SPC FLOOR Full Precision Coater Instruction Manual Book

Time:2019-11-18

Content:

  • Machine Introduction
  • Safety Precautions
  • Transportation, storage, commissioning, connection
  • Machine Operation Instructions
  • Maintenance and Repair
  • Troubleshooting of Faults and Errors
  • Technical Parameters
  • Full Precision Coater Instruction Manual File

Machine introduction

1.1 Overview

The coating machine is mainly designed for the flat coating of various wood and plate types, especially for the coating requirements of high quality products. It can be operated by single machine or connected in the coating line. 

1.2 Machine construction and function

1.2.1 Machine construction

Conveyor   

The conveying device is composed of a conveyor belt and a main/passive wheel opposite to each other, and is configured to adjust the conveyor belt against the   deviation device.

Conveyor belt anti-bias control   

The automatic sensing anti-biasing device, when the conveyor belt runs to a single side, pushes the anti-offset wheel and pulls the conveyor belt back in the opposite direction to achieve automatic adjustment.  Repeat these actions continuously to ensure that the conveyor belt remains in the correct center.  (only for high models)

Coated on the seat          

The coating upper seat is mainly composed of a combination of hard chrome-plated uniform cloth wheel and rubber coated coating wheel, and is independently driven. The speed can be adjusted separately through the control panel. The uniform cloth wheel can be horizontally moved by the adjusting device, so that  The cloth wheel contacts the coating wheel to form a “V” shaped groove between the two wheels.  The uniform wheel can be equipped with a “thermostat device”.

Scraper device

The scraper device consists of a scraper blade and a scraping blade. It is applied to the coating wheel and the uniform wheel. The effect is as follows:

  1. The doctor blade on the coating wheel scrapes off excess paint to ensure uniformity of coating film per turn of the coating wheel.
  2. The scraper on the uniform wheel prevents the paint from overflowing when the wheel is reversed, which affects the uniformity of the paint on the rubber wheel.
  3. The scraper group of the uniform cloth wheel can automatically swing, the speed increases and decreases with the uniform wheel, and the angle of the doctor blade is adjusted by the manual hand wheel.  (only for high-end optional devices)

Paint cycle

The pump is powered by air pressure. The diaphragm is pumped through the switching valve to pump the paint to the “V” groove in the middle of the two rollers. After the paint is evenly distributed on the wheels, the remaining paint will follow the oil retaining plates at both ends of the wheel.  It flows back into the return tank and returns to the paint bucket for recycling.  The flow rate of the coating amount is adjusted by the metering valve.

Height adjustment

The height adjustment device is adjusted by the screw jack to raise or lower the coating upper seat, so the height of the coating upper seat can be adjusted in time to adapt to different work-piece heights.  You can use an automatic or manual handwheel to fine tune the rise or fall of the coated upper seat.

Intelligent lifting

Can be equipped with encoder to set the height

[Caution] When the conveyor belt stops abnormally, the coated upper seat will rise to protect the coating wheel.

When the intelligent PLC-controlled model starts to work normally, the upper seat will return to the originally set height value.

1.2.2 Pneumatic system

Optional conveyor belt anti-biasing device, floating coating upper seat (optional) and oil pumping are driven by air pressure.

[Note] The air pressure source of the machine is required to be at least 6.5 BAR or more.

1.2.3 Electronic control instructions

The electronic control system of the machine is connected to each electrical part by a distribution box, and various parts of the machine can be controlled through the control panel.  The control chart and the attached figure are detailed in Appendix III.

1.2.4 How the machine works

 

Workpiece placement

The workpiece to be machined can be manually placed in the conveyor system (in stand-alone operation) or sent to the conveyor system via the conveyor (when the line is in operation).

Painting process  

After the paint circulation system is started, the paint continuously circulates between the paint bucket and the coated upper seat, and the amount of paint supply must be greater than the coating consumption of the workpiece.  According to the setting of the machine, the workpiece will be coated with a certain thickness of paint after passing through the rubber wheel. Before the painting operation, the height between the rubber wheel and the conveyor belt must conform to the height through which the workpiece can pass.

1.3  Operational introduction

Control section Features
control panel The machine is operated through the control panel.
Scraper adjustment screw Use a scraper to adjust the screw to set the angle of the scraper on the coating wheel and the uniform wheel。
Forward and backward hand wheel Shake the forward and reverse handwheel to adjust the distance between the uniform wheel and the coating wheel.  The hand wheel counter can display the distance between the coating wheel and the uniform wheel.
Rising and falling hand wheel Shake the ascending and descending handwheel to adjust the distance between the coating wheel and the conveying bottom wheel.  The hand wheel counter can display the distance between the coating wheel and the conveyor belt.
Rise and fall automatic control button Press this button to automatically and quickly adjust the distance between the coating wheel and the conveyor belt。
Air pressure regulating valve The operating pressure of the pump can be adjusted by a gas pressure regulating valve。

1.4 Control panel

Button Functions
                        The machine starts or stops the switch. This switch is used to control the start and stop of the machine.
                        Emergency stop switch. Press this switch to stop all activity of the machine immediately.
                 Control the uniform wheel, the right knob is the uniform wheel rotation switch, the rotation speed of the uniform wheel can be adjusted by rotating the left knob, and the speed value will be directly displayed on the left screen.
                 The coating wheel is controlled, and the right knob is the coating wheel rotation switch. The rotation speed of the coating wheel can be adjusted by rotating the left knob, and the speed value will be directly displayed on the screen on the left side.
                 Control the conveyor belt, the right knob is the conveyor start switch, the conveyor speed can be adjusted by rotating the left knob, the speed value will be directly displayed on the screen on the left.

