Instruction Manual Lawson Pre-Treat Zoom XL (Version 2.1)

Transcription

1 Instruction Manual Lawson Pre-Treat Zoom XL (Version.) SCREEN & DIGITAL PRODUCTS, INC. 50 Penrose St. St. Louis, MO golawson.com May 05

2 Pre-Treat Zoom XL Manufactured by: Lawson Screen & Digital Products, Inc. 50 Penrose St., St. Louis, MO 635 Service Telephone: Serial Number: (Please fill-in for future reference) Refer to this serial number when speaking to the Service Department. It contains valuable information related to this piece of equipment. Congratulations on your purchase of the Lawson Zoom XL. To insure successful performance of your Zoom XL, please read this entire manual thoroughly. If you have any questions or do not understand certain content, please call for clarification and additional information. Like ink jet printing, your Zoom XL will require some preventive maintenance and a complete understanding of its operations and control systems to provide optimum performance. This manual is offered to help you get the best possible performance and results from this equipment. The Lawson Zoom XL has been designed to work in conjunction with your direct-to-garment printer. To achieve optimum printing results, the proper amount of pretreat solution needs to be deposited on your printing surface on a consistent basis. The amount of required solution depends on your printer, garment, artwork and shop environment. Important Notes: Always Disconnect the Air line while servicing this unit! Do Not operate this machine without reading this entire instruction manual first! Do Not start adjusting the unit until its entire function and operation is fully understood. If you have any questions, please call prior to operation. It is important that the spray nozzles always be kept clean. If the pre-treat solution is allowed to dry in the nozzle, the nozzle will become clogged and damaged - nozzles and filters are not covered by the parts warranty. Use Distilled Water after use to flush the nozzle and other important components. Never use tap water because tap water contains a variety of minerals (that form deposits) that can be harmful to various spray components. These mineral deposits can damage the spray tip and valves. This machine is designed for the industrial/commercial user it is not designed for hobby, or retail/consumer usage. This manual is meant to serve as a general instructional guide and reference manual for the Pre-Treat Zoom XL sprayer. Design details are subject to change without notice and the manufacturer assumes no obligation regarding changes to the unit, herein described. If you have any questions about the Pre-Treat Zoom XL, please contact your authorized dealer or Lawson. We are always ready to help. Your comments and suggestions are always welcome. Should you need additional support, we are available to assist via phone, web site or . All the information contained herein is proprietary to Lawson s Pre-Treat Zoom XL system. This publication may not be reproduced, copied, or transmitted in any way without written permission from Lawson Screen Products, Inc., St. Louis Missouri. Copyright 04 Lawson Zoom XL (version.) May 05

