TEC TRUV-30A Operating And Safety Manual

1

TRU UV Coater

OPERATING AND SAFETY MANUAL

For the following Models:

TRUV-16D, TRUV-21D, TRUV-30A

TRUVF-16D, TRUVF-21D, TRUVF-30A

S/N_____________________

TEC Lighting, Inc.

555 Vanguard Way

Brea, Ca. 92821

www.teclighting.com

Phone (714) 529-5068 Fax (714) 529-0344

2

Application

This manual has been issued by TEC Lighting, Inc. for qualified persons to operate, install, maintain

and repair this TRU UV Coater and feeder.

Corrections

This manual may contain technical inaccuracies or typographical errors due to improvements or

changes to the feeder. In the event of major changes to the feeder, TEC Lighting will update and

issue a new edition of this manual.

Disclaimer

This manual goes through the entire operation procedure of the TRU UV Coater. Every adjustment

and operation is describe throughout this guide. If anything looks/acts different than it is explained in

this manual please call a TEC Lighting service representative immediately.

3

Preventative Maintenance for TRUV Systems

DAILY (OR EVERY USAGE)

-Disengage all rollers and Doctor Blade, to prevent flat spot on rubber roller.

-Clean three rollers with UV wash, to prevent damage/swelling of rollers and to eliminate buildup of

uncirculated coating.

-Clean Doctor Blade thoroughly (top and bottom side) with UV wash, to prevent build of coating and

contamination.

-Disengage peristaltic pump from black (neoprene) hose, to prevent flat spots in hose.

WEEKLY

-Fluid hoses, flush out any UV Coating from the fluid hoses. (to prevent dry coating build-up).

-Check level of UV coating, to prevent running rollers dry.

-General cleaning of machine, (outside panels, coating cabinet, electrical cabinet, underneath rubber and

metering roller) , to prevent buildup of contamination (dirt, coating, grease, paper dust) which can cause

damage to paint and all moving parts.

MONTHLY

-Monitor position of conveyor belt, to ensure that belt has not stretched and track to one side which will

cause damage.

-Check lamps (UV and IR), to ensure no damage or wear has occurred, which can ruin quality of coat.

-Grease and tighten all red and white marks, to ensure that all moving parts remain in top running condition.

-Purge fluid pump line with UV wash, to prevent buildup of uncirculated coating that will damage hoses.

-Check all three rollers for potential damage from misuse, if caught early preventative measures can be taken

to prevent serious, permanent damage.

IF ANY PREVENTABLE DAMAGE IS FOUND ON THE MACHINE REPORT IT TO TEC LIGHTING IMMEDIATELY!

TEC Lighting, Inc. 555 Vanguard Way, Brea, CA. 92821 p 714-529-5068 f 714-529-0344

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TITLE PAGE

1.0 Safety 3

1.2 Safety Decals 4

2.0 General Overview 5

2.1 Description 6

3.0 Warranty policy 7-8

4.0 System Specification – 16” 9

4.1 System Specification – 21" 10

4.2 System Specification – 30” 11

5.0 Panel control Terminology 12

6.0 Pre set-up Instruction 13

6.1 Feeder table 13

6.2 Catch tray station 14-16

7.0 UV Lamp installation 17-21

8.0 I.R. Lamp Inspection 21-22

9.0 Feeder, Pre set-up 23-26

10.0 Electrical input power hook-up 27

11.0 UV Coating Set up 28-30

12.0 Start up Process 31-42

13.0 Shut down Process 42-47

14.0 UV Coater Clean-up process 48-50

15.0 Fast Stop Process 51-54

16.0 E-Stop Process 55

17.0 Error Message 55

18.0 Restart Process 56

19.0 Coater Restart Process 57

20.0 Sheet Counter and UV Lamp hour meter 58

21.0 UV Lamp Replacement

22.0

23.0 I.R. Lamp Replacement

Rubber Roller Replacement

59-62

24.0 Metering Roller Replacement

25.0 Impression Roller Replacement

26.0 Conveyor Belt Replacement 63- 65

27.0 Doctor blade Replacement 66-70

28.0 BOM for Feeder

29.0 BOM for UV Coater 71-73

30.0 BOM for UV Dryer 74-76

31.0 Grease Lubrication 77

32.0 Trouble Shooting Solution Guide

TRU UV Coater Safety Kit 78

Conveyor Belting Heating Kit 79

Warranty Validation Form (XCWF) 80

TABLE OF CONTENTS

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Read the following section carefully. Failure to operate this or any type of machine without a

full understanding of the possible dangers will result in serious injury.

