Instruction Manual for

Corona-Plus
Equipment

VETAPHONE elektronik a-s

Fabriksvej 11, DK- 6000 Kolding
Tlf +45 75526133 / Fax +45 75526207
www.vetaphone.com sales@vetaphone.com
 Contents

1 GENERAL INFORMATION
- Order confirmation
- Overview drawing
- General instructions for use
- Safety precautions
- EC Declaration of Conformity

2 TREATMENT OF PLASTIC
- The purpose of treatment
- The electrical process

3 INSTALLATION
- Mechanical installation
- Cable connections
- Checklist – Start up

4 GENERATOR
- The control panel
- Set-up mode parameters
- Diagram
- Bus interface (Profibus-DP / Canbus / etc).

5 STATION
- Operating the station
- Drawing

6 OZONE EXTRACTION
- What is ozone
- The fan / Ozone-Eliminator

7 MAINTENANCE
- Lubrication and cleaning
- Oil for HP-transformer

8 MECHANICAL TROUBLE SHOOTING

- Service / Trouble shooting

9 ELECTRICAL TROUBLE SHOOTING

- Service / Trouble shooting
- Service / Advanced troubleshooting

10 OPTIONAL EQUIPMENT

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 General Information 1

Chapter 1

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 General Information 1

THE CORONA EQUIPMENT

In order to improve the adhesion on a web surface the web is moved through a roll station in which an
electrical energy, called the Corona, is discharged on the surface of the web.

The equipment is composed of 4 basic parts: a generator, a high voltage (HP) transformer, a roll
station and an exhaustion system. The pre-treatment itself is carried out in the roll station, where a
system of electrodes gives an efficient electrical discharge on the film. The electrical power comes
from the generator and it’s high voltage transformer. During the discharge in the roll station heat and
ozone are created, which is why an exhaustion of the air in the roll station is necessary.

The electrical system consists of a strong power supply, ensuring an efficient DC tension to the output
stage. The output amplifiers are designed with IGBT transistors in order to ensure a reliable working of
the high effects and tensions. The output signal from the generator is sent to the high voltage
transformer, which step up the signal to the electrodes. The control and monitoring parts are taken
care of by a central control card, to which the remote control and the control signals are connected.

The electrical Corona-Plus principle is centred around a resonant circuit, of which the web material is a
part. The working frequency of the electronic system is controlled automatically by a feedback system
to a frequency of more than 25 kHz. This ensures a maximum efficiency and thus an optimum pre-
treatment. The Corona effect comes from a specially designed HP-transformer with a minimum HF-
loss and optimum output voltage. The discharge emanates from the electrodes and hits the film
surface on the way towards the roll.

The generator output power is controlled by the pulse-width-modulation principle (PWM-power).

Keeping the power supply to the PA-switch-transistors constant and adjusting the power –i.e. the
treating effect - according to the time factor. This way you avoid the dangerous high tension potential,
which causes pinholes.

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 General Information 1

GENERAL INSTRUCTIONS FOR USE

ON - Start generator - Flashing = Automatic start.

OFF - Stop generator - Cancel error message

DOWN - Power down

UP - Power up

OPEN UP - Open electrode - The button can be set to other functions

BELL - Stop alarm relay - The button can be set to other functions

Switch to SETUP mode for data input.

Hold down the button and then press the button for a few seconds.

Toggle between "WATTmin/m2" and "WATT" display modes

Hold down the button and the button for 1 second.

PRESETTING OF POWER LEVEL

Before pressing the ON-button the power level can be adjusted with the and buttons.

READY TO START
The generator is ready to start when OFF is displayed and all LED's are GREEN.

ERROR INDICATION – Red LED's indicate the following errors:

1) Generator, internal error 5) Station, HP-flashover to ground
2) Generator, external error 6-7) Fan, no ozone extraction
3) HP-transformer, missing feedback 8) Remote control, error
4) Station open, or door switches not closed 9) Station, roll not rotating
For further information see "Control panel error messages AFTER start up" in chapter 9.

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 General Information 1

DISPLAY READOUT
The display can be toggled between two types of readout:

WATT : Shows the total output power on the electrodes.

If set to 'Automatic power control' the output power will automatically follow the line
speed up and down. (See SETUP MODE - parameter A – in chapter 4)

WATTmin/m2 : Shows how many watts are applied to each square meter film per minute.
This is possible when the parameters for 'Length of electrode' and 'Number of
sides to treat' are entered in the SETUP mode (factory preset), and at the same
time the generator detect the line speed.
If no line speed is detected the displayed value is always zero (- -.-), and the
WATTmin/m2 can not be calculated.

The standard readout is WATTmin/m2 if the 'Automatic power control' mode is switched ON.

CHANGE OF DISPLAY MODE

To toggle between the two display modes press the buttons for 1 second.

OPEN TREATERSTATION
If the generator is delivered with pneumatic controlled opening, the treaterstation can be opened remotely
with the pushbutton.

If the treaterstation is open the display shows OPEN:

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 General Information 1

SAFETY PRECAUTIONS
Not included
The VETAPHONE equipment does not include the following safety aspects :

EMERGENCY STOP:
The VETAPHONE equipment typically is only a small part of A larger installation, and is therefore
not equipped with a separate emergency stop.

GUARDING OF ROTATING PARTS:

Rolls are not guarded. Guarding should be provided, where necessary, by the user.

THE CLOSING SYSTEM OF THE STATIONS:

As standard there is no optical or mechanical safety surveillance to monitor the station when
closing, therefore, separate individual safety systems should be fitted, such as two-hand closing
mechanisms or other suitable safety systems.

NOISE AND VIBRATION:

The user should make suitable arrangements during planning and installation, to keep noise and
vibration to a suitable level.

ROTATION SENSING AND CONTROL OF ROLLER:

By deactivating of the rotation control system the roller can remain stationary while the Corona
discharge is on. This can cause the roller covering and product to be burned through.

REMOVING OF ELECTRODE COVER

After mechanical removing of electrode cover for cleaning and maintenance, you must
reinstall cover before switching on the Corona

TREATMENT OF ITEMS:
The dwell-time for treatment of items should be limited to avoid the material and the electrode
being burned through.

LIMITS FOR USE:

The VETAPHONE equipment must for safety reasons not be used by:

1) Employees not trained in the use of equipment and who have not been instructed on the
safety aspects.

The VETAPHONE equipment may for safety reasons not be used in:

1) HAZARDOUS atmospheres unless it is approved EXPLOSION-PROOF equipment

2) Dusty areas which could support combustion or explosion
3) Moist areas where electric shock could be caused.

The VETAPHONE equipment may for safety reasons not be used for:

1) Pull equipment. l.e. Neiter the backing roller nor any idler rollers should be used for
driving the web.
2) Line tensions over 1000 Nm
3) Applications, where metals can be conveyed into the corona discharge compartment.
4) Film paths where the direction of rotation of the roller is opposite to the designed
direction. See the assembly drawing to check the specified direction.

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 General Information 1

EC DECLARATION OF CONFORMITY

▌ MANUFACTURER : Frank Eisby

▌
▌ Company Name : VETAPHONE elektronik a-s
▌
▌ Address : Fabriksvej 11, DK- 6000 Kolding, Denmark
▌
▌ Telephone : +45 75 52 61 33 / Telefax: +45 75 52 62 07

▌ REPRESENTATIVE :
▌
▌ Company Name :
▌
▌ Address :
▌
▌ Telephone :

hereby declare that

▌ MACHINE :
▌
▌ Name :
▌
▌ Type :
▌
▌ Serial no. :
▌
▌ Year of construction :

was manufactured in conformity with the provisions in the COUNCIL DIRECTIVE of 14 June 1989 on
mutual approximation of the laws of the Member States on the safety of machines (89/392/EEC as
amended by directive 91/368/EEC) with special reference to Annex 1 of the Directive on essential safety
and health requirements in relation to the construction and manufacture of machines.

