CORONA TREATING SYSTEM

USER AND MAINTENANCE MANUAL

Translation from the original instructions

Me.Ro Order No. ****

Manufacturing Year ****

Customer ****

Customer Order No. ***

2014 © Me.Ro S.p.A. – ITALY

Edition 2014,
Prepared 11/2014
CORONA TREATING SYSTEM

Manufacter Me.Ro S.p.A.

Via Balestreri,430
55100 Ponte a Moriano (LU) ITALY
Phone: +39.0583.406060
Fax: +39.0583.406050
E-mail: [email protected]
Internet: www.mero.it
Customer

End client
 REVISION HISTORY

REVISION HISTORY

First Date Description Redaction Check Compilation

edition

1 20/11/2014 First edition Riccomini S. M.DS A.M.

2 17/11/2016 Revision Picchi Giacomo M.DS A.M.

3 3/8/17 Added paragraph 3.13 (glittering plant) Riccomini S. G.P A.M.

4 22/9/17 Added paragraph description vacuostato types Riccomini S. M.DS A.M.

(cap.3)

5 3/10/17 Added paragraph description ozone suction Riccomini S. M.DS A.M.

connection

6 4/11/17 Removing the section "Removing and cleaning Riccomini S. M.DS A.M.
ceramic electrodes»

7 21/3/18 Added paragraph “INTERMITTENCE” mode Riccomini S. D.S. M.DS.

REVISION HISTORY 1
 PRESENTATION

PRESENTATION

Thank you for purchasing the Corona Treatment Unit from Me.Ro. S.p.A.
Who these instructions are for.
This use and maintenance manual is designed for all those who are to install,
work with and carry out maintenance on the Corona Treatment Unit from
Me.Ro. S.p.A., and in particular for operational personnel.

This document has been produced by the Technical Documentation

Copyright.
Department of Me.Ro. S.p.A.

No part of this document may be re-used, reproduced and/or distributed by

electronic means without prior authorisation from Me.Ro. S.p.A.

The descriptions and illustrations in this manual refer to a standard

machine/unit (unless specified otherwise). Me.Ro S.p.A. reserves the right
to make changes at any time that it deems appropriate for standard
production.

This manual is an integral part of what is supplied and must be read in order
to meet essential minimum safety standards.

If lost or damaged, a copy can be requested from Me.Ro. S.p.A. by

communicating the serial number and order number on the unit's
identification plate.

Me.Ro. S.p.A.. does not accept liability for any error in this documentation.

For any questions or problems during installation, contact Me.Ro. S.p.A.

We will be pleased to help you

Me.Ro. S.p.A.
Zona Industriale – Via Balestreri 430
55100 Ponte a Moriano - LUCCA
Italy
Tel: +39 0583.406060
Fax: +39 0583.406050
E-mail: [email protected]
Internet : www.mero.it

PRESENTATION 2
 DECLARATION OF CONFORMITY

DECLARATION OF CONFORMITY

I, the undersigned Mennucci Lamberto, as legal representative of ME.RO S.p.A.,

manufacturer of the machine identified in the references below, hereby declare
that said machine complies with the essential safety requirements as set forth in
European Community Directives 2006/42/EC and 89/336. In particular, it is
compliant with the requirements in the following harmonised norms:

UNI EN ISO 12100:2010 , UNI EN 13857 , UNI EN 349 , UNI EN 1088, CEI EN 60204-
1 , EN 55011 , EN 50082-2.

Manufacturer Factory ME.RO S.p.A.

Via Balestreri 430-Ponte a Moriano-LUCCA-ITALY-

Machine Electronic Generator Discharge Station

Type *** ***

Manufacturing Year 2018

The end user MUST NOT install the above mentioned machine within others without having verified compliance
with the 2006/42/EC directive.

Ponte a Moriano, on 04/04/2018

GENERAL INFORMATION 3
 GENERAL INFORMATION

GENERAL INFORMATION

Section profile:
Who is this chapter for?
This section is intended for all individuals who install, use and perform
maintenance on the Corona Treatment Unit from Me.Ro. S.p.A.

This section contains the main details about the product and the operating
Contents of this chapter manual.

MANUFACTURER’S GUARANTEE

Conditions of guarantee

All equipment manufactured by Me.Ro. S.p.A. is made using tested

materials, and tests are carried out again by our technical personnel when
construction is complete.

Our equipment is guaranteed for 12 months ex works Ponte a Moriano,

12-month guarantee Lucca, Italy.

If callouts are requested during the guarantee period, you will be charged
for travel time, travel costs, board and lodging; the cost of the time spent
on repairs and any spare parts will be met by us.

Exclusion of guarantee

Damage caused by incorrect use or by unauthorised operations on the

Corona Treatment Unit from Me.Ro. S.p.A. are excluded from this
guarantee.

GENERAL INFORMATION 4
 GENERAL INFORMATION

DOCUMENT STRUCTURE

General

With Me.Ro. S.p.A. two types of document are supplied:

 Use and maintenance manual

The manual contains of all necessary instructions for the installation, start-
up and maintenance of the unit.

 Technical documentation regarding the unit

The technical documentation for the unit includes the layout, drawings and
materials list. (Attached at the end of this manual)

This document is the use and maintenance manual.

Structure of the use and maintenance manual

 The manual describes all operations to be performed for the start-up and the
safe operation of the Corona Treatment Unit from Me.Ro. S.p.A. Also
described are the construction technologies and the corresponding
maintenance operations for the Corona Treatment Unit from Me.Ro. S.p.A.

 Attached to the use and maintenance manual are the mechanical and
electronic diagrams, including the components list.

GENERAL INFORMATION 5
 GENERAL INFORMATION

DESCRIPTION OF SYMBOLS

Danger!

This symbol indicates that there is a risk of personal injury..

High voltage hazard!

This symbol warns of a hazard due to the presence of high voltage (risk of
electric shock).

Danger: High frequency!

This symbol warns of a hazard due to high-frequency radiation. People

with pacemakers or prostheses must not enter areas where this symbol is
displayed. Pacemaker operation may be affected and prostheses may
overheat.

Warning!

This symbol draws attention to important information.

TECHNICAL TERMINOLOGY AND ABBREVIATIONS

DESCRIPTION OF ABBREVIATIONS

P Power

I Current

V Voltage

F Frequency

L Inductance

C Capacity

GENERAL INFORMATION 6
 SUMMARY

SUMMARY

REVISION HISTORY 1
PRESENTATION 2
DECLARATION OF CONFORMITY 3
GENERAL INFORMATION 4
Manufacturer’s guarantee 4
Document structure 5
Description of symbols 6
Technical terminology and abbreviations 6

SUMMARY 7
TECHNICAL SPECIFICATIONS OF THE CORONA TREATMENT SYSTEM 9
1 SAFETY 10
1.1 End use 10
1.2 General Warnings 11
1.3 Dangerous areas: maintenance and repair 12
1.4 Dangerous areas: Discharge station - ozone 13
1.5 Safety Measures 13
1.6 Residual risk 13

2 DESCRIPTON - TECHNOLOGY 14
2.1 Corona treatment composition 14
2.2 Components and their functions 15
2.3 Control modes 17

3 INSTALLATION 19
3.1 Transport, positioning 19
3.2 Indications for movement 19
3.3 Assembly and fitting instructions 20
3.4 Space required for use and maintenance 20
3.5 Environmental conditions 20
3.6 Istruction for connecting the machine to its power supply 21
3.7 Recommendations for safety measures which must be taken by the user 21
3.8 Detailed description of the machine, its accessories, guards and/or safety devices 21
3.9 Indications regaring measuring methods to use 22
3.10 Ozone exhaust of the discharge station 23
3.11 Unpackaging 24
3.12 Connections 25
3.13 Instructions for starting-up the generator with operator terminal installed on the electronic generator 26
3.14 Start the plant with an external contact (only corona treater for glittering plant) 31
3.15 Warnings on first use of the unit 31
3.16 Description of the workplace 31
3.17 Places of use 31

SUMMARY 7
 SUMMARY

3.18 Spare parts 32

4 OPERATION, CONTROL 33
4.1 Commissioning 33
4.2 Type of operator terminal 34
4.3 Terminal operator structure 35
4.4 Touch screen control panel 36
4.5 Plant parameter setting 38
4.6 Function mode 46
4.7 Alarms and warnings 60

5 ELECTRONIC GENERATOR 67
5.1 Internal structure of the electronic generator 67

6 GENERAL DESCRIPTION AND MAINTENANCE OF ME.RO DISCHARGE STATIONS 72

6.1 Discharge station 72
6.2 Normal discharge station 73
6.3 Universal discharge station 75
6.4 Description of the manual controls of the discharge station 77
6.5 Instruction for the calibration and adjustment of the discharge station 77
6.6 How to stop the plant 78
6.7 Dismantling the discharge roller 79

7 ADAPTING GENERATOR TO LOAD 80

7.1 Variable impedance 80
7.2 Adjust variable impedance 81

8 INSTRUCTIONS AND WARNING 83

8.1 General safety regulations 83
8.2 On-off of the system 85

9 MAINTENANCE 86
9.1 General notes for maintenance 86
9.2 Safe maintenance 87
9.3 Maintenance intervals 87
9.4 Maintenance procedures 88
9.5 Procedure for checking the double igbt modules 89
9.6 Mending the silicone insulated rollers 90
9.7 Repairing silicon sleeve insulated rollers 91
9.8 Repairing ceramic coated rollers 93

10 UNISTALL AND DISPOSAL 94

10.1. Iunsulating the unit 94
10.2 Packaging 94
10.3 Disposal 95

ANALYTICAL INDEX 97

SUMMARY 8
 TECHNICAL SPECIFICATIONS OF THE CORONA TREATMENT SYSTEM

TECHNICAL SPECIFICATIONS OF THE CORONA TREATMENT SYSTEM

TECHNICAL SPECIFICATIONS OF THE CORONA TREATMENT SYSTEM 9

 1 SAFETY

1 SAFETY

Section profile:

This section is intended for all individuals who install, use and perform
Who is this chapter for? maintenance on the Corona Treatment Unit from Me.Ro. S.p.A.

This chapter contains the main details regarding safe operation of the
Contents of this chapter product

1.1 END USE

Danger!

Personal and system protection is not guaranteed if the generator is not

operated in compliance with its designated use.

Any maintenance or repairs to the electronic generator and to the

discharge station of the corona must be carried out only by authorised
specialised personnel of Me.Ro. S.p.A.

Designate use

The system described in this manual applies exclusively to Corona effect

Electronic generator treatment.
applications
Depending on the type of discharge station provided, one can determine on
what kind of materials and filmscorona treatment can be carried out.

Refer to the "GENERAL DESCRIPTION AND MAINTENANCE OF ME.RO

DISCHARGE STATIONS" chapter on page 9 to determine the types of
materials that can be treated.

The Corona Treatment Unit from Me.Ro. S.p.A may only be used for its
specified intended use.

SAFETY 10
1 SAFETY

1.2 GENERAL WARNINGS

High Voltage Hazard

The electronic generator converts mains voltage to DC (Direct Current) and

then to AC (Alternating Current) at the inverter stage. Components supplied
with these voltages can give electric shocks.

Before working on the generator and the discharge station, position

the main switch on the generator to OFF and disconnect the electrical
supply from the unit altogether.

SAFETY 11
1 SAFETY

1.3 DANGEROUS AREAS: MAINTENANCE AND REPAIR

Dangerous areas: main switch OFF

When the main switch is in the OFF position, there are no live areas inside
the electronic generator.

Control and protection device

Caution!

Warning!!!

The operator is responsible for working safely on the Corona Treatment

System from Me.Ro. S.p.A. It is their responsibility to be acquainted with the
regulations and to apply them.

The electronic generator is equipped with a main switch which also

performs the function of emergency disconnection.

ON

OFF

Fig. 1
Danger!

Before working on the electronic generator, wait for approximately 30” to

allow the DC link to discharge.

