Application of 3M Scotchlite Engineer Grade Reflective Sheeting Using Heat Lamp Vacuum Applicator

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1 3 Application of 3M Scotchlite Engineer Grade Reflective Sheeting Using Heat Lamp Vacuum Applicator Information Folder 2.1 April 1998 Replaces IF 2.1 dated May 1992 Health and Safety Information Read all health hazard, precautionary, and first aid statements found in the Material Safety Data Sheet, and/or product label of chemicals prior to handling or use. Follow the Instructions 3M recommends the standard practices outlined in this information folder, to the exclusion of deviations or procedures and materials which do not literally conform to these instructions. See Important Notice. Heat Lamp Vacuum Applicators are designed to apply Scotchlite Reflective Sheeting, or Scotchcal Film to flat sign surfaces. Vacuum underneath a rubber diaphragm holds the sheeting or film onto the application surface while heat produced by controlled infrared heat lamps activates the heat sensitive adhesive to form a permanent bond of the sheeting or film to the sign surface. All Engineer Grade sheeting, except Scotchlite sheeting 2290 Parkway White and 3290 Parkway White, is perforated at the factory to aid in the evacuation of the air between the reflective sheeting and the sign blank. If the sheeting is screen processed or clear coated, it is necessary to hand perforate before vacuum application. Lay the sheeting face up on a metal topped table and perforate, using a long-tined pattern tracing wheel. Long-tined Needle Point Pattern Tracer manufactured by Schul-Sons or its equivalent are generally available from fabric or dress material stores. Details covering heat vacuum applicator installation instructions, maintenance procedures, and replacement parts lists are found in Information Folder 1.1. Caution: The procedures in this brochure should be used for Engineer Grade sheeting and Scotchcal films and should not be used for High Intensity Grade sheeting. A. Heat Lamp Vacuum Applicator Warm-up Run the applicator one full cycle, with a roomtemperature sign blank under the thermoswitch before beginning sign applications. 1 B. Vacuum Gauge Readings At sea level, the vacuum gauge readings should be at least 26 inches (66cm) of mercury. The reading will drop about 1 inch (2.54cm) for each 1000 feet (305m) above sea level. For instance, at 2000 feet above sea level, the reading should be at least 24 inches (61cm) of mercury. With the diaphragm frame open, the vacuum gauge reading should be below 10 inches (25cm) of mercury. C. Telatemp Recorders Telatemp recorders should be used to check temperatures at the beginning of each shift or when changing sign backing types. Telatemp recorders should be adhered to an unscreened area of the sign surface. If the Telatemp recorder shows the first two bars ( F, C) blacked out after a heat cycle (see Table I), it means the applicator is operating in the proper temperature range for the application of Engineer Grade sheeting. See Information Folder 1.1 for complete calibration instructions. 1 If there is more than a 5-10 minute interval between application cycles, run one warm-up cycle before resuming sign application.

2 Table I Temperature Teletemp Indication Recorder Within 6 in. of Sensor Interpretation 210 F and 220 F Below 230 F Proper Temp. bars blacked out Above 220 F Sheeting Application Procedure A. Remove adhesive liner from sign face (see Figure 1). B. Position sign face on blank. Cover the sign face with adhesive liner, unprinted side against the sheeting face (see Figure 2). C. Place sign on loading board 2 in applicator with sign positioned under the thermoswitch (Figure 3) (see Appendix). D. Turn vacuum pump ON (see Figure 4). E. Lower diaphragm frame and latch. Wait for one minute with pump gauge at proper reading 3 (see Figure 5). F. Lower heat lamp bank. Switch on lamps (see Figure 6). G. When heat cycle is complete, lights will go out automatically. Raise diaphragm frame, turn off pump (see Figure 7). H. Remove sign, allow to cool. Remove slipsheeting and trim edges (see Figure 8). I. Replace slipsheet and store on edge (see Figure 9). Figure 2 Figure 3 Figure 4 Figure 1 2 See Loading Boards, in Appendix. 3 Proper reading will depend on altitude. See Vacuum Gauge Readings, page 1. 2