▌ POSITION : Managing Director

▌
▌ Name : Frank Eisby
▌
▌ Company : VETAPHONE elektronik a-s

.........…... ...........................
Date Signature

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 General Information 1

Warranty

Warranty
1. Vetaphone equipment is covered by a general warranty for a period of one year from date of start-up in
production, but maximum 13 months from date of shipment.
2. The warranty covers defective components for the Vetaphone equipment, as well as the working hours
used by a Vetaphone technician repairing the delivered equipment. Charges for technicians’ transportation
and accommodation are not covered. The warranty does not cover failures or loss of production in which
the equipment is used, nor does it cover any loss in profits or other indirect losses arising from any such
failure in the supplied equipment.
3. Defective components will be exchanged free of charge during the warranty period, provided that the fault
can be traced back to Vetaphone, and provided that the damaged part is returned to Vetaphone.
4. Wearing parts, such as electrodes, ceramic electrodes, silicone sleeve, vulcanised silicone, ceramic
coatings etc., are not covered by this warranty.
5. The warranty does not cover failures arising from faulty connection of the equipment or unskilled operation
of it. Also the guarantee is not valid for any failures arising as a consequence of using non-original
equipment or alternative parts, which Vetaphone has not approved in advance.
6. Customer personnel may attempt to repair the Vetaphone equipment and the guarantee will remain valid in
such a case although it does not cover any extra damage, which customer personnel may cause in
attempting such a repair.
7. This Vetaphone guarantee is not valid if the terms of payment are not fulfilled.
8. Exceptions on warranty:
1. Unauthorised components used for repair attempts
2. Tampering with print-cards
3. Additional holes made in the Vetaphone parts
4. Transportation damage
5. Incorrect installation, operation and poor maintenance.
6. Force Majeure

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 Treatment of plastic 2

Chapter 2

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 Treatment of plastic 2

THE PURPOSE OF TREATMENT

It is often very difficult to make printing ink, lacquer and glue bond effectively to plastic. This is because
plastics have a low surface energy, a force that is closely related to adhesion. The commonly used units
that describe surface energy are dynes/cm. It has been shown that, to be sure of a good bond between
printing inks and plastic substrates, the surface energy of the substrate must be appreciably higher than
that of the ink.

If a plastic material has a surface energy of, for example, 31 dynes/cm, as is the average for freshly
produced polyethylene film, the result will be a very poor bond. It is therefore necessary to raise the
surface energy of the plastic.

Examples of how ink bonds to plastic with high and low surface energy

In order to carry out a particular process, the surface energy of the material needs to be raised from the
basic surface energy to one of the level ranges prior to application.

Material – Basic Dynes/cm

PP 29
PE-LD 31
PE-HD 32
BOPP 32
Process – Application Dynes/cm
Print - solvent based ink 40-42
Print - water based ink 46-48
Coating 44-54
Lamination 46-56

Basic surface energy of materials, and required dyne level for various applications

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 Treatment of plastic 2

THE ELECTRICAL PROCESS

ALTERING THE SURFACE ENERGY
This can be done in several ways. VETAPHONE uses electrical Corona-plus discharge, which is the most
suitable treatment method for plastic films, cables and tubes. It is easy to control, requires little
maintenance and the system is inexpensive to run.

Plastic is a man-made synthetic material, which contains long homogeneous molecular chains that form a
strong and uniform product. The chains of molecules are normally joined end to end forming even longer
chains, leaving only a few open chain ends, thus providing only a small amount of bonding points at the
surface.
During corona discharge treatment, electrons are accelerated into the surface of the plastic causing the
long chains to rupture, producing a multiplicity of open ends and free valences are formed. The free
valences are then able to form carbonyl groups with the atoms from the ozone created by the electric
discharge, which gives the improved adhesion.

PE molecular chain ruptured by corona discharge

The adhesion is further enhanced by the cleaning effect that the ozone causes, by oxidation on the
surface of the material.

In spite of the fact, that accelerated electrons cause rupturing of the surface, the strength of the material is
not affected, as the reactive force of the upper molecular layers dramatically reduces the acceleration.
Thus, the essential properties of the material are maintained, and less than 0,1 of the material is
penetrated.

POWER CALCULATION
The generator power required to treat the plastic sufficiently on various types of materials and various
treatment areas, can be calculated by using the following formula:

Power = T  S  W  M

P = Total Power (Watt) required

T = Number of sides to Treat (single/double sided)
S = Line Speed (in metres per minute)
W = Film Width (in metres)
M = Material factor (required Watt per m² per minute)

The material factor is the number of watts needed to raise the surface energy of a film to a sufficient level.
The factor typically varies between 10 and 50 Wattm²/min for most materials, depending on type of
material, age, additive content, etc. The exact value is best determined by testing a sample of the actual
film that is used for a specific application.

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 Treatment of plastic 2

Table showing required power for different materials

POLYETHYLENE PE (LDPE, HDPE):
LOW SLIP Fresh extruded PE Curve 1
MEDIUM SLIP Fresh extruded PE - 2
HIGH SLIP Fresh extruded PE - 3

LOW SLIP Aged PE Curve 2

MEDIUM SLIP Aged PE - 3
HIGH SLIP Aged PE - 4

EMBOSSED PE PE - 2

POST TREAT. PE (on paper or board) PE - 2

POLYPROPYLENE (Copolymer) PP - 1

POLYPROPYLENE (Homopolymer) PP - 3

ORIENTED POLYPROPYLENE OPP - 3

BIAXIAL ORIENTED POLYPROPYLENE BOPP - 4

POLYESTER Pure material PET - 1

POLYESTER With additives PET - 3

ALU. FOIL AL 20 watt m²/min

KRAFT PAPER (before coating) 16 watt m²/min

PE FOAM (more than 30 kg/m3) for 56 dyn/cm 50-200 watt m²/min

Typical required dyn/cm level for:

PRINTING : 40 - 42 dyne/cm. For solvent inks
- : 46 - 48 dyne/cm. For water based inks
COATING : 44 - 54 dyne/cm. Depending on coating type
LAMINATING : 46 - 48 dyne/cm. Solvent adhesives
54 - 56 dyne/cm. Water based adhesives

Typical values for slip additives (Oleamide & Erucamide)

0 - 400 PPM : Low slip
400 - 700 PPM : Medium slip
700 - 1200 PPM : High slip
1200 - 2000 PPM : Extremely high slip

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 Treatment of plastic 2

Material-factor curves

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 Treatment of plastic 2

DURABILITY OF THE TREATMENT

The increase in surface energy (dynes/cm), that is induced into a film begins to decay immediately
following treatment, and again this depends upon the same factors mentioned above, with the additional
considerations of storage conditions and temperatures. Generally speaking, the more difficult a material is
to treat the quicker it is likely to decay with time. It has been established. that film with very high slip
additives (over 1200 ppm) can be totally resistant to printing just 24 hours after treatment, and it may be
necessary to process the film immediately following treatment, or boost the treatment in line with the
printer. Ageing of such films can render them impossible to treat if they are not treated during production.

Typical decay in surface energy on PE-materials over a 6 month period

As can be seen from the graph, the level of treatment decays more quickly immediately following
treatment, and less rapidly as the time passes, depending on different dynes/cm start levels.

MEASURING THE SURFACE ENERGY

Using the test method described by DIN 53364 and ASTM D2578-67, which is a liquid test, carries out the
measurement of surface energy of a film. Vetaphone supply test liquid. The liquid is applied as a broad
line in a thin layer with either a brush or a pen.

The surface tension is then determined visually by estimating how the liquid reacts within the first two
seconds following application. The test liquid can shrink and/or form itself into globules (individual
droplets) or it can remain unchanged.

When a test liquid shrinks or forms into droplets it indicates that the film has a lower surface energy than
the liquid applied. The test should be repeated as many time as necessary with a liquid of a lower surface
tension until it remains unchanged for a period of two seconds or more. Once that has been achieved, the
film can be said to have that level or surface energy at least equal to that of the liquid applied. Further
applications should be made until shrinkage or droplets occur within two seconds. This last measurement
should be taken as failure, and the surface energy of the liquid used for the previous measurement should
be taken to be the surface energy of the film.

