TECHNICAL BULLETIN TB-6545
Chargebuster® Overhead Ionizer
Installation, Operation and Maintenance
Description
Made in the
United States of America
Figure 1. EMIT 50682 Chargebuster® Overhead Ionizer
Figure 2. EMIT 50681 Chargebuster® Overhead Ionizer
EMIT Chargebuster® Overhead Ionizers are
steady-state DC ionizers designed for use in ESD
protected areas. The 2-fan ionizers (50682, 50602)
have a 2' x 4' coverage area, and the 3-fan ionizers
(50681, 50603) have a 2' x 5' coverage area. The
Chargebuster® Overhead Ionizers’ discharge times
(< 3 seconds at 18") and low offset voltage (±10 volts)
meet the required limits of ANSI/ESD S20.20 < ±35
volts tested per ANSI/ESD STM3.1 and ESD TR53.
Its emitters are made of pure tungsten and spaced
further apart to minimize ion recombination, increase
discharge efficiency and provide a broader coverage
area. The fans have 3 speeds (high, medium, low)
which produce consistent performance at all 3 settings.
The Chargebuster® Overhead Ionizers utilize an
auto-feedback system that continuously optimizes its
performance and automatically alarms and shuts down
should its supply voltage drop.
The EMIT 50602 and 50603 Chargebuster® Overhead
Ionizers include 700 lumen light panels (cool white)
that provide additional illumination to the work area and
improve visibility and productivity. The 50602 features
one light panel, and the 50603 features two.
“Necessary non-conductors in the environment cannot
lose their electrostatic charge by attachment to ground.
Ionization systems provide neutralization of charges on
these necessary non-conductive items (circuit board
materials and some device packages are examples of
necessary non-conductors). Assessment of the ESD
hazard created by electrostatic charges on the
necessary nonconductors in the work place is required
to ensure that appropriate actions are implemented,
commensurate with risk to ESDS [ESD sensitive] items”.
(ANSI/ESD S20.20 Foreword)
“In order to mitigate field-induced CDM [Charged Device
Model] damage, the ESD program shall include a plan
for the handling of process-required insulators. If the
field exceeds 2,000 volts/inch, steps shall be taken to
either: A) Separate the insulator from the ESD-sensitive
device by a distance of 30 cm (12 inches); or B) Use
ionization or other charge mitigating techniques to
neutralize the charge.” (ANSI/ESD S20.20 section 8.3)
“The primary method of static charge control is direct
connection to ground for conductors, static dissipative
materials, and personnel. A complete static control
program must also deal with isolated conductors that
cannot be grounded, insulating materials (e.g., most
common plastics), and moving personnel who cannot
use wrist or heel straps or ESD control flooring and
footwear.”
Figure 3. EMIT 50602 Chargebuster® Overhead Ionizer
with Light
Figure 4. EMIT 50603 Chargebuster® Overhead Ionizer
with Lights
EMIT
- 3651 Walnut Avenue, Chino, CA 91710 • (909) 664-9980 • Website:
DescoEMIT.com
TB-6545
Page 1 of 9
October 2017
© 2017 DESCO INDUSTRIES, INC.
Employee Owned
“Air ionization is not a replacement for grounding
methods. It is one component of a complete static
control program. Ionizers are used when it is not
possible to properly ground everything and as backup
to other static control methods. In clean rooms, air
ionization may be one of the few methods of static
control available.” (ESD Handbook ESD TR20.20
Ionization, section 5.3.6.1)
The Chargebuster® Overhead Ionizer is available in
four models:
Item
50682
50681
50602
50603
Fans Lights
2
3
2
3
0
0
1
2
Input
Voltage
220 VAC
220 VAC
220 VAC
220 VAC
Power Cord
None
None
None
None
Figure 5. Fan Speed Switch, Power Input and Power
Switch
Packaging
1
1
2
3
1
Chargebuster® Overhead Ionizer
Hanging Kit
Emitter Point Cleaners (50682, 50602)
Emitter Point Cleaners (50681, 50603)
Certificate of Calibration
Operation
1. Set the fan speed switch to the LOW, MED, or
HI position. Higher airflow will result in faster
neutralization rates.
2. Position the ionizer so that maximum airflow is
directed towards the items or area to be neutralized.
3. Turn the unit ON. When the unit is first turned on,
it conducts a self-test. The audible alarm will sound
and the LED will cycle through the colors red,
yellow and green. The LED will remain green during
normal operation.
4. Toggle the light switch on the front of the ionizer to
ON to power the LED panel(s) (50602, 50603 only).