3 Basic Operating Instructions: Getting Started. The unit will need an air compressor that can produce at least 75 p.s.i. The air connection fitting for the hose requires a /4 quick-connect female fitting. The use of an air dryer or air separator is essential because moisture develops when air is compressed and this can cause damage to the air stroke cylinder and air valves. Failure to use an adequate air dryer (or separator) will void the warrantee of the cylinder and related air components which are damaged by wet or dirty air.. The unit s air regulator has been preset at 50 p.s.i. The recommended setting is p.s.i. 3. Two pre-treat solution/waste collecting buckets are provided and need to be installed at the rear of the unit to collect the overspray fluid. 4. Distilled water is the only water to be used to clean the fluid circuit and tip. Never use tap water because tap water contains a variety of minerals (that form deposits) that can be harmful to various spray components and especially the spray tip. 5. To add fluid to the canisters, turn the air supply off and then release the safety pop valve. This will allow the pressure to escape from the canisters. If there is pressure on the canisters, the operator will not be able to remove the canister. 6. The Zoom XL has two Fluid Canisters. The first canister is used for the pre-treat solution. Often the second canister is filled with water for the cleaning procedure or can be used for additional or a different style pre-treat solution. What is important is only one canister is turned on at a time. 7. On the models with a digital air guage, the p.s.i. will be displayed when the center button is depressed. Basic Operating Instructions. The Lawson Pre-Treat Zoom XL Unit is designed to spray a fabric with pretreat solution prior to printing the fabric. The amount of pre-treat solution deposited onto the fabric (measured in grams) is determined by many factors. It is important to understand the principles of spraying the fabric so that the process does not become frustrating when you are trying to maintain consistency of the deposited fluid. The amount of pretreat fluid deposited on the fabric is controlled by: ) the travel speed of the spray nozzle, ) the design of the spray tip, 3) the distance of the tip to the fabric and 4) the amount of air pressure spraying the fluid. The width of the spray pattern is primarily controlled by the design/size of the spray tip. Lawson can provide many different types of spray tips for a variety of special purposes. Generally speaking, the standard tip provided with your Lawson Zoom XL will be sufficient for the vast majority of applications. If you feel you can benefit from one of our specialty tips, give us a call and we can discuss your requirements. The Zoom XL also has different size platens available. Although the standard Adult Platen that came with your unit is the most popular, we also offer a child and youth platen; and can custom platen for specialty purposes. The Air Pressure Setting will affect the spray pattern in two ways. First, it will affect the volume of fluid being sprayed. More air pressure will actually result in less fluid coming out of the same tip (yes, this seems illogical but it is accurate). This means that by adjusting the air pressure you can fine-tune the amount of fluid deposited on the fabric. Second, the more air pressure that is used can affect the absorption rate of the fluid on the fabric. Too much pressure will actually allow the fluid to bounce off the fabric before it is absorbed. This is not necessarily a bad thing, just a fact that needs to be understood. Lawson Zoom XL (version.) May 05 3

4 . Starting the spray cycle is a simple process. The air regulator has been pre-set to 50 p.s.i. This pre-set regulator setting may need to be changed depending on your air source s pressure to maintain this setting. The first spray of the unit when the air line is first connected is considered the priming spray and probably will not yield a consistent spray. To start the spraying process, the operator must flip the Platen Toggle Switch to extend the drawer. The unit will not spray unless the drawer is extended. After the drawer is extended, the drawer will automatically close at the start of the spray cycle. After the spraying cycle is completed, the drawer will automatically open to remove the sprayed garment and load the next garment. When you are finished spraying garments and want to close the drawer, you will manually flip the Platen Toggle Switch on the control panel for the drawer to close. The drawer will open and close manually by flipping the Platen Toggle Switch or once in the open position, will automatically cycle with the spray start cycle button. Once the air hose is connected, simply push the start button and the spraying cycle will start. The spray carriage will move forward, pause, and then start the spraying cycle. Note: the unit may not spray consistently if the air pressure is below 45 p.s.i. The ideal air pressure is 50 p.s.i. The air pressure will affect the pre-set dial of grams per cycle deposited onto the garment. The pause time before the spraying starts is adjustable. 3. The Zoom XL s spray speed of the spray is adjustable. The range of the speed has been pre-set at the factory. The dial speed of 00 is equals approximately grams of fluid and zero indicator mark on the dial will equal approximately 30 grams. The range can be changed with ease. The more fluid to be deposited on the garment, the more the dial needs to be turned clockwise. Turning the dial clock-wise will slow down the carriage movement and thus spray more fluid. The spray adjustment knob can be adjusted to the range of deposit (within one revolution of the dial) by loosening the stop bolt and positioning it on the spray valve stem. The range of the fluid volume of the spray can be grossly adjusted by removing the spray stop range bolt (allowing more than one revolution) and turning the knob until the desired range is achieved. And then the speed knob can be tuned by adjusting the knob on the speed valve stem to match the range of fluid for one revolution that you desire. 4. The Zoom XL features the Lawson quick exchange tip/cap system. This is an exclusive Lawson feature pioneered for the pre-treat industry. It does not matter which way you install the tip into the holder because the holder will locate the tip in the correct spraying position. This feature also allows the operator after cleaning the system, to soak the tip in water so as to prevent the tip from clogging due to any particles that could have been left in the tip by not cleaning the tip correctly. 5. To add solution to the Pressure Canister, the air to the unit must be off and if the canister has been pressurized, the canister s air must be released. This process is simple; just pull the attached Canister Ring to release the air. Always be sure to install the Slip-On Fluid Post Filter. By using this filter, it will minimize the need to clean a clogged tip during production spraying. 6. The front and return carriage length travel is set at the factory and should not be moved. Changing the length of the travel does not affect the spraying pattern. Note: the settings of the start and stop limit switch is effected by the unit s air pressure setting. The front travel limit switched may need to be adjusted if the carriage does not reverse directions after cycling forward; and the rear limit switch will need to be adjusted if the fluid does not stop spraying at the end of the return cycle. Your air setting needs to be at least 50 p.s.i. before making any adjustments. 7. Adjusting the length of the spray is accomplished by moving the spray limit switch bracket. The spray always starts after the nozzle/tip travels to the forward position and reverses the travel position, and starts to move toward the rear of the chamber. The start of the spray can be changed; the stopping of the spray is always after the tip passes the rear of the platen. The full spray pattern has been set at the factory. Lawson Zoom XL (version.) May 05 4

