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Mero电晕维修手册

Declaration of Conformity

I the subscriber Mennucci Lamberto, in my quality of legal representative of the factory ME.RO spa manufacturer of the machine as identified by the references below, declare that the said machine complies with the essential safety requirement as stated in the European Community directives 2006/42/EC Appendix IIA and 89/336, in particular the requirements of the following harmonized normatives have been accomplished:

UNI EN ISO 12100-1 , UNI EN ISO 12100-2 , UNI EN 294 , UNI EN 349 , UNI EN 1088, CEI EN 60204-1 , EN 55011 , EN 50082-2. Manufacturer Factory ME.RO S.p.A.

Via Balestreri 430-Ponte a Moriano-LUCCA-ITALY- Commission 1577\10 - HET BRüCKNER

Machine Electronic Generator Discharge Station

Type

MR\B 55K-IGBT

BHSNM

3\3\15\F\M\8600\8220

Serial number

100301-100303-100305-

100307-100309\C.1577\10

100311-100312\B17-4066-Year of

construction

2010

SUPPLIER DECLARATION

It is forbidden to the end user to install the above stated machine within others without having verified the compliance with the directive 2006/42/EC.

Ponte a Moriano, October 20, 2010 Signature.................................

WARNING!

IN ORDER TO FULLY TAKE ADVANTAGE OF ANY FORM OF WARRANTY OF THE PLANT, THE FOLLOWING FORM, MUST BE PROPERLY FILLED IN AND RETURNED TO ME.RO, BY REGISTERED LETTER WITH ADVICE OF RECEIPT.

Corona Discharge System consisting of:

Electronic Generator N°5 MR\B 55K-IGBT

Serial No. 100301-100303-100305-100307-100309\C.1577\10

Discharge Station BHSNM 3\3\15\F\M\8600\8220

Serial No. 100311-100312\B17-4066-

0 20/10/10 First Edition

Rev. Date Description Compiled Checked Approved

This manual is for everyone who works with the MR\B-55K-IGBT

generator and for operating personnel in particular.

This document is produced by the Me.Ro . s.p.a. Technical

Documentation Department.

No part of this document can be reused, duplicated or electronically

distributed without the prior authorisation of Me.Ro . spa

Me.Ro. spa declines all responsibility for any errors in this

documentation.

The product description given in this documentation is as precise as

possible.

The product may undergo technical changes without prior notice.

For any installation questions or problems, please contact Me.Ro.

spa We will be pleased to help you.

INTRODUCTION

Declaration of Conformity

UNI EN ISO 12100-1 , UNI EN ISO 12100-2 , UNI EN 294 , UNI EN 349 , UNI EN 1088, CEI EN 60204-1 , EN 55011 , EN 50082-2. Manufacturer Factory ME.RO S.p.a.

Via Balestreri 430-Ponte a Moriano-LUCCA-ITALY- Machine Electronic Generator Discharge Station

Type

MR\B 55K-IGBT

BHSNM

3/3/15/F/M/8600/8220

Year of

construction

2010

SUPPLIER DECLARATION

It is forbidden to the end user to install the above stated machine within others without having verified the compliance with the directive 2006/42/EC.

Ponte a Moriano, Oct. 20, 10

Contents

1 page n°3 Machine transport, handling and storage

1.1 Machine storage conditions

1.2 Size, weight(s), position of centre(s) of gravity

1.3 Handling

2 page n°4 Machine commissioning

2.1 Assembly conditions

2.2 Area required for operation and maintenance

2.3 Permissible ambient conditions

2.4 Connecting the machine to the power supply

2.5 Recommended precautionary measures to be adopted by the user

3 page n°5 Information on the machine

3.1 Detailed description of the machine and the accessories, guards and/or safety

devices

3.2 Purpose of the machine and uses not permitted

3.3 Measuring methods

3.4 Electrical system

3.5 Generator operating principless

3.6 Generator START-UP

3.7 Repair and maintenance

4 page n°1

5 Operating the machine and description of manual controls

4.1 Discharge station- Start-up and adjustments

4.2 Stopping procedures

5 page n°29 System maintenance

6 page n°30 Instruction and warning

6.1 General safety regulations

1 Machine transport, handling and storage

conditions

1.1 Storage

The machine must be adequately protected from water and dust.

