Duplo ULTRA 200PRO Operation Manual
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Duplo ULTRA 200PRO Operation Manual

Duplo ULTRA 200PRO Operation Manual

Uv coater
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ULTRA 200
PRO
UV COATER
OPERATION MANUAL
Rev: 052815
1

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Summary of Contents for Duplo ULTRA 200PRO

  • Page 1 ULTRA 200 UV COATER OPERATION MANUAL Rev: 052815...

  • Page 2: Declaration Of Conformity

    2009 EN61000-6-4 Coater EN-1010-1: 2004 CISPR16-3-2 EN-1010-2: 2006 CISPR16-2-1 CISPR16-1-2 IEC61000-4-2 IEC61000-4-3 IEC61000-4-5 IEC61000-4-6 IEC61000-4-8 IEC61000-4-11 Keeper of the technical file in the European Community: Duplo International Inc. Automated Precision House, Hamm Moor Lane, Addlestone, Surrey KT15 2SD, United Kingdom...

  • Page 3: Declaration Of Incorporation

    EN-1010-2: 2006 EN61000-6-4 by UL Taiwan CISPR16-3-2 In-line CISPR16-2-1 Bridge/Feeder CISPR16-1-2 /Flipper IEC61000-4-2 IEC61000-4-3 IEC61000-4-5 IEC61000-4-6 IEC61000-4-8 IEC61000-4-11 Keeper of the technical file in the European Community: Duplo International Inc. Automated Precision House, Hamm Moor Lane, Addlestone, Surrey KT15 2SD, UK...

  • Page 4: Table Of Contents

    Contents Declaration of Conformity ..............2 Declaration of Incorporation ..............3 1. Safety Rules ..................6 1.1 Precautions ................6 1.2 Avoid Accidents .................7 1.3 Safety Issues & General Safety Rules ...........7 1.4 Caution for UV Lamp ..............8 2. Introduction ..................9 2.1 What Ultra 200 UV Coater Does ..........9 2.2 Symbol Description ..............9 2.3 Name Plate ..................11...
  • Page 5 5.14 How to View the Permanent Count ...........41 5.15 View the Lamp Hour..............42 6. Error Message and Trouble Shooting ..........43 7. Maintenance ..................47 8. Q and A.....................48...

  • Page 6: Safety Rules

    1. SAFETY RULES After receiving the machine, if end users require any further modification or change of one part or several parts of the machines, they are obligated to advise the machines back to the manufacture for this treatment. We do not have any Legal responsibilities if the breakdown of the machines or operator’s injuries is caused by the importer’s modifications or changes to one part or several parts of the machines performed by end users.

  • Page 7: Avoid Accidents

    1.2 Avoid Accidents Most accidents are caused by the failure of some individual to follow simple and fundamental safety rules and precautions. For this reason, most accidents can be prevented by recognizing the real cause and doing something about it before the accident occurs. With any machinery, a careful and trained operator is the best insurance against an accident.

  • Page 8: Caution For Uv Lamp

    1.3 CAUTIONS FOR THE UV LAMP Mercury vapor lamps emit ultraviolet radiation which is harmful to eyes and skin. Avoid looking at a lamp in operation. Suitable eyes and skin protection should be employed when lamps are in operation. Clear fused quartz is used for the standard ultraviolet curing lamp and will generate ozone during operation.

  • Page 9: Introduction

    2. INTRODUCTION 2.1 What is the Ultra 200 UV Coater Does Ultra 200 UV Coater is design for in-line and near-line with the digital press for applying UV flood coating to digitally printed papers used for example in the production of photo albums, posters, magazine and book covers, labels and greetings cards.
  • Page 10 Be careful of touching the blades. The blades are extremely sharp which could result in a serious injury when coming into contact with hands or other parts of the body It is highly recommended to use gloves, in order to protect your hands It is strongly recommended to wear safety goggles in order to protect your eyes.

  • Page 11: Name Plate

    2.3 Name Plate 2.3.1 200Pro UV Coater – CE 2.3.2 200Pro UV Coater – UL...

  • Page 12: Risk Area

    2.4 Risk Area...

  • Page 13: Usage Precaution

    2.5 USAGE PRECAUTIONS 2.5.1 Before Operation a. Understand emergency stop button and main power location. In addition normal operation must be confirmed. b. Tools and sundries should not be put on the machine. c. No obstacles should surround, or be placed on top of the machine. d.