The electronic generator will automatically go to OFF if there is:

Protection systems
 Overvoltage
 Overheating
 Overload
 Interlocking
 Main switch On

SAFETY 12
1 SAFETY

1.4 DANGEROUS AREAS: DISCHARGE STATION - OZONE

Ozone (O3) is produced by crown discharge.

It is a highly oxidizing, toxic, corrosive gas and depending on the

concentration it can pose a health hazard.

The exposure limit for operators detected in the immediate vicinity of the
discharge station should not exceed 0.1 ppm (0.2 mg / m3). Greater
concentrations need to be avoided.

If the current regulations for exhaust gas in the atmosphere permit, ozone
can be extracted from the discharge station and ejected through the ozone
extractor provided.

1.5 SAFETY MEASURES

In the event of an emergency, carry out the following steps in the order
given:

1. Disconnect the external power line to the electronic generator and any
auxiliary power lines on the discharge station.
2. Extinguish fire by using the appropriate extinguisher.

High voltage hazard!

Due to the presence of high voltage, water must never be used to extinguish
fires; use appropriate extinguishing agents.

1.6 RESIDUAL RISK

You can not reduce to zero the risk for those who use the facilities. It draws
attention to the residual risk

 An operator that works near the discharge station, must take care to the
moving roller, as it may cause injury to fingers if inadvertently inserted
between the roller and the hood.

 Always check that the ozone pipe is properly connected between the
discharge station and the ozone aspiration. Also check that the aspiration is
efficient and that the pipe is not blocked.

SAFETY 13
 2 DESCRIPTON - TECHNOLOGY

2 DESCRIPTON - TECHNOLOGY

Chapter profile:

This section is intended for all individuals who install, use and perform
Who is this chapter for? maintenance on the Corona Treatment Unit from Me.Ro. S.p.A.

This section contains the main details about the functionality and
Contents of this chapter technology of the Corona Treatment Systems, their operation and fields of
application.

2.1 CORONA TREATMENT COMPOSITION

The Corona Treatment Unit from Me.Ro. S.p.A is mainly composed of the
following fundamental components:

 Electronic Generator
 Operator terminal
 High Voltage Transformer
 Discharge station

Optionals

 Ozone suction fan (supplied only upon request, not described in the
present manual)
 Ozone Reducer (supplied only upon request, not described in the
present manual).

DESCRIPTON - TECHNOLOGY 14
2 DESCRIPTON - TECHNOLOGY

2.2 COMPONENTS AND THEIR FUNCTIONS

GENERATOR CONSTRUCTION

The Electronic Generator is constructed in a metal cabinet. The cabinet can

be equipped with wheels. All Me.Ro. S.p.A electronic generators have a
cabinet with two hinged panels for internal inspection. The electronic
generator is air-cooled.

N.B.: Electronic generators up to 10kW of power are equipped with wheeled

cabinet by Me.Ro S.p.A. as standard.

COMPONENTS

The electronic generator is essentially composed of:

 Rectifier
 Chopper
 Inverter
 Control electronics
 Operator terminal
 High Voltage Transformer
OPTIONAL
 Conditioner (optional)

The rectifier converts mains AC voltage into DC voltage to feed the Chopper.

The Chopper adjusts output power of the electronic generator, controls

current and voltage limits and supplies the inverter by the impedance IMF2.

The inverter is composed of two IGBT modules in a full-bridge

configuration. It is electrically powered and coupled with a resonant circuit
formed by the primary inductance of the output transformer and by CVOL
flywheel capacity.

The control electronics cover all functions for the control and piloting of the
power stages of the generator.

The operator terminal is the operator interface between the electronic

generator and the user. Refer to chapter 4 “OPERATION, CONTROL” for
more information regarding its operation.

The High-voltage transformer is an integrated part of the inverter, the

multi-pole secondary winding allows it to be easily adapted between
generation and charging.

DESCRIPTON - TECHNOLOGY 15
2 DESCRIPTON - TECHNOLOGY

May be supplied individually (for electronic generators which are not

installed in a cabinet) or placed inside the electronic generator cabinet.

Separately supplied High Voltage High Voltage Transformer placed

Transformer inside generator cabinet

Fig. 3 Fig. 2

OPTIONAL

The conditioner (optional) allows for improved cooling in the cabinet, and
is recommended for generators that are located in tropical climates or areas
of high humidity.

DESCRIPTON - TECHNOLOGY 16
2 DESCRIPTON - TECHNOLOGY

COMPOSITION OF THE DISCHARGE STATION

The discharge station is mainly composed of:

 Discharge electrodes in the suction hood

 Discharge roller
 Electrode moving unit
 Station Box with cables for managing the discharge station.
 Pressure roller (optional)
 Transmission rollers

The discharge electrodes are contained in / protected by the hood and are
connected to the generator by the High Voltage Cable. The hood is used as
duct for suction of the ozone generated during the corona treatment
procedure.

The discharge roller supports the material to be treated and can be coated
with different types of materials.

The Electrode moving unit, composed of pneumatic cylinders, guides and

buffers, allows for the operation of some functions, such as: smooth
insertion of the film to be treated; regulating the Air Gap; possibility to
move the hood further from the discharge roller to allow for unit
maintenance.

The station box is positioned on one side of the discharge station and its
functions as the interface between the generator and the safety devices on
the discharge station itself.

The pressure roller has the main function of eliminating the problem of
“counter-treatment”. This inconvenience may occur when air bubbles
appear between the film and the discharge roller.

The transmission roller (optional) functions as “guide” of the film to be

treated on the discharge roller.

2.3 CONTROL MODES

The electronic generator can operate with your operator terminal.

The operator terminal can be inserted into the front door of the cabinet, or
placed in a special box to allow the remote installation of the same.

The electronic generator PLC has an PROFINET® input connector that the
operator terminal is connected to.. Via an Ethernet-switch module (e.g.
CSM 1277 Siemens not supplied) the PLC can also be connected to a
PROFINET® node.

On the customer's request, an interface module can also be installed on the

electronic generator (e.g. PROFIBUS®-DP) for connecting the PLC of the

DESCRIPTON - TECHNOLOGY 17
2 DESCRIPTON - TECHNOLOGY

electronic generator to the company PROFIBUS® node. In this way the

system can be managed locally, by the operator terminal, or remotely by
the PROFIBUS-DP® node.

DESCRIPTON - TECHNOLOGY 18
 3 INSTALLATION

3 INSTALLATION

Section profile:

This section is for everyone who installs the Corona Treatment System from
Who is this chapter for? Me.Ro. S.p.A.

This chapter contains information regarding the proper mechanical and

Contents of this chapter electronic installation for the Corona Treatment System from Me.Ro. S.p.A.

3.1 TRANSPORT, POSITIONING

TRANSPORT

After receiving the system:

Control the integrity of all parts.

Immediately advise of any damage occurring during transport.

POSITIONING

Adequate protection of the machine against water and dust is essential.

Environmental conditions
It can be stored at temperatures between -25°C and +70°C.

It is preferable to install the machine in a dry place (not necessary).

3.2 INDICATIONS FOR MOVEMENT

During shipment, the plant components are stored in suitable containers

with wooden base.

Do not remove the packaging until the machine is close to its definitive
position.

The generator may be handled using a fork-lift truck of adequate power.

The gross weight is indicated on the packaging.

When handling without packaging, both the electronic generator and the
discharge station must be lifted using the appropriate eye-bolts.

Blocking (example = using metal strips) prevents accidental opening of the

discharge station.

When the discharge station is positioned and locked, and the electrical and
pneumatic systems are ready, the locks must be removed, paying particular
attention to the pistons which must be in the closed position.

INSTALLATION 19
3 INSTALLATION

3.3 ASSEMBLY AND FITTING INSTRUCTIONS

The discharge station must be firmly anchored to the supporting structure.

When installing, consider any requirements for alignment and parallel

positioning in relation to the other components up or down the line.

3.4 SPACE REQUIRED FOR USE AND MAINTENANCE

The electronic generator can be accessed via the two hinged panels.

Position the electronic generator so that all sides are accessible (except for
the bottom of the container) and ensure clearance on each side of 80 cm.

Should the electronic generator have to be placed close to other parts (so
as to cover one or more sides), fix the generator so that it may be moved in
order to be accessed for maintenance.

Pay particular attention to the electronic generator air cooling intakes;

these intakes must be unobstructed and freely accessible for maintenance
(cleaning filters etc.).

The discharge electrodes inside the station can be adjusted using screws on
the inside of the station itself. Refer to the diagrams attached to the use and
maintenance manual for perfect adjustment of the air-gap.

For visual checking of the Corona effect discharge inside the station, there
are a number of windows on the side of the discharge station; which must
be left easily accessible.

3.5 ENVIRONMENTAL CONDITIONS

The electronic generator can operate at temperatures between +5°C and

+40°C and humidity between 30-95%, without condensation. The Discharge
Station can operate at temperatures between +5°C and +55°C, humidity
between 30-95%, without condensation.

The environmental conditions (temperature and humidity) must be checked

with particular attention when the conditions for the formation of
condensation on the inside and outside surfaces of the Electronic Generator
and discharge station are approached.

In particular, avoid operating the plant when there is condensation in the

Discharge Station to prevent possible high voltage discharges to ground.

Bear in mind that due to the ozone suction fan, the Discharge Station is
under a slight vacuum compared to the surrounding environment and so in
certain environmental conditions, condensation may form on the inside
before or more than on the outside or in other equipment (Electronic
Generator).

INSTALLATION 20
3 INSTALLATION

3.6 ISTRUCTION FOR CONNECTING THE MACHINE TO ITS POWER SUPPLY

The protective devices on the mains power supply panel (switch + fuses)
and the power supply line must be sized according to the power supply
voltage and the max. current drawn by the generator. Refer to the electric
INPUT data on the generator itself.

3.7 RECOMMENDATIONS FOR SAFETY MEASURES WHICH MUST BE TAKEN BY THE USER

Place barriers beside the discharge station to prevent access by

unauthorised persons.

Please note: if the barriers are opened when the machine is in operation,
the electronic generator must switch off.

3.8 DETAILED DESCRIPTION OF THE MACHINE, ITS ACCESSORIES, GUARDS AND/OR

SAFETY DEVICES

 The Discharge Station electrodes are rotated by a pneumatic system.

 Double acting pistons are mounted on the Discharge Station and the
pneumatic connection is made inside the discharge station.
 The input jacks and global output for the compressed air connection are
available on one of the pistons (usually on the operator side).
 The Discharge Station is equipped with an inductive sensor for detecting
roller rotation and of a series of station closed position microswitches
(contact closed when the station is closed).
 An electrical junction box is position on one side of the discharge station
containing the board or terminal block where the following is connected:
inductive sensor for measuring micro station station closed solenoid
command speed.
 The connection between the box on the Discharge Station and the
terminal block inside the electronic generator must be made by the user
(see attached wiring diagrams)
 The high voltage input is via a high voltage insulator, (the high voltage
cable must be connected to the discharge electrodes inside the station).
 The Discharge Station is prepared for the suction of ozone that is formed
as a result of discharge, through the sockets placed on the mobile part of
the station.
 When connecting the ozone outlet and ozone suction device (to be carried
out by the user), bear in mind that the ozone has an oxidising effect and
therefore piping in stainless steel or plastic must be used.
To allow the discharge station to be opened, flexible piping must be used at
the start of the connection between the ozone outlet and the suction
device. discharge station The pneumatic system is composed of a shut-off
valve, a flow regulator, a manual valve (or solenoid), cylinders, flow
regulators and valves. Place the manual valve (or remote box for solenoid
management), in the vicinity of the discharge station and outside the

INSTALLATION 21
3 INSTALLATION

protections of the same, so that the operator visually follows the opening
or closing stages of the discharge station.

The compressed air supply (4 bar minimum and 10 bar maximum) is applied
to the plug valve. The latter has a working position as well as a safety
position for maintenance operations. These positions are shown on the
label near the valve itself. In the safety position, discharge station opening
or shutting is allowed under no circumstances.

