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Uninet iColor, User Manual

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15

Make Ready & Operating Instructions

You will soon be on 

y

our way to coating and curing!

Once  the 

iColor  coater

  is  installed  by  you  or  your 

iColor

  certified  technician  and  connected  by  a 

licensed electrician you will be able to start coating and curing. Please follow the step-by-step instruc-

tions on the operation of the 

 iColor coater

 to guarantee success.

Chapter 4

Digital Control Panel

Cooling Filters

Coating Unit

UV Lamp 

Housing

Figure -

 iColor coater

 System

Coating Pump

Summary of Contents for iColor

Page 1: ...www icolorprint com Sales icolorprint com ICDS 10 254mm Digital UV Coating System with Auto Pump User Manual ...

Page 2: ...ling Replacing Your UV Lamp 13 Chapter 4 15 16 20 21 22 23 24 25 26 27 28 30 Make Ready Operating Instructions Digital Control Panel Establishing iColor Coating Unit Settings Testing the iColor Coating Unit Calibration Calibrating the iColor Coating Unit Setting Form to Impression Roller Pressure Power ON the Coater Make Ready the Coating Pump Unit Setting the Optional Automatic UV Coating Sensor ...

Page 3: ...tenance Troubleshooting Guidelines Daily UV Cleanup Procedure Weekly or Holiday UV Cleanup Procedure Aqueous Coating Primer Cleanup Procedure Lubrication Schedule Replacing the Doctor Blade Procedure Tracking the Conveyor Belt Replacing the Conveyor Belt Decimal Millimeter Conversion Table ...

Page 4: ...tion and care should be taken to avoid injury or damage REMARKS A REMARK symbol provides you with additional information such as options that are available WARNING UV Light Avoid looking directly at UV Light Use only with shielding in place Protect eyes skin from exposure to UV Light WARNING HOT WARM metal surface WARNING HIGH VOLTAGE WARNING Keep hands and fingers clear Sever injury may occur Do ...

Page 5: ...s the following topics Introduction Equipment Specifications Unpacking Installing iColor Coater Safety Precautions Operation Maintenance Troubleshooting Coating Consumables Please familiarize yourself with the content of this manual before unpacking installing and operating the iColor coater In an effort to ensure safety please read and pay close attention to all safety relat ed comments I UNITED ...

Page 6: ...siness Card Business Card Speed up to 80 feet minute up to 24 meter minute Stock Weight 7pt to 30pt 150 up to 600 g m UV Lamp Solid State UV 70 watts to 200 watts Infinitely Variable 70 watts to 200 watts Infinitely Variable Total Weight Approx 200 lbs Approx 91 kgs Electrical 208 230v 1Φ 50 60Hz 25amps 208 230v 1Φ 50 60Hz 25amps Noise Level 60 dB 60 dB ...

Page 7: ...e lamp and catches fire Class A extinguishers are for ordinary combustible materials such as paper wood cardboard and most plastics Class B fires involve flammable or combustible liquids such as gasoline kerosene grease and oil Class C fires involve electrical equipment such as appliances wiring circuit breakers and outlets Never use water to extinguish class C fires the risk of electrical shock i...

Page 8: ... eyes CAUTION When handling the UV Coating please use safety gloves provided for skin protec tion CAUTION Please read and observe the UV coating Material Safety Data Sheets MSDS for the various personal work and environmental recommendations The MSDS sheets should be easily accessible in the event of an emergency CAUTION Keep UV coating away from heat and or open flame Keep UV containers in a cool...

Page 9: ...t safety guard is opened the conveyor will shut down immediately the UV light will drop to the lowest setting and the reflector hous ing will rotate to the idle position The fan will continue to operate If the rear safety guard is opened the UV lamp conveyor fans will instantly shut down Upon closing the rear guard the fan will begin to operate and begin running the cooling cycle You may turn on t...

Page 10: ...e to Apply aqueous coatings as well as water based primers such as Sapphire to papers and plastics to be printed with the HP Indigo Flood coat a 10 254mm x unlimited length product Provide faster job turnaround Reduce time to bindery Apply various finishes gloss satin specialty and primer Handle a variety of substrates and thicknesses NOTE The iColor coater is rated to handle a minimum stock weigh...

Page 11: ... set d There is ample coating in the nip of the coating unit if using optional UV automatic sensor make sure sensor light is on e The correct coating is being used for your job f You have a supply of lint free rags and cleaner available g When feeding stock be sure it is existing the UV chamber stock that does not exit the UV chamber will result in a FIRE 11 Always mix your coating prior to use 12...