  • Page 14: Specification

    3. SPECIFICATION Specifications Ultra 200 SF-300 Suction Feeder Max. Speed 34M (112ft) / min 45M(148ft) / min Max. Paper Size 21” x 30” (535 x 750mm) 21” x 30” (535 x 750mm) Paper Weight 170gsm ~ 600gsm 120gsm~600gsm Power Requirement 400V, 50/60HZ, 25A 110/220V, 50/60HZ, 6A Time Delay 208-220V, 50/60HZ, 43.5A...

  • Page 15: Integrate With Sf300 Suction Feeder

    3.1 Integrate with SF-300 3.2 Integrate with SF-300F Pile Feeder and ST-300 Pile Stacker...

  • Page 16: Accessories

    3.3 Accessories Item Quantity Catcher Stopper 983-906-000B Catcher Side Guide 983-909-000B UV Bucket Asm– 20L 984-307-000A Heat Jacket 984-306-050A 984-602-090A UV Lamp (Primarc-7801398-18mm) Installation Manual Operation Manual Waste Bucket – 5 L...

  • Page 17: Key Components & Control Switches

    3.4 KEY COMPONENTS Name Description System Main Power Switch Turn ON/OFF system main power Control Panel See the function key of the control panel Emergency Stop Press this switch to stop system in emergency. Normally use stop key on touch panel to stop coater.

  • Page 18: Control Panel

    4. CONTROL PANEL 4.1 MAIN POWER SWITCH Main Power switch...

  • Page 19: Control Panel And Function Key

    4.2 CONTROL PANEL AND FUNCTION KEY Control Error LED Display Thermometer Code Panel 4.2.1FUNCTION KEY...
  • Page 20 4.2.2 INTRODUCTION OF PANEL FUNCTION KEY FUNCTION Start / Stop UV Coater Setting IR On / Off before the coater is in operation and setting AUTO GAP On/Off during the coating operation Setting coater to POWER SAVE mode Cleaning coater rollers Jog paper forward or backward and + or –...

  • Page 21: Thermometer

    4.3 THERMOMETER 4.3.1 HOW TO SET SV, AL1 and ALH 4.3.1.1 Hold button for 3 seconds then, 4.3.1.2 SV: After 4.3.1.1, press button to move cursor left, button to increase, button to decrese. SV default value is 120℃ 4.3.1.3 AL1: After 4.3.1.1, then press button once unitl AL1 displayed, AL1 default value is 120℃, If necessary press button to set.
  • Page 22 4.3.2 Function of SV, AL1, ALH 4.3.2.1 SV: Different digital press needs different IR Temp, different UV coating needs different Temp setting as well: HP Indigo Not necessary Konica Minolta -6500 165℃ Konica Minolta -1070 175℃ Konica Minolta -1085 175℃ Xerox EA Toner 165℃...
  • Page 23 4.3.3 Ct and ALt 4.3.3.1 Ct default value is 0 Hold button for 3 seconds, then press button to move cursor left, button to increase, button to decrease temperature setting 4.3.3.2 Alt default value is 11 Hold button for 3seconds, then press 6 times, Alt will be displayed, then use , and...

  • Page 24: How To Set Thermometer Control Factor

    4.4HOW TO SET THE THERMOMETER ◎ Hold for 3 seconds ◎ Press to select Ct ◎ Press to set Ct to 0 ◎ Press to choose hys, Using to adjust the figure. hys is the key to set IR On/Off timing. For Example, if set the SV to 120℃ , setting hys to 1 means IR will be automatically On when PV drop to 119 ℃...

  • Page 25: How To Set Cooling Fan Off Temp

    ◎ Press once, the display shows AL 1 as below: ◎ Use to set the Temperature 120℃ as the UV lamp heating reference 4.7 HOW TO SET COOLING FAN OFF TEMP ◎ HOLD FOR 3 SECONDS. ◎ Press 2 times, ALH will be displayed, using to set the figure.
  • Page 26 ◎ Press 3 times to confirm the setting.