The blocking valves do not allow the shutting of the discharge station (with
the valve in maintenance position) even in the event of failure of the
compressed air pipes; for this reason it can only position the station as
shown in the picture.

If the discharge station is to be installed upside down, the position of the

station's pneumatic piston valves must be inverted in order for safety
devices to operate correctly.

This operation must in any case be carried out by specialised personnel

authorised by Me.Ro S.p.A..

3.9 INDICATIONS REGARING MEASURING METHODS TO USE

The discharge station rollers are dynamically balanced and comply with
class _6.3_ for balancing.

The ozone concentration near the discharge station, less than one metre
from it, must be 0.1 ppm or less. Use (for example) the DRAGER system with
OZON 0.05/b ozone reactor phial.

INSTALLATION 22
3 INSTALLATION

3.10 OZONE EXHAUST OF THE DISCHARGE STATION

Ozone (O3) is an oxidizing, toxic, corrosive gas, depending on

concentration, can pose a health hazard.

Ozone is a crown discharge effect in the air.

Exposure Limits

The exposure limit for operators detected in the immediate vicinity of the
discharge station should not exceed 0.1 ppm (0.2 mg / m3). Greater
concentrations need to be avoided.

The concentration measurement can be done using the Dräger vial. This
is a simple to use and economical and reliable system.

If the current regulations for exhaust gas in the atmosphere permit, ozone
can be extracted from the discharge station and ejected through the
ozone extractor provided. It is dimensioned taking into account the output
power of the generator, the length of the discharge station, the discharge
losses of the ejection duct and the speed of production.

Suction duct

Prepare the ejection duct, between the discharge station and the ozone
suction fan, and between the fan and the atmosphere. Use corrosion
resistant materials such as stainless steel or plastic materials such as PVC.

Avoid as much as possible right-angle curves that can limit the expulsion
and suction capacity.

Both the aspirator and the evacuation duct must be made of ozone
resistant materials (stainless steel or plastic materials such as PVC - PET).

Reduction of ozone produced

Where the rules for exhaust gas in the atmosphere do not allow high
ozone concentrations, ozone destroyer must be used.

Ozone destroyer are equipment that destroys it before it is ejected. With

these devices (suitably sized depending on the amount of product ozone),
concentrations below 0.1ppm are obtained.

This is typically lower than the norm required and in these working
conditions it is allowed to eject into the atmosphere.

INSTALLATION 23
3 INSTALLATION

3.11 UNPACKAGING

Unpackage the various unit components with care

A complete system of Corona Treatment consists mainly of:

 Electronic Generator (with operator terminal).

 High Voltage Transformer

 Discharge Station.

 Ozone Suction.

The electronic generator (with operator terminal) can be supplied as a

stand-alone unit on request, when the existing installation already has a
discharge station and ozone suction present.

The operator terminal can be supplied in a case (and not fitted inside the
electronic generator cabinet) in order to be positioned in the desired area.
(remote operator terminal)

The packaging contains all cables required for setup, except for the main
power supply line of the electronic generator (and of the ozone suction fan
if supplied).

Ensure that the packaging contains all of the items listed above.

Furthermore, check all parts for completeness of the Discharge Station, the
covering, the discharge roller (if supplied), and the high voltage cable
normally attached to the discharge station.

INSTALLATION 24
3 INSTALLATION

3.12 CONNECTIONS

Electronic Generator supply line

The protections on the general supply panel (switch + fuses) and the power
supply line have to be dimensioned on the basis of the supply voltage and
the maximum absorbed power by the generator. Refer to the electrical data
described on page 9 of this manual or on the identification plate on the
generator cabinet.

High voltage hazard!

The electrical connections of the system have to be made by authorised

personnel specialised for working on electrical devices.

Please respect the local safety rules for the installation of this unit.

INSTALLATION 25
3 INSTALLATION

3.13 INSTRUCTIONS FOR STARTING-UP THE GENERATOR WITH OPERATOR TERMINAL

INSTALLED ON THE ELECTRONIC GENERATOR

Fig. 4

N.B.: Standard treatment plant connections.

Prepare the power supply terminals L1-L2-L3-PE with the voltage on the
back plate of the Electronic Generator or those on page 9 of this manual.

In the standard connection example given above [Fig. 4], the installation is
composed of an electronic generator [-1- Fig. 4] and a discharge station (if
supplied) [-4- Fig. 4].

[optional] Can be supplied with a suctionFig. 4 fan for the ozone generated
by the corona discharge [-5- Fig. 4]. A complete magnetothermal switch
board is installed inside the generator to start ozone suction, and for the
protection of the ozone suction fan motor. The intervention level of the this
magnetothermal switch is calibrated at the factory by technicians from
Me.Ro. S.p.A.

1) Power the electronic generator [cable –10- Fig. 4 not supplied] using a
voltage corresponding ot the value indicated on page 9 of this manual, on
the plate on the electronic generator, or near the power terminals.

N.B.: The generator power supply line must be protected by a differential

switch in order to interrupt the supply in event of insulation loss.

INSTALLATION 26
3 INSTALLATION

The size of the electronic generator power lead should take into account
the maximum current absorbed (see INPUT data plate on the electronic
generator). Connect the power cable to the appropriate terminal socket on
the back of the electronic generator.

If present, the size of the ozone suction fan [cable -11- Fig. 4 not supplied]
cable should take into account the maximum current absorbed (see plate
on the side of the ozone suction fan motor). Connect the ozone suction fan
to the terminal on the back of the electronic generator.

Electronic Generator
supply line

Ozone Suction Fan supply line

Fig. 5

INSTALLATION 27
3 INSTALLATION

2) Establish the connection between the B7673 or B9018 board and the
Electronic Generator and the Station Box [point –9- Fig. 4] placed on the side of
the discharge station using the service cable from the discharge station[ cable –
13- Fig. 4 supplied]. Refer to the service box electrical diagram for correct
connection instructions.

B7673 Electronic
Generator terminal card
12K ÷ 60K.

B9018 Electronic Generator

terminal board 4K ÷ 10K

Fig. 6
Box on
discharge
station.
(station box)

Pressure
regulation

Ground point
(gnd point)

Solenoid valve

Discharge hood
Open/Close
selector switch
[optional]
Fig. 7

INSTALLATION 28
3 INSTALLATION

3) Establish the connection with the High Voltage cable [cable –12- FIG.5 ]
between the High Voltage Transformerand the high voltage input on the
discharge station. Usually, during the inspection phase, the high voltage
cable is left connected to the high voltage input point on the discharge
station. It is then connected to the high voltage transformer using one of

the 3 available sockets on its output.

Fig. 8

To find the correct socket to use, refer to the plate on the cover of the high
voltage transformer. The socket used is the one marked with a dot. [see
label example Fig. 9]

H.V. transformer
label example

Fig. 9

4) Establish the connection between the output of the suction fan on the
discharge station and the input on the ozone suction fan by using a flexible
plastic tube of a diameter corresponding with one of the outputs on the
discharge station. [tube–15- Fig. 4 not supplied]

If the discharge station is of the Universal type, the ozone suction fan will
be supplied with a vacuum switch. This device must be connected to the
terminal contained in the discharge station box. Refer to the wiring
diagrams attached.

INSTALLATION 29
3 INSTALLATION

The plant can be supplied with one of the following ozone suction units:

 Ozone suction switch HUBA CONTROL 625.6132

 Ozone suction switch IFM SA4100

HUBA CONTROL IFM SA4100

The vacuum cleaner IFM SA4100 requires the parameter setting relative to
the diameter of the ozone suction pipe. Refer to the manual (attached) for
the correct settings of the device.

5) Make a connection to ground ( cable–14- Fig. 4 supplied) between the

electronic generator. and the discharge station. (6mm² minimum cable
section)

Check the oil level using the marking on the side of the High-Voltage
Transformer.

6) Adjust the discharge electrode axes and the Air Gap (air gap between the
electrodes and the discharge roller). Refer to the diagrams accompanying
this manual to perform AIR-GAP adjustment operations.

The air gap depends on the length of the electrodes, the type of dielectric
coating on the discharge roller ( silicone or ceramic) and the type of
electrode (ceramic bar electrode , aluminium electrode, stainless steel
electrode)

Dielectric silicone coating.

 Aluminium or stainless steel electrodes
 Length up to 4m. (air-gap 1.5÷2mm)
 Lengths over 4m (air-gap 2.5÷2.8mm)

Dielectric ceramic coating

 Lengths up to 4m (air-gap 1.2÷1.5mm)

Electrodes with ceramic bars (Universal Discharge Stations)

 Electrode lengths up to 3m (air-gap: 1,5÷1,8mm

7) Check that the coating of the discharge roller has no holes and is not
damaged.

INSTALLATION 30
 3 INSTALLATION

3.14 START THE PLANT WITH AN EXTERNAL CONTACT (ONLY CORONA TREATER FOR
GLITTERING PLANT)

Avaiable only “Automatic speed” Mode

It is possible to start the corona treater plant Me.Ro. S.p.A. on\off

throughout a N.O. contact.

When this contact closes the electronic generator start to work and
treatment begins if the contact opens the electronic generator stops and
the treatment too.

See the electrical drawing for the connections or Discharge Station diagram
attached of this manual. A PLC digital input is avaible as N.O. external
contact.

Once the connection is ended, the ON button must be pressed to start the
cycle after with the external contact will manage the START\STOP.

This option is available only corona treater for glittering plant. For this
application use AUTOMATIC (SPEED) operation mode.

3.15 WARNINGS ON FIRST USE OF THE UNIT

WARNING! Do not start the generator without having connected the A.T. transformer.

Turn ON the switch on the operator terminal as well as the main switch on
the electronic generator.

N.B. before starting the generator, read the operator terminal operating
instructions carefully.

3.16 DESCRIPTION OF THE WORKPLACE

The electronic generator does not require a fixed position for operation.
The unit is mainly controlled from the operator terminal

3.17 PLACES OF USE

The plant cannot be used in the presence of water on the floor of the work
place. The system can not be used outdoors. We recommend using in a dry
area to prevent the formation of condensation inside the discharge station

INSTALLATION 31
3 INSTALLATION

3.18 SPARE PARTS

Pay attention to the following replacement parts:

 Main safety switch (must be replaced with a like-for-like model)

 Safety control unit (must be replaced with a like-for-like model)

We recommend you always use original replacement parts.

INSTALLATION 32
 4 OPERATION, CONTROL

4 OPERATION, CONTROL

Section profile:

This section is intended for all individuals who use the electronic generator
Who is this chapter for? on the Corona Treatment Unit from Me.Ro. S.p.A.

This chapter contains information regarding the proper of the operator

Contents of this chapter terminal on the Corona Treatment System from Me.Ro. S.p.A.

4.1 COMMISSIONING

The Corona treatment system has been tested by Me.Ro. S.p.A. in its
factory.

It can be commissioned immediately, without any special inspection

procedures. Before starting the system, you must read the following
instructions for use of the operator terminal.

The electronic generator PLC has an PROFINET® input connector that the
operator terminal is connected to.. Via an Ethernet-switch module (e.g.
CSM 1277 Siemens not supplied) the PLC can also be connected to a
PROFINET® node.

S7 Ethernet.
ISO on TCP.
Modbus TCP

N.B.: On units with PROFIBUS-DP® modules (optional) or other control

types, the electronic generator can be managed by connecting the
PROFIBUS-DP®to the main network node.

Fig. 10

Standard supply

Optional supply
(on request)

OPERATION, CONTROL 33
4 OPERATION, CONTROL

4.2 TYPE OF OPERATOR TERMINAL

The operator terminal is mounted in the front door of the electronic

generator.

On request, it can be mounted in a box (remote operator terminal). In this

way, it can be used remotely of the electronic generator.

OPERATION, CONTROL 34
4 OPERATION, CONTROL

4.3 TERMINAL OPERATOR STRUCTURE

Fig. 11

It consists of:

1. Main Switch: main line break

2. Line: line lamp
3. Touch Screen Control Panel: to control the generator
It has the following buttons:

 RESET : resets the electronic generator (e.g. after

an alarm being triggered).