The machine can be stored at temperatures between -25°C a nd +70°C.

A dry ambient is preferable but not essential.

1.2 Size, weight(s), position of centre(s) of gravity

See

-A-

figure

instructions

1.3 Handling

For the purposes of despatch, system components are packed in special containers with bases.

wooden

It is recommended that the packing be removed only when the machine has been brought close to its final position.

Generator handling can be effected by means of a fork lift of sufficient power.

Cables of suitable strength must be used to lift the discharge stations at the appropriate points indicated on the container. N.B. Do not use a fork lift.

The gross weight is shown on the packing.

When handling without packing, the generators must be lifted using the eye-bolts provided.

N.B. Ensure that the lifting cables do not press against the delicate parts of the discharge station (they should come into contact with the main tube only).

commissioning

2 Machine

conditions

2.1 Assembly

The discharge station must be securely anchored to the support structure.

For correct positioning, refer to 4.1.

2.2 Area required for operation and maintenance

The generator is completely enclosed by side panels (removeable by unscrewing) and by two hinged panels (front and rear).

Position the generator so that it is accessible from all sides (with the exception of the base) with a clear area of 80 cm all round.

If the generator has to be positioned near other parts (so that one or more sides are covered), it must be fixed in such a way as to allow it to be moved and to provide access for maintenance.

The generator’s cooling air intakes must be unobstructed and easily accessible for maintenance (filter cleaning,etc).

The discharge station is completely enclosed. Access to the inside is gained by unscrewing the side panels.

Two transparent windows on the sides are provided for visually checking the corona discharge inside the station.

2.3 Permissible ambient conditions

The electronic generator can operate in temperatures of between +5°C and +40°C, and in humidity levels of 30-95%, without condensation.

In a working environment where the temperature is close to the maximum, it is advisable to place the generators in an air-conditioned ambient or provide air-conditioning at the cooling air intakes.

The discharge station can operate in temperatures of between +5°C and +55°C, and in humidity levels of 30-95%, without condensation.

Special care must be taken to check temperature and humidity when conditions compatible with the formation of condensation on the internal and external surfaces of the generator and discharge station occur.

In particular, the system must not be operated when there is condensation on the discharge station as there could be high voltage discharges to ground.

Bear in mind that because of the ozone suction fan, the discharge station is in a condition of slightly lower pressure than the ambient. It is thus possible that in certain ambient conditions interior condensation may form earlier, or more abundantly, than outside, or in other equipment (electronic generator).

2.4 Connecting the machine to the power supply

The size of the protection devices (switch and fuses) in the general power supply panel, and the size of the power line must match the voltage and the maximum current absorbed by the generator (see INPUT electrical data plate on the back of the generator housing).

2.5 Recommended precautionary measures to be adopted by the user

Place barriers beside the discharge station to prevent access by unauthorized persons.

N.B. Opening of the barriers while the machine is in operation, must switch off the electronic generator and stop the rollers.

3 Information on the machine

3.1 Detailed description of the machine and the accessories, guards and/or safety devices

The power supply passes through a high-voltage bushing in Teflon (the high-voltage cable must be connected to the discharge electrodes inside the station).

The ozone formed by the discharge is sucked away from the discharge station through outlets positioned on the station itself.

Due to the oxidizing effect of the ozone, stainless steel or plastic piping should be used to connect the ozone outlet, the ozone suction fan and the exhaust duct (to be installed by the user).

3.2 Purpose of the machine and uses not permitted

The generator is designed exclusively for the corona discharge treatment of plastic film, paper, and bonded materials, etc.

The treatment of metal film (conductive) or metallized film (on the surface or internally) is not permitted with this type of discharge station.

3.3 Measuring methods

The concentration of ozone at a distance of one metre from the station must be 0.1 ppm or less.