  • Page 27: Operation Procedures

    5. OPERATION PROCEDURE 5.1 POWER UP SEQUENCE 5.1.2 Power-up Feeder and Stacker before UV coater 5.1.1 Fill up the Varnishing into UV Coating Bucket The Heat Jacket Temp default is 45℃, if ambient temperature is lower than 10℃, the Temp needs to set higher or wait 20 minutes to let coating get warm 5.1.2 Switch UV Valve to ON Cleaning Valve...
  • Page 28 5.1.3 Put Circulation Pan in Coating Funnel Coating Funnel Cleaning Funnel 5.1.4 Close the metering knob to 0000 and close the applicator knob to 0000 Indicator Lamp Applicator Roller Knob and Dial Metering Roller Knob and Dial 5.1.5 Power-up UV Coater Main Power switch Waiting 20 Minutes until UV coating is Warm then...

  • Page 29: After Warming Up

    5.2 AFTER WARMING UP 5.2.1 Engage scraper blade for 5 seconds then release it 5.2.2 Feed 3 sheets of unprinted paper to absorb the residual coating left on the impression roller 5.2.3 Feed a coating job sheet to see coating result is OK 5.2.3.1 In case of smearing on the back side of image ◎...
  • Page 30 5.3 ADJUST AUTO GAP TIMING The auto gap timing can be adjusted to optimum coating quality. 5.3.1 Leading edge has no enough coating It means the roller engagement is after paper is come into engagement point; the auto gap timing needs to be decreased by holding whilst pressing the button briefly when the coater is running.

  • Page 31: Adjust Auto Gap Timing

    5.3.4 Trailing Edge has no enough coating or flat spot It means applicator roller disengagement time is too soon. The auto gap timing needs to be increased by holding whilst pressing the button briefly when the coater is running. Setting a figure greater, auto gap disengagement time will be longer.

  • Page 32: Auto Gap Off

    5.4 AUTO GAP OFF In case doesn’t need Auto Gap function by holding then press the button briefly to switch the Auto Gap to OFF. 5.5 IR SETTING and WARMING UP 5.5.1 Switch the IR function to ON ◎ Before warming up the coater, holding then press button briefly to switch IR to ON...
  • Page 33 5.5.2Turning the IR function OFF ◎Before starting the coater by holding then press button briefly to set the IR to OFF Note: The IR ON/OFF setting has to be carried before the system is initiated 5.5.3 Press button, the warming up sequence will be started from 5.5.3.1 IR set to OFF The display starts from 5.5.3.2 IR set to ON The display start from 5.5.3.3...

  • Page 34: Setting Coater Speed

    5.6 SETTING THE COATING SPEED 5.6.1 UV Coater speed is from 20M/min ~ 34M / min. For speed selection, hold button then press button briefly to change the speed. 5.6.2 Speed selection for offline operation: 5.6.3.1 Slower speed can handle thinner paper 5.6.3.2 Feeder speed is in sync with coater speed, so 5.6.3.3 Change coater speed, feeder speed will be change accordingly.

  • Page 35: Clear Jam

    5.8 CLEAR PAPER JAM 5.8.1 Paper at coater rollers ● button to remove the paper; if necessary, jog the paper with the forward or backward key then open the top cover to clear the jam. When the coater top cover is opened the power to the coating application assembly will be cut off.

  • Page 36: Emergency Stop

    5.9 EMERGENCY STOP In the event of an emergency, press any E-Stop button to stop the coater. Once the emergency stop button has been pressed, the UV Lamp and IR will be off, and the UV Curing Conveyor, Hot Air Extraction Fan and the IR Cooling Fan will be on for cooling down.

  • Page 37: Stop Coater And Cleaning

    5.10 STOP COATING and ACTIVATE CLEANING 5.10.1 Press button to stop coating operation. The fault indicator will flashing, once the light is stop means cooling down is complete. 5.10.2 Switch the pumping valve from UV to Cleaning Cleaning UV Valve Valve 5.10.3 Slid the circulation pan to cleaning funnel.

  • Page 38: Priming And Auto Cleaning

    5.11 PRIMING and AUTO CLEANING 5.11.1 Hold button, then switch the main power to on and release button immediately. This will turn UV lamp to off and turn IR to on for Priming. Other procedure same as UV coating. Separate UV circulation pan and priming bucket from UV coating is necessary.

  • Page 39: Power Off

    5.12 POWER OFF 5.12.1 Once the cleaning operation has finished, fault indicator stop. Switch the Main Power to OFF System Main Power Switch 5.12.2 Set Applicator and Metering Roller to “0010” IMPORTANT: Please ensure that once all of the UV coating operations have been completed and the main power is turned to OFF, then the application and impression control knobs are turned counterclockwise to 0010 to ensure that the rollers are not in contact with each other.