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 Treatment of plastic 2

OZONE
Ozone is a gas that is formed during the process of corona discharge, and plays an important part in the
chemical and molecular changes that take place in the surface of the plastic.

Ozone is hazardous to health and has an unpleasant smell, even at relatively low levels. The average
human can smell ozone at 0.01 ppm. and the threshold of safety of the gas in the area occupied by
personnel is 0.1 ppm. All of VETAPHONE's equipment is therefore designed to remove ozone effectively
from the treater station by means of an ozone-protected fan, and a specially designed exhaust system.

An option instead of ducting the ozone through the roof to atmosphere is to use an ozone eliminator. This
is an independent, catalytic filter system that accelerates the decomposition ozone, eliminating it
completely.

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 Installation 3

Chapter 3
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 Installation 3

MECHANICAL INSTALLATION
INSPECTION
When unpacking the equipment it has to be checked that it has arrived in good and sound condition,
correct delivered and all components are according to the order confirmation. Contact Vetaphone
immediately in case of damages or missing parts.
After this the Corona treatment equipment, usually consisting of generator, HP-transformer, treater station
and extraction fan, is ready for installation. Before start-up of the system please complete the installation
procedure by checking the items on the CHECKLIST placed in the end of this chapter.

STATION
During unpacking and installation the station must only be lifted parallel by using wires through the lifting
ring bolts. Do NOT lift at the bottom side of the station using a fork truck.
The treater station has be to installed in accordance with the order specification and certified drawing.
Make sure to mount the station correctly in relation to the web direction and cable connection. Unless
specified otherwise the station is as a standard equipped with mounting brackets for easy installation and
adjustment.
Before start-up the distance between electrode and web has to be checked or adjusted to 2.0mm.

STATION ALIGNMENT
Before fixing the station to the main machinery, it has to be mounted and adjusted correctly in relation to
the production line. During installation it is very important that the station is not mounted in a twisted or
unparalleled way when seated and adjusted. Twisting the station will result in excessive wear of all
moveable parts and causes non-alignment of the electrodes, resulting in poor and uneven treatment of
the film.

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 Installation 3

PNEUMATICS
Stations fitted with pneumatic open/close-system must be supplied with 6-8 bar of compressed air. Air
connection is marked with a label and is located on the cable connection-side of the station. The
moveable part of the station can now be opened on the control lever (or other type of delivered operating
system). In the event of loss of the remote opening signal, the station opens automatically.

HP-TRANSFORMER – See also HP-Cable

Place the HP-transformer close to the treater station. The HP-cables conduct a high frequency high
tension and will have a maximum length of 3 meter. The HP cable is made ready for connection by
Vetaphone. DO NOT SHORTEN THE CABLE.

OIL FILLING (except CP1C)

The external HP-transformers are delivered without oil in them. The oil is supplied separately. To fill the
HP-transformer with oil the top plate has to be removed first. To avoid bubbles fill up slowly using a clean
funnel. Oil is filled up to the label on the inside of the transformer box. Vetaphone recommend only
premium oil with excellent insulating properties, such as Shell Diala D, Esso Univolt 52, BP Energol JS-V
or JS-P, Statoil Voltway E7.
Health and safety data for Voltway E7 enclosed - See also Maintenance chapter.

GENERATOR
During unpacking and installation the generator is only to be lifted by using wires through the lifting
ringbolts. Do not lift at the bottom of the generator using a fork truck.
The generator is placed on the floor or on a platform. Make sure that there is plenty of open space at the
top and front of the generator for the built-in cooling fans to allow a free airflow in and out.
All cables enter the cabinet through the bottom, and connection them is done from the front.
Before start up a visual check of all relays etc. is performed to ensure that nothing was loosened during
transport.

OZONE EXTRACTION FAN

During the corona treatment the electrical discharge creates ozone and heat. It is very important that this
warm mixture of ozone and air is extracted from the station. The extraction fan is placed as close to the
station as possible (max. 3 m away). If movability is required the fan and station are connected via the
supplied flexible hose. Wherever possible, it is preferable to use a fixed and straight pipe connection
made of ozone resistant materials, preferably with a large diameter. This has the advantage of smoother
inside surface, to avoid any the air resistance.

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 Installation 3

CABLE CONNECTIONS
MAINS CONNECTION
The correct mains supply to be connected to the equipment is stated in the order confirmation and on the
generator rating plate (also indicating name of model and serial number). The mains cable is connected
to the main switch in the cabinet. Safety earth must be connected at the mains connection terminal.

IMPORTANT:
In case of CP-2, CP-3 or CP-5 generators it is important that the phases are connected correctly. False
connection causes reverse rotation of the internal cooling fans. Check visually that the internal fans rotate
correctly according to the RED arrow on the fan. Switching 2 of the phases correct wrong rotation.

OZONE EXTRACTION FAN

The fan can be connected to an external mains supply, having the voltage specified in the order con-
firmation. It is important that the fan continues to extract air from the station for another 20-60 seconds
after the corona discharge has stopped.

Unless specified otherwise in the circuit diagrams, a 24VDC relay for controlling an ozon extraction fan
can be connected between 24VDC (X12-1) and open collector output OUT4 (X12-13) on the generator.
When the generator is switched ON the output is activated, but the generator itself remains on STAND-
BY until the airflow is correct (typically 10 sec. (setup [b t._x x.])). After the generator is switched
OFF the output remains activated (typically 20 sec. (setup [b d._x x.])) for the purpose of
removing what is left of ozone in treaterstation and exhaust system.

The 24VDC output (X12-1) is internally fused and can be loaded by 400mA maximum.
The open collector output OUT4 (X12-13) has a maximum current rating of 300mA, and should not be
subjected to more than 30VDC

STATION CABLE (Standard but please refer to - circuit diagrams)

The station-cable is a screened cable that is connected to generator and station. It is a multi function
cable, that carries information from auxiliary components such as air pressure and nip-roll (see circuit
diagrams for specification), as well as the usual information about safety switches and rotation control.

MICROSWITCH CABLE (If included - See circuit diagrams)

The microswitch-cable is connected between station and generator terminal -X12 connection 3+14.
Additional safety switches can be connected in series to connection 3+14 on terminal -X12.

ROTATION CONTROL CABLE (If included - circuit diagrams)

The rotationcontrol-cable (RC) is connected to station and to generator terminal -X12 connection 2+14.
Monitoring the webspeed (rotation of roll) is done by means of an inductive sensor on the roll-end.

REMOTE CONTROL (If included - See Order confirmation)

A remote control, complete with cable, is required to make changes in the set-up of the generator. It is
connected to the -X11 terminal on the generator. Although the remote control is required for set-up, it
need not be connected for the generator to operate, in fact it can be connected and disconnected during
operation.

Several remote controls can be arranged in parallel on the 4 wires in -X11.

HA-CABLE
The HA-cable is a screened powercable that is connected to generator and HP-transformer. Please do

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 Installation 3

not shorten the length of the HA cable, unless accepted by a VETAPHONE technician.

MULTI CABLE
The multi-cable is a screened cable that is fixed connected at the HP-transformer and is to be connected
to -X10 terminal on the generator.
This cable carries Overload and Feedback information from the HP-transformer to the generator control.

EARTH WIRING
The earth cable (yellow/green) comes with the equipment as one complete piece, together with a number
of cable eyes. It is IMPORTANT that the cable is connected between Station and HP-transformer, use
the screws marked (earth connection). The cable is to be kept as short as possible. For safety
purposes, the conductivity of the earth wiring should be verified after installation.

HP-CABLE
The cable(s) is connected to HP-transformer and treater station.
The HP-cables conduct a high frequency high tension and will have a maximum length of 3 meter. The
HP cable is made ready for connection by Vetaphone cable and is connected to the output terminal on the
HP-transformer.

