CE COMPLIANCE DECLARATION

DC1

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 13857 , 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 5257\13 ROTOMEC
Machine Electronic Generator Discharge Station

Type
MR/b 8K IGBT UU1X5C-298-1220-
Serial number
130333\C.5257\13 130335\r25-5257-

Year of 2013
construction
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, Sep. 6, 13

Signature.................................

Stamp:
 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.

I, THE SUBSCRIBER
IN FUNCTION OF
FROM COMPANY

DECLARE TO HAVE RECEIVED FROM ME.RO COMPANY THE USAGE

AND MAINTENANCE MANUAL OF ITS RELATIVE PLANT
(COMM. N°5257\13 ROTOMEC)

SIGNATURE..................................................DATE.........................................

FACTORY STAMP
Ing. Eugenio Caniglia Type test on Discharge Station,
Via Passamonti 179 part of a corona treatment system
55100 LUCCA

The undersigned Ing. Eugenio Caniglia, registered in the Roll of

Engineers of the Province of Lucca under No. 492, as the
Technical Expert appointed by ME.RO S.p.A. for the verification
of electromagnetic emissions produced by the "Discharge
Station", part of a corona treatment system, as a result of
instrumental tests carried out in nominal conditions, hereby
declares that the electromagnetic emissions detected along the
perimeter of the machine itself, at the distance expected for a
hypothetical operator, are well below the exposure limit values set
out in Table 2 of Annex XXXVI to Legislative Decree 81/08.

The machine in question therefore complies with the safety

criteria established by Title VIII, Chapter IV of Legislative Decree
81/08, with regard to exposure to electromagnetic fields.

Lucca October 5, 2010

 Fabrication of hf generating apparatus and electronic command
devices for industrial use
55100 PONTE A MORIANO – LUCCA – ITALIA
Z.I. – Via Balestreri , 430
Tel.: +39 0583.406060 – Fax: +39 0583.406050
e-mail: [email protected] - web: www.mero.it

Use and maintenance manual

GENERATOR T400\8\1220\50
TYPE MR/b 8K IGBT
N° 130333\C.5257\13 (C.C. 60683) ROTOMEC

i
Warning!
This operating manual is required for the safe use of the generator; it is therefore
recommended to keep it near the machine.

0 06/09/13 First edition

Rev. Date Description Compiled by Checked by Approved

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Art. : Electronic Generator MR/b 8K IGBT
 This manual is for everyone who works with the MR/b 8K IGBT generator
Who are these instructions and for operating personnel in particular.
for?

This document is produced by the Me.Ro. S.p.A.Technical

Copyright Documentation Department.

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

distributed without the prior authorisation of Me.Ro. S.p.A.

Me.Ro. S.p.A.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.

S.p.A.We will be pleased to help you.

Me.Ro. S.p.A.

Z.I. – Via Balestreri , 430

55100 Ponte a Moriano (Lucca)

Italy

Tel.: +39 0583.406060

Fax: +39 0583.406050

E-mail : [email protected]

Internet : www.mero.it

Use and Maintenance Manual Page. 2 a 40

Art. : Electronic Generator MR/b 8K IGBT
1 DECLARATION OF CONFORMITY

I the subscriber Mennucci Lamberto, in my quality of legal representative of the factory

ME.RO S.p.A. 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 13857 , UNI EN 349 , UNI EN
1088, CEI EN 60204-1 , EN 55011 , EN 50082-2.

Manufacturer Factory ME.RO S.p.Q.

Via Balestreri 430-Ponte a Moriano-LUCCA-ITALY-
Machine
Electronic Generator Discharge Station
Type
MR/b 8K IGBT UU1X5C-298-1220-

Year of 2013
construction

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, set. 6, 13

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Art. : Electronic Generator MR/b 8K IGBT
 INDEX
1 DECLARATION OF CONFORMITY ..................................................................................................... 3
2 GENERAL INFORMATION ................................................................................................................... 6
2.1 Manufacturer’s guarantee .............................................................................................................. 6
2.2 Documentation structure ................................................................................................................ 7
General .................................................................................................................................................. 7
2.3 Technical terminology and abbreviations ....................................................................................... 8
3 SAFETY ................................................................................................................................................. 9
3.1 Designated use............................................................................................................................... 9
Designated use ...................................................................................................................................... 9
3.2 General warnings ........................................................................................................................... 9
High-voltage hazard............................................................................................................................... 9
3.3 Dangerous areas: maintenance and repairs ................................................................................ 10
DANGEROUS AREAS: MAIN SWITCH TO OFF ................................................................................ 10
Control and protection device .............................................................................................................. 10
3.4 Safety measures........................................................................................................................... 11
4 DESCRIPTION, TECHNOLOGY......................................................................................................... 12
4.1 Components and their functions .................................................................................................. 12
4.2 Control mode ................................................................................................................................ 13
5 INSTALLATION .................................................................................................................................. 14
5.1 Transport, Setting up .................................................................................................................... 14
Setting up ............................................................................................................................................. 14
5.2 Unpacking..................................................................................................................................... 14
5.3 Positioning .................................................................................................................................... 14
PERMITTED ENVIRONMENTAL CONDITIONS ................................................................................ 14
5.4 Connections.................................................................................................................................. 15
Power line ............................................................................................................................................ 15
Electrical specifications ....................................................................................................................... 16
5.5 Matching between generator and electrodes ............................................................................... 17
Instructions for setting up the generator .............................................................................................. 22
6 OPERATION, CONTROL ................................................................................................................... 24
6.1 Start up ......................................................................................................................................... 24
7 PROFIBUS-DP ROTOMEC - MERO v1.2 INTERFACE (mod speed) ................................. 25
7.1 Operation modes .......................................................................................................................... 29
7.2 MANUAL ....................................................................................................................................... 29
7.3 AUTOMATIC WITH SPEED ......................................................................................................... 29
7.4 AUTOMATIC WITH SPECIFIC POWER ...................................................................................... 30
8 SETTING THE PARAMETERS ........................................................................................................... 31
8.1 Starting/Stopping the generator ................................................................................................... 33
Checking safey devices ....................................................................................................................... 33
Preparation for operation ..................................................................................................................... 33
8.2 Operation ...................................................................................................................................... 33
8.3 Stopping the generator ................................................................................................................. 33
8.4 Setting up and adjustment instructions ........................................................................................ 34
8.5 Procedure for checking the double IGBT modules . .................................................................... 35
9 MAINTENANCE .................................................................................................................................. 36
9.1 General notes about maintenance ............................................................................................... 36
technical support.................................................................................................................................. 36
9.2 Safe maintenance......................................................................................................................... 37
Removing residual voltages ................................................................................................................ 38
9.3 Maintenance intervals .................................................................................................................. 38
9.4 Maintenance work ........................................................................................................................ 38
9.5 Dismantling and packing .............................................................................................................. 39
Isolating the unit................................................................................................................................... 39
Packing ................................................................................................................................................ 40
Transport ............................................................................................................................................. 40
Demolition ............................................................................................................................................ 40

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Art. : Electronic Generator MR/b 8K IGBT
Use and Maintenance Manual Page. 5 a 40
Art. : Electronic Generator MR/b 8K IGBT
2 GENERAL INFORMATION

Who is this section for? Section profile:

This section is for everyone who installs, uses or carries out maintenance
on the electronic generator.

Section contents This section contains the main details about the product and the
operating manual.

2.1 MANUFACTURER’S GUARANTEE

CONDITIONS OF GUARANTEE:

Me.Ro. spa equipment is built from materials which are tested and
inspected when construction is completed.

12-month guarantee Our equipment is guaranteed for 12 months ex factory, Ponte a Moriano,
Lucca, Italy. If callouts are requested during the guarantee period, you
will be charged for travel time, travel costs, board and lodging; the cost of
the time spent on repairs and that of any spare parts will be met by us.

EXCLUSIONS FROM GUARANTEE:

Damage caused by incorrect use or by unauthorised operations is

excluded from the guarantee.

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Art. : Electronic Generator MR/b 8K IGBT
2.2 DOCUMENTATION STRUCTURE

GENERAL

Two types of documents are provided with Me.Ro. spa products:

• Use and maintenance manual

The manual contains all the details required for installation, start
up and maintenance of the equipment

• Technical documents

The technical documentation includes the equipment layout,

drawings and materials list.

