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BROWN FireFly FY2x36-45, Instructions Manual

The BROWN FireFly FY2x36-45 is a cutting-edge product designed to provide efficient lighting with its powerful LED technology. To ensure a hassle-free setup and operation, you can easily access the comprehensive Instructions Manual by simply visiting manualshive.com. Download this manual for free and unlock the full potential of your FireFly FY2x36-45.

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Purpose of this document: 

 
This Technician’s reference is intended for anyone interested in having a solid grasp of how to use the 
Brown Firefly Curing System to its greatest potential. It contains useful information on how to optimize 
curing parameters, explanations of how major sub-systems work and may be tweaked to suit one’s 
particular needs, and tips to help avoid problems that can pop up any production environment.  
 
Most of the sections included in this document are a direct response to real-world issues encountered in 
the field. This document will probably be most useful to someone who is already familiar with the basic 
operation of the Firefly, and who may have already encountered one or more of the issues dealt with by 
this manual. 
 
This document should be studied and understood by at least one person in each department utilizing a 
Firefly Curing System. It can be used as the basis of a training program for standard operators, and as a 
quick reference for advanced users. As such, it is recommended this guide be kept in an easily accessible 
location close to the Firefly Curing System. 
 
Program Settings:.........................................................................................................................................3 

Temp: .........................................................................................................................................................3 
Belt Speed: .................................................................................................................................................3 
Convection Top & Bottom: ........................................................................................................................3 
Exhaust and Cooler: ..................................................................................................................................4 
Bulb Powers:..............................................................................................................................................4 

Default Program: .........................................................................................................................................4 
Bulb Control Modes: ...................................................................................................................................5 

singleBulb: .................................................................................................................................................5 
tripleBulb: ..................................................................................................................................................5 
twoBulb: .....................................................................................................................................................6 
leadingBulb:...............................................................................................................................................6 

Prewarm Settings:........................................................................................................................................7 
Object Detection:..........................................................................................................................................8 
Load Detect:..................................................................................................................................................9 
Loading Belt Correctly:.............................................................................................................................10 

Snags ........................................................................................................................................................10 
Wrinkles....................................................................................................................................................10 
Folds.........................................................................................................................................................10 

Height Sensor Reset & Adjustment..........................................................................................................11 
Changing Program Barcode IDs...............................................................................................................12 
Troubleshooting Common Problems: ......................................................................................................13 
 
 

Summary of Contents for FireFly FY2x36-45

Page 1: ...84 FireFly Curing System Synergy Pretreat System The Synergy Industrial Pretreat Module provides complete multi variate control of each garment The system is designed for high volume digital decorators and connects directly to the FireFly curing system allowing for rapid evaporation of pretreat solution and delivery to the digital output device 150 00 April 2019 US Patent 10 011 136 ...

Page 2: ...Brown Manufacturing Group Inc 4661 Stafford Ave S W Wyoming MI 49548 Phone 616 249 0200 Fax 616 249 3211 www brownmfg net customerservice brownmfg net Conveyor Dryer Setup Guide ...

Page 3: ...LLER MODULE DRONE LOWER CONTROL CABINET DRONE UPPER CONTROL CABINET FRONT BULB COVERS TOP AIR FILTERS CAMERA ACCESS PLATES LEVELING FEET Figure 2 PRIMARY HEAT MODULE DRONE UPPER CONTROL CABINET DRONE LOWER CONTROL CABINET CAMERA ACCESS PLATES TOP FILTERS LEVELING FEET Figure 3 DRONE HEAT MODULE TAKEUP ROLLERS BELT TRACKING ADJUSTMENT KNOBS LEVELING FEET Figure 4 TAKE UP ROLLER MODULE CONDENSATION ...

Page 4: ... tracks for maintenance access to the center of the machine Ensure that nothing blocks the movement of the heat sections front back as shown in Figure 8 HEAT SECTIONS SEPARATE Figure 8 ACCESSING CENTER OF SYSTEM Assembly Step 2 Identify and Arrange Using the figures in this manual identify the modules that shipped with your dryer Arrange the modules in the location you wish to install the machine ...

Page 5: ...igure 9 Assembly Step 5 Install Belts First loosen the Belt Tracking Knobs Figure 11 on both the front and rear of the machine Slide the rollers as far back as they will go BELT TRACKING KNOBS BELT ROLLERS Figure 11 LOOSENING BELT TENSION Next run the belt through the body of the machine The belt may have a flap covering the seam Make sure when the seam is on the top side of the roller the attache...

Page 6: ...Connect supply power directly to the open terminals of the disconnect switch and a ground wire to the grounding lug located adjacent to the disconnect switch DISCONNECT SWITCH ES INPUT POWER CONNECTS HERE POWER ACCESS HOLE GROUNDING LUGS CONTROL PANEL DOOR Figure 14 CONTROL PANEL POWER HOOK UP Assembly Step 7 Connect control kiosk The control kiosk connects to the logic control panel using three c...

