ELTEX R45 Series User manual

Operating Instructions
Series R45 Discharging Bars
for AC Operation
BA-en-2045-1808
F00035y

2BA-en-2045-1808_R45

BA-en-2045-1808_R45 3
List of contents
1 Outline of appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Identification of risks and hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Work and operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Contact protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Inspection of the protective resistors - contact protection . . . . . . . . . 8
2.6 Technical advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Installation and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Assembling the discharging bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Length of the high voltage cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Connecting the high voltage cable to the power supply . . . . . . . . . 11
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Function control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
10 Spare parts and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4BA-en-2045-1808_R45
Dear customer,
The new Series R45 discharging bars are designed for the active dis-
charging of disruptive static charges which develop in production proc-
esses. The bars are operated with an alternating voltage of 5 or 6 kV at
50…60 Hz and are designed for discharging moving surfaces.
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 R45 discharging bars:
• ultimate discharging range and hence enhanced depth effect
• high active discharging power through patented, isolated ground con-
ductors
• high safety standards through passive discharging power with deacti-
vated power supplies
• safety through function and malfunction monitoring
• easy assembly
• no health hazards in case of electric shocks when making contact with
the 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-2045-1808_R45 5
1. Outline of appliance
AL = active length
GL = total length
max. active length = 2600 mm
Grid width emission tips 20 mm
non-detachable connection of the high voltage cable
axial design
Fig. 1:
Overview of the
R45 discharging
bar
Z00500y
≥R30
35
20
AL
GL
16
35

6BA-en-2045-1808_R45
2. Safety
The Series R45 discharging bars have been designed, built and tested
using state-of-the-art engineering and have left the factory in a technically
and operationally safe condition. If used improperly, the bars may never-
theless be hazardous to personnel and may cause injury or damage.
Read the operating instructions carefully and observe the safety notices.
Warning!
Do not touch the emission tips of the discharging bars when the supply
voltage from the power supply is switched on. Always disconnect the sup-
ply voltage to the power supply before carrying out any cleaning or main-
tenance work.
The manufacturers will not assume any liability and warranty if the units
are used improperly or outside the intended purpose.
2.1 Proper use
The Series R45 discharging bars must be used only for discharging 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.
Modifications or changes to the discharging bars 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 ion blower heads
and the ion blower pistol are referred to in these operating instructions
with the following symbols:
Warning!
This symbol appearing in the operating instructions refers to operations
which, if carried out improperly, may result in serious personal injury.
Caution!
This symbol appearing in the operating instructions refers to operations
which, if carried out improperly, may result in damage to property.

BA-en-2045-1808_R45 7
2.3 Work and operational safety
Warning!
Carefully observe the following notes!
• Before carrying out repairs, cleaning or maintenance work and before
resetting the unit after malfunctions, switch off the power supply and
disconnect the supply voltage.
• Any work involving the units and the discharging bars must be carried
out by qualified personnel.
• The bars passively absorb energy from the moving substrate web. The
high voltage cable must be plugged in or grounded to the power supply.
An unconnected grounding cable may cause a spark discharge and
may lead to a risk of injury.
• Check the discharging bars and the high voltage cables at regular inter-
vals for any damage. Damaged components must be repaired or
replaced before continuing to operate the unit, or the bar or cable must
be disabled.
• Keep the bars clean at all times.
• Do not touch the emission tips - risk of injury!
If the high voltage supply is connected, reflex responses to electrical
irritation may increase the risk of secondery accidents, especially in the
vicinity of unguarded rotating assemblies. The charging bar as such is
safe to touch. If contact is made, the energy transferred is so low that
there is no risk of injury.
• Potential risk for wearers of cardiac pacemakers:
If persons with a cardiac pacemaker approach or contact the bar, a
malfunction of the pacemaker cannot be ruled out; affix the appropriate
warning sign.
• 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.
• 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 instal-
lation 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).

8BA-en-2045-1808_R45
2.4 Contact protection
As the site of installation and/or use of the units is outside the control of
Eltex, contact protection against inadvertent contact by personnel as
specified by the employers’ liability insurance association (e.g. DGUV V3
in Germany) may have to be provided.
Contact protection 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). Eltex recommend inspection intervals of 6 months.
The function of the series resistors must be checked using a suitable
measuring device. The test voltage must be 1,000V. The measured resist-
ance between the high-voltage connection and the individual emission tip
must not fall below 10.8 MOhm and not exceed 13.2 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.
3. Installation and assembly
3.1 Assembling the discharging bar
The series R45 discharging bar is attached to the machine via the oblong
holes in the cover caps. Alternatively, the bar can be attached using
mounting clamps. Fig. 2 shows the bar with the mounting clamps and the
required installation distances.
Depending on use, other attachments and fittings (e.g. threaded holes in
the machine wall) are also allowed.
Warning !
In applications involving moving bars (e.g. film draw strips), the high volt-
age cable must be attached such that there is no cable movement near
the connection zone of the power supply unit.

