ELTEX R50 Series Operating Instructions Manual

for AC Operation BA-en-2016-2006 F00015y

3 List of contents 1 Outline of appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.2 Identification of risks and hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.3 Work and operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.4 Contact protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.5 Inspection of the protective resistors - contact protection . . . . . . . . 10 2.6 Technical advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3 Installation and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3.1 Assembling the discharging bar . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3.2 Length of the high voltage cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.3 Adjust the angle coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.4 Connecting the high voltage cable to the R51A discharging bar . . 16 4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4.1 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4.2 Function control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 6 Trouble-shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 7 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 8 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 9 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 10 Spare parts and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Dear customer, The new Series R50 and R51A discharging bars are designed for the active discharging of disruptive static charges which develop in production processes. The bars are operated with an alternating voltage of 5 kV to max. 8 kV at 50…60 Hz and are designed for discharging moving sur- faces. Due to differences in the surface charge profiles on different materials, charges with both polarities are provided by the discharging bars. The corona section with its optimized geometrical configuration ensures ulti- mate discharging efficiency. The advantages of the R50 / R51A discharging bars: • ultimate discharging range and hence enhanced depth effect • high active discharging power through patented, isolated ground conductors • high safety standards through passive discharging power with deacti- vated power supplies • safety through function and malfunction monitoring • continuous assembly slotting guarantees flexible installation • no health hazards in case of electric shocks when touching individual tips (≤ 10 tips) The optimum discharging effect is guaranteed in conjunction with the Eltex high voltage power supplies. Please read the operating instructions carefully before operating the unit. This will help you prevent personal injuries and damage to property. Please give us a call if you have any suggestions, proposals or ideas for improvements. We greatly appreciate the feedback from the users of our appliances.

5 1. Outline of appliance * for R51A: 40 mm EL = installation length AL = active length GL = total length Z00062y 32 X 16 R60 31,5 AL EL 95 GL X 35* 35* 19 Ø17 Ø10 30 ca. 50 34 Fig. 1: Overview of the R50 / R51A discharging bar Z00004y 0...360° (max. 1 turn)

Design variants R50 discharging bar • fixed connection of the high voltage cable • high voltage cable leads out from the bar in axial or radial direction • radial connection rotatable by 360° and locked in the desired position by means of a lock nut • maximum active length = 5910 mm • grid width 15 mm R51A discharging bar • detachable connection of the high voltage cable • high voltage cable leads out from the bar in axial direction • maximum active length = 5910 mm • grid width 15 mm • design variant with two axial connections for serial interconnection of several discharging bars

7 2. Safety The units have been designed, built and tested using state-of-the-art engi- neering, and have left the factory in a technically and operationally safe condition. If used improperly, the units may nevertheless be hazardous to personnel and may cause injury or damage. Read the operating instruc- tions carefully and observe the safety instructions. 2.1 Proper Use The Series R50 / R51A discharging bars must be used only for dischar- ging static charges from material surfaces. Other uses are not permitted. The discharging bars must be operated only together with the dedicated Eltex power supplies. These power supplies guarantee the optimum adap- tation to the required operational data for the different active bar lengths. Safe operation of the bars is ensured only by using the Eltex power sup- plies. Other uses are not permitted. The manufacturers will not assume any lia- bility and warranty if the units are used improperly or used outside the intended purpose. Modifications or changes made to the devices are not permitted. Use only original Eltex spare parts and equipment. 2.2 Identification of risks and hazards Possible risks and hazards resulting from the use of the units are referred to in these operating instructions by the following symbols: Warning! This symbol appearing in the operating instructions refers to operations which, if carried out improperly, may result in serious personal injuries. Caution! This symbol appearing in the operating instructions refers to operations which, if carried out improperly, may result in damage to property.

