ELTEX R50 Series User manual

Operating Instructions
Series R50 / R51A Discharging Bars
for AC Operation
BA-en-2016-2006
F00015y

2BA-en-2016-2006_R50 / R51A

BA-en-2016-2006_R50 / R51A 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

4BA-en-2016-2006_R50 / R51A
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.

BA-en-2016-2006_R50 / R51A 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)

6BA-en-2016-2006_R50 / R51A
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

BA-en-2016-2006_R50 / R51A 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.

8BA-en-2016-2006_R50 / R51A
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).

BA-en-2016-2006_R50 / R51A 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.

10 BA-en-2016-2006_R50 / R51A
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.

BA-en-2016-2006_R50 / R51A 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

12 BA-en-2016-2006_R50 / R51A
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
2GRProd
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

BA-en-2016-2006_R50 / R51A 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!

14 BA-en-2016-2006_R50 / R51A
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

BA-en-2016-2006_R50 / R51A 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
Σlengths of h.v. cable [m]
Σlengths 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)

16 BA-en-2016-2006_R50 / R51A
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

BA-en-2016-2006_R50 / R51A 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
123456 7
157
6
35,5+0,5
0

18 BA-en-2016-2006_R50 / R51A
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.

BA-en-2016-2006_R50 / R51A 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.

20 BA-en-2016-2006_R50 / R51A
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.