1. ALWAYS disconnect / lockout input power to the coater and UV conveyor system before

opening electrical panel or working within the system.

2. DANGER, Do not operate without guards in place.

3. DANGER, High voltage and current are used to energize UV lamp in UV processors.

4. This system has rotating rollers and can cause serious injury. The system is only as safe as

the individual operating it.

5. DO NOT remove or modify safety covers – guards, safety switches.

6. DO NOT operate system while wearing a neck tie, loose fitting clothing or long hair. Loose

articles may get caught in the machine.

7. DO NOT look directly into the UV light; it can cause severe burns to the eyes and skin.

You must wear protective UV blocking eyewear.

8. DO NOT make modifications to the machine without written agreement from TEC Lighting.

9. DO NOT leave tools, equipment or any material lying on the machine.

10. Keep metal container near by the system for sheet disposal.

11. AUTHORIZED TEC Lighting

service technicians should do all service / repairs.

12. ONLY trained qualified personnel may operate this equipment.

13. READ and understand all safety decal that are posted on this machine.

14. NEVER leave the rollers engaged for more than 20 minutes, when not in operation. This will

cause a flat spot on the rubber roller and affect coating quality.

15. ALL parts must be replaced with manufacturer’s original parts.

16. YOU MUST wear safety goggles and gloves at all times when you are setting-up, cleaning the

UV coating machine.

17. Never leave the machine running unattended.

18. DO NOT run the UV coater rollers dry.

Failure to follow these safety guidelines can result in serious injury or fatality.

TEC Lighting will not be responsible for damage or accidents caused by irresponsible

operation of this equipment.

SECTION 1.0 SAFETY

6

It is very important that you read, understand and follow all safety guidelines and operating

instruction. Any Machine with rotating rollers and UV lighting can be dangerous. Be sure all

safety guards are in place and fully secured before operating the system.

SECTION 1.2 SAFETY DECALS

7

The purpose of the unit is to transfer UV coating to the sheet in a continuous fashion, either off-line or

in-line with your current production processes.

Note: Printed material must be 100% dry before sending through the UV coater

 Sheets are hand-fed or Auto-fed into an input table, which sends the substrate through an

applicator and impression roller point that applies coating.

 The coating is dispensed or pumped in automatically from a UV coating container.

 A generous amount of coating stays between the two rollers when the metering roller

adjustment knobs apply pressure.

 The sheets then exit the roller coater and are transported with a conveyor system to the IR and

UV lamps.

Production speed will be determined by a number of factors, including;

 Sheet size

 Sheet thickness (minimum thickness 100lb text)

 Sheet Quality

 Sheet Feeding

 Coating Viscosity

 Coating Temperature

 Sheet Temperature

 Dwell Time (Time the sheet spends on the conveyor after coating but prior to curing)

 Lamp and IR Quality.

 Required Gloss Level

 Machine control settings

The importance of each of these factors cannot be overlooked.

Note: sheet stock thickness must be greater than 100lb text.

SECTION 2.0 GENERAL OVERVIEW

8

This machine consists of several major sub-assemblies functioning together to instantly “apply” and

“dry” or “cure” UV coatings. All TRU UV Coater systems are 100% tested and inspected before

shipping.

