at the end of the Charging Bar.
Eliminate this stress by gradually reducing the operating voltage from the power
supply.
Troubleshooting Electrical Arcing
• If electrical stress occurs between the bar and frame member on which the bar
is mounted, the bar may be improperly mounted. Verify that all equipment has
been properly mounted and grounded.
• If electrical stress occurs from the end of the bar to the side frame of the
machine, slide the bar away from the side frame if possible. If it is not possible
to do this, it may be necessary to install an arc shield, please call your Simco-Ion
representative for more details.
Troubleshooting Low Pinning Strength
• If pinning strength is not adequate and the power supply is already at maximum
output voltage, moving the bar closer to the target material can increase
pinning strength. Reduce the bar-to-material distance until pinning strength
is adequate. At this new distance, it may be necessary to adjust the operating
voltage of the power supply.
• Low pinning strength may also be due to erosion of the emitter points. Sharp
points promote the best ionization of air molecules. Inspect the emitter points,
if they are visibly eroded or corroded follow these steps:
a) Remove contamination by brushing the emitter pins with a non-metallic
brush.
b)If acceptable performance is not restored after cleaning, the pins of the
Pinner-R Bar should be replaced (NOTE- Emitter pins of the Pinner and
Pinner-T Bar are NOT replaceable). Remove existing emitter pins using
needle-nose pliers and replace with new pins in each socket.
c) If acceptable performance is not restored, contact Simco-Ion Customer
Service at [phone].

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Chargemaster Pinner 5200710 Rev. H
8. REPLACEMENT PARTS
Part Number Description
4104481 Cable Support, 7/16” diameter cable
4100286 SLCC HV Connector Kit (30 kV)
5050328 SLCC HV Connector Kit (50 kV)
4670204 Nylon Cleaning Brush
5050690 Replacement Pin Kit (110 emitter pins)
4810276 High Voltage Cable
4800293 High Voltage Cable Sleeve
4006320 Connector Block Kit (30 or 50 kV)*
* Allows the bar to be removed from service without disturbing other cables running to a remotely
located power supply.

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Chargemaster Pinner 5200710 Rev. H
9. WARRANTY
Simco-Ion warrants its products to be free of defects in components, workmanship,
or materials for a period of one year from date of purchase. This warranty does not
apply to any physical or electrical damage caused by misuse, abuse or negligence
(such as any modifications made to the unit or service work done by any other than
Simco-Ion authorized technicians). Any unit with altered or removed serial number
is ineligible for warranty.
Simco-Ion will not be liable for loss or damage due directly or indirectly to an
occurrence or use for which the product is not designed or intended. In no event
shall Simco-Ion be liable for incidental or consequential damages except where state
or regional laws override.
This warranty extends to the original purchaser and is not transferable. No person,
agent, distributor, dealer or company is authorized to change, modify, or amend the
terms of this warranty in any manner whatsoever.
All products returned must have an “RA” (Return Authorization) number regardless
of warranty status. Call Simco-Ion for an assigned RA number.
Information in this document is subject to change without notice and does not
represent a commitment on the part of Simco-Ion. No part of this manual may be
reproduced or transmitted in any form or by any means, electronic or mechanical,
including photocopying and recording, for any purpose other than the purchaser’s
personal use without written permission of Simco-Ion.

Chargemaster Pinner 5200710 Rev. H
Simco-Ion
2257 North Penn Road
Hatfield, PA 19440
[phone]
[phone]
www.Simco-Ion.com
[email protected]
© 2019 Simco-Ion. Printed in the U.S.A.