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6.3 Troubleshooting

The following table lists problems that may occur when using the SW-2600 or
SW-3300 Liquid Coater. Recommended corrective actions are provided for
all commonly encountered problems.

Problem / Symptom

Causes

Corrective Action

Very thin coating

Sealant is diluted with
water

Remove old coating and refill
with new

Heavy coating

Weight of coating in
application area causes
material to sag and not get
wiped off properly

Increase tension on the
Unwind Roller

Dirty Draw-Down Applicator
or Meyer Bar

Clean the Draw-Down
Applicator and Meyer Bar

Overly thinned coating can
dry quickly and streak

Remove old coating and refill
with new

Streaked finish

Contaminated coating can
clump up and streak

Remove old coating and refill
with new

Substrate has been
overheated

Cool down heaters or speed
up drive

Roll-feed to take-up
alignment is poor

Realign the substrate

Substrate wrinkles

Insufficient back-tension

Increase tension on the
Unwind Roller

Telescoping substrate

Roll-feed to take-up
alignment is poor

Realign the substrate

Coated Substrate is

wet coming out of the

dryer panel

Insufficient drying

Reduce web speed

Increase the heat panel

temperature

Substrate surface is
contaminated

Ensure substrate is free form
contaminates

Sealant is contaminated

Remove old coating and refill
with new

Non-wets (areas

where the sealant has

not adhered to the

film or paper)

Substrate or inks and
sealant are incompatible

Use a compatible substrate

Substrate is too hot and is
beginning to melt

Cool down the heaters and/or
speed up the drive

Distortions in

substrate

Substrate is hot and back
tension is too high

Decrease tension on the
Unwind Roller

Содержание AquaSEAL SW-2600

Страница 1: ...Seal Brands the finishing touch AquaSEAL SW 2600 SW 3300 Owner Operation Manual Important Read and understand all safety information before operating ...

Страница 2: ...ent Nor does it make expressed or implied warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose SEAL Graphics shall not be liable for incidental or consequential damages in connection with or arising out of the furnishing performance or use of this document and the program material which it desc...

Страница 3: ...Seal Brands the finishing touch AquaSEAL SW 2600 SW 3300 Manual Status OMSW26_33 Rev D June 2005 I ...

Страница 4: ......

Страница 5: ...s please do not hesitate to contact us The address and phone numbers are listed in Section 8 Technical Support Topics Covered in This Manual Section 1 Safety Information An explanation of equipment environmental and operating safety issues Section 2 Features Control Panel AquaSEAL SW 2600 and SW 3300 features explanations and Control Panel layout and usage Section 3 Specifications Lists the genera...

Страница 6: ...ranty period stated herein All Demo Equipment comes with a specific warranty which will be stated at the time of purchase If warranty period is not detailed in writing there is no remaining warranty Please ask your dealer distributor or sales representative for details Please ask your dealer distributor or sales representative for details NOTE Used Equipment that has not been refurbished to Seal G...

Страница 7: ...ure Feedback System 2 2 Brake Tension Control 2 3 Main Circuit Breaker 2 4 Connections 2 4 1 Power 2 4 2 Compressed Air 2 5 Cooling Fan 2 6 Draw Down Applicator 2 7 Dryer Panel 2 8 Emergency Stop Buttons 2 9 AccuCure IR Heat Sensor 2 10 Photo Eyes 2 11 Sealant Distribution Valves 2 12 Sealant Drain Pan 2 13 Sealant Pump 2 14 Sealant Tank 2 15 Take Up Roller 2 16 Unwind Roller Control Panel 2 17 Co...

Страница 8: ...ed 5 3 Pre heating the Coater 5 4 Loading Sealant 5 5 Priming the Sealant Pump 5 6 Loading the Substrate 5 7 Webbing Coater 5 8 Running the Coater in Speed Mode 5 9 Running the Coater in Temp Mode 5 10 Process Control Data Sheet 5 11 Unloading Substrate 6 Maintenance 6 1 Cleaning between Runs 6 2 Periodic Maintenance 6 3 Trouble Shooting 7 Glossary 8 Technical Support 13 13 14 15 15 15 16 17 18 18...

Страница 9: ... to page 14 NOTICE Ground wire of power cord must be 2 inches 50mm longer than other wires L1 L2 P E 3 P H A S E U S C a n a d a 1 P H A S E U S C a n a d a LT BLUE L2 L1 L3 L3 3 P H A S E E u ro p e P E L2 L1 N G R E E N G R E E N G R N Y E LLO W BLUE WHITE BLACK RED BROWN BLACK BLACK WHITE PE SuperWide Installation Technical Support Tips 1 Before applying power to machine make sure all electrica...