DO NOT SHORTEN THE CABLE.

A correct connection inside the HP-transformer is very IMPORTANT.

Correct Wrong

Correct Wrong

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 Installation 3

CHECKLIST

STATION :

1)Is the station installed in accordance to the order specification and certified drawing?

2)Is the electrode air gap distance set correct?

Check distance is max. 2.0mm between electrode and roll face.

3) Is the electrode completely straight? Check air gap / alignment along the whole electrode.

4) Is the HP-cable(s) mounted correctly?

5) Is the EARTH-cable connected? (Between station and HP-transformer and generator)

6) Is the STATION cable connected? (If included. See Cable drawing diagram)

7) Is the MICROSWITCH cable connected? (If included. See Cable drawing diagram)

8) Is the ROTATION cable connected? (If included. See Cable drawing diagram)

9) Is air supplied 6-8 Bar? (Only station with pneumatic)

GENERATOR :

1) Is the generator mounted at the desired location? (CP1C max. 5m from station)

2) Is the mains cable supplied and does it carry the correct voltage? In CP-2, CP-3 and CP-5
check visually that the internal cooling fans rotate the correct way (swap two of the phases if
not). Voltage and recommended prefuse see cable drawing diagram.

3) (Only CP1C) Is the HP-cable(s) mounted correctly?

4) (Only CP1C) Is the EARTH-cable connected? (Between station and HP-transformer and
generator)

5) Is the HA-cable (do not shorten) connected? (except CP1C)

6) Is the MULTI cable mounted correctly to terminal -X10 ? (except CP1C)

7) Is the STATION cable connected? (If included. See Cable drawing diagram)

8) Is the MICROSWITCH cable connected? (If included. See Cable drawing diagram)

9) Is the ROTATION cable connected? (If included. See Cable drawing diagram)

10) Is the remote control panel (if supplied) mounted?

TRANSFORMATOR: (except CP1C)

1) Is the transformer mounted at the desired location max.5m from station?

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 Installation 3

2) Is the HP-transformer filled with oil

3) Is the HP-cable(s) mounted correctly?

4) Is the EARTH-cable connected? (Between station and HP-transformer and generator)

FAN:

1) Is the fan mounted at the desired location?

2) Check visually that the external fan is rotating the correct way according to the arrow on the
fan (Swap two of the phases if not).

3)Are the flexible exhaust tubes from station to fan mounted?

4)Is the pipe from fan out of the factory sufficient according to the airflow on cable drawing
diagram?

The Corona equipment is now ready for use. Please refer to ‘General instruction for use’ in chapter 4.

Note:

All cable length on cable drawing diagram.

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 Generator 4

Chapter 4
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 Generator 4

THE GENERATOR RANGE:

All generators are computerised with PWM resonant circuit.

CP1 MKII power outputs from 1-2KW

CP1C MKII power outputs from 1-2KW with integrated transformer.
CP2 MKII power outputs from 3-5KW
CP3 MKII power outputs from 6-10KW
CP5 MKII power outputs from 12-40KW
CP7 MKII power outputs from 50-80KW

MKII generators are with IGBT techniques.

GENERAL INSTRUCTIONS FOR USE

The generator is turned ON and OFF by using the mains switch on the front of the generator.

ON - Start generator - Flashing = Automatic start.

OFF - Stop generator - Cancel error message

DOWN - Power down

UP - Power up

OPEN UP - Open electrode - The button can be set to other functions

BELL - Stop alarm relay - The button can be set to other functions

Switch to SETUP mode for data input.

Hold down the button and then press the button for a few seconds.

Toggle between "WATTmin/m2" and "WATT" display modes

Hold down the button and the button for a few seconds.
Alternative press the for a few seconds.

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PRESETTING OF POWER LEVEL

Before pressing the ON-button the power level can be adjusted with the and buttons.

READY TO START
The generator is ready to start when OFF is displayed and all LED's are GREEN.

ERROR INDICATION – Red LED's indicate the following errors:

1) Generator, internal error 5) Station, HP-flashover to ground
2) Generator, external error 6-7) Fan, no ozone extraction
3) HP-transformer, missing feedback 8) Remote control, error
4) Station open, or door switches not closed 9) Station, roll not rotating
For further information see "Control panel error messages AFTER start up" in chapter 9.

DISPLAY READOUT
The display can be toggled between two types of readout:

WATT : Shows the total output power on the electrodes.

If set to 'Automatic power control' the output power will automatically follow the line
speed up and down. (See SETUP MODE - parameter A – in chapter 4)

WATTmin/m2 : Shows how many watts are applied to each square meter film per minute.
This is possible when the parameters for 'Length of electrode' and 'Number of
sides to treat' are entered in the SETUP mode (factory preset), and at the same
time the generator detect the line speed.
If no line speed is detected the displayed value is always zero (- -.-), and the
WATTmin/m2 can not be calculated.

The standard readout is WATTmin/m2 if the 'Automatic power control' mode is switched ON.

CHANGE OF DISPLAY MODE

To toggle between the two display modes press the buttons for a few seconds.
Alternative press the for a few seconds.
This will allow you to see the opposite readout for approx. 10 seconds.

OPEN TREATERSTATION
If the generator is delivered with pneumatic controlled opening, the treaterstation can be opened remotely
with the pushbutton.

If the treaterstation is open the display shows OPEN:

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IF GENERATOR DOES NOT START

If the generator does NOT start when the ON button is activated the following combinations of displayed
error messages and RED LED's have to be checked.

Control panel messages BEFORE start up

Red LED's MESSAGE

High temperature in Power Unit

Check that the internal cooling fans operate correctly, and
that they are not blocked with dirt
Check for high ambient temperature
Check for easy airflow around the generator
Driver error
Internal hardware error
PSU error
Internal hardware error

Mains tolerance error

Mains input voltage is out of tolerance

Station not closed

Close the station and make sure that all doors/windows on
the station are closed.

No air flow
Check that the extraction fan works and that there is airflow
through the station.
If the generator controls the extraction fan, the generator
will flash "stand by" on the ON-button until the minimum
airflow is maintained again, then the generator
automatically starts up ( Max timer “b t - -“, see SETUP ).

Communication error
Check the cable between the remote control and the
connection to terminal -X11.

Roll not rotating

The minimum speed of the line is not reached, or the
rotation sensor is not in correct position.

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Setup mode

FACTORY SETTINGS
The generator is delivered with all parameters set from the factory. A list showing the actual settings of
your equipment is stated in the “setup list” in this chapter, and a copy of it is placed inside the generator.
Alteration of the electrical functions can be done by changing the parameters in the setup list.

SETUP List
The SETUP parameter list is made with more sub-menues for easy access to the actual data :
SETUP :
OPEr Typical operator settings.
USEr Typical application depending settings. *1
CHECk Maintenance intervals / timers . *1
UnIt Vetaphone units connected. Remotecontrols etc. *1
FACt Factory settings of electrical parameters. *2
PULS1 Factory settings for matching 1. *2
PULS2 Factory settings for matching 2. *2
ProG1 Factory program 1 – depending of application. *2
ProG2 Factory program 2 – depending of application. *2
tESt Service test facilities – See CP-servicemanual. *2
In the beginning of each submenu a Code must be entered to allow changing of the parameters.
For the first 3 menues (*1) the code can be obtained by calling Vetaphone service +4575526133.
For code (*2) in the other menues please contact a technician from the Vetaphone service department.

ENTERING SETUP MODE

Hold down the button and then press the button.

The display now shows SETUP:

Use the arrow buttons to change to actual submenu.

To enter the actual submenu press the ON button .

Using the ARROW buttons to change between the different parameters.

CHANGING PARAMETERS
To change a parameter setting press the ON button . The displayed parameter value is now flashing
and can be changed by using the ARROW buttons. The new setting is stored by pressing the ON button
again (the flashing stops), or cancelled by pressing .

LEAVING SETUP MODE

Hold down the button and then press the button.
If no button is pressed for 10 minutes the display will automatically return to standard mode.