 STOP : switches the electronic generator OFF

(corona treatment off).

 START : switches the electronic generator ON

(corona treatment ON).

 HOME : Accesses the home page

4. Blinker: light\sound column (mounted on
the top of the generator cabinet
Flashing red light + buzzer = alarm
Steady green light = generator ON
Flashing orange light + buzzer = power alarm active

OPERATION, CONTROL 35
4 OPERATION, CONTROL

4.4 TOUCH SCREEN CONTROL PANEL

Fig. 12

The TOUCH SCREEN CONTROL PANEL displays:

1. Working sizes of the corona treatment unit, such as voltage (V DC [V]), current (I DC [A]), speed
of unit (Speed) etc.

2. Corona treatment unit warnings and alarms.

3. Power Level (PL [%] or PL [Wmin/m²]) to adjust the power output of the electronic generator.

4. Pwr Out [W] which represents the absolute value of the generator power output. (in
Autom.Specif.Pwr mode is displayed [Wmin/m²].

5. Bar-Graph graphically representing the value of the electronic generator output power in
percentage value (only in Manual % and Automatic Speed modes)

Pressing the button enables access to the HOME PAGE (main page). (Fig. 13)

Fig. 13

OPERATION, CONTROL 36
4 OPERATION, CONTROL

From this page you may access:

Fig. 14

Furthermore, it is possible to select the operating mode between:

Fig. 15

Warning: the”INTERMITTENCE” operating mode is only

available on enabled corona treatment plants.

OPERATION, CONTROL 37
4 OPERATION, CONTROL

4.5 PLANT PARAMETER SETTING

PARAMETERS

Before placing corona treatment on START, certain operating parameters must be set on the Touch Screen
Control Panel.

N.B. the values displayed in the screens are only used as an example. These may vary depending on the
plant supplied.

From the HOME PAGE press the button to enter

the relative parameters page (PARAMETERS). (Fig. 16).

From this page it is possible to set or modify values of the

corona treatment plant.

The variables to be set are:

Fig. 16 (N.B. the values reported are random)

H.V. transformer coils [No.]

Number of secondary winding coils of the high-voltage
transformer. Enter the number of the A.T. transformer
socket used (see identification plate on A.T. transformer
cover)

Pulses revolution [No.]

Number of pulses for one revolution, detected by the
proximity sensor mounted on the discharge roll. (Set the
number of pins present on the toothed corona of the
discharge roll).

OPERATION, CONTROL 38
4 OPERATION, CONTROL

Roll diameter [mm]

Diameter of discharge roll in millimetres.

Electrode length [cm]

Length of the discharge electrode in centimetres.

Maximum speed [m/min]

Maximum speed of the line in metres/minute.

Minimum speed [m/min]

Minimum speed setting in metres/minute below which the
electronic generator shuts down (STOP).

Allowed variation percentage of generator output power

[%]
Percentage of variation of the output power of the
generator permissible. The variation is relative to the value

stored by pressing the key. The variation threshold is

only in power decrease.

Ascending ramp to the PL max [s]

Time, within which, (with pressing of the key ) the

electronic generator increases the power output, until
reaching the PL set. Further increases of PL are applied to
the output power after the RampUp time set.

Descending ramp from PL max [s]

Time within which (after a decrease of PL) the electronic
generator reduces the output power.

OPERATION, CONTROL 39
4 OPERATION, CONTROL

CHANGING PARAMETERS

The data is protected by User and Password, 2nd level

(administrator) created by the Me.Ro S.p.A.software
department and cannot be changed by unauthorised users.
A document containing the afore-mentioned User and
Password is attached to this manual (in a sealed envelope).

To vary one parameter logON must be carried out via User

and Password. Another password level can be added. Refer
to chap. Password on p. 44

To change a parameter, press the value to be modified.

Pressing the desired value, the password entry field

appears. (Fig. 17)
Fig. 17
Enter User and Password in the appropriate fields and

confirm with the key .

Press the value to be changed once more.

The numeric keyboard appears. (Fig. 18)

Modify the value by typing the desired value on the

numerical keypad.

Press to confirm the value set.

Pressing the key disables the Log-ON previously

executed. In this way the parameters are once again
protected by User and Password.

Fig. 18 When the changes have been performed press to exit

the PARAMETERS setting page.

DELETE ALARM HISTORY

From the PARAMETERS page, press the button to

remove all stored alarms from the memory.

OPERATION, CONTROL 40
4 OPERATION, CONTROL

MERO SETTINGS

This page displays adjustment values, important for the

correct operation of the electronic generator.

These are set in the factory, are password protected - 1st

level, and may only be changed by Me.Ro S.p.A technical
personnel.

ALARM HISTORY

From the HOME PAGE press the button to enter

the relevant page (ALARM HISTORY). (Fig. 19)

This page displays all the alarm messages activated together

with the Date (DD : MM : YY) and Time (HH : MM) of which
they occurred.

Press the button to exit the ALARM HISTORY page.

N.B. Do not press the key to quit the page. This

button is for returning to the operating system of the touch
panel (MS Windows™ interface). If pressed, a menu appears.
Press the START button.
Fig. 19

OPERATION, CONTROL 41
4 OPERATION, CONTROL

TREND

From the HOME PAGE press the button to

enter the relevant page (TRENDS).(Fig. 20)

In this page the graph displays the power supplied by the

generator Pwr Out [W] according to the time (h).

The numerical values (graduated scale) of the graph indicate

the power of the generator.

The numerical values (graduated scale) of the x-axis of the

graph indicate the time.

This provides a graphical display of possible power

variations during the work cycle.

Fig. 20
The Value box displays the relative value in numeric format
of the output power of the electronic generator.

Press the button to exit the TREND page.

OPERATION, CONTROL 42
4 OPERATION, CONTROL

PANEL SETTING

From the HOME PAGE press the button to enter

the relevant page (PANEL SETTING).

On this page it is possible to set the display language from

those available, the PASSWORD which allows you to log-in
to your account by means of the USER and PASSWORD, and
the SETTING to set system date and time.

The window (local) or (remote)

indicates in which mode the electronic generator is
controlled.

Fig. 21
 Local: control via touch screen control panel.
 Remote: control via an additional optional device
(esp. PROFIBUS®-DP module).

MULTIPLE LANGUAGES

Press the desired display language to activate the relative

translation of the Touch Screen Control Panel.
Fig. 22

SETTING DATE/HOUR

Press the value to be modified (the numerical keypad will

appear).
Fig. 23
Modify the value by typing the desired value on the
numerical keypad.

Pressed send to confirm the set value.

Fig. 24

OPERATION, CONTROL 43
 4 OPERATION, CONTROL

PASSWORD

Access to the machine is structured on 3 different levels

(groups):

 Level of access Operator (unauthorised): allows use

of the machine but parameters cannot be modified.
 Access level Change (user): allows use of the
machine and parameters can be modified.
 Access level Administration (admin): Allows
creation/editing/deletion of the login information of all
other users
Anyone who has access to the panel, automatically has
Operator access. The entering of a password is not
required.
Enter USER
To access with the option of Change or Administration the
Enter PASSWORD relevant login details must be entered in the
"PASSWORD" field.
Group Membership
In the top field of the Login area the user name (USER)
must be entered while in the lower field the password
(PASSWORD) is required. (see Fig. 25)
Fig. 25 The last field displays the name of the group to which the
user logged in belongs.

ADMINISTRATOR FUNCTIONALITY

Main User and Password of the Administrator user are

created by the Me.Ro S.p.A software department. A
document containing the afore-mentioned User and
Password is attached to this manual (in a sealed
envelope). When you Log-ON with these details it is
possible to access the machine as a system administrator
(all the features are active). The administrator can change
their details and can create new users and passwords for
other operators, who will have access with one of the
three available levels ( operator (unauthorized), edit
(user) or administrator (admin).

To create new USERS log on as administrator user and

press the key .

OPERATION, CONTROL 44
4 OPERATION, CONTROL

CREATING A NEW USER

From this page, it is possible to modify existing login
information or to create new information.
On the user list page press on an empty space.
Using the alphanumeric keypad enter, in the user column,
the user name, and in the password column the keyword
to correspond to the new user created. (Fig. 26).
In the Group column, select, using the drop-down menu,
one of the three groups to which the new user will belong.
(Fig. 27)

The Logoff time column shows the time (in seconds) the
elapse before automatic Log-OFF. If in this period of time,
the panel is not pressed, the logged-in user automatically
Fig. 26
disconnects. To make new changes, you must log in again
with your details.

DELETING A USER
Press the User box relating to the user to be deleted. The
alphanumeric keyboard appears. (see Fig. 28). Press the
key to delete the selected user.

PARAMETER MODIFICATION FUNCTIONALITY

Login with the change (user) details allows you to change
the values on the Parameters page.
To change the parameters, simply press the
corresponding value.
Refer to the paragraph on p. 38 to modify the parameters
of the corona treatment plant. Fig.

Fig. 27

Fig. 28

OPERATION, CONTROL 45
4 OPERATION, CONTROL

4.6 FUNCTION MODE

There are three modes of operation of the Electronic

Generator:

 Manual %: Manual operation (manual adjustment of

the electronic generator output power).

 Automatic Speed: Automatic operation. (Automatic

adjustment of the electronic generator output power
referring to the speed of the machine).

 Autom.Specif.Pwr: Operation with a specific power

Wmin/m² (automatic adjustment of the electronic
generator output power [W] applied to the material to be
treated per minute/m²).

 Intermittence: Intermittent operation of the treatment

plant. It allows to make interruptions of corona treatment
on the material, managed through an external electrical
contact. (N.B: only available on systems with intermittent
mode)

OPERATION, CONTROL 46
4 OPERATION, CONTROL

MANUAL %:

From the HOME PAGE press the button to enter

the page relating to PWR REG.MAN %.

In this operating mode, are shown the output power

PwrOut [W], the power level set, power level PL%[IDC]
(from 0 to 100), the operating values (Operat. Values) and
any indications of information or alarms.

In MANUAL % IDC mode, the Power Level PL%[IDC] is the

set point to adjust the electronic generator power output.
The IDC [A] value [inverter operating current] is the size of
working that is compared with the set PL%[IDC] value.

The PLC CPU, through proportional control, instantly

Fig. 29
calculates, compares and adapts the IDC [A] value to the
PL% [IDC] value set.

Nevertheless, there is no correspondence between the

numerical IDC [A] value displayed, and the numeric PL
%[IDC] value set. The minimum PL %[IDC] value does not
correspond with the IDC [A] = 0 ampere value, but is forced
to the minimum IDC [A] value (calculated between the
minimum and maximum in the Mero setting).

With PL %[IDC] = 100, the PwrOut [W] value cannot be the

maximum yield of the electronic generator. The causes
could be: load resistance variations (discharge station)
(variations mainly due to electrode (ceramic) temperature,
the dielectric roller coating and the AIR-GAP, small leaks of
high voltage to ground due to dirt and humidity

Another cause could be non-optimum matching between

the electronic generator and the discharge station (load).
Refer to chap. 7 on page 80 to optimise matching between
electronic generator and load.

Any conditions that cannot be controlled by the regulating

algorithm are indicated with the message

OPERATION, CONTROL 47
4 OPERATION, CONTROL

POWER LEVEL SETTING (PL% [IDC])

To set the Power Level PL [%]; press the

value on the numerical introduction window

"PL%[IDC] and input the desired value using the number
pad which appears as an overlay.

The set value is then displayed as "PL%[IDC] (0%=minimum

output power, 100% maximum output power).

Fig. 30

The PwrOutput [W] value represents the actual power

output of the generator in absolute value read in the
relative display window. The Bar Graph below also
graphically represents the PwrOut [W] level, (see Fig. 31)

Fig. 31

PLANT OPERATIONAL VALUES

In the MANUAL % operating mode, the OPERAT.VALUES

window displays the following plant operational values of
the corona treatment:

Speed [m/min]
Machine/line production speed in metres/minute.

