Koganei IONIZER Small Size Blow Type Instruction manual

Instruction Manual
Ionizer Blow Type [DTY-ELK01]
Thank you very much for your purchase of the DTY-ELK01. Although this
product is not classified as a high -voltage device under any electrical
equipment standards, it uses a 2000VAC high voltage. Please read this
manual diligently in order to handle this unit carefully and correctly. Keep
this manual in a safe place.
1. Safety Precautions
Because a high voltage is used in this product, improper use of the unit
may cause an accident resulting in injury or dea th, or may lead to a
malfunction of the product. Koganei will not be held liable for any usage
outside the Product Specifications or for any accident caused by
noncompliance with the Safety Precautions.
DANGER
WARNING
CAUTION
ATTENTION
1.1
Expresses situations that can be clearly predicted as
dangerous. If the noted danger is not avoided, it could
result in death or serious injury.
It could also result in damage or destruction of assets.
Expresses situations that, while not immediately
dangerous, could become dangerous. If the noted danger
is not avoided, it could result in death or serious injury.
It could also result in damage or destruction of assets.
Expresses situations that, while not immediately
dangerous, could become dangerous. If the noted danger
is not avoided, it could result in light or semi-serious injury.
It could also result in damage or destruction of assets.
While there is little chance of injury, this content refers to
points that should be observed for appropriate use of the
product.
DANGER
Do not use in locations where explosives, flammables, or other dangerous
substances are present. This product is not an explosion-proof type unit. Explosion
or ignition may occur.
When any wiring, installation, or inspection work is to be carried out, make sure that
the unit is disconnected from the power supply, otherwise, an accident, an electrical
shock or a malfunction may be caused.
Never attempt to remodel the product. It could result in abnormal operation
leading to injury, electric shock, fire, etc.
Do not splash water on the product. Spraying it with water, washing it, or using it
underwater could result in malfunction of the product leading to injury, electric
shock, fire, etc.
A high voltage is applied to the discharge needle. Do not allow any conductive
material, including fingers, any part of the body, wires or tools to come close to the
needle. Otherwise, an electric shock or a malfunction of the unit may occur.
1.2
WARNING
Do not use the product in excess of its specification range. Such use could result
in product breakdowns, function stop, damage or drastic reduction in the
operating life.
The discharge needle has a sharp edge. Pay special attention to handling of the
needle, or you may injure yourself.
Always make sure that the air supply is active before turning ON the unit. If the
air supply is not active when the power supply is applied there may be a build-up
of ozone inside the unit due to electrical discharge that could have an adverse
effect on the equipment and the environment.
When using the nozzle, do not point it toward a person’s body, and particularly
not toward the face and eyes. You may injure yourself or other persons.
1.3
CAUTION
The ionizer generates ozone in the atmosphere. Although the concentration will
become saturated and will not exceed a certain level when a single unit is used, if
multiple units are used there may be a smell of ozone. In this case, increase
ventilation. However, putting your face up against the ozone air emission port to
check for an ozone smell is not recommended. It could cause injury to the nose or
throat.
1.4
ATTENTION
When the product can no longer be used or is no longer needed, dispose of it
appropriately as industrial waste.
* For any other items of danger, warning, or caution, please refer to the “Safety
Precautions” in the Catalog for the “Static Electricity Removing Unit: Ionizer” (Catalog
No. BK-R0001). (Be sure to refer to the latest version of the Catalog.)
2. Product Overview
This product is a blow type ionizer (a device for eliminating static electricity).
This product is helpful in quickly resolving problems with static electricity.
Ionized air quickly and efficiently neutralizes the static electricity on charged
objects, and rem oves dust attracted by the static e lectricity. This effectively
controls static electricity problems and dust contamination problems .
You can also select an air-saving type of ionizer that reduces air consumption
or a low-dust type that suppresses dust generation, depending on uses and
needs.
