Solo Systems, Inc.
4001 Industrial Street * Rowlett, TX 75088
800.259.5570 * 972.475.5569
TROUBLESHOOTING
Often, treat problems may be solved by minor changes in the treating system.  Below are
some common problems and their causes.  The bullet points show how to fix those
problems.   

Problem:  Inadequate Treat Levels

Cause:    Insufficient power for line speed, web width, web material

Action:  
*  Be sure electrode & roll coating are sized to deliver full-rated generator power to
the web.
*  Increase generator power.
*  Slow line speed.

Cause:    Power leakage from high voltage lead. Lead too long or too small.

Action:
*  Shorten lead if possible, increase size of lead wire, insulate lead wire.

Cause:   Treater roll ground insufficient.

Action:
*  Ground treater roll by means of a ground brush, increase ground brush size.

Cause:   Electrode area too great or too small to develop full rated generator output on the
 web.

Action:
*  Increase electrode area per recommendations.  
Contact Solo Systems for help.

Cause:   Generator/transformer malfunction, inaccurate settings.

Action:
*  Troubleshoot generator according to manufacturer's recommendations.

Cause:   Inaccurate treat level testing methods.

Action:
*  Standardize treat test method.

Problem:   Back side treat

Cause:   Floating web or wrinkled web.

Action:
*  Increase wrap on treater roll, increase web tension.
*  Install lay on nip against treater roll to eliminate trapped air.
*  True treater roll.
*  Trim edge bead before treating.

Problem:   Pinholes in web

Cause:   Air gap too wide, power level too high for electrode area, Overtreating.

Action:
*  Set air gap to .062".
*  Change transformer tap to lower voltage.
*  Check electrode area vs. power and frequency

Problem:   Static charge on treater rolls

Cause:   Web slipping on treater rolls.

Action:
*  Increase line tension if practical.
*  Increase wrap on treater rolls.
*  Balance treater rolls so they turn freely.
*  Check and grease bearings.

Cause:   Poor ground path for corona.

Action:
*  Secure treater rolls grounding system.

Problem:    Deposits of corrosive materials on equipment

Cause:   Excess slip and other carboneous materials may precipitate out of the web
during the treat process and deposit on the treater rolls, electrodes and cabinet.

Action:
*  Use minimum amount of slip for required COF.
*  Avoid overtreating.
*  Clean rolls and electrodes regularly with a good industrial, non-abrasive cleaner.
*  Establish regular maintenance schedule.

Problem:   Premature roll coating failures

Cause:   Mechanical damage from rough handling or knife cuts.

Action:  
*  Review coating characteristics section to determine best coating for installation.
*  Review
installation and maintenance sections of this website.

Cause:   Burned coating from line stopping with power on.

Action:
*  Install motion detector (zero speed switch) to cut generator power if line stops.  

All Solo Systems' stations come with zero speed switches.

Cause:   Insufficient treater roll surface area to dissipate heat efficiently.  This shortens
 insulating life and increases the chance of electrical breakdown.

Action:
To increase coating life:
*  Install larger diameter roll.
*  Cool treater roll during operation.
*  Reduce generator power/slow line speed.
*  Avoid overtreating.  Use the lowest possible power settings to develop the treat
levels required.
*  Avoid treating off edge of the web - use an
adjustable length electrode.

Cause:   Narrow or electrically mismatched electrode.

Action:
*  Install shoe electrode matched to generator power.

Cause:   Inaccurate air gap setting between electrode and roll surface.

Action:
*  Set air gap according to recommendations.
Email Elissa Westerheim for printable PDFs of the following:

* E-3 Epoxy roll coating cleaning procedures

* Epoxy repair instructions

* Checklist for general treater maintenance (A great resource to have on hand for your
staff)

* Troubleshooting checklist (Also a great resource to have on hand)
If you are still
having trouble with
your treater, please
contact us.  
We are happy to
help!
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