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PARAMETER EXPLANATION

OPer - Submenu

ELECTRODE LENGTH - [b._ x.x x ]

Length of electrode in meter, used to correct calculating of Automatic Power Control.

NUMBER OF SIDES TO TREAT - [E._ _ _ x.]

Number of film sides to treat, used to correct calculating of Automatic Power Control.
When using automatic HP-switches this parameter will be changed automaticly.

USER SETTINGS - [U._ _ _ x.]

For special features – depending of application.

USEr – Submenu

CODE FOR CHANGING IN THIS SUBMENU - [C._ x x x.]

The code can be informed by calling Vetaphone service phone +4575526133.

DYNAMIC POWER CONTROL - [d P._ _ x.]

The dynamic power control is used to limit the output power but still maintaining a uniform discharge.
Setting 0 = OFF DPC is deactivated – this is the standard setup.
Setting 1 = 1/2 DPC is active – output power is 50%.
Setting 2 = 1/3 DPC is active – output power is 33%.
Setting 3 = 1/4 DPC is active – output power is 25%.
Setting 4 = 1/5 DPC is active – output power is 20%.
Setting 5 = 1/6 DPC is active – output power is 16%.
Setting 6 = 1/7 DPC is active – output power is 14%.
Setting 7 = 1/8 DPC is active – output power is 12%.

LEVEL ALARM - [N L.x x x.]

Level Alarm +/- 0-100%. Check of variation in actual output power caused by mismatching etc.

AUTOMATIC POWER CONTROL - [A._ _ _ x.]

Setting 0 = OFF The output power will be stable independent of line speed variations.
Setting 1 = ON The output power will automatically follow the line speed up and down
and the Wattmin/m2 will be fixed independent of line speed changes.

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 Generator 4

ROTATION CONTROL AUTOMATIC - [r._ _ _ x.]

Setting 0 = OFF Rotation control is OFF.
Setting 1 = ON The generator can only be switched ON if the minimum line speed
[r.─ _ _ x.] is achieved. If the line speed is reduced below
minimum the generator will switch OFF and has to be restarted manually
if the line speed again increases.
Setting 2 = AUTO The generator automatically restarts if the line speed exceeds the
minimum setting [r.─ _ _ x.], and the ON flashes STAND-BY
until the minimum speed is reached.

MINIMUM SPEED - [r -._ x x.]

Minimum speed in meters per minute before switching the generator switches OFF automatically.

EXTERNAL FAN CONTROL - [b t._ x x.] [b d._ x x.]

A 24VDC relay for controlling an ozon extraction fan can be connected between 24VDC (X12-1) and open
collector output OUT4 (X12-13) on the generator. When the generator is switched ON the output is
activated, but the generator itself remains on STAND-BY until the airflow is correct (typically 10 sec.
(setup [b t._x x.])). After the generator is switched OFF the output remains activated (typically 20
sec. (setup [b d._x x.])) for the purpose of removing what is left of ozone in treaterstation and
exhaust system.

The 24VDC output (X12-1) is internally fused and can be loaded by 400mA maximum.
The open collector output OUT4 (X12-13) has a maximum current rating of 300mA, and should not be
subjected to more than 30VDC.

AUTOMATIC RESTART OF GENERATOR - [E c._ x x.][E t.x x x.][E d.x x x.]

In case of a flashover from the electrode to the backingroll the generator will stop and then restart
automatically after [E d.x x.x ] sec. (typically 1 sec.). In case of [E c._ x x.] flashover
(typically 3) the generator will stop permanently and indicate E-5 on the display.
If less than [E c._ x x.] flashovers occurs within [E t.x x x.] seconds (typically 60 sec.)
the error status will be reset.

PINHOLE OBJECT REJECT - [P H._ x x.]

Number of blocking signals after an error to eject pinhole object.

EXTERNAL REGULATION OFFSET - [N A._ x x.]

Interface card CP-IO power regulation: If 0=0-10V/..-20mA. If 40=2-10v/4-20mA

EXTERNAL REGULATION RANGE - [d 1.x x x.] [d 2.x x x.]

The power level minimum [d1] in watt.min/m .
2

The power level maximum [d2] in watt.min/m .

2

SHOW MODE FOR SPECIAL DISPLAY - [S H.x x x.]

If special display mode is needed – specified from Vetaphone.

LANGUAGE IN DISPLAY - [L G._ _ x.]

A few information on the display can be written in special Languages (1=English / 2=German)

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 Generator 4

USER DEFINED - [x x.x x x.]

More user defined parameters can be incorporated depending of application.

CHECK - Submenu

[c._ x x x.] .......... Code for changing. Call Vetaphone service phone +4575526133
[c 1.x x x.] .......... Days left. Clean the air inlet filters in the generator
[c 2.x x x.] .......... Days left. Check internal interior and connections.
[c 3.x x x.] .......... Days left. Check the oil level in HP-transformer
[c 4.x x x.] .......... Days left. Clean the insulators and the HP-connections
[c 5.x x x.] .......... Days left. Check electrode insulators and HP-connections
[c 6.x x x.] .......... Days left. Check the ozone blower and ozon pipes
[c 8.x x x.] .......... Days left. Check remote control connection
[c 9.x x x.] .......... Days left. Check the ball bearings and carbon brushes

UnIt – Submenu
Code for changing.
[C._ x x x.] Code for changing is this sub-menu. The code can be obtained by
calling Vetaphone service, phone +4575526133.
[A F._ _ x.] Number of total units, such as remote control, I/O-Module etc.
[F 0._ _ x.] .......... Unit type
[A 0.x x x.] .......... Unit number
[F 1._ _ x.] .......... Unit 1 type
[A 1.x x x.] .......... Unit 1 number
[F 2._ _ x.] .......... Unit 2 type
[A 2.x x x.] .......... Unit 2 number

Fact – Submenu
On time -[O t.x x x.] ..........
Indicates how many hours the equipment has been in operation with corona discharge.

The remaining parameters are all specific for matching or programs. Only authorised
Vetaphone personnel have access to change these parameters. If changed by
personnel without specific authorisation, can cause severe damage to the
equipment, and it will no longer be covered by warranty.

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Chapter 5
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 Station 5

THE OPEN TOU TREATER STATION

The basic contents of the treaterstation:

* - Easy film thread-up

* - Wide in/out film angle
* - Easy maintenance
* - Fast exchange of electrodes
* - Many standard electrode types

Design
The Open-station is a totally "open" station where the
electrode units are placed on top of the exposed backing
roller. The electrode units are pneumatically activated and
can be turned away giving a minimum 50 mm opening during
film thread-up.

The electrode units are kept in position by pneumatic. In case of web breaks, etc. it only takes a minimum
force to push the electrode-unit away. The pneumatical force can be adjusted, whereby the design is the
same, even if the station is mounted up-side down.

Electrode air gap adjustments are placed for each 400 mm, and can as an option be equipped with digital
readouts for precise adjustment and ensuring a uniform corona discharge. The station has inspection
windows and the statically and dynamically balanced backing roller is mounted on stainless steel shafts
with ball bearings sealed for life.

Ozone is very effectively extracted through the square electrode-unit. At the same time the airflow cools
the electrodes, thereby maintaining a very uniform corona discharge.

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Electrodes

The PF5-16 profile electrode is widely used for non-conductive substrates in widths up to 8 metres. It is
especially suitable for fast lines demanding high effect, and can take a loading of 6 kW/metre. The
electrode is a 5-16 finned anodised aluminium profile. The wide discharge area provides a long dwell- ti-
me giving high treatment levels. The special mounting of the electrode allows it to expand without
distorting when warm, ensuring uniform treatment of the film. As an optional extra, the electrode can be
mounted with a spring-loaded lock, which makes it quick and easy to change between different electrode
lengths.

