Gen4 Super Ion Air Knife™

Gen4 Super Ion Air Knife™

Powerful static eliminator prevents jamming, tearing, shocks and dust up to 6.1m (20-feet) away!

Bumpers, car bodies and fascia are cleaned of dust and fibres prior to painting.

What Is The Gen4 Super Ion Air Knife™?

EXAIR’s Gen4 Super Ion Air Knife offers 34% improved performance at low pressures allowing you to achieve the same or better results, which saves compressed air and money. Gen4 Super Ion Air Knives remove static electricity from plastics, webs, sheet stock and other product surfaces where tearing, jamming or hazardous shocks are a problem. The laminar sheet of air sweeps surfaces clean of static, particulate, dust and dirt. Production speeds, product quality, and surface cleanliness can improve dramatically.

The Gen4 Super Ion Air Knife floods an area or surface with static eliminating ions – up to 6.1m (20 feet) away. A uniform airflow across its length will not cause misalignments to critical surfaces such as webs. Force can be adjusted from a “blast” to a “breeze”. The Gen4 Super Ion Air Knife is electrically powered, is shockless and has no moving parts. It also requires only 3.7 SCFM of compressed air per foot (305mm) of length at 5 PSIG (105 SLPM per 300mm of length at 0.3 BAR). Sound level is surprisingly quiet at 50 dBA for most applications.

How the Gen4 Super Ion Air Knife™ Works

Compressed air flows through an inlet (1) into the plenum chamber of the Gen4 Super Ion Air Knife. The flow is directed to a precise, slotted orifice. As the primary airflow exits, it creates a uniform sheet of air across the entire length that immediately pulls in surrounding room air (2). An electrically powered Gen4 Ionising Bar (3) fills the curtain of air with positive and negative charges. The airstream delivers these static eliminating ions to the product surface (4) where it instantly neutralises static and cleans off dust and other particulates.

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Performance

Pressure Supply		Air Consumption per 12″ (305mm) of Length		Sound Level @ 3′ (914mm)	Dissipates 5kV @ 6″ (152mm) From Target
PSIG	BAR	SCFM	SLPM	dBA	SECONDS
5	0.3	3.7	105	39	0.40
10	0.7	5.5	156	51	0.33
20	1.4	13.2	372	57	0.26
40	2.8	20.4	576	61	0.23
60	4.1	27.6	780	65	0.21
80	5.5	37.8	984	69	0.20
100	6.9	42.0	1,188	72	0.18

Enhanced Performance and Reliability

Gen4 Ionizing Bars are most effective with an air delivery system that allows the static eliminating ions to reach farther with greater coverage. Gen4 Ionizing Bars are less effective without an air delivery system. When used by itself, a bar must be mounted within 102mm (4”) of the charged surface to fully neutralise it. This close mounting is impossible when the static is generated in confined areas of a machine. Ion coverage is minimal on oddly configured parts or when high production speeds are involved.

The right type of air delivery is critical. Blowers produce an uneven, turbulent airstream that can cause the positive and negative ions to recombine before hitting the charged material. They are large, suffer mechanical wear and provide limited airflow control. The compact Gen4 Super Ion Air Knife uses a small amount of compressed air to produce a balanced, laminar sheet of air to carry the ions to the charged surface, even when it is far away. Flow and force are easily controlled and there are no moving parts to wear out.

A small Model 112103 3” (76mm) Gen4 Super Ion Air Knife System eliminates contaminants from syringes prior to packaging.

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Applications

Web cleaning
Moulding machinery
Sheeters and trimmers
Cleaning parts
Pre-paint dust removal
Shrink wrappers
Package cleaning
Bag opening/fill operations
Printing equipment

Advantages

Up to 34% improved performance
Rugged metal armoured and electromagnetically shielded cable
Integrated ground eliminates additional ground connection
Durable stainless steel connections to Power Supply
Low air consumption
Quiet
Effective up to 6.1m (20 feet)
Shockless, non-radioactive
Compact, rugged, easy to install
Unlimited system lengths of uninterrupted airflow
Low maintenance
UR/CE
EMC Compliant
Modular power supply cable eases connections and routing

Added Features

Compressed air inlets are provided on each end and the bottom of the Gen4 Super Ion Air Knife. Unlimited lengths available up to 119” (3.02m).
Thicker shims can be installed easily if additional hard-hitting velocity is required.
Primary air does not impact any surface of the Gen4 Super Ion Air Knife which keeps the sound level low.
Insertion moulded emitter points eliminate potential dirt accumulation that could degrade performance or eventually short the Ionizing Bar
Emitter points are sharp, durable stainless steel.
The high voltage cable is armoured to resist cuts and abrasion and has integral grounding, which prevents an additional connection. The threaded bayonet connector is fully assembled and ready to use.
Electromagnetically shielded cable protects sensitive electronics.
Gen4 Super Ion Air Knife Kits, which include all components necessary for operation, are available.