Page 7: ... red light above each sensor is activated when the sensor detects the target If the target is not detected when nothing is blocking the beam the sensor lenses and target should be cleaned with a rag Mild solvents may be used to clean off stubborn deposits Sensors must be pointed at targets and targets must be located directly in the line of sight of the sensors Height Sensor Adjustment and Cleanin...

Page 8: ...ld of BrownDigital and increase production rates exponentially while reducing floor space power requirements and increasing operator control Brown Manufacturing Group Inc 4661 Stafford SW Wyoming MI 49548 616 249 0200 fax 616 249 3211 www brownmfg net customerservice brownmfg net 150 00 June 2015 FF 3X27 30 Linx Control System Integration ...

Page 9: ... information PREWARMING If a lane has been set for a prewarm mode this will display with a countdown timer JOB STOPPED If a lane has been paused this mes sage will illuminate The Lower Section of the control panel can display the following information CONVECTION TOP This is the percentage speed of convection air movement in the upper air chamber CONVECTION BOTTOM This is the percentage speed of co...

Page 10: ... TIME The current time of day Press this button to access the MAINTE NANCE area If a scheduled task has passed its due date the icon will flash This button will access the SETTINGS menu Press this button at the end of the day to allow the dryer to cool off before turning power off ...

Page 11: ...nges in the Middle Window parameters will cause this label to change to SAVE If the new parameters need to be saved as a program press SAVE The PROGRAM NAME window will pop up Type the name you wish to refer to this program and select the To cancel press the The toggles the key board from upper to lower case The button changes the key board to accented letters To erase a typo press the icon Changi...

Page 12: ...f the icon To change the fan speed press COOLER icon and the SET COOLER FAN window will pop up Use the keypad to se lect a new fan speed and then press the icon If you wish to return to the previously set temperature press the icon TEMP To change the set temperature press the TEMP button The SET TEMPERATURE window will pop up Use the keypad to select a new temperature and then press the icon If yo...

Page 13: ...e tasks The Maintenance icon gives access to these tasks and will blink when one of them is due to be complet ed Press the and the MAINTENANCE window will appear There are 12 programs available Programming these will be discussed in the section Managing Maintenance Tasks Select this icon and the Settings menu will appear Pro gramming these will be discussed in the section Setting Section At the en...

Page 14: ...orrect date o NEXT SCHEDULED DATE This is calculated based on the FREQUENCY and the LAST DATE PERFORMED o COMPLETED TASK TODAY When the task is due select the button and the calendar will reset to the current date and a new scheduled date will be calculated Click and hold This allows programs to be reor dered Click and drag any program to the trash to remove it from the list Figure 14 Maintenance ...

Page 15: ...tt per hour o HOURS PER DAY Enter your standard workday length o DAYS PER WEEK Enter your standard workweek length PRINT PREHEAT TAG This prints a preheat com mand bar code label PRINT RESET HEIGHT TRIP TAG This prints a command bar code label to reset the lane when a garment has tripped the height sensor CALIBRATE TOUCH SCREEN Contact Brown Manufacturing Group Inc if the touch screen is not viewi...

Page 16: ...e operator to the main running screen MENU Returns the operator to the MENU screen PROGRAM NAME Select any program button and that will replace the one currently running Once pressed the system will ask which prompt SELECT ZONE and then return to the HOME screen SE LECT ZONE is referring to which lane the program needs to run See Working With Control Panel Icons for infor mation on the individual ...

Page 17: ...Brown Manufacturing Group Inc 4661 Stafford Ave S W Wyoming MI 49548 Phone 616 249 0200 Fax 616 249 3211 www brownmfg net customerservice brownmfg net Conveyor Dryer Maintenance Guide ...

Page 18: ...ensors The bridges should be positioned properly such that the sensors are located directly over the reflective target TRIP BAR TRIP INDICATORLIGHT S TRIP TARGET LOAD SENSOR LOADTARGET INDICATOR LIGHT Figure 1 Trip Sensor System Clean and Adjust Load Sensor System The load sensors are located at the front of the belt Figure 1 The sensor indicator lights on top of the sensors should be on when no o...

Page 19: ... Bulb Before replacing a bulb it is important to determine that the bulb is in fact the problem 1 With nothing on the belt make sure the lane with the suspect bulb has been started use start stop job option on main kiosk 2 On drone control panel select Menu 3 Select Factory Setup 4 Select Bulb Setup 5 Choose belt zone in question Figure 4 6 Circles at the right of the image represent bulbs in the ...