5 Note: The setting of this switch is sensitive. Not only is the length position important in triggering the start of the spray but the position (angle) of the roller ball contacting the carriage plate will effect the start of the spray. If the spray limit switch is positioned too close to the front of the unit/ operator, the switch will not be engaged to spray. Move the switch towards the rear of the unit for engagement. 9. Clean the unit at the end of the day. This is a critical task! Skipping this task will result in your nozzle/tip not working the next time. If you spray the unit one time or a hundred times, the same cleaning procedure must take place. Remember, the pre-treat solution that coats the fabric will also coat your spray tip. And a tip with a coated and dried film solution will clog the tip. It is very important to read and follow the daily maintenance procedures. Note, after the cleaning procedures have been achieved, remove the quick exchange cap and soak the tip in distilled water so as to prevent the tip from clogging due to any partials that could have been left in the tip by not cleaning the tip correctly. Maintenance Procedures It is critical that the unit is cleaned on a daily bases. Most Pre-Treat fluids in simple terms are glue in salt water. And if the glue is not cleaned upon completion after each production day, the unit will not preform correctly and will void the manufacture s warrantee: ). It is critical that distilled water flushes the system to rid the pre-treat fluid from the fluid valve and the spray tip. Cycle the unit till the fluid lines are visually cleared of pre-treat. This might take 0-5 seconds. This step cannot be over-stated on how important to insure the successful consistent spraying. You can cycle the system as in spraying a garment or use the purge button with a container under the tip to contain the flushing fluid. ). Remove the tip and soak it in distilled water at the end of production day. This procedure will help prevent the pre-treat from clogging the tip in case the tip was not cleaned properly. 3). The tip should be cleaned weekly with a tooth brush to clean the outside and inside of the tip. This will help remove any lingering salt deposits that could form on the tip to prevent staining and tarnishing effects on the tip. To clear a blockage on the tip s opening, a toothpick, toothbrush and compressed air pressure are the best way to clear the blockage. Note: any hard item such as a needle will most likely score the metal opening and ruin the spray nozzle. A device like a needle is never recommended and usually always unsuccessful. Note: If there are excessive drips (3 or more) at the end of the spray cycle, most likely the tip is not clean. The drippings are a sign of debris in the tip trapping the free flow of the fluid. 4). It is recommended that Magic Clean Solution be flushed through the system for a more thorough cleaning. This solvent-based product is especially needed to clean the fluid valve. 5). The inside surfaces must be cleaned after each use. Without cleaning, the pre-treat fluid will cause corrosion to the interior paint finish. Also without cleaning on a regular bases, the interior of the unit will become so caked and sticky it is a monumental task to clean. If your clean garment drags on this compromised surface, undesired results might occur. To clean the unit, a sponge and warm soapy water is all that is needed. Be sure to clean all the surfaces and dry the unit. This procedure usually only takes 5 minutes. 6). Once a week, the canister (or canisters pending design option) needs to be cleaned with a soft bush. The salty residue inside the canister, if not removed, will cause a pinhole leakage with time. This is a simple but important step to protect your investment. If a pinhole develops, it is not a warranteed item because proper maintenance prevents the chance of this occurrence. Lawson Zoom XL (version.) May 05 5