Idc [A]
Operating current of the inverter in Amperes.

Vdc [V]
Operating voltage of the inverter in Volts
Vout [RMS]
Fig. 32 Voltage on electrodes (Effective RMS value in Volts).

OPERATION, CONTROL 48
4 OPERATION, CONTROL

AUTOMATIC SPEED

From the HOME PAGE press the button to enter

the relevant page AUTOM.SPEED.

In this operating mode, are shown, the output power

PwrOut [W], the set power level PL (da 0 a 100), the
operating values window and any report of information or
alarm.

Using this operating mode, the output power of the

generator “PwrOut [W],” increases (or decreases) in
proportion to production speed Speed (m/min); up to the
max output power of the generator if the PL [%] is equal to
100 and the production speed Speed (m/min) is equal to
Fig. 33 the maximum speed [m/min] set on the PARAMETERS
page. Lowering the PL[%] decreases the output power of
the generator. Fig. The Set Point that controls PwrOut [W]
output power is obtained by taking into account the instant
line speed and PL%[IDC] set. PL%[IDC] can be set between
30% (minimum) and 100% (maximum), allowing for PwrOut
[W] output power regulation (as well line speed) also with
PL%[IDC]. The IDC [A] value [inverter operating current] is
the size of working that is compared with the set PL%[IDC]
value.

The PLC CPU, through proportional control, instantly

calculates, compares and adapts the IDC [A] value to the
PL% [IDC] value set.

Nevertheless, there is no correspondence between the

numerical IDC [A] value displayed, and the numeric PL
%[IDC] value set. The minimum PL %[IDC] value (30) does
not correspond with the IDC [A] = 30 ampere value, but is
forced to the minimum IDC [A] value (set during initial
testing). With PL%[IDC] = 100, the PwrOut [W] value cannot
be the maximum yield of the electronic generator. The
causes could be: load resistance variations (discharge
station) (variations mainly due to electrode (ceramic)
temperature, the dielectric roller coating and the AIR-GAP,
small leaks of high voltage to ground due to dirt and
humidity Another cause could be non-optimum matching
between the electronic generator and the discharge
station (load). Refer to chap. 7 on page 80 to optimise
matching between electronic generator and load. Any
conditions that cannot be controlled by the regulating
algorithm are indicated with the message

OPERATION, CONTROL 49
4 OPERATION, CONTROL

POWER LEVEL SETTING (PL% [IDC])

To set the Power Level PL%[IDC]; press the value on the

numerical introduction window “PL%[IDC] and

enter the desired value by means of the displayed numerical
keypad which appears superimposed.

The set value is then displayed as "PL%[IDC]

(30%=minimum output power, 100% maximum output
power).

Fig. 34

The PwrOutput [W] value represents the actual power

output of the electronic generator in absolute value read in
the relative display window. The Bar Graph below also
graphically represents the PwrOut [W] in percentage value
[0 - 100%].

Fig. 35

OPERATION, CONTROL 50
4 OPERATION, CONTROL

PLANT OPERATIONAL VALUES

In AUTOM. SPEED mode, the OPERAT.VALUES window

displays the following plant operational values:

Speed [m/min]
Machine production speed in metres\minute.
Idc [A]

Operating current of the inverter in Amperes.

Vdc [V]
Operating voltage of the inverter in Volts

Vout [RMS]

Fig. 36 Voltage on electrodes (Effective RMS value in Volts).

OPERATION, CONTROL 51
4 OPERATION, CONTROL

AUTOM.SPECIF.PWR:

From the HOME PAGE press the button to

enter the relevant page AUT.SPEC.PWR.

The Automatic Specific Power operating mode maintains

the specific power [ACT] applied to the film constant, even
when production speed varies, or when load resistance
varies.

The Automatic Specific Power operating mode

(maintaining the specific power constant) genuinely
guarantees the Dyne wettability level on the film obtained
with the specific power applied.

Fig. 37 In this operating mode are shown the actual specific power
(ACT) applied to the film and the (set-point) specific power
value requested, set in PL [Wmin/mq]. The PLC CPU
calculates the specific power Spec.PWR in Wmin/m²,
where: Spec.PWR = PwrOUT[W] / Production[m²/min].

The PLC CPU, through proportional control, instantly

calculates, compares and adapts the ACT [Wmin/m²]
specific power value to the PL [Wmin/m²] value set.

This regulation system takes into account production speed

and any load resistance variation (variations mainly due to
electrode (ceramic) temperatures, dielectric coating of the
roller and the AIR-GAP, small high voltage leaks to ground
due to dirt and humidity) by automatically correcting the
movement of specific power that these factors have caused.

By using this operating mode, once the specific power

value for the desired treatment has been decided, the film
is certain to be treated uniformly. Fig.

Any conditions that cannot be controlled by the regulating

algorithm are indicated with the message

N.B.: The electrode length (light discharge) [cm]

must be set on the
PARAMETERS page. (see page 38).

OPERATION, CONTROL 52
4 OPERATION, CONTROL

POWER LEVEL SETTING (PL [WMIN/M²])

To set the Power Level PL [Wmin/m²]; press the value on

the numerical introduction window “PL [Wmin/m²]”

and enter the desired value by means of the

displayed numerical keypad which appears superimposed.

The PL is the specific power that must be applied to the film

in Wmin/m2 and it is the point set for generator power.

The PLC CPU, through proportional control, instantly

calculates, compares and adapts the ACT [Wmin/m²]
specific power value to the PL [Wmin/m²] value set.

Fig. 38

OPERATION, CONTROL 53
4 OPERATION, CONTROL

Bar-Graph view, two values:

 PL: expresses, both graphically and numerically,

the specific power value set in the POWER LEVEL
window PL [Wmin/m²].
 ACT expresses, both graphically and numerically,
the currene specific power value set, supplied by
the electronic generator.

Fig. 39

PLANT OPERATIONAL VALUES

In the automatic mode with specific power

(AUT.SPEC.PWR) the OPERAT.VALUES window displays the
following plant operational values of the corona treatment:

Speed [m/min]
Machine production speed in metres\minute.
Idc [A]

Operating current of the inverter in Amperes.

Vdc [V]

Operating voltage of the inverter in Volts

Fig. 40 Vout [RMS]

Voltage on electrodes (Effective rms value in Volts).

PwrOut[W]
Effective output power (in Watts) from the electronic
generator as an absolute value.

OPERATION, CONTROL 54
4 OPERATION, CONTROL

INTERMITTENCE

Connecting the external intermittence contact.

Prepare an electrical contact (N.O. contact-e.g. CAM with an
inductive sensor or microswitch). It is also possible to use a
positive logic digital signal (PNP).
To make one of the connections described above, refer to
the wiring diagram of the generator terminal board
attached to the manual. The terminal board features the
terminals to connect the intermittence signal. After making
the desired connection, the “intermittence” operating
mode must be enabled on the operator terminal.

Enabling the intermittence operating mode on the operator terminal.

Before activating the “Intermittence” operating mode, the

three-phase supply voltage of the electronic generator
must be set. This operation is password-protected. To
change the value, it is necessary to log-in in edit or
administrator mode. Refer to paragraph Password on page
44.

On the HOME page press the button .

Set the supply voltage of the electronic generator. The

three-phase voltage values are pre-set by Me.Ro and are
the following:

Press the blue box repeatedly until the desired supply

voltage appears. Press the button to go back to the

HOME page.

OPERATION, CONTROL 55
4 OPERATION, CONTROL

Enabling the INTERMITTENCE operating mode.

WARNING!

When the intermittence mode is OFF, the electrode is

always powered (even if the discharge effluvium is not
visible). It is disconnected completely only when the
electronic generator is turned Off by pressing the button

or when the discharge station is open.

IMPORTANT: the Air-Gap of the discharge electrode is

adjusted by Me.Ro technicians during the testing phase.

In case of treatment present (corona discharge effluvium)

even with the intermittence signal OFF, switch off the
electronic generator, (main switch OFF). and intervene on
the discharge electrode, increasing the Air-Gap slightly.

OPERATION, CONTROL 56
4 OPERATION, CONTROL

INTERMITTENCE operating mode

On the HOME page press the button

The intermittence operating mode is enabled.

In this operating mode, the output power PwrOut, the set

power level, PL%[PWM], the operational values (Operat.
Values) and any other information messages or alarm
messages are displayed.

In the INTERMITTENCE operating mode, the Power Level

PL%[PWM] is the set-point to adjust the output power of
the electronic generator. The maximum output power of
the electronic generator is set by Me.Ro during the testing
phase and it is mainly determined by the maximum length
Fig. 41
of the discharge electrode and by the three-phase supply
voltage of the electronic generator.

When the increase of the PL%[PWM] is equal to or greater

than the set factory value, the background colour of the

button will go from blue to red alternately. This

indicates that further increases of the PL%[PWM] are not
possible.

The reference value of the PL%[PWM] can be changed only

by specialised Me.Ro technicians.

With PL %[PWM] = max settable value, the PwrOut value

may not be the maximum deliverable by the electronic
generator. The causes may be: variations of the load
resistance (discharge station) to the dielectric coating of the
roller and to the AIR-GAP, small losses of High Voltage to
earth due to dirt and humidity; another cause can be a non-
optimal matching between the electronic generator and
the discharge station (load). Refer to chapter 7 on page 80
to optimise the matching between the electronic generator
and the load.

Any out of control conditions of the control algorithm are

indicated by the message

IMPORTANT: with the intermittence signal OFF (absent) the

PLC stores and displays the last operating values of the
corona treatment plant.

IMPORTANT: the Air-Gap of the discharge electrode is

adjusted by Me.Ro technicians during the testing phase.

In case of treatment present (corona discharge effluvium)

even with the intermittence signal OFF, switch off the

OPERATION, CONTROL 57
4 OPERATION, CONTROL

electronic generator, (main switch OFF). and intervene on

the discharge electrode, increasing the Air-Gap slightly.

OPERATION, CONTROL 58
 4 OPERATION, CONTROL

Setting the Power Level (PL%[Idc])

To set the Power Level PL [PWM], press the value

on the numerical input window “PL%[PWM] and

enter the desired value using the keypad that appears.

Fig. 42
The PwrOutputFig.[W]
45 value represents the actual power

output of the generator in absolute value read in the

relative display window. The Bar Graph below also shows
the graphical representation of the PwrOut value.

Fig. 43

4.6.1 PLANT OPERATIONAL VALUES

In the INTERMITTENCE operating mode, the

OPERAT.VALUES window displays the following operational
values of the corona treatment plant:

Speed [m/min]
Production speed of the machine/line in metres/minute.
Idc [A]
Operating current of the inverter in Amps.

Vdc [V]
Operating voltage of the inverter in Volts

Fig. 44

OPERATION, CONTROL 59
4 OPERATION, CONTROL

4.7 ALARMS AND WARNINGS

ALARMS

The ALARMS window displays the status of the alarm

messages present in the corona treatment plant.

If any of these alarms is triggered, the generator cannot

START, and if already running in START it places it in STOP
until the alarm is eliminated and the work status is reset by

means of the button .

In standard plant operating mode, the symbol near

each ALARMS item is green .

If an ALARM is triggered, the symbol turns red and this

Fig. 46
message appears .

The alarm message is acquired and displayed in the Alarms

History.

When the alarm is reset, the symbol turns green .

The message disappears .

Pressing the key allows the generator once again to be

ready to operate and to display the message
.

Pressing the key activates the generator.

OPERATION, CONTROL 60
 4 OPERATION, CONTROL

ALARM MESSAGES

N.B. the warnings below refer to a standard plant. They can vary based on the specific customer requirements.

EMERGENCY

Intervention of emergency contact

o GENERATOR STATUS
The electronic generator automatically goes to
STOP conditions.
The Buzzer emits an intermittent sound and the
red lamp turns on.

o CAUSES

Emergency contact open.

OZONE SUCTION

No ozone suction

o GENERATOR STATUS
The electronic generator automatically goes to
STOP conditions.
The Buzzer emits an intermittent sound and the
red lamp turns on.

o CAUSES

Circuit breaker tripped. Ozone suction sensor

adjusted improperly.
Insufficient suction flow rate.

