User manual Corona Generator Uni-Systems LF1 - · PDF file11. Service guidelines ... •...

SICATECH A/S • Roedebrovej 17, Linde • DK-7600 Struer • Denmark • Phone: (+45) 97 48 70 17 • Fax: (+45) 97 48 70 27

www.sicatech.dk • E-mail: [email protected] • VAT no: 21161108 • Jyske Bank, SWIFT: JYBADKKK, 7590-4870179

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User manual

Corona Generator

Uni-Systems LF1

Standard model Part no: 111003 Output detection module Part no: 111004

V4.11



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Table of contents

1. Safety warning................................................................ 3

2. Corona pre-treatment ...................................................... 4

3. How does it work............................................................. 4

4. Spare part list................................................................. 4

5. Operation....................................................................... 5

6. Installation and operating the generator ............................. 6

7. Control connector ............................................................ 9

8. Interface examples.........................................................10

9. Mounting the treating head..............................................11

10. FAQ..............................................................................12

11. Service guidelines ..........................................................12

12. Output detection module .................................................14

13. Connection example Output detection module.....................15



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1. Safety warning The generator must only be installed and operated by qualified and authorized personnel.

The generator must only be moved or transported using suitable hoisting equipment.

Please check the specifications section for information on weight and dimensions. At least two persons should be used should it be necessary to transport the generator

manually. Please check your local regulations regarding lifting and transporting heavy equipment.

The generators treating head emits a visible high voltage arc, which is hazardous to touch.

Install the generator according to local electrical regulations and laws

and in a way that prevent accidental exposure to the arc. Additional shielding and safety equipment may be necessary to ensure operator safety.

Be aware of the risk of the flame touching metal or conductive materials (fixtures) and

thereby could lead the current outside the protective area. Connecting the metal part to the M8 ground connection on the back of the generator could eliminate this problem.

Never use the treating head as a handheld unit.

Disconnect and secure main generator power source, before beginning service and/or installation. One way might be to remove the power plug from the back of the

generator and remove the fuse holder from the power socket inlet.

Take the necessary precaution of probability of interference of the function of cardiac pacemakers. Possible consequences such as fatality, severe injury or health

impairment cannot be entirely excluded. A minimum amount of ozone is generated when using the generator. Depending on the

room air exchange and treating time an exhaust system should be installed.

The HV cables must be feed in a way that they are protected from sharp edges and wear.

The safety instructions in this quick guide do not cover all conditions and situation that can occur. Common sense and caution are factors that cannot be built into the

equipment. These factors can only be added by the personnel who is installing and operating the equipment.



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2. Corona pre-treatment Corona treating has become one of the most effective and common method of pre-treatment of virtually any material.

The low surface energy of many polymer-based substrates often leads to poor

adhesion of inks, glues and coatings. The poor wettability of the surface makes it necessary to increase the surface energy to a level that is higher than the material to be applied.

Corona treating results in good wetting of the material over the surface of the

substrate and so improves the adhesion.

3. How does it work

The corona discharge is formed by a collision of neutral molecules and electrically loaded molecules. Upon collision, the neutral molecules become electrically loaded, resulting in a heavily loaded zone

Substrates placed in this discharge field, suffer electron impacts that have 2-3 times

the energy required to break the molecular bonds found on most surfaces. Oxygen can then react with the free radicals formed, rapidly producing chemical

functional groups on the substrate surface. These groups are most effective at increasing the surface energy and enhancing bonding to the surface.

The surface energy will decrease over time. The rate the surface energy declines pending on the particular material and the handling of it.

4. Spare part list

Part no Description

116001 Small head, 6mm

116002 Medium head, 12 mm

116002 Large head, 95 mm

118001 HV cable, 2m

215006 Ceramic part for small head

215007 Ceramic part for medium head

215008 Ceramic part for large head

216004 Electrode for small and medium head

216003 Electrode for large head



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5. Operation The corona system is activated via the treating input on the interface connector of the generator.

To achieve the corona arc the generator is equipped with an internal blower giving an air flow from the corona head even if the corona arc is not present. The blower turns

ON when generator is powered ON. This air flow can move light weight part away from the head if it is not sufficient mounted in a fixture.

The treating time and distance is depending of which material is treated and what dyne level is required. Typical distance from the tip of the head to the part should be 5mm.

Often only test can indicate the correct treating time distance (and velocity if the part is moved past the treating head.

Too long treating time over the same area can result in burn marks whereas too short time

results in insufficient treating level. Again test must be done to find the correct parameters.

There is also a risk of changing the glossiness or ‘tiger’ stripes of the surface if then treating time

is too long. ‘Tiger’ stripes, caused by the small lines in the

corona arc which can bee seen in the picture, can sometime be avoided by using the small or

medium size treating head.

