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BrownDigital FireFly set-up guide

Figure A.3: 3-Lane Firefly Machine Wiring Diagram

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Summary of Contents for Firefly

Page 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 User s Manual Revision 6 0 ...

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 Setup Guide Revision 6 ...

Page 3: ...veral modular assemblies which are joined together to create a complete conveyor dryer unit Common modules are Figure 1 DRIVE ROLLER MODULE Figure 2 FRONT DRONE HEAT MODULE Figure 3 BACK DRONE HEAT MODULE Figure 4 BACK ROLLER MODULE Figure 5 HOOD ASSEMBLY Figure 6 TV STAND 1 ...

Page 4: ...iguration you purchased Consult your salesperson for an engineering drawing of your particular system Clearance is required around the heat modules in order to open control panel doors pull out filters and clean camera boxes See Figure 7 for specific clearance numbers Figure 7 GENERAL CLEARANCES Clearance is also required for the heat modules to slide on their tracks for maintenance access to the ...

Page 5: ...odules Remove the cover grills from the frames of each section Bolt each module to each adjoining module using the connection holes at the end of each frame Figure 10 FRAME CONNECTIONS Assembly Step 4 Mount Accessories Depending on the exact configuration of your system you may have to locate and set into position some or all of the following accessories Load Detect Sensor s Scanners Mount on scan...

Page 6: ...hrough the supplied hole at the bottom of the panel or the customer may elect to punch a hole in the sidewall of the panel 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 Figure 14 CONTROL PANEL POWER HOOK UP Assembly Step 7 Connect Control Kiosk The control kiosk connects to the logic con...

Page 7: ...tors Adjustment and Cleaning The load sensors and object detection trip sensors must work correctly for proper operation of the machine These sensors send an invisible beam of light to a reflective target located under the belt The beam is reflected by the target and detected by the sensors A red light above each sensor is activated when the sensor detects the target If the target is not detected ...

Page 8: ...BrownDigital FireFly set up guide Appendix A Firefly Machine Wiring Diagrams 6 ...

Page 9: ...BrownDigital FireFly set up guide Figure A 1 1 Lane Firefly Machine Wiring Diagram 7 ...

Page 10: ...BrownDigital FireFly set up guide Figure A 2 2 Lane Firefly Machine Wiring Diagram 8 ...

Page 11: ...BrownDigital FireFly set up guide Figure A 3 3 Lane Firefly Machine Wiring Diagram 9 ...

Page 12: ...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 User s Manual Revision 6 0 ...

Page 13: ... 2 Action Icons 3 Programs and Cure Settings 3 Default Program 3 Creating a Program 3 Loading a Saved Program 4 Editing a Program 5 Deleting a Program 5 Maintenance 5 Creating a Maintenance Task 6 Editing a Maintenance Task 6 Deleting a Task 7 Settings Screen 7 Locks 8 Firefly Drone Software 9 1 ...

Page 14: ...eating up to the selected target temperature If Start Stop Job is selected the belt will start moving without initiating a prewarm After the belt starts moving the operator can begin loading garments The product has to be loaded within the edges of the belt Anything outside of the belt boundary could catch inside of the dryer leading to a potential fire For more information about loading technique...

Page 15: ...h the Linx System this print button will print the barcode label for the selected Program Note Some of these options may not be available Your Firefly system may not be equipped with Top Fans Bottom Fans Cooler or Linx Connection Print option If you are unsure of the features included with your machine contact your Brown Manufacturing Sales Representative The settings for the fans determine how fa...

Page 16: ...amber Action Icons Located in the bottom right corner of the Home Screen are four icons POWER DOWN Pressing this icon will initiate a total system shutdown sequence SETTINGS This button will redirect the user to the SETTINGS menu MAINTENANCE This button will redirect the user to the Scheduled Maintenance page It will also flash if a Maintenance Task is overdue More information about Maintenance ca...