6 Suggested Replacement Parts to Keep On-Hand Spray Tips The quantity of spray tips that you stock will depend on your frequency of use, whether you are using distilled water as recommended, and your level of maintenance. Having at least one spare tip is important, just like having a spare tire for your automobile. You never know when you might need one. WENL Tip: Part # Slip-On Fluid Post Filter This is an inexpensive filter that removes debris and larger mass particulates from the pretreat solution, before it continues past the pressure canister. It is suggested that four (4) each of these be kept on-hand. Slip-On Fluid Post Filter: Item # EA Fluid Valve: Solution Canisters Important Note: Remember to Turn the Air Off, before loosening any of the canisters! Also, you should pull the ring attached to the safety pop valve, and keep it pulled out for about 5 seconds this will allow the air in the system to escape. Canister Air Leakage: There are times air may leak out of the solution container. Check to make sure the canister is tight and secure, or that it is not over-tight! Screwing the canister on too tight crushes the gasket and will cause air leakage! Leakage on the lid can also occur if not cleaned, as the salty residue will eventually either build-up around the threads and/or create small holes and airpockets through the metal and around the seal. Removing the Canister Installing the Canister Note: Spraying a teflon spray or a 3 in lubricant on the canister threads will make it easier to install and remove the canister. It also allows for a tighter seal, preventing air leakage without extreme pressure. Tip: When reinstalling the canister, it is easier if you support the bottom of the can with one hand and turn your bottom hand in unison with your upper hand. This method seems to allow the threads to align easier. We also suggest you use Vaseline on the threads, as this helps to eliminate minor air leaks around the screw threads/top. Also, the inside of the canister will need to be thoroughly cleaned out with water, each week, and the inside brushed clean. Do not leave any salty residue on the inside of the pretreat solution canister for longer than one () week, as salty residue remains will eventually eat through the canister and create a pin hole. Also be sure to clean the canister Lid. Lawson Zoom XL (version.) May 05 6

7 To add solution to any of the Canisters, simply turn the can counterclockwise to loosen; and clockwise to tighten. It is important when reinstalling the canister to make sure you do not crossthreat the top when tightening. There is no need to over tighten; simply turn with firm pressure (shown above). Do not over-tighten and crush the gasket. This photo shows an example of someone who did not clean and scrub away the salty residue inside their canisters on a regular basis. As a result, this canister developed a leak, not covered by the warranty, because of customer neglect. This photo shows dried pretreat solution being pealed up from the inside of the spray chamber. Leveling Leg Adjustment Bolts Lawson Zoom XL (version.) May 05 7

8 Control Panel Fluid Stop Bolt: Can be removed to completely change the range of the spray speed. # Speed Valve Stem: Allows the operator to adjust the maximum fluid to a pre-determined deposit. # Spray Travel Dial: The lower the speed spray number, the more fluid will be sprayed. Valve. # Start Button: The spray button only works when the platen drawer is extended open. # Platen Door Extend/Retract Switch: Opens and closes the drawer. # Drawer must be open to start the spray cycle. When not in use, retract the drawer to save space. Platen and Drawer - Zoom XL a Standard Platen 6 w x 0 l # a. Platen Attachment Flat Screw # Top Platen Stand * # Top platen Stand Bolts # Bottom Platen Stand * # Bottom Platen Stand Bolts # Drawer Slide #4 # B * Original model uses a different design height. Lawson Zoom XL (version.) May 05 8