Page 12: ... on the impression roller 6 DO NOT run the coater unit without the seals in place The rollers will be damaged This damage will not be covered by the warranty 7 DO NOT forget to perform the end of day procedure WARNING Do not use Flammable Non Approved coatings 8 NEVER leave the coating unit in the ON position when running light weight stocks without paper going through the system This will continu...

Page 13: ...e padding If reusable nylon ratchet tie downs have been used remove by using the release handle If plastic strapping please cut with a razor blade Take care not to damage your iColor coater when cutting with a razor 2 Remove the boxes or packages that may have been included and place them in safe keeping until needed 3 With a minimum of two people carefully lift the iColor coater from the wooden w...

Page 14: ...to provide at least 3 feet 1 meter of space around the iColor coater for operation and service 2 The iColor coater is equipped with approximately 8ft of electrical cord 3 Have the Electrician connect the iColor coater cord to the existing plant power 4 If it is necessary to hardwire the equipment it is very important that it is completed by a licensed certified electrician WARNING Once the power i...

Page 15: ...h the drain hole until secure 3 Install the Drip Pan in the mounting bracket below the impression roller by tilting the rear of the pan high back insert the high back behind the impression roller level off the drip pan and place in the mounting bracket Be sure the Drip Pan is facing the correct direction Figure Drip Pan Close Up Figure Drip Pan Plug Figure Drip Pan Drip Pan Plug Drip Pan Installed...

Page 16: ...mmended that you also remove the black heat sink for additional access to the UV bulb 7 Disconnect the bulb wires from the terminal block on each side using a Flat Head screwdriver 8 Using a 4mm Allen key remove UV bulb access cover on both OP NOP side Figure Remove OP Side Cover Figure Remove NOP Side Cover Side Cover Side Cover Figure Bulb Disconnect UV bulb access cover Figure Bulb Disconnect U...

Page 17: ... bulb with Isopropyl Alcohol IPA as soon as possible 11 Reinstall Bulb Access Covers making sure the tab is on top of the bulb end caps This will ensure the bulb remains properly seated in the mounts Failure to do so will result in bulb breakage when the shutter is activated 12 Connect the wires to the terminal blocks Make sure to place the wire into the terminal block above the incoming wire 13 R...

Page 18: ...ur iColor certified technician and connected by a licensed electrician you will be able to start coating and curing Please follow the step by step instruc tions on the operation of the iColor coater to guarantee success Chapter 4 Digital Control Panel Cooling Filters Coating Unit UV Lamp Housing Figure iColor coater System Coating Pump ...

Page 19: ...r at the touch of a button Adjust UV bulb intensity belt speed on the fly Manually pump coating to the coating unit when needed Jog forward reverse Alerts when rear guard is open CAUTION DO NOT use the Jog button with the Coating Unit ON Impression as this will dump the contents of the coating unit Figure Digital Control Panel ...

Page 20: ...3 Coating Pump Screen F4 Forward Reverse Job Screen BELT SCREEN Get to this screen by pressing F1 Function Key from the Home Screen The speed is controlled by the Left Right Arrow Keys whether the belt is ON or OFF Press F5 Function Key to Turn ON Belt The belt will not turn on if the Front Guard is OPEN Press F6 Function Key to Turn OFF Belt Press F0 Function Key to return to the Home Screen Belt...

Page 21: ...row Keys This can ONLY be adjusted when the lamp belt are ON Press F5 Function Key to Turn ON Lamp Press F6 Function Key to Turn OFF Lamp Press F0 Function Key to return to the Home Screen PUMP SCREEN Get to this screen by pressing F3 Function Key from the Home Screen Press F9 Function Key to turn ON the MANUAL pump Pump will stay ON as long as you hold the button Press F7 Function Key to turn ON ...

Page 22: ...tion Key from the Home Screen Press F8 Function Key to FORWARD Jog the Belt Press F9 Function Key to REVERSE Jog the Belt The Machine will jog for as long as you hold the button REAR GUARD OPEN SCREEN This screen appears whenever the Rear Guard is Open When in this screen all functions are disabled ...

Page 23: ...m Low pressure Normal to Heavy Film of Coating 3 Position Medium pressure Normal Film of Coating 4 Position Highest pressure DO NOT EXCEED Thin Film of Coating REMARKS The recommended Coating Unit pressure setting is between 2 and 3 CAUTION When shutting the system down for the day it is VERY IMPORTANT that you set the coating unit metering controls to the END OF DAY POSITION Failure to set the ro...

Page 24: ... on the metering gauges 2 At approximately 25mm 1 inch from each end of the form metering roller nip roll two strips of bond paper 25mm x 250mm 1 x 10 of 80 g m 20lb or 004 between the rollers 3 Pull each strip vertically from the nip while preventing the rollers from rotating Assess the resis tance between the rollers 4 If you have equal tight resistance No adjustment required 5 Reset the meterin...