Page 20: ...pect camera cooling fan filters above main heat sections Figure 6 Replace as necessary Clean Blinders 1 Remove camera access plate Figure 6 2 Clean lint dust from camera cooling fans and camera bulb blinders CAMERA ACCESS PLATE BLINDER CAMERA COOLING FAN COOLING FAN FILTER Figure 6 Camera Access Clean Camera Lenses 1 Remove camera access plate Figure 6 2 Use a lint free cloth to gently clean any l...

Page 21: ...he machine a series of dark lines will show up on each camera image These lines will be slightly curved but should overall run straight left right across the image If a camera is twisted in its socket the lines will tend to run downhill from one side of the screen to the other To fix this issue 1 Remove camera access plate Figure 6 2 Loosen camera holder screws a very small amount 1 2 turn each sc...

Page 22: ...1 Brown Manufacturing Group Inc 4661 Stafford Ave S W Wyoming MI 49548 Phone 616 249 0200 Fax 616 249 3211 www brownmfg net customerservice brownmfg net Conveyor Dryer Technician s Reference ...

Page 23: ... Firefly and who may have already encountered one or more of the issues dealt with by this manual This document should be studied and understood by at least one person in each department utilizing a Firefly Curing System It can be used as the basis of a training program for standard operators and as a quick reference for advanced users As such it is recommended this guide be kept in an easily acce...

Page 24: ... an intelligent algorithm to control the belt speed When no product is being cured the belt runs at a default usually fast speed When product has been detected and is being cured the belt runs at the slowest speed required to guarantee the longest cure time product will spend exactly the right amount of time in the heat chamber If other product requiring less cure time is in the chamber at the sam...

Page 25: ...naging the intensity of heat in the system Setting all bulb powers at 100 ensures maximum intensity heat for maximum production throughput Lower power settings allows for moderate intensity heat for delicate applications Varying powers can be set to optimize specific jobs such as setting high bulb powers on the front few bulbs to act as an initial bump and setting the rest of the bulbs lower to ma...

Page 26: ...also called a zone can be controlled independently by selecting from the zone drop down menu at the top of the screen Figure 9 The Bulb Control Mode is shown along with several other setup parameters on this screen and can be changed by pressing on the BULB CONTROL button Figure 9 Figure 9 Bulb Mode Button The available control modes are as follows singleBulb In this mode when the product has reac...

Page 27: ...reas Figure 10 Bulb Heating Areas twoBulb This mode works similarly to tripleBulb but it turns off only the bulb in question and the bulb in front not the bulb behind the area at temp This mode is best used when product is running at medium speeds and it is desirable to reduce temperature overshoots leadingBulb In this mode when the product has reached cure temperature in a bulb s heating area Fig...

Page 28: ...is determined to no longer be hot This time is shorter than the time for the dryer to be cold The prewarm settings are largely a personal preference for each user influence by how they use the dryer For users with a large number of very short runs it is usually advantageous to have short preheat times 5 10 seconds and short cold after and warm after times 10 20 seconds For users with a small numbe...

Page 29: ...ted the sensor status light illuminates and the machine knows that no product is entering the cure chamber Empty Belt No Product Detected Sensor Status Light Object Detection Sensor Sensor Target Under Belt Figure 14 Object Detect Sensor Empty Belt When product is laid on the belt and travels under the object detection sensor Figure 15 it covers the target and the sensor status light turns off The...

Page 30: ... object detection Reflective Product No Product Detected Figure 16 Object Detect Sensor Reflective Product Load Detect The Firefly Curing System uses sensors at the front roller Figure 17 to detect product loaded onto the belt and assign cure parameters Load Detect Sensor Sensor Status Light Sensor Target Under Belt Figure 17 Load Detect Sensor s The system works by detecting product covering the ...

Page 31: ... ensure that all product lands completely within the edges of the belt with no arms laces straps or anything else hanging off the edge Figure 19 Product hanging off the edge of the belt may get caught while traveling through the heat chamber which may cause product behind to snag and pile up creating a fire hazard Any snags should be dealt with immediately Figure 19 Poorly Loaded Belt Wrinkles Pro...

Page 32: ...tice on the main control kiosk by scanning the barcode on the notice or by scanning a reset height sensor barcode printed from the Settings Screen Figure 24 Figure 23 Height Sensor Event Notice Figure 24 Print Reset Height Sensor Barcode Button The height sensor system may be adjusted to increase or reduce the allowable object height Adjustment is accomplished by loosening the screws holding the l...

Page 33: ...racking system etc it can be changed using the Edit Program screen On the main control kiosk choose Settings Figure 25 then Programs Figure 26 Figure 25 Settings Button Figure 26 Programs Button Find the program you wish to edit and drag it to the Edit icon at the bottom of the screen Figure 27 The Edit Program screen will open allowing the barcode ID to be set Figure 28 Valid IDs must fall betwee...