3. Contents of the Package
On receipt of the product, please check the package for any missing parts or
for any abnormality or dam age that may have occurred during delivery before
using the unit. In case any dam age should be found or any abnormal oper ation
should be observed, please contact the outlet (the agency) at which you
purchased the product, or the nearest Koganei service station.
5. Appearance
DTY-ELK01 (Standard type)
3.1 Content of Package
・Main unit: 1
・Discharge needle unit*1: 1
・Mounting bracket: 1
・Mounting bracket screws: 2
・Power and signal cable (2 m): 1
・Instruction Manual (this booklet): 1 ・Air-saving nozzle*1,2 (DTY-ELK01-S only)
* 1. Attached to main unit at time of shipping.
2. For products other than DTY-ELK01-S, the nozzle is not included.
Please purchase the nozzle separately.
4. Specifications
4.1 List of Specifications
Type
Input power source
Current consumption
Output voltage
Displays
POWER LED
(Green)
H.V LED
(Blue)
CHECK LED
(Yellow)
ALARM LED
(Red)
Output
Ionizer ON/OFF control input
Ion balance*1
Static elimination time*1,2
Generated ozone volume
Dust volume
Air tube connection diameter
Range of air pressure used
DTY-ELK01
(Standard)
DTY-ELK01-S
DTY-ELK01-L
(Air-saving)
(Low-dust)
24VDC ± 5%
70 mA
Approx. 2 kV (High frequency type)
When the power is ON
When discharge is in operation
When abnormal discharge occurs
(H.V LED goes OFF)
When abnormal function occurs
(H.V LED goes OFF)
Contact point output when CHECK LED and
ALARM LED are ON
(24V 50 mA MAX Open Drain)
At 0V, discharge stops with short-circuited
(No-voltage input, internal drop voltage 0.5V or less)
±15V or less
(at a distance of 50 mm
and air pressure of 0.3 MPa)
0.5 sec or less
0.8 sec or less
0.5 sec or less
DTY-ELK01-S (Air-saving type)
0.03 ppm or less
(at a distance of 300 mm
and air pressure of 0.3 MPa)
50 particles or
less*1,3
Rc1/8
6 quick fitting
0.05 MPa to 0.5 MPa
Air supply flow volume*4
(ANR)
Media
280 ℓ/min
Mass
Operating
Temperature
environment
Humidity
Altitude
Safety approvals
60 g*5
60 ℓ/min
280 ℓ/min
Air (Clean air devoid of moisture and oil)
75 g*6
66 g*5
0 to 40C (indoor)
15% to 65% RH (with no condensation)
2000 m or less
IEC61010-1
(Over voltage category I, Pollution degree 2)
*1. Measured under the measuring conditions specified by Koganei
2. Measurement distance 50 mm, air supply pressure 0.1 MPa, standard
nozzle in use
3. 0.3 μm or more, 1 cf/min
4. Air supply pressure of 0.5 MPa
5. W hen the bracket and nozzle are not attached.
6. W hen the standard nozzle and bracket are not attached.
DTY-ELK01-L (Low-dust type)
6. Installation, Wiring and Tubing
6.3 Air Tubing
Tube-tip
6.1 Installation
1) Connect air tubes (outer diam eter 6 mm) to the DTY-ELK01 and
DTY-ELK01-S main unit air fittings.
For DTY-ELK01-L, use fittings that match the tubing used (port size: Rc1/8).
2) Use a regulator to connect the air tube to the air source.
CAUTION
DTY-ELK01-L (low-dust type) uses clean room packaging. Always open the
packaging in a clean room environment.
A nozzle is not included with the product (exception: installed in the air-saving type).
Separately purchase a nozzle matching your utilization.
Nozzles are made specifically for each type. Always use the right nozzle for each
type.
Nut A
Tube-tip
WARNING
Always supply air before switching ON the power, and use within the specified
pressure range.
1) Attach the nozzle to the m ain unit, and use the pin provided with the nozzle
to fix it to the main unit.
* To replace the nozzle, pull out the pin and then rem ove the nozzle.