Use the DRAGER system with ozone test phial OZON 0.05/b.

3.4 Electrical system

Solid-state ELECTRONIC GENERATOR MR\B 55K-IGBT Electrical characteristics

SUPPLY VOLTAGE 3x400 V 50 Hz MAXIMUM POWER ABSORBED 61 kVA

MAXIMUM OUTPUT POWER 55 kW

OPERATING FREQUENCY 20-25 kHz

Main characteristics

Modular construction.

Continuous power control adjustment from zero to maximum power. High levels of efficiency due to solid state construction. Automatic adjustment for different load conditions.

High output frequency value (20-25 kHz).

Decentralized peripheral equipment using ET200S.

Monitoring of generator work magnitudes and safety devices: (analogue magnitudes 0-10 V)

Corona discharge current

Effective Vrms voltage on the electrode +

Inverter operating current

Inverter operating voltage

(digital outputs)

Overtemperature of power semiconductor devices

Overcurrent of high-voltage transformer

Indication that main CN1 contacter has closed on generator start-up. Size of generator housing: 800x1920x800 mm

Generator weight: 510 kg

3.5 GENERATOR OPERATING PRINCIPLES

From the generator block diagram (see operation and maintenance manual) we can see that it basically consists of four parts:

- Rectifier

- Chopper

- Inverter

- High voltage transformer

- The rectifier converts alternating current into direct current, the value of which depends on the Vrms of the line itself.

- The chopper is composed of IGBT Q1, which, together with impedance IMF2, supplies power to the inverter. The chopper also adjusts and stabilises the output power, limits voltage and current, and provides rapid protection in the event of accidental overloads.

- The inverter is full-bridge configured ( D4 - D7 Q2 - Q3 ). It is current supplied and coupled on a resonant circuit consisting of the H.V. transformer primary and the stabilizing capacitance CVOL1.

The two branches of the bridge are driven to resonance frequency alternately by a 50% duty cycle. Switching takes place when the resonance voltage passes through zero. As a consequence, switching losses are dramatically reduced and higher conversion efficiency is obtained.

The zero voltage switching technology (ZVS), used for power conversion, offers many advantages compared to traditional converters using PWM technology for non-resonant loads.

The main advantages are:

Power dissipation equal to zero in switching transition

Reduced EMI/RF on switching

No high current peaks

Increased efficiency with high input voltages and working frequencies.

Ch1 = voltage driver

Ch2 = inverter supply voltage

Ch3 = resonant converter voltage

Ch4 = resonant converter current

-The H.V. transformer isolates the resonant

converter from the load and raises the output

voltage sufficiently highly to permit

ionization of the air-gap between electrode

and discharge roller.

While referring to the block diagram, the

following is a detailed analysis of generator

operation.

Through switch IN1, mains filter FL1, circuit breaker IA1, and contactor CN1, the line voltage at terminals L1 L2 L3 is applied to bridge rectifier PD1, which converts the sinusoidal mains current into direct current.

Through resistances R5 R6 the bridge rectifier output is applied to electrolytic filter condensers C2 C3.

Resistances R5 R6 limit the load voltage and after the delay time imposed by timer TEMP1 (about 2sec.) the resistances are bypassed by contactor CN2. The value of the direct current at the ends of the electrolytic condensers is approximately 525 Vdc with a mains voltage of 380 Vrms (different mains voltages will obviously give different Vdc values).

Resistance R15 discharges the electrolytic condensers when contactor CN1 is open. This ensures the complete discharge of the condensers a few seconds after the generator has been switched OFF, so allowing any maintenance operations to be carried out immediately. When the electrolytic condensers have been discharged, led DL1 goes off.

-Chopper

Through fuse F4, Vdc power is applied to the chopper stage. This is composed of IGBT Q1, diodes D1 D2 D3, and impedance IMF2. The operational frequency is approximately 19kHz. The function of this stage is to adjust the generator’s output power, to guarantee current and voltage limitations, and through impedance IMF2 to supply power to the inverter.

Diode D3 (when Q1 does not conduct) circulates power as a consequence of the energy stored in inductance IMF2 when Q1 was previously positioned to ON.