The Model 112118 18” (457mm) Gen4 Super Ion Air Knife System eliminates dust from body care products prior to sealing the boxes in cellophane.

The Gen4 Super Ion Air Knife eliminates the static charge on labels being applied to PET soft drink bottles.

This 96” Long Gen4 Super Ion Air Knife cleans an acrylic sheet before protective wrap is applied.

The 54" (1372mm) wide laminar airstream full of static eliminating ions is effective at high speeds and provides superior cleaning up to 6.1 metres away.
Poor print quality, dust attraction, tearing, jamming, and related equipment downtime can be eliminated.

Gen4 Super Ion Air Knives eliminate the static charge on this high-speed printing press.

A 6” Gen4 Super Ion Air Knife is the perfect size for the elimination of static from this bottle line. Gen4 Super Ion Air Knife sizes start from as small as 3”, compact and easy to install in tight spaces within production lines.

The Model 112048 48" (1219mm) Gen4 Super Ion Air Knife neutralises the static electricity and cleans the surface of the paper.

Cleaning Porcelain Dishes Prior To Glazing

The Problem

A manufacturer of fine porcelain dinnerware products had a problem with dust ruining the finish on their dishes. Dust particles were adhering to the surface of the dishes and created imperfections that were greatly magnif...

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Dust Removal from Car Bodies

The Problem

Car bodies are primer coated, then sanded before entering the paint booth. Priming dust, attracted to the car body by a static charge, creates imperfections that are captured and magnified in the painting process.

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A Manufacturer of Perfumes and Fragrances Eliminates Dust from Their Packages

The Problem

A manufacturer of perfumes and fragrances had a problem with the packaging of their fine perfumes. The conveyor belt used to transport the boxes to the cellophane sealer rubbed against the box surface and induced a sizabl...

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Specifications

EXAIR Model 7960 or 7961 Gen4 Power Supply (5kV) is required for bar operation.

Certifications: Gen4 Ionizing Bars and Gen4 Power Supplies are UL Component Recognised to US and Canadian safety standards, and are CE and RoHS compliant.

Electrical: For use with Model 7960 or 7961 5 kVrms, 5 milliamperes (max.) power supply.

Electrical Hazard: Shockless (less than 40 microamperes short circuited).

Do not use near flammable materials or gases.

Materials of Construction:
Metal Parts: Aluminium
Plastic Parts: UL rated 94 HB
Emitter: Stainless Steel

Maximum Ambient Temperature: 74°C (165°F)

Shims: Thicker shims can be installed easily if additional hard-hitting velocity is required.

Compressed Air: 1/4 NPT inlets are provided on each end and the bottom.

Airflow Pattern

Dimensions

Models

Gen4 Super Ion Air Knife
Gen4 Super Ion Air Knife		includes the Super Air Knife and Gen4 Ionizing Bar assembly
Gen4 Super Ion Air Knife Systems		include a Gen4 Super Ion Air Knife and Model 7960 Gen4 Power Supply (115V, 230V, 50/60Hz)
Gen4 Super Ion Air Knife Kits		include a Gen4 Super Ion Air Knife, Model 7960 Gen4 Power Supply, shim set, filter separator and pressure regulator (with coupler)
Gen4 Deluxe Super Ion Air Knife Kits		include a Gen4 Super Ion Air Knife, Model 7960 Gen4 Power Supply, EFC, Universal Mounting System, shim set, filter separator and pressure regulator (with coupler)
Airflow Length	Gen4 Super Ion Air Knife Model	Gen4 Super Ion Air Knife Systems Model	Gen4 Super Ion Air Knife Kits Model	Gen4 Deluxe Super Ion Air Knife Kits Model
3″ (76mm)	BP112003	BP112103	BP112203	BP112203DX
6″ (152mm)	BP112006	BP112106	BP112206	BP112206DX
9″ (229mm)	BP112009	BP112109	BP112209	BP112209DX
12″ (305mm)	BP112012	BP112112	BP112212	BP112212DX
18″ (457mm)	BP112018	BP112118	BP112218	BP112218DX
24″ (610mm)	BP112024	BP112124	BP112224	BP112224DX
30″ (762mm)	BP112030	BP112130	BP112230	BP112230DX
36″ (914mm)	BP112036	BP112136	BP112236	BP112236DX
42″ (1067mm)	BP112042	BP112142	BP112242	BP112242DX
48″ (1219mm)	BP112048	BP112148	BP112248	BP112248DX
54″ (1372mm)	BP112054	BP112154	BP112254	BP112254DX
60″ (1524mm)	BP112060	BP112160	BP112260	BP112260DX
72″ (1829mm)	BP112072	BP112172	BP112272	BP112272DX
84″ (2134mm)	BP112084	BP112184	BP112284	BP112284DX
96″ (2438mm)	BP112096	BP112196	BP112296	BP112296DX
108″ (2743mm)	BP1120108	BP1121108	BP1122108	BP1122108DX