Safety Precautions

This chapter will outline the most important safety regulations. If the safety rules are not followed, the wrong use of the machine can be dangerous and even threaten the life and personal safety of the system and other property of the person.

2.1 Security risks  

2.1.1 Paint, detergent

The use of paints and cleaners can cause rashes and other health problems, and paints splashed on the ground

It is possible to make people slip. therefore:

  1. Read safety knowledge about paints and cleaners.
  2. Pay attention to the manufacturer’s safety tips.
  3. Put on suitable overalls.
  4. Thoroughly clean the machine after each use.
  5. Avoid leakage of paint and detergent。
2.1.2 Gas and vapor

Paints and cleaners may release hazardous gases and vapors during operation, which may

Cause poisoning.

  1. Read safety knowledge about paints and cleaners.
  2. Pay attention to the manufacturer’s safety tips.
  3. Containers that are no longer in use must be sealed immediately.
  4. Ensure that adequate ventilation air is provided.
2.1.3 Electrostatic charge

Misuse of the machine can cause an increase in electrostatic charge, which can cause an explosion. therefore:

  1. When the uniform cloth wheel, rubber wheel or scraper device is in working condition, it is not allowed to use the uniform cloth wheel and glue.

Wheel and scraper.

  1. During the operation, make sure that the container contains enough paint to allow the pump to work properly.
  2. Use only conductive containers.
  3. The base of the container must be completely metal and kept clean.
2.1.4 Roller in rotation

This machine has a rotatable drum. Improper handling can cause a part of the body to get into the wheel. Therefore:

  1. Do not put your hands in the machine under rotation.
  2. When cleaning the machine, observe the following rules:

— Adjust the direction of the blade to the other side before cleaning the coating wheel and the uniform wheel.

— Do not wrap the cleaning cloth in your hand.

— Wear fit clothes, never wear loose clothing or carry jewels, belts and other strips.

(For example: jacket without buttons, loose jacket with sleeves, etc.)

— The oil baffle, paint recovery tank and scraper holder can be removed or reinstalled after the mains supply has been switched off.

2.2 Dangers during downtime maintenance

Maintenance and repair work cannot be carried out under production conditions. Any move or start of the machine can cause unexpected damage. therefore:

  1. When performing maintenance work, the machine must be turned off (set the main switch to “O” or “OFF”, cut

Shut off the supply of compressed air) and reconfirm that the machine is turned off to prevent inadvertent machine restart.

  1. Maintenance work can only be carried out by professionally trained and instructed personnel.
  2. Specify the operator’s authority for the machine.
  3. After completing the repair work, reassemble and test the disassembled safety device.

Air Control Section Improper tampering of the machine’s pneumatic system can cause large amounts of gas to leak from cylinders and pipes at high speed. causing harm. therefore:

  1. Depressurize the pneumatic system before use.
  2. Switch off the compressed air supply before running the pneumatic equipment.

[Note] The main switch of the air compression system of the machine cannot be cut off!

Electronic Control Section

After the main switch is turned off, the electrical equipment may still operate, which may cause the human body to be hit by current. Therefore:

  1. Keep the main power supply off the power distribution cabinet.
  2. Disconnect the power cord of the power distribution box before performing the power distribution cabinet repair check.
  3. Only qualified electricians (with a professional electrician certificate) can perform electrical equipment repair and inspection.

Replacing the roller

During the handling process, the roller may fall and collide with the machine and cause deformation. Therefore:

  1. Use appropriate handling methods that will not damage the machine, such as load-bearing lifting equipment or cranes.
  2. Make sure there are no obstacles to the handling route.
  3. Avoid bumps during handling.
  4. Do not walk under the load.

2.3 Operator’s conditions

  Allow operator

  1. Only qualified personnel can operate the machine.
  2. Operators in the work area are responsible for the safety of third parties.
  3. If the operator is unfamiliar with the machine’s reaction, the operator must not use any division to be safe.

Qualified professional

  1. Only qualified personnel can transport, assemble, install, commission, and operate the electrical machinery of the machine.
  2. The person responsible for safety should refer to the training and knowledge of the personnel according to whether they understand the above information.

User responsibility

  1. Only properly trained and instructed personnel can perform various operations on the machine (operation, assembly,

Commissioning, operation, repair and maintenance). Even if it is temporary, it can’t be done without the necessary training.