9 Cannister with Pop Valve Safety pop valve # Canister Lid Body # Canister Band # Hose Clamp # Canister # A B 9b 9c 9a Regulator # a. Pressure Adjustment Knob - /8 Allen Wrench 9c. Drain Bowl (if the bowl is letting air escape all the time, the automatic drain device could be stuck with debris. The bowl can be removed to be cleaned.) 0. Digital Air Gage # Push button to read. Regulator Mounting Bracket #XXX-XXX-X. Fitting # Air Flow Shut Off Knob # Hose Connection, /4 # Pre-Treat # - On/Off Mechanical Valve # Canister Used for Water or Second Fluid (B). Pre-Treat # - On/Off Mechanical Valve # Canister Used for Pre-Treat (A) Lawson Zoom XL (version.) May 05 9

10 Right Operator Front Side #05 - Zoom XL Spray Range Knob # Controls where the spray starts on the platen. a 4 3. Fluid Spray Tee # Quick Exchange Cap # a. Cap/Tip Gasket (not shown) # Spray Tip WENL (subject to change) # Manual Spray Purge Button # Black Canister Gasket Replacement Canister Lid # Replacement Canister # Black Canister Gasket # B Slip On Post Filter # In-Line Fluid Check Valve # Lawson Zoom XL (version.) May 05 0

11 Left Operator Front Side #06 - Zoom XL 8A: Open: Puff of air is released from fluid valve. 8A Stop Bumper # Front Stop Limit Switch * # Front Stroke Limit Switch Bracket # Head Rail Mount Bracket # Carriage Ramp # * Tilting the bracket down will make the reverse direction (start of the spray) happen faster. 6. Rod End # Stroke Cylinder # Fluid Stop Limit Switch (stops spray) # A. Open Nipple - Puff of air is released via fluid valve. 9. Drawer Extend Limit Switch # Spray Rod Block # Lawson Zoom XL (version.) May 05

12 Pre-Treat Zoom Parts List A Spray Range Knob # Controls where the spray starts on the platen. Front Right View # Description Part # Stop Bumper Stop Range Bolt Fluid Limit Switch A Fluid Ball Roller Spray Start Upon Carriage Return XXX-XXX-X 4 Fluid Switch Bracket Placement of Adjustable Stroke Length Knob The Fluid Limit Switch starts the spraying action, via the fluid valve. The Carriage Ramp will pass under the Fluid Ball Roller, and then when the spray carriage motion is returning to the start position, the ball is activate and the spraying cycle starts. The spraying cycle stops when the rear fluid limit switch is depressed and activates the fluid valve to stop spraying (not shown in this photo). If the Fluid Spray Switch is out of range, the Fluid Ball Roller may be touched by the carriage ramp when the carriage is going forwards, but will not be activated on the return motion. Again, without activation, the spray will not start. The number # bolt has been set to keep the motion of the switch in range. To access the working components under the protective cover, the stroke length knob must be removed, #5. Lawson Zoom XL (version.) May 05

13 Pre-Treat Zoom XL Fluid System # Description Part # Fitting #A Head Stroke Valve Fitting #B Mechanical Fluid/Water Valve Brass Fitting Way Tee Shuttle Valve Air Swivel Fitting (Part of 8) XXX-XXX-X 0 Fluid Valve Air Swivel Fitting (Part of ) XXX-XXX-X 3 Drawer Brass Fitting Drawer Muffler Drawer Hose Fitting Drawer Cycle Valve Drawer Brass Fitting Fluid Check Valve - Start Spray Switch Y Fitting Fluid Check Valve - Purge Button Way Tee Drawer Air Valve Lawson Zoom XL (version.) May 05 3

14 Drawer Cylinder Overall View #0 Front Rear The rear cylinder s speed control adjusts the speed of the drawer going out. The front cylinder s speed control adjusts the speed of the drawer closing Drawer Slide Cylinder # Speed Control # Turning the knob clockwise slows the travel speed 4. Drawer Home Switch # (This switch must be depressed before the drawer will extend out) 5. Fluid Switch Bracket # Flat Head Bolt # A 7. Bracket Insert (not shown) # B Lawson Zoom XL (version.) May 05 4