There are 3 different head sizes available depending on the area to be treated.

Small head

6mm width Part no: 116001

Medium head


Large head




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6. Installation and operating the generator After unpacking the generator, check for damages to the equipment.

The content of the shipment is as following:

Qty Description

1 Corona generator, model Uni-Systems LF1

1 Treating head.

1 HV cable.

1 Power cord.

1 Plug for control connector.

1 User manual for Uni-Systems LF1 generator.

Mount the generator on a flat horizontal surface, free from vibrations, moisture and

dust. Optionally the generator feet can be unscrewed and permanent M8 mounting screws can be used. The screws going into the generator should not exceed 10mm.

The ambient temperature must be between 5°C (43° F) and 45°C (110° F) and relative

humidity not exceeding 85%. Keep sufficient space on the sides for ventilation. Minimum 30mm (1.2”).

Install the treating head, making sure it is properly fastened, keeping a safe distance

to conductive parts. A special care should be taken to the ceramic tips of the treating head. These are

fragile and can break or crack on impact with hard surfaces.

Never operate the equipment with defect heads or without heads mounted. Turn off the equipment and have a qualified person replace the defective part.

Ceramic tip



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Before inserting the high voltage cable into the generator, make sure that the nylon

screw is unscrewed. Insert the high voltage cable into the ‘Treating head’ socket on the back of the

generator and secure it using the nylon screws.

A safety switch will prevent any treating output if the plug is not inserted completely into the socket.

Set the ‘Input voltage selector’ according to the appropriate setting and connect the

‘Power input’ to a grounded 220-240 / 110-120 VAC power source. The power input is protected with a 8A slow blow fuse.

Treating head socket Control connector

Power input socket

Nylon screw Voltage selector

Main fuse



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The generator has two main modes:

Standby mode: The internal power is disconnected from the output stage. Indicated by illumination of the red Standby lamp.

Ready mode: The internal power is connected to the output stage. An activation of the treating input by it self will not generate any

corona treatment. Indicated by illumination of the green Ready lamp.

The Standby/Ready mode is controlled using a power relay and need external wiring to enable a change to Ready mode.

The enclosed control connector plug has the Standby links pre-wired. This means that by inserting the plug into the control connector socket, the generator is able to go into

Ready mode by pressing the Ready button on the front panel.

When the Standby link is wired the generator can switch between Standby and Ready mode by using the front plate buttons.

Activation of the treating input on the control connector will generate corona treatment as long as the generator is in Ready mode. This is indicated by illumination of the

white treating lamp The treating can also be tested by pressing the Ready button and Treating button

simultaneously.

Please see the control connection section for more information regarding activation and linking of the external control connector.



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7. Control connector The external interface is a standard industrial 16 pin Harting connector.

Pin no Function Description 1 +24VDC out

0.5 A max.

Power supply output for inputs and external sensors.

2 Standby safety

link +

Must be connected to pin 1 in order to be able to go

into ready mode. See also pin 10.

3 Ready mode

link +

If connected to pin 11 the generator will automaticly go

into ready mode on power up as long as the conditions for pin 2 and 10 are meet.

4 Treating 1 Connect to pin 1 to activate treating head. See also pin 12 information.

5 NC No internal connection.

6 Common out + Common connection for output signals


8 Ready mode out Output signal for generator in ready mode.

This signal can be used as indication to external equipment that the generator is powered ON and ready.

9 0 VDC Ground for power supply. Note: this pin is also connected to PE (protective earth)

10 Standby safety link -

Must be connected to pin 9 in order to be able to go into ready mode. See also pin 2.

11 Ready mode link -

See pin 3 description.

12 Input common - Common connection for input signals. This terminal must be connected to pin 9 if not

controlled from an external control system.







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8. Interface examples

1: Standby links jumpered.

External foot switch or relay contact to activate the treating head.

2: Standby links connected to safety door switch. Ready link jumpered for automatically Ready mode when Standby link is closed

External foot switch or relay contact for activation of treating head.



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9. Mounting the treating head

If the arc comes close enough to grounded metal there will be a certain leakage from the arc to

ground.

Depending on which heads you are using the distance will vary. The large head will easier arc to

ground due to the open electrodes, where the medium and small heads is more isolated and

need to be closer to ground before a leakage current will run.

In a system where the arc does not touch any conductive materials the current in the HV side

will loop inside the head and transformer. See picture below.

The center point of the transformer is actually the earth connector on the back of the generator

(along with the ground of the incoming power supply connector 120/230V).

Generator

Current pathLeak current path

If the treating head is mounted close to a metal part, the leakage current will try to run back to

this point possible creating undesirable current in the ground/machine frame. See picture

below.

