LABORATORY CORONA TREATER

OPERATORS MANUAL
N010-020 (60Hz) & N010-021 (50Hz)

!! CAUTION !!

This instrument emits a high frequency, high voltage spark. Keep the electrode tip away from the body.
Care should be taken to avoid letting the spark be attracted to metal objects worn on the body such as
rings and jewelry. A spark to the body will not cause harm, but might cause a slight discomfort, like the
sensation felt when a spark jumps from the finger tip to a metal object after having walked across a
carpet on a dry day. The output of the instrument is at a very low current. Also, the skin of the body
has a very high resistance to the high frequency current, causing any current to flow harmlessly over the
skin.

Do not operate in or around flammable liquids or gases as the spark may ignite them.

Ozone gas is generated around the tip of the electrode when oxygen in the air is ionized. The gas has a
pungent odor, but is harmlessly dissipated in a normally ventilated area. Do not use in a confined area
where high concentrations of ozone gas can develop.

This instrument generates an output at the radio-frequency level. Users who wear a pacemaker, or use
other medical electronic devices which might be affected by radio-frequency waves, are advised to
consult a physician before using this instrument.

SECTION 1 - GENERAL INFORMATION

1.1 Description

1.1.1 The Models BD-20C and BD-20CV High Frequency Generators produce a high voltage, high
frequency spark at the tip of an electrode. The electric field created around the electrode is used for
surface treating of polymers.

1.1.2 The Generator and associated electronic and mechanical assemblies are housed in a durable
Bakelite case which can be held comfortably in the hand. It has a 6 ft (1.8 m) power cord to permit
ample movement over the work surface. Power is supplied by a transformer which is housed in a
separate unit for better heat dissipation. This case is finished in a durable, silicone-based paint which
is scratch resistant. Metal tabs are incorporated into the case for permanent mounting.

1.1.3 The Power Supply is furnished with a polarized and grounded power line cord 6 ft. in length.
Operation is from 115 volts, 50/60 Hz for the Model BD-20C, and 230 V, 50/60 Hz for the Model BD-
20CV. Each model is equipped with a line cord plug which meets US electrical code configurations
for that voltage.

1.1.4 Both models are supplied with two electrodes.

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1.2 Packing List

1.2.1 Carefully remove the instrument and accessories from the packing materials. Check all parts against
the Packing List. Report any shortages immediately.

Quantity Part/Model No. Description

1 080-1201-1 Generator
1 080-1200-1 Power Supply, 115 V (BD-20C)
1 080-1202-1 Power Supply, 230 V (BD-2OCV)
1 12801 Electrode, Round, 1/2 in.
1 13811 Electrode, Field Effect, 3 in.
1 085-0057-3 Instruction Manual

1.3 Specifications

Output Voltage 10,000 to 50,000 volts

Frequency 4 to 5 MHz
Operating Duration Continuous
Input Voltage BD-20C: 115 V, 50/60 Hz
BD-20CV: 230 V, 50/60 Hz
Generator (L x D) 11 x 2-1/2 in. (28 x 6.4 cm)
Power Supply (H x W x D) 4-1/8 x 7-3/4 x 3-1/8 in. (10.5x19.7x8cm)
Shipping Weight BD-20C: 6 lbs (2.7 kg)
BD-2OCV: 7 lbs (3.2 kg)

1.4 Warranty Repair / Replacement Information

1.4.1 Forward the instrument, freight prepaid to the factory or distributor from which it was purchased,
along with a copy of the invoice for warranty verification. The instrument is date coded as to the date
of manufacture.

1.4.2 UV Process Supply, Inc. reserves the right to repair or replace any instrument sent in for warranty
repair.

1.4.3 Instruments found to be out of warranty will be repaired for a minimal labor and parts charge, unless
directed to do otherwise. If it is determined that repair costs will exceed the cost of a new instrument,
the customer will be so advised.

1.4.4 Parts for discontinued models will be made available, wherever possible, for a minimum period of
five years after the model has been discontinued.

SECTION 2 - INSTALLATION

2.1 Installation

2.1.1 The instrument should be located away from sources of heat or air conditioners. Avoid areas of high
humidity or highly corrosive atmospheres; if operation is required under any of these conditions, use
intermittently and remove to another location for storage.

2.1.2 Do not use near flammable liquids or explosive gases.

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2.2 Assembly

2.2.1 Connect the plug from the Generator into its matching receptacle on the Power Supply. The plug is
polarized to fit into the receptacle only one way. Arrows indicate its proper position in the socket. Do
not attempt to force the plug into the receptacle. Rotate until it fits easily; once properly seated, push
firmly into place.