15 Zoom Series Fluid Valve Cleaning Procedures, Part It is best to clean the fluid valve with Lawson s Magic Clean, sold in quart and gallon container units. It is recommended that the Magic Clean be run through the unit once a week to help keep the system clean from pre-treat residue. It is recommended that a spare fluid valve and spray tip be kept in stock. These two parts are most effected by not doing proper maintenance.. Squeeze the connecting spring ring clip to allow the top valve head to be removed.. Once the ring spring clip is not connected to the valve head, slowly twist the valve head left to right to remove the top section. 3. View of the top section. Be sure to push the plunger back to the orginal position after cleaning. 4. You can take your fingers, no tools needed, to pull the plunger device toward the front. The plunger will not come out of the housing. It simply will move in and out. This will allow one to clean the area from debris. 5. If the valve needs more intense cleaning, the bottom of the valve can be removed from the bottom base. 6. Be sure to be careful in the cleaning process. There are no spare parts if the valve parts are lost. Lawson Zoom XL (version.) May 05 5

16 Zoom XL Customer Quiz ) I push the Start Button but the unit does not cycle or spray fluid: The most likely reason, see page 4, paragraph. ) If the Spray Head moves forward but does not travel back: Two probable reasons, see page 4 3) If the Spray Head cycles but no fluid sprays: Four probable reasons, see page 4 & 5 4). If the Spray Head keeps spraying fluid, and Does Not Turn Off at the end of the cycle: Two probable reasons, see page 4 5) The Spray Head dribbles fluids for - seconds upon the completion of the spray cycle: One probable reason, see page 5 6) The top of the canister is Leaking Air: Three probable reason, see page 6 7) If the opening and/or closing of the Drawer Speed is too fast or too slow: One probable reason, see page 4 8) The pre-set Spray Fluid Deposit Range is not acceptable: One easy way to achieve the spray deposit range you want, see page 4 9) I wish I would not have to Fill the fluid Canister so often: Two popular ways to solve the problem, see page 3 0) Why would the Canister develop a Pin Hole leak: One probable cause, see page 6 ) The only way to know if the fluid deposited on the garment is Consistent: One answer: page 3 ) The normal spray cycle sequence is: the spray head goes forward, delays and then sprays on the return travel back to the start position. If the delay is too long, what can I do? See page 3) I wish I had a floor leg kit and/or I wish I had a wheel kit to be able to move the unit around with ease. Answer: these items can be purchased after your unit is installed. Call your salesperson for details 4) What happens if I don t flush the pre-treat solution at the end of the production day? Lawson Zoom XL (version.) May 05 6

17 Warranty/Service Information Highlights Please thoroughly read the entire instruction manual prior to operating this piece of equipment. Please call if you have any questions regarding the operation and maintenance of your equipment. Lawson s Service Department is here to help! Note: this Warranty/Service Info. Highlights is a supplement, and does not supersede Lawson s standard warranty policies, terms and conditions. Service Hotline = (Mon. - Fri. 8:00 am - 5:00 pm - Central Standard Time) After Hours/4 Hour Service Pager = and press option #6. Your Warranty is a Parts Warranty and excludes the Nozzles/Tips, and Filters. The warranty does not include installation, site training, maintenance, repairs or general labor. These services are available at an additional charge on an as needed basis.. Replacement parts may be sent prior to receiving the original parts back for evaluation. Payment via credit card for the part must be paid prior to shipment. If the part is a warrantee item, credit will be issued to the credit card used within 5 days. Warrantee parts must be received within 5 days of the replacement part being sent, returned f.o.b to Lawson, St. Louis, Mo. 3. Lawson will pay for standard, ground UPS on warranty parts shipped within the United States. We do not pay for Air Shipments! If air shipment is desired, these charges must be paid by your company. Payment terms are Credit Card only: We accept Master Charge, Visa, Discover or American Express for payment. 4. Lawson s warranty is to the original owner for the specified period. It is based on a single eight (8) hour shift, five (5) days per/week operating schedule. Lawson Zoom XL (version.) May 05 7