This document is the use and maintenance manual.

STRUCTURE OF USE AND MAINTENANCE MANUAL

This manual consists of the following sections which contain all the
information required for using the equipment:

• Section 1 “GENERAL INFORMATION”

• Section 2 “SAFETY”

• Section 3 “DESCRIPTION, TECHNOLOGY”

• Section 4 “INSTALLATION”

• Section 5 “OPERATION, CONTROL”

• Section 6 “INTERFACING”

• Section 7 “SETTING PARAMETERS”

• Section 8 “IGBT CONTROL PROCEDURE”

• Section 9 “MAINTENANCE”

• Appendices (declaration of conformity, test certificate)

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Art. : Electronic Generator MR/b 8K IGBT
 DESCRIPTION OF SYMBOLS

Danger!
This symbol indicates that there is a risk of personal injury.

High-voltage hazard!

This symbol warns of a hazard due to the presence of high voltages (risk
of electric shock).

Danger: High frequency!

This signal warns of a hazard due to high-frequency radiation. People

with pacemakers or prostheses must not enter areas where this symbol
is displayed. Pacemaker operation might be affected and prostheses
might overheat.

i
Warning!

This symbol draws attention to important information.

2.3 TECHNICAL TERMINOLOGY AND ABBREVIATIONS

DESCRIPTION OF ABBREVIATIONS

P Power

I Current

V Voltage

f Frequency

L Inductance

C Capacity

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Art. : Electronic Generator MR/b 8K IGBT
3 SAFETY

Section profile:

Who is this section for? This section is for everyone who installs, uses or carries out maintenance
on the electronic generator.

Section contents The section contains the main details about working on the product in
safety.

3.1 DESIGNATED USE

Danger!

Personal and system protection is not guaranteed if the generator is not

operated in compliance with its designated use.

Any maintenance or repairs to the electronic generator and

the electrodes must be carried out only by authorised
specialised personnel.

DESIGNATED USE

GENERATOR The generator is used exclusively for the corona discharge treatment of
applications plastic or metalised film, paper, combinations, etc.

The generator must be used only for this purpose.

3.2 GENERAL WARNINGS

HIGH-VOLTAGE HAZARD

High-voltage hazard!

The generator converts mains voltage to DC and then to AC at the

inverter stage. Components supplied with these voltages can give electric
shocks.

Before working on the generator and the discharge station,

position the main switch to OFF.

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Art. : Electronic Generator MR/b 8K IGBT
3.3 DANGEROUS AREAS: MAINTENANCE AND REPAIRS

DANGEROUS AREAS: MAIN SWITCH TO OFF

When the main switch is positioned to OFF, there are no live sections
inside the generator.

Safety devices

CONTROL AND PROTECTION DEVICE

Caution!

i The operator is responsible for working on the generator in safety. It is

his responsibility to know about the regulations and to apply them.

The electronic generator is not fitted with a main switch.

A main switch must be installed to protect the generator. Its size must be
calculated on the basis of the supply current and the max. current
absorbed by the generator (see input electrical data plate on the
generator housing).

Danger!

The main switch does not guarantee personal safety and must not be
used as an emergency switch.

Before working on the generator, wait for approximately 30” to allow the
DC link to discharge.

Protection systems The generator will automatically go to OFF if there is:

• Overvoltage

• Overheating

• Overload

• Interlocks

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Art. : Electronic Generator MR/b 8K IGBT
3.4 SAFETY MEASURES

If there is an emergency, carry out the following steps in the order

given:

1. Disconnect the external power line to the generator and any auxiliary
power lines.

2. Extinguish fire by using the appropriate extinguisher.

High-voltage hazard!

Because high voltage is present, water must never be used to extinguish

fires; use the appropriate extinguishing agents.

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Art. : Electronic Generator MR/b 8K IGBT
4 DESCRIPTION, TECHNOLOGY

Section profile:

Who is this section for? This section is for everyone who installs, uses or carries out maintenance
on the electronic generator.

Section contents This section contains information about generator operation and
technology, its use and fields of application, and technical data.

4.1 COMPONENTS AND THEIR FUNCTIONS

GENERATOR CONSTRUCTION

The air-cooled generator is constructed inside a metal cabinet.

COMPONENTS

The generator is composed of:

• Rectifier

• Chopper

• Inverter

• H.V. transformer

• Electronic control

• Decentralised periphery system with S7-200.

The rectifier converts mains alternating current into direct current to

supply the Chopper stage.

The Chopper adjusts generator output power, controls current and

voltage limitations and supplies the inverter by means of impedance
IMF1.

The Inverter is formed by two full-bridge configured IGBT modules. It is

current supplied and coupled to a resonant circuit formed by the output
transformer primary inductance and flywheel capacitor CVOL.

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Art. : Electronic Generator MR/b 8K IGBT
 The output transformer is an integral part of the inverter and the
multipolar secondary winding simplifies generator adaptation to load.

The electronic control performs all the functions for controlling and
driving the generator power stages.

The decentralised periphery system with S7-200 handles generator

operation and allows it to be remotely controlled from a panel.

4.2 CONTROL MODE

The generator will operate only with an appropriate remote control

system connected by PROFIBUS to S7-200.

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Art. : Electronic Generator MR/b 8K IGBT
5 INSTALLATION

Section profile:

Who is this section for? This section is for everyone who installs the electronic generator.

Section contents This section contains information about the correct mechanical and
electronic installation of the generator and the station.

5.1 TRANSPORT, SETTING UP

TRANSPORT

After receiving the equipment:

Check the integrity of all parts.

Give immediate advice of any damage that has occurred during

transport.

SETTING UP

Environmental conditions The machine must be suitably protected from water and dust.

It can be stored at temperatures between -25°C and +70°C.

A dry environment is preferable (but not essential).

5.2 UNPACKING

Carefully unpack the various generator components

With the exception of the main power cable, the packaging contains all
the cables required for start up.

5.3 POSITIONING

PERMITTED ENVIRONMENTAL CONDITIONS

Operation environmental The electronic generator can operate at temperatures between +5°C and
conditions +35°C, humidity between 30-95%, without condensation.

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Art. : Electronic Generator MR/b 8K IGBT
5.4 CONNECTIONS

POWER LINE

Size of power line The size of the protection devices in the general power supply panel
(switch + fuses) and the power line must be appropriate for the supply
voltage and the max. current absorbed by the generator; see input
electrical data plate on rear of generator housing.

8
4

1. GROUND CABLE
2. SIGNALS CABLE
3. POWER CABLE
4. VACUUM CAGE ON OZONE SUCTION
5. SUPPLY LINE CABLE (not provided)
6. INDUCTIVE SENSOR SPEED CABLE
7. H.V. CABLE
8. TUBOFLEX FOR OZONE SUCTION FAN

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Art. : Electronic Generator MR/b 8K IGBT
 ELECTRICAL SPECIFICATIONS

ELECTRONIC GENERATOR TYPE MR/b 8K IGBT

SUPPLY VOLTAGE: 3x380-480V* – 50/60 Hz

MAX. ABSORBED POWER: 9 kVA

MAX. OUTPUT POWER: 8 kW

OPERATING FREQUENCY: 20÷30 kHz

GENERATOR DIMENSIONS:

LxHxD=432x869x226

GENERATOR WEIGHT: 30 kg.

H.V. TRANSFORMER DIMENSIONS:

LxHxD=320x350x400

H.V. TRANSFORMER WEIGHT: 49 kg.

*The voltage of the TR1 services transformer inside the

generator must be the same as the supply voltage

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Art. : Electronic Generator MR/b 8K IGBT
 The AIR-GAP (the air space between the discharge electrode and the
roller) where the corona-effect discharge takes place must be
adjusted on the discharge station.

• The electrode group is composed of five ceramic bars positioned

so that roll discharge takes place over more than one line.
• The air gap depends on the electrode length , the type of
dielectric coating of the discharge roller ( silicone or ceramic ) ,
the type of electrodes ( ceramic bar electrode , aluminum
electrode , stainless steel electrode )
Dielectric coating in silicone
Aluminum or stainless steel electrodes
Length up to 4m ( air gap 1,5 – 2mm )
Length over 4m ( air gap 2,5 – 2,8mm )
Dielectric coating in ceramic
Length up to 4m ( air gap 1,2 – 1,5mm )
Electrodes with ceramic bars ( universal station )
Electrode length up to 3m ( air gap 1,5 – 1,8mm )

• To accurately adjust the airgap, ensure that with 5 kV on the

electrodes the discharge is even along the entire length of the
ceramic bars.

