Master Instruction Guidebook Lawson Pre-Treat Zoom Pro v. 2

Transcription

1 Master Instruction Guidebook Lawson Pre-Treat Zoom Pro v. 2 SCREEN & DIGITAL PRODUCTS, INC Penrose St. St. Louis, MO

2 To insure successful performance of your Zoom-Pro, 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-Pro 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-Pro has been designed to work in conjunction with any brand 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. Your comments and suggestions are always welcome. (Standard office hours are 8:00 am 5:00 pm (CST) Page 2 of 14

3 Zoom-Pro #1618 Manufactured by: Lawson Screen & Digital Products, Inc Penrose St., St. Louis, MO Service Telephone: Serial Number: (Please fill-in for future reference) Refer to this serial number when speaking the Service Department. It contains valuable information related to this piece of equipment. Important Notes: Always Disconnect the Power from the outlet and the Air from the unit itself while performing service on 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. Remember, even though the Zoom-Pro is shipped fully assembled and is easy to set-up and operate, if you want special and/or individualized instruction, feel free to call and arrange for special training at our St. Louis factory, or at your facility (additional expense). It is important that the spray nozzle always be kept clean. If the pretreat 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. This machine is designed for the industrial/commercial user it is not designed for hobby use, or for retail consumer usage. - For Industrial Use Only. This manual is meant to serve as a general instructional guide and reference manual for the Zoom- Pro. Design details are subject to change without notice and the manufacturer assumes no obligation regarding changes to the unit, herein described. All the information contained herein is proprietary to the LawsonZoom-Pro. This publication may not be reproduced, copied, or transmitted in any way without written permission from Lawson Screen & Digital Products, St. Louis Missouri. Copyright 2012 Page 3 of 14

4 Getting Started 1. 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 1/4 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. 2. The unit s air regulator should be set between p.s.i. This is the recommended setting. 3. You have two (2) Supply Feed Tubes, that are designed to be used for Bulk feeding. One is for Pretreat Solution and the other is for Distilled Water. Important Note: You must raise the level of your bulk containers (typically a 5 gallon container) about above the floor, in order for the product to be pumped to the spray head. 4. Two waste collecting buckets are provided and need to be installed at the rear of the unit to collect the overspray fluid. 5. 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. Level Leg Adjustment Bolt Page 4 of 14

5 Basic Operating Instructions The Lawson Zoom-Pro is designed to spray fabric with pretreat solution prior to printing on the fabric. The amount of pretreat solution deposited onto the fabric (measured in grams, based off an area of 16 x 20 (35 cm x 40 cm) 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: 1) the travel speed of the spray nozzle, 2) the design of the spray tip, and 3) the distance of the tip to the fabric. 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-Pro 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-Pro 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 design platens for specialty purposes. The air pressure is used to control the operation of the drawer cylinder. As illustrated on the Zoom Pro Air Control page, the speed of the cylinder is controlled by the control knob on the cylinder. The digital air gauge will display the air pressure when the gauge button in the center of the device is depressed. Note: the drawer mechanism magnetic drawer switch must be engaged before the drawer will open. The switch is located under the drawer. The spray head height has been adjusted by the factory but can be changed pending your production demands. The height is adjustable by the adjustable spray height post. The closer the spray head is to the garment, the smaller the spray pattern will be; a higher location will yield a wider pattern. The proximity switch reads the motor speed for extremely accurate and consistent spray results. This information can also be captured on your computer for automatic storage via the PLC controller controlling the unit. At the start of each day, or if the main power to the unit is turned off during the day, you must push the Platen In/Out button on the control panel to place the platen in the ready to load the garment position.. 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 push the platen In/Out button on the control panel for the drawer to close. Page 5 of 14

6 Maintenance Procedures 1. It is critical that you clean the spray nozzle on a daily basis. If you do not clean the nozzle/tip with distilled water after use, the nozzle/tip will clog and be ruined. (We strongly suggest you purchase extra nozzles, as they will one day become clogged, and this is not covered by your warranty) 2. Once a week water should be purged through both fluid lines to clean the valves. Purging water to clean the tip will not clean the main fluid valve. 3. Once a week check the regulator bowl for fluid to manually drain. 4. Once a week clean the slip-on fluid post filter. 5. The DC motor brushes should be replaced every 1,000 hours, 6. The spray head gasket kit will need to be replaced when the spray pattern becomes inconsistent and this pattern is not due to the tip. This is a wear item (part # ). Average replacement based on 8 hours is one year. The life of the gasket kit will be shortened if the head is not cleaned correctly. Follow these Daily Cleaning Instructions: A. Simply Press the Purge Button and hold for approximately 10 seconds. B. With warm, soapy water and a sponge, clean all surfaces where pretreat solution has been sprayed. There should be no pretreat fluid left anywhere on the machine, as this solution causes corrosion if not cleaned up each day. C. You are now ready to turn the unit off for the day. D. Remove the Spray Tip and soak in distilled water, until you use again. Periodically remove the tip, soak in warm soapy water and clean with a soft-bristle toothbrush. This will ensure that deposits that cannot be seen do not accumulate at the edges of the stainless steel tips. If you have a high-pressure air gun (or Lawson Dust-Off aerosol can item # EA), you can also spray air through the tip to help loosen/remove any unwanted particles; this is a very useful procedure. Then use a high-powered magnifier to examine the spray tip (you cannot properly inspect the tip without magnification). Suggested Replacement Parts to Keep On-Hand Spray Tips The quantity of Spray Nozzle/Tips that you stock will depend on how much you use your unit, whether or not you are using distilled water as recommended, your level of maintenance, routine of daily cleaning, and what safety factor or comfort level you desire. The suggested quantity would be at least 2 of the Full Spray Nozzle. The standard nozzle (tip) is WENL, part # The tip selection is a customer production preference. 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 onhand. Slip-On Fluid Post Filter: Item # EA Page 6 of 14

