Vortec 921 Series, 921-3, 981 Series, 930-8, 930-9 Operation & Safety Instructions

TABLE 1: FILTER RECOMMENDATIONS

FILTER AND REPLACEMENT PART ITEM NUMBERS

Vortec Model 5 Micron Air Filter Oil Removal Filter Pressure Regulator .002”, .003” or .004” shims

921-3 701S-24A 701S-48 208R 930-8, 930-9, 930-10

921-6, 981-6 701S-24A 701S-48 208R 930-8, 930-9, 930-10

921-12, 981-12 701S-40A 701S-54 208R 930-8, 930-9, 930-10

921-18, 981-18 701S-40A - 208RX 930-8, 930-9, 930-10

921-24, 981-24 701S-40A - 208RX 930-8, 930-9, 930-10

TABLE 2: DETERMINING COMPRESSED AIR LINE SIZE

1. Calculate total product compressed air consumption (SCFM, SLPM).

2. Determine length of compressed air line required for connection to main supply.

3. Locate pipe length in left column and read to the right to nd the compressed air requirements.

4. Locate pipe size at top of column.

MAXIMUM AIRFLOW (SCFM) THROUGH PIPE AT 5 PSIG PRESSURE DROP (100 PSIG AND 70OF)

Pipe Length

(Feet)

10 29 65 120 254 480 978 1483 2863 4536

20 21 46 85 180 340 692 1049 2024 3208

30 17 37 70 147 277 565 856 1653 2619

40 15 32 60 127 240 489 792 1431 2268

50 13 29 54 114 215 437 663 1280 2029

60 12 26 49 10 4 19 6 399 606 116 9 1852

70 11 25 46 96 18 1 370 561 1082 17 15

80 10 23 43 90 170 346 524 1012 1604

90 10 22 40 85 160 326 494 954 1512

100 9 21 38 80 152 309 469 905 1435

1/4 3/8 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2

Pipe Size (Nominal) - Schedule 40

OPERATION & SAFETY

INSTRUCTIONS

AIR KNIVES &

IONIZING AIR KNIVES

Models 921-X and 981-X

(Includes all BSP versions of models listed above)

MAXIMUM AIRFLOW (SLPM) THROUGH PIPE AT 0.3 BAR PRESSURE DROP (6.9 BAR AND 21OC)

Pipe Length

(Meters)

3 821 1840 3396 7188 13584 27677 42117 81023 128369

6 594 1302 2406 5094 9622 19584 29687 57279 90786

9 481 1047 1981 4160 7839 15990 24225 46780 74188

12 425 906 1698 3594 6792 13839 20999 40497 64184

15 368 821 1528 3226 6085 12367 18763 36224 57421

18 340 736 1387 2943 5547 11292 17150 33083 52412

21 3 11 708 1302 2717 5122 10471 15877 30621 48535

24 283 651 1217 2547 4811 9792 14829 28640 45393

27 269 623 11 3 2 2406 4528 9226 13980 26998 42790

31 255 594 1075 2264 4302 8745 13273 25612 40611

Rubber hose maximum airow rating: 1/2” I.D. rubber hose = 3/8” pipe; 3/4” I.D. rubber hose = 1/2” pipe

LIT0080

1/4 3/8 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2

Pipe Size (Nominal) - Schedule 40

IMPORTANT

Please read all instructions BEFORE

attempting to use this product

10125 Carver Road, Cincinnati, OH 45242

Phone: [phone] • Fax: [phone]

Toll Free: 800-441-7475

www.vortec.com • [e-mail]

GENERAL SAFETY CONSIDERATIONS

WARNING: COMPRESSED AIR COULD CAUSE
DEATH, BLINDNESS OR INJURY

1. Do not operate Air Knives at compressed air pressures
above 150 psig (10.3 Bar).

2. Avoid direct contact with compressed air.

3. Do not direct compressed air at any person.

4. When using compressed air, wear safety glasses with side
shields.

INTRODUCTION

Air Knives are airow ampliers that can reduce compressed air
consumption by up to 50% while helping to meet OSHA dead-end
pressure and noise specications. Air Knives produce a high velocity,
highly uniform airow for blow off or surface cooling of moving webs,
sheets, strips and large or small objects and wide surfaces.

Ionizing Air Knives are used for static neutralization and blow off of
moving webs, sheets, strips and large or small objects and wide
surfaces.

COMPRESSED AIR SUPPLY

The compressed air supply must be ltered to remove water and dirt
using a 5 micron or smaller lter. Failure to use a lter may cause
clogging of the compressed air paths inside the Vortec product. Filter
recommendations are given in Table 1.

Filter elements must be changed on a regular basis. Frequency of
change is determined by the condition of the compressed air supply.
Filters should be installed in the compressed air supply line as close as
possible to the Vortec product.