• Bear in mind that the ceramic electrodes must be very

precisely adjusted.

5.5 MATCHING BETWEEN GENERATOR AND ELECTRODES

The first operation is the AIR-GAP REGULATION (as explained on page

4.4 )and the right transformer output used . there are 3 taps and the right
one is marked on the HV transformer label.

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Art. : Electronic Generator MR/b 8K IGBT
 Select manual working mode

Push the start button (on)

Slowly increase the power level gradually up to 100% and read the
values of VDC IDC POUT.

If the values read are closed the max allowed IDC 20A VDC 400V
Pout 8000W,the matching is correct

When VDC is around 400V and more but IDC remains below 20A, (with
the air gap well adjusted)

An higher transformer tap must be chosen.

Viceversa ,when VDC doesn’t reach 400V but IDC is 20A full select the
lower transformer tap.

If the problem persists after have done the mentioned procedures,and all
the values are too much distant from the nominal ,we ask to contact our
customer care.

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Art. : Electronic Generator MR/b 8K IGBT
 High-voltage hazard!

The generator’s electrical connections must be made by qualified

personnel trained to work with electronic equipment.

Observe local safety regulations for the installation of the equipment.

SUPPLY CABLE
(LINE 3x400-460V 50Hz)
SERVICE CABLE (INPUTS-OUTPUTS)
PROFIBUS

HEART CABLE
(TO H.V. TRANSFORMER)
POWER CABLE
(TO H.V. TRANSFORMER)

INDICATOR CABLE
(TO H.V. TRANSFORMER)

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Art. : Electronic Generator MR/b 8K IGBT
 CONNECT THE H.V. CABLE TO THE
TAP INSULATOR INDICATED ON THE
NAMEPLATE TRANSFORMER

EARTH POINT ON THE

DISCHARGE STATION

ELECTRODES

TO CONNECT THE H.V. CABLE TO

THE H.V. OUTLET

FROM GENERATOR
OIL LEVEL

TO CON NECT TH E EARTH CABLE

TO CON NECT TH E EARTH CABLE TO THE GENERATOR
TO THE DISCH ARGE GROUP.

EARTH POINT ON THE

GENERATOR

Connect one of the two cables supplied land directly on the side group
download cable to another point of land on the generator.

CERAMIC ELECTRODES

Carefully adjust the distance of the ceramic electrodes from the

discharge roll.

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Art. : Electronic Generator MR/b 8K IGBT
 The air gap depends on the electrode length , the type of dielectric
coating of the discharge roller ( silicone or ceramic ) , the type of
electrodes ( ceramic bar electrode , aluminum electrode , stainless steel
electrode )
Dielectric coating in silicone
Aluminum or stainless steel electrodes
Length up to 4m ( air gap 1,5 – 2mm )
Length over 4m ( air gap 2,5 – 2,8mm )
Dielectric coating in ceramic
Length up to 4m ( air gap 1,2 – 1,5mm )
Electrodes with ceramic bars ( universal station )
Electrode length up to 3m ( air gap 1,5 – 1,8mm )

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Art. : Electronic Generator MR/b 8K IGBT
 INSTRUCTIONS FOR SETTING UP THE GENERATOR

Type MR\B 8K IGBT- (see connection diagram pag.14)

The system is made up of a generator, a high-voltage transformer and a

discharge unit.

1) Apply a three-phase 3x380÷480*V 50/60Hz (9kVA maximum absorbed

power) to input line filter terminals L1-L2-L3-PE (CABLE –5- not
provided)

*The voltage of the TR1 services transformer inside the generator

must be the same as the supply voltage

Apply 24VDC to terminals L+ and M (terminal board –X1-) to supply the

SIMATIC PLC

Connect the inductor sensor for discharge roll rotation detection to

terminals L+, 20, M (see layout pag. 14 or electrical diagram).

Connect:

the discharge unit micro safety switch (electrodes closed) and the
emergency contact (auxiliary) between terminals 12 and 16 on terminal
board X1;

if present, the contact for activating ozone suction fans to terminals 21

and 22;

the contact of the vacuostat (CABLE –4- provided) for detecting ozone
suction and for cooling the discharge unit (electrodes) between L+ and
I0.4.

An external emergency pushbutton can be connected to terminal board

X1 (see electrical diagrams) by disenabling the insertion of the main
contactors on the generator (even if the generator is switched on, it
cannot operate if the emergency pushbutton has been activated).

2) Connect the generator to the High Voltage transformer by using the

cables provided. (CABLE –2- and -3-)

3) Use the HIGH VOLTAGE cable (CABLE –7-provided) to connect the

H.V. transformer to the electrodes in the discharge unit.

Connect the H.V. transformer and the discharge unit to earth

(CABLE –1- provided) (minimum cable section, 6mm2)

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Art. : Electronic Generator MR/b 8K IGBT
 Check the oil level shown on H.V. transformer indicator.

4) Adjust the axes and the AIR-GAP (the distance between the
electrodes and the discharge roll).

N.B. The generator power line must be protected by a differential

switch which will cut off the power if insulation is lost.

The size of the power cable must be appropriate for the maximum
absorbed current (see INPUT data plate on the generator).

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Art. : Electronic Generator MR/b 8K IGBT
6 OPERATION, CONTROL

Section profile:

Who is this section for? This section is for everyone who uses the electronic generator.

Section contents This section gives a description of the operating modes and conditions.

6.1 START UP
The generator has been tested at the factory by Me.Ro. SpA.

It can be started up immediately as no special control procedures are

required.

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Art. : Electronic Generator MR/b 8K IGBT
 7 PROFIBUS-DP ROTOMEC - MERO V1.2 INTERFACE
(MOD SPEED)
X= Address basic device S7 master (Rotomec)

MASTER ROTOMEC INDICATIONS TO ME.RO S7 200 SLAVE ME.RO

PAW X Bit 0 GENERAT. START‐STOP 1 = START 0 = STOP V0.0

Bit 1 RESET 1 = RESET (Impulso) V0.1
Bit 2 REMOTE CONTROL 1 = REMOTE ENABLED (Rotomec default) V0.2
Bit 3 SEL MANUAL 1 = MANUAL MODE SELECTED V0.3
Bit 4 SEL AUT SPEED 1 = AUT SPEED MODE SELECTED V0.4
Bit 5 SEL AUT SPEC POWER 1 = AUT SPEC POWER MODE SELECTED V0.5
Bit 6‐15 Spare
PAW X +2 MAXIMUM SPEED MAX. SPEED FOR 100% POWER (m/min) VW2
PAW X +4 POWER MAX DEVIATION MAX. POWER DEVIAT. ADMISSIBLE 0‐100 % VW4
PAW X +6 ELECTRODE LENGTH ELECTRODES LENGTH (cm) VW6
PAW X +8 SP MAN. 0 – 100 [%] VW8
PAW X +10 SP AUT. SPEED 0 – 100 [%] VW10
PAW X +12 SP AUT. SPECIFIC POWER 0 ‐ 100 [Wmin/m2] VW12
PAW X +14 SPEED SPEED [m/min] x 10 VW14
PAW X +16 SPEED ACTIVATION
SPEED ACTIVATION THRESHOLD [m/min]
THRESHOLD VW16
PAW X +18 Spare VW18

MASTER ROTOMEC READ BY ME.RO S7 200 SLAVE ME.RO

PEW X Bit 0 GENERATORE ON 1 = GENERATOR ACTIVE V20.0
Bit 1 ALARM 1 1 = GENERATOR FAULT V20.1
Bit2 ALARM 2 1 = POWER DEVIATION ALARM V20.2
Bit 3 ‐15 Spare
PEW X+2 I. Dc GENERATOR WORKING CURRENT [A.] VW22
PEW X+4 V.Dc GENERATOR WORKING VOLTAGE [V.] VW24
PEW X+6 P.Out GENERATOR POWER OUTPUT [W.] VW26
PEW X +8 SPEC POWER ACT GEN. ACTUAL SPEC. POWER [Wmin/m2] VW28
PEW X +10 V.Out rms V. OUTPUT H.V TRANSFORM. [V.rms] VW30
PEW X +12 ALARM WORD ALARM VW32
PEW X +14 SIGNALLING WORD SEGNALLING VW34
PEW X +16 Spare VW36
PEW X +18 Spare

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Art. : Electronic Generator MR/b 8K IGBT
VW34 //Word signalling

//VW34 = 1 Ready to start

//VW34 = 2 Station open
//VW34 = 4 Running
//VW34 = 8 Low speed
//VW34 = 16 Alarm present
//VW34 = 64 Power alarm

VW32 //Word alarms (Alm #0 - Alm#15)

//VW32 = 1 Low speed
//VW32 = 2 Station open
//VW32 = 4 Vcc fault
//VW32 = 8 Overtemperature
//VW32 = 16 Ozone suction
//VW32 = 32
//VW32 = 64 Overload
//VW32 = 128 H.V. discharge
//VW32 = 256 Vdc absence
//VW32 = 512 Inverter fault

INDICATOR AREA: VW34

They indicate generator status.

