Xps-prodry User`s Guide

Transcript

XPS-ProDry User’s Guide XPS-ProDry User’s Guide Dryer Base For Use with Inkjet Imaging Systems Manual Part#: M-3120 Revision: August 2005 XPS-ProDry User’s Guide Written by Frank Mauri & John Brand Published by: RENA Systems, Inc 136 Green Tree Road Oaks PA 19456-1069 610-650-9170 All Rights reserved. No Part of this manual may be used or reproduced in any form or for any means either electronic or mechanical without prior written permission of RENA Systems, Inc. Producing copies of any part of this manual for any purpose other than personal use is a violation of copyright laws. Copyright © 2002 First Edition 2002 This manual is provided as is, without warranty of any kind, either express or implied, including but not limited to implied warranties for the manuals quality, performance, merchantability, or fitness for any particular purpose. Neither the provider of this manual nor its dealers, distributors or agents shall be liable to the purchaser or any other person or entity with respect to any liability, loss, or damage caused or alleged to be caused directly or indirectly by use of this manual. Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base Table of Contents 1. General Information ........................................................................................................... 1 1.1 Description.....................................................................................................................................2 1.2 Features.........................................................................................................................................3 Infrared Drying Assembly ................................................................................................................3 Center Vacuum Belt ........................................................................................................................3 Variable Speed Control Selector .....................................................................................................3 Control Panel...................................................................................................................................3 XPS-ProDry Compatibility ...............................................................................................................3 1.3 Specification ..................................................................................................................................4 Material Handling ............................................................................................................................4 Physical ...........................................................................................................................................4 Electrical ..........................................................................................................................................4 Electrical Installation Requirements ................................................................................................5 1.4 XPS-ProDry Graphic.....................................................................................................................6 2. Operator Instructions ........................................................................................................ 7 2.1 Control Panel Functions ................................................................................................................8 Main Power Selector Switch..........................................................................................................10 Vacuum Power Selector Switch ....................................................................................................10 Heater Power Selector Switch.......................................................................................................10 XPS-ProDry Start and Stop Pushbuttons......................................................................................10 Speed Potentiometer.....................................................................................................................10 2.2 Material Guide Adjustments ........................................................................................................11 Material Guide Adjustments ..........................................................................................................11 To Adjust the Rear Exit Wheel ......................................................................................................11 3. Technical Adjustments and Maintenance...................................................................... 12 3.1 Vacuum System...........................................................................................................................13 Overview........................................................................................................................................13 Maintenance ..................................................................................................................................13 Filter Replacement Graphic...........................................................................................................14 3.2 XPS-ProDry Drive System..........................................................................................................15 Drive Motor Belt Adjustment..........................................................................................................15 Drive Motor Belt Replacement ......................................................................................................16 Maintenance ..................................................................................................................................17 3.3 Mailpiece Transport Belts ............................................................................................................18 Tension Adjustment.......................................................................................................................19 Outer Belt Width Adjustment .........................................................................................................19 Belt Replacement ..........................................................................................................................20 Maintenance ..................................................................................................................................20 3.4 IR Drying System.........................................................................................................................21 Overview........................................................................................................................................21 Safety Precautions ........................................................................................................................21 Infrared Lamp Replacement..........................................................................................................22 Preventive Maintenance................................................................................................................25 Drying Assembly Graphics ............................................................................................................25 3.5 XPS-ProDry Covers....................................................................................................................27 Removal ........................................................................................................................................27 Installation .....................................................................................................................................27 Maintenance ..................................................................................................................................27 3.6 General Troubleshooting .............................................................................................................28 Electrical ........................................................................................................................................28 Electrical ........................................................................................................................................32 Vacuum Pump ...............................................................................................................................33 XPS-ProDry Drive Motor ...............................................................................................................33 Mailpiece Transport Belts..............................................................................................................33 3.7 Replacement Parts ......................................................................................................................34 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base Chapter 1 General Information 1. General Information 1.1 Description 1.2 Features • Infrared Drying Assembly • Center Vacuum Belt • Variable Speed Control Selector • Control Panel • XPS-ProDry Compatibility 1.3 Specifications • Material Handling • Physical Dimensions • Electrical Requirements 1.4 Overview • Transport Base Graphic 1 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 1 General Information 1.1 Description The XPS-ProDry is a mailpiece transportation and drying system consisting of a variable speed vacuum enabled transport mechanism that is operated by means of a centrally located control unit. The XPS-ProDry was designed as a compact, heavy-duty mailpiece transport and drying system engineered to optimize the performance of any Ink-jet imaging system. The XPS-ProDry transport system consists of three high-temperature variable speed transport belts, one vacuum operated center belt and two outer adjustable belts. Operation of the XPS-ProDry is achieved by the use of a front mounted control panel consisting of a series of clearly labeled On/Off selector and On/Off pushbutton switches. The control panel houses On/Off selector switches for Main Power, Vacuum Power, and Heater Power. On/Off pushbutton switches are provided for the dryer base Start and Stop functions. The control panel contains a Speed Control adjustment to aid in optimizing the mailpiece drying quality. The XPS-ProDry has been quality engineered and manufactured to provide years of reliable and trouble free operation. WARNING! The XPS-ProDry’s electrical connection should only be performed by a certified electrician. Please see page 5 for additional information. 2 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base Chapter 1 General Information 1.2 Features Infrared Drying Assembly The IR Drying Assembly is a source of high intensity light in the short to medium infrared spectrum. The IR lamp transfers its energy to the stock in the form of heat. The increased temperature causes the ink to “set” at a faster rate than normal. An intensity control is included to compensate for varying job runs. Center Vacuum Belt The high temperature center vacuum belt, which transports the mailpieces from an inkjet imaging system to the mailpiece drying area has vacuum applied to it to maintain the mailpiece positioning with relation to the dryer. Two additional high temperature outer adjustable belts are provided to allow drying on mailpieces from 3” minimum to 18” maximum widths. Variable Speed Control Selector The transport base belt speed can be adjusted to optimize the drying quality of the mailpieces depending on the stock size and speed of delivery from the inkjet imaging system. This is achieved by adjusting the Speed Control knob as needed. Control Panel The controls required to operate the XPS-ProDry are easily accessible and housed in a front mounted control panel. The control panel is equipped with easily identifiable selector or pushbutton switches for all the XPS-ProDry functions. The control panel also contains the Speed Control selector and the majority of the base control electronics. XPS-ProDry Compatibility The XPS-ProDry can be used in conjunction with any inkjet imaging system. 