2.3 Work and operational safety Warning! Carefully observe the following notes and the complete chapter 2 "Safety”, page 7! • Before carrying out repairs, cleaning or maintenance work and before resetting after malfunctions, switch off the power supply and disconnect the mains supply voltage (see chapter 5 "Maintenance”, page 20, chap- ter 6 "Trouble-shooting”, page 21). • Before carrying out any work involving the units, the machine which has the units fitted must not be in operation (see chapter 5 "Maintenance”, page 20, chapter 6 "Trouble-shooting”, page 21). • Any work involving the units must be carried out by qualified electri- cians (see chapter 5 "Maintenance”, page 20, chapter 6 "Trouble- shooting”, page 21). • The bars passively absorb energy from the moving substrate web. The high voltage cable must be plugged in or grounded to the power supply. If the high voltage cable is disconnected, the plug is live (high voltage) and applies with full power on the plug; this may cause a spark dis- charge and may lead to a risk of injury. Disconnected high voltage plugs are not permitted or have to be grounded (see chapter 5 "Mainte- nance”, page 20). • When connecting the high voltage cables to the power supply unit resp. the high voltage distributors, the machine which has the discharging bars fitted must be switched off and also the supply voltage to the power supply must be disconnected (see chapter 3.4 "Connecting the high voltage cable to the R51A discharging bar”, page 16, chapter 5 "Maintenance”, page 20, chapter 6 "Trouble-shooting”, page 21). • The bar must be mounted such that mechanical damage to the bar tips is ruled out (see chapter 3.1 "Assembling the discharging bar”, page 11). • To attach the cables, use only sliding nuts and bolts made of plastic (see chapter 3.1 "Assembling the discharging bar”, page 11). • When routing the cable, select the attachment points such that mechanical damage to the cable (e.g. chafing against rotating machine parts) is ruled out (see chapter 3.1 "Assembling the discharging bar”, page 11). • In applications involving moving bars (e.g. film draw strips), the high voltage cable must be attached such that there is no cable movement near the connection zone of the power supply unit (see chapter 3.1 "Assembling the discharging bar”, page 11). • Switch off the bar when working with metal film or metal composites (see chapter 3.1 "Assembling the discharging bar”, page 11).

9 • In bilateral discharging, the bars must not be mounted in opposition to each other (see chapter 3.1 "Assembling the discharging bar”, page 11). • Both the lengths of the high voltage cable and of the active bars are limited, observe maximum lengths (see chapter 3.2 "Length of the high voltage cable”, page 15). • The maximum permissible angle of turn of the angle coupling is 360° (see chapter 3.3 "Adjust the angle coupling”, page 15). • The shielded high voltage cable of the R51A discharging bar is de- tachable at the bar. Connect or disconnect the high voltage cable only with the power supply switched off (see chapter 3.4 "Connecting the high voltage cable to the R51A discharging bar”, page 16). • Check the units and the high voltage cables at regular intervals and before startup for any damage. Any damaged components must be repaired professionally or replaced before continuing to operate the unit, or the units must be disabled. • Make sure that the units are clean at all times. Dirt results in malfunctions and in premature wear of the units. • Do not touch the emission tips - risk of injury. Reflex responses to electrical irritation may increase the risk of secon- dery accidents, especially in the vicinity of unguarded rotating assem- blies. The charging bar as such is safe to touch. If contact is made (single touch, ≤ 10 tips), the energy transferred is so low that there is no risk of injury (see chapter 5 "Maintenance”, page 20, chapter 6 "Trou- ble-shooting”, page 21). • Potential risk for wearers of cardiac pacemakers: Moving the chest closer than 3.5 cm to the emission tips of the discharging bars or making surface contact with several emission tips (touching a single tip is not critical) can result in a temporary switchover of the cardiac pacemaker into the fault mode. Permanent proximity or contact can therefore cause severe problems. If it is likely that the chest of such a person comes closer than 3.5 cm to the emission tips of the discharging bar, or if several emission tips are touched at the same time, the appropriate warning notices must be dis- played. • The operation of the bars can generate ozone. The ozone concentra- tion levels developing near the bars depend on many different factors such as site of installation, bar current and voltage, air circulation, etc. and can therefore not be specified in general terms. If the maximum allowable concentration of ozone must be observed at the site of installation of the bar, the concentration must be measured on site.