VDC FAULT

No direct voltage powering the CHOPPER stage of the

generator.

o GENERATOR STATUS
The electronic generator automatically goes to
STOP conditions.
The Buzzer emits an intermittent sound and the
red lamp turns on.

o CAUSES

Incorrect power supply voltage

Power fuse open.
Automatic switch IA1 open.
Contactors CN1 and CN2 open

OPERATION, CONTROL 61
4 OPERATION, CONTROL

THERMAL OVERLOAD

Overtemperature on generator power component

radiators

o GENERATOR STATUS
The electronic generator automatically goes to
STOP conditions.
The Buzzer emits an intermittent sound and the
red lamp turns on.

o CAUSES

Failure of cooling fans installed on our

component radiators.
Failure of dual metal thermostat (thermal
switch) installed on power component
radiators.

IDC OVERCURRENT

Exceeding maximum set current limitIDC[A]

o GENERATOR STATUS
The electronic generator automatically goes to
STOP conditions.
The Buzzer emits an intermittent sound and the
red lamp turns on.

o CAUSES

High-voltage [H.V.] discharge towards the

ground.
Perforation of dielectric cover of discharge roll
or perforation of ceramic bars.
Loss of insulation of isolators supporting
electrodes.
Generator fault.

OPERATION, CONTROL 62
4 OPERATION, CONTROL

HIGH-VOLTAGE DISCHARGE [H.V.]

Presence of high-voltage discharge[H.V.] towards the

ground.

o GENERATOR STATUS
The electronic generator automatically goes to
STOP conditions.
The Buzzer emits an intermittent sound and the
red lamp turns on.

o CAUSES

High-voltage [H.V.] discharge towards the

ground.
Perforation of dielectric cover of discharge roll
or perforation of ceramic bars.
Loss of insulation of isolators supporting
electrodes.

CORONA INTERLOCK

Intervention of interlock contact

o GENERATOR STATUS
The electronic generator automatically goes to
STOP conditions.
The Buzzer emits an intermittent sound and the
red lamp turns on.

o CAUSES

Opening of interlock between generator and

corona treatment plant upon which it is
connected.

INVERTER POWER SURGE

Power surge in the inverter module.

o GENERATOR STATUS
The electronic generator automatically goes to
STOP conditions.
The Buzzer emits an intermittent sound and the
red lamp turns on.

o CAUSES

Power surge to the inverter.

OPERATION, CONTROL 63
4 OPERATION, CONTROL

WARNINGS

The WARNINGS window displays the status of the warning

messages present in the corona treatment plant.

Intervention of one of these WARNINGS will not allow the

electronic generator to START, and if already operational
will place it in STOP until the alarm is eliminated.

The generator START is performed automatically as soon as

the warning is reset.

In standard plant operating mode, the symbol near

each WARNINGS item is green .

Fig. 47
If a WARNING is triggered, the symbol turns red and

this warning appears

When the WARNING is reset, the symbol turns green .

N.B.: the POWER ALARM warning does not stop the

generator from operating.

OPERATION, CONTROL 64
 4 OPERATION, CONTROL

WARNING MESSAGES

N.B. the warnings below refer to a standard plant. They can vary based on the specific customer requirements.

LOW SPEED

Speed of the production line less than that set on page

.

o GENERATOR STATUS
The electronic generator automatically goes to
STOP conditions.

o CAUSES
Low production line speed.
Failure of sensor detecting speed installed on
the discharge station.

STATION OPEN

Discharge station open.

o GENERATOR STATUS
The electronic generator automatically goes to
STOP conditions.

o CAUSES
Discharge station open.
Failure of microswitch on discharge station
hood.

OPERATION, CONTROL 65
4 OPERATION, CONTROL

POWER ALARM

Variation of set power output limit %.

This control is always active in all operating modes:

Manual %[Idc] ; Automatic Speed ; Automatic Spec.
PWR. The electronic generator power output PwrOut[W]
is constantly compared with the percentage variation set in
. on the PARAMETERS page.
(see page 38).

If the PwrOut[W] output power decreases more than the

set percentage, the warning is
triggered.

o GENERATOR STATUS
The electronic generator remains in START
status.
The light column lets out an intermittent sound
and the orange light switches on.

o CAUSES
Variation of power output caused by probable
change of discharge station work conditions.

OPERATION, CONTROL 66
 5 ELECTRONIC GENERATOR

5 ELECTRONIC GENERATOR

Section profile:

This section is for everyone who installs, uses or carries out maintenance on
Who is this chapter for? the corona treatment system from Me.Ro. S.p.A..

This section contains a description of the main internal components of the

Contents of this chapter electronic and electrical mechanical part of the electronic generator of the
Corona treatment system from Me.Ro. S.p.A.

5.1 INTERNAL STRUCTURE OF THE ELECTRONIC GENERATOR

ELECTRONIC GENERATOR WITH POWER FROM 4KW UP TO 20KW.

Only valid for Electronic Generators from 4kW to 20kW.

The Electronic Generator is constructed in a metal cabinet. The cabinet can

be equipped with wheels. All Me.Ro. S.p.A electronic generators have a
cabinet with two hinged panels for internal inspection. The electronic
generator is air cooled.

N.B. Electronic generators up to 10kW of power are equipped with wheeled

cabinet by Me.Ro S.p.A. as standard.

Inside the electronic generator generator (at the back) are both the
electromechanical part that provides the power needed for the treatment,
both the electronic part that manages the power supplied, the operation
and the alarms and \ or safety of the plant.

In the figure below is represented the inside of the generator (the back) with
the arrangement of the main components.

N.B. The photo represents a standard 8kW electronic generator. Herewith

follows a brief description of the main components:

ELECTRONIC GENERATOR 67
5 ELECTRONIC GENERATOR

Fig. 48

What generators with greater power, the components remain the same,
while it can vary their arrangement inside the cabinet.

A) Magnetothermic main switch.

B) IGBT (Insulated Gate Bipolar Transistor), power device used to commute

high voltages and high powers. Composed by the chopper card (n°1
module) and the inverter card (n°2 module) of the Electronic Generator.

C) Power fuse for the protection of the electrical mechanical part from the
electronic power side.

D) B5294 Circuit Board: for interface between the power and electronic
parts of the generator controller. N.B.: in electronic generators with a
power greater than 10kW, the board is replaced by physical connections
(with suitably rated cables) between the power components.

E) B8198 Circuit Board interface between the PLC control parts and the
power parts (Chopper and Inverter).

ELECTRONIC GENERATOR 68
5 ELECTRONIC GENERATOR

F) Level Condenser for the chopper’s continuous supply voltage. It is

comprised of the loading resistances and the contactor the DC Link.

G) Load resistors of the level condensers.

H) Fuses with fuse carriers for the supply voltage protection 110 Vac, fans,
etc. N.B. If 220Vac is also fitted with an extra fuse and fuse holder.

I) Output fan for cooling electronic generator.

J) Line switch for switching the electronic generator on or off.

ELECTRONIC GENERATOR 69
5 ELECTRONIC GENERATOR

ELECTRONIC GENERATORS WITH POWER FROM 25KW UP TO 60KW.

Only valid for: Electronic Generators from 25kW to 60kW

The Electronic Generator is constructed in a metal cabinet. All Me.Ro. S.p.A

electronic generators have a cabinet with two hinged panels for internal
inspection. The electronic generator is air-cooled.

Inside the generator (the back) are positioned both the electromechanical
part that provides the power needed for the treatment, both the electronic
part that manages the power supplied, the operation and the alarms and \
or safety of the plant.

In the figure below is represented the inside of the generator (the back) with
the arrangement of the main components.

N.B. The photo represents a standard 25kW electronic generator. N.B. the
picture is a standard generator power 30kW.

Fig. 49

ELECTRONIC GENERATOR 70
5 ELECTRONIC GENERATOR

A) Load resistors of the level condensers.

B) Power fuse for the protection of the electrical mechanical part from the
electronic power side.

C) Magnetothermic main switch.

D) Line switch for switching the electronic generator on or off.

E) IGBT Inverter (Insulated Gate Bipolar Transistor), power device used to

commute high voltages and high powers. Composed by the inverter
module (n°2 or 4 module) of the Electronic Generator.

F) IGBT Chopper (Insulated Gate Bipolar Transistor), power device used to

commute high voltages and high powers. Composed by the ichopper
module (n°1 module) of the Electronic Generator.

G) B8198 Circuit Board interface between the PLC control parts and the
power parts (Chopper and Inverter).

H) PLC to control the electronic generator.

I) Level Condenser for the chopper’s continuous supply voltage. It is

comprised of the loading resistances and the contactor the DC Link.

L) Variable Impedance (model in this picture is IV-1D).

ELECTRONIC GENERATOR 71
 6 GENERAL DESCRIPTION AND MAINTENANCE OF ME.RO DISCHARGE
STATIONS

6 GENERAL DESCRIPTION AND MAINTENANCE OF ME.RO DISCHARGE STATIONS

Section profile:

This section is for everyone who installs, uses or carries out maintenance on
Who is this chapter for? the corona treatment system from Me.Ro. S.p.A..

This section contains a general description of the discharge stations of the

Contents of this chapter Corona treatment system from Me.Ro. S.p.A.

6.1 DISCHARGE STATION

Discharge Stations by Me.Ro. S.p.A. are mainly divided into two macro
categories

 Normal discharge station

 Universal discharge station

ADAPTING GENERATOR TO LOAD 72

6 GENERAL DESCRIPTION AND MAINTENANCE OF ME.RO DISCHARGE
STATIONS

6.2 NORMAL DISCHARGE STATION

The discharge stations are mainly used in the treatment of plastic film. With
this type of stations is not possible to perform the treatment on the metal
films or metallized.

They are composed by aluminum or stainless steel electrodes.

The electrodes can be a fixed bar (for the treatment of the entire plastic film
width), or choke type (for the treatment of single points of the plastic film).
The support of the electrodes can be fixed or rotary (in foil direction).

The stations with the rotary electrodes support are used in CAST
applications and have the advantage of maintaining the AIR GAP constant
during the initial heating phase. They can then rotate on their on axis and
therefore allow the passage of joints and/or nods without causing any
damages in the case of impact.

The discharge roller can be silicon rubber coated or sleeved with a silicon
sleeve.

In some particular applications a ceramic coated discharge roller is supplied

(version CRAF).

The discharge stations can be unilateral (for treatment of a single side of the
plastic film) or bilateral (for applications which require treatment of both
sides).

Fig. 50

NORMAL STATION EXAMPLE

GENERAL DESCRIPTION AND MAINTENANCE OF ME.RO DISCHARGE STATIONS 73

6 GENERAL DESCRIPTION AND MAINTENANCE OF ME.RO DISCHARGE
STATIONS

NORMAL DISCHARGE STATION NOMENCLATURE

Here below the recognition code of a normal discharge station.

U 1 ER – 250 – 2000
(example of a station with n°1 rotary electrode mounted)

U Indicates that the discharge station is of unilateral type. Letter “B”

indicates that the discharge station is of bi-lateral type

1 Indicates the number of electrodes mounted on the discharge

stationa

ER Indicates the type of electrode mounted. In this case the suffix “ER”
indicates that the electrodes are of rotary type.

250 Indicates the diameter of the discharge roller.

2000 Indicates the max. width (LUCE) on which the corona treatment
can be performed.

See table below in order to know the different types of stations:

STATION NAME STATION DESCRIPTION

UT Unilateral station with aluminium or stainless steel

electrodes

BT Bilateral station with aluminium or stainless steel

electrodes

UTL Unilateral station with aluminum electrodes with

choke blades

BTL Bilateral stations with aluminum electrodes with choke

blades

U1ER Unilateral stations with rotary electrodes in stainless

steel

B1ER Bilateral stations with rotary electrodes in stainless

steel

GENERAL DESCRIPTION AND MAINTENANCE OF ME.RO DISCHARGE STATIONS 74

6 GENERAL DESCRIPTION AND MAINTENANCE OF ME.RO DISCHARGE
STATIONS

6.3 UNIVERSAL DISCHARGE STATION

The universal discharge stations can be used for the treatment of plastic
film and for the treatment of metallic film. The particular characteristic of
these stations are the ceramic bars which compose the electrode. Thanks
to this ceramic coat conductive films (e.g. metallic films) can be treated.

