Duplo ULTRA 200PRO Operating instructions

1

ULTRA 200PRO

UV COATER

OPERATION MANUAL

Rev: 052815

2

DECLARATION OF COMFORMITY

PrintFinishing Co. Ltd., located at 625 Sec. II, Wende Road, Hsin-Pu, Hsin-Chu 30544, Taiwan declares that

the product compliances with the provision defined in the regulations as below.

Product

Name

Model

Regulation

Machinery Directive

2006/42/EC

Low Voltage

Directive :2006/95/EC

RoHs Directive:

2011/65/EC

Electromagnetic

Compatibility

Directive

2004/108/EC

UL/CUL

Standard File No

Ultra

Violet

Coater

Ultra

200

PRO

Annex I of

Machinery Directive

EN60204-1:2006+A1:

2009

EN-1010-1: 2004

EN-1010-2: 2006

EN60204-1:

2006+A1: 2009

EN50581

EN61000-3-2

EN61000-3-3

EN61000-6-2

EN61000-6-4

CISPR16-3-2

CISPR16-2-1

CISPR16-1-2

IEC61000-4-2

IEC61000-4-3

IEC61000-4-5

IEC61000-4-6

IEC61000-4-8

IEC61000-4-11

E305160 Under

certification by

UL Taiwan

Keeper of the technical file in the European Community:

Duplo International Inc.

Automated Precision House, Hamm Moor Lane, Addlestone, Surrey KT15 2SD, United

Kingdom

3

DECLARATION OF INCORPORATION

PrintFinishing Co. Ltd., located at 625 Sec. II, Wende Road, Hsin-Pu, Hsin-Chu 30500, Taiwan declares that:

◎ The essential requirements of the Machinery Directive are applied to the product mentioned in the

table below and:

◎ The product complies with the provisions defined in the regulations mentioned below and:

◎ The technical documentation is complied in accordance with the Machinery Directive Annex VII part

B:

And under takes:

◎ To transmit relevant information of the product by appropriate method in response to reasoned

request by the national authorities. However that transmission shall be without prejudice to our

intellectual property rights of the product:

And state:

◎

the product is partly completed machinery and must not be put into service until the final machinery

into which it is to be incorporated has been declared in conformity with the provisions of the

Machinery Directive.

Product

Name

Model

Regulation

Annex I of Machinery

Directive 2006/42/EC

Low Voltage

Directive:2006/95/

EC

RoHs Directive:

2011/65/EC

Electromagnetic

Compatibility

Directive

2004/108/EC

UL/CUL

Standard File No

Ultra Violet

Coater

Accessories

WB Varnishing

Kit

EN60204-1:2006+A1:

2009

EN-1010-1: 2004

EN-1010-2: 2006

EN60204-1:

2006+A1: 2009

EN50581

EN61000-3-2

EN61000-3-3

EN61000-6-2

EN61000-6-4

CISPR16-3-2

CISPR16-2-1

CISPR16-1-2

IEC61000-4-2

IEC61000-4-3

IEC61000-4-5

IEC61000-4-6

IEC61000-4-8

IEC61000-4-11

E305160

Under

certification

by UL Taiwan

In-line

Bridge/Feeder

/Flipper

Keeper of the technical file in the European Community:

Duplo International Inc.

Automated Precision House, Hamm Moor Lane, Addlestone, Surrey KT15 2SD, UK

4

Contents

Declaration of Conformity .................................................................... 2

Declaration of Incorporation ................................................................ 3