If an isolation of the fixture is not possible it is strongly recommended that a separate ground

wire is connected to the fixture and directly back to the earth bolt on the back of the generator.

Generator

Leak current pathCurrent path

Leakage current can also, in extreme case, influence the effect of the treating and in some

cases also give burn marks. The closer the head is to ground the worse the influence. If the

generator is equipped with at Output Detection module, the output of this module can be

influenced by leakage current to ground.



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10. FAQ

1. Do you have a hand held shielding of the ceramic tip? Never use the treating head as a handheld device.

General it is not allowed to expose any voltage which a person can come in contact with.

This means that the person/company that install the equipment must full fill the local or

national regulation regarding electrical equipment. We recommend you contact a local

electrician should you have questions regarding you local or national regulations and laws.

Special care should be taken because of the high voltage involved in using a corona

generator.

2. What is the applied voltage/current and could it be dangerous to the operator?

The output voltage of the generator and at the treating head is approx. 7kV with a limited

current at approx. 40mA (50Hz).

There is a high risk for an operator to get shocked from a non-enclosed treating head,

risking direct and/or indirect injuries and or death.

You should also note that if the treating head arc is pointing toward or touching metallic

parts fixture there are a risk of unwanted leakage current, which can be hazardous to

touch or introduce electrical noise in other control equipments.

3. What is the recommended distance to the work piece?

The treating distance varies from application to application.

Normal distance is approx. 5mm from the head to the part, but also depends on the area

to be treated.

Normally you would make some trials to determine the distance, from the area to be

treated and the required dyne level.

4. How long are the activation time / relative velocity? This question relates to you question no. 3 where trails must be made to obtain the

required dyne level.

These parameters vary depending on the used material and distance.

5. Do you recommend a wet chemical pre-cleaning process?

If the material is clean and free from dust, we do normally not recommend any pre-

cleaning process, though mould release could influence the result.

6. The generator does not give any output when activated?

Make sure that the HV connector is proper inserted into the back of the generator. A

switch is detection for proper insertion.

7. Can I use different head type on the same generator?

If the generator version has multiple outputs it is possible to mount different type of

treating head which can be activated individually.

8. Can I use fewer head if the generator has multiple outputs?

Yes, either remove the HV cable from the back of the generator (not only the head) or

prevent activation of the relevant input signal.

9. How close can the heads be mounted to each other?

If the heads are mounted too close to each other there is a risk of arcing between the

head, reducing the effect of the treatment.

11. Service guidelines

The generator is virtually maintenance free with very few wearing parts. Regarding service and maintenance of the Corona generator we recommend the following

things are checked at a regular time interval.

• The electrodes in the corona head will wear out over time.

Depending on how long the actual treating time is the electrode can last from 3 month

(24/7) to several years when only short treatment cycles are used.

• Occasionally clean the air filter mounted in the side of the generator depending in which

environment the unit is placed.

• Otherwise general check the external wiring/cabling for damage every ½ year.



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Electrical schematics, Standard version



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12. Output detection module Generator part no 111004 has a built-in circuit that measures the electrical output of the generator.

Description:

The ‘Output detection’ module measures the current loop and the contents of HF signal in the ground side of the HV side of the HV transformer.

The module detects the following fault: • No treating head installed • No airflow from the generator • Short to earth/ground or between heads • Badly worn or no electrodes.

If these parameters are found to be OK the ‘Treating OK output’ will be activated.

Each HV output has it own sensing circuit which will be activated at the same time as the ‘Treating input’ signal. The sensing circuit has a response time of 200mS.

If one of the OK signals is not present after 200mS the corresponding HV output is

disabled disregarding of the ‘Treating input’ signal. This is to prevent burning or earth short if an error has occurred. The HV output is

disabled until the generator power has been recycled or the ‘Fault reset input’ has been activated.

The ‘Fault reset input’ can disable or reset the ‘HV output disable’ by connecting the input to 0V. Note that this input normally needs to be pulled to 0V.



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13. Connection example Output detection module

9 0V 1 +24V output, 0.5A max.

10 Standby link input - 2 Standby link input +

11 Ready link input - 3 Ready link input +

12 Common input signals 4 Treating input

13 NC 5 NC

14 Treating OK output 6 Common output signals

14 NC 7 NC

16 Fault reset input 8 Ready mode output PE Protective earth.

NOTE: Treating input and output signal are opto-isolated.

Treating OK signal to control circuit e.g. PLC or OK lamp.

Treating input

connected to one activation device



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Electrical schematics, Output detection module version

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User manual Corona Generator Uni-Systems LF1 - · PDF file11. Service guidelines ... •...

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