  • Page 40: Power Save

    5.13 POWER SAVE The system provides an energy saving feature when the UV coater is not going to be used for short periods of time. Hold the button then press button briefly will turn the UV lamp off, but the coating rollers and UV pump will keep running.

  • Page 41: How To View The Permanent Count

    5.14 View the Permanent Count Press and hold the button whilst switching on the main power. Keep holding button for five more seconds to get into service mode, the display will change to “U-XX” (XX is revision of the firmware), and then press button briefly to view.

  • Page 42: View The Lamp Hour

    5.15 View the Lamp Hour Press and hold the button whilst switching on the main power. Keep holding button for 5 more seconds to get into service mode, the display will change to “U-0X” (0X is revision of the firmware), and then press button briefly to set the new lamp hour to “0000”.

  • Page 43: Error Message And Trouble Shooting

    6. ERROR MESSAGE and TROUBLE SHOOTING Code Description Possible Cause and Solution E001 S1 Jam Sensor Error 1. Paper wrap around the roller 2. Use to remove the paper 3. Slow down the coating speed, or 4. Change paper feeding direction E002 S2 Input Sensor Error to move the paper forward or...
  • Page 44 3. Call for service E008 S8 E-Stop 2 Error 1. Reset Emergency Stop Switch 2. Emergency Stop has malfunctioned 3. Call for service E009 S9 Oil Pan Sensor Error 1. Put Oil Pan in coating position 2. Sensor has malfunctioned 3.
  • Page 45 3. Scraper blade damaged 3. Call for service 4. Coating gap too small 4. Call for service 5. Operation procedure not 5. Refer to the manual followed Paper has a little 1. The applicator roller is not 1. Set Auto Gap to OFF bit coating or it setting to “0000”...

  • Page 46: Maintenance

    7. MAINTENANCE 7.1 Introduction The periods of general maintenance are divided into daily, weekly, monthly and twice yearly periods, this is in order to reduce possible breakdowns and extend the life of the components. Before performing any maintenance the AC power has to be switched to OFF. 7.2 THE PERIODIC MAINTENANCE Keys：...
  • Page 47 Clean the UV lamp and reflector UV Lamp Make sure the belts are tight. If the belts become loose then adjust the tension or Curing Conveyor change the belt. Driving Belt As the blower fan blade will collect dust particles it is recommend to clean it every three months.

  • Page 48: Q And A

    Q and A Q1: Leading edge has flat spot or very little coating Reason: Auto gap engagement too soon or “0000” gap too wide Actions: 1.1 Hold the then tip on to increase the number, default is 62, greater figure will make the engagement timing longer. If not 1.2 Reduce the “0000”...
  • Page 49 Q3. Trailing edge has flat spot or little bit coating Reason: Auto gap engage timing too soon, or auto gap is too wide Actions: 3.1 Hold the then tip on to increase the number, default is 62, greater figure will increase the dis engagement timing longer. If cannot solve 3.2 Readjust the gap to 0.15mm Q4: Smearing strip from 2 sheet...
  • Page 50 Q5: Coating Result is not Consistency Reason: Auto gap on/off timing uneven 4.1 The driving pulley is loosed, or 4.2 The auto gap driving shaft coupling screw loose Action: Check driving pulley and couplin screw Q6: Bottom image has smearing on whole page Reason: Scraper plate is not engaged after warming up is complete Action:...
  • Page 51 Q8: Coating cracked and scratch off Reason: IR is not hot enough or incorrect UV varnishing Action: 8.1 Adjust the SV higher 8.2 Konica Minolta C8000 print out needs extra IR unit or need special varnishing Q9: Coated image becomes dull or has bubble Reason: IR too hot Action:...
  • Page 52 Q11: Image has check mark Reason: IR too hot Action: Adjust the SV lower on thermometer Q12: Coating not cured Reason and Action 12.1 Check UV varnishing is clean, fresh, correct and valid date is not expired 12.2 Set the secondary output voltage higher such as L2-L2, L2-H1 …etc., Default is setting L1-L2 12.3 Check UV lamp hour has reached to 700 hours...
  • Page 53 Q13: No Display Reason: 13.1 Interface cable inside the control panel is loose, not connect well 13.2 DC control circuit breaker tripping Action: .Open the control panel to check the interface is fastening secure and tight, if yes .Check motor has detent torque, if not, replace driver box. If yes .Check DC Control Circuit Breaker is tripping.

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