During the discharge process the ceramic heats and reaches high
temperatures. Therefore the system is provided with a fan, which allows an
efficient refrigeration of the ceramic bars of the discharge electrode, and
eliminates the ozone produced by the corona treatment.

The ceramic coated discharge roller is made of aluminum which makes its
more resistant and protects it from the ozone.

The universal stations can be supplied in unilateral and bilateral versions as

the normal stations, depending on the kind of treatment

Fig. 51

UNIVERSAL STATION EXAMPLE

GENERAL DESCRIPTION AND MAINTENANCE OF ME.RO DISCHARGE STATIONS 75

6 GENERAL DESCRIPTION AND MAINTENANCE OF ME.RO DISCHARGE
STATIONS

UNIVERSAL DISCHARGE STATION NOMENCLATURE

Here below the recognition code of a universal discharge station.

(example of a station with n°1 rotary electrode mounted) Each electrode

hood is made up of 4 ceramic bars

U 3 ER – 250 – 2000
U Indicates that the discharge station is of universal type

B In this case the discharge station is of bi-lateral type. If the

character “U” is present it indicates that the discharge station is of unilateral
type.

3 Indicates the number of electrode-bearing hoods mounted on the

discharge station.

X4C Indicates the ceramic bars mounted on each hood of the discharge
station. (R= indicate that the elctrode can rotate).

250 Indicates the diameter of the discharge roller.

2000 Indicates the max. width (LUCE) on which the corona treatment
can be performed.

See table below in order to know the different types of stations:

STATION NAME STATION DESCRIPTION

UU Unilateral station with ceramic electrode

UB Bilaterale station with ceramic electrodes

GENERAL DESCRIPTION AND MAINTENANCE OF ME.RO DISCHARGE STATIONS 76

6 GENERAL DESCRIPTION AND MAINTENANCE OF ME.RO DISCHARGE
STATIONS

6.4 DESCRIPTION OF THE MANUAL CONTROLS OF THE DISCHARGE STATION

The opening of the hood containing the discharge electrodes in order to

introduce the film can be performed as follows
1-) Through the control lever of the compressed air distributor (only
for stations without solenoid valves)

2-) Through the selector in proximity of the discharge station (only for
stations with solenoid valves). This selector can be replaced or
integrated at the customer’s expenses with a PLC remote control

6.5 INSTRUCTION FOR THE CALIBRATION AND ADJUSTMENT OF THE DISCHARGE

STATION

The AIR GAP of the discharge station has to be adjusted (space of

compressed air between the electrode and the roller) where the discharge
of the corona effect takes place. For the regulation of AIR GAP refer to the
drawings in the manual of use and maintenance.

WARNING!!
BEFORE ANY INTERVENTION ON THE DISCHARGE STATION (FOR
ADJUSTMENT OR MAINTENANCE), TURN THE PLUG VALVE LOCATED ON
THE STATION FRAME IN SAFETY FOR MAINTENANCE; ENSURE THAT THE
MACHINE IS AT A COMPLETE STANDSTILL AND THE PARTS WHICH MAY BE
MOVED (NIP ROLLERS ETC.) BY PNEUMATIC OR ELECTRIC ACTUATORS ARE
LOCKED IN A SAFE POSITION.

GENERAL DESCRIPTION AND MAINTENANCE OF ME.RO DISCHARGE STATIONS 77

6 GENERAL DESCRIPTION AND MAINTENANCE OF ME.RO DISCHARGE
STATIONS

AIR-GAP
The air gap depends on the length of the electrodes, the type of dielectric
coating on the discharge roller ( silicone or ceramic) and the type of
electrode (ceramic bar electrode , aluminium electrode, stainless steel
electrode)

Dielectric silicone coating.

 Alluminium or stainless steel electrode

 Length up to 4m. (air-gap 1.5÷2mm)
 Lengths over 4m (air-gap 2.5÷2.8mm)

Dielectric ceramic coating

 Lengths up to 4m (air-gap 1.2÷1.5mm)

 Electrodes with ceramic bars (Universal Discharge Stations)

 Electrode lengths up to 3m (air-gap: 1,5÷1,8mm)

The electrode is shaped in order to upload on more lines depending on the

generators of the discharge rollers.
In the case of a discharge station with ceramic electrodes, make sure that
the discharge is equal on the whole width of the ceramic bars with a
voltage of 5,5-6 Kvolt on the electrodes.
Take into consideration that the ceramic electrodes have to be adjusted
very carefully.

6.6 HOW TO STOP THE PLANT

The electronic generator is equipped with a main supply switch which acts
as emergency switch.

An external Emergency switch can be connected to the terminal of the

electronic generator (see wiring diagrams) disabling the insertion of the
main contactor of the electronic generator itself (electronic generator
while the power can not work with the emergency button on).

GENERAL DESCRIPTION AND MAINTENANCE OF ME.RO DISCHARGE STATIONS 78

6 GENERAL DESCRIPTION AND MAINTENANCE OF ME.RO DISCHARGE
STATIONS

6.7 DISMANTLING THE DISCHARGE ROLLER

To dismantle the roller proceed as indicated in the following steps:

 Consider the weight of the roller;

 Sling the roller with two belt slings, with the adequate capacity,
positioned symmetrically with respect to the middle of the roller and with a
distance between them of approx. 1 metre;
 Tension the 2 slings with a rocker arm of adequate length and capacity;
 Remove the fixing bolts;
 Let the roller slide until it is completely out of the machine;
 Place the roller on appropriate supports.

GENERAL DESCRIPTION AND MAINTENANCE OF ME.RO DISCHARGE STATIONS 79

 7 ADAPTING GENERATOR TO LOAD

7 ADAPTING GENERATOR TO LOAD

Section profile:

This section is for everyone who works with the Corona Treatment System
Who is this chapter for? from Me.Ro. S.p.A..

This section contains a general description of the variable impedance

Contents of this chapter contained in electronic generator of the Corona treatment system from
Me.Ro. S.p.A.

7.1 VARIABLE IMPEDANCE

Variable impedance Once the treatment plant is in operation with the film
in production, a further tuning may be necessary, in order to better adapt
the generator to the load. This is a HV transformer adjustment with the
discharge station. Is done to transfer the max power to the load. This
adjustment is made by means of the variable impedance.

Being tested at our factory, the H.V. transformer and the variable
impedance are adjusted so as to obtain the maximum power transfer.
Sometimes, however, it is necessary to intervene in the impedance variable
because the film into production load conditions vary.

ATTENTION!!!
Fig. 52

This operation can be carried out if the generator has externally-fitted

Double Variable Impedance IV-1D variable impedance (see photo). Me.Ro. externally mounts variable
(16kW ÷ 45kW electronic generators) impedance as standart only on generators with a power greater than
16kW; in order to better adapt the electronic generator to the discharge
station.

With the electronic generators lower power is already has an optimal fit
with the discharge station and it is not necessary to intervene often variable
impedance.

It is mounted internally in the H.V. transformer.

It can however be modified to adapt the electronic generator to the load,

but this operation must be passed is made by technical personnel of Me.Ro.
S.p.A.
Fig. 53

Fig.

(50kW ÷ 65kW electronic generators)

INSTRUCTIONS AND WARNING 80

7 ADAPTING GENERATOR TO LOAD

7.2 ADJUST VARIABLE IMPEDANCE

To adjust variable impedance proceded as follow:

1. Setting the manual mode

2. Position the setpoint for power regulation to zero and push the
ON/MEMORIZE button.

3. Position the setpoint for power regulation to zero and push the
ON/MEMORIZE button.

IDC = Current supplied to the inverter

VDC = Voltage supplied to the inverter

VDC x IDC = Power supplied

Gradually increase PL up to 100 and check I.OUT. If the generator is not

correctly adapted to the load, it will not provide the maximum power. In
this case two situations could occur..

1. The VDC value reaches the max, but the IDC current remains low.
2. The IDC value reaches the max, but the VDC voltage remains low.

By using the nuts on the four ends, the space between the two magnetic
circuits can be adjusted.

Due to this a different value of the inductance can be chosen varying the
reluctance of variable impedance. This reel is connected in series to the
primary on the high voltage transformer. By varying the impedance, a fine
adjustment of IDC and VDC is possible and the whole primary power can be
transferred to the secondary.

Situation 1

Open variable impedance so that the VDC value decreases with the increase
of IDC. If with the variable impedance completely open, the IDC current
does not reach the max and the VDC remains high, an higher secondary tap
on the output transformer must be selected.

Situation 2

Close the impedance so the VDC increases and the IDC decreases. If with
the variable impedance completely closed the VDC does not reach its MAX
and the IDC remains high, you must choose a lower socket on the
transformer.

ADAPTING GENERATOR TO LOAD 81

7 ADAPTING GENERATOR TO LOAD

Generator optimum operating conditions with maximum output

power are.

GENERATOR TYPE IDC VALUE VCD VALUE

12 kW 30 A 400 V

15 kW 37.5 A 400 V

16 kW 40 A 400 V

18 kW 45 A 400 V

20 kW 50 A 400 V

25 kW 62.5 A 400 V

30 kW 75 A 400 V

35 kW 82.5 A 420 V

40 kW 95 A 420 V

45 kW 107 A 420 V

50 kW 120 A 420 V

55 kW 130 A 420 V

60 kW 140 A 430V

65 kW 150 A 430V

These values are obtained by adjusting variable impedance and by

selecting an output on the output transformer secondary
(approximate adjustment).

ADAPTING GENERATOR TO LOAD 82

 8 INSTRUCTIONS AND WARNING

8 INSTRUCTIONS AND WARNING

Section profile:

This section is for everyone who installs, uses or carries out maintenance on
Who is this chapter for? the corona treatment system from Me.Ro. S.p.A..

This section contains a description of the main rules to carry out safe
Contents of this chapter maintenance on the Corona treatment system from Me.Ro. S.p.A.

8.1 GENERAL SAFETY REGULATIONS

For your safety, follow the rules and security measures described below.

INSTRUCTIONS AND WARNING 83

 8 INSTRUCTIONS AND WARNING

ALL MAINTENANCE AND REPAIR WORK INSIDE THE ELECTRONIC GENERATOR AND THE
DISCHARGE STATION MUST ONLY BE PERFORMED BY AUTHORISED AND SPECIALISED
PERSONNEL.

BEFORE ANY INTERVENTION ON THE DISCHARGE STATION (FOR ADJUSTMENT

OR MAINTENANCE), TURN THE PLUG VALVE LOCATED ON THE STATION FRAME
IN SAFETY FOR MAINTENANCE; ENSURE THAT THE MACHINE IS AT A COMPLETE
STANDSTILL AND THE PARTS WHICH MAY BE MOVED (NIP ROLLERS ETC.) BY
PNEUMATIC OR ELECTRIC ACTUATORS ARE LOCKED IN A SAFE POSITION.

N.B.: BEFORE ANY WORK ON THE ELECTRICAL AND MECHANICAL EQUIPMENT,

ENSURE THAT THE MAIN POWER SUPPLY AND THE ALARM DEVICE LINE ARE
DISCONNECTED.

WARNING! DO NOT PUT THE GENERATOR AT WORK WITHOUT HAVING CARRIED OUT ALL THE
ELECTRIC CONNECTIONS TO THE HV TRANSFORMER.