Страница 10: ...ne Comply with all safety warning signs labels and instructions Operators should be trained on the proper use of the machine and all safety procedures Provide fresh water clean towels and rubber gloves for use doing cleanup It is advisable to wear eye protection when filling emptying sealant tank Always provide an approved emergency eyewash station adjacent to the machine Machine Unpacking Instruc...

Страница 11: ...NS 1 2 Environmental Place the unit in a well lit dust free and adequately ventilated work area with plenty of room to process jobs The coater should be level With heating elements in the unit there is always an issue with fire Make certain there are fire extinguishers close by An extinguisher rated Class C is required for fires involving energized electrical equipment WARNING RISK OF FIRE OR EXPL...

Страница 12: ...5 Chemical When handling any chemical products read the manufacturers container labels and the Material Safety Data Sheets MSDS for important health safety and environmental information To obtain MSDS Sheets for AquaSEAL Products please call your local distributor CAUTION ALWAYS OBSERVE MANUFACTURERS RECOMMENDATIONS WHEN HANDLING CHEMICALS 1 6 Pneumatics There can be up to 125psi pounds per square...

Страница 13: ...oth Ends Figure 1 Locations of Warning Decals Pinch Decal Areas to avoid the mechanism from pinching or pulling Warning Decal Fire or Explosion Risk Solvent Tank and Dryer Panel Danger Decal Electrical Danger Dryer Panel Electrical Decal Areas to avoid getting an electrical shock Hot Spot Decal Areas to avoid getting burned or combustion Figure 2 Types of Warning Decals 3 ...

Страница 14: ...unit until it is connected to the proper power source DO NOT place unit near open flames DO train operators on the proper use of the machine and all safety procedures DO NOT wear loose clothing or loose jewelry and contain loose hair to avoid becoming entangled with moving parts of the machine DO familiarize operators with the layout of the Control Panel and with the operation of the sealant deliv...

Страница 15: ...5 Section 2 Features Control Panel 14 1 2 4 6 7 5 8 3 9 12 13 11 11 10 Figure 4 SW 2600 SW 3300 Features Front View ...

Страница 16: ... Cabinet Lock Section 1 3 11 Photo Eye Section 2 10 12 Emergency Stop Button Sections 1 8 2 8 13 Meyer Bar Assembly optional accessory Section 3 3 14 Control Panel Sections 2 17 2 22 15 Identification Label Section 3 2 16 Power Connection Section 2 4 1 17 Main Circuit Breaker Switch Sections 2 3 18 Cooling Fans Section 2 5 19 Take Up Roller Section 2 15 20 Compressed Air Connection Section 2 4 2 2...

Страница 17: ...eration The Brake Tension Control knob increases or decreases braking pressure on the Unwind Roller Turning the knob clockwise adds braking pressure and counter clockwise reduces braking pressure Figure 6 Brake Tension Control 2 3 Main Circuit Breaker Switch The Main Circuit Breaker Switch controls all ON OFF power coming to the machine 60 Amp Single Phase 50 Amp Three Phase 30 Amp Three Phase Fig...

Страница 18: ... apply The machine is in RUN mode The Dryer Panel Switch on the Control Panel is set to DOWN The Run Drive is ON There is no obstruction blocking any of the Photo Eyes NOTE The Dryer Panel has fans in the top of it that force air through perforations in the face of the heaters These fans are used to push humidity away from the substrate as it passes underneath the Dryer Panel IT IS VERY IMPORTANT ...

Страница 19: ...sing pneumatic cylinders that lift up to web the machine and draw down to run substrate The Photo Eyes are a safety feature that will raise the assemblies when the beam is crossed The Photo Eyes are active for 5 seconds upon initiation of lowering the Draw Down Applicator and or Dryer Panel Once these assemblies are lowered into position the safety hazard is removed and the Photo Eyes become inact...

Страница 20: ...nk Main Drain Valve for Drain Pan From Drain Pan Drain Pan Return Valve Sealant Flow Sealant Pump Filter Quick Disconnect Tank shut off and flow valves Figure 10 Dual Tank Plumbing System shown 2 14 Take Up Roller The Take Up Roller collects the coated substrate as it is exiting the coater NOTE Both the Take Up and the Unwind Rollers are designed to accommodate a 3 ID substrate roll that is remova...