Page 34: ...ngs Bulb Powers Bulb control mode may be incorrect for speed of belt See Bulb Control Modes Problem Product is snagging in dryer Solution Belt is being loaded incorrectly See Loading Belt Correctly Problem Burn marks are appearing on product Solution Oversize product may be touching bulbs due to height sensor being set too high See Height Sensor Reset and Adjustment Problem Height sensor is consta...

Page 35: ...wnmfg net Sy 36 Synergy Pretreat System The Synergy Industrial Pretreat Module provides complete multi variate control of each garment The system is designed for high volume digital decorators and connects directly to the FireFly curing system allowing for rapid evaporation of pretreat solution and delivery to the digital output device 150 00 May 2018 ...

Page 36: ...ansfer issues to the FireFly A colored rectangle will appear on the pretreat belt This image represents where the spray will be located on the belt Image 2 Note The shirt must be loaded as follows The collar should be placed on the right hand side of the belt The front edge sleeve should be folded under to lay within the red box The other sleeve should be folded under to stay within the red bounda...

Page 37: ...the tanks are changed a bleed of the lines must be performed See the Maintenance Section for additional information To power down both the Synergy and the FireFly click the HOME icon Image 7 Image 7 Home icon That will bring up the Home screen Image 8 Image 8 HOME screen Select the POWERDOWN icon Image 9 Image 9 POWER DOWN icon WARNING To prevent injury keep fingers and clothing clear of the motor...

Page 38: ...Synergy Software Brown Manufacturing Group Inc 4661 Stafford SW Wyoming MI 49548 616 249 0200 fax 616 249 3211 www brownmfg net customerservice brownmfg net Sy 36 Synergy Pretreat System ...

Page 39: ...s to load garment settings To Toggle between Modes press the Queue Manual Toggle Button the white highlighted option is the option which is currently selected The System can be powered down from any one of the Synergy modules or the FireFly kiosk by pressing the Power Down icon from the Home Screen Image 1 Image 1 Spray Screen Webcam FireFly feedback Mode selection Home Belt operations Spray contr...

Page 40: ...ress the label above the spray settings When you load a program the label will contain the name of the program When you change a setting the label will contain Save When you press the label you will be prompted to enter a name After you enter the name the new area will appear in the Settings Program List To Save a Spray Area Program press the label above the spray area When you load a program the ...

Page 41: ...the queue will be displayed If the garment queue is empty then the Default Program from Manual Mode is loaded instead The queue can hold several thousand garments at a time Image 3 The the order of the garments in the queue can be changed to the following from the Scanning Settings screen accessible from the Home menu REPLACEACTIVE The selected garment in the queue will replace the active garment ...

Page 42: ...centage power for the bottom convection fan in the dryer Exhaust Power Percentage power for the exhaust fans on the dryer Cooler Power Percentage power for the cooler fan at the end of the dryer Control Mode How the dryer is to maintain the cure temperature on the garment Default is CAMera mode which utilizes IR cameras to read the temperature on the garment ALGOrithm mode uses predictive math to ...

Page 43: ...he belt but not spray it This can also be used to move a garment that is in Spray Chamber into the dryer at the end of a production run The advanced garment will use the Cure Settings set when the user pressed ADVANCE meaning the garment will not be sprayed but may be cured in the FireFly Note that even if a garment is not loaded the system will act as though one has been and will still attempt to...

Page 44: ... status of the FireFly black the FireFly is operating normally and awaiting garments to enter green there are currently garments being cured in the FireFly red there is something wrong with the FireFly that requires attention or the FireFly is not communicating with the Synergy The Feedback Window provides all the details the operator needs to know about the FireFly The Cure Time Cure Temp Control...

Page 45: ... Cache button will clear the Queue Mode Images cache in case there is something wrong with the images being pulled in Queue Mode Exhaust Power controls the Exhaust Fan above the Spray Chamber with 0 turning the fan off and 100 being full power on Maintenance Cards The system is broken down into four Maintenance Cards on this screen allowing the operator to manually run maintenance Tasks Two of the...

Page 46: ...ame for the fluid in the line can be set in this card as well ie renaming Fluid 1 to GTX or GT3 To change the name of the fluid click on the top green bar where it says FLUID Your Fluid Name and enter the new fluid name Image 11 Image 11 Pretreat 1 Maintenance Card The maintenance card also allows the operator to disable that line preventing further mixing and spraying with that fluid This is usef...

Page 47: ...through the nozzles associated with this Spray Head and begins spraying When Stop is pressed the system closes the nozzles Remove Head Fills all Heads in the carriage with Water and Depressurizes the carriage for removal This operation is the same regardless of which Spray Head Maintenance Card is it initiated on De Pressurize Depressurizes the head by closing all source valves and opening all noz...

Page 48: ...cription If there is a specific time at which the task will run the countdown timer in the top left will display the time left until execution in Hours Minutes Seconds format Image 14 Image 14 Maintenance Task Card Maintenance Task Settings Task The maintenance operation to be performed by this task Full Performs a Flush Line operation of the indicated fluid line as defined in the Pretreat Mainten...