The trained and instructed personnel operate the machine.

  1. Read and understand the operating manual and be safety conscious.
  2. Authorized personnel are required to operate the machine.
  3. During operation, determine if the relevant personnel are consciously performing a timed inspection of the machine safety aspects.

Operator equipment

  1. Wear protective goggles to prevent sprays of paint and detergent.
  2. Wear solvent resistant gloves to protect against paint and detergent.
  3. Put on rubber shoes to prevent falling objects.

2.4 Requirements for the machine commissioning site

 Ground condition

  1. The machine must be placed on a flat, sturdy, load-bearing floor, otherwise the machine will fall if it falls on the ground.It will cause life in danger.
  2. The floor must be resistant to electricity and electricity to avoid static electricity.

Management measure

Management Mistakes To have appropriate internal guidelines and inspections, you must always keep your work environment clean and tidy.

  1. Collect spilled coatings and cleaners in a timely manner, and do not allow them to penetrate into the ground and drain system.
  2. Apply a warning smear to the cable conduit in the protruding position.
  3. Do not store flammable chemicals in the operating room.
  4. Place the used cleaning cloth in a sealed container outside the operating room.

   Fire Extinguisher

Install the fire extinguisher in an easily accessible location.

   Ventilation technology

Ensures that there are no active, combustible (potentially explosive) gases.

2.5 Allowable operating environment

     Do not operate the machine in an active and flammable environment (explosion hazard). The installation site must be dry and moisture-proof. The following external conditions must be observed to avoid interference with machine operation:

[Note] Installation location conditions

              Temperature: between 10 °C and 40°C.

              Humidity is below 80%.

2.6  Machine security settings

Upper protective cover

The upper protective cover is used to prevent foreign matter from entering between the two rollers to cause machine damage, and also to prevent physical injury caused by physical contact.

Emergency stop switch

The emergency stop switch on the control panel interrupts all operations of the machine, pressing the emergency stop switch, and all machine operations are stopped immediately.

Feed safety barrier

The safety baffle on the collision feed will immediately stop the conveyor belt operation, and the coated upper seat will instantly rise to protect the coating rubber wheel.

Static electricity

The machine needs to be grounded to prevent the potential difference from being generated. The potential difference may cause a spark to cause an explosion.

Distribution box

The distribution box can only be opened with the handle and do not open the distribution box during operation.

2.7 Safety sign

Transportation, storage, commissioning, connection

3.1 Machine delivery

Check the goods

  1. Remove the shipping package from the machine and parts.
  2. Inspect the machine and parts for damage during transportation.
  3. Check that the goods are complete according to the delivery note.

When the damage is found

  1. Report the damage to the transport carrier in a timely manner.
  2. Contact us or your transportation insurance company immediately.
  3. Protect the machine and parts from damage.

3.2  Precautions when moving the machine

 Machine transportation

When transporting the machine with a forklift, pay attention to the minimum load of the forklift is 3T, during the transportation process, the machine

The device may fall down, which will cause serious damage to the human body and even threaten life safety!

  1. Note that the center of gravity of the machine is offset from the center of the carrier.
  2. Use a lifting device that has sufficient load-bearing capacity in a suitable shipping method that will not damage the machine.
  3. Make sure that there is an unimpeded transportation route.
  4. The center of gravity of the machine is very high and avoid tilting the fork when lifting the machine.
  5. Avoid bumps during transportation.
  6. Do not move the machine up and down.
  7. Do not walk under the load.

Precautions The machine may be damaged during transportation.

  1. Before lifting the fork, make sure that there is no excessive load on the edge of the machine. Do not support or move the machine in vulnerable parts such as motor reducers and handwheels.
  2. Carefully handle the machine with a forklift.

3.3 Storage when the machine is idle

If the machine is not in use for a while, the machine must be in a good environment. Considering the location and duration of temporary storage, measures must be taken to protect the machine from the external environment.

Short-term storage

Store in a room temperature room at approximately 25 °C.

  1. Apply the anti-rust oil to the metal part of the leak.
  2. Wrap the uniform wheel and rubber wheel on the wrapping paper.
  3. Cover the machine to prevent dust from entering.
  4. The rubber wheel should not be placed in direct sunlight.

Long-term storage

Do not store in a room below 20 °C. (The room must be dry and weatherproof)

  1. Remove the rubber wheel
  2. Remove the control panel from the machine
  3. Use durable anti-rust oil to preserve all bare metal
  4. The machine is placed on a wooden foundation

[Caution] Improper storage methods can cause damage to power supply components and rubber wheels!

The power distribution box, operation panel and rubber wheel of the machine are stored in a dry room at room temperature.

3.4 Installing the machine

      Install the unit in the designated location as described below and ensure that the floor has sufficient load-bearing capacity before installation.