The appropriate size of the compressed air supply line should be
selected to ensure optimal performance of the Vortec product. Please
refer to Table 2 to determine what supply line size is recommended for
your application. Contact Vortec at 1-800-441-7475 for further assistance.

INSTALLATION AND OPERATION

Air Knives can be cycled on and off to match machine cycle times. In
order to vary the volume of airow from the Air Knife, an appropriately
sized pressure regulator can be used to control the compressed
air pressure, (less pressure = less airow). Pressure regulator
recommendations are given in Table 1.

Air Knives have no moving parts, and require only ltered compressed
air for proper operation. Ionizing Air Knives must be connected to a
suitable power supply (Vortec models F167 or D167RY). The power
supplies are capable of operating up to two or four separate Ionizing Air
Knives respectively. The total effective length of all Ionizing Air Knives
connected to one power supply should not exceed 200 inches.

Multiple Air Knives can be installed by connecting to an air manifold or
by directly plumbing to the appropriately-sized, hard piped, compressed
air source that does not exceed 150 psig (10.3 Bar). Air Knives will be
most effective if securely mounted at 18 inches or less from the surface
to be blown off.

MAINTENANCE

It is critical to the performance of the Air Knives that the internal air
passages remain clean. If performance suddenly drops, carefully
disassemble the unit and inspect for debris. If debris is found, it may be

necessary to change the lter element. Clean the debris from the unit
and reassemble. For detailed instructions on cleaning or reassembly
contact your authorized distributor or Vortec.

If uneven airow is present from the Air Knife, it may be partially clogged
with dirt. You may disassemble the Air Knife and clean any debris that
may be blocking airow out of the extremely small air gap. Use a soft
brush and/or pure isopropyl alcohol on a clean cloth to remove stubborn
deposits. Be careful not to damage the thin aluminum shim(s) inside the
unit. When reassembling the Air Knife, use the same thickness shims
that were removed from the unit. Red colored shims are 0.002”, green
are 0.003” and silver are 0.004”. Tighten the cap screws that secure the
two main components together from the center of the unit out to the
ends. Replace the end caps and gaskets.

Ionizing Air Knives

In order for the ionizing system to function, the ionizing high voltage
cable must be kept at least 1/4” (6mm) from any grounded surface. Two
cable supports are provided to help position the cable and keep it in
place away from grounded surfaces. To install the cable supports, push
the plastic bushing out of the metal support. Screw the metal support
into the desired location; then snap the plastic bushing onto the cable
(the bushing is split to allow this) at the desired position. Push the cable
onto the metal support and press the bushing back into the support.

Run the green ground wire from the ionizing bar back to the power
supply. Attach the ground wire ring terminal to the ground stud on the
power supply. Secure the ground wire to the power supply with a locknut.
Keep the green ground wire at least 1/4” away from the high voltage
cable.

Insert the spring loaded connector on the end of the high voltage cable
into one of the high voltage receptacles on the power supply. Finger
tighten the knurled knob on the connector into the receptacle. Be

sure that the power to the power supply is disconnected before
attempting to connect the high voltage power cable.

Verify that all electrical connections are securely attached before
plugging the power supply into the appropriate 115 VAC receptacle. The
receptacle must have a good ground connection for the ground pin on
the plug. If it does not, bolt the power supply to a well grounded metal
machine frame. The Ionizing Air Knife will not operate unless properly
grounded.

If you suspect that your ionizing bar is not functioning properly, you may
test it when the unit is operating. Using an insulated handle screwdriver,
place the metal shaft of the screwdriver on the metal surface of the
ionizing bar. While the metal shaft of the screwdriver is touching one
of the metal sides of the ionizing bar, position the tip of the screwdriver
near one of the sharp emitter points on the bar. A small spark should
jump a 1/16” to 1/8” (1 to 3mm) gap between the emitter point and the
tip of the screwdriver. Continue this test on each emitter point. The
emitter points can be cleaned with a soft brush and small amounts of
isopropyl alcohol. Disconnect power to the power supply when cleaning
the emitter points.

TROUBLESHOOTING

Insufficient airow may be caused by the following:

1. Undersized compressed air line size.

2. Compressed air pressure too low.

3. Partial or complete blockage of internal air path, due to dirt. See
Maintenance section for cleaning instructions; and Compressed Air
Supply section for lter recommendations.

4. Insufficient compressed air volume.

If trouble persists, please contact Vortec at 1-800-441-7475.

AIR KNIFE DIMENSIONS AND FUNCTIONALITY

IONIZING AIR KNIFE

(Drawings shown above are not to scale)

LIMITED WARRANTY

Vortec compressed air products manufactured by ITW Air Management
will be replaced or repaired if found to be defective due to manufacture
defect within ten years from the date of invoice. Refer to our website
www.vortec.com for full warranty details and limitations. ITW Air
Management makes no specic warranty merchantability or warrant of
tness to a particular purpose.