1= ready to start

the generator is ready to be placed in START mode.

2=discharge station open

the generator is kept in STOP mode (close discharge station)

8= Low speed

The film speed is lower than that set at LOW SPEED (VW16)

The generator is kept in STOP mode.

16= Alarm present

Indicates the presence of an alarm in the word ALARMS

The generator is kept in STOP mode.

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Art. : Electronic Generator MR/b 8K IGBT
64=Power alarm

Lower power alarm.

The generator power is lower than that requested.

The generator is not in OFF mode.

For example, with specific power set too high in automatic mode, the generator is in the
maximum output power condition but cannot achieve the specific power set (low power
alarm activated).

WORD ALARMS VW28

1= Low speed

The film speed is lower than that set at LOW SPEED (VW16)

The generator is kept in STOP mode.

2=Discharge station open

The generator is kept in STOP mode (close discharge station)

4=Vcc fault
No direct voltage at chopper.
Supply voltage too low, power supply stage missing, or fault in generator power supply
component.
The generator is kept in STOP mode.

8=Overtemperature
Overtemperature at generator power module dissipator.

The generator is kept in STOP mode.

The alarm is reset automatically when the temperature drops.

Check the cooling fans and filters.

Use and Maintenance Manual Page. 27 a 40

Art. : Electronic Generator MR/b 8K IGBT
16=Ozone suction fan

Suction or depression (vacuostat) insufficient for normal system operation.

The generator is kept in STOP mode.

Check correct operation of ozone suction fan, piping, suction and discharge.

64= Overload

The generator is kept in STOP mode.

To reset the generator, activate RESET (V0.1)

128= H.V. discharge

High voltage discharge to earth in discharge unit.

The generator is kept in STOP mode.

To reset the generator, activate RESET (V0.1)

If the fault persists, check the discharge unit and the high voltage supply cable between
the H.V. transformer output and the discharge unit input.

256= Vdc absence

No output voltage at chopper (the chopper does not operate).

The generator is kept in STOP mode.

Check the chopper and inverter power modules.

512= Inverter fault

The inverter does not operate.

The generator is kept in STOP mode.

Check the inverter power modules and the High Voltage transformer.

Use and Maintenance Manual Page. 28 a 40

Art. : Electronic Generator MR/b 8K IGBT
7.1 OPERATION MODES
SEL MANUAL 1 = MANUAL MODE SELECTED V0.3
SEL AUT SPEED 1 = AUT SPEED MODE SELECTED V0.4
SEL AUT SPEC 1 = AUT SPEC POWER MODE V0.5
POWER SELECTED

7.2 MANUAL
1 = MANUAL MODE SELECTED V0.3

In MANUAL MODE the generator output power can be

adjusted from minimum to maximum by means of the 0 to
100 value given in VW8.
SP MAN. 0 – 100 % VW8

7.3 AUTOMATIC WITH SPEED

1 = AUT SPEED MODE SELECTED V0.4

In AUTOMATIC SPEED MODE the generator output power

increases in proportion to the increase in line speed.

The line speed at which maximum generator power is

MAX. SPEED FOR 100% POWER (m/min) VW2
required must given.

Generator power can also be adjusted by

SP AUT SPEED 0 – 100 % VW10
setting a figure between 0 and 100

In AUTOMATIC SPEED MODE, the generator output power increases in proportion to line speed and is
at maximum power when the speed reaches the MAX. SPEED set and with SP AUT SPEED equal to
100.

If the reduction in power with SP AUT SPEED equal to 0 is insufficient, the MAX. SPEED must be set
higher than the maximum production speed.

Use and Maintenance Manual Page. 29 a 40

Art. : Electronic Generator MR/b 8K IGBT
7.4 AUTOMATIC WITH SPECIFIC POWER

1 = AUT SPEC POWER MODE SELECTED V0.5

In AUTOMATIC SPECIFIC POWER MODE the value set at

(SP AUT SPEC POWER) is the specific power applied to the
film at Wmin/m2 and the set point for the power produced by
the generator.
SP AUT SPEC POWER 0 – 100 (Wmin/m2) VW12
The PLC CPU calculates the specific power produced by the
generator, compares it with the set point and keeps it
constant by means of an adjustment algorithm (equal to the
value set).

This adjustment system takes in consideration production

speed and any changes in load resistance (variations mainly
due to the temperature on the electrodes, the dielectric
coating of the roll and the airgap).

Once the specific power value to be used with the required

treatment has been determined, this operation mode will
ensure that the film is treated evenly.

Any conditions that cannot be controlled by the adjustment

algorithm are indicated by a POWER ALARM signal.

If the specific power inserted is too high, the POWER

ALARM is also displayed when the generator must produce
more than the maximum power allowed in order to maintain
the specific power required.

Use and Maintenance Manual Page. 30 a 40

Art. : Electronic Generator MR/b 8K IGBT
8 SETTING THE PARAMETERS

Before starting up the equipment, certain parameters must be set.

i
Settino the remote control (enabled)
REMOTE CONTROL 1 = REMOTE ENABLED V0.2

SEL MANUAL 1 = MANUAL MODE V0.3

SELECTED
SEL AUT SPEED 1 = AUT SPEED MODE V0.4
SELECTED
SEL AUT SPEC POWER 1 = AUT SPEC POWER V0.5
MODE SELECTED

Line speed at which maximum generator power is required.

MAX. SPEED FOR 100% POWER (m/min) VW2

Setting the minimum speed below which the generator will go

to OFF mode.
LOW SPEED (m\min) VW16

Power value as a percentage of nominal value.

MAX. POWER DEVIAT. ADMISSIBLE % VW4

The VW32 = 64 Power alarm signal is activated when the

generator power drops below the set power limit %.

Electrode length in cm (to calculate specific power)

ELECTRODE LENGTH (cm) VW6

Use and Maintenance Manual Page. 31 a 40

Art. : Electronic Generator MR/b 8K IGBT
 SP MAN. 0 – 100 % VW8

SP AUT SPEED 0 – 100 % VW10

SP AUT SPEC POWER 0 – 100 (Wmin/m2) VW12

Use and Maintenance Manual Page. 32 a 40

Art. : Electronic Generator MR/b 8K IGBT
 8.1 STARTING/STOPPING THE GENERATOR

CHECKING SAFEY DEVICES

Before starting the generator, check the following:

• All safety devices must be activated

• All remote interlocks must be closed

PREPARATION FOR OPERATION

Check of electricity supply Connect the generator to the electricity supply.

Check the operator terminal for any messages or alarm signals

The electronic control checks all alarm inputs after the main generator
switch has been positioned to on.

If the electronic control detects a malfunction, the alarm menu will appear
on the operator terminal display.

The generator can be started only after all alarms have been eliminated.

8.2 OPERATION

The generator is positioned to ON from the operator terminal.

8.3 STOPPING THE GENERATOR

The generator is positioned to OFF from the operator terminal.

