ITW Simco Ion Conveyostat User manual

Conveyostat®
In-Line Ionizer
For Pneumatic Conveyors
INSTALLATION AND OPERATING INSTRUCTIONS

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CONVEYOSTAT
IN-LINEIONIZER 5100577RevJ
TABLE OF CONTENTS
1. SAFETY WARNINGS............................................................................ 1
2. DESCRIPTION ................................................................................... 2
Features.................................................................................................................................2
Receipt of Equipment ...........................................................................................................2
Return Shipments .................................................................................................................2
3. SPECIFICATIONS................................................................................ 3
4. INSTALLATION .................................................................................. 4
Mounting and Grounding the Power Supply ........................................................................5
High Voltage Connections ....................................................................................................5
Installation of Conveyostat In-Line Ionizer..........................................................................8
5. OPERATION ...................................................................................... 9
6. MAINTENANCE .................................................................................10
Power Supply ......................................................................................................................10
Conveyostat In-line Ionizer.................................................................................................10
7. WARRANTY.....................................................................................11

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CONVEYOSTAT
IN-LINEIONIZER 5100577RevJ
1. SAFETY WARNINGS
Simco-Ion recommends that these instructions be read completely before installation or
operation is attempted. Failure to do so could result in serious injury and/or damage to
the equipment.
NOTE – Statements identified with a NOTE indicate precautions necessary to
avoid potential equipment failure.
CAUTION – Statements identified with a CAUTION indicate potential safety
hazards.
CAUTION – This equipment must be correctly installed and properly maintained.
Adhere to the following cautions for safe installation and operation:
1. Read instruction manual before operating or installing device.
2. Qualified service personnel must do installation and repairs.
3. Ground equipment properly.
CAUTION – Electrical Shock Hazard
Do not touch emitter pins when power supply is energized
CAUTION – Electrical Shock Hazard
Disconnect supply voltage to power supply before connecting Conveyostat or
performing any maintenance to the system.
CAUTION – Fire Hazard
Do not install or operate Conveyostat in close proximity to any flammable
solvents.

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CONVEYOSTAT
IN-LINEIONIZER 5100577RevJ
2. DESCRIPTION
Simco-Ion’s Conveyostat Systems are designed to provide in-line static elimination
for neutralizing static charges on materials in pneumatic conveying systems. In-line
ionization eliminates clogs caused by static charge buildup within the conveying system.
Once the charges are neutralized, products flow freely and productivity increases.
Conveyostats are typically mounted at the input to a cyclone or collection vessel so that
trim or other conveyed materials are neutralized as they pass through the unit.
Features
• Ionization prevents large pneumatic conveying systems from becoming jammed
• Dual-phase ion generation ensures high neutralization rates
• Units are available for indoor and outdoor installations
• Outdoor style incorporates a protective outer bellows and liquid-tight conduit to
help protect the high voltage cables from the environment.
• Outdoor bellows can be easily unclamped and re-clamped during installation to
provide access to mounting hardware.
• Available in standard and custom sizes
Receipt of Equipment
Carefully remove the equipment from the carton.
Inspect contents for damage that may have occurred during shipment. If any damage has
occurred during shipment, the local carrier should be notified at once. A report should
be forwarded to Simco-Ion, 2257 North Penn Road, Hatfield PA 19440 (215-822-6401).
Empty the carton to insure that small parts are not discarded.
Return Shipments
Prior to returning goods, contact a Simco-Ion Customer Service representative (215-822-
6401) for a Return Authorization Number. This number should be included on the packing
list. All correspondence should also reference the Return Authorization Number. Any
item being returned should be shipped prepaid and packed to provide adequate protection.

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CONVEYOSTAT
IN-LINEIONIZER 5100577RevJ
3. SPECIFICATIONS
System Components One ionizer housing tube and a dual-phase AC power supply
Housing Material Stainless steel
Standard Lengths 24”, 36”, 48” (other lengths available)
Standard Diameters 2” to 12” (larger diameters available)
Cable Length 10-ft from housing to power supply (other lengths available)
Power Supply Simco-Ion’s Dual Phase+ Power Supply produces high voltage to generate
both positive and negative ions in extremely high quantities. This allows
neutralization of static charges on products moving at high speeds.
Input Voltage 120 VAC, 60 Hz, 0.50A; 220 VAC, 60 Hz, 0.25A
Weight 22 lbs
Options Flanged and outdoor models available