  1. Transport the equipment to the location where it will be installed. See Section 3.2 for shipping methods.
  2. Remove the outer packaging on the machine, such as plastic film, wooden box, etc.
  3. Place the machine slowly on the ground.
  4. Remove the distribution box from the distribution box support beam.
  5. Remove the distribution box support beams from the rack.
  6. Fix the distribution box on the ground. Be sure to have a certain distance between the distribution box and the machine. The distribution box of the machine is not explosion-proof.
  7. Set the height of the machine.

3.5 Connecting the machine

3.5.1 Connecting pneumatic devices

The machine needs to be connected to 6BAR of compressed air and the pneumatics are ready to wait.

3.5.2 Connecting wires

A professional electrician must be asked to connect the wires, and they must be connected in strict accordance with the circuit diagram.

3.6 Machine commissioning

  1. Make sure the machine is connected before commissioning.
  2. Make sure all the states of the machine are working.
  3. Confirm the direction of rotation of the motor.
  4. Thoroughly clean the machine
  5. Machine operation instructions

You must read the operating manual carefully before operating the machine to determine that you are already familiar with the function of the machine. You must understand

Basic operating principles, and know where the safety switch is located.

4.1 Turn on the machine

In order for the machine to function properly, the following points must be noted:

  1. The power cord is connected properly.
  2. Connect the communication lines between the machines (configure the full-line model).
  3. There is no problem with the compressed air supply and the supply must be maintained at 6.5 BAR.

After the above check has no problem, you can start the machine.

Note: Paint may cause rash or cause poisoning. The following points must be observed:

  1. Observe the safety instructions for the paint.
  2. Wear goggles and protective gloves.
  3. Wash thoroughly after each touch.
  4. Make sure the air is flowing.

Boot

  1. Turn on the main power switch in the power distribution box.
  2. Open the control power supply on the operator panel to set the working production height.
  3. Check each safety switch on the machine.
  4. Check if there is any abnormality in the machine and solve it if there is any problem.
  5. Adjust the gap between the scraper, the uniform roller and the rubber wheel to the same distance.
  6. Install the oil baffles on both sides, return to the oil sump and the paint collection tank and fix.
  7. Fill the paint container to be used or place the container containing the paint on the backing plate.
  8. Introduce the suction and return lines of the paint circulation system into the vessel.
  9. Install the oil discharge pipe of the paint circulation system (above the upper seat).
  10. Set up the paint circulation system as described below.

— Gently open the metering valve of the oil line.

— Close the return valve of the circulation system.

  1. Open the pressure control valve to set the pressure at 1.5 BAR.
  2. Open the flow valve. If there is a problem with the start of the pump, temporarily reduce the operating air pressure.
  3. Adjust the paint supply rate using the flow valve of the circulation system. Note that incorrect operation will cause delivery belt damage.

— Do not start the uniform wheel and the rubber wheel when the coating has not formed a cycle. Do not use the scraper or paint.Do not open when placed for too long.

— Do not use a scraper when using a sponge wheel.

— Ensure the amount of paint supplied to allow the pump to operate properly during operation.

— If the conveyor belt is deflected, it must be connected to the power supply immediately.

  1. Adjust the rubber blade to the working position (if there is a technical requirement).
  2. Turn on the uniform wheel switch first, then turn on the rubber wheel switch.
  3. Adjust the uniform wheel scraper to the working position (if there is a technical requirement), so that the uniform wheel must be reversed a uniform cloth scraper.
  4. Set the machine parameters (reference to section 4.2).
  5. Turn on the conveyor switch.

4.2 Setting up the machine

4.2.1 Setting the conveying speed

On the operation panel, you can set the uniform wheel, rubber wheel and conveying speed. The frequency displayed on the frequency is m/min. The speed setting will affect the final coating effect. 4.2.3 In the chapter we will explain the machine Set the effect on the coating effect.

 4.2.2 Setting the working height

The height adjustment to be processed can be adjusted by the up and down adjustment button or the hand wheel.

4.2.3 Setting the amount of coating

There are two factors that affect the coating thickness as follows:

  1. The working pressure of the uniform wheel on the rubber wheel and the rubber wheel, the thickness of the coating will decrease as the pressure rises.
  2. The speed difference between the uniform wheel and the rubber wheel:

— When the uniform cloth wheel is rotating forward, the uniform speed difference is smaller for the uniform wheel than the rubber wheel. The thicker the coating, the thinner the coating.

— When the uniform wheel is reversed, the opposite is true in this case. The smaller the difference in the speed of the uniform wheel relative to the rubber wheel, the thinner the coating, and the greater the difference in speed, the thicker the coating.

The wrong method of operation will damage the rubber wheel. Please observe the following principles:

  1. Make sure that the speed of the rubber wheel is the same as the speed of the work-piece. The speed difference between them must be small.
  2. When the speed of the rubber wheel is lower than the conveying speed of the work-piece, there will be changes in the coating structure that are invisible to the naked eye.
  3. When the rubber wheel speed is higher than the work-piece conveying speed, paint accumulation will occur.
  4. The viscosity of the coating used will affect the thickness of the coating.
  5. The hardness of the rubber wheel will also affect the finished effect.