1. Safety Rules .......................................................................................6

1.1 Precautions ...............................................................................6

1.2 Avoid Accidents .........................................................................7

1.3 Safety Issues & General Safety Rules ...........................................7

1.4 Caution for UV Lamp ...................................................................8

2. Introduction ......................................................................................9

2.1 What Ultra 200

PRO UV Coater Does .............................................9

2.2 Symbol Description .....................................................................9

2.3 Name Plate ..................................................................................11

2.4 Risk Area .....................................................................................12

2.5 Usage Precaution ........................................................................13

3. Specification ......................................................................................14

3.1 Integrate with SF300 Suction Feeder ...........................................15

3.2 Integrate with SF-300F Pile Feeder and ST-300 Pile Stacker ........15

3.3 Accessories ..................................................................................16

3.4 Key Components & Control Switches ..........................................17

4. Control Panel ....................................................................................18

4.1 Main Power Switch ......................................................................18

4.2 Control Panel and Function Key ...................................................19

4.3 Thermometer ..............................................................................21

4.4 How to set Thermometer control factor ......................................24

4.5 How to set SV ..............................................................................24

4.6 How to set UV ON reference Temp ..............................................24

4.7 How to set cooling fan OFF Temp ................................................25

5. Operation Procedures .......................................................................27

5.1 Power Up Sequence ....................................................................27

5.2 After Warming Up. ......................................................................29

5.3 Adjust Auto Gap Timing...............................................................31

5.4 Auto Gap Off. ..............................................................................32

5.5 Start and IR On/Off ............................................................ ……….32

5.6 Setting Coater Speed ...................................................................34

5.7 Setting Pumping Speed ...............................................................34

5.8 Clear Jam .....................................................................................35

5.9 Emergency Stop ..........................................................................36

5.10 Stop Coater and Cleaning ..........................................................37

5.11 Priming and Auto Cleaning ........................................................38

5.12 Power Off ..................................................................................39

5.13 Power Save. ...............................................................................40

5

5.14 How to View the Permanent Count ...........................................41

5.15 View the Lamp Hour. .................................................................42

6. Error Message and Trouble Shooting ..............................................43

7. Maintenance .....................................................................................47

8. Q and A. ............................................................................................48

6

1. SAFETY RULES

After receiving the machine, if end users require any further modification or change of one part or

several parts of the machines, they are obligated to advise the machines back to the manufacture for

this treatment.

We do not have any Legal responsibilities if the breakdown of the machines or operator’s injuries is

caused by the importer’s modifications or changes to one part or several parts of the machines

performed by end users.

Since the machine is used in non-potentially explosive atmospheric environment: the manual does

not indicate that, and the used liquid should be not flammable, non-low flash point liquid (a flash

point below 55

℃

is not allowed), no volatile liquid.

The machine has many safety features which make it a safe machine to operate. Regardless of your

experience, safety instructions must be read carefully, completely understood, and applied to your daily

work habits. If you do not understand or are confused by certain safety instructions presented in this

manual, discuss them with your supervisor. Machine setup, cleanup, and maintenance operation will

vary. Therefore, it is essential all employees to practice safe work habits. SAFE WORK HABITS PREVENT

INJURIES. The main rule to follow is to ALWAYS make sure the main drive is STOPPED and LOCKEDOUT

when performing setup, cleanup, and maintenance operations.

The safety precautions in this manual provide guidelines for the protection and for that of fellow

workers.

1.1 Precautions

Before any maintenance is performed on the machine, switch off all sources of energy, electrical,

hydraulic, pneumatic, potential, stored, etc. do not operate the equipment when panels and safety

guards are not in place. Failure to observe this warning could result in personal injury.

7

1.2 Avoid Accidents

Most accidents are caused by the failure of some individual to follow simple and fundamental safety

rules and precautions. For this reason, most accidents can be prevented by recognizing the real

cause and doing something about it before the accident occurs. With any machinery, a careful and

trained operator is the best insurance against an accident.

1.3 Safety Issues & General Safety Rules

DO

DO NOT

1. Read and understand this manual before

attempting to operate or service the

machine.

1. Do not attempt to operate or service the machine

without reading and understanding this manual.

2. Be familiar with the machine safety rules

and practices.

2. Do not remove the safety devices. Including

electrical interlocks.

3. In case of an accident while the machine, is

running press the emergency stop button

to stop the machine.

3. Do not start the machine unless you are sure there

is no danger to you or your fellow workers.

4. Warn

others of an intended action that may

endanger them.

4. Do not clean or lubricate moving parts of a machine

that is running.

5. Perform lubrication and oiling of the

machine only when it is stopped.

5. Do not unauthorized persons to operate the

machinery.

6. Verify that all guards are installed before

operating the machine.

6. Do not wear jewelry, neckties, or loose clothing

near moving machine.

7. When working on electrical equipment,

power must be shut off to all circuits

before any work is attempted. Individual

switches must be opened and the

equipment circuits tested to make sure

there is no power.

7. Do not place tools on a machine that is running.

8. Be sure all operators are aware of all areas

and operations that require extra safety

measures.

8. Do not reach into the machine to make

adjustments while it is running.

9. Keep the floor clean around the machine.

9. Do not use a rag on rotating rollers. Do not use any

cleaning cloths or paper on rotating rollers

10. Keep aisles and walkways clear. 10. Do not have anything (coins, pens, etc.) in your

pockets.

11. Return tools to their proper places after

use.

11. Do not allow horseplay in the work area.

8

1.3 CAUTIONS FOR THE UV LAMP

Mercury vapor lamps emit ultraviolet radiation which is harmful to eyes and skin. Avoid looking at a

lamp in operation. Suitable eyes and skin protection should be employed when lamps are in

operation. Clear fused quartz is used for the standard ultraviolet curing lamp and will generate

ozone during operation. Equipment direct or reflected radiation from UV lamps is harmful to eyes

and skin. When using this type of lamp there should be adequately ventilated to comply with OSHA

regulations. While ozone is unstable, it will be at a safe level by the time it leaves the equipment’s

exhaust stack.

Before using the machine, please read the operation manual. In addition, place this

manual where you may access it easily.

9

2. INTRODUCTION

2.1 What is the Ultra 200PRO UV Coater Does

Ultra 200PRO UV Coater is design for in-line and near-line with the digital press for applying UV flood

coating to digitally printed papers used for example in the production of photo albums, posters,

magazine and book covers, labels and greetings cards. The Ultra 200PRO UV Coater will provide a

flood coated finish using UV Gloss, Matte, Silk, Satin or Aqueous varnishes.