Page 17: ...t corner 4 Press the SAVE button 5 Press HOME to return to the Home Screen Creating a Program Creating a Program was designed to be convenient to users Any time a cure setting is changed on the Home Screen the header that typically displays the Program Name will switch to SAVE Note changing a parameter does NOT mean that a Program needs to be saved The Firefly will use whichever parameters are sel...

Page 18: ...reen where the selected Program will be displayed in the Lane settings To return to the Home Screen without selecting a Program press HOME in the top left corner of the PROGRAMS Screen Option 2 Program Selection from Settings This option involves a few extra steps but the user can select a Program for all the Lanes while in this screen 1 Press 2 Press 3 Select the desired Program Name from the lis...

Page 19: ...user will be redirected to the Programs page a Can press RESET then BACK to return to the Programs page without making changes 6 Press the newly edited Program Name to apply it to a Lane 7 Enter the desired Lane number then press to load the Program or press to cancel 8 As necessary repeat steps 3 5 for the other Lanes 9 Press HOME in the top left corner Deleting a Program 1 Navigate to the Progra...

Page 20: ...h the text to OFF indicating that the notifications are disabled b Can also disable all maintenance task notifications from any of the Task Scheduling Screens 3 Press HOME to return to the Home Screen Notice that will no longer be displayed on the Home Screen when the notifications are disabled Even though the icon is not displayed the user will still be able to press in the empty icon box to navi...

Page 21: ...ssing a task the screen will redirect the user to the Task Scheduling Screen The user can then edit the desired details of the selected task including the name of the task If the user would like to replace an existing task with a new one they can follow the same procedure above When in the Task Scheduling Screen they can enter the details for the new task and then rename it by pressing on the titl...

Page 22: ...e bottom left corner to generate a report of this information PRINT START STOP JOB TAG This sends a copy of the Start Stop Job barcode to the barcode printer This is the same barcode that operators can scan on the Home Screen to Start Stop Job Can be placed next to Lanes to be more accessible Also a physical barcode may be easier to scan than one on a monitor PRINT PREHEAT TAG Sends a copy of the ...

Page 23: ...le to manually change any cure parameters on the Home Page not even with a password The only way to change a Lane s parameters would be to change the Program or to unlock the CURE PARAMS in LOCKS The user can press on any of the options listed on this screen to lock it To lock all the options listed press the LOCK ALL button A lock icon will appear next to an option when it is locked Similarly pre...

Page 24: ...e images the user will be able to monitor temperatures while also tracking the movement of the garment The Drone has two cameras designated to each Lane Camera 1 for each Lane is the camera on the side closest to the Kiosk see image below Camera Physical Layout In the software Camera 1 is the bottom image in each Lane rectangle On Screen Camera Layout Note the cameras may also be referred to as Ca...

Page 25: ...ots in an otherwise red image The user can hide these blue sections by pressing on the button that says HIDE INVALID DATA underneath the SETTINGS button If a camera square is completely blue that means the camera is disconnected The system will attempt to reconnect the camera by turning both cameras on that Lane on off Additional features that the user may see on the Drone Home Screen include the ...

Page 26: ...ation Click on the UPDATE text to initialize the update Belt Positions shows the current belt positions for each Lane If this value is not changing it could indicate that the Drone is not receiving commands from the Firefly Main software ERROR will appear in the bottom right corner of the screen under the Key when the Drone is experiencing an error Click on the ERROR text to view the errors 14 ...

Page 27: ...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 Revision 6 ...

Page 28: ...or System Clean and Adjust Load Sensor System Clean Control Panel Fan Filters Check Belt Tracking Check Bulb Status Recommended Monthly Maintenance Check Camera Cooling Fan Filters Clean Blinders Clean Camera Lenses Check Bulb Blinders Alignment Check Camera Alignment Clean Belt Movement Sensor 1 ...

Page 29: ...ctive target Clean Control Panel Filters Each Drone Upper Control Panel has three filters located on top of the panel and three located below Figure 2 Lift up the cover that is connected to the top of the control panel to access the top filters Remove the filters by unscrewing the acorn nuts located in the corners of all the filters Reattach filters and close the top filter cover when finished The...