Use and Maintenance Manual Page. 33 a 40

Art. : Electronic Generator MR/b 8K IGBT
8.4 SETTING UP AND ADJUSTMENT INSTRUCTIONS

• The AIR-GAP (the air space between the discharge

electrode and the roller) where the corona-effect discharge
takes place must be adjusted on the discharge station.

• The electrode group is composed of five ceramic bars

positioned so that roll discharge takes place over more than
one line.
• The air gap depends on the electrode length , the
type of dielectric coating of the discharge roller ( silicone or
ceramic ) , the type of electrodes ( ceramic bar electrode ,
aluminum electrode , stainless steel electrode )
Dielectric coating in silicone
Aluminum or stainless steel electrodes
Length up to 4m ( air gap 1,5 – 2mm )
Length over 4m ( air gap 2,5 – 2,8mm )
Dielectric coating in ceramic
Length up to 4m ( air gap 1,2 – 1,5mm )
Electrodes with ceramic bars ( universal station )
Electrode length up to 3m ( air gap 1,5 – 1,8mm )

• To accurately adjust the airgap, ensure that with 5 kV

on the electrodes the discharge is even along the entire
length of the ceramic bars.

• Bear in mind that the ceramic electrodes must be

very precisely adjusted.

Use and Maintenance Manual Page. 34 a 40

Art. : Electronic Generator MR/b 8K IGBT
8.5 PROCEDURE FOR CHECKING THE DOUBLE IGBT MODULES .

IGBT module

The double IGBT module is composed of 2 IGBTs with a parallel diode connected
between the collector and the emitter.

To check the module, proceed as follows.

1. disconnect the connections from the module terminals.

2. with the tester on diode, connect the tester positive terminal to terminal C2E1 (1) and
the negative terminal to terminal E2 (2).

The reading will be OL if the IGBT junction is integral.

3. Reverse the tester terminals (negative to terminal C2E1 (1) and positive to terminal
E2 (2) )

The reading will be approximately 0.3-0.4V if the diode parallel to the IGBT junction is
integral.

4. with the tester on diode, connect the tester positive terminal to terminal C1 (3) and
the negative terminal to terminal C1E1 (1).

The reading will be OL if the IGBT junction is integral.

5. Reverse the tester terminals (negative to terminal C1 (3) and positive to terminal
C2E1 (1) )

The reading will be approximately 0.3-0.4V if the diode parallel to the IGBT junction is
integral.

6. with the tester on OHM, check terminals G1-E1 (8-9).

The reading will be OL= high resistance, if the IGBT GATE is integral.

7. with the tester on OHM, check terminals E2-G2 (10-11).

The reading will be OL= high resistance, if the IGBT GATE is integral.

If one or more measurements are incorrect, the module must be replaced.

Use and Maintenance Manual Page. 35 a 40

Art. : Electronic Generator MR/b 8K IGBT
9 MAINTENANCE

Section profile:

Who is this section for? This section is for everyone who carries out maintenance on the
electronic generator.

Section contents This section contains advice and information about generator
maintenance.

9.1 GENERAL NOTES ABOUT MAINTENANCE

This section gives advice about maintenance and describes the work that
must be done to keep the generator operating correctly.

Extraordinary maintenance must be carried out by Me.Ro. spa. technical

personnel.

TECHNICAL SUPPORT

Me.Ro. spa technical personnel can be contacted by telephoning the

company’s offices.

Use and Maintenance Manual Page. 36 a 40

Art. : Electronic Generator MR/b 8K IGBT
9.2 SAFE MAINTENANCE

i
To ensure personal safety, observe the safety regulations and measures
described below.

ALL MAINTENANCE AND REPAIR OPERATIONS INSIDE THE ELECTRONIC

GENERATOR AND THE DISCHARGE STATION MUST BE CARRIED OUT BY
AUTHORISED SPECIALISED PERSONNEL ONLY.

BEFORE CARRYING OUT ADJUSTMENT OR MAINTENANCE WORK ON THE

DISCHARGE STATION, PLACE THE VALVE ON THE SIDE OF THE DISCHARGE
STATION TO THE SAFETY POSITION FOR MAINTENANCE. ENSURE THAT THE
MACHINE HAS STOPPED COMPLETELY AND THAT PNEUMATICALLY- OR
ELECTRICALLY-OPERATED PARTS (PRESSURE ROLLS, ETC.) ARE BLOCKED IN
SAFE POSITIONS.

NB.:

BEFORE WORKING ON THE ELECTRICAL AND MECHANICAL EQUIPMENT,

ENSURE THAT THE ELECTRICITY SUPPLY TO THE MAIN LINE AND TO THE
ALARM DEVICES HAS BEEN DISCONNECTED.

CAUTION! DO NOT OPERATE THE GENERATOR BEFORE MAKING ALL THE

ELECTRICAL CONNECTIONS TO THE HIGH VOLTAGE TRANSFORMER.

The following must be remembered when carrying out generator repairs:

• The voltage at power parts (supply autotransformer output, voltage regulator,

inverter and high voltage transformer) can be as much as 600 VOLTS.

• The maximum voltage from the output of the high voltage transformers to the
discharge electrodes could be over 15 KVOLT 20 KHz. A discharge could therefore
occur at a distance of up to 3-4 cm, depending on environment humidity levels.

• Due to capacitivity, unwanted currents could be present near the discharge

electrodes and high voltage parts. It is therefore important to check the EARTH
connections of all high voltage parts in panels, locks and screens.

Use and Maintenance Manual Page. 37 a 40

Art. : Electronic Generator MR/b 8K IGBT
 High-voltage hazard!

The generator converts low frequencies and electrical power into DC

power. High-voltage components can give electric shocks.

Ensure that the dangerous parts of the generator are known about.

REMOVING RESIDUAL VOLTAGES

High-voltage hazard!
After the generator has been switched off, there may be residual voltages
in certain parts (see section 2: “Safety”)

Disconnect the generator and observe the safety regulations for systems
with high electric voltages.

9.3 MAINTENANCE INTERVALS

Regular maintenance Inspect the generator at regular intervals.

When carrying out maintenance work, the time required and the
environmental conditions in which the generator operates must be taken
into consideration.

9.4 MAINTENANCE WORK

Visual inspection

It is advisable to regularly carry out a general visual inspection.

Check the generator to identify any areas of humidity, corrosion and dirt.
To ensure perfect plant efficiency, it is essential to regularly clean the
discharge station and eliminate residues of plastic material and dirt that
has accumulated inside. In particular, perfectly clean the high-voltage
insulators with non-flammable solvents, the discharge electrodes (with
copper-wire brushes and solvent), the high-voltage electrical connections
and the roll.

• For perfect maintenance, the ceramic electrodes are easily

removed from the electrode housing.

Use and Maintenance Manual Page. 38 a 40

Art. : Electronic Generator MR/b 8K IGBT
 • To remove them, proceed as follows:

• Support the electrode unit;

• release the electrode unit by turning the three knobs on the top of
the electrode housing 90° anticlockwise;

• Using non-flammable solvents, carefully clean the internal parts

of the electrode unit, taking care not to damage the ceramic bars, which
are fairly delicate.

• It is important to clean the ceramic electrodes frequently as the

air that passes through the ceramic bars is essential for cooling them and
preventing them from burning.

On the generator, check:

• the oil level in the H.V. transformer;
• the operation of the cooling fans;
• clean or replace the air filters.

9.5 DISMANTLING AND PACKING

ISOLATING THE UNIT

1. Switch off the generator

2. Disconnect the power line from the generator

3. Remove all the external electrical connections

If the H.V. transformer is to be replaced, it must be remembered that it

contains approximately 10 litres of insulating oil for transformers, which
must be disposed of only by authorised disposal or recycling firms.

Use and Maintenance Manual Page. 39 a 40

Art. : Electronic Generator MR/b 8K IGBT
 PACKING

Take the size of the generator into consideration when packing it.

Place on a pallet, cover it with a plastic sheet and secure with belts.

TRANSPORT

See section 5.1 “Transport”

DEMOLITION

The generator is mainly composed of the following materials.