Installation
The Chargebuster® Overhead Ionizer is designed to
mount above the work area, providing even coverage
without using valuable worksurface area. Mounting
is a matter of personal preference. Use the included
hanging kit to suspend the ionizer with its brackets, or
secure its brackets to a shelf. Ensure that the mounting
is secure and capable of supporting the weight of the
ionizer. The power cord should be supported as well to
protect the operator from any hazard.
The ideal mounting height is 18" above the worksurface,
although the ionizer may be located slightly higher or
lower if required. For optimum performance, ensure that
the intake grills for the fans are not obstructed.
Verify that the ON/OFF switch located at the back of the
ionizer is in the OFF position. Plug the power cord into
the ionizer, and plug the other end into a properly wired
power outlet.
Figure 6. Light Switch (50602 and 50603 models only)
EMIT
- 3651 Walnut Avenue, Chino, CA 91710 • (909) 664-9980 • Website:
DescoEMIT.com
TB-6545
Page 2 of 9
© 2017 DESCO INDUSTRIES, INC.
Employee Owned
Maintenance
“All ionization devices will require periodic maintenance
for proper operation. Maintenance intervals for ionizers
vary widely depending on the type of ionization
equipment and use environment. Critical clean room
uses will generally require more frequent attention. It
is important to set-up a routine schedule for ionizer
service. Routine service is typically required to meet
quality audit requirements.” (ESD Handbook TR20.20
section 5.3.6.7 Ionizer Maintenance / Cleaning)
EIA-625, recommends checking ionizers every 6
months, but this may not be suitable for many programs
particularly since an out-of-balance may exist for months
before it is checked again. ANSI/ESD S20.20 section
6.1.3.1 Compliance Verification Plan Requirement
states: “Test equipment shall be selected to make
measurements of appropriate properties of the technical
requirements that are incorporated into the ESD
program plan.”
CLEANING THE EMITTER POINTS
Under normal conditions, the ionizer will attract dirt and
dust (especially on the emitter points). To maintain
optimum neutralization efficiency and operation,
cleaning should be performed on a regular basis.
In the event of circuit failure, the unit will enter shutdown
mode.
When the unit enters shutdown mode, ionization will be
stopped, the LED on the front of the unit will illuminate
a constant red, and the audible alarm will continuously
sound. The user must then reset the unit by turning it
OFF and back ON.
The emitter points should be cleaned using the included
Emitter Point Cleaners or a swab dampened with
Isopropyl alcohol.
1. Turn the unit OFF and unplug the power cord.
2. Open the top screen
by loosening the screw
and swinging the grill to
one side.
3. Clean the emitter points
using the included
Emitter Point Cleaners
or a swab dampened
with Isopropyl alcohol.
4. Reattach the top
screen.
5. Plug in the power cord
and turn the unit ON.
6. Verify the performance
of the ionizer by
using a charged plate
monitor, or ionization
test kit.
With normal handling, the emitter points should not
require replacement during the life of the unit. If
necessary, item 50659 Replacement Emitter Points are
available for purchase.
Adjustments and Compliance Verification
BALANCE OFFSET VOLTAGE ADJUSTMENT
The Chargebuster® Overhead Ionizer is an
auto-balancing unit. However, tuning or manual
adjustment can be accomplished by inserting a small
screwdriver or trimmer adjustment tool into the balance
adjustment hole. To increase the output in a positive
direction, turn the potentiometer clockwise. To increase
the output in a negative direction, turn the potentiometer
counter-clockwise.
INPUT VOLTAGE CONFIGURATION
WARNING - Risk of electric shock
These servicing instructions are for use by qualified
personnel only. Do not perform any servicing of
internal parts unless you are qualified to do so.
NOTE: The AC power cord MUST always be
disconnected before the unit is disassembled.
The input voltage may be verified or reset by opening
the ionizer’s enclosure. This can be accomplished by
removing the 10 screws that secure the cover to the
base.
The ionizer’s input voltage can be configured to 120
VAC or 220 VAC using the JH1 jumpers located on its
PCB. See Figures 7 and 8 for these configurations.
Figure 7. 120 VAC jumper
setting
Figure 8. 220 VAC jumper
setting
If the supply voltage drops from 110 Volts to below 85
Volts or from 200 Volts to below 170 Volts, the unit will
shut down, the audible alarm will beep and the LED will
blink red. The unit will automatically reset when the
minimum voltage is restored.
EMIT
- 3651 Walnut Avenue, Chino, CA 91710 • (909) 664-9980 • Website:
DescoEMIT.com
TB-6545
Page 3 of 9
© 2017 DESCO INDUSTRIES, INC.