4.3 How to use the machine

Using the rubber wheel The rubber on the surface of the rubber wheel is very easy to damage. If it is not handled properly, it may damage the wheel. Therefore:

  1. Check that the rubber is low-resistance to any chemical in the paint and detergent before use. Please contact us if you have any questions.
  2. When the uniform wheel rotates or the scraper is in the working position, the rubber wheel is not allowed to dry, otherwise the rubber surface may peel or damage.
  3. Make sure that there is enough paint in the oil tank during operation and the pump can work normally.
  4. Make sure that the rubber wheel is even.
  5. Avoid touching the rubber surface of the rubber wheel with sharp objects.
  6. When the rubber wheel is not used, make sure that the uniform wheel or the scraper does not apply pressure, otherwise the rubber surface will be deformed for a long time.
  7. Thoroughly clean the circumference and surface of the rubber wheel before the end of production.
  8. Before using the coating, the rubber wheel is first wetted with a solvent compatible with the coating so that the rubber surface does not absorb the solvent in the coating.

Using the two side oil plates Incorrect operation can result in oil plate damage and squeezing.

  1. When retracting the uniform wheel, the oil plate must be removed from the machine.
  2. Before installing the oil pan, the uniform roller must be moved to the working position.

Using a scraper Improper handling can result in damage to the rollers and contamination of the conveyor belt! therefore:

  1. When using a sponge rubber material, do not use a scraper.
  2. After the uniform cloth is wetted with the paint, let the scraper contact the uniform wheel.
  3. When the uniform wheel reversing operation, the scraper must first be adjusted to the working position.

Using Pumps Incorrect operation can result in pump damage and malfunction. therefore:

  1. Check that the pump is resistant to any chemicals in the paint before use.
  2. The pump must not be operated for a long time without the supply of paint.
  3. Wash the pump with a detergent compatible with the coating before the end of production.

Using the conveyor belt Wrong handling can result in damage to the conveyor belt. therefore:

  1. Check that the belt is resistant to any chemicals in the paint before use.
  2. Do not open the conveyor belt without compressed air. (Only for models with automatic offset adjustment)
  3. If the belt is biased to one side, immediately turn off the belt switch again.
  4. Thoroughly clean the conveyor belt and the conveyor belt will run freely only when the surface is clean.

Cleaning conveyor belt

  1. Dip a little detergent with a cloth and the inside of the belt must be dry.
  2. Clean the surface of the conveyor belt with water.
  3. After cleaning the conveyor belt, dry the conveyor belt.

4.4 Cleaning the machine

A thorough routine cleaning machine is absolutely essential to avoid unnecessary problems. The machine must be thoroughly cleaned before and after production. It is also necessary to replace the different coatings.

Idling paint circulation system:

  1. Close the conveyor belt.
  2. Turn off the pump (turn off the metering valve on the pump).
  3. Remove the scraper from the rubber wheel.
  4. Set the paint cycle value as follows:

— Fully open the metering valve of the discharge pipe.

— Turn on the switch of the return line on the paint circulation system.

  1. Allow the wheel gap and the feed tube of the paint circulation system to idle.
  2. Set the clearance between the rubber wheel and the uniform wheel to 0mm.
  3. First turn off the uniform wheel in front of the rubber wheel.
  4. Remove the scraper from the uniform wheel.
  5. Close the metering valve on the feed line of the paint circulation system.
  6. Reduce the operating pressure of the pump (turn the pressure control on the pump).
  7. Take the paint circulation suction tube out of the oil sump.
  8. Quickly switch the pump (turns the throttle on the pump on and off).

The pump draws in air and drains. 

Cleaning

  1. Block the return tank with a clean cloth.
  2. Clean the oil sump with detergent.
  3. Remove the suction and return lines from the paint circulator and place them in the wash tank.
  4. Remove the cleaning cloth from the return tank.
  5. Set the paint circulation system value as follows.

— Gently open the metering valve of the paint circulation system feed tube.

— Close the throttle valve on the discharge tube of the paint circulation system.

  1. Turn on the pump (turn on the throttle on the pump).If there is a problem with the pump start, increase or decrease the operating pressure slightly.
  2. Set the delivery rate of the cleaning agent through the metering valve on the feed line of the paint circulation system.
  3. Open the coating wheel first, then open the uniform wheel; in order to cooperate with the cleaning, the gear position of the uniform wheel switch must be placed in forward rotation.
  4. Continue to circulate the cleaning agent until the coating on the wheel and paint circulation system has dissolved.

[Caution] Incorrect operation may result in damage to the wheel rubber. The cleaning agent must be seen in the return tank before the coating wheel or the uniform wheel is turned on.

Under dry conditions, no pressure can be applied to the rubber.