The ceramic electrode is used for treatment of both electrically conductive (aluminium foil and metallised
film) and non-conductive substrates (PE, PP, etc.) in widths of 0.1 metre to 3 metres. Each individual
ceramic tube can take an a load of 1.25 kW/metre, and with a maximum of 4 tubes in one treater head,
the total output can be 5 kW/mtr.The electrodes consist of square section ceramic tubes, with metal inner
conductors. They are mounted in special insulators, and each tube can be changed individually, with
provision for expansion, ensuring uniform treatment of the film. Contrary to metallic electrodes a ceramic
electrode does not need a dielectric covering on the backing roll. This eliminates downtime in connection
with changing of defective sleeves or coverings.

Both the PF and the ceramic type are mechanically stable electrodes, mounted in pneumatically
actuated assemblies that automatically pivot away for splices and returns to its starting position again.
Digital readout for air gap adjustment is optional.

The DS, PF4 and PFL electrodes are widely used for low to medium/high capacity production lines. They
are made of anodised aluminium that gives a prolonged durability. Their location devices allow expansion
to take place without distortion, when getting warm, ensuring uniform treatment of the film. All 3 types of
electrodes are mounted in a spring-loaded attachment that automatically pivots away for splices and
returns to its starting position again. Digital readout of air gap adjustment is optional.

The PFL segmented electrode has the same features of the PF4 profile electrode, with the added
advantage that sections can be tilted away to provide pattern treatment in increments of 2.5, 5 or 10 mm.
The segments are locked in both their working position, and in their off position, making this the perfect
choice for frequent width and/or pattern changing. As an optional extra, equipment can be supplied for
fully automatic set-up of the pattern.

The DS electrode is a very flexible electrode that comes in widths up to 3 mtr. The 2 blades together can
accept loadings of 3 kW/mtr. The blades are easily exchanged for quick alteration of treatment width.
Pattern treatment is possible, as the blades are easy to cut in, leaving gaps in the treatment.

The PF4 electrode is a highly effective electrode that is used for applications where high power output is
needed. Working widths can be from 0.1 metre to 4 metres. The PF4 can take a load of 4 kW/metre,
which, combined with its wide discharge area, provides a long dwell-time giving high treatment levels.

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The electrode, including insulators, is easy to dismount. This is done for cleaning purposes, or if it is
necessary to use electrodes with a different width.
To dismount the electrodes first remove the front plate (A). Then loosen screw C (through hole D). The
complete set of insulators and electrode can now be removed.
The electrode is mounted again without need to readjust the digital air gap adjustments.

Quick-Change Electrode Cartridge

The new Open-Design Vetaphone treater stations can all be fitted with the new unique Corona Quick
Change Electrodes.

The complete Corona electrode is mounted in a specially designed pull-out/push-in cartridge, enabling
quick and extremely easy cleaning or changing of the complete set of electrodes, in a matter of seconds,
without the use of tools, and ensuring minimal downtime and increases productivity.

Automatic power disconnection and reconnection is incorporated in the design, as is electrode realign-
ment and air gap-settings.

There is an added bonus where pattern treatment is used, as electrode set-up can take place quickly and
easily when the cartridge is out of the station.

The electrode cartridge is available with segment-, profile and ceramic electrodes.

The innovative Quick Change (QC) electrode cartridge is aimed at film lines with widths
from 100 mm to up to 2500 mm. Powerful simplicity brought to the Open Corona Plus stations.

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Alignment
It is possible to adjust the angle of the electrode in proportion to the roll, so that the complete electrode fits
the correct angle, ensuring a uniform and maximum corona treatment.

WRONG CORRECT WRONG

Option
As an option the station can be delivered with digital electrode adjusters. These make it easy to adjust an
exact air gap between electrode and roll surface.

Pneumatic
The electrode unit is typically opened/closed manually with a pneumatic valve placed on the operation-
side of the station.

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Connection
All connections to an open station (ozone extraction, power, etc.) are all made at the same side. At which
side A or B, the connections are to be placed (in proportion to film direction) must be defined by the
customer. Please remember that the electrode unit can turn away for splits in the film direction.
The station is equipped with control- and safety switches. In case the electrode units are opened, the
ozone extraction stops, a signal is given to the connected generator, and the power to the electrodes is
cut immediately.

Pressurised
The open station can also be delivered in an encapsulated version for use in hazardous areas. The
additional side plates can be opened, so the station is still easy to operate and clean even under these
special conditions.

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 Station 5

Inductive sensor
The inductive sensor (proximity switch) is used for rotation control of the backing roll, and is as such a
safety device that will stop the corona discharge in case the roll stops rotating, or the rotation speed drops
below a pre-set minimum speed limit. This to prevent damage to film and roll covering due to overheat.

If the roll has been removed from the station it is necessary to adjust the inductive sensor after mounting
the roll again. If the roll-body, for any reason, should ever be moved side wards on the shaft away from
the sensor it will also be necessary to re-position the inductive sensor. If not adjusted, the sensor will not
be able to detect the sensor-holes on the roll and the generator will stop.

The distance between sensor-head and sensor-holes must be adjusted to be approx. 1 mm.

PLEASE NOTE: The sensitivity of the sensor CAN NOT be checked by the use of an Ohmmeter!

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How to exchange VP 207 silicone sleeve

1) Dismount the roll from the station and remove the worn out silicone sleeve. This is easily done by
cutting up the sleeve with a knife. Avoid scratching the roll with the knife.

2) Clean the roll surface thoroughly and check that there are no metal burrs that can damage the
new sleeve. The surface must be smooth and even so that air bubbles underneath the sleeve are
avoided.

3) IMPORTANT ! To make sure the new silicone sleeve fit tight to the roll the sleeve has a smaller
diameter than the roll. When mounted the sleeve expands in diameter, thereby contracting the
sleeve in the longitudinal direction. For that reason the new piece of sleeve has to be cut 50-
100 mm longer than the roll width.

4) Powder the inner side of the sleeve with a little talcum powder and it is now ready to be mounted
on the roll. The silicone sleeve is pulled manually by hand onto the roll while blowing compressed
air in between sleeve and roll surface (see fig. 1).

5) IMPORTANT ! After mounting the sleeve all air bubbles trapped underneath it have to be
removed. In case of air bubbles a corona is created on both sides of the sleeve, which quickly
leads to pinholes in the sleeve.
The air bubbles are removed by pulling a tight rubber ring (O-ring) slowly over the roll a
couple of times (see fig. 2). The O-ring is included in the shipment with silicone sleeve from
Vetaphone.

6) PLEASE NOTE! Do not lay the roll with the new covering on the ground or on a workbench as
swarf and dirt might damage the soft silicone thereby enhancing the chances of pinholes and
electrical flashover.
Before the roll is mounted again the new sleeve has to be cleaned with spirit/alcohol. Avoid
damaging the silicone with tools or sharp instruments.
It is preferable to leave the surplus sleeve at the roll ends as this will help the sleeve get a tighter
grip to the roll, and make it less possible for it to travel sideward under pressure.

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 Station 5

THE TOW3 TREATER STATION

The basic contents of the treaterstation:

* - Easy film thread-up

* - Easy maintenance
* - Fast exchange of electrodes

Design
To meet the increasing demands for up-to-date film extrusion machinery, Vetaphone has introduced a
new series of new corona treaters for blown-film extrusion lines.

The new TOW3 type treater stations are 30% cheaper than the excisting TOW8 stations. The major
differance compared to the TOW8 model is the choise of electrodes. We can only deliver the TOW3 type
with (S) Single snap-in + (DS) Double snap-in and (PLF) segmented electrodes. The reason for this is
that the treater station is very compact in size, and therefore it's impossible to fit in larger electode types.
Ozone is, due to the new design, extracted evenly along the whole electrode. Besides providing effective
ozone removal, this also ensures efficient cooling of the backing rollers and extended lifetime on roller
covering. Safety requirements are met by safety switches that disconnect the power when the electrodes
pneumatically open.Maximum treatment length is 1800mm

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The DS, PF4 and PFL electrodes are widely used for low to medium/high capacity production lines. They
are made of anodised aluminium that gives a prolonged durability. Their location devices allow expansion
to take place without distortion, when getting warm, ensuring uniform treatment of the film. All 3 types of
electrodes are mounted in a spring-loaded attachment that automatically pivots away for splices and
returns to its starting position again.