Page 49: ...urity is enabled for that feature You can identify items as being locked when they have the Lock Icon on them Image 15 Security Screen Temporary Disable Disables the security system for 1 Hour after being enabled During this time the operator will not be prompted to enter a password for any screen which normally requires it After the hour has passed the security system will re enable itself Spray ...

Page 50: ... Spray Area The system will then use density calculations based on the Spray Area and Nozzle Spray Densities to determine the Carriage Speed Density Density setting will be displayed in grams in2 The system will then use density calculations based on the Spray Area and Nozzle Spray Densities to determine the Carriage Speed Speed Speed setting will be displayed in in s which will directly control h...

Page 51: ... this indicates how many cycles the system will spend filling with water Mix Ratio Alarm Determines how far off the Mix Ratio has to be before it will alert the operator Load Orientation Determines where Top is displayed on the Load Zone and how sprays are to be oriented Collar Right Top is displayed to the Right of the operator and garments are meant to be loaded with the collar towards the right...

Page 52: ...Synergy Maintenance Brown Manufacturing Group Inc 4661 Stafford SW Wyoming MI 49548 616 249 0200 fax 616 249 3211 www brownmfg net customerservice brownmfg net Sy 36 Synergy Pretreat System ...

Page 53: ...iolently when in operation and even when on will only kick occasionally if pressure is being maintained in the line there is no open outlet for the fluid Pumps in the System will be labeled PMPx Image 1 Image 1 Pump Ball Valves are used throughout the system to control and redirect flow as needed depending on the current operation Valves in the system will be labeled SVx Image 2 Image 2 Ball Valve...

Page 54: ...ot in operation Image 5 Image 5 Inline Bowl Filter Spray Chamber Components The Spray Carriage contains 2 nozzle sets referred to as heads each containing 3 nozzles Each nozzle is designed to spray a specific width 6 12 or 18 The system automatically decides which nozzle is best depending on the given spray area for a spray The system is designed to use ball valves to route either Pretreat Fluid t...

Page 55: ...n ufacturing The 4 Switch Dip Switch at the center of the board is for addressing and uniquely identifies each board when replacing a board it is critical that the new boards ad dress switches be set the same as the old board Image 10 Image 10 ZMTR117 Control Board The Spray Chamber also contains an exhaust fan which can be controlled from the Maintenance Screen The exhaust fan works to prevent pr...

Page 56: ...the carriage has been removed the new carriage can be installed by placing it in the carriage holder in the Spray Chamber With the new carriage resting in the chamber reconnect the tubes and electrical connections which go into the carriage After the new carriage has been installed pressurize the carriage by going to the Maintenance Screen and press ing Pressurize After the carriage has been press...

Page 57: ...nnected unscrew the mounts for the pump To install the replacement pump mount it first then connect the plumbing then connect power Remember to re enable the plumbing line associated with the pump after Maintenance is complete See Maintenance Screen under Pretreat Maintenance Cards You can verify that the pump is operational by manually operating it from the Diagnostic Screen See Diagnostic Screen...

Page 58: ...the zipper rods With the holes lined up in the sections reinsert the zipper rod Clean Pretreater Belt Brush The Operator Guard at the front of the machine houses a brush that extends along the width of the belt Lint gets trapped in the guard To remove the guard remove the bolts on either side of the guard Scoop lint out by hand and if necessary replace the brush Replace Exhaust Filter To replace t...

Page 59: ...ss pretreat off Carriage Belts Weekly Maintenance Flush Pretreat Lines Can be automated Clean Pretreater Belt Brush Monthly Maintenance Clean Pretreater and Transfer Belts Flush System with Cleaning Solution Can be auto mated if using a premixed solution Replace Exhaust Filters BiMonthly Maintenance Clean Replace Bowl Filters Clean Carriage Trough As Needed Check for Clogs in Waste Tub Bleed Assoc...

Page 60: ...a gasket the black rubber piece which is placed in the Quick Connect Adapter after the nozzle For more information see page 54 of the User Manual The placement of the nozzles are also crucial See the diagram below Bleeding Pumps If you want this process to be automated Create a Maintenance task for each pump if there aren t any created already Go to the Maintenance Screen The pretreater came with ...

Page 61: ...to be bled every time a source tank is refilled Shutdown Instructions Flush nozzles There should be a Maintenance Task created to flush the nozzles See page 48 of the User Manual for more information Go to the Maintenance screen The system came with a task already created to flush the nozzles under MAINTENANCE on the right side of the screen verify that there is a green check mark next to POWER DO...

Page 62: ...ras for each drone on every lane You can either reach underneath the camera or unscrew the two screws on the sides and lift it out so you can clean the lens Clean Replace Bowl Filters The bottom of the filter unscrews from the top The contents can be dumped back into the source jug connected to the filter The filter is a removable cylinder that is attached to the top of the filter Remove the filte...