Cleaning machine

  1. Remove the oil supply tube that coats the coating circulation system on the upper seat and place it in the cleaning tank.
  2. Remove the scraper completely from the applicator wheel and the uniform wheel.
  3. Remove the oil plate from the machine, return to the tank, and wash thoroughly.
  4. Clean the applicator wheel and the scraper on the uniform wheel and wipe the blade continuously until dry.
  5. Set the uniform wheel and height adjustment device to a safe distance       (≥70mm).
  6. Carefully remove any dry paint residue from the sides of the wheel with a brush or plastic shovel.
  7. Slowly start the coating wheel and the uniform wheel. In order to cooperate with the cleaning, the gear position of the uniform wheel switch must be placed in forward rotation.
  8. Clean the applicator wheel and the uniform wheel again and wipe the wheel continuously until dry.
  9. Close the uniform wheel.

10 When the cleaning agent has completely evaporated from the rubber, close the coating wheel. If the coating wheel is closed too early,the cleaning agent will form water droplets under the wheel side, causing the surface rubber to swell.

  1. Clean the transfer zone and wipe the main and passive wheels and conveyor belt continuously until dry.

[Note] The rotating wheels have the risk of getting involved in the body parts!

Do not wrap a clean crepe on your hands.

Wear fit clothes, no loose clothes or jackets (like buttons with jackets, flammable long sleeves, necklaces, watches, etc.)

[Caution] The rubber on the wheels during cleaning may be damaged! Do not use any sharp or hard material to clean the rubber on the wheels.

Prepare for the next production

  1. Adjust the position of the uniform wheel and adjust it to the coating wheel.
  2. Install the oil plate and return groove.

4.5 Switching off the machine

4.5.1 End of production

After thoroughly cleaning the machine, turn off the machine! Do not leave paint on the machine.

  1. Clean the machine in accordance with Section 4.4.
  2. Turn off the control power (press and hold the OFF button on the operation panel)
  3. Turn off the machine (set the main switch on the control cabinet to O or OFF).
4.5.2 Stop in an emergency

In the event of an emergency, immediately press the emergency stop switch or disconnect a safety cutout, all machine activity stops immediately, but the main switch and cable are still energized.

4.5.3 Restart after emergency stop

Follow the steps below to start the machine again.

  1. Make sure that the start up of the machine does not threaten the operation
  2. Release the emergency stop switch.
  3. Check the machine for faults and correct any faults that have occurred (refer to Chapter 6).
  4. Press the ON button on the control panel.

Maintenance and repair

  5.1, maintenance precautions

  5.1.1 Maintenance schedule

Assuming the machine is running for eight hours a day, check the machine during working hours according to the table below.

Working time  Check focus Responsible person Reference chapter
40 hours (weekly) Pneumatic system

1. Eliminate condensate in the air filter.

2. Check the oil quantity of the oil mist lubricator and add the oil quantity as needed.

3. Check the oil speed of the oil mist lubricator and adjust as needed.

4. 4. Check the outside of the oil tank and clean if contaminated. 。

Operator 6.1.2

6.1.3

40 hours (weekly) Uniform wheel adjustment / height adjustment

1. Check if the two rollers are parallel and adjust as needed.

2. Check the height adjustment device and the position indicator on the uniform wheel and adjust as needed.

Professional

 

6.1.3
160 hours (monthly)
500 hours (per quarter) pneumatic system

1. Clean the condensate and the outside of the oil water filter. 。

Professional 6.1.2
Conveyor

1. Clean and lubricate the drive bearings.

Professional
Uniform wheel adjustment / height adjustment / scraper device

1. Clean and lubricate the screw rod, chute, and threaded spindle.

2. Lubricate the bearings in all parts of the frame.

Professional
Scraper/oil plate

1. Check the scraper blade and replace if necessary.

2. Check the consumables on the oil plate and replace if necessary.

3. Check the pressure contacts on the oil plate and adjust as needed.

Professional 6.2.1

6.2.2

6.3.5

Electric control cabinet

1. Clean the air filter of the electric control cabinet and replace it if it is seriously polluted.

Professional
1000 hours (every half year) Professional
2000 hours (annual) Machine overall

1. Check all spiral contact points, plug contact points, wiring, piping conditions (such as contact conditions, insulation of the circuit terminals and connection conditions), and replace as needed.

2. For a stable bracket, check all spiral contact points, plug contacts, and tighten as needed.

Professional

In addition to the repairs in the above table, please observe the following principles:

  1. Lubricants may cause damage to the rubber surface of the drum! Therefore, when repairing the machine, be sure to take extra care that the coating wheel must not touch the lubricant.
  2. The above table does not include any information about the inspection and maintenance of the gear motor. Please refer to the corresponding manufacturer’s operating rules.
  3. Refer to Chapter 2 of this User’s Guide to check the safety device.