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CONVEYOSTAT
IN-LINEIONIZER 5100577RevJ
4. INSTALLATION
Before placing the Conveyostat and the Dual Phase+ Power Supply in operation, be sure
that all grounds and connections have been made as described in the following steps. Turn
the power OFF when the equipment is not in use.
1. The power supply is selected by the factory depending on the type of Conveyostat
to be powered. Therefore the power unit must be used only with the unit for which
it was originally supplied. Do not remove equipment or add equipment without first
consulting a Simco-Ion representative.
2. Both indoor and outdoor power supplies consist of two transformers (Phase A
and Phase B) housed in an industrial NEMA Type 12/13 enclosure (see Figure 1).
Connections to the transformer primary windings are alternated so that a pair of
transformers will produce both polarities simultaneously at the outputs. This means
that both negative and positive ions are produced at the same time by adjacent static
bars within the Conveyostat In-Line Ionizer.
3. Power requirements for the Conveyostat Power Supply are 120 VAC, 60 Hz, 0.5A or
220 VAC, 60 Hz, 0.25A.
Figure 1

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CONVEYOSTAT
IN-LINEIONIZER 5100577RevJ
Mounting and Grounding the Power Supply
CAUTION – Electrical Shock Hazard
Failure to properly ground the power unit may result in electrical shock hazard
to personnel and inefficient operation of the Conveyostat.
1. Mount the power unit to the machine frame or to a convenient wall or post. Mount
the power unit to a flat surface using the mounting flanges at the base of the power
unit. Be sure to position it so that the power unit’s case is properly grounded in order
to ensure safe and efficient operation of the Conveyostat.
2. Ground the Dual Phase+ Power Supply by the following method: When installing the
AC line power wiring, use 3-conductor cable. Two conductors will supply the line
voltage. The third conductor will provide the ground connection between the ground
at the power source (junction box or panel) and the ground post on the inner side of
the wiring compartment of the power unit’s case.
High Voltage Connections
The Conveyostat wiring always terminates in to two black cables. Each cable is connected
to altering static bars in the Conveyostat and then to two different transformers in the
power supply.
Because we are using high voltage, 4000 VAC, and sources that are out of phase with
each other, it is important that the black cables be separate from each other and isolated
from any grounded material. If wire isolation is not adequate, damage to the wire may
occur, degrading system performance. Technically, the cables may be 100 feet long with
no problems if isolated.
To insure the best possible performance, the ground wire (braided metal strap) should be
used to connect the power supply to the Conveyostat. If not possible, the electrician must
insure that both the power supply and Conveyostat are connected to the same ground level
The outdoor units have special needs. The cables must be in weather tight conduit until
they connected to the power supply or run into the building. Any supply wiring to the
power from inside the plant must be sealed so no plant air can enter the outdoor box. The
box itself must be sealed from the outside environment.
The power supply is to be connected to a grounded, 120 VAC supply. As mentioned
before, the supply ground must be the same ground that the Conveyostat is connected to.
That is accomplished by using the braided cable or ensuring the common grounding of
both devices. If the grounding is not as specified here, the power supply transformers will
fail in a very short time.

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CONVEYOSTAT
IN-LINEIONIZER 5100577RevJ
1. Make certain the power is OFF.
2. Open the door to the Power Unit.
3. Feed the high voltage cables through the grey bushings on the bottom side of the box
(see Figures 2 & 3).
4. Cut the high voltage cable to the desired length. Be sure to allow additional length
to reach the high voltage output terminal blocks inside the power unit’s case.
5. Strip 3/8” insulation from the end of the high voltage cable and insert the cable
through a straight-through fitting.
6. Loosen one of the connection screws on the high voltage output terminal block.
Insert the stripped end of the cable under the screw and tighten. Tighten the straight-
through fitting until snug. Pull gently on the cable to make certain the connection is
secure.
7. Repeat previous steps for high voltage cable (B) and connection to right high voltage
terminal block.
8. High voltage connections for two Conveyostats are shown in Figure 2.
Figure 2

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CONVEYOSTAT
IN-LINEIONIZER 5100577RevJ
Figure 3
AC Line Power (Low Voltage) Connections
CAUTION – Do not apply line voltage to the Power Unit until all grounds and
high voltage connections have been completed and the Conveyostat has been
installed.
1. Connection should be made only to a 3-wire 120V, 60 Hz or 230V, 60 Hz AC source.
2. For rigid cable connection to the power unit: the use of local code approved solid
3-conductor cable through ½” size conduit with approved fittings is recommended
(not supplied). On installations subject to Canadian Standards Approval: the use of
conduit is required.
3. For flexible connection to power unit: the use of local code approved 3-conductor line
cord is recommended (not supplied). Secure line cord to power unit with an approved
cable clamp.
4. Connect the power source to the black and white leads using proper size wire nuts.
Connect the grounded conductor to the ground post.
NOTE – If the Conveyostat is to be used on machinery, it is recommended that
the power unit’s input wiring be connected to the machine’s RUN button. This
will enable the power unit to be turned ON and OFF with the machine.