The chopper’s average output voltage varies in accordance with the generator’s output power up to a maximum of 400 Vdc.

The Idc and Vdc operational values are detected by two Hall-effect transducers. The Idc detector is mounted near the chopper output and the Vdc detector is mounted on board B2640 (see relevant diagram).

The boards that drive the chopper are:

B2136 B2488 and B2487 when Q1 is an intelligent IGBT module ( IPM )

B2136 B2561 when Q1 is not an intelligent IGBT module.

The wave-form of the output voltage downstream from impedance IMF2 is shown in the figure.

1) Ch: 250 V\div 10μsec

-Inverter

The inverter consists of IGBT modules Q2 Q3, diodes D4 D5 D6 D7, capacitance CVOL1, and the H.V. transformer.

As described above, the inverter is the resonant type and therefore uses sinusoidal current and voltage with low switching losses.

The working frequency changes with charge conditions in the 19 kHz ( fully charged ) to 28 kHz (empty ) range.

As the working frequency depends on charge conditions, the system is governed by a phase-locked loop (PLL), which keeps the drive impulse frequencies in modules Q2 Q3 perfectly locked-in to the resonance frequency of the charge.

The inverter drive boards are:

B2660 where the impulse transformers are mounted.

B1378 where the system control electronics are mounted.

B1766 where the PLL feedback transformer is mounted. A signal is also taken from this transformer for board B2136 (chopper) and is used to limit max. Vrms in the resonant circuit.

1) Ch: 250 V\div 10μsec

- H.V. transformer

The H.V. transformer is an integral part of the inverter and, as described above, the primary winding with capacitance CVOL1 forms the resonant circuit onto which the inverter is coupled. Since the electrode discharge surface, the distributed capacitances in the discharge station, the distributed capacitance in the H.V. cable, the type and thickness of the insulated covering on the discharge roller, the air-gap and the power supply all influence the inverter’s coupling and working frequency, in order to better adapt the generator for different charges, 3 sockets are provided on the transformer secondary. These will permit the best operating conditions to be selected.

At pins 1 3 of the circular connector , Iout (discharge current) and Vout (voltage at discharge electrode) signals are available.

To obtain the value of Vout, the Vrms measured at pin 3 must be multiplied by the number of H.V. secondary windings (see relevant plate).

To obtain the value of Iout, the Vrms measured at pin 2 must be divided by the value of resistance R20 (see components list).

3.6 GENERATOR START-UP

1) Ensure that the voltage supplying terminals L1-L2-L3-PE corresponds to what is indicated on the plate on the rear of the generator housing.

Connect terminals L+ and M to a 24 VDC supply (ET200M module supply).

Temporary oil plug is mounted on the high-voltage transformer for transport purposes; replace this with the correct plug and check the oil level.

Remove the guard from the

transformers’ high-voltage output

and connect the high-voltage cable

supplied to the tap n_ on the high-

voltage insulator.

Connect the other end of the high-voltage cable

to one of the electrodes in the discharge station

or, if available, to the high-voltage switch in

accordance with the diagrams enclosed with the

technical documentation.

14 25 36

N.B. CONNECT THE GENERATOR, DISCHARGE STATION AND DISCHARGE ROLLER TO GROUND.

In the discharge station, adjust the distance between the electrodes and the insulated roller

to 2.5 mm. Check that the electrodes are perfectly axial with the insulated roller (see section 4.2). Make the connections between the terminal boards of the discharge station generator and the AIR-GAP control panel, in accordance with the diagrams attached.

Check that all the safety devices between the film production line, the generator and the discharge station are operating correctly.

In particular check:

that the generators are OFF before the discharge station opens;

that the generators are ON only if the discharge roller is turning and the ozone suction fan is in operation;

that the FILM BREAK detectors are operating correctly and that the discharge station opens immediately as soon as they come into operation;

that the emergency safety devices (protective gates, etc) are operational;

that the generator cuts out when the electrode is not in the operating position.

On completion of the above checks, the generator can be started up.