Metals:

a. Aluminium

b. Copper

c. Steel

d. Brass

e. Galvanised iron sheets

f. Steel sheets

Plastics:

g. Teflon, PA and others

Other materials:

h. Electronic circuit boards

i. Ceramic

Use and Maintenance Manual Page. 40 a 40

Art. : Electronic Generator MR/b 8K IGBT
 ENERGIZED (GENERATOR MR/b 8K IGBT) PE
OZONE SUCTION TYPE
RD 65 ELEKTROR
L1
GENERATOR MR/b 8K IGBT SUPPLY COSTUMER
3x400V 50/60Hz L2 (OZONE SUCTION)
MAX.POWER INPUT 3kVA
L1 L1 L3

3
L2 L2
SUPPLY COSTUMER
3x380..-..480V 50/60Hz L3 L3
MAX.POWER INPUT 9kVA
PE PE (RECTIFIER)

(LINE
FILTER)

(H.V. BOX)
(DISCHARGE
STATION)
(H.V.TRANSFORMER)
H.V. TRANSFORMER
(SHIELD)
(POWER CABLE)
U1
(H.V CABLE CONNECTION)

(ELECTRODE)
U2
(H.V.OUTPUT)
(CHOPPER) (INVERTER)

(GROUND CONNECTION)

(ROLLER)

(ARMOURED)
(SIGNAL CABLE)

(CONTROL MODULE)
CNS CNST

DIAGRAM N°5512

(GROUND CONNECTION) (OZONE SUCTION SWITCH)

PE
(HUBA CONTROL
625.6132 -4-30mBAR)

(PROFIBUS DP)
(PLC CONTROL
SIMATIC S7-200
SIEMENS)

(X1 SOCKET (MICRO SWITCH

INSIDE CHASSY) (GENERATOR-SIGNAL DISCAHRGE
STATION INTERFACE)
STATION CLOSED)

PE

L+

I0.4

21
(AUX CONTACT FOR TURN ON
22 OZONE SUCTION CONTACTOR
[OUT O0.6]
12
X1
(EMERGENCY)

DIAGRAM N°5584

16

M F5
M
(PROFIBUS-DP INPUT)
L+ F6 (SUPPLY 24VDC
L+ FOR S7-200)

PE

Me.Ro S.p.A. Electronic Industrial Equipment

Via Balestreri, 430 Ponte a Moriano - 55100 - Lucca - ITALY

GENERATOR MR/b 8K IGBT

Size Directory DWG NO Rev

1
C C:\DIS2N 7928\A3 COM.5257\13 ROTOMEC

Friday, September 06, 2013 Sheet

1 of 1
 B5294 CHOPPER3-INVERTER3
13
(FROM JP3 [PIN5] (FROM X2) 13
R1-R2-R3 - AWG10 black ON B4728) 24
S1-S2-S3 - AWG10 black (FROM X2) 12
MV2
T1-T2-T3 - AWG10 black (FROM JP3 [PIN6] D10 D9 D14
ON B4728) 25 12
+A - 3xAWG14 black (+3 - 2xAWG12 black) C12 R14 R13
+C - 3xAWG14 black (+4 - 2xAWG12 black) HR1
IMF1
- - AWG10 black F1
CN2 B5294
(2xAWG12 black)
+A
CARATT.IM1-IMF2 L+
(FROM PLC) L+

F1

F1

D10

D10

I1

I2

C12

C12

R14

R14

R13

R13

TC1

TC2

D9

D9

D14

D14
DIAGRAM N°3524 (TO JP1 [0.7]
ON B5436 D.I) I0.7 +C
I0.7
+C 1

(3XAWG14 black)
R5E 2
M (FROM 1-JP4 ON +2 3
(FROM PLC) M THE B4728) +2
CN1-AUX 4
BS1

JP1M
+3 5
(FROM JP1 [0.2]
ON B5436 D.O) Q0.2 (2xAWG12 black) 6
Q0.2 JP1
- 7
R6E 8
PD1 +4 9
10

+
FL1
IA1
CN1
L1 R1 R2 R3

GSCR
L1

AG11
AE11
L1 L1' IMF2

JPI1

JPI2
JPC

G21

G11

G12

G22
E21

E11

E12

E22

JP2
Q1

Q1

Q1
U1

U1
U1

U2

U2
U2

U3
U3

U3
L2 S1 S2 S3
L2 L2 L2'

RC1-AUX
L3 T1 T2 T3

CN1-AUX
L3

(FLAT CABLE 14P)

(FLAT CABLE 10P)

L3 L3' DIAGRAM N°5294 U1 Q1 3 U2 U3 B5294 CHOPPER3-INVERTER3
3 A 3 3
PE PE' B758 B3052

-
4 1 AK 4 4

(FLAT CABLE 10P)

PIL.INV
BOX INSIDE
C2E C3E
+ 5 5 5
7 S 3 4 G1
- 2 5 JPI2
K1
1 U1 1 1 1 1 1 1
K
R19E JPI1
2
F2 - 1AM 6x30mm 758
S1 B758
F3 - 1AT 5x20mm (SCR CROWN BAR)
T1
F5 - 2AT 5x20mm (red wire)
F5 - 2AT 5x20mm - 6 6 6

(WIRE 10)

(WIRE 1)

(WIRE 2)
(AWG10 black) 7 7 7
F3 (MONTARE SCHEDA CON
2 2 2 TRASFORMATORE
110 12 (FLAT CABLE 6P) PIL.IGBT IMPULSI 130608)

DC-LINK +2
TP4 1-JP2 (CHOPPER IGBT) (INVERTER IGBT)
TR1 220 2-JP2
460
TERM1 (FLAT CABLE 14P)
(FROM JP2 ON B4728) JP17
F2 (N°1 RED)
11 400 110 SB-INTERF B4728 TERM2 (MODIFICHE B2561)
(TO JP1 [0.5]
ON B5436 D.O) Q0.5 Q0.5 (FLAT CABLE 14P) B2561 DIAGRAM N°6087
- (TOGLIERE D1;D2;R2)
S 1-2 JP-LEM1 JP1
-20 + 3-4 JP-LEM1 (SOSTITUIRE R3 CON 10ohm 2W)
JP2M
DIAGRAM N°7821
0 M 5-6 JP-LEM1
(FROM PLC) M

1
2
3
4
5
6
X2
A1+

JP1 (FLAT CABLE 14P)

A2-

RL1 B6626
11

+20
0
X1 JP2 (TO JP17 ON B3052)
U1 (AWG20 black)

U1
U2
3-JPVOL1 U1 (FROM PIN 3 ON JP2)
21 (FROM TR1) 12 U2 (AWG20 black)
(FROM X1) 21 3-JPVOL1 U2 (FROM PIN 4 ON JP2)
14

12

VOL.C
(TO JP1 [0.6] (TO MV1) 12 4 CNVOL1 1-JPSBC
ON B5436 D.0) Q0.6 Q0.6 M B6627
2 CNVOL1 VOL.I 2-JPSBC
(TO MV2) 12 12 (TO X1.9) 1 CNVOL1 3-JPSBC
M 15 (TO JP5 [PIN6] DIAGRAM N°6626
(FROM PLC) M 12 ON B4728)
A1+
A2-

RL2
11

12 (TO AL1) B2136 MC-CHOPP1 B2136

(TO JP5 [PIN5]
(FROM TR1) 13 13 ON B4728) CN1 CN3
16 VOL.C - AWG20 blue
DIAGRAM N°4962 M - AWG20 blue
(TO MV1) 13 13 (TO AL1) (ARROTOLARE LA
14

12

B1378 VOL.I - AWG20 blue

RC2 B1378 MC-INVERT1 CALZA SUL
(TO MV2) 13 CONNETTORE)
CN2 CN4
CN2 CN1
RC1 DIAGRAM N°1378
22 13
(TO X1) 22
GND (SHIELD) (SHIELD CABLE 2x0,5)
5-JP6 V.OUT (BROWN WIRE) (SHIELD)
4-JP6
I.OUT (WHITE WIRE)
2-JP6
(SHIELD) I.OUT

(POWER CABLE 7x1,5mm BLACK+ SHIELD)

U2

V.OUT
+4 (+VDC) +1 - AWG20 black U1
6-JP4 +4
- (-VCC) (TO JP1M ON THE B5294) - - AWG20 black U1
4-JP4 -
+2 (+VCC) +4 - AWG20 black U2
1-JP4 +2
X1
U1
U2
CONNECTION PLC S7-200