Page 25: ... nip roll two strips of bond paper 25mm x 250mm 1 x 10 of 80 g m 20lb or 004 between the rollers 4 Pull each strip vertically from the nip while preventing the rollers from rotating Assess the resis tance between the rollers 5 Adjust each clicker till an even tight drag is felt on each side regardless of the number on the number gauge 6 Then loosen the clicker arm locking screw 7 Turn the clicker ...

Page 26: ...hine at each side c Adjust the Impression Clicker Knobs until there is a LIGHT even drag on each of the strips d Check that you can see a slight gap between the Form Roller and Impression Roller If the roll ers are touching there is too much pressure NOTE Turning the Impression Clicker Knob Clockwise will decrease the pressure between the Form Roller and Impression Roller and Counterclockwise will...

Page 27: ...lamp to be turned on without the belt in motion This allows you to warm up the system during set up or work with the front guard open while the lamp is ON 3 Go to the Belt Screen by pressing F1 from the Home Screen Press F5 to Turn the Belt ON a The average time that the UV lamp takes to reach full capacity can vary from 30 seconds to 2 minutes When the lamp reaches full capacity it will automatic...

Page 28: ... to mix your coating well shake the bucket prior to use 2 Make sure the hose is secure in the coating pump and is in the proper coating bucket 3 Be sure to adjust the Metering Pressure to the desired setting before filling If left in the END OF DAY POSITION while filling coating could leak through the gap 4 Go to the Pump Screen by pressing F3 from the Home Screen 5 Press F9 to turn ON the MANUAL ...

Page 29: ...ating i If the coating automatically stops near the imaginary fill line NO adjustment is required ii If the coating does not automatically stop once it reaches the imaginary fill line immediately open the front guard to stop the belt and auto pump a With the safety cover open adjust the sensor by turning the screw clockwise with a small flat head screwdriver until the light turns OFF iii If the co...

Page 30: ...an come in a variety of brands and qualities It is very important that you use a good quality coating like Uninet UV Aqueous Coating Always shake the coating well before use Coating can separate due to excessive heat and cold It should be stored in a climate controlled area Uninet recommends storing using your coatings at a temperature between 70 90 F 21 32 C Temperatures lower than 70 F 21 C coul...

Page 31: ... in a climate controlled environment As coating gets colder it thickens and is much harder to deal with Ideally coating likes to be at a temperature between 70 90 F 21 32 C This allows for good flow out and a smooth look 4 Paper can make a tremendous difference in the way your coating looks especially absorbent paper The same job run on the same printer with different paper can coat differently Th...

Page 32: ...completely clean the coating unit and set the metering controls to the END OF DAY POSITION Failure to set the roller pressure to the END OF DAY POSITION may result in a flat spot on the form roller that will show up on your coated material This problem is NOT covered by our Warranty 10 You should get into a habit of lightly scratching an occasional piece of coated material to make sure that the co...

Page 33: ...equence is complete c The average cool down time is 4 minutes d If starting from cold or hot conditions the lamp may take longer to ignite 2 Check Set the Form to Impression Roller pressure setting 3 Set the Belt Speed to the desired setting 4 Set the UV Lamp Intensity to the desired setting and wait for the UV lamp to reach full capacity 5 Now you are ready to begin feeding the product 6 Feed one...

Page 34: ... can ONLY be adjusted when the lamp belt are ON 3 Increasing Decreasing Coating Unit Pressure a Increasing pressure will Decrease the amount of Coating b Decreasing the pressure will Increase the amount of Coating 4 Increasing Decreasing Form to Impression Roller Pressure a Increase pressure if areas on sheet have little or no coating b Decrease pressure if the Form Roller is contacting the Impres...

Page 35: ... There is an adjustment on the left and right side for fine tuning the amount of coating Remember MORE IS NOT BETTER 5 A larger number on the dial will give you a smaller amount of coating on the job 6 If the coating scratches off frequently when tested with your finger nail it may indicate that your UV Bulb needs to be replaced Contact UniNet Customer Service 7 After running several test sheets i...

Page 36: ...set E Stop Main motor is on but the Belt is not running a Loose Belt a Check Belt Coating getting on the backside of the sheet a Form to Impression roller pressure is too tight a Decrease the Form to Impression roller pressure Coating is not even on the sheet a Form to Impression roller is not even b Form to Metering roller nip pressure is too light c Form to Metering roller nip pressure is not ev...

Page 37: ...substrate you are using c For best results store the coating in a climate control room 70 90 F 21 32 C d Decrease belt speed e The appearance of most all coatings can be improved with the addition of the Optional Oscillating roller See the Komplete Roller section of the Con sumables page or contact Uninet Customer Service for more information Coating scratching off a Improper coating solution b No...