BA-en-2045-1808_R45 9
Caution!
Observe adequate creepage paths!
The minimum distance between the emission tip brackets and the conduc-
tive machine environment must be 20 mm.
1 oblong holes for mounting, use only enclosed bolts made of plastic
2 alternative attachment via mounting clamps, bolts made of plastic or
metal can be used
3 one additional clamp for AL >1,000
(two additional clamps for AL > 2,200)
Fig. 2:
Assembling the
discharging bar
Z00501y
35
20
AL
GL
==
16
≥
R30
ø
5,5
GL
10
GL
10
16
16
ø19
35
13
18
18
≤
≤
3
8,5
2
2
AL+60
1
±1

10 BA-en-2045-1808_R45
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. 3). 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.
Fig. 3:
Zone free of any
grounded conduc-
tive material with
the dimensions R
Z00616y
R
R
3R
R

BA-en-2045-1808_R45 11
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. 4 demonstrates this principle for the ES51 power supply.
3.3 Connecting the high voltage cable to the power supply
Warning!
Connect or disconnect the high voltage cable only with the power supply
switched off.
For the connection to power supplies ES5_ resp. ES24, refer to the sepa-
rate operating instructions for the power supply.
Fig. 4:
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

12 BA-en-2045-1808_R45
4. Operation
The discharging bars must be operated only in connection with the Eltex
power supplies with 5 kV AC or 6 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 points. Quote Article No. 109136 when ordering
the Volt Stick from Eltex.

BA-en-2045-1808_R45 13
5. Maintenance
Warning!
• Switch off the power supply unit and disconnect the supply voltage
before carrying out any maintenance or repair work.
• The machine in which the discharging bars are installed must not be
running.
• The bars passively absorb energy from the moving substrate web. The
high voltage cable must be plugged in or grounded to the power supply.
An unconnected grounding cable may cause a spark discharge and
may lead to a risk of injury.
• Repairs and maintenance work must be carried out by qualified
personnel.
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 (cleaning gasoline). 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!
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). Eltex recommend inspection intervals of 6 months.
The function of the series resistors must be checked using a suitable
measuring device. The test voltage must be 1,000V. The measured resist-
ance between the high-voltage connection and the individual emission tip
must not fall below 10.8 MOhm and not exceed 13.2 MOhm.

14 BA-en-2045-1808_R45
6. Troubleshooting
Warning!
Electric shock hazard!
Switch off the supply voltage to the power supply before carrying out any
repair or maintenance work. No voltage must apply at the discharging
bars.
Repairs must be carried out by qualified personnel.
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 (cleaning gasoline).
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!
Allow the solvent to evaporate completely before restarting the unit.

BA-en-2045-1808_R45 15
7. Warranty
The units are warranted for a period of 12 months provided that the oper-
ating conditions have been maintained, that the units have not been tem-
pered with and that the units show no mechanical damage.
The warranty applies only if the operating and assembly instructions spec-
ified 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.

16 BA-en-2045-1808_R45
8. Technical specifications
The current approvals with their supplements can be found at:
http://service.eltex.de.
Discharging bar R45
Bar element glass-fibre-reinforced plastic GRP
Emission tips stainless steel
Installation via the oblong holes in the cover caps,
alternative attachment via mounting clamps
Operating
ambient temperature 0...+70 °C (+32...+158° F)
Ambient humidity max. 70% RH, non-dewing
Dimensions profile: 16 x 16 mm
end caps: 18 x 22.5 mm
max. active length 2,600 mm
see Fig. 5.
Weight approx. 0.40 kg/m
Operating voltage max. 6 kV AC, 50/60 Hz
High voltage supply via Eltex power supplies
High voltage
connection
high voltage cable, axial lead-out
Short-circuit current 0.5 mA
Contact protection according EN 61140
UL Approval File No. E227156
as shown on
appliance
marking:

BA-en-2045-1808_R45 17
9. Dimensions
AL = active length
GL = total length
Fig. 5:
Dimensions of the
R45 discharging
bar
Z00500y
≥R30
35
20
AL
GL
16
35

18 BA-en-2045-1808_R45
10. Spare parts and accessories
Please specify the article number when ordering.
Article Article No.
High voltage distributor, discharging, 5 terminals
(1 input, 4 outputs) ESV
High voltage distributor, discharging, 4 terminals
(1 high voltage cable, 4 outputs)
(specify plug type and cable length) ESV61
High voltage distributor, discharging, 2 terminals
(1 high voltage cable, 2 outputs)
(specify plug type and cable length) ESVY61/__
High voltage cable without flexible tube from power
supply ES50 resp. ES51 to distributor ESV resp.
ESVY61/_S (specify cable length) KE/Ss
High voltage cable without flexible tube from power
supply ES24 to distributor ESV61 resp. ESVY61/_Z
(specify cable length) KE/Zs
Plug "S"
Set for prefabricating the high voltage cable without
flexible tube from power supply ES50 resp. ES51 to
distributor ESV resp. ESVY61/_S 101366
Plug "H"
Set for prefabricating the high voltage cable without
flexible tube for power supply ES33 104273
Plastic mounting clamps 102599
Cheese-head screw, M5 x 25 KSR00015
Volt Stick 109136
Operating Instructions (specify language) BA-xx-2045

Eltex-Elektrostatik-Gesellschaft mbH
Blauenstraße 67-69, D-79576 Weil am Rhein
Phone [phone] - 230
Fax [phone] - 330
eMail static-con[email protected]
Internet www.eltex.com
Eltex offices
and agencies
The addresses of all
Eltex agencies can be
found on our website at
www.eltex.com
Z01007y