Page 63: ...ll Line with Water for Pretreat2 Place the source tubes for Pretreat1 and Pretreat2 back into the tanks Perform a Fill Line with Pretreat for Pretreat1 Maintenance Card Pretreat1 tab on the bottom of the page Click Fill Line with Pretreat Perform a Fill Line with Pretreat for Pretreat 2 Maintenance Card Pretreat2 tab on the bottom of the page Click Fill Line with Pretreat Bimonthly Instructions Ho...

Page 64: ...ier to leave the mount in place and take the ball valve out of the case There is a case around the valve Remove the screws and take the ball valve out of the case Place the new valve in that case Re mount the ball valve Attach the tubes Reconnect the power cable Go back to the maintenance screen and set the Plumbing Configuration to normal To test the valve Go to the Diagnostic Screen under Plumbi...

Page 65: ...hat holds the carriage in place Lift the carriage out of the Spray Chamber using the built in handles Place the new carriage in the carriage holder in the Spray Chamber Reconnect the tubes and electrical connections Pressurize the carriage by going to the Maintenance Screen Spray Head 1 pressurize Repeat for Spray Head 2 Click the Begin Spray button on the Spray Head 1 tab Verify that all nozzles ...

Page 66: ...4001 Red Nozzles are attached to Spray Head Check for correct bleed operation Pump 1 Water Pump 2 Source 1 N A if not used Pump 3 Spray Mix 1 Pump 4 Source 2 N A if not used Pump 5 Spray Mix 2 Check Line Pressure Line 1 Check Line Pressure Line 2 Check for Leaks Shutdown Flush Nozzles Flush only tubes to carriage not whole line Initiate Proper Shutdown Remove nozzels and soak in cleaning solution ...

Page 67: ...Week 3 Week 4 Weekly Clean Refer to Preventative Maintenance document for instructions Pretreater Belt Brush Firefly Bulb Check Lane 1 Lane 2 Lane 3 Lane 1 Lane 2 Lane 3 Lane 1 Lane 2 Lane 3 Lane 1 Lane 2 Lane 3 Drone 1 Drone 2 Drone 3 Date Completed Inspected by ...

Page 68: ... Dec Monthly Check for Software Updates Refer to Preventative Maintenance document for instructions Pretreater Software Wipe Down IR Cameras in Firefly Replace Clean Bowl Filters in Pretreater Firefly Camera Filters Flush lines with Cleaning Solution Pretreat 1 Pretreat 2 Date Inspected by ...

Page 69: ...ocation Pod Month 2 Month 4 Month 6 Month 8 Month 10 Month 12 BiMonthly Deep Clean Refer to Preventative Maintenance document for instructions Pretreat Belt remove and clean Transfer Belt remove and clean Carriage Trough Date Inspected by ...

Page 70: ...Synergy Troubleshooting Guide Brown Manufacturing Group Inc 4661 Stafford SW Wyoming MI 49548 616 249 0200 fax 616 249 3211 www brownmfg net customerservice brownmfg net Sy 36 Synergy Pretreat System ...

Page 71: ... Schematic to determine which ball valve is used in mixing that fluid Follow the steps for Troubleshooting a Ball Valve to confirm the operation of the ball valve If you corrected an issue with the Ball Valve attempt to Refresh Mixture again If the valve is working and the issue persists then deter mine what flow sensors are used for mixing that fluid and follow the steps for Troubleshooting Flow ...

Page 72: ...laced Troubleshooting Flow Sensors Locate the Flow Sensors for the pump on the Diagnostic Screen and press Reset on each of them For the pump connected to the flow sensors open a source valve on the suction side of the pump This can be either water or pre treat Disconnect the output of the flow sensors manifold and aim it into an empty container Set the Pump Duty to 25 then turn the pump on Time f...

Page 73: ...ng page Mixing Ratio Does the error go away after refreshing mixture but returns after a couple sprays Go to Mixing Ratio page The source tank was just refilled and now there is a mixing error Go to Mixing Ratio page Mixing Errors Go to Mixing Ratio page Overflowing Tanks Tanks overflowing Go to Overflowing Tanks page Belts FFY belt running slow on Pretreater lane Go to Belts Page Shirts getting c...

Page 74: ...The pressure might be set too high on the Pressure Bypass Switch Open the small box that the pump power is plugged into There should be a blue knob Turn that CW a small amount to lower it Yes Go to settings and check nozzle densities Is the nozzle s density significantly lower than the others Yes Most likely a clogged nozzle High Spray Density ...

Page 75: ...zle valve could have failed open and is relying on backup valve No Is there a dribble before after it sprays Or does it spray after it was supposed to be completed Air in lines Make sure there is liquid in the mixing tank and then bleed the pump Try to spray the air out Yes Does it look like its spitting Click here to go to Pressure tab Not Spraying Enough Low Spray Density ...