— at the beginning of each proposal (after termination)

— Once a week (without stopping)

— After each sale and repair

5.1.2 Maintenance of oil water filter

Drain condensate

  1. Place a collection bin under the condensate drain hole.
  2. Pull the condensate drain pin outward.

Cleaning

  1. Switch off the compressed air supply to the machine.
  2. Open the container counterclockwise.
  3. Find the oil filter.
  4. Remove the filter cartridge.
  5. Clean the filter cartridge with detergent (do not use a detergent containing trichloroethylene, such as benzene. If the filter cartridge is too dirty, replace it)
  6. Blow the filter cartridge out with compressed air from inside to outside.
  7. Clean the container with a special paint.
  8. Dry the container.
  9. Install the components in reverse order.
5.1.3 Maintenance of lubricating oil

Replenishing oil can be full in operation

  1. Unscrew the screw and replenish the oil with a spray gun.

or

  1. Open the container clockwise and fill it with oil. Before removing the container, unscrew the screw to ventilate it and indicate the maximum amount of oil on the container.

Set the oil measurement rate

Set the oil velocity to the compressed air by the metering screw. Turn the screw clockwise to decrease the amount of the drop, and counterclockwise to increase the amount of the drop. The recommended oil measurement rate can be seen through the observation hole.

  1. Tighten the metering screw so that it is completely closed.
  2. Unscrew the screw a half turn.

Cleaning

  1. Switch off the compressed air supply to the machine.
  2. Unscrew the screws to ventilate the container.
  3. Open the container counterclockwise.
  4. Wash the container with solvent or paraffin oil.
  5. Dry the container.
  6. Install the container in reverse order.

5.2 Replacement Parts (Maintenance)

5.2.1 Replacing the doctor blade
Checking the scraper  The applicator wheel and the scraper on the uniform wheel should be inspected at least every 3 months to check if the condition is intact and normal.
The doctor blade should be able to use more than three sides before the blade must be replaced.。
Installing the scraper To install the scraper blade, the scraper holder must be clamped so that it is completely parallel.。
A flat-clamped doctor blade does not rub the drum well, and the rubber side of the rubber wheel may wear on one side.
5.2.2 Replacing the rubber wheel
Action step
Removing the rubber wheel 1. Remove the oil plate from the machine.

2. Set the safety distance between the uniform wheel and the height adjustment (≥70mm).

3. Remove the upper side cover of the coating wheel near the motor.

4. Run the coating wheel at low speed until the coupling is level.

5. Turn off the machine (set the main switch to O or OFF).

6. Loosen the housing retaining screws close to the motor. This fastening screw is used to secure the wheel.

7. Use a rope or belt with sufficient load-bearing capacity to cover the surface of the coating wheel and follow the rules for the transportation of the glue.

8. Gently clamp the rope or belt with a crane.

9. Remove the bearing mount.

10. Pull the rubber wheel onto the support frame.

11. Lift the rubber wheel off the machine.

12. Remove the coupling on the rubber wheel.

Install the rubber wheel Install the rubber wheel in reverse order in the above order and observe the following points:

1. The coating wheel should be completely parallel to the uniform wheel and adjusted with a rubber hammer or other tools.

2. After the coating wheel is completely parallel with the uniform wheel, fix the coating wheel to the bearing holder with the fastening screw.

3. Fix the coating wheel coupling so that the shaft clearance on both sides is at least 1.5 mm.

4. Check if the rubber wheels are parallel, please refer to section 5.3.

5. Check the position indicator, please refer to section 5.3.

Repairing the rubber wheel 1. If the rubber surface of the rubber wheel is damaged, or the rubber wheel is unevenly rotated due to shrinkage expansion, it can be reground.

2. When the diameter of the rubber wheel is less than 232mm, the rubber wheel must not be ground again. It must be re-coated to make the diameter of the roller suitable for the controller.

5.2.3 Purchase accessories (please refer to the accessories list)

5.3 Settings and adjustments

  1. The position of the uniform distribution wheel must be checked regularly, and the height adjustment of the upper seat and the parallelism of the wheel should be applied.
  2. The expansion and re-repair of the rubber surface of the roller may cause a change in the position of the wheel or cause the two rollers to be non-parallel and must be adjusted in time.
5.3.1 Correction of the height of the uniform wheel

Check parallel

  1. Place a strip of the same thickness on the left and right sides of the gap between the rubber wheel and the uniform wheel.
  2. Slowly adjust the distance between the rubber wheel and the uniform wheel until the paper strip is slightly clamped.
  3. Carefully pull out the paper strips. If you feel the force on both sides of the paper strip, then the two rollers are not parallel.

Set zero

  1. Loosen the fastening screws on the counter on the inside of the hand-wheel.
  2. Take the meter out.
  3. Hold the meter firmly with the thumb and forefinger of one hand and adjust the dial with the other hand until the correct setting is obtained.
  4. Install the gauge on the inside of the hand-wheel and adjust it parallel to the hand-wheel.
  5. Retighten the fastening screws.
5.3.2 Correction of rubber wheel height

Check parallel

  1. A strip of paper of the same thickness is placed on the left and right sides of the gap between the rubber wheel and the uniform wheel.
  2. Slowly adjust the distance between the rubber wheel and the uniform wheel until the paper strip is slightly clamped.
  3. Carefully pull out the paper strips. If you feel the force on both sides of the paper strip, then the two rollers are not parallel.