The AGW value (maximum admissible concentration) serves to assess the ozone concentration at the workplace. The user must make sure that the appropriate national AGW value is at no times exceeded, e.g. in Germany the ozone concentration occurring during the operation of the system must not exceed the recommended value based on interna- tional limits of 0.06 ml/m³ (0.12 mg/m³). • Mechanical or electrical modifications of the discharging bars are not permitted. Shortening the shielded high voltage cable on the connecting side of the power supply is permitted. Extending the cable is permitted only when using the Eltex distributor as well as original high voltage cables and glands. 2.4 Contact protection The site of installation and/or use of the units is outside the control of Eltex, contact protection against inadvertent contact of the bars and of live com- ponents by personnel as specified by the employer’s liability insurance association may have to be provided (e.g. DGUV V3 in Germany). Contact protection devices made of conductive material must be grounded. 2.5 Inspection of the protective resistors - contact protection The function and the appearance of the protective resistors must be inspected at regular intervals. The inspection intervals are specified in the accident prevention regulations, as amended (e.g. in Germany DGUV V3). The function of the series resistors must be checked using a suitable measuring device. The test voltage must be 1,000V. The measured resis- tance between the high-voltage connection and the individual emission tip must not fall below 120 MOhm and not exceed 180 MOhm. 2.6 Technical advance The manufacturer reserves the right to make changes to the technical specifications without prior notice in order to adapt the units to state-of-the- art engineering. Eltex will provide the latest information on any changes or modifications in the operating instructions on request.

11 3. Installation and assembly 3.1 Assembling the discharging bar Attach the Series R50 / R51A discharging bars to the machine wall, using flame-retardant GRP assembly material. For easier installation we recom- mend using the assembly material offered by Eltex. Fig. 2 shows the installation principle. The profiled assembly section of the discharging bar is grooved. The sli- ding nuts pushed into this groove serve as bolt attachments for the GRP material, allowing the discharging bars to be installed. Max. bolt depth 6.5 mm Torque 0.4 Nm Secure bolts (e.g. Loctite 243) Caution! Use only sliding nuts and bolts made of plastic! below 1 meter total length: 2 per bar below 2 meters total length: 3 per bar below 3 meters total length: 4 per bar below 4 meters total length: 5 per bar below 5 meters total length: 6 per bar below 6 meters total length: 7 per bar An optional alternative is attaching the bars using a GRP round rod. Fig. 4 shows an assembly example. The bar is attached to the GRP round rod via plastic holders plugged into the installation groove. Longer bars require an additional angle bracket bolted to the GRP rod to prevent the bar from sagging. Fig. 2: Assembling the discharging bar Z00335y 7 7 15 15 5 40 M5 (3x) ~50 30

Plastic holders below 1 meter total length: 3 per bar below 2 meters total length: 5 per bar below 3 meters total length: 7 per bar below 4 meters total length: 9 per bar below 5 meters total length: 11 per bar below 6 meters total length: 13 per bar 1 bar 2 GRP rod 3 plastic holder 4 machine wall 5 high voltage cable with flexible tube Fig. 3: Assembly example R50 with GRP rod and steel brackets for attachment to the machine wall Z00121y 2 1 4 5 Fig. 4: Assembly R50 with GRP round rod Z00334y 4 3 2 1 3 5 >200

13 Warning ! For safety in operation, please note the following: • The bar must be mounted such that mechanical damage to the bar tips is ruled out. • When routing the cable, select the attachment points such that mechanical damage to the cable (e.g. chafing against rotating machine parts) is ruled out. • To attach the cables, use only sliding nuts and bolts made of plastic. • In applications involving moving bars (e.g. film draw strips), the high voltage cable must be attached such that there is no cable movement near the connection zone of the power supply unit. • Switch off the bar when working with metal film or metal composites!

