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Troubleshooting Your Corona Treating System: Common Issues and Solutions

Corona treating systems are essential for improving the surface adhesion of materials in various industries. However, like any machinery, they can sometimes encounter issues that affect their performance. If you're facing problems with your corona treating system, such as electrode failure, web wrinkling, or high voltage arcing, don't worry. We've put together a comprehensive guide to help you troubleshoot these problems and ensure your corona treating systems are achieving their best results.


1. Electrode Treatment Failure

Electrode failure can disrupt the corona treating process and cause uneven treatment and poor surface quality. If you are experiencing this, try the following steps:

  • Check for Mechanical Shock: Ensure that the web or a splice has not struck the electrode, which could lead to a broken electrode or mounting insulator.
  • Exhaust Fan Functionality: Make sure the exhaust fan is functioning correctly. Ensure the exhaust fan is rotating in the correct direction.
  • Exhaust Airflow: Verify that the exhaust airflow meets the station requirements by referring to the station ID drawing for the correct CFM rate
  • Exhaust Passages: Inspect the exhaust passages for any obstructions.
  • Electrode Air Gap: Verify that the electrode's air gap is adjusted to 0.060 inches across the entire length of the electrode and front to back.
  • Operating Temperature: Check the steady-state operating temperature of the electrode. It should not exceed 180°F.


2. Web Wrinkling

Web wrinkling can impact the quality of your corona treatment and cause uneven treatment on the web. Here's how to troubleshoot and resolve this problem:

  • Station Alignment: Ensure that the station alignment is correct.
  • Ground Brush: Check the ground brush to ensure it makes good contact with the roll shaft and that the contact point is not oxidized.
  • Web Tension: Check the tension of the web.
  • Roll Bearings: Check the ground roll bearings and idler roll bearings and lubricate them as necessary. Check for free motion and replace as necessary.
  • Clean Ground Roll: Ensure the ground roll is clean and free of debris or oxidation.


3. High Voltage Arcing

High voltage arcing can lead to inconsistent corona treatment results or catastrophic failure. To resolve this problem, follow the steps below:

  • Clean Insulating Standoffs and Shrouding: Verify that the insulating standoffs and shrouding is clean and free of debris and carbon tracking.
  • Inspect High Voltage Wire: Carefully inspect the high voltage wire for insulation breakdown.
  • Maintain Insulation Separation: Confirm that the high voltage wire insulation is separated from any ground surface or other wiring by a minimum of 1 inch.
  • Isolate Failed Electrode: Isolate each electrode assembly to locate a possible failed electrode.
  • Prevent Moisture Condensation: Moisture condensation during shutdown periods can result in high voltage arcing. To prevent this, operate the system exhaust blowers before production is scheduled. Use humidity compensation on power supply to help dry electrodes.


By following these troubleshooting tactics, you can resolve common issues with your corona treating system and ensure that it operates at its best, delivering consistent and high-quality corona treatment results. If you need further assistance in troubleshooting your specific application, contact Pillar at or call 262.912.7200.