DTRY-ADN-□00B
DTRY-ADN-FT01
DTRY-ADN-SW60,-SW90
CAUTION
6.2 W iring
WARNING
Check that the nozzle is securely inserted and securely held in place by the pin. If
not perfectly set, the nozzle could come loose during use, damaging the product and
equipment.
1) Use the power signal cable provided, and connect as shown in the figure
below.
If taking power from input 100VAC, use the AC adaptor (DTY -ZKPS), sold
separately.
CAUTION
The nozzle insertion part is made in a D-shaped cut to prevent rotation. When
attaching, align the main unit nozzle insertion port with the nozzle insertion part.
1. Nozzle
2. Pin
Lock nut
Nut B
Shape of nozzle
insertion port
2) W hen using the mounting bracket for installation, use the two mounting
bracket screws (enclosed with the packaging) to mount the mounting
bracket to the main unit.
CAUTION
Securely connect the ground wire (with a grounding resistance of 100Ωor less).
Otherwise, ionizer performance may not be adequate.
Securely insert the connector.
Contact capacity for each output is 24V 50 mA MAX. Check the capacity of the
connected equipment before use.
When selecting a power supply for use with this product, always use one that has
been certified by the EU Notified Body (as a limited power source defined in
IEC/EN60950-1 or IEC/EN61010-1), or the optional AC adapter.
0VDC, F.G, nozzle and mounting bracket are connected to the internal circuit.
Use a mechanical switch, photo coupler, or relay for external input. If the
grounding potential of the external device to be used and the grounding potential
of this product are different, the external device should have an insulated on/off
procedure for the 0V line.
① 24VDC (red)
CAUTION
⑤ALARM NO (brown)
⑥CHECK NO (yellow)
3) Use the m ounting holes on the side of the main unit ( 3-3.4) or the mounting
holes in the mounting bracket (4-3.4) to fix the product in place.
* Provide the mounting screws separately.
4) If using a tube, insert the tube firmly all the way to the base of the nozzle.
5) If using a nozzle and tube capable of adjusting the ionized air blow direction,
fix the nozzle so that the ionized air blow port is pointed toward the static
charge removal target.
6) If using a tube-tip nozzle, firmly insert the tube-tip nozzle into the tube, and
use the bracket provided to fix it in place.
* For details, refer to the Instruction Manual provided with the tube-tip nozzle.
<W hen using the nozzle unit for the bender nozzle>
1) Rem ove the tip of the bender nozzle.
2) Always tighten the various nozzle units securely to the bender nozzle.
The recommended tightening torque for the nozzle unit used for the bender
nozzle is 30 N･cm.
3) To adjust the direction of the bar nozzle unit (DTRY-ADN-□00B) ionized air
blow port, loosen nut B.
To adjust the direction of the flat nozzle unit (DTRY -ADN-FT01) attach the
ionized air blow port at the tip, and use the lock nut to fix in place .
CAUTION
When loosening nut B, be sure that nut A is fixed in place, and check that no
force is being applied to the bender nozzle.
7.1 Steps W hen Starting Operation
1) Check that the nozzle and discharge needle unit are co rrectly connected to
the ionizer.
2) Check the ionizer wiring and air tubing.
3) Supply air to the unit from the air equipment that is being used.
4) Supply 24VDC power to the unit. The POW ER LED and H.V LED on the
unit light up and electrostatic eliminati on begins.
* If the optional power adapter is used, supply 100 -240VAC, 50/60 Hz.
* W hen using external controls (H.V OFF) to control the unit, the H.V LED
goes OFF when discharge is OFF.
* Use the input power side (24V DC side) to switch power ON/OFF.
Load
Load
7.2 Steps W hen Stopping Operation
③H.V OFF (blue)
1) Stop the supply of power to the unit.
2) Stop the supply of air.
② 0VDC (black)
⑦F.G. (green)
Inside ionizer
8. Maintenance
*①-⑦ show the main unit pin number.