Locating the discharging bar The best possible discharging results are achieved if the bar is located in areas with minimum web capacities. In practical terms this means placing the bar with maximum distances from the machine environment, i.e. no discharging against the idler roller. A rough guideline: A space with the radius R of the bar distance to the web ought to be kept free of any conductive material (Fig. 5). The distance of the emission points to the conductive, earthed printing press area should be greater than to the substrate to be discharged. Depending on application, the distance between discharging bar and sub- strate ought to be 30...100 mm. In bilateral discharging, the bars must not be mounted in opposition to each other. The distance between both bars should be greater than twice the bar distance from the web. Fig. 5: Zone free of con- ductive material with the dimen- sions R Z00076y R >2R R R

15 3.2 Length of the high voltage cable The total length of discharging bar and high voltage cable is limited due to the loading capacity of the transformer in the power supply. The maximum loading capacity is a function of the active bar length and the length of the high voltage cables. Fig. 6 demonstrates this principle for the ES51 power supply. 3.3 Adjust the angle coupling If the bar has a angle coupling, then it is aligned towards the tips during ex factory delivery. 1 lock nut 2 angle coupling To turn the angle connection, proceed as follows: • loosen the lock nut • align the angle coupling in its desired position • re-tighten the lock nut The maximum permissible angle of turn of the angle coupling is 360°. Fig. 6: Loading capacity of the ES51 power supply as factor of active bar length and total length of the high voltage cable Z00041e Σ lengths of h.v. cable [m] Σ lengths of active bars [m] 15 10 5 10 20 30 40 50 permissible range Fig. 7: Angle coupling Z00065y 1 2 0...360° (max. 1 turn)

3.4 Connecting the high voltage cable to the R51A discharging bar The shielded high voltage cable of the R51A discharging bar is detachable at the bar. Warning! Connect or disconnect the high voltage cable only with the power supply switched off. Connection: Note! The cable must be clean. If necessary, clean the cable before connecting with benzine. Allow the solvent to dry off before connecting. • Remove the blanking plug from the screw connection. • Insert the high voltage cable together with the flexible tube as far as possible into the connection socket and secure the adapter with the U-shaped clip. Cables without adapter carry a coloured marking on the flexible tubing. This marking must lie flush with the outside edge of the coupling. Assembly: If the plug connection has not been prefabricated for connection, prepare the high voltage cable as follows. This will ensure proper ground contact and hence the proper function of the discharging bar without the risk of electric shocks. Fig. 8: Connecting the high voltage cable to the R51A dis- charging bar Z000004y

17 • Strip the high voltage cable as shown in Fig. 9. 1 shielded braid turned back 2 high voltage cable • Push the multidisc plug (4) over the stripped core (3) as shown in Fig. 10 and solder the plug at the tip (8). The projecting length of wire must be cut off. • Push the adapter (6) over the cable and the flexible tubing (1) and fix it in place with the clip (5). • The flexible tubing must be pulled back for the next steps. • Push the contact sleeve (7) over the folded back braiding (2) and crimp the sleeve using a hexagonal crimper (5.41 mm). • The collar of the contact sleeve (7) must lie flush with the adapter (6). • Now connect the cable as described in the above instructions. The shielded high voltage cable of the R50 discharging bar is encapsu- lated in the bar and therefore not replaceable/ detachable. For the connection to power supplies, refer to the separate operating instructions for the power supply. Fig. 9: Stripping the high voltage cable Z00005y 45,5 12,2 10,5 8 1 2 +0,5 0 Fig. 10: Prefabricating the high voltage cable Z00006y 8 1 2 3 4 5 6 7 1 5 7 6 35,5 +0,5 0

Disassembly: Remove the safety clip in the cable gland using a screwdriver. Pull off the high voltage cable. To protect from dirt, close the screw connection with the blanking plug.