2.2.2 Connect the power line cord to its matching three wire power line receptacle. This provides power
properly polarized and grounded. Operation in any other way will result in a potential shock hazard
and may affect the performance of the instrument.

2.2.3 If it is necessary to replace the power line plug with a different type for use outside of the United
States, use one with a ground connection and install following this wiring convention: black wire to
the high side of the power line; white to the neutral side of the power line; green wire to earth ground.

2.3 Accessory Information

2.3.1 Push either of the electrodes furnished into the matching socket in the Generator. To remove the
electrode, firmly grasp the metal base of the electrode which protrudes about 1/4 in. (6 mm) from the
case and gently rock back and forth while pulling it out. Do not install or remove the electrode while
in operation.

SECTION 3 - OPERATION

3.1 Operation Controls

3.1.1 Power ON/OFF Switch. Located on the side of the Power Supply case. In the ON position, circuitry
is energized.

3.1.2 High Voltage Adjust Knob. Located on the end of the Generator case opposite the electrode, adjusts
the spark length by changing the spacing between the tungsten contacts inside. A clockwise rotation
increases the spark length.

3.2 Calibration

3.2.1 The instrument requires no user calibration internally. However, use of a Peak Voltage Calibrator is
recommended if setting the output voltage accurately and with repeatability is required.

3.3 Operation

3.3.1 Bring the electrode tip near a large metal object or a ground connection. Turn the Power Switch to
the ON position. If no spark is seen to jump from the electrode, the spark is being confined between
the two internal tungsten contacts in the Generator. (NOTE: An associated electric field can be felt
near the location of the tungsten contacts located opposite the electrode side of the Generator.)
While the electrode is near the metal object, turn the High Voltage Adjust Knob until the spark is
seen to jump from the electrode to the metal surface.

3.3.2 Continue to turn the knob until a spark of the desired length emanates from the electrode. A nearly
linear relationship exists between spark length and spark voltage. A 1 in. (25 mm) spark represents
peak voltages of approximately 50,000 volts; a 1/2 in. (13 mm) spark, 25,000 volts. Adjust the length
of the spark most suitable for the application. Usually the proper spark length is determined through
experience; however, the shortest possible spark length should be used to achieve the desired

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 effect. This device is classified as a Tesla Coil, which is an induction coil generating high frequency,
high voltage.
3.4 Corona Surface Treating

3.4.1 The surface of polymers is modified by corona treatment at a characteristic rate which varies with the
material treated. Also, the degree of treatment, or extent of surface modification required, will
depend on the particular application.

3.4.2 The guidelines below are given to help determine the optimal conditions for a particular application,
as the surface effect produced by corona treatment depends upon the following:

• treatment time
• power
• distance between electrode and surface to be treated
• electrode size and shape
• area being treated
• material being treated

3.4.3 Treatment Time The most important variable in nearly all applications is treatment time.
Treatment effect, measured by an increase in surface energy, is approximately an exponential
function of time, and most of the treatment effect therefore occurs quickly. The characteristic time, is
determined by electrode size, power, etc.

3.4.4 Power Power is adjusted by the control knob of the end of the handle. The product of power and
time is effectively constant for any application. In other words, reducing the power in half will double
the time required to obtain the same treatment, when all other parameters are held constant.

3.4.5 Distance between electrode and surface The distance between the electrode and the surface to be
treated can be varied. Normally the most efficient treatment is obtained at distances between 1/8
and 1/4 in. Significant treatment can still be obtained at distances as great as 2 in., though treatment
times become longer.

3.4.5.1 For example, the treatment done in 0.25 seconds at 1/2 in. may take 15 seconds to do the same
treatment at a distance of 1 1/2 in. A qualitative feel for the distance over which the corona is
effective can be obtained by visual inspection of the purple corona. This is best done in a darkened
room.

3.4.5.2 A metallic conductor within about 2 in. of the electrode (a floating ground plate) will pull the corona in
the direction of the plate. This may permit more efficient treatment at larger distances from the
electrode, but the treated area is somewhat smaller. The conductor may be quite thin (e.g., copper
clad printed circuit board material, standard aluminum foil), but it must be covered with a dielectric to
prevent arcing from the electrode.

3.4.6 Electrode Size and Shape Two electrodes are furnished, a circular and a field-effect electrode.
Larger size electrodes in these shapes are not practical for use with the Models BD-20C and BD-
20CV because of power limitations.