Page 76: ...s If they don t turn on go to the Pumps Not Turning on Not Pulling or Pushing Liquid tab The nozzle valve could have failed open and is relying on backup valve Yes Yes Do all the valves in the path open close to completion Replace nozzle No Yes Do the source pumps turn on during recirculation No Yes Do they pull liquid No Yes Is the nozzle clogged Click here to go to the Source Pumps not pulling t...

Page 77: ...e start Move away from trough side increasing offset on settings page 7 Move towards trough decreasing offset You also might have to calibrate the projector No Yes Is there pressure No Nozzle with 4005 goes to the red holder and 6500 goes with the green Go to Pressure tab The nozzle valve could have failed open and is relying on backup valve Yes Does it look like the spray area isn t wide enough n...

Page 78: ...lve Go to Pressure page The nozzle valve could have failed open and is relying on backup valve Valves don t open close to completion Yes Inspect the wires did a crimp pin come out No Look at the board does the green light turn on and the red light turn off when the valve is open Yes There is still a possibility that the cables got mixed up or and you have a bad ball valve Replace the cable Valves ...

Page 79: ...es the spray pump turn on when bleed valve is opened Yes No Is liquid being pulled from the source tank s No No Open valves in the path Do they all open close to completion Go to Pumps Not Turning on Not Pulling or Pushing Liquid page Go to Valves page Go to Valves page Go to Source Pump not Pulling page Go to Pumps Not Turning on Not Pulling or Pushing Liquid page Pressure ...

Page 80: ...ass the bypass switch box No Yes Try the power cable from a working pump does it turn on The pressure bypass switch probably failed If this is pump 1 2 or 4 you can leave the pump plugged directly into the power cable Turn down the PWM You will have to do a lot of Refresh Mixtures until the software can find the right mixing point Go to Source Pumps not pulling page Yes No Cycle through valves in ...

Page 81: ...k Yes Is there a crack in the dip tube Is the connector pushed down all the way Yes No Cycle through source valve does it open close to completion Push tube down Go to Valves page No Replace acrylic tube or push down connector Fill tank Pump lost suction Source Pump Not Pulling Liquid ...

Page 82: ...nd can t maintain pressure Replace pump or switch to other line Yes Is there a leak somewhere No Yes Is this a spray pump Replace whatever is leaking Explain to the customer the importance of bleeding the pump No Is it pulling liquid Go to Source Pump not Pulling page No Yes Swap ZMAIN134 with a known working one Does the pump stop Replace ZMAIN134 Bypass Switch Pump Continuously Running ...

Page 83: ... flow sensors to give an accurate reading Lower the refill min on tanks 3 5 settings page 3 Change devices to tanks raise max PWM and min PWM settings page 2 Go to Valves page Yes No Does the mix error go away if you refresh mixture but comes back after a couple sprays Check the refill min max for tanks 3 5 in settings pg 3 Click the drop down next to Devices and go to tanks If the refill min and ...

Page 84: ...et tubes might not have a slit at the bottom and it s trying to push in liquid with too much pressure Yes Are they mixing Yes Cycle through the inlet valves SV6 SV12 do they open close to completion No Go to Pumps Not Turning on Not Pulling or Pushing Liquid page Overflowing Tanks Is the hardware enforcement checked in settings for Tank3 5 settings pg 3 change devices to tanks ...

Page 85: ...st Yes Is the system not allowing us to hit start advance or return Yes Loading error The shirt has to be loaded within the projected box That s how the software knows where the garment is you can also increase the garment width a small amount Check the number of belts in settings make sure that it says 3 Settings page 5 No Is it only happening a couple times of day Middle Front Is the shirt being...

Page 86: ...t need to be replaced Yes Is this for a ZMAIN131 Is there a jumper between V and the grounding terminal on the power supplies Add a jumper to power supplies make sure there is a jumper on all of the power supplies to avoid future problems Does it reconnect when you restart the software Yes Install new software version Board Disconnects ...

Page 87: ...oblems Plug power cord back in Is the projector displaying No No Are the wires from the power cord connected to the power supply Yes Is the HDMI cable connected Go through calibration settings for the projector Display No Yes Are the computer settings set to display on only one display Yes No Is there a panel mount HDMI Yes No If you plug it directly into the Synergy computer does it work No Yes T...

Page 88: ...r left hand Max Velocity During Home Moves RPM 500 Homing Target Change of Input A Input Turns On Offset Move 0 Homing Offset Direction Same as Home Yes Did the Carriage go past home Yes Is the Carriage movement jerky The belt might have slipped Go to ClearView push carriage past home and try again Carriage has to be realigned Loosen belts and realign Carriage Movement ...

