ELTEX flexBAR R60L Series User manual

Operating Instructions
vario Discharging Bar flexBAR
Series R60L for AC Operation
BA-en-2082-2207
F01052y

2BA-en-2082-2207_R60L

BA-en-2082-2207_R60L 3
List of contents
1 Outline of appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Outline of appliance R60L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Installation and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1 Assembling the R60L discharging bar . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Length of the high voltage cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Adjust the angle coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4 Operation without air support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5 Operation with air support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5.1Number of air connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5.2Connecting oil and waterfree compressed air supply . . . . . . . . . . . 20
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Function control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7 Technical specifications R60L . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9 Spare parts and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4BA-en-2082-2207_R60L

BA-en-2082-2207_R60L 5
Dear customer
The series R60L discharging bars flexBAR are designed for the active dis-
charging of disruptive static charges which develop in production pro-
cesses. The bars are operated with an alternating voltage of max.5 kV at
50 - 250 Hz and are designed for discharging moving and non 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 discharging bar flexBAR:
• high discharge range at minimum operating high voltage, hence great
depth effect
• excellent active discharging performance at close and far range due to
patented bar design
• flexible, free-standing emission tip with new resistance technology
• high level of safety due to passive discharge even when the power
supply is off
• variable use in tight, grounded machine spaces
• 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)
• flexible, free-standing emission tips; no danger of injury e.g. during
chleaning
• wear-protected emission tip
• 4 times more emission tips compared to other products
• flexible installation due to a lateral continuous mounting groove
• easy to clean thanks to an extremely hard, dirt-resistant surface
• More efficient, best possible ionization of the amount of the aiding air to
increase the range of the discharging effect of active discharging bars
for medium and long ranges.
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.

6BA-en-2082-2207_R60L
1. Outline of appliance
1.1 Outline of appliance R60L
1 high voltage connection
2 bracket
3 emission tips / spring tips
4 air connection
5 additional air connection
EL = installation length
AL = active length
GL = total length
Discharging bar R60L
• fixed connection of the high voltage cable
• high voltage cable axial and radial design
• radial connection rotatable by 300° and locked by lock nut
• max. active length: 2,715 mm
• grip spacing of the discharging tips: 15 mm
active length minus 15 must be divisible by 30; AL = 15 + (n x 30)
Fig. 1:
Overview
Discharging bar
R60L
Z-116289cy_1

"-

(-
&-
3





0...330°
(max. 1 turn)

BA-en-2082-2207_R60L 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.
For warranty conditions, please refer to the General Terms and Conditions
(GTC), see www.eltex.de.
2.1 Proper Use
The Series R60L discharging bars flexBAR air must be used only for dis-
charging static charges from material surfaces. Other uses are not permit-
ted.
The R60Ldischarging bars must be operated only together with the dedi-
cated Eltex power supplies. These power supplies guarantee the optimum
adaptation to the required operational data for the different active bar
lengths. Safe operation of the bars is ensured only by using the Eltex
power supplies.
Other uses are not permitted. The manufacturers will not assume any
liability 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.

8BA-en-2082-2207_R60L
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 22, chap-
ter 6 "Troubleshooting”, page 23).
• 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 22, chapter 6 "Troubleshooting”, page 23).
• Any work involving the units must be carried out by qualified electrici-
ans (see chapter 5 "Maintenance”, page 22, chapter 6 "Troubleshoo-
ting”, page 23).
• 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 22).
• The bar must be mounted such that mechanical damage to the bar tips
is ruled out (see chapter 3.1 "Assembling the R60L discharging bar”,
page 12).
• 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 R60L discharging
bar”, page 12).
• To attach the bar, use only the provided brackets made of plastic. It is
also recommended to use the mounting material offered by Eltex (see
chapter 3.1 "Assembling the R60L discharging bar”, page 12).
• 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 R60L discharging bar”, page 12).
• When metal foils or metal composite materials are processed, the
owner must ensure that the metal foil/layer is connected to ground
potential (see chapter 3.1 "Assembling the R60L discharging bar”,
page 12).
• 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 (see chapter 3.1 "Assembling the
R60L discharging bar”, page 12).