3
PE BOX OUTSIDE U8
(SHIELD FLAT CABLE 26P)
U8
2 1
(HUBA CONTROL 24
24 (TO CN1 N.O (TO BS1 COIL) Q0.2
Q0.2
6-JP3 0.2 JP2 B5426 D.O
(FROM PLC) L+
L+ 625.6132 -4-30mBAR) 25
25 CONTACT) (TO RL1 COIL) Q0.5
Q0.5
5-JP3 Q0.6 0.5 JP2 B5436 D.O XM1
4-JP3 (FARE PONTICELLO) (TO RL2 COIL) Q0.6 0.6 JP2 B5436 D.O
(TO JP1 [0.4] I0.4 M
ON B5436 D.I) I0.4 1-JP3 (FROM F5) M M JP2 B5436 D.O
L+
(FROM F6) L+ L+ JP2 B5436 D.O
21 XF2 (G\Y)
(TO RL2) 21 GND JP2 B5436 D.O
(AUX CONTACT FOR TURN ON
22 OZONE SUCTION CONTACTOR 12 2 1
(FROM RL2) 22 [OUT Q0.6] 6-JP5 12 (FROM X2)
13 (SUPPLY
5-JP5 13 (TO X2) 110VAC)
12 I0.4
(FROM X2.3) 12 (FROM X1) I0.4 0.4 JP1 B5436 D.I

3
-15V I0.7
(EMERGENCY) 3-JP5 (FROM CN1-AUX) I0.7 0.7 JP1 B5436 D.I
0V M
(FROM F5) M

V.OUT 3
2-JP5 +15V M JP1 B5436 D.I 4 2

(SHIELD)
1-JP5 6

I.OUT
5 1
(MICRO SWITCH
16 STATION CLOSED) M U1 - PIN 1;4 OF XF3
(TO CN1 COIL) 16 B4728 (FROM F5) M M UP3
DIAGRAM N°4854 L+ XF3 U2 - PIN 2;5 OF XF3
(FROM F6) L+ L+ UP3
(TO PLC S7-200) M
M F5
M PE UP3 G\Y - PIN 3
(SUPPLY 24VDC
L+ F6 FOR S7-200)
(TO PLC S7-200) L+ L+ N° WIRE TYPE-COLOR DIAGRAM N°5701

BOX OUTSIDE
12 - AWG20 red
PE
13 - AWG20 white SIGNAL CABLE
15 - AWG20 red (armured cable 3x0,75)
16 - AWG20 red
LISTA COMPONENTI CHASSY
24 - AWG20 red
25 - AWG20 red
13 AL1 +2 - AWG20 black DIAGRAM N°5740
(FROM X2.7) 13

V.OUT
(SHIELD)
- - AWG20 black

I.OUT
12 12 (110VAC) +4 - AWG20 black
(FROM X2.2) 12 (FROM X2) 12 L1
+15
MV1 C20 +15V - AWG20 blue
0
0V - AWG20 blue
13 (110VAC) N -15V - AWG20 blue
(FROM X2) 13 -15

B
ME.RO S.r.l PONTE A MORIANO LUCCA ITALY
GND 21 - AWG24 light blue Title
22 - AWG24 light blue GEN. MODULE MR\B 8K-CH\S7-200
L+ - AWG24 light blue A C
M - AWG24 light blue Size Document Number Rev
XM2 C 5584\A3

Date: Friday, September 06, 2013 Sheet 1 of 1

 8 7 6 5 4 3 2 1

B5436 D.O

B5436 D.O. PLC S7-200 INTERFACE

(SHIELD FLAT CABLE 26P)
(FROM U8 ON B4728 CARD) U8

PE ATTENZIONE: NEL
M GND JP1 COLLEGAMENTO FLAT FRA JP3
(FROM F5) M M JP1 E JP4 TOGLIERE I FILI
L+ 11-12-13-14 DEL CAVO FLAT)
(FROM F6) L+ L+ JP1
D+ JP1
1.1 JP1
D 1.0 JP1 JP3 D

Q0.6 0.7 JP1

(TO RL2 COIL) Q0.6 0.6 JP1
N° Q0.5

GND JP1
(TO RL1 COIL) Q0.5 0.5 JP1

19 - U8

17 - U8

23 - U8

25 - U8
0.2 JP1

0.3 JP1

0.4 JP1

0.5 JP1

0.6 JP1

0.7 JP1

1.0 JP1

1.1 JP1
TYPE-COLOR

L+ JP1

L+ JP1

L+ JP1
WIRE

6 - U8
M JP1

M JP1

M JP1

M JP1

M JP1

M JP1

M JP1
7 -U8
0.4 JP1
Q0.2 0.3 JP1
(TO BS1 COIL) Q0.2 0.2 JP1
L+ - AWG24 light blue DIAGRAM N°5436
M - AWG24 light blue
+ +
1M 1L 0.0 0.1 0.2 0.3 0.4 2M 2L 0.5 0.6 0.7 1.0 1.1 PE M L+ RA A+ A- RB B+ B- RC C+ C- RD D+ D-
SIEMENS
I0.4 - AWG24 light blue S7-200
I0.7 - AWG24 light blue DIGITAL OUTPUT (Q) ANALOG INPUT PROFIBUS DP
EM235
235-OKD22-OXAO EM277
Q0.3 - AWG24 light blue CPU224 OFFSET 277-OAA22-OXAO
Q0.5 - AWG24 light blue 214-1AD23-OXBO CONF
Q0.6 - AWG24 light blue UP1 UP2 GAIN UP3

ON
OFF
OFF
OFF
OFF
ON
DIGITAL INPUT (I)
1M 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 2M 1.0 1.1 1.2 1.3 1.4 1.5 M L+ M L+ PE MOVO IO M L+ PE
(FROM CN1-AUX
N.O. CONTACT FOR
6-8K CH) 0.0 JP2
I0.4

M JP2

0.0 JP2

3 - JP4

5 - JP4

9 - JP4

0.4 JP2

7 - JP4

1 - JP4

0.7 JP2

M JP2

1.0 JP2

1.1 JP2

1.2 JP2

1.3 JP2

1.4 JP2

1.4 JP2

M JP2

2 - JP4

M JP2

2 - JP4

GND JP2

M JP2

8 - JP4

I.O JP2
C (FROM X1) I0.4 0.4 JP2 C
I0.7
I0.7 0.7 JP2 M
1.0 JP2 (FROM F5) M
1.1 JP2
L+
1.2 JP2 (FROM F6) L+
(FROM CN2-AUX
N.O. CONTACT FOR 1.3 JP2
12-15-18K CH) 1.4 JP2
1.5 JP2
(FLAT CABLE 14P)
M I.O JP2
(FROM F5 ON X1 SOCKET) M M JP2 JP4
GND JP2
ATTENZIONE: NEL
B5436 D.I. PLC S7-200 INTERFACE B5436 D.I DIAGRAM N°7359 COLLEGAMENTO FLAT FRA JP3
E JP4 TOGLIERE I FILI
11-12-13-14 DEL CAVO FLAT)

ATTENZIONE: PONTICELLARE
PE CON MO SU UP2

CPU224
DIGITAL INPUT
B B

X1 2-JP2 ON B5436
I0.4 (OZONE SUCTION SWITCH)
INPUT-OUTPUT LOGICAL PLC
CN1/CN2 CONT. 3-JP2 ON B5436 (CN1/CN2 CLOSED)
I0.7 (STATION-EMERGENCY)

(FROM CARD B4728) (pin24-U8)

I0.1 (H.V. DISCHARGE)
EM235
(FROM CARD B4728) (pin16-U8)
I0.2 (OVERLOAD)
ANALOG INPUT
(FROM CARD B4728) (pin14-U8)
I0.5 (THERMAL OVERLOAD)
(FROM CARD B4728) (pin26-U8)
I0.6 (VCC-FAULT)
(FROM CARD B4728) (19-U8)
A+ (IDC )
(FROM CARD B4728) (17-U8)
B+ (VDC)
DIGITAL OUTPUT
(FROM CARD B4728) (23-U8)
C+ (V.OUT)