The PFL segmented electrode has the same features of the PF4 profile electrode, with the added
advantage that sections can be tilted away to provide pattern treatment in increments of 2.5, 5 or 10 mm.
The segments are locked in both their working position, and in their off position, making this the perfect
choice for frequent width and/or pattern changing. As an optional extra, equipment can be supplied for
fully automatic set-up of the pattern.

The DS electrode is a very flexible electrode that comes in widths up to 3 mtr. The 2 blades together can
accept loadings of 3 kW/mtr. The blades are easily exchanged for quick alteration of treatment width.
Pattern treatment is possible, as the blades are easy to cut in, leaving gaps in the treatment.

The PF4 electrode is a highly effective electrode that is used for applications where high power output is
needed. Working widths can be from 0.1 metre to 4 metres. The PF4 can take a load of 4 kW/metre,
which, combined with its wide discharge area, provides a long dwell-time giving high treatment levels.

Pneumatic
The station is opened/closed manually with a pneumatic valve placed on the operation-side of the station.

Connection
All connections to the station (ozone extraction, power, etc.) are all made at the same side. At which side
A or B, the connections are to be placed (in proportion to film direction) must be defined by the customer.
The station is equipped with control- and safety switches. In case the station is opened a signal is given to
the connected generator, and the power to the electrodes is cut immediately.

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 Station 5

Pressurised
The station can also be delivered in an encapsulated version for use in hazardous areas. The additional
side plates can be opened, so the station is still easy to operate and clean even under these special
conditions.

Inductive sensor
The inductive sensor (proximity switch) is used for rotation control of the backing roll, and is as such a
safety device that will stop the corona discharge in case the roll stops rotating, or the rotation speed drops
below a pre-set minimum speed limit. This to prevent damage to film and roll covering due to overheat.

If the roll has been removed from the station it is necessary to adjust the inductive sensor after mounting
the roll again. If the roll-body, for any reason, should ever be moved sidewards on the shaft away from the
sensor it will also be necessary to re-position the inductive sensor. If not adjusted, the sensor will not be
able to detect the sensor-nuts on the roll and the generator will stop.

The distance between sensor-head and sensor-nuts must be adjusted to be approx. 1 mm.

PLEASE NOTE: The sensitivity of the sensor CAN NOT be checked by the use of an Ohm-meter!

1) Roll-body
2) Ballbearing holder
3) Shaft
4) End-disk with sensor-nuts
5) Sideplate of treaterstation
6) Inductive sensor with holder

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 Station 5

How to exchange VP 207 silicone sleeve

1) Dismount the roll from the station and remove the worn out silicone sleeve. This is done by cutting
up the sleeve with a knife. Avoid scratching the roll with the knife.

2) Clean the roll surface thoroughly and check that there are no metal burrs that can damage the
new sleeve. The surface must be smooth and even so that air bubbles underneath the sleeve are
avoided.

3) IMPORTANT ! To make sure the new silicone sleeve fit tight to the roll the sleeve has a smaller
diameter than the roll. When mounted the sleeve expands in diameter, thereby contracting the
sleeve in the longitudinal direction. For that reason the new piece of sleeve has to be cut 50-
100 mm longer than the roll width.

4) Powder the inner side of the sleeve with a little talcum powder and it is now ready to be mounted
on the roll. The silicone sleeve is pulled manually by hand onto the roll while blowing compressed
air in between sleeve and roll surface (see fig. 1).

5) IMPORTANT ! After mounting the sleeve all air bubbles trapped underneath it have to be
removed. In case of air bubbles a corona is created on both sides of the sleeve, which quickly
leads to pinholes in the sleeve.
The air bubbles are removed by pulling a tight rubber ring (O-ring) slowly over the roll a
couple of times (see fig. 2). The O-ring is included in the shipment with silicone sleeve from
Vetaphone.

6) PLEASE NOTE! Do not lay the roll with the new covering on the ground or on a workbench as
swarf and dirt might damage the soft silicone thereby enhancing the chances of pinholes and
electrical flashover.
Before the roll is mounted again the new sleeve has to be cleaned with spirit/alcohol. Avoid
damaging the silicone with tools or sharp instruments.
It is preferable to leave the surplus sleeve at the roll ends as this will help the sleeve get a tighter
grip to the roll, and make it less possible for it to travel sideward under pressure.

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 Station 5

THE TOU TREATER STATION FOR NARROW WEB

Vetaphone has, especially for narrow web applications, and for the label industry, developed a range of
small and solid compact treater stations, with a quick changeable electrode cartridge for easy film thread-
up and maintenance. The stations can handle up to 4000 watts, which is sufficient to treat almost any type
of substrate, and sizes have been kept to a minimum, ensuring mounting directly in-line in an appropriate
position on narrow web presses.

The stations are equipped with ceramic electrodes for

treatment of both electrically conductive substrates
(i.e. metallised film) and non-conductive film (PP,
PE, etc.).

Vetaphone have added a very user-friendly quick

changeable electrode system, making maintenance
and cleaning a very easy task. The ceramic
electrode system can be upgraded from four (C4) to
six (C6) highly efficient ceramic electrodes if
treatment of difficult materials is required.

The units can be supplied with ozone extraction

from the back (through the mounting plate) of the
station, or from the top.

Besides removing the ozone the extraction also has

a cooling effect on the ceramic electrodes, giving
them prolonged durability.

All parts utilized in the stations are made from cor-

rosion and ozone-proof materials.

Features:
* No tools required for maintenance
* Specially designed pull-out / push-in cartridge
* Offline maintenance in a matter of seconds
* Ceramic high power electrodes
* Rotating accuracy = 0,02 mm
* Stainless steel roller
* Low friction = 2.2 Nmm/m
* Parallelism of rollers = 0.02 mm
* Standard length of 280mm, 420mm & 560mm
* Double or single sided
* Upgradeable ceramic electrode system for treatment of difficult materials

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 Station 5

Connection narrow web

All connections to a narrow web station (ozone extraction, power, etc.) are exchangeable from either top
or side.
The station is equipped with control- and safety switches. In case the electrode cassette is opened,a
signal is given to the connected generator, and the power to the electrodes is cut immediately.

Pressurised
The station can also be delivered in an encapsulated version for use in hazardous areas. The additional
side plates can be opened, so the station is still easy to operate and clean even under these special
conditions.

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 Ozone extraction 6

Chapter 6

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 Ozone extraction 6

WHAT IS OZONE

OZONE
Ozone is a gas that is formed during the process of corona discharge, and plays an important role in the
chemical and molecular changes that take place in the surface of the plastic.

Ozone is hazardous to health and has an unpleasant smell, even at relatively low levels. The average
human can smell ozone at 0.01 ppm. and the threshold of safety of the gas in the area occupied by
personnel is 0.1 ppm. All of VETAPHONE's equipment is therefore designed to remove ozone effectively
from the treater station by means of an ozone resistant fan, and a specially designed exhaust system.

An option ducting the ozone through the roof to atmosphere is to use an ozone eliminator instead. This is
a freestanding, catalytic filter system that accelerates the decomposition ozone, eliminating it completely.

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 Maintenance 7

Chapter 7

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 Maintenance 7

LUBRICATION AND CLEANING

IMPORTANT ! Before maintenance work always turn off the power.

Daily maintenance
STATION (only if fitted with ceramic electrodes)
Before start-up it has to be checked that the ceramic electrode-bars and electrode-holders (insulators) are
clean and free of grease and dirt. Cleaning of the electrodes should be given special attention, especially
the cleaning between the ceramic bars. An accumulation of dirt will prevent an effective cooling of the
bars, resulting in overheating, which again causes the ceramic surface to crack. This leads to machine
stop, and the defective ceramic bars will have to be replaced before production can start again.
Electrodes covered with dirt will result in an uneven corona treatment of the film.
It is very important to keep bars and insulators clean. Cleaning can be done with spirits/alcohol.