2.2

Symbol Description

This manual’s symbols correspond to the specific area on the machine. These safety warnings are

placed to protect both the user and anyone within the machine’s vicinity. These are also positioned to

ensure that the machine is operated properly and safely. Each symbol and its meanings are explained

below.

Keep your hands away. Something heavy might fall

from above.

Be careful of high voltage or the risk of electric shock.

Power Switch

Be careful of rollers, and keep your hands away.

CAUTION

Be careful of UV light. Do not look directly into the

beam or view directly with any optical instruments.

10

Be careful of touching the blades. The blades are

extremely sharp which could result in a serious injury

when coming into contact with hands or other parts

of the body

It is highly recommended to use gloves, in order to

protect your hands

It is strongly recommended to wear safety goggles in

order to protect your eyes.

Hot surface around this area. Do not touch with any

parts of your body.

11

2.3 Name Plate

2.3.1 200Pro UV Coater – CE

2.3.2 200Pro UV Coater – UL

12

2.4 Risk Area

13

2.5 USAGE PRECAUTIONS

2.5.1 Before Operation

a. Understand emergency stop button and main power location. In addition normal

operation must be confirmed.

b. Tools and sundries should not be put on the machine.

c. No obstacles should surround, or be placed on top of the machine.

d. Personnel staying in risk areas are forbidden.

e. Do not place any liquids on top of the machine

2.5.2 During Operation

a. Do not open any doors or guards.

b. No personnel in risk areas.

c. No maintenance and repair.

2.5.3Maintenance

a. Power must be turned off before leaving the machine.

b. The location of each limited switch is identified.

c. Power must be turned off when personnel enter risk areas.

d. Check all buttons and switches are in the normal position.

e. Switches must be turned off before opening any door/guards.

2.5.4 Others

a. Damaging all external and internal panels and controls is forbidden.

b. Do not cover each button and switch.

c. The machine should be kept clean at all times.

d. Warning signs and tags on the machine should not be removed or destroyed. If you have

any questions, please contact your agent or dealer.

14

3. SPECIFICATION

Specifications

Ultra 200

PRO

SF-300 Suction Feeder

Max. Speed

34M (112ft) / min

45M(148ft) / min

Max. Paper Size

21” x 30” (535 x 750mm)

Paper Weight

170gsm ~ 600gsm

120gsm~600gsm

Power Requirement

400V, 50/60HZ, 25A

208-220V, 50/60HZ, 43.5A

110/220V, 50/60HZ, 6A Time Delay

Dimension 56.7” x 41.9” x 49.3”

(1440mm x 1063mm x 1251 mm)

32.4” x 30.8” x 47.1”(823 x 782 x 1196mm)

Weight

926lbs (420Kgs)

305 lbs (120Kgs)

15

3.1 Integrate with SF-300

3.2 Integrate with SF-300F Pile Feeder and ST-300 Pile Stacker

16

3.3 Accessories

Item P/N Quantity

Catcher Stopper 983-906-000B

1

Catcher Side Guide

983-909-000B

2

UV Bucket Asm– 20L

984-307-000A

1

Heat Jacket 984-306-050A

1

UV Lamp

984-602-090A

(Primarc-7801398-18mm)

1

Installation Manual 1

Operation Manual 1

Waste Bucket – 5 L

1

17

3.4 KEY COMPONENTS

No.

Name

Description

1

System Main Power Switch

Turn ON/OFF system main power

2

Control Panel

See the function key of the control panel

3 Emergency Stop Press this switch to stop system in emergency.

Normally use stop key on touch panel to stop

coater. When the switch is pressed, the UV

Lamp will be off and cooling fan will be on.

4

Faults Indicator

Indicates to the operator of a possible error or

fault

5 Suction Feeder Connector Cover feeder communication

6 UV Coating Section Apply UV oil on media

7 UV Lamp Dry UV coated media

8

IR Lamp

Penetrate coated media

9

Conveyor

Transport the media

10

Catcher

Receive coated media

11

Safety Switch

Top cover safety

12

Interlock Switch

UV oil tray cover safety

13

Safety Switch

UV hood safety

18

4. CONTROL PANEL

4.1 MAIN POWER SWITCH

Main Power

switch

19

4.2 CONTROL PANEL AND FUNCTION KEY

4.2.1FUNCTION KEY

LED Display

Control

Panel

Error

Code

IR

Thermometer

20

4.2.2 INTRODUCTION OF PANEL FUNCTION KEY

Key

FUNCTION

Start / Stop UV Coater

Setting IR On / Off before the coater is in operation and

setting AUTO GAP On/Off during the coating operation

Setting coater to POWER SAVE mode

Cleaning coater rollers

Jog paper forward or backward and + or – the

applicator roller coating time when the machine is in

operation

Changing coater speed

Changing UV pump speed

Confirmation function key when changing individual

settings

Reset the error message

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Duplo ULTRA 200PRO Operating instructions

Duplo ULTRA 200PRO Operating instructions

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