BA-en-2082-2207_R60L 9
• 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 17).
• The maximum permissible angle of turn of the angle coupling is 300°
(see chapter 3.3 "Adjust the angle coupling”, page 18).
• The number of air connections depends on the length of the bar. If the
air is supplied via both air connections, then all hoses from the distribu-
tor to the connections must be of the same length (same pressure con-
ditions), see chapter 3.5.1 "Number of air connections”, page 19.
• An internal hose diameter of 10 mm (DN10) is required to connect the
air hose to the air hose joint. The operating pressure must not exceed
1 x 105 Pa and must be measured at the air distributor. The distributor
crosssection must be dimensioned to match the number of hose con-
nections or in compliance with the consumption volume (see chapter
3.5.2 "Connecting oil and waterfree compressed air supply”, page 20).
• The R60L discharging bars must be operated only in connection with
the Eltex power supplies with max. 5 kV AC output (see chapter 4
"Operation”, page 21).
• Check the units and the high voltage cables at regular intervals and
before startup for any damage. Any damaged components must be
repaired 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.
• When cleaning the bars do not soak the bars and the high voltage cable
in solvent and do not damage the emission tips; allow the solvent to
evaporate completely before restarting the unit (see chapter 6 "Trouble-
shooting”, page 23), chapter 5 "Maintenance”, page 22).
• Do not touch the emission tips - risk of injury.
If the high voltage supply is connected, reflex responses to electrical
irritation can lead to secondary accidents; the charging bar as such is
safe to touch. If contact is made (≤ 10 tips), the energy transferred is so
low that there is no risk of injury.
• Potential risk for wearers of cardiac pacemakers:
Moving the chest closer than 3.5 cm to the emission tips of the dischar-
ging bars or making surface contact with several emission tips (tou-
ching 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.

10 BA-en-2082-2207_R60L
• 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-
tio-nal 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 connect-
ing side of the power supply is permitted. Extending the cable is permit-
ted only when using the Eltex distributor as well as original high voltage
cables and glands.
• If any liquids seep into the spring tips and bar during cleaning, they
must dry completely before start-up. Until the components are comple-
tely dry, the shock-proofing is temporarily impaired and can lead to a
damage of the bar.
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
components by personnel as specified by the employer’s liability insu-
rance 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 measured resistance between the high voltage
connection and the individual emission tip must not fall below 105 MOhm
and not exceed 195 MOhm.

BA-en-2082-2207_R60L 11
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.

12 BA-en-2082-2207_R60L
3. Installation and assembly
3.1 Assembling the R60L discharging bar
Attach the R60L discharging bars to the machine wall, using special
brackets. For easier installation we recommend using the assembly mate-
rial (see Fig. 2) offered by Eltex. Fig. 3 / Fig. 4 show the installation princi-
ple.
1 Discharging bar 4 Adapter
2 Bracket 5 Clip
3 Bracket small 6 Mounting angle
The profile of the bar features a through-going sideways groove in which
the bar holders are positioned at regular distances. The bar is fixed in
place simply by tightening two bolts each for every holder; torque: 0.8 Nm.
Caution!
Evenly space the brackets across the full length.
below 1 meter total length: 2 per bar
over 1 meter total length: 1 per meter
Use plastic mounting materials whenever possible to ensure optimum
functionality and discharging performance.
Fig. 2:
Assembling the
R60L
discharging bar
Z-115593y










BA-en-2082-2207_R60L 13
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. An additional angle permitting easy fastening of sys-
tem profiles is available as an option, see Fig. 3.
1 Discharging bar 4 Maschine wall
2 GRP round rod 5 Grounding cable
3 Aluminum profile 6 Mounting angle
Fig. 3:
Assembly example
R60L with steel
brackets and alu-
minum profile
Z-115574cy_1

 


Fig. 4:
Assembly R60L
with GRP round
rod
Z-115574cy_2




14 BA-en-2082-2207_R60L
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 bar, use only the provided brackets 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.
• When metal foils or metal composite materials are processed, the
owner must ensure that the metal foil/layer is connected to ground
potential.