Monthly maintenance
STATION
For the maintenance of the station it is important that it is cleaned thoroughly once a month. When an
insulator or other parts applied to high voltage is covered with dirt, there is a big risk of an electrical flash-
over in the station, which results in a break down. It will eventually be necessary to exchange the insulator
after a flash-over has occurred.

Once every 3 months, or after 500 hours of operating

GENERATOR
If the generator is dirty on the inside use compressed air (very gently) and a vacuum cleaner to clean the
electric parts (avoid physical contact with the components).

AIR FILTER
Remove the air-cleaning filter from the generator. The filter is placed in the air inlet device - there is no
filter at the air outlet. Inspect the surface of the filter. If it is very dirty, it has to be replaced, but if only
moderately dusty it may be cleaned by blowing compressed air from the back (blue) side of the filter. Also
use compressed air to remove any dust from where the filter is seated. After cleaning reinstall the filter
with the white side outwards and the blue side inwards. If filter or holder is damaged call Vetaphone sales
department for replacement parts.
Do not start the generator with the air filter removed.

CABLES
Check that all cables and cable fixing points are without any damages. If damaged it is important to fix
them or replace the damaged parts.
IMPORTANT! A damaged cable is dangerous and can cause an electric shock.

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 Maintenance 7

Once a year, or after 2000 hours of operation

GENERATOR
Lubricate the door hinge and the locking system with a drop of oil.

STATION (general instructions)

Lubrication of ball bearings in the rollers is not necessary (only closed bearings). The bearings in backing
roller and guide rollers are closed bearings sealed for life and they will operate for many years with no
need for lubrication.
If the station is dirty use compressed air and a vacuumcleaner to clean off all loose particles. Do not blow
compressed air directly on any electrical or pneumatic parts.
If further cleaning is necessary use water with a low pH detergent for the metal parts of the station. Wipe it
dry with soft towels or soft paper.

OPEN STATION
The bearings in the electrode unit are made of a special bearing material for heavy duty operation and will
operate for years without lubrication.

ENCLOSED STATION
If the glide shafts are dirty they have to be cleaned with oil on a soft towel. At the same time the linear ball
bearings have to be lubricated with a lithium grease type KP2P-35 DIN51825 or equivalent.
The windows in the station are made of acrylic or glass and can be cleaned with water with a normal
detergent for dishwashing without any alcohol or ammonium chloride. Do not use alcohol, gasoline or any
strong solvent to clean the windows, as this will damage the material.

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 Mechanical trouble shooting 8

Chapter 8

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 Mechanical trouble shooting 8

CHECKLIST

STATION :

5) Is the electrode air gap distance set correct?

Check distance is max. 2.0mm between electrode and roll face.

2) Is the electrode completely straight? Check air gap / alignment along the whole electrode.

3) Is the HP-cable(s) mounted correctly?

4) Is the EARTH-cable connected? (between station and HP-transformer and generator)

5) Is the STATION cable connected? (If included. See Diagram 1)

6) Is the MICROSWITCH cable connected? (If included. See Diagram 1)

7) Is the ROTATION cable connected? (If included. See Diagram 1)

GENERATOR :

1) Is the HP-transformer filled with oil?

2) Is the HP-cable(s) mounted correctly?

3) Is the HA-cable connected?

4) Is the MULTI cable mounted correctly to terminal -X10 ?

5) Is the STATION cable connected? (If included. See Diagram 1)

6) Is the MICROSWITCH cable connected? (If included. See Diagram 1)

7) Is the ROTATION cable connected? (If included. See Diagram 1)

8) Does the mains supply carry the correct voltage?

FAN:

1) Check visually that the external fan is rotating the correct way according to the RED arrow on
the fan (Swap two of the phases if not).

The Corona equipment is now ready for use. Please refer to ‘General instruction for use’ in chapter

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 Electrical trouble shooting 9

Chapter 9

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 Electrical trouble shooting 9

SERVICE / TROUBLE SHOOTING

Control panel error messages AFTER start up

DISPLAY Red LED's MESSAGE

High temperature in Power Unit

Check that the internal cooling fans operate
correctly, and that they are not blocked with
dirt.
Check for high ambient temperature
Check for easy airflow around the generator.

Generator Overload
Too high output current from the generator.
Electrode adjusted too close to roller.
Too long electrodes. Overload can also be
caused by a flashover in the treater station,
clean insulators and electrode.

No HF-feedback
Flash over at low power, clean electrode and
insulators, 80% of E-3 errors are caused by
this.
The airgap distance between electrode and
backingroll in the treaterstation can be too
big.
Check for flashover at the electrode (defec-
tive HP-cable) or missing ground cable.
The electrode width in the station can be too
small (especially when using adjustable
segmented electrodes).

Station is open
Close the station and make sure that all
doors/windows on the station are closed.
Check that all micro switches at the
doors/windows are connected and working.
Check station cable.

Flashover in station
Check for pinholes in the roll-covering,
burned insulators or defective HP-cable.
At high humidity the insulators must be dried
and cleaned before start up.
Check ground cable.

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 Electrical trouble shooting 9

No air flow
Check that the extraction fan works and that
there is airflow through the station.
If the generator controls the extraction fan,
the generator will flash "stand by" in the ON-
button until the airflow is correct. When the
problem is solved the generator automatically
starts up again.
Check rotation of the fan.

Roller not rotating

The minimum speed is lower than set in
parameter [r -._ x x.].
Check the rotation sensor.
The rotation sensor is not in correct position
at the roll-end (max. 1mm), or it is defective.
In connection with exchange of roll-covering
the roll can have been turned around, so that
the roll-end with the metal knobs is not
placed in the same side as the rotation
sensor.

DC-link charge-up error.

Charge-up of the internal DC-link capacitors
was not successful.
Short circuit in Power Unit.

Mains power error.

Mains power was removed while the
generator was ON.The power supply
charge-up error (E-10) has

Power supply charge-up repeat error.

The power supply charge-up error (E-10) has
occurred more than 3 times in a row. Before
it is possible to reset the error, remove mains
power and power on again.

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 Electrical trouble shooting 9

Control panel error messages AFTER start up (... continued)

Saturation error.
Internal error in driver circuit or output
stage.

Driver error.
Internal error in driver circuit.

Power supply error.

Error in the internal power supply.

Mains overload error.

Mains input current was too high, causing
automatic shutdown of the power rectifier.
Can be caused by heavy surges and
transients on mains input or dropouts in
mains supply.
Wait minimum 10 seconds before restarting.

Mains tolerance error.

Mains input voltage is or was out of
tolerance.

Communication error.
Errors belonging to the group from E-80 to
E- 89 indicate a communication error. The
second digit (0 to 9) denotes the unit
causing the error. This unit can either be an
external device connected to -X11
(remote control etc.) or it can be the I/O-
Module (Profibus etc.) placed inside the
generator enclosure. Unit 0 (E-80) is
always the controller in the CP-0
generator, whereas the numbers of the
remaining units are as set up in the UnIt sub-
menu.

Display readings mode for electrical information.

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 Electrical trouble shooting 9

ENTERING READINGS MODE

Hold down the buttons for 5 seconds.

The display now shows DISP:

In this menu use the arrow buttons to toggle between the following readings:
[S.XXX.X] The measured line speed in mtr/min.
[A.XXX.X] The PA current in ampere
[U.-XXX.] The PA voltage in volt
[XXXXX] The calculated power in watt
[t.--XX] Timing parameter
[P.--XX] Pulse width parameter
[F.-XX.X] Frequency in KHz

LEAVING READINGS MODE

Press the buttons and you return to standard display mode again.

If no button is pressed for 10 minutes the display automatically returns to standard display mode.

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 Optional equipment 10

Chapter 10

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 Optional equipment 10

OPTIONAL EQUIPMENT

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