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The CSR+ advanced corona power supplyand the benefits to the converter

Corona discharge treatment at atmospheric pressure for improving adhesion of various polymer substrates is now standard practice for most converting lines such as laminators, flexo and gravure printers, says Corona Supplies


he past few years have seen some marked improvements in the production, reliability, machine

interfacing and ease of use of corona systems. But now the standards achieved to- date have been re-written, by Corona Supplies, with the company’s CSR+ range of corona power supplies. The CSR+ generation of corona power supply

represents an extension of the industry-leading standard in reactive power units, the Sherman GXR range. CSR+ represents a significant step forward in terms of efficiency, reliability, functionality, standardisation and ease of use hitherto not seen with existing systems. Resonant load matching the power supply

output to that of the discharge treater station has always been the key to reliable, efficient, powerful corona treatment. CSR+ self-matching circuitry automatically tunes to load conditions (the treater station), using an output frequency operating in the range 10-25kHz. The automatic matching circuitry enables the power unit to be ‘plug and play’ as connection to a different treater station does not require any set up time. Fast over-current detection circuitry prevents output stage damage, as short circuit (dielectric pin- hole), is detected within one output cycle. The unit operates from a wide range of three-phase mains voltages (380V, 460V and 50/60Hz) without additional transformers. More power out for much less input, means a

saving to the converter in terms of quoted power needed, to achieve a desired surface tension level. The CSR+ operator panel

incorporates a menu-driven, touch- screen HMI and Siemens PLC to enable greater control and visualisation of both the power supply and the treater station. Display is separated into three

distinct access levels - operator, supervisor and engineer, with password protection for supervisor and engineer levels.

KEY FUNCTIONS - Treater station visualisation: A graphical representation of the actual treater station gives the user instant real- time feedback of the treatment process. - Fault status with self-help diagnostic info: If a fault occurs the user can instantly call up a screen that details the fault, possible causes and fixes. - Recipes: Store multiple jobs that can be called up in an instant. Parameters stored include job title, power control method/set-point and minimum line speed. - Power output trend, date stamp:The user can scroll back and check the output condition of the power supply at any point in the past, and event- log of all past corona parameters. It is now possible to highlight exactly where in a given reel of film, changes in the settings of the treater occurred, eliminating the need to scrap complete reels due to treating errors, a treatment quality guarantee. - Remote control: The HMI screen can be located many meters away from the power supply enabling the control to be integrated into an existing desk or the power supply cabinet to be located in a separate location to the treater. This flexible and up-gradable controller

incorporates menu-driven treater control software that has a real time treater status window visible at all times with comprehensive power analysis displayed on the operator screen. Interlock status is individually monitored, machine line speed measured and displayed in the real time window, along with 20 programmable treatment/film recipes, and all multi-language supported allowing storage of treater data for individual films/production runs. The integrated Siemens PLC allows seamless addition of corona control functions, previously achieved only with the addition of extra hardware and other systems.

10 September 2016

The new CSR+ graphical display operator panel

PLC FUNCTIONS INCLUDE: Closed loop watt density/power factor control – maintaining power per unit of film area, and changing output power with line speed changes. Splice control – lifting the discharge electrodes only at the correct moment, minimising un- treated film length as the splice tail passes through the treater station. Skip treat function, setting a treatment pattern not only across the film width but in the machine direction, leaving heat-seal lines non-treated ensuring much stronger welded films. Communications protocols such as RS232, AS-I,

Profibus, Industrial Ethernet and CanBus are available to allow the CSR+ corona power supply to deliver real-time data and control to production line computers for ease of customer access and interface. Mounting a corona treater in-line can give the

converter a form of ‘insurance’ that desired results will be obtained, and a previously treated substrate will re-treat more easily than untreated materials, even where the surface energy level has decayed since the original treatment. This permits smaller treating equipment to be fitted to the line than would be the case with material not treated at the manufacturing stage. Fitting a corona system with a CSR+ power supply means that the converter has the industry’s leading technology, in terms of efficiency, reliability, the most technically advanced, and with more benefits than any other system available.

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