3.4.6.1 The circular electrode is used primarily to treat flat surfaces. The diameter of the maximum width of
the surface to be treated is generally about 1 in. greater than the diameter of this electrode.

3.4.6.2 The field-effect electrode is used to treat thick or irregularly-shaped surfaces. This patented
electrode can project the corona up to 2 in.

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3.4.7 Treated Area The treated area is determined by several factors, including the electrode size and
shape, power and time. A larger electrode will treat a larger area, but the effect at any one point will
take longer to occur.

3.4.7.1 The function: [(time x power) / area] is an effective constant. So doubling the treated area (by using an
electrode which is twice the size) will require twice the time to achieve the same treatment level if the
power setting is unchanged.

3.4.8 Material Treated The untreated surface energy and the maximum surface energy obtained by corona
treatment depend on the material. The amount by which the surface energy is to be increased must
be established for each application.

SECTION 4 - MAINTENANCE

4.1 General

4.1 .1 The instrument contains no user adjustable components inside either the Power Supply or
Generator. Any attempt at repair while the instrument is in warranty will void the warranty.

4.1.2 Several components will exhibit wear with extended use and will eventually require replacement. The
failure modes of several of these components are very similar to what causes the failure of a
tungsten-filament incandescent light bulb after extended use.

a) Due to a combination of corona discharge, high voltage, and high temperature, the insulation
in the capacitors and resonator coil may eventually fail. Corona discharge develops around
microscopic bubbles within the insulation material. Within time the corona discharge creates
larger bubbles. The process accelerates until eventually a voltage breakdown occurs.

b) In time the tungsten contacts will require replacement in order to maintain the proper setting
of the high voltage output.

c) When used continuously or for extended periods of time, the tungsten contacts will begin to
evaporate and condense on the plastic molded base of the Part Number 035-0002-1
Generator Mechanical Assembly, causing a short to develop across this component.

4.1.3 It is recommended that whenever this instrument requires service, it be returned to the factory or
distributor freight prepaid, with a statement concerning the problem. The instrument will be repaired
for a nominal labor and parts charge.

4.2 Repair

4.2.1 Only personnel familiar with electronic circuitry should attempt repair. If it is necessary to repair while
either the Power Supply cover or Generator housing are removed, be cautious as high voltage will
be present at various locations in the circuitry. Refer to the Schematic Wiring Diagram at the end of
this manual.

4.2.2 The Power Supply cover is removed as follows:

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 a) Remove the two screws from the side flap of the cover.

b) Carefully lift the cover from the case and move it to the side. The wiring attached to the jack
prevents the complete removal of the case cover.

4.2.3 The Generator housing is disassembled as follows:

a) Remove the electrode from the socket.

b) Carefully remove the recessed hex nut holding the electrode socket to the threaded nylon
stud attached to the resonator coil. Remove the electrode socket.

c) Turn the High Voltage Adjust Knob fully counterclockwise. Place a small wrench on the
flattened portion of the shaft to hold it from turning while the knob is turned counterclockwise
and removed from the shaft.

d) Note the number of washers around the shaft, and then remove them. Washers are placed
on the shaft to prevent the possibility of the two tungsten contacts inside the housing from
shorting whenever the High Voltage Adjust Knob has been turned fully clockwise. The
number of washers will vary from unit to unit, from none at all, to as many as three.

e) Remove the wax covering the two screws on the Generator housing near the High Voltage
Adjust Knob and remove the screws.

f) The Generator housing is in two parts. Grasp the grooved portion and turn the other portion
counterclockwise to remove.

g) Carefully remove the electronic and mechanical assemblies from the grooved portion of the
housing. The high voltage cord set attached to the electronics will prevent the complete
removal of the assemblies from the housing.

4.2.4 The factory maintains stock of replacement parts. Consult the Parts List. A Parts Price List is
available upon request.

4.2.5 Refer to Section 4.1.2 for assistance in troubleshooting possible failure modes. If the Generator were
accidentally dropped on the High Voltage Adjust Knob, it may be necessary to replace the Part
Number 059-0004-1 Bridge Yolk Assembly to repair the unit.

4.2.6 Once repair is completed, carefully reassemble the Power Supply cover and Generator housing.

a) Reinstall the proper number of washers on the shaft of the Generator. When any of the
mechanical components of the Generator are replaced, the number of washers required after
repair may be different than before. Use a sufficient number of washers to preclude the
possibility of the tungsten contacts from shorting.

b) Replace the protective wax over the two screws on the Generator housing.

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