3 Figure 5 Figure 8 Figure 6 Figure 7 Figure 9 Special Application Procedures A. Two Sided Signs 1. Side One a. Apply sign face following standard procedures described on page Side Two a. Place foam pad FR-2 (available from 3M) on the loading board. If more than one pad is needed, butt padding closely together to prevent surface impression on faces laid across pad seams. b. With the sign outside of the HLVA, position sign face on side two. Cover with adhesive liner. c. Leave slipsheeting in place on side one and position sign with side one down on foam pad (FR-2). See Figure 10 for proper layer sequence. d. Run a complete cycle. e. When the lights shut off automatically 1. Open lamp bank and raise the diaphragm. 2. Shut off pump. 3. Remove signs. 3

4 Allow signs to cool before removing part of the slipsheeting for inspection. Replace slipsheeting on the face for storage. Store finished sign on edge. Note: If cut-out letter copy is to be used for each face, apply the background sheeting with a one minute heat cycle to pre-adhere background. Remove and position the cut-out copy on the background sheeting, run steps d and e. Trouble Shooting Figure 10 Slipsheet Slipsheet Condition Possible Causes Corrective Steps A. Sheets do not lie flat in stack. Roll Set remains in sheets. Roll sheet gently against curl or stack sheets in pack overnight. B. Poor adhesion of applied sheeting. 1. Inadequate heat. a. Some bulbs burned out a. Replace bulbs (HL-15) or or dimly glowing fuses as necessary. b. Thermoswitch mal- b. Run applicator temperature functioning. check as directed in IF 1.1. If applicator is shutting off before reaching the necessary temperature, replace thermoswitch or adjust retaining patch. 2. Contamination of sign surface. 2. Test by spraying or sprinkling water on the sign blank; if it beads up rather than flowing out evenly on the surface, the blank may have oil or was on it. Solvent wipe with VM&P Naptha. Aluminum must be etched and degreased before application. See IF Sign blank dusty. 3. Use a tack rag to wipe the surface, then solvent wipe with VM&P Naptha or alcohol. See IF Sign blank not properly 4. Check with transparent tape to prepared. The surface may be see whether surface has loose too smooth to permit proper coating. See IF 1.7. adhesion, or may have a loose phosphate or chromate conversion coating. Painted surfaces may be contaminated with waxes, silicone, or other agents. 5. Inadequate vacuum (vacuum gauge operating properly). a. Pump not functioning a. Remove the hose from the properly. pump inlet and hold hand over the pump inlet. If vacuum goes up to normal with the inlet blocked, there is a leak in the connecting hose or the applicator unit. If vacuum remains low, flush the pump as 4 directed in IF 1.1 and check filter jar seals.

5 Condition Possible Causes Corrective Steps b. Connecting hose or fittings b. If the hose is heavily checked leaking. or cracked, replace it. Check and tighten all connections. c. Diaphragm punctured or torn. c. Locate hole and patch as out- lined in IF 1.1. d. Diaphragm brittle or heavily patched. d. Replace diaphragm. See IF 1.1. e. Diaphragm leaking at seal e. (1) Remove diaphragm and strip due to (1) improper reinstall so the seal strip mates alignment or (2) sheeting properly with the bedplate build-up on bedplate under surface. seal strip. (2) Run applicator cycle to soften adhesive, then scrape sheeting from surface, and open any plugged vacuum holes in bedplate with a needle or pick. 6. Vacuum bed partially clogged. 6. See IF 1.1 for bedplate cleaning instructions. C. Sheeting bubbles during application. 1. Air not completely evacuated 1. Allow one full minute for air before heat lamp bank turned evacuation before beginning heat on. cycle. This is particularly important when applying large signs. Increase over 1 minute if required. 2. Sheeting not perforated. 2. Manually perforate sheeting. 3. Perforations have been filled 3. Manually perforate sheeting. by screen process color or clear coat. 4. Sign blanks have been solvent 4. Sign blanks must be thoroughly wiped; solvent has not dry. Allow plywood blanks to completely evaporated. dry at least 8 hours after surface preparation before making application. 5. Painted surface not completely 5. Paint must be completely dry dry; escaping solvent causes before application. Bake bubbling. surface if possible. 6. Moist sign blanks. 6. Blanks must be thoroughly dry. If sign blanks are stored outdoors or in an unheated area during wet or cold weather, they should be individually dried (not in a stack) at shop temperature for at least 24 hours before use. 7. Fiberglass or plastic blanks. 7. Users are urged to carefully Escaping solvents or unreacted evaluate any application to plastic constituents may cause or laminate type surfaces and bubbling. determine that it is suitable for the intended use before proceeding. See IF Process color not thoroughly 8. Thoroughly dry processed faces dry; solvent is causing adhesive and emblems before application. to preadhere. See IF