3 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base Chapter 1 General Information 1.3 Specification Material Handling Minimum Maximum Thickness (Standard) 3” x 5” 18” x 22” Single Sheet to 1.5” Overall Length (Base Only) Overall Height Overall Width Weight Crated Weight 43” 31” Min. - Height Adjustable 26¼” 305 lbs. 474 lbs. Physical Electrical Voltage 208 - 220 V.A.C. Single Phase Current 20 Amps* *Recommended 20 AMP Dedicated Outlet. Please see the next page for important installation information. Transport Motor 1/3 H.P. 90 VDC 3.2 A., 1750 Max. RPM Geared to 875 Max. RPM Vacuum Pump 1/8 H.P. 115 VAC 2.0 A., 3450 RPM IR Drying Assembly 220 V.A.C. Single phase 20 Amps 2-2000 Watt IR Lamps Control Panel Main Power Vacuum Power Transport Base Start Transport Base Stop Heater Power Speed Potentiometer 4 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base Chapter 1 General Information Electrical Installation Requirements WARNING! The XPS-ProDry’s electrical connection should only be performed by a certified electrician. The XPS-ProDry requires a 220 VAC, four wire, single phase service. A dedicated 20 Amp service is recommended. Please have a certified electrician install and verify the supply type, rating and voltage, before connecting the XPS-ProDry to the outlet. If the XPS-ProDry is connected to an incorrectly configured outlet the equipment will be damaged and or personal injury may result. Please have a certified electrician verify that the installation meets all “local electric code” requirements. The XPS-ProDry is shipped without a plug on the end of its power cord. Please have a certified electrician install the correct power cord plug for your location. Power Cord Wiring Description: Wire Color Electrical Connection Red HOT Black HOT White Neutral Bare Wire Earth Ground 5 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base Chapter 1 General Information 1.4 XPS-ProDry Graphic (Original release pictured above, your machine may vary slightly) 6 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base Chapter 2 Operator Instructions 2. Operator Instructions 2.1 Control Panel Functions • • • On/Off Selector Switches On/Off Pushbuttons Speed Potentiometer 2.2 Material Guide Adjustments • Rear Exit Wheel 2.3 Vacuum System • • Vacuum Pump Overview Maintenance 2.4 XPS-ProDry Drive System • • • Belt Adjustment Belt Replacement Maintenance 2.5 XPS-ProDry Belts • • • Center Vacuum Belt Outer Belts Maintenance 2.6 Drying Lamp Assembly • • • • Drying Assembly Overview Safety Precautions Preventive Maintenance Drying Assembly Graphic 2.7 XPS-ProDry Covers • • • Removal Installation Maintenance 2.8 Troubleshooting 2.9 Replacement Parts 7 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base Chapter 2 Operator Instructions 2.1 Control Panel Functions The Transport Base is outfitted with a centrally located control panel which houses all the necessary controls to easily operate the unit. The controls are grouped in three categories of functions: • • • Main Power, Vacuum Power, and Heater Power On/Off Selector Switches Transport base Start and Stop Pushbuttons Transport base Speed Control Potentiometer Main Power Vacuum Power Start Stop Heater Power Speed Control Figure 2.1.1 Control Panel Detailing Main Power, Vacuum Power, Start, Stop, Heater Power, and Speed Control (Original revision shown) 8 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base Chapter 2 Operator Instructions Figure 2.1.1a Control Panel (Latest revision shown above) 9 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base Chapter 2 Operator Instructions Main Power Selector Switch The Main Power switch provides power to the Heater Power switch and the dryer base drive system, (Start and Stop pushbuttons). Vacuum Power Selector Switch The Vacuum Power switch provides power to the vacuum pump and initiates vacuum to the dryer base tabletop. When the switch is in the On position the noticeable sound of the vacuum pump’s compressor will be heard. The circuit is protected with a field replaceable 5A cartridge fuse. Heater Power Selector Switch The Heater Power switch provides power for the IR drying lamp assembly. When the switch is in the On position power is provided to the drying lamps. The drive system MUST be started (START) before power is available to the Heater Power switch. Power is removed from the Heater Power circuit when the STOP button is depressed. The IR lamp controller is protected by a 20AMP ceramic fuse. XPS-ProDry Start and Stop Pushbuttons The dryer base Start pushbutton powers the dryer base drive motor and initiates the belt movement. When the Start pushbutton is engaged the transport base belts will run continuously. Pressing the Stop pushbutton will immediately stop the dryer base drive motor and movement of the belts. This will also remove power to the IR Drying assembly Speed Potentiometer The Speed Control potentiometer allows adjustment of the dryer base belt speed. A