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CONVEYOSTAT
IN-LINEIONIZER 5100577RevJ
Installation of Conveyostat In-Line Ionizer
1. Locate the Conveyostat as close as possible to the inlet of receiver vessels (such as
dropout boxes, cyclones, fabric filters, etc.). In these chambers, the speed of particles
is lower and the detrimental effects of static electricity can be easily observed as clogs
and material sticking.
2. The Conveyostat must be installed in the line with the flow direction of the material
being from the cable end side of the static bar thru to the dead end side of the static
bar.
3. Ground the Conveyostat by connecting its ground braid to the ground stud on the
outside of the power unit.
4. The high voltage leads must be kept isolated from each other and from ground.
Failure to do so may result in poor performance, cable insulation failure, and/or
power supply nuisance tripping.

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CONVEYOSTAT
IN-LINEIONIZER 5100577RevJ
5. OPERATION
Before operating the equipment, make certain all grounds and connections have been
completed and the Conveyostat has been properly installed.
To begin operating the equipment, simply apply line power to the Power Supply. The
green light indicates power to the unit.
Always turn the power OFF when the equipment is not in use.
A “Check System” warning indicator is located on the face of the Power Supply. Loss of
high voltage, or a short circuit within the Conveyostat or its cables, will disable the Power
Supply’s high voltage output and cause the red indicator to flash.
To reset a fault condition and extinguish the flashing “Check System” indicator, you must
first remedy the cause of the fault. Then simply press and hold the RESET button until
normal operation is resumed.

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CONVEYOSTAT
IN-LINEIONIZER 5100577RevJ
6. MAINTENANCE
CAUTION – Maintenance must be performed by qualified service personnel
only.
CAUTION – Electrical Shock Hazard
Turn off power supply before cleaning bar or performing any maintenance on
the system.
Power Supply
Under normal conditions, the power supply requires no periodic maintenance. Occasionally
check to make certain all ground and electrical connections are clean and tight.
Conveyostat In-line Ionizer
Periodic cleaning of the static bars on the Conveyostat is necessary. Turn power OFF to
the system before cleaning the static bar.
Cleaning frequency of the static bar emitter pins, located inside the Conveyostat, depends
on the type of material being run through the tube, humidity, air velocity and other factors.
The Conveyostat may be self-cleaning in certain applications where contaminants are
wiped from the emitter pins by bulk solids flowing through the system. Each unit should
be inspected frequently when first installed to determine how often cleaning is needed.
To clean emitter pins, obtain access to the inside of the Conveyostat. This may be
achieved through access doors built into the unit or by removing one or both ends of the
unit from its placement in the conveying line.
A cleaning brush with nylon bristles should be used to keep the ionizing pins of the bar
clean. Periodic use of the brush will prevent deposits from accumulating on the pins. The
ionizing pins must remain sharp for optimum operation.
NOTE – Do not scrape pins with any hard of sharp object that may damage points.
Built-up deposits on the points may be removed by pressing a soft pencil eraser down over
each point and then twisting the pencil. A clean emitter point will have a shiny polished
appearance
Inspect the static bars for physical damage such as missing pins and cracked (or broken)
housings. Such damage would most likely occur from foreign particles traveling through
the unit. Abrasive wear on the exposed surfaces of the static bar is to be expected in
normal operations. Wear depends on the materials being conveyed.

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CONVEYOSTAT
IN-LINEIONIZER 5100577RevJ
7. WARRANTY
This product has been carefully tested at the factory and is warranted to be free from
any defects in materials or workmanship. Simco-Ion will, under this warranty, repair
or replace any equipment that proves, upon our examination, to have become defective
within one year from the date of purchase.
The equipment being returned under warranty should be shipped by the purchaser to
Simco-Ion, 2257 North Penn Road, Hatfield PA 19440, transportation prepaid and insured
for its replacement cost. Prior to returning any goods for any reason, contact Simco-Ion
Customer Service at [phone] for a Return Authorization Number. This number
must accompany all returned items.
This warranty does not apply when the equipment has been tampered with, misused,
improperly installed, altered, has received damage through abuse, carelessness, accident,
connected to improper line voltage, or has been serviced anyone other than an authorized
factory representative.
The warranty does not apply when Simco-Ion parts and equipment have been energized
by other than the appropriate Simco-Ion power supply or generator, or when a Simco-
Ion power supply or generator has been used to energize other than Simco-Ion parts
and equipment. Simco-Ion makes no warranty, expressed or implied, nor accepts any
obligation, liabilities, or responsibility in connection with the use of this product other than
the repair or replacement of parts stated herein.

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CONVEYOSTAT
IN-LINEIONIZER 5100577RevJ
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5100577 Rev J
CONVEYOSTAT
IN-LINE IONIZER
Simco-Ion
2257 North Penn Road
Hatfield, PA 19440
[phone]
[phone]
www.simco-ion.com
[email protected]
© 2017 Simco-Ion. Printed in the U.S.A.