* Note in parentheses ( ) shows the lead wire color in the power signal cable.
* Use a no-voltage contact point or NPN open collector to connect ③ H.V OFF.
(when ② 0VDC shorted, discharge OFF)
* W hen discharge OFF (when ③ H.V OFF and ② 0VDC shorted), H.V LED
goes OFF.
No.
①
②
③
④
Signal
24VDC
0VDC
H.V OFF
ALARM NC
⑤
ALARM NO
⑥
CHECK NO
⑦
F.G.
CAUTION
If the POWER LED is not illuminated or if the CHECK LED or ALARM LED lights up,
immediately shut off the power and air, and see “6. Installation, Wiring and Tubing” in
this manual. If problems still do not resolve, see “8. Maintenance” and “9.
Troubleshooting” in this manual.
External connection example
I/O Circuit Diagram
CAUTION
Hold the pipe portion securely when removing the tip of the bender nozzle.
7. Operating
Take soundproof measures, such as wearing earplugs, when working at close
proximity to the unit.
Main
circuit
Internal circuit
CAUTION
Although the DTY-ELK01-L (low-dust type) is subjected to clean-room cleaning
and packaging using clean air at time of shipping, the effects of vibration, etc.,
during transport can generate particles. Flush out the unit and clean it thoroughly
before commencing initial use.
For connection to or replacement of a DTY-ELK01-L (low-dust type) fitting,
proceed by holding the female screw (Rc1/8) hexagonal part in position.
Application of excessive force to the main unit could cause damage to the main
unit.
WARNING
④ALARM NC (white) Load
Tightening torque for mounting the bracket to the main body should be 50 N･cm
or less.
As piezoelectric ceramic is built into the main unit, do not apply shocks due to
dropping or vibration, etc. Such action could result in product malfunction.
The various tubes used for the standard nozzle are consumable items that require
periodic replacement.
When bending the bender nozzle, maintain the base of the bender nozzle in place.
The main body could be damaged.
Do not use nozzles not specifically designed for the unit. Also, do not make
modifications to the nozzle. Such action could be the cause of product
malfunctions, function shutdown, or damage.
Do not install in locations prone to condensation, or subject to large humidity and
temperature swings. The product could be subjected to damage.
WARNING
As the tip of the discharge needle is very sharp, care is needed when removing
the discharge needle and during cleaning. The needle tip can cause injury. In
addition, be extremely careful to avoid bending or breaking the discharge needle.
Performance will be affected.
Securely attach the bushing and the discharge needle unit.
If not securely fixed in place, performance will be affected, and the discharge
needle unit may become loose during use, causing damage to the product and
equipment.
Function
Power input 24VDC±5%
Power 0V and output 0V
Discharge OFF when shorted at ②
Contact point output when performance
malfunction occurs
(b contact point 24VDC 50 mA MAX)
Contact point output when performance
malfunction occurs
(a contact point 24VDC 50 mA MAX)
Contact point output when abnormal
discharge occurs
(a contact point 24VDC 50 mA MAX)
Functional earth (with a grounding
resistance of 100Ω or less)
CAUTION
The abnormality output circuit of this product will be active about one second after the
power is switched on. Sufficient care should be taken to design an error detection circuit
during installation.
When the power to the main unit of the ionizer is switched ON immediately after being
switched OFF, an abnormality output may occur. When performing such an operation, be
sure to wait for a period of at least one second after switching off.
When the ionizer main unit is switched OFF, an abnormality output may occur. Pay careful
attention to the design of the error detection circuit not to detect the ionizer’s abnormality
output for a one-second period after the power supply to the ionizer main unit is switched
OFF.
If the discharge needle is soiled, the electrostatic elimination effects will be
reduced. Periodically clean the discharge needle and surrounding area to
maintain performance.
<Discharge needle unit cleaning m ethod >
1) Rotate the discharge needle unit counterclockwise, and pull it from the main
unit.