19 4. Operation The discharging bars must be operated only in connection with the Eltex power supplies with 5 kV to max. 8 kV AC output. These power supplies guarantee the optimum adaptation to the specified operating conditions. 4.1 Startup Once all the connections have been correctly made, the system is opera- tional and the supply voltage can be switched on at the power supply. 4.2 Function control Use the Eltex Volt Stick or a glow-lamp voltage tester to check the proper function of the emission tips. Quote Article No. 109136 when ordering the Volt Stick from Eltex.

5. Maintenance Warning! Electric shock hazard! • Do not carry out any maintenance or repair work without first switching off the power supply and disconnecting the supply voltage. • The machine which has the units fitted must not be in operation. • The bars passively absorb energy from the moving substrate web. The high voltage cable must be plugged in or grounded to the power supply. If the high voltage cable is disconnected, the plug is live (high voltage) and applies with full power on the plug; this may cause a spark dis- charge and may lead to a risk of injury. Disconnected high voltage plugs are not permitted or have to be grounded. • Repairs and maintenance work must be carried out by qualified electri- cians only. To ensure the trouble-free function of the discharging bars, clean the bars at least once a week with compressed air free of oil and water (max. 6 bar and standard compressed air pistol) and a brush with soft plastic bristles. Clean grease, ink, glue, paper dust, etc. off the discharging bar using a suitable solvent (benzine). Do not soak the bars and the high voltage cable in solvent! Caution! Do not damage the emission tips when cleaning. Brush only in longitudinal direction. Warning! Risk of deflagration! Allow the solvent to evaporate completely before restarting the unit. Inspection of the protective resistors - contact protection The function and the appearance of the protective resistors must be inspected at regular intervals. The inspection intervals are specified in the accident prevention regulations, as amended (e.g. in Germany DGUV V3). The function of the series resistors must be checked using a suitable measuring device. The test voltage must be 1,000V. The measured resis- tance between the high-voltage connection and the individual emission tip must not fall below 120 MOhm and not exceed 180 MOhm.

21 6. Trouble-shooting Warning! Electric shock hazard! • Do not carry out any maintenance or repair work without first switching off the power supply and disconnecting the supply voltage. • The machine which has the units fitted must not be in operation. • Repairs and maintenance work must be carried out by qualified electri- cians only. Malfunction: Effectiveness of the application declining. Cause: Dirty discharging bars. Measure: Clean bar with compressed air and a brush. Clean grease, ink, oil, etc. off the bar with a suitable solvent (benzine). For further malfunctions, refer to the operating instructions for the power supplies. Caution! Do not leave the discharging bar to soak in the solvent! Warning! Risk of deflagration! Allow the solvent to evaporate completely before restarting the unit.

7. Warranty The units are warranted for a period of 12 months provided that the opera- ting conditions have been maintained, that the units have not been tam- pered with and that the units show no mechanical damage. The warranty applies only if the operating and assembly instructions spe- cified by Eltex have been observed. The warranty period begins on the date of delivery. In the event of defects occurring during the warranty period, the units or defective components will be repaired at Eltex. Defective components will be replaced and installed free of charge. If repairs are required at the customer's premises, the costs for sending a technician (travel, travel time, expenses) will be charged to the customer.

23 8. Technical specifications The current approvals with their supplements can be found at: http://service.eltex.de. Discharging bar R50 / R51A Bar element glass-fibre-reinforced plastic GRP Encapsulation material polyurethane, UL-94 V-0 Emission tips stainless steel Installation material plastic sliding nuts Operating ambient temperature 0...+80 °C (+32...+176° F) Ambient humidity max. 70% RH, non-dewing Dimensions profile: 16 x 32 mm, max. length R50: 5,980 mm; R51A: 5,990 mm, see Fig. 11 Weight approx. 0.75 kg/m Operating voltage R50: max. 8 (5) kV AC, 50/60 Hz R51A: max. 5 kV AC, 50/60 Hz High voltage supply via Eltex power supplies High voltage connection R50: high voltage cable encapsulated, axial or radial (rotatable by 360°) lead-out R51A: exchangeable high voltage cable, axial lead-out, optional: 2 connections for serial link-up of several bars Short-circuit current/tip max. 0.046 mA Contact protection according to EN 61140 UL Approval File No. E227156 (max. 6 kV AC, 50/60 Hz) as shown on appliance marking:

9. Dimensions Design variant with two axial connections for serial interconnection of several discharging bars. * for R51A: 40 mm EL = installation length AL = active length GL = total length Fig. 11: R50 / R51A discharging bar Z00062y 32 X 16 R60 31,5 AL EL 95 GL X 35* 35* 19 Ø17 Ø10 30 ca. 50 34 Fig. 12: R51A/D discharging bar Z00562y EL ≥ AL + 270 GL AL 40 31,5 40 31,5 ∅17 0...360° (max. 1 turn)

25 10. Spare parts and accessories Article Article No. High voltage distributor, discharging, 5 terminals (1 input, 4 outputs) ESV High voltage distributor, discharging, 2 terminals (1 high voltage cable, 4 outputs) (specify plug type and cable length) ESV61 High voltage distributor, discharging, 4 terminals (1 high voltage cable, 2 outputs) (specify plug type and cable length) ESVY61/__ High voltage cable with flexible tube frompower supply ES50 / ES51 or distributor ESV / ESVY61/_S to bar R51A (specify cable length) KE/LL___ High voltage cable without felxible tube from power supply ES50 / ES51 or distributor ESV / ESVY61/_S to bar R51A (specify calbe length) KE/SS___ High voltage cable with flexible tube frompower supply ES33 to bar R51A (specify cable length) KE/PL___ High voltage cable without felxible tube from power supply ES33 to bar R51A (specify calbe length) KE/HS___ Plug "L" Set for prefabricating the high voltage cable with flexible tube for power supply ES50/ES51 and distributer ESV/ESVY61/_S 103289 Plug "S" Set for prefabricating the high voltage cable without flexible tube for power supply ES50 / ES51 and distributer ESV / ESVY61/_S 101366 Plug "P" Set for prefabricating the high voltage cable with flexible tube for power supply ES52B and ES33 102889 Plug "H" Set for prefabricating the high voltage cable without flexible tube for power supply ES52B and ES33 104273 Blanking plug for high voltage output 102742

Please specify the article number when ordering. Article Article No. Mounting material for bars: slide nut with screws and washers 105826 Plastic countersunk screw, M5x8 101020 Plastic countersunk screw, M5x10 KSR00030 Plastic countersunk screw, M5x30 108525 Plastic cheese-head screw, M5x10 KSR00012 Plastic cheese-head screw, M5x16 KSR00013 Plastic cheese-head screw, M5x20 KSR00014 Plastic cheese-head screw, M5x25 KSR00015 Plastic cheese-head screw, M5x35 KSR00016 Plastic cheese-head screw, M5x50 KSR00017 Adapter plate, with screws 2 x M5 by 1 x M8 101807 Adapter plate for version S01with screws 2 x M5 by 1 x M8 101824 GRP round rod Ø 20 mm 100864 Bar holder for round rod 101075 Attachment clip for round rod MCH02434 GRP reinforcement angle bracket 102568 Flexible tube for high voltage cable MCH02438 Kit - Bar holder: Bar holder with clamps HA01/___ Bar holder with perforated plate HA02/___ Bar holder for frame attachment HA03/___ Bar holder for shaft attachment HA04/___ Bar holder with assembly angle bracket HA50/___ Volt Stick Operating Instructions (specify language) 109136 BA-xx-2016

Phone +49 (0) 7621 7905-422 eMail [email protected] Internet www.eltex.de Eltex offices and agencies The addresses of all Eltex agencies can be found on our website at www.eltex.de Z01007y