7 Using the Data Pad/Control Panel 1. Turn on the Power Switch (light illumines) - it take about 60 seconds to power-up. [Fig. A] 2. Set your Spray Length. The Start Value is typically set to 1. The Stop Value is typical changed to fit the length of spray you desire. To change the Stop Value, take your finger and Depress and Hold the Stop Box; you will notice a Numeric Data Screen appears. Simply enter the approximate spray length desired and Press Enter (the value is not saved until you press Enter). [Fig. B] Fig. A 3. Select which fluild you want to spray: Pretreat or Water. [Fig. C] Fig. B Fig. C 4. Select the Spray Head Speed. A good starting point is 45%, but this is a controlled variable based on the amount of fluid you desire to apply. 5. Press the Go Button or Activate the Foot Pedal and the Platen Drawer will automatically close and the spray cycle will begin. Upon conclusion of the spray cycle, the platen drawer will open and remain until the next cycle. 6. You have two (2) methods of Purging the Distilled Water through the system. You can A) use the Purge Button, located on the Control Panel and simply Depress/Hold for any desired time you desire [Fig. A]; or B) you can pre-set the length of purge time automatically by entering the Purge Functions Button, located on the Data Pad. Screen sets are intuitive and are adjusted by using the touch screen. [Fig. D] Fig. D Important Note: The front and return carriage micro-switches should not be moved. These switches control internal settings - not the length of spray. Page 7 of 14

8 General Explanations of How The Unit Functions: The power supply, #1 converts 120 volts to 24 volts DC voltage to run the majority of the controls. The ice cube relay #2 controls the motor going forward (K1), relay #3 engages the motor to reverse (K2). Relay #4 controls the pump turning on and off (K3). Relay #5 inhibits (stops the motor when engaged) (K4). Relay #6 engages the fluid valve (photo #2 rear control box #1012), (K5) and relay #7 engages the water valve (photo #1 in rear control box), (K6). 16 The isolator board converts the speed signal from the PLC to the DC motor drive. Fuse #10 is related to the motor control, #11 for the DC power supply, #12 for the pump, #13 for the signal isolator. 1. Power Supply Small Ice Cube Relay Ice Cube Relay Base Isolator Board Fuse- 3amp Fuse- 3amp Fuse- 3amp Fuse-1amp Fuse holder Motor Speed Control Zoom Pro Electric Control Box # Touch Screen PLC Pilot Light Toggle Switch Start Push button Start Push button Start Push button Female Socket Male Comm. Socket E-Stop Switch Page 8 of 14

9 Zoom Pro Rear Control Box # c a 5b 7 1. Water (or second fluid) fluid valve Pre-treat solution fluid valve Active air start spray valve Air fitting small union Electric Pump a. Fluid Out 5b. Fluid In 5c. Pump connection rotation change 6. Platen valve Air fitting large union Page 9 of 14

10 Zoom Pro Air Controls 6 7a b 9b c 1. Spray Head Nozzle Cap Tip (customer s preference) Standard WENL Fluid Air Line 5. Air Spray Line 6. Adjustable Spray Height Post 7. Regulator a. Pressure Adjustment Knob (lift to turn) 8. Digital Air Gage Regulator Mounting Bracket 10. Fitting Air Flow Shut Off Knob Hose Connection, 1/ Platen and Drawer 1 1a Standard Platen 16 w x 22 l # a. Platen Attachment Flat Screw # Top Platen Stand * # Top platen Stand Bolts # Bottom Platen Stand * # Bottom Platen Stand Bolts # Drawer Slide #24 # B * Original model uses a different design height. Page 10 of 14

11 Motor Head Drive # Head Motor Head Motor Pulley Drive Belt Timing Plate Design # Timing Srew Bolt Idler Pulley Idler Pulley Bolt Belt Tension Bolts - 9. Idler Tension Plate Electric Limit Switch Limit Switch Contact Roller Limit Switch Ramp Factory Set Bolt DO NOT ADJUST Page 11 of 14

12 If the tip won t screw into place, be sure #3 gasket is not interfering. Spray Head Gasket Rebuilding Kit # Never Use Pliers to tighten the tip! Over tightening will damage the packings and using a pliers will strip the housing metal. Optional: Tip Alignment Tool # EA Page 12 of 14

13 Drawer Cylinder Overall View #1012 Front Rear 1 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 - Electric # (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 Page 13 of 14

14 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/24 Hour Service Pager = and press option #6 1. Your Lawson warranty is a Parts Warranty and excludes the Nozzles/Tips, Filters, Gaskets & Strainers. 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. 2. Replacement parts are sent at your request (or upon our diagnosis) prior to receiving the potentially defective part back. As a result, down time is minimized. However, it is your responsibility to return the defective part within ten (10) days! Otherwise, credit may not be issued. We need the part returned as soon as possible for analysis. 3. We require a valid credit card number to be provided when warranty replacement parts are sent, in the unlikely event you do not return the warranty part within 10 days, so billing can occur. 4. 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. 5. Payment terms are Credit Card only: We accept Master Charge, Visa, Discover or American Express for payment. 6. 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. Page 14 of 14