CAUTION
To maintain performance, be sure to perform cleaning of the discharge needle and
the surrounding area periodically. Performance will be affected, and lack of cleaning
may cause damage to equipment and workpieces.
When performing maintenance, always disconnect the connection cables before
proceeding.
When using alcohol or similar substances, make sure that there is adequate
ventilation. In addition, always thoroughly dry off the alcohol after using it for
cleaning, and check that none has spilled on to the main unit.
Because it can result in damage to the main unit, absolutely never use a wire
brush for cleaning.
<Main unit filter replacement method>
For DTY-ELK01-S, a filter is installed on the outside air intake port.
A dirty filter will result in reduced outside air intake efficiency, and static charge
removal perform ance will become inadequate.
Replace the filter if it has becom e dirty.
1) Rem ove the pin fixing the nozzle in place.
2) Pull out the filter in the nozzle direction.
If difficult to remove, use a precision
screwdriver or tweezers.
3) Insert the new filter so that it slips in from the
nozzle direction, and then rem ount the pin.
9. Troubleshooting
If product operation appears to be abnormal, immediately shut off the power to
the m ain unit, disconnect the connection cable from the m ain unit’s power
connection terminal, and check the ite ms in this section. If the abnormal
situation continues, it may mean that a breakdown has occurred. Contact the
outlet (the agency) at which you purchased the product, or the nearest
Koganei service station.
The POWER LED does not light up.
→ Verify that the wiring and power source are connected correctly.
The POWER LED lights up but the H.V LED does not.
→ Verify that the H.V OFF terminal is not shorted.
CHECK LED and ALARM LED are illuminated.
→ Verify that the unit is securely grounded.
→ Verify whether the discharge needle is soiled or damaged, and whether the
surrounding area is soiled. If it is soiled, see “8. Maintenance” in this manual,
and perform maintenance or replacem ent of the discharge needle unit.
No electrostatic elimination effect
→ Verify that ionized air is blown to the object eliminating static electricity.
→ Verify whether the discharge needle is soiled or damaged, and whether the
surrounding area is soiled. If it is soiled, see “8. Maintenance” in this manual,
and perform maintenance or replacem ent of the discharge needle unit.
Any other abnormal condition
If any other abnormal condition has been observed, immediately turn off the
power from the product, and please contact the outlet (the agency) at which
you purchased the prod uct, or the nearest Koganei service station.
2) Rotate the discharge needle unit bushing
counterclockwise, and rem ove the bushing.
CAUTION
Do not apply excessive force when removing the bushing from the discharge
needle unit.
The discharge needle unit could be damaged.
When replacing the discharge needle unit, use the specified discharge needle
unit. Discharge needle units are specifically designed for each type.
You can determine the correct discharge needle unit by its color.
3) W hen the discharge needle unit has been rem oved, use a cotton swab
soaked in anhydrous alcohol (IPA) to clean the discharge needle and
bushing.
4) After drying the unit carefully with anhydrous alcohol, reassemble the
discharge needle unit onto the
main unit in reverse sequence to
removal.
At this time, rotate until the ∆
mark on the side of the main unit
is aligned with the ∆ mark on the
discharge needle unit.
10. Consumables and Optional Parts
・ Discharge needle unit: DTY-ZKEM (standard type: W hite)
DTY-ZKEMS (air-saving type: Light blue)
DTY-ZKEML (low-dust type: Gray)
・Air-saving type replacement filter: DTY-ZKFS (5 filters/set)
・AC adapter: DTY-ZKPS
・Controller: DTY-ZKCR
・Controller unit: DTY-ZKCRU (Unit with solenoid valve)
JUST CONSULT US:
KOGANEI CORPORATION OVERSEAS DEPARTMENT
3-11-28, Midoricho, Koganei -shi, Tokyo, 184-8533, Japan
TEL:+81- 042-383-7271 FAX:+81- 042-383-7276
W ebsite: http://www.koganei.co.jp
The specifications or the appearance of this product are subject to change any
time without prior notice.
X903918 Rev1.5
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