ITW SIMCO ION Pinner-LP User manual

Chargemaster Pinner-LP 5201229 Rev A
INSTALLATION AND OPERATING INSTRUCTIONS
Chargemaster
Pinner-LP
Arc Resistant Charging Bars

Chargemaster Pinner-LP 5201229 Rev A
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TABLE OF CONTENTS
1. SAFETY WARNINGS............................................................................ 1
2. DESCRIPTION ................................................................................... 2
3. FEATURES ....................................................................................... 3
4. SPECIFICATIONS................................................................................ 4
5. INSTALLATION .................................................................................. 5
Unpacking.............................................................................................................................5
Determining Pinner-LP Bar Location ..................................................................................5
Mounting Charging Bars ......................................................................................................7
Installing High Voltage Cables .............................................................................................9
6. OPERATION .....................................................................................10
7. MAINTENANCE .................................................................................11
Cleaning Emitter Pins.........................................................................................................11
Troubleshooting Electrical Stress.......................................................................................11
Troubleshooting Electrical Arcing......................................................................................11
Troubleshooting Low Pinning Strength..............................................................................12
8. REPLACEMENT PARTS........................................................................13
9. WARRANTY.....................................................................................14

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1. SAFETY WARNINGS
NOTE: Statements identified with a NOTE indicate precautions necessary to avoid
potential equipment failure.
CAUTION! Statements identified with a CAUTION indicate minor or moderate injury
is possible.
WARNING! Statements identified with a WARNING indicate serious injury is possible.
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.
4. To prevent damage to bar, observe and follow all operating specifications.
CAUTION! Electrical Shock Hazard
Always disconnect power supply before connecting or disconnecting charging equipment.
Never touch a charging bar when power supply is energized.
WARNING! Fire Hazard
Do not install or operate equipment in close proximity to any flammable solvents or
flammable materials.

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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 VCM30,
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-LP bar is 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-LP 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.

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3. FEATURES
• Increased voltage consistency and pinning action.
• Low profile design.
• 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.
• Secure mounting options.

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4. SPECIFICATIONS
Input Voltage: ±30 kVDC max
Output Current: Continuous Use: 0.75 mA/ft max
Intermittent Use: 1.50 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 dependent)
Weight: 1.4 lb per foot
Dimensions: 1” W x 1.9” H x (EL + 2”) L
EL = Effective Length 3” to 144” in 3” increments
Enclosure: Glass filled polyester (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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5. 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-LP Bar Location
Although Simco-Ion’s Pinner-LP 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-LP 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. The bar should operate below this threshold for best results. The operating
current of the bar should also be observed. To prevent damage to the bar, do not exceed
the current ratings specified in Section 4.
WARNING! Fire Hazard
Do not install or operate equipment in close proximity to any flammable solvents or
flammable materials.
NOTE: Bar width should be slightly narrower than the application’s film width
for all charging applications.
NOTE: Operating current should not exceed the specifications shown in Section
4.

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DC
(-)
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.
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.
AC
DC
(-)
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.
DC
(-)
Figure 1
Figure 2
Figure 3

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DC
(-)
DC
(+)
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
WARNING! 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. Precaution should be
taken to shut down and lockout charging generator prior to service.
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.
Figure 4

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Determine the best location for the Pinner-LP Bar using the above applications for
guidance.
1. The Pinner-LP bar includes blue plastic mounting brackets, perforated metal strips
and assorted hardware.
2. Slide the mounting brackets onto the “T” channel on the back of the bar.
3. The perforated strip may be installed on the mounting bracket at right angle to the
bar or parallel to the bar. The perforated strip may be bent or twisted to suit the
application and will hold its shape as installed.
4. Once the bar is loosely installed, tighten all hardware.
5. Install (2) set screws into the holes in the side of the mounting bracket using the
provided hex key wrench. The set screws engage the “T” on the base of the bar
securing it in place.
Area to be free of all
ground references
Target to be neutralized
R
Charging Bar
High Voltage Cable
Perforated Strip
Mounting
Bracket Mounting Hardware

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Installing High Voltage Cables
CAUTION! Electrical Shock Hazard
Turn off power supply and lock out before connecting high voltage cable or servicing.
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.

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6. OPERATION
CAUTION! Electrical Shock Hazard
Do not touch Charging Bar during operation.
WARNING! 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.
• DO NOT exceed either the continuous or intermittent current ratings.
• 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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7. MAINTENANCE
NOTE: Only qualified service personnel are to perform maintenance tasks.
CAUTION! Electrical Shock Hazard
De-energize all power supplies and lock out, if possible, before performing any
maintenance tasks.
Cleaning Emitter Pins
Dust or dirt around the emitter pins will reduce the effectiveness of the Pinner-LP 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, clean, and clear of debris for optimal performance
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.

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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 nonmetallic brush.
b) If acceptable performance is not restored, contact Simco-Ion Customer Service
at [phone].

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

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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.

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Chargemaster Pinner-LP 5201229 Rev A
Simco-Ion
2257 North Penn Road
Hatfield, PA 19440
[phone]
[phone]
www.simco-ion.com
[email protected]
© 2014 Simco-Ion Printed in the U.S.A.