BA-en-2082-2207_R60L 15
Locating the R60L 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 R60L discharging bar
and substrate ought to be 100...1000 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
Z-115574cy_3

16 BA-en-2082-2207_R60L
Protection profile SP (optional)
In the case of installations on material webs, changes in the distance bet-
ween the web and the electrode or as a result of a web break can lead to
a possible getting caught on the spring tips. This can damage the spring
tips. To avoid this, we recommend the optionally available protection pro-
file. This can be easily adapted and is available with a protective strip on
one or both sides.
• Type of bracket for R6x discharging bars
• Height of protective strip 45 mm for R60L bars
• one- and two-sided protective strip
• Length adapted to the total length of the bar
Fig. 6:
Protection profile
SP
Z-117727y
 



BA-en-2082-2207_R60L 17
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. 7 - Fig. 9 demonstrates this principle for the PI, ES51, ES60, ES50
and ES24 power supplies.
Fig. 7:
Loading capacity
of the PI, ES51
and ES60 power
supplies as factor
of
active bar length
and total length of
the high voltage
cable
Z01162e
Fig. 8:
Loading capacity
of the ES50 power
supply as factor of
active bar length
and total length of
the high voltage
cable
Z01164e
Fig. 9:
Loading capacity
of the ES24 power
supply as factor of
active bar length
and total length of
the high voltage
cable
Z01165e
Σlengths of h.v. cable [m]
Σlengths of active bars [m]
10
5
10 20 30 40 50
permissible
range
 lengths of h.v. cable [m]
 lengths of active bars [m]
5,0
2,5
5 10 15 20 25
permissible
range
 lengths of h.v. cable [m]
 lengths of active bars [m]
2,0
1,0
0,7 2 4 6
permissible
range

18 BA-en-2082-2207_R60L
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 300°.
Fig. 10:
Angle coupling
Z-116289cy_3
 
30...300° (max. 1 turn)

BA-en-2082-2207_R60L 19
3.4 Operation without air support
We recommend leaving the air connections on both sides closed with the
pre-assembled blind plugs.
3.5 Operation with air support
3.5.1 Number of air connections
The number of air connections depends on the length of the bar. If the air
is supplied via both air connections, then all hoses from the distributor to
the connections must be of the same length (same pressure conditions).
Fig. 11:
Position of the air
connections as
factor of total
length GL
Z-116289by_4
(-


No. Designation
1 Air connection, closed with blind plugs
on delivery
2 additional air connection, closed with
blind plugs on delivery
GL
[mm] Number of air connections
GL  1000 1
1000 < GL 2800 2

20 BA-en-2082-2207_R60L
3.5.2 Connecting oil and waterfree compressed air supply
Depending on the air flow, you can connect the air supply parallel to the
high voltage cable or on the opposite side or on both sides. For this pur-
pose, please remove the pre-assembled blind plug and screw the air con-
nection nipple into the thread provided (G1/4").
An internal hose diameter of 10 mm (DN10) is required to connect the air
hose to the air hose joint. The operating pressure must not exceed
1 x 105 Pa and must be measured near the air distributor. The distributor
cross section must be dimensioned to match the number of hose connec-
tions or in compliance with the consumption volume.
1 Pressure gauge (* not shown)
2 Pressure source
3 DN20 hose
4 Throttle valve 7 DN10 hose (e.g. 2 x 2.5 m)
5 Rota flowmeter 8 Distributor
6 R60L discharging bar 9 Manometer
Fig. 12 shows the installation diagram for the air supply.
The air distributor is not included with the delivery.
Caution!
If the air supply is realized via both air connections, all hoses from the dis-
tributor to the connecting points must have the same length (identical
pressure conditions).
Fig. 12:
Installation of the
compressed air
supply
Z-116294y