BS1 2-JP1 ON B5436

A Q0.2 (BS1 COIL) A
RL1 COIL 3-JP1 ON B5436
Q0.5 (ON CN2) ANALOG OUTPUT
RL2 COIL 4-JP1 ON B5436
Q0.6 (CN1/CN2 CLOSED)
ME.RO S.p.A PONTE A MORIANO LUCCA ITALY
(TO CARD B4728) (12-U8) Title
VO (POWER REGULATION)
(TO CARD B4728) (6-U8) PLC S7-200 SIEMENS CONNECTIONS FOR ROTOMEC
Q0.0 (ON-OFF GENERATOR)
M
MO
(TO CARD B4728) (7-U8) Size Document Number Rev
Q0.1 (RESET)
5701\A3

Date: Friday, September 06, 2013 Sheet 0 of 0

8 7 6 5 4 3 2 1
GENERATOR MR/b 8K IGBT Revised: Friday, September 06, 2013
5842\A3 COM.5257\13 ROTOMEC Revision: 1

Me.Ro S.p.A. Electronic Industrial Equipment

Via Balestreri, 430 Ponte a Moriano ‐ 55100 ‐ Lucca ‐ ITALY

Bill Of Materials September 6,2013 10:39:47

N° Quantity Diagram Reference Component Type Component Model Me.Ro Code

______________________________________________

1 1 AL1 POWER SUPPLY MEAN WELL T40‐C 15400

2 1 BS1 RELEASING MECHANISM LAUNCH A‐PKZ0 24VDC 84724
3 1 B758 ELECTRONIC CARD B758 LEM CIRCUIT 200945 EST
4 1 B1378 ELECTRONIC CARD B1378 INVERTER CONTROL BOARD 200164 EST
5 1 B2136 ELECTRONIC CARD B2136 CHOPPER CONTROL BOARD 200450 EST
6 1 B2561 ELECTRONIC CARD B2561 CHOPPER PILOTAGE BOARD 200945 EST
7 1 B3052 ELECTRONIC CARD B3052 INVERTER PILOTAGE BOARD 200552 EST
8 1 B4728 ELECTRONIC CARD MOTHER BOARD B4728 200998 EST
9 1 B5294 ELECTRONIC CARD B5294 INVERTER\CHOPPER BOARD 200594 EST
10 1 B6627 ELECTRONIC CARD B1766 REACTION BOARD 200190 EST
11 1 CN1‐AUX AUX CONTACT AUX DILA‐XHI02 2XNC 198755
12 1 CN1 CONTACTOR DILM32‐10 110VAC MOELLER
13 1 CN2 CONTACTOR DILM 9‐10 110VAC MOELLR 198709
14 2 C2E,C3E CAPACITOR C‐44U 600uF 900VDC *****
15 1 C12 CAPACITOR 2,5uF 850V CUBO PMB ICEL 36108
16 1 C20 POLYESTER CAPACITOR 0,1uF 630V 36149
17 3 D9,D10,D14 DOUBLE DIODE DSEI2X101‐12B IXYS 148101
18 1 FL1 POWER LINE FILTER FN3258‐30‐47 SCHAFFNER 68130
19 1 F1 FUSE ET56 56A 660V E1000‐56 = ET‐56 74211
20 1 F2 FUSE 1AM 6x30 PORTAFUSE ST4HESI 6X32MM PHOENIX 196335
21 1 F3 FUSE 1AT 5x20 PORTAFUSE ST4HESI 5X22MM PHOENIX 196130
22 2 F5,F6 FUSE 2AT 5x20 PORTAFUSE ST4HESI 5X22MM PHOENIX 196130
23 1 HR1 THERMAL SWITCH 70°C N.C. A BASE ELLITTICA 58102
24 1 IA1 MAGNETOTHERMIC SWITCH PKZM0‐20 MOELLER 84127
25 1 IMF1 IMPEDANCE TOROIDE 43x43x13MM D10468
26 1 IMF2 IMPEDANCE IMP. MR\B 8K‐IGBT 114X93 176806
27 1 JP1M CONNECTOR CONN. 10P MA/FILO STVS10SS WEID 42645
28 1 JP2M CONNECTOR CONN. 6P MA/FILO STVS6SS WEID 42448
29 1 MV1 CABINET FAN 120x120MM 110V 15W 4715MS12TB5A 184054
30 1 MV2 CHOPPER‐INVERTER FAN 172X150MM 110V 35W 5915PC12TB30 184143
31 1 PD1 BRIDGE PSD 51/16 51A 1600V 3F ******
32 1 Q1 SCR MODULE SKKH 106/16E SEMIKRON ******
33 2 RC1,RC2 RC FILTER 0,1uF‐100 OHM 630V ARCOTRONIC 68004
34 1 RC1‐AUX RC FILTER 0,1uF 1600V IC + 100ohm 2W 36068+136285
35 2 RL1,RL2 RELAY PHOENIX CONTACT PLC‐24VDC/21 196847
36 2 R5E,R6E RESISTOR 110 OHM 50W RSC‐50 IRE 134510
37 1 R13 RESISTOR 22 OHM 25W RCH‐25 134722
38 1 R14 RESISTOR 47 OHM 25W RCH‐25 134747
39 1 R19E RESISTOR 500 OHM 25W RCC‐1364 134157
40 1 TR1 SERVICE TRASFORMER 150VA 250VA PRI.+20;0;‐20:400:460V SEC.0‐110‐220V 171512
41 1 U1 SENSOR CURRENT LEM LA55P ******
42 3 U1,U2,U3 IGBT MODULE SKM 100GB 125DN SEMIKRON ******
43 1 XF2 CONNECTOR SRCN6A13 3S FE‐VO JAE 42139
44 1 XF3 CONNECTOR 6P FE/VO PFCN63SC12 42112
45 1 XM1 CONNECTOR SRCN2A13‐ 3P MA/PA JAE 42180
46 13 CAB1 CABLE N°13 MT ‐ SIGNAL CABLE 3X0,75MMQ ARMATO OLFLEX 110SY 44030
47 13 CAB2 CABLE N°13 MT ‐ POWER CABLE 7X1,5MMQ OLFLEX CLASSIC 110CY BLACK 44971
48 1 CH CHASSY PIASTRA CENTRALE CHASSY MRB/GST 4‐6K/IGBT D9777
49 3 CH CHASSY N°3 PASSACAVO ANELLO D9,5MM G. NERO RS543210 108137
50 1 CH CHASSY MONT. LAT. SX CHASSY GST/MRB 4/6K‐IGBT D9775
51 1 CH CHASSY SPALLA SX LATERALE CHASSY 4/6/8K BASSO D14705
52 2 CH CHASSY N°2 DISTANZ. 4MA F/F 15MM PLASTICA 6031
53 1 CH CHASSY MONT. LAT. DX CHASSY GST/MRB 4/6K‐IGBT D9774
54 20 CH CHASSY N°20 ‐ DISTANZ. 3MA M/F H=10MM RS606686 6020
55 1 CH CHASSY SPALLA DX LATERALE CHASSY 4/6/8K BASSO D14706
56 8 CH CHASSY N°8 ‐ DISTANZ. 3MA M/F H=8MM RS221134 6020
57 2 CH CHASSY N°2 ISOLATORE Ø19XH25MM 5MA F/F ROSSI 94005
58 1 INV INVERTER DISSIPATORE X MRB‐GST 4/6+8K‐IGBT D8432
59 2 INV INVERTER SQUAD. FISS. DISS. CHASSY GST/MRB 4/6K D9778
60 1 INV INVERTER N°3 SPESSORE ALLUMINIO A CUBO X DIODI DSEI2X D7002
61 4 JP INVERTER N°4 FERMACAVO X CONN. 7X2P FE/VO FLAT CABLE 42753
62 3 JP INVERTER N°3 FERMACAVO X CONN. 5X2P FE/VO FLAT CABLE 42953
63 1 PRT CHASSY PROTEZIONE B CONDENSATORI 6/8K‐CH LEXAN D14693
64 1 PRT CHASSY PROTEZIONE A RESISTENZE 6/8K‐CH LEXAN D14692
65 1 PRT CHASSY PROTEZIONE C FILTRO RETE 6/8K‐CH LEXAN D14694
66 1 PRT CHASSY PROTEZIONE LEXAN INVERTER 4/6K‐CH/22U D12829
67 2 PRT CHASSY N°2 TAPPO SUPER. CHASSY 6/8K‐CH D14219