Page 38: ...t that you remove the hose kit prior to cleaning the Coating Unit as coating and or cleaner may flow out of the hose nozzle 6 Pour a small amount of UV Klean into the coating unit and run it for 30 seconds Run for another 30 seconds to clean the rollers Turn OFF the belt open the safety guard and remove UV Klean from the nip with the Vac or Bulb Syringe Repeat until all coating is removed CAUTION ...

Page 39: ...he equipment with the seals removed as this will cause damage to the rollers which is NOT covered by the roller warranty 5 Remove the coating drip pan and clean with UV Klean 6 Remove the doctor blade and clean with UV Klean 7 While you have the Doctor Blade and the Drip Pan removed completely clean the Impression roller with UV Klean Reinstall drip pan doctor blade 8 Dispose of all coating rags a...

Page 40: ...the coating unit and run the Coater for 30 seconds Turn the coating lever to ON and run it for another 30 seconds to clean the rollers Turn OFF the belt open the safety guard and remove Aque Klean from the nip with the Vac or Bulb Syringe Repeat until all coating is removed CAUTION Never put the Vac nozzle into the nip with the machine running as damage to the rollers can occur which is NOT covere...

Page 41: ...minutes b Disconnect the hoses from the pump pour a small amount of Aque Klean into each hose and slosh back and forth until the Aque Klean flows freely in the hoses and then discard the Aque Klean into a cup with a paper towel and dispose of in the trash no biohazard will exist 13 Dispose of all coating rags and cleaner as directed per your local regulations 14 Pour the contents of the Kompac Vac...

Page 42: ...oller every 80 100 hours DRIVE SPROCKETS It is very important to Grease the NOP side Drive Sprockets at least twice a year Please Note you must remove the side covers to access these Sprockets Below is an image of the NOP Side Drive Sprocket Coating Unit Gear Impression Roller Gear Figure Lubrication Locations Figure NOP Side Drive Sprocket NOP Side Drive Sprocket ...

Page 43: ...tor Blade is an important part of the coating process and should be cleaned and replaced as needed To remove the Doctor Blade Assembly 1 Turn the Main Power Switch OFF 2 Remove the Coating Drip Pan 3 Remove the Button Head Screw on each side using a 5mm Allen key 4 Remove the 2 two Cap Screws on each side using a 4mm Allen key 5 Remove the Guide Pin and Doctor Blade Spring on each side and set asi...

Page 44: ...crews using a 3mm Allen key 3 Remove the Doctor Blade and dispose of accordingly CAUTION Use caution when handling the Doctor Blade as the edges are sharp 4 Install a new Genuine Uninet Doctor Blade NOTE Be sure the stepped edge of the Doctor Blade is facing downward and that the doctor blade is all the way seated in the cutout area Figure Doctor Blade Assembly 3mm mounting screws Figure Doctor Bl...

Page 45: ...ten the two cap screws on each side using a 4mm Allen key 9 Tighten the Button Head Screw on each side using a 5mm Allen key 10 The Doctor Blade should Float in the mounting bracket when pulled back 11 Install the Coating Drip Pan Figure Coating Drip Pan Coating Drip Pan Figure Mounting Bracket Mounting Bracket Doctor Blade Assembly Figure Mounting Bracket Assy Button Head Screw Guide Pin Doctor B...

Page 46: ...belt If the belt is walking to the Right tighten the Right Tracking Bolt or Loosen the Left Tracking Bolt approximately one eighth of a turn 3 Facing the belt If the belt is walking to the Left tighten the Left Tracking Bolt or Loosen the Right Tracking Bolt approximately one eighth of a turn CAUTION Do Not Overtighten the Tracking Bolts as this will damage the Conveyor Belt The belt should be jus...

Page 47: ...osen the Belt Tracking Bolts just enough so the Belt Pin pulls out freely Loosening the bolts too much will result in the bolts coming out of the flange bearing blocks 3 Remove the old belt by removing the belt pin with a pair of Needle Nose pliers 4 Install the New Belt making sure to route the belt properly and secure the Belt Pin in place 5 Tension the belt until the belt no longer slips on the...

Page 48: ...762 11 16 0 6875 17 462 13 64 0 20303 5 159 45 64 0 70313 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 23438 5 953 47 64 0 73438 18 653 1 4 0 25 6 350 3 4 0 75 19 050 17 64 0 26563 6 747 49 64 0 76563 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 29688 7 541 51 64 0 78688 20 240 5 16 0 3125 7 937 13 16 0 8125 20 637 21 64 0 32813 8 334 53 64 0 82813 21 034 11 32 0 34375 8 731 27...

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