Employee Owned
Calibration
When an alarm sounds, most users will clean emitter
pins (see Maintenance / Alarms section) and calibrate
the ionizer. Per ESD TR53 section 5.3.6.7.1 “The best
practice is to measure the offset voltage and discharge
times, clean the unit, including emitter points and air
filters if present, offset voltage to zero (if adjustable),
and then repeat offset voltage and discharge time
testing. If the unit does not meet offset voltage
specifications or minimum established discharge time
limits, further service is indicated. Manufacturers should
provide details on service procedures and typical
service intervals.”
Most companies will assign a number or otherwise
identify each ionizer and setup a Compliance
Verification / Maintenance / Calibration schedule. If the
ionizers all test good, the data can justify lengthening
the calibration period. If ionizers require adjustment the
calibration period should be shortened. Although ESD
TR53 does not advise a test frequency, JESDD625-A
(Revision of EIA-625) recommends ionizers be tested
semiannually, noting to use “S3.1 except the number
of measurement points and locations may be selected
based on the application.”
NOTE: A charged plate analyzer or monitor should be
used in order to properly calibrate the Chargebuster®
Overhead Ionizer (see the EMIT 50571 Charged Plate
Analyzer).
1. Properly setup the ionizer as described in the
Installation procedure on page 1.
2. Turn the unit ON and set the FAN SPEED to HIGH.
3. Position the charged plate analyzer 18 inches
underneath one of the fans of the ionizer.
4. Push and hold the ALARM RESET button on the
ionizer until the STATUS LED turns red. Release
the button and the LED should switch back to green.
This allows the user to calibrate the balance (offset
voltage) of the ionizer without setting off the alarm.
5. The balance (offset voltage) of each fan should be
within 0 and ±10 volts. The required limit per ANSI/
ESD S20.20 is less than ± 35 volts. To increase
the output in a positive direction, turn the BALANCE
ADJUST potentiometer in a clockwise direction.
To increase the output in a negative direction,
turn the BALANCE ADJUST potentiometer in a
counter-clockwise direction.
6. Test the neutralization (discharge) times by
applying ±1,000 volts on the charged plate. The
neutralization (discharge) time typically will be
less than 3 seconds when charged plate analyzer
is directly under a fan. See the “Neutralization
(Discharge) Times” section for typical discharge
times. The required limit per ANSI/ESD S20.20 is
“user defined”.
7. Submit the balance (offset voltage) to the
ionizer’s control circuit by quickly pressing the
ALARM RESET button. The STATUS LED should
turn off and then illuminate green to verify that the
control circuit was successfully programmed.
8. Test each fan’s alarm by shorting its two grills
located on the bottom side of the ionizer. The
alarm should sound and the STATUS LED should
illuminate red.
Figure 9. Calibration controls
Figure 10. Shorting the ionizer’s two fan grills
EMIT
- 3651 Walnut Avenue, Chino, CA 91710 • (909) 664-9980 • Website:
DescoEMIT.com
TB-6545
Page 4 of 9
© 2017 DESCO INDUSTRIES, INC.
Employee Owned
Neutralization (Discharge) Times
All data was taken with the fan speed set to high. All time measurements are in seconds. The distance between
the overhead ionizer and charged plate is 18" per ANSI/ESD STM 3.1.
NOTE: Discharge times in seconds are representative only and are not a guarantee. Discharge times are actual
measurements recorded in a factory ambient environment.
Per ANSI/ESD S20.20, the test method for Product Qualification test is ANSI/ESD STM3.1, and for Compliance
Verification is ESD TR53 which advises “Measurements should be made at the location where ESD sensitive items
are to be ionized.” A larger area may require additional ionizers. Per S20.20 the required limit for ionizer discharge
time is user defined. Use Table to determine the number of ionizers to achieve ionization of area to be neutralized
to meet your company’s ESD control plan specified discharge times.
16"
16"
16"
10.4(+)
11.8(-)
TP1
3.4(+)
3.7(-)
Charged Plate TP4
3.3(+)
3.6(-)
TP7
9.1(+)
9.7(-)
TP10
12"
4.1(+)
4.8(-)
TP2
2.0(+)
2.3(-)
TP5
2.2(+)
2.7(-)
TP8
3.4(+)
3.9(-)
TP11
12"
TP3
7.5(+)
8.4(-)
TP6
2.6(+)
3.2(-)
TP9
3.0(+)
3.9(-)
TP12
7.0(+)
9.1(-)
Figure 11. 50681, 50603 Neutralization (Discharge) Times at 100VAC, 50Hz input
EMIT
- 3651 Walnut Avenue, Chino, CA 91710 • (909) 664-9980 • Website:
DescoEMIT.com
TB-6545
Page 5 of 9
© 2017 DESCO INDUSTRIES, INC.
Employee Owned
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