UV COATER/CONVEYOR SYSTEM

The sub-assemblies are:

 Roller drive assembly with adjustment controls

 UV coating pump system, with re-circulating system

 Control panel – Touch screen

 In feed table

 Auto or Manual Deep-pile vacuum cup feeder

 Safety covers

 Lamp housing - with mercury vapor arc lamp and elliptical reflector

 IR Lamp housing – with (3) IR lamp and elliptical reflector

 Air moving plenum system / blower

 Enclosed power supply cabinet

 Conveyor belt system with speed control

 Catch tray station or automatic receding stacker

 Exhaust pipe / hose system – (option)

 Starter Kit / Plus – (option)

Your system may include some or all of these components, depending on your model.

SECTION 2.1 DESCRIPTION

9

UV CONVEYOR SYSTEM

 The UV & I.R. lamp housing assemblies, power supply, control panel, blowers and related

components are warranted for twelve (12) months or 1000 hours (whichever comes first) on

parts and 6 months on labor from the date of shipment.

 Any manufacturing defects in workmanship, equipment failure, or operational performance

below reasonable tolerances are covered by this warranty.

 This does not include physical damage, abuse, neglect, wiring or unauthorized

installation.

 TEC Lighting, Inc. reserves the right to make the final determination of all warranty claims and

product dispositions. Tec Lighting Inc. is not responsible for any lost production time due to

machine downtime.

EXCEPTIONS TO THIS AGREEMENT

 Conveyor belts

 Exhaust tubing

 Reflector inserts

 Capacitors

 UV Lamp (see below)

 IR Lamp (see below)

UV COATER SYSTEM

 The UV Coater assembly, motor and motor drive and related components are warranted for

twelve (12) months or 1000 hours (whichever comes first) on parts and 6 months on labor from

the date of shipment.

 Any manufacturing defects in workmanship, equipment failure, or operational performance

below reasonable tolerances are covered by this warranty.

 This does not include physical damage, abuse, neglect, wiring or unauthorized

installation.

 TEC Lighting, Inc. reserves the right to make the final determination of all warranty claims and

product dispositions.

EXCEPTIONS TO THIS AGREEMENT

 Rubber Applicator Roll

 Doctor Blade

NOTE:Please fill out the Warranty Validation Form and fax or mail to:

TEC Lighting, Inc.

555 Vanguard Way

Brea, CA 92821

Ph (714) 529-5068 Fax (714) 529-0344

SECTION 3.0 WARRANTY POLICY

10

UV AND IR LAMPS

 All lamps are warranted for 1,000 hours

 Refer to the hour meter within the touch screen

 Lamps that fail due to physical damage, abuse, neglect, wiring or unauthorized installation,

will not receive credit

 Make sure that the lamp is well packed prior to its return - Broken lamps will not receive

credit

RETURNED / REPLACEMENT PARTS

 Please contact TEC Lighting Inc. or your sales representative for repair or warranty

replacements.

 Make sure that the item is well packed prior to its return – broken items will not receive

warranty replacement.

 TEC Lighting must receive the defective part, test and evaluate before shipping any

replacement.

 Warranty replacement parts will ship via “ground”

 If customer requires replacement parts sooner, customer needs to provide the shipping

account number.

 All parts must be replaced with manufacture’s original parts.

 TEC Lighting Inc. reserves the right to make the final determination of all warranty claims and

product dispositions.

INSPECTION

 TEC Lighting UV Coater /Conveyor system are inspected before crating to insure safe

shipping.

 Upon receipt of shipment inspect outer crate for any damages caused by shipping. After

uncrating and removing your machine, inspect your UV system carefully for any damages.

 Report any damages caused by shipping to the truck driver (Transport Company) and to your

sales representative (Please take pictures and document all damages).

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Lamp Arc Length: 16”

Number of Lamps: 1

Wattage Per Inch: 200 W.P.I.

Wattage K.W: 3,200 K.W.

Primary Input Voltage: 208-220/240vac 60Hz 1ph

Total System Running Amperage: 32A no feeder

40A with feeder

Service Disconnect: 40A no feeder.

50A with feeder.

Conveyor Belt Part No.: BELT-425

UV Lamp: TR16UVL

IR Lamp: TR16IR

SECTION 4.0 16” ELECTRICAL

SPECIFICATIONS

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Lamp Arc Length: 21”

Number of Lamps: 1

Wattage Per Inch: 200 W.P.I.