In case any repair must be done on electronic generator, bear in mind that:

 The power units (power supply output, voltage regulator, inverter and high voltage primary transformer) can
carry voltages around 600 VOLT.
 From the output of the high voltage transformers to the discharge electrodes, maximum voltage may be very
high. Therefore, depending on ambient humidity, the discharge may trigger from up to 3-4 cm. See the data label
on the electronic generator.
 Due to capacitive effect, in the proximity of the discharge electrodes and the parts carrying high voltage, there
may be circulation of undesired currents and therefore it is important to control and maintain the connections to
GROUND of all the panels, the closures and the shielding of all the high voltage parts.
 If the event of replacing the high voltage transformer bear in mind that it contains transformer insulation oil
which must not be disposed of in the environment (it must be handed over to a company authorised for disposal or
recovery).

INSTRUCTIONS AND WARNING 84

 8 INSTRUCTIONS AND WARNING

8.2 ON-OFF OF THE SYSTEM

SAFETY CHECK

Before starting the system check the following:

 All safety devices must be on

 All remote interlock devices must be closed
Check the power supply PREPARATION PROCEDURES TO THE OPERATION

Provide power to the electronic generator.

Check if there are alarm signal messages on the operator terminal

The electronic controls check all alarm and/or warning inputs after the main
switch of the electronic generator has been turned on.

If the control electronics detect a malfunction, the indicator beside the

active alarm and/or warning lights up red.

The electronic generator can only be started after having cancelled all
alarms and warnings.

INSTRUCTIONS AND WARNING 85

 9 MAINTENANCE

9 MAINTENANCE

Section profile:

This section is for everyone who carries out maintenance on the Corona
Who is this chapter for? treatment system from Me.Ro. S.p.A..

This section contains advice and notes for the maintenance of the Corona
Contents of this chapter treatment system from Me.Ro. S.p.A..

9.1 GENERAL NOTES FOR MAINTENANCE

This section contains suggestions for maintenance in order to guarantee the

correct functioning of the corona treatment system.

Extraordinary maintenance must be carried out by specialised technicians

of the company Me.Ro. S.p.A. S.p.A.

Technical Support

The technicians of Me.Ro. S.p.A. S.p.A. can be contacted by phone. Please

find the telephone and fax numbers of Me.Ro. S.p.A. on the second page of
this manual.

Telephone and Fax numbers of Me.Ro. S.p.A. are on page 2 of this manual.

ANALYTICAL INDEX 86
9 MAINTENANCE

9.2 SAFE MAINTENANCE

For your own safety, please respect the safety rules and measures described
below

Dangerous areas

High voltage hazard!

The electronic generator converts low frequency, electrical energy to DC

power. Components supplied with high voltage can be electrical shocks.

Make sure to know all dangerous components of the machine.

Eliminating residual voltage

High voltage hazard!

High-voltage hazard! After having switched off the electronic generator,

some components may have residual voltage

Disconnect the electronic generator and respect the safety norms

regarding maintenance of high-voltage systems.

9.3 MAINTENANCE INTERVALS

Check the system at regular intervals.

Regular maintenance
Maintenance procedures have to be performed in consideration of the
working hours and the environmental conditions of the corona treatment
system.

MAINTENANCE 87
9 MAINTENANCE

9.4 MAINTENANCE PROCEDURES

VISUAL CHECK

It is recommendable to regularly perform a general visual check.

Check the system in order to detect signs of moisture, corrosions and dirt.

In order to guarantee the efficiency of the system it is necessary to provide

for general cleaning of the discharge station , eliminating residuals of plastic
materials and the dirt accumulated inside the machine once a month. The
high-voltage insulators have to be cleaned accurately with non-flammable
solvents, the discharge electrodes with brass brushes and solvents, and also
the electrical high-voltage connections and the roller have to be cleaned.

The machine has to be checked for:

 the oil level in the A.T. transformer;

 the operation of the refrigeration fans;
 clean and replace the air filters.

MAINTENANCE 88
9 MAINTENANCE

9.5 PROCEDURE FOR CHECKING THE DOUBLE IGBT MODULES

The double IGBT module is composed of 2 IGBTs with a parallel diode

connected between the collector and the emitter.

To check the module, proceed as follows.

1° disconnect the connections from the module terminals.

2° with the tester on diode, connect the tester positive terminal to

terminal C2E1 (1) and the negative terminal to terminal E2 (2).

The reading will be OL if the IGBT connection is intact.

3° reverse the tester terminals (negative to terminal C2E1 (1) and positive
to terminal E2 (2)

The reading will be approximately 0.3-0.4V if the diode parallel to the IGBT
junction is integral.

4° with the tester on diode, connect the tester positive terminal to

terminal C1 (3) and the negative terminal to terminal C1E1 (1).

The reading will be OL if the IGBT connection is intact.

5° reverse the tester terminals (negative to terminal C1 (3) and positive to

terminal C2E1 (1)

The reading will be approximately 0.3-0.4V if the diode parallel to the IGBT
junction is integral.

6° with the tester on OHM, check terminals G1-E1 (8-9).

The reading will be OL= high resistance, if the IGBT GATE is intact.

7° with the tester on OHM, check terminals E2-G2 (10-11).

The reading will be OL= high resistance, if the IGBT GATE is intact.

If one or more measurements are incorrect, the module must be replaced.

MAINTENANCE 89
9 MAINTENANCE

9.6 MENDING THE SILICONE INSULATED ROLLERS

The roll mending is performed using a special two compound silicone rubber
(silicone + hardner) supplied by Me.Ro s.p.a.

Before applying the silicone rubber to the roller this must be cleaned in the
proximity of the hole or cut using non flammable solvent.

In order to better fix the rubber, the damaged rubber parts have to be
removed with a blade, enlarging the hole or the cut until rubber in perfect
conditions appears and the aluminum or iron surface of the roller.

Once accomplished to these preliminaries we will mix a 10% of hardner to

the silicone rubber. Depending on the room temperature this compound
will dry up within 5 to 15 minutes.

It is possible to vary this time by increasing or decreasing the percentage of

hardner.

Apply the silicon on the roller and after drying remove excessive rubber with
abrasive paper and perfectly close the surface of the roller.

MAINTENANCE 90
9 MAINTENANCE

9.7 REPAIRING SILICON SLEEVE INSULATED ROLLERS

Remove the old sleeve from the roll cutting it with with a blade.

Carefully clean the roller surface.

If the roller has a pass-trough shaft then seal, using adhesive tape, one of
the ends where air could exit. Also, the shaft can be removed and one end
of the roller be sealed.

The new silicone sleeve must be some 10 cm longer than the roller.

For rollers longer than two metres increase the sleeve lenght by sone 15 or
20 cm. To insert the new sleeve the following must be available: two or
three people, compressed air; a tampon having the diametre of the sleeve,
a retaining ring to secure the sleeve on the tampon; some industrial talc.

Insert by hand some 4-5 cm of sleeve onto the roll from the sealed side.

Put a small quantity of talc in the sleeve.

Insert the tampom with compressed ait intake into the other end of the
sleeve. In case the tampon is not available we can insert the sleeve by some
10 cm, insert a compressed air pipe into the other end and grasp firmly.

Grasp firmly the sleeve already on the roller.

Slowly open the compressed air tap to inflate the sleeve.

Once the sleeve is inflated press and drive it on the roll.

To insert the other end ( where the tampon is) use a compressed air gun
blowing between the sleeve and the roll while pushing the sleeve.

Trim out the sleeve with a sharp blade.

MAINTENANCE 91
9 MAINTENANCE

Fig. 54

MAINTENANCE 92
9 MAINTENANCE

9.8 REPAIRING CERAMIC COATED ROLLERS

 Once the puncture has been spot mark the surface around it

 Using a drill with a diamonded point of 5mm make a hole directly on the
puncture until the roll iron surface has been found. Clean carefully the
hole with solvent and await it gets dry.

 Blend at least 10ml of resin with the relative hardener (20%) (supply
production by Me.Ro. S.p.A.This is a special cycloalifatic resin.

 Mix at least 10 ml of resin with the hardener (20%)

 This is a special cycloaliphatic resin.

 The hole has to be covered completely by the compost in a way to create

an evident hill.

 Let the resin to become hard for at least 24h. Remove the resin out of
the hole using a suitable sandpaper to uniform the roll radius, paing
attention to not create any hollow.

 Carefully remove the excess resin to the exact radius of the roller using
a suitable abrasive paper, being careful not to create a depression. At
the end a small 5mm spot will be visible.

 From this moment on the roll is ready to be used.

MAINTENANCE 93
10 UNISTALL AND DISPOSAL

10 UNISTALL AND DISPOSAL

Section profile:
Who is this chapter for?
This section is for everyone for all persons who are authorised to dismantle
and dispose of Corona Treatment Systems from Me.Ro. S.p.A.

This section contains advice and suggestions for a successful dismantling

Contents of this chapter and disposal of components of the Corona treatment system from Me.Ro.
S.p.A.

10.1. IUNSULATING THE UNIT

1. Turn the electronic generator OFF.

2. Switch off the electronic generator power supply line.

3. Disconnect all external electrical connections.

To dismantle the roller proceed as indicated in the following steps:

 Secure the roller with two belt slings, with the adequate capacity,
positioned symmetrically with respect to the middle of the roller and with
a distance between them of approx. 1 metre;

 Tension the 2 slings with a rocker arm of adequate length and capacity;

 Remove the fixing bolts;

 Let the roller slide until it is completely out of the machine;

 Place the roller on appropriate supports.

10.2. PACKAGING

Package the electronic generator and/or the high voltage transformer

and/or the discharge station considering its dimensions.

Place it on a pallet, cover it with a plastic film and wrap it with belts.

UNISTALL AND DISPOSAL 94

10 UNISTALL AND DISPOSAL

10.3. DISPOSAL

Disposal The main component materials of the electronic generator are:

Metals:

a. Aluminium
b. Copper
c. Steel
d. Brass
e. Galvanized iron plates
f. Steel plates

Plastics:

g. Teflon , PA and others

Other materials:

h. Electronic cards
i. Ceramic

The main component materials of the high-voltage transformer are:

Metals:

j. Aluminium
k. Copper

l. Steel
m. Brass
n. Galvanized iron plates
o. Steel plates

Plastics:

p. Teflon , PA and others

UNISTALL AND DISPOSAL 95

10 UNISTALL AND DISPOSAL

The high-voltage transformer also contains mineral oil not produced by

Me.Ro. S.p.A. For safe disposal, request the technical specifications from
Me.Ro. S.p.A.

The main components of the discharge station are:

Metals:

q. Aluminium
r. Steel
s. Brass
t. Galvanised iron plates
u. Steel plates

Plastics:

v. Teflon , PA and others

Other materials:

w. Ceramic

UNISTALL AND DISPOSAL 96

 10 UNISTALL AND DISPOSAL

ANALYTICAL INDEX

A
I
Air-Gap; 78
AIR-GAP; 30; 47; 49; 52; 57; 73 IGBT; 68; 71; 89
Inverter; 15

C
O
ceramic coated rolls; 93
Chopper; 15 operator terminal; 15; 24; 26; 31; 33; 34; 35; 81; 85
control electronics; 15 Operator terminal; 14; 15
ozone; 22
Ozone Reducer; 14
D
Ozone Suction; 14; 24
discharge station; 10; 11; 13; 19; 20; 21; 22; 24; 26; 28; 29;
30; 31; 65; 66; 72; 74; 76; 77; 78; 80; 88; 94; 96 P
Discharge Station; 14; 24; 65
Pay attention not to spoil the roller core.; 91
PROFIBUS-DP; 33
E
electronic generator; 10; 11; 13; 15; 16; 19; 20; 21; 24; 26; R
27; 30; 31; 33; 34; 36; 39; 64; 65; 66; 67; 69; 70; 71; 78;
80; 84; 85; 87; 95 Rectifier; 15
Electronic Generator; 14
S
G silicone rubber; 90
guarantee; 4 Station Box; 28

H T
high voltage; 11; 13; 14; 15; 20; 21; 24; 25; 29; 30; 38; 62; TRENDS; 42
63; 84; 87; 88; 94; 95; 96
V
variable impedance; 80

UNISTALL AND DISPOSAL 97

Me.Ro S.p.A. © 2014 http www.mero.it mail [email protected]