Position the MAIN SWITCH on the generator housing to ON.

N.B. It is inadvisable to operate the generators at maximum power during system warm-up (after the first start up or after the line has been shut down for a long time), to avoid the risk of high-voltage discharges towards ground due to humidity or to the formation of condensation.

Before starting-up the generators, the inside of the discharge stations must be checked and all work process dirt and residue removed, particularly from the ceramic insulators and from all parts exposed to high voltage.

Position the generators to ON.

Check the film treatment level and adjust the generator power accordingly to obtain the treatment required.

3.7 Repairs and maintenance

ALARM SIGNALS POSSIBLE CAUSES REMEDY

Phase fault Incorrect power supply to

generator Check :

-That main switch IN1 and circuit breaker IA1 are ON

- The presence and correct value of rms at terminals L1-L2-L3.

Main supply fault No supply from AL1 to

generator control boards Check:

- the 110 Vrms supply

- fuses F2-F3

- the + - 15 Vdc output voltage - Replace supply unit.

Main contactor CN1-CN2 OFF Contactors CN1 - CN2 are

not energized.

Check:

- that led D17 on board B2643 is lit

- timer TEMP1.

Vdc fault No supply reaching

generator chopper stage. Check:

- fuse F4. If fuse F4 is blown, check the state of Q1 - Q2 – Q3 - Q4 - D3 - D4 - D5 - D6 - D7

Heatsink over temperature Activation of thermal

protection on IGBT

heatsinks. Check:

- operation of relevant cooling fans. - fuse F1

Over Temperature from chopper module IGBT (IPM). Activation of thermal

protection within chopper

module IGBT (IPM).

Check:

- Operation of relevant cooling fan

- fuse F1

- Press reset to reposition generator to

Over current Generator overload Press reset and reposition generator to

ON. If the over current signal

persists, check:

- power modules Q2 - Q3 – Q4 – D3 -

D4 - D5 – D6 - D7

- stabilizing capacitance CVOL1

- H.V. transformer TR2

- feedback transformer TRVOL1

mounted on board B1766

- replace inverter control module

(board B1378)

- replace chopper control module

(board B2136)

Over current from chopper module IGBT (IPM) Activation of one of the OC

– SC - UV protections inside

module IGBT.

OC - Over Current

SC - Short Circuit

UV - Under Voltage lock-out

Press reset and reposition generator to

ON. If the over current signal persists,

check:

- power modules Q2 - Q3 – Q4 – D3-

D4 - D5 - D6 - D7

- stabilizing capacitance CVOL1 -

H.V. transformer TR2.

- feedback transformer TRVOL1

mounted on board B1766

- replace inverter control module

(board B1378)

- replace chopper control module

(board B2136)

- check chopper drive (board B2488 –

B2487, see relevant testing procedure)

H.V. short circuit Short circuit at high voltage

output Check:

- insulated coating on discharge roller - that there are no discharges between electrode and ground in the discharge station

- the H.V. cable

- the H.V. insulators mounted in the discharge station at the H.V. transformer output and on the H.V. cable

Vdc fault The chopper stage

inoperative Check:

- IGBT Q1

- The correct operation of control modules B2488 - B2487 - B2136 (see relevant testing procedure)

Inverter fault No power from inverter

stage Check:

- power modules Q2 - Q3 - D4 - D5 - D6 - D7

- the correct operation of control modules B1378 - B1765 (see relevant testing procedure)

- the H.V. transformer (TR2)

4 Operating the machine and description of manual controls

4.1 Discharge station . Start-up and adjustments

* The discharge station requires AIR GAP adjustment (the air space between the electrode and the silicone-rubber insulated roller) where the corona discharge takes place.

* The shape of the electrode permits discharges over a number of lines according to the discharge roller drives.

?All points of the electrode must be 2,5 mm from the discharge roller. To make adjustments, use the special screws provided for the purpose (see following sections).

(1) single, 7 mm dia electrode element in stainless steel

(2) electrode guide

The electrode consists of 15 elements (1) supported by guides (2).