Wattage K.W: 4,200 K.W.

Primary Input Voltage: 208-220/240vac 60Hz 1ph

Total System Running Amperage: 37A no feeder

46A with feeder

Service Disconnect: 50A no feeder.

60A with feeder.

Conveyor Belt Part No.: BELT-375

UV Lamp: TR21UVL

IR Lamp: TR21IR

SECTION 4.1 21” ELECTRICAL SPECIFICATIONS

13

Lamp Arc Length: 30”

Number of Lamps: 1

Wattage Per Inch: 200 W.P.I.

Wattage K.W: 6,000 K.W.

Primary Input Voltage: 208-220/240vac 60Hz 3ph

Total System Running Amperage: 50A no feeder

55A with feeder

Service Disconnect: 60A

Conveyor Belt Part No.: BELT-380

UV Lamp: TR30UVL

IR Lamp: TR30IR

SECTION 4.2 30” ELECTRICAL SPECIFICATIONS

14

1. Coater Speed- Controls the belt and roller speed

2. Feeder Speed- Controls how fast the feeder suction cup picks-up the substrate and deliver into the

UV Coater.

3. I.R. Intensity - Controls the heat temperature that is applied to the substrate.

4. Touch Screen- Main control panel for operation.

5. Emergency Stop- Complete shutdown, blower remains on.

6. Feeder Table Up- Raises feeder table.

7. Feeder Table Down- Lower the feeder table.

8. Feeder Auto / Manual- Auto will raise the feeder table automatically. Manual-Allows you to

lower or raise the feeder table manually with the feeder control table up or table down

9. Emergency Stop Feeder- Complete shutdown, blower remains on

SECTION 5.0 PANEL CONTROL TERMINOLOGY

15

A. Read and understand all safety warning decals.

B. Check for damages caused by shipping – report damages to shipping carrier and your

dealer.

C. Carefully uncrate your system. A forklift is required.

D. Check and ensure that all sheet metal bolts are not loosened from transport vibration.

Use proper tools for tightening.

E. Electrical power is ready for hook-up; refer to Section 4.0 - 4.2

F. Make sure your work area is clean and ready for set-up.

(Table is not required when using an auto feeder: Refer to section 6.5)

1) Set the feed table into

position as shown.

2) Under the feed table

secure with 4pc thumb screws.

SECTION 6.0 PRE SET-UP

SECTION 6.1 FEED TABLE

16

1) Adjustable Catch Tray

station.

2) Insert the LEFT side of

the catch tray insertion

pin into its holding block.

3) Remove the RIGHT side

holding block. Place the

block on the insertion

pin (as shown).

SECTION 6.2 CATCH TRAY STATION

17

4) Re-attach the holding

block into position and

secure with screws.

5) Set the supporting legs into position.

Make sure the legs are straight.

6) Set the height adjustment per

your requirement .

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7) Insert the handles threaded

stud into paper guide and

thru the catch tray slotted hole.

8) On the back side of the

catch tray secure with

flat washer and hex nut.

9) To lock the handle, push

downward.

To open, lift up the handle.

Adjustment to the hex nut

maybe required for locking

position.

19

NOTE: Safety Glass and Cotton Gloves are Required.

 UV lamps are packaged in its own container, open box and inspect the

lamp for shipping damages.

 Clean UV lamp glass body with TEC Lighting cleaning solution TECAL70.

 Handle the UV lamp carefully

1) Open the electrical panel

door.

2)

Lift open top panel.

3) Set the panel support latch

into locking position.

SECTION 7.0 UV LAMP INSTALLATION

20

4) Lift open the UV lamp compartment

panel. Move the panel to the side.

Caution: Do not pull on connected

internal wiring.

5) Lift up the extrusion and place

on work bench.

6) Rotate the assembly to expose the reflector mirror.

NOTE: Extra cleaning of the reflector mirror maybe required, use TEC

Lighting cleaning solution TECAL70. Remove the lamp holder supporting

block (one side only).

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