6 Condition Possible Causes Corrective Steps 9. Diaphragm installed upside 9. The diaphragm must be installed down. with the rough side down to permit complete air evacuation. 10. Air evacuation holes in bedplate plugged. 10. Open holes using a needle or pick. See IF 1.1 for bedplate cleaning. 11. If blistering still occurs. 11. Cover slipsheeted sign with cloth, such as bed sheet, to allow more complete air evacuation. 12. Hydrogen occluded in galvanized steel blanks. 12. Heat blanks at 300 F (150 C or above for 1/2 hour to drive off gas.) 13. Proper vacuum not attained. 13. See IF 1.1 on vacuum pumps. D. Wrinkles in Applied Sheeting. 1. Positioning sign face on blank 1. Position sign face on a cool blank on hot applicator bedplate outside of applicator. Use loading causes preadhesion. boards. 2. Unapplied faces may become 2. Remove liner and rack faces overwavy if exposed to moisture or night, adhesive side up, taking care excessive dampness during to protect adhesive from exposure shipment or storage. to daylight or dust. Use cool loading boards. E. Slipsheeting sticks and transfers to 1. Incorrect slipsheeting. 1. Use adhesive liner with glossy sign face. unprinted side against sign face. If problem persists, switch to SCW- 82 slipsheet. SCW-82 slipsheeting used with High Intensity Grade Sheeting is more resistant to transfer. 2. Remove slipsheet from a hot 2. DO NOT remove slipsheet until sign. sign has cooled to room temperature. 3. Excessive heat. 3. Run temperature check using temperature test described in IF 1.1. Replace thermoswitch or adjust retaining patch. 4. Color not thoroughly dry. 4. Check drying procedures. Increasing drying time, reducing shop humidity, or oven drying may alleviate condition. F. Surface impression in sheeting Sheeting or paint may soften Use adhesive liner as slipsheeting during or printed background. when heated, and impressions vacuum applications. Use SCW 82 if from the rough rubber diaphragm. adhesive liner does not eliminate impressions. G. Applicator won t shut off. 1. Thermoswitch has come out 1. Replace in pocket. Adhere in of its pocket and may have place with Rubber Patching Kit fallen out of applicator. (HL-29). 2. Thermoswitch defective. 2. Replace thermoswitch (HL-26). 3. Mag-con relay defective. 3. Replace relay (HL-126). 4. Thermoswitch leadwire 4. Replace lead wire (HL-33 or 34 or defective. 35) or have electrician repair internal wiring as necessary. 6