Page 30: ...ulb is the bottom circle 7 Press circle corresponding to suspect bulb If the circle turns green the bulb is being commanded to turn on 8 Visibly inspect the bulb to see if it is on or on or not If the bulb is truly not coming on it should be replaced 1 Turn off the machine 2 Turn off all disconnect switches red knobs on drone panels 3 Pull sections apart if necessary to access the bulb rack with a...

Page 31: ...es above 290 degrees push the bulb rack as far as it can go in its track If temperatures continue to be high contact Brown Manufacturing for instructions on adjusting the camera bulb blinders Check Camera Alignment During normal operation of the 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...

Page 32: ...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 Technicians Reference Revision 6 ...

Page 33: ...are mentioned in this document can be easily avoided by following the maintenance activities described in the Firefly Maintenance Manual It is suggested that at least one person per operating shift becomes familiar with the information outlined in this document This will reduce production down time and teach users how to use this system to its full potential Due to the amount of information covere...

Page 34: ...nvection Top Bottom 4 Exhaust and Cooler 5 Bulb Powers 5 Default Program 5 Bulb Control Modes 6 singleBulb 7 tripleBulb 7 twoBulb 7 leadingBulb 7 Prewarm Settings 7 Object Detection 8 Load Detect 10 Proper Loading Technique 11 Snags 11 Wrinkles 12 Folds 12 Height Sensor Adjustment 12 Editing Program Barcode IDs 13 Troubleshooting Common Problems 14 2 ...

Page 35: ...es not include time spent outside the heat chamber or under the exhaust section The Firefly Curing System uses an intelligent algorithm to control the belt speed When products are not being cured the belt runs at a default usually fast speed Once a product is detected the belt will adjust its speed based on the Program settings for that product The Belt Speed that was defined in the product s Prog...

Page 36: ...allows flexibility in managing the intensity of heat in the system Setting all bulb powers at 100 ensures maximum intensity heat which is ideal for production performance 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 t...

Page 37: ...e 6 Drone Settings Button Figure 7 Factory Setup Button Figure 8 Belt Setup Button Each belt 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...

Page 38: ...ture overshoots leadingBulb In this mode when the product has reached cure temperature in a bulb s heating area Figure 10 the next bulb in line is turned off until the product drops back down below cure temp The bulb above the heating area in question is not turned off This mode is best used when a product is running at high speed where bulbs must be controlled in anticipation of the product arriv...

Page 39: ...tween programs For example a program is changed to one that is 60 degrees lower A short cool down time would not give the system enough time to reach the lower target temperature This would cause the first few products to be inaccurately cured each at varying temperatures The disadvantage to having long cool down times is that the belt will need to stop more frequently to execute prewarm cycles To...

Page 40: ...e when they are not needed This then results in lower efficiency and reduced bulb life In rare circumstances reflective products can be mistaken as the sensor target Imitating the function of the sensor target the product reflects the IR light beam back to the object detection sensor Figure 16 In this case the sensor status light remains illuminated showing that the machine is continuing to detect...

Page 41: ...y program changes Loading Product from Side of Belt If a product is loaded from the side such that it does not cover the load detect target then the machine does not know the product has been loaded The machine will consider the entire belt to be a free area and will apply new program settings to the entire belt as soon as the settings are changed In this case if the program settings need to be ch...

Page 42: ...ject blocks the laser beam from hitting the receiver a height sensor event is triggered stopping the belt When this occurs a notice appears on the main control kiosk Figure 23 along with a barcode The belt can be restarted by pressing the notice 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 Fi...

Page 43: ...program If it is necessary to change this barcode ID to match another Firefly Curing System an order tracking 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 Th...

Page 44: ... Settings 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 ...

Page 45: ... the date of installation 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 Product purchase WHAT IS NOT COVERED This warranty does not cover 1 Physical damage to this Product 2 Damage caused by improper Instal...

Page 46: ...d 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 a new Machine or component part s only if i you do not return your original Machine o...

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