Страница 21: ...ant Pump switch the Heat display LED and the Speed Control Display are illuminate when ON 1 2 3 4 5 6 ITEM NO DESCRIPTION 1 Control Panel Switch Section 2 17 2 Pre Heat Run Switch Section 2 18 3 Temperature Control Display Section 2 19 4 Dryer Panel Switch Section 2 20 5 Speed Control Display Section 2 21 6 Sealant Pump Switch Section 2 22 ...

Страница 22: ...de Damage to substrate may occur 2 19 Temperature Control Display The Temperature Control Display shows the Dryer Panel temperature measured by internal thermocouples on an LED read out Figure 12 The Dryer Panel temperature is set using this control Adjust the temperature by holding down the star button far left and using the up and down arrow buttons to make changes Figure 12 Temperature Control ...

Страница 23: ...een Speed Mode Screen The Speed Mode Screen controls starting or stopping the substrate DRIVE To start the DRIVE touch the RUN DRIVE button To stop the DRIVE touch the STOP DRIVE button In addition the desired speed of the substrate running through the coater can be set on this screen The FPM MPM ft min or meter min speed is set with the up down arrows at this menu The top speed displayed is the a...

Страница 24: ...x 13 5 5m x 5m x 4m 18 x 16 x 13 5 5m x 5m x 4m Temperature 50 F C C 50 F 35 C 95 F 16 35 95 F 16 C Moisture If igh m a ould accordance with local building codes located in a h oisture are installation sh be in Ventilation n Clean dust free area with adequate circulation and ventilatio Max Coat Width 105 2 6m 129 3 2m Max Coat Thickness 82 micron wet 82 micron wet Coating Means Meyer Bar eyer Bar ...

Страница 25: ...re gun eas consult Integrated Graph S CAUTION Installation should be completed by qualified personnel At delivery the coater is packed in plastic to avoid moisture penetration and is ith three tie down straps unless shipped by ter from the pallet it in shipping packaging Pallet tie down straps 4 1 Unpacking and Assembly fastened onto a wood pallet w padded van Remove the tie down straps from the p...

Страница 26: ... and on the lower compartment Cradle Brackets and hardware Cut the ties using care not to damage the parts and remove plastic Unwind Roller Storage Cradle Bracket Storage Figure 14 Parts tie down locations Bolt the Cradle Brackets to both sides of the unit with hardware provided and install the Unwind Roller see Figure 15 below Unwind Roller Cradle Bracket Figure 15 Cradle Bracket and Unwind Rolle...

Страница 27: ...e fitted If in doubt please contact Technical Services or consult a local electrician see Section 3 Compressed air supply 100psi 3CFM If No fax customer services on 800 257 7325 to order Adequate building sub structure to support the weight of the machine supplies and operators Adequate space and ventilation Clean water source and drain as close as possible to the intended working area Check that ...

Страница 28: ...ing the coater Switch machine ON at the Control Panel Switch The coater will power up with the Dryer Panel and Draw Down Applicator in the UP position On the Temperature Control Display see Section 2 2 3 press and hold the star key to check the set point temperature Adjust the set point temperature measured by internal thermocouples by holding the star key down and using the up and down arrow keys...

Страница 29: ...priming the Sealant Pump may result in damage to the pump assembly The pump will fail if run without liquid in it for any length of time Sealant Pump Refer to Figure 16 for reference Connect a hose provided in the accessory kit to Pump Evacuation Valve and place the other end in the Sealant Tank Open the valves between the Sealant Tank discharge and the pump If equipped with Dual Tank Option ensur...

Страница 30: ...ibution Valves From Drain Pan Sealant Drain Pan Valves Pump Evacuation Valve Pump Side View Sealant Drain Pan Drain Valve Figure 16 Sealant Pump Valve System Dual Tank option shown 5 6 Loading the Substrate It is recommended that two 2 people load the substrate The substrate must be oriented on the Unwind Roller to feed into the coater with the image side up see Figure 19 Locking Pin Remove the Lo...

Страница 31: ...Roller and slide a roll of substrate down the roller until centered then set the roller end back into Cradle Lift and push the Unwind Roller back into operating position Turn the roller locking knob back 90 degrees or until it sets with the Roller Shaft Lock sliding in Return the locking pin 20 21 ...