Set zero

  1. Loosen the fastening screws on the side gauge of the hand-wheel.
  2. Take the meter out.
  3. Hold the meter firmly with the thumb and forefinger of one hand and adjust the dial with the other hand until the correct setting is obtained.
  4. Install the gauge on the inside of the hand-wheel and adjust it parallel to the hand-wheel.
  5. Retighten the fastening screws.
5.3.4 Setting the contact pressure of the baffle
  1. Adjust the position of the uniform wheel so that it just touches the coating wheel.
  2. Loosen the nut on the hold-down unit.
  3. Place the hand oil plate on the side of the rubber wheel and the uniform wheel, do not put it down.
  4. Insert a pin at the drill collar of the hold-down unit.
  5. Adjust the compression device so that the groove of the elastic bushing is level with the outer edge of the oil pan support.
  6. Retighten the nut on the compression unit.
5.3.5 Adjusting the uniform wheel anti-rotation device
  1. Gently loosen the fastening screw.
  2. Adjust the anti-rotation device with the set screw to know that the anti-rotation device is in close contact with the gear motor.
  3. Retighten the fastening screws.

Troubleshooting of faults and errors

6.1 Troubleshooting

6.1.1 Mechanical abnormality
Phenomenon cause solution
 

The machine is not working properly

The fuse is burned. Find out the cause and replace the fuse.
Emergency stop switch reset  Turn the emergency stop switch clockwise
Overload causes the appliance to trip  Re-cut the power after reset, restart
Touch the safety switch to reset the touch object
The power indicator is on but not activated after power-on Adjust any two phases of the three-phase power supply
Limit switch start  height reset
6.1.2 Abnormal phenomena during production
Phenomenon cause solution
Appearance of the horizontal stripes too tight or too loose, and the left and right gaps are too tightly tangent  to adjust the tightness of the blade and loosen the left and right gaps.
Pattern spread  low ink concentration adjust ink concentration
The pattern can’t be printed, the shade is different The ink dries too fast Adjust the ink viscosity properly.
 6.1.3 Oil pump abnormal phenomenon
Phenomenon  cause solution
The air pump diaphragm pump does not work The pump inlet and outlet are blocked The pump suction port is cleaned.
Air pressure is too low Check the barometer to show the pressure
Diaphragm rupture Replacement of new diaphragm
Reversing valve block damage Replacement reversing valve block

6.2 Coating Frequently Asked Questions

Frequently phenomenon Situation Description Schematic Causes and Solutions
Horizontal stripes  uniform horizontal stripes  Reducer failure, maintenance reducer
Perimeter mark Replacement rubber wheel
Irregular horizontal stripes Please contact us
Straight line bright strips with obvious lines on the work-piece 1. Pulling the surface of the coating wheel

Injury, replace the coating wheel.

2. There are impurities on the scraper. Clean the scraper

Pile head Accumulation of material in the head of the work-piece The speed of the coating wheel is faster than the speed of the conveyor belt, and the speed is adjusted to be consistent.
Pile end Accumulation of paint in the tail end of the work-piece The coating wheel speed is less than the conveyor speed and is adjusted to the same speed.
Zhou Changyin Printing of the perimeter of the paint 1.1. The bottom wheel and the coating wheel are not on a center line, and the position is adjusted.

2.2. The hardness of the coating wheel is too high, and the low hardness coating wheel is replaced.

The yin and yang surface There is a color difference on the work-piece 1.. Use a coating wheel with a hardness of 50-55 degrees.

2. Add a scraper to the coating wheel.

3. Change the paint.

Full precision double roll coating machine specifications:

Name 600# 1000# 1300#
Appearance specifications L*W*H 1700mm*2150mm*1650mm 1700mm*2550mm*1650mm 1700mm*2900mm*1650mm
Machine weight 1200KG 1400KG 1600KG
Effective processing width 600mm 1000mm 1300mm
Effective machining thickness 3-80mm 3-80mm 3-80mm
Minimum processing length 200mm 200mm 200mm
Rubber wheel size 750*∮250mm 1150*∮250mm 1450*∮250mm
Electric light wheel size 750*∮164mm 1150*∮164mm 1450*∮164mm
Conveying speed 5-20m/min 5-20m/min 5-20m/min
Transmission power 0.75KW 1.5KW 1.5KW
Rubber wheel power 0.75KW 1.5KW 1.5KW
Electric light wheel power 0.75KW 1.5KW 1.5KW
Total power 7.49KW 9.75KW 9.75KW

Note: When the wheel is equipped with other specifications, or when the other configurations of the machine are special.

The corresponding specifications are also different, and the above specifications are not used as the standard.

7.Full Precision Coater Instruction Manual File(Click to read it)

Full precision coater instruction.pdf

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