Page 89: ... Deactivate Check to see if the Chain came off sprocket Yes Is it communicating but FFY belt not moving Does unplugging and replugging the ethernet cables fix it No Yes Is the Windows Firewall activated on any of the computers Replace Ethernet Connect Connection Between FFY ...

Page 90: ... Technician s Software Reference Guide Brown Manufacturing Group Inc 4661 Stafford SW Wyoming MI 49548 616 249 0200 fax 616 249 3211 www brownmfg net customerservice brownmfg net Sy 36 Synergy Pretreat System ...

Page 91: ...bration It is not advised to change the values presented in this screen without a Brown Manufac turing Technician available Calibrate Projector This sequence calibrates the size and placement of the load zone on the belt If the load zone had drifted or it is not displaying correctly go through these steps to correct any miscalibration in the projector Calibrate Belts This sequence allows for calib...

Page 92: ...econd window that can be moved around and resized similar to the Camera Window The Tanks are squares that display how full they are and are labeled TNKx They will display the Raw board value on top and the Volume in either Gallons or Ounces on the bottom Gray represents empty Blue represents fluid in the tank and indicates how full the tank is If there is Red then there is an issue with the tank T...

Page 93: ...o the set Tar get Position at the set Target Velocity Move Velocity Moves the Motor continuously at the set Target Velocity Stop Performs a decelerating stop on the motor Hard Stop Performs a Hard Stop on the motor stopping it immediately and clearing any errors on the motor Belt Feedback The Belt Feedback Screen will display the belts and their contents as the system is aware of them The Load Zon...

Page 94: ...ds between other Synergy Systems and Fireflies Enable Experimental Enables experimental features this is preserved between restarts This is used to hide experimental features that have not been fully tested or implemented Enable Diag Controls Enables an Error indicator signal that appears in the Navigation Bar whenever an error is written to the User Interface Errors Log Modbus Feedback Displays C...

Page 95: ...ng the Density based on the area selected Entered in grams Density Set the carriage speed based on the nozzle that is selected and the desired laydown density Entered in g in2 Speed Directly set the carriage speed in in s Fixed Area For Grams The value used in Density calculations when using Fixed Area Grams to set the Carriage Speed Value entered is in2 Auto Start Mode Determines when the countdo...

Page 96: ...w This setting means Bleed Spray Pump will waste a small amount of fluid Carriage Flush Time How long the system spends flushing during automated Carriage Flushes Flush Line Iterations The Number of iterations the system spends filling the line with water during a Full Flush Then the number of iterations the system spends filling the line with Pretreat Fill Tank Iterations The number of itera tion...

Page 97: ... when mixing will stop Calibration F Associates a Raw input with a Volume based on the assembly of the scale Feedback from tanks can be non linear so multiple inputs are needed to add a curve Valves F Each Valve requires indication of its type and its board address If the Valve is a Ball Valve two ports are required Otherwise one port is enough to initialize the valve Flow F The Flow Sensors requi...

Page 98: ...t the belts move Cleaning Auto Spray During the Clean Belt Operation as defined in the System Maintenance Card Section this indicates if the carriage should automatically sweep and spray water during the operation Cleaning Spray Velocity During the Clean Belt Operation as defined in the System Maintenance Card Section this indicates how fast the carriage moves during its spray sweeps Cleaning Spra...

Page 99: ...lt Page 7 Carriage and Spray Head Settings Motor ID F ID of the motor used to move the carriage Acceleration F Acceleration the carriage motor uses Control Method F Determines what form of feedback and control is used to trigger turning valves on and off Position The motors position feedback is used to trigger May experience lag due to communica tions delay Time Pre Calculated Time is used to trig...

Page 100: ...lve and Nozzles Line 2 Source Valve F Source Valve used to route the Line 2 Source Pump through the Spray Valve and Nozzles Nozzle X Each Nozzle has its own set tings Valve F Which valve is assigned to this nozzle Offset I How far the carriage must move to spray the top of the Load Zone with that nozzle density for that nozzle Width F The Ideal Spray Width used to determine which nozzle to spray w...

Page 101: ...Brown Manufacturing Group Inc 4661 Stafford Ave SW Wyoming MI 49548 Phone 616 249 0200 Fax 616 249 3211 customerservice brownmfg net www brownmfg net ...

Page 102: ... iii registration gates are warranted for seven 7 years from the date of Installation iv Machine chassis are warranted for fifteen 15 years from the date of Installation frames rollers linear rails bearings gears plastic and metal with this Productpurchase WHAT IS NOT COVERED This warranty does not cover 1 Physical damage to thisProduct 2 Damage caused by improper Installation improper or abnormal...

Page 103: ...s after receipt of the replacement Machine Brown will require that you provide a valid major credit card number Brown may issue a hold against the credit card account number that you provide until Brown receives your original Machine or component part s and determines that your original Machine or component part s is entitled to warranty coverage Your credit card will be charged up to the cost of ...

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