Страница 32: ...oller and under the Draw Down Applicator see Figure 19 Ensure that the substrate edge is being webbed straight and perpendicular to the Web Idler Roller directly above the Unwind Roller Figure 18 Take Up Roller Tighten the Tension Control Knob clockwise to add a small amount of tension to the Unwind Roller may make webbing the coater easier Pull the substrate under the Dryer Panel to the Take Up R...

Страница 33: ...image side up Substrate must be 22 23 Dryer Panel Draw Down Assembly Web Idler Roller Take up Roller Unwind Roller Figure 19 Webbing Diagram ...

Страница 34: ...ge If there is an obstruction in front of the Photo Eyes located on either side of the Dryer Panel the panel will not go down or will go back up if an obstruction passes through the photo eye beam while the Dryer Panel is going down see Section 2 10 During DRIVE mode the coater is sensing for movement of the Web Idler Roller to ensure that the substrate is always moving If no motion is detected fo...

Страница 35: ...ealant should be removed from the substrate and the substrate should be dry before it is pulled through the Dryer Panel to avoid getting sealant on the coater 5 9 Running the Coater in Temp Mode It is not recommended to use TEMP Mode until the optimum substrate output temperature setting has been determined by running the process in SPEED Mode See Section 5 8 Once the coater reaches the temperatur...

Страница 36: ...ocess push the STOP DRIVE button on the Speed Control Display After about 1 minute check the substrate exiting the Dryer Panel for correct dryness If the sealant is tacky raise the temperature set point by 5 degrees Fahrenheit or 3 degrees Celsius on the Speed Control Display Recheck the dryness after about 1 minute and adjust the temperature if necessary Prior to the last piece of substrate going...

Страница 37: ...p this record so the application can be repeated at a later date Process Control Data Sheet Date Substrate Used Substrate Size Meyer Bar Sealant Used Temp Settings Speed Settings Web Tension Process Description Notes Date Substrate Used Substrate Size Meyer Bar Sealant Used Temp Settings Speed Setting Web Tension Process Description Notes Date Substrate Used Substrate Size Meyer Bar Sealant Used T...

Страница 38: ...eriod of time any excess sealant should be wiped out of the Sealant Drain Pan A large 4x6 sponge works well CAUTION The use of solvent based cleaners is NOT recommended NOTE Use a Scotchbrite green abrasive pad to remove dried sealant buildup from bare metal parts Do not attempt to clean painted or otherwise coated parts with an abrasive pad 6 2 Periodic Maintenance Detailed cleaning is recommende...

Страница 39: ... securely Remove the Sealant Tank dispose of the excess water Re install Sealant Tank and re fill with Sealant Purge all water from the system by closing the Sealant Tank Drain Pan Return Valve s With a hose connected to the System Drain Valve or a bucket under the valve run the pump until only sealant flows out of the Application Tubs repeat this step for 2nd tank if equipped Ensure all valves ar...

Страница 40: ...d refill with new Substrate has been overheated Cool down heaters or speed up drive Roll feed to take up alignment is poor Realign the substrate Substrate wrinkles Insufficient back tension Increase tension on the Unwind Roller Telescoping substrate Roll feed to take up alignment is poor Realign the substrate Coated Substrate is wet coming out of the dryer panel Insufficient drying Reduce web spee...

Страница 41: ...essions occur at the Take Up Roller Insufficient drying Reduce web speed Increase heater panel temperature There is a leak at the pump or inlet plumbing Check for leaks and correct them Sealant tank is low and is sucking air Add more sealant to tank Sealant was frozen before use Remove old sealant and refill with new The sealant is foaming Pump has malfunctioned Check for air trapped in the pump a...

Страница 42: ...icator A liquid that is permanently applied or coated onto the base substrate or image see Coating The assembly unit that applies and smoothes the sealant coating to the substrate Take Up Roller Dryer Panel The roller that captures and roles up the processed substrate as it exits the coater The assembly that dries and cures the sealant as the substrate passes underneath Unwind Roller Earth Linkage...

Страница 43: ...Notes 31 33 ...

Страница 44: ...ith electrical codes in your area Specifications subject to change without notice Seal Graphics Americas Corporation 7091 Troy Hill Drive Elkridge MD 21075 Tel 410 379 5400 Fax 410 579 8960 Seal Graphics Canada 1601 Matheson Blvd E Unit 4 Mississauga Ontario Canada L4W 1H9 Tel 905 212 9232 Fax 905 212 9313 Seal Graphics U K Ltd Unit 1 1 Watkins Close Burnt Mills Industrial Estate Basildon Essex SS...

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