Gen4 Super Ion Air Knife with Plumbing Kit
Gen4 Super Ion Air Knife with Plumbing Kit		includes the Super Air Knife with plumbing kit installed and Gen4 Ionizing Bar assembly
Gen4 Super Ion Air Knife Systems with Plumbing Kit		include a Gen4 Super Ion Air Knife with plumbing kit and Model 7960 Gen4 Power Supply (115V, 230V, 50/60Hz)
Gen4 Super Ion Air Knife Kits with Plumbing Kit		include a Gen4 Super Ion Air Knife with plumbing kit, Model 7960 Gen4 Power Supply, shim set, filter separator and pressure regulator (with coupler)
Airflow Length	Gen4 Super Ion Air Knife Model	Gen4 Super Ion Air Knife Systems Model	Gen4 Super Ion Air Knife Kits Model
24″ (610mm)	BP112024PKI	BP112124PKI	BP112224PKI
30″ (762mm)	BP112030PKI	BP112130PKI	BP112230PKI
36″ (914mm)	BP112036PKI	BP112136PKI	BP112236PKI
42″ (1067mm)	BP112042PKI	BP112142PKI	BP112242PKI
48″ (1219mm)	BP112048PKI	BP112148PKI	BP112248PKI
54″ (1372mm)	BP112054PKI	BP112154PKI	BP112254PKI
60″ (1524mm)	BP112060PKI	BP112160PKI	BP112260PKI
72″ (1829mm)	BP112072PKI	BP112172PKI	BP112272PKI
84″ (2134mm)	BP112084PKI	BP112184PKI	BP112284PKI
96″ (2438mm)	BP112096PKI	BP112196PKI	BP112296PKI
108″ (2743mm)	BP1120108PKI	BP1121108PKI	BP1122108PKI

Accessories

Gen4 Power Supplies

Exair Model 7960 or 7961 Gen4 Power Supply (5 kv) is required for ioniser operation. Selectable voltage: for use with all Gen4 Static Eliminators

The Two and Four Outlet Gen4 Power Supplies have selectable voltage, which allows you to choose input voltages of 115VAC or 230VAC. The modular cable with electromagnetic shielding protects sensitive electronics against electromagnetic interference while easing connections and routing. An integrated fuse on the primary protects against voltage spikes.

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Digital Static Meter

Locate the source of the static problem

EXAIR’s Model 7905 Digital Static Meter is sensitive and responsive. It indicates the surface voltage and polarity on objects up to ±20 kV when measured 25mm (1”) away.

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Universal Air Knife Mounting System

Provide precise positioning for your air knife

The Model 9060 Universal Air Knife Mounting System is used to provide secure, precise positioning for any of the EXAIR Air Knives. The Air Knife can quickly and easily be moved within close proximity of the part to improve effectiveness.

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Super Air Knife Plumbing Kits

Provide properly sized hose and fittings for best performance.

Super Air Knives that are 24″ or longer must be supplied with compressed air at multiple inlets on the Air Knife. EXAIR’s Air Knife Plumbing Kits make it easy to ensure proper airflow to each inlet.

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EFC Electronic Flow Control

Turn off the compressed air when it isn’t needed

EXAIR’s EFC™ is a user-friendly electronic flow control for compressed air that is designed to minimise compressed air use on blowoff, drying, cooling, conveying and static elimination operations. The EFC combines a photoelectric sensor with a timing control that limits compressed air use by turning it off when no part is present. The timing control permits easy tuning to the application requirements while providing flexibility in sensing distance.

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Filters, Regulators, Valves & More

With proper filtration of dirt, moisture and oil from the compressed air supply, EXAIR compressed air products will operate for years with no maintenance required. Use a 5 micron or smaller filter separator on the compressed air supply. To prevent problems associated with oil, use a 0.03 micron or smaller oil removal filter on the compressed air supply. Pressure regulators permit easy selection of the operating pressure, providing infinite control of flow, force and air consumption.

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Installation and Maintenance Guides

Gen4 Super Ion Air Knife

282.81 KB

High Voltage Gen4 Power Supply Model 7960

212.49 KB

High Voltage Gen4 Power Supply Model 7961

228.79 KB

Universal Air Knife Mounting System

409.96 KB

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Email info@caasafety.com.au

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+61 8 8983 3999

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