7 Condition Possible Causes Corrective Steps H. Lamp Bank won t turn on. 1. TC-2 cycle circuit fuse defective. 1. Replace fuse (6 amp) (HL-162). 2. Thermoswitch connection 2. Check to be sure plug is firmly in (Jones plug) unplugged or receptacle. partially unplugged. 3. Mag-con relay defective. 3. Replace relay (HL-126). 4. Thermoswitch defective. 4. Replace thermoswitch or have electrician repair internal wiring as necessary. 5. TC-2 controller unplugged in ON mode. 5. Push white power button to turn TC-2 off. 6. Fuse blown. 6. Have electrician determine cause and repair. Replace main fuse. 7. Thermoswitch lead wire 7. Replace lead wire (HL-33 or 34 or defective. 35). I. Pump won t operate Overload heater trips. 1. Reset overload heaters and determine cause for overload. 2. Pump frozen due to dirt and 2. Rotate pump shaft at coupling sludge accumulation. manually. If it turns, flush per IF 1.1. If it will not turn, disassemble per IF Fuse blown. 3. Have electrician determine cause and repair. Replace fuse. 4. Improper overload heaters. 4. Replace with proper overloads. 5. Defective switch. 5. Have electrician replace or repair. J. Diaphragm tears or punctures 1. Sign blanks have sharp or 1. Smooth edges by grinding or frequently. rough edges. sanding. 2. Sign blanks too thick. 2. Maximum thickness of blanks used in the 3' x 4', 4' x 6' applicators is 1-1/2 inches (28.6mm). Maximum thickness of blanks used in the 5' x 12' applicator is 2 inches (50.8mm). When applying to blanks which are more than 1 inch (25.4mm) thick in the 5' x 12' applicators, a spacer, which is supplied with the applicator, must be installed as directed in IF Improper hood travel on 3. Correct hood travel. 5' x 12". K. Pump uses excessive or Wick or oil spout not properly Adjust oiler as directed in IF 1.1. insufficient amount of oil. adjusted. 4 Moisture contamination from infrequent use can cause vanes to stick, rotor to freeze, and operation failure. The possibility of occurrence can be minimized by properly operating oiled pump at least one hour (continuous run) per week. 7

8 Appendix A. Loading Boards For uniform temperature and to minimize the possibility of premature adhesion, the use of loading boards of muslin covered plywood or tempered hardboard is recommended (see Figure 11). There are two systems used: 1. A single board, constructed as described in Figure 11, is taped in place with duct tape 5, or 2. A set of three boards are used in rotation, so that a cool board receives unapplied blanks. In this system, one board is in the applicator, one is cooling, and one is loading. The use of three boards speeds application of small signs. Cloth and holes cover entire board area. Literature Reference IF 1.1 3M Heat Lamp Vacuum Applicator (Specifications, Assembly and Installation, and Maintenance) IF 1.7 Sign Base Surface Preparation for Scotchlite Reflective Sheeting Application IF 1.8 Instructions for Using Scotchlite Process Colors 700, 840, 880I on Scotchlite Reflective Sheeting IF 1.10 Cutting, Matching, Premasking and Prespacing of Scotchlite Reflective Sheeting and Scotchcal Film IF 1.11 Storage, Packing, Installation, Sign Positioning, Cleaning, Nighttime Inspection, Sign Face Replacement and Sheeting Removed for Scotchlite Reflective Sheeting PB 700 Scotchlite Process Color Series 700 PB 2800, Scotchlite High Intensity Grade 3800, 5800 Reflective Sheeting Series 2870, and PB , and 5870 High Intensity Grade Figure 11: Loading Board Construction 5 Scotch Silver Duct Tape #393 or #425 Foil Tape have been used and found satisfactory. 3M assumes no responsibility for any injury, loss or damage arising out of the use of a product that is not of our manufacture. Where reference is made in literature to a commercially available product, made by another manufacturer, it shall be the user s responsibility to ascertain the precautionary measures for its use outlined by the manufacturer. Important Notice All statements, technical information and recommendations contained herein are based on tests we believe to be reliable, but the accuracy or completeness thereof is not guaranteed, and the following is made in lieu of all warranties, express or implied. Seller s and manufacturer s only obligation shall be to replace such quantity of the product proved to be defective. Neither seller nor manufacturer shall be liable for any injury, loss or damage, direct or consequential, arising out of the use of or the inability to use the product. Before using, user shall determine the suitability of the product for his/her intended use, and user assumes all risk and liability whatsoever in connection therewith. Statements or recommendations not contained herein shall have no force or effect unless in an agreement signed by officers of seller and manufacturer. 3 Traffic Control Materials Division 3M Center, Building 225-5S-08 3M Canada 3M Mexico, S.A. de C.V. P.O. Box P.O. Box 5757 Apartado Postal Printed on recycled paper St. Paul, MN London, Ontario N6A 4T1 Mexico, D.F