clockwise rotation of the Speed Control dial will increase the belt speed, a counter-clockwise rotation of the Speed Control dial will result in a belt speed decrease. The drive axle RPM range is from 0 – 875RPM. The circuit is protected with a field replaceable 5AMP Armature fuse. 10 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base Chapter 2 Operator Instructions 2.2 Material Guide Adjustments Material Guide Adjustments Rear Exit Wheel Locking Collar (2) Adjustment Nut Figure 2.2.1 Rear Exit Wheel Assembly To Adjust the Rear Exit Wheel The rear exit wheel is used to direct the mailpiece exiting the dryer base. The adjustment will compensate for transferring the mailpiece to additional inline equipment or directed down to a mailpiece collection bin. 1. Loosen the locking collars and center the exit wheel on the center vacuum belt. Tighten the locking collars when complete. 2. Loosen the adjustment wheel to retract or extend the exit wheel on the mounting bracket. Extending the exit wheel to the end of the mounting bracket will direct the mailpiece downward. Retracting the exit wheel to the beginning of the mounting bracket will allow the mailpiece to be transferred to additional inline equipment. 11 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base Chapter 3 Adjustments and Maintenance 3. Technical Adjustments and Maintenance 3.1 Vacuum System • • Vacuum Pump Overview Maintenance 3.2 Transport Base Drive System • • • Belt Adjustment Belt Replacement Maintenance 3.3 Mailpiece Transport Belts • • • Belt Adjustments Belt Replacement Maintenance 3.4 IR Drying System • • • Overview Safety Precautions Preventive Maintenance 3.5 Transport Base Covers • • • Removal Installation Maintenance 3.6 General Troubleshooting • • • • • Electrical IR Drying System Vacuum Pump Transport Base Drive Motor Mailpiece Transport Belts 3.7 Replacement Parts These maintenance instructions are provided as is, without warranty of any kind, either express or implied, including but not limited to implied warranties for the instructions quality, performance, merchantability, or fitness for any particular purpose. Neither the producer of this document nor its dealers, distributors or agents shall be liable to the purchaser or any other person or entity with respect to any liability, loss, or damage caused or alleged to be caused directly or indirectly by use of these instructions 12 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 3 Adjustments and Maintenance 3.1 Vacuum System Overview The XPS-ProDry vacuum system consists of a control panel mounted On/Off selector switch, a vacuum pump, distribution piping and a tabletop mounted vacuum manifold. Vacuum Feed Hose Replaceable Filter Location Figure 3.1.1 Vacuum Pump and Associated Piping Maintenance The vacuum pump is accessed by removing the front panel. Power must be disconnected before servicing. Be sure all rotating parts have stopped. Electric shock or severe injury can result if the hazard is ignored. • Clean intake and exhaust filters as often as needed, blowing down against the current to clean them. Change the cartridges when cleaning no longer gets the cartridges clean. A dirty cartridge causes high intake resistance resulting in an increase of differential pressure, absorbed power and an increase in working temperature. • The motor bearings are greased for long life and require no user intervention. • Check Vacuum Pump mounting bolts annually and tighten as needed. 13 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 3 Adjustments and Maintenance Filter Replacement Graphic Figure 3.1.2 Figure 3.1.3 14 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 3 Adjustments and Maintenance 3.2 XPS-ProDry Drive System The XPS-ProDry drive system consists of a Start pushbutton, Stop pushbutton, drive motor, drive pulley, driven pulley and a timing cog belt. Belt Deflection ¾” Timing Belt Adjusting Bolts (4) Pulley Locking Screw Figure 3.2.1 XPS-ProDry Drive System Drive Motor Belt Adjustment The drive motor is accessed by removing the front panel. The correct belt deflection has been set up at the factory and under normal use should not require adjustment If timing cog belt does require adjustment: 1. Remove the front cover. 2. Loosen the four (4) drive motor adjusting bolts 3. Adjust the belt deflection measured at the midpoint of the drive and driven pulleys to ¾” 4. Tighten the four (4) drive motor mounts and verify the proper deflection. 5. Repeat steps 1 & 2 if necessary 15 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 3 Adjustments and Maintenance Drive Motor Belt Replacement 1. Remove the end cover closest to the driven end of the machine. 2. Loosen four (4) drive motor adjusting bolts. 3. Raise drive motor to the top of the mounting bracket and tighten one bolt to hold the drive motor in place. This provides the least amount of belt tension for belt removal and replacement. 4. Loosen the drive motor pulley set screw. 5. Remove the two (2) roller drum shaft end caps. 6. Loosen the two (2) set screws on the roller drum shaft-locking collar. 7. Remove the five (5) rail fastening screw from the tabletop. 8. Remove and set aside the rail-insulating strip. 9. Remove the drive motor pulley from the drive shaft. 10. Tap on the rail to move the roller drum locking collar from the roller drum shaft enough to allow belt removal. 11. Remove belt and replace with new drive belt 12. Place the new belt on the drive motor pulley and replace the pulley on the drive motor shaft, align and install keyway. DO NOT tighten the pulley set screw at this point. 13. Install the roller drum-locking collar on the roller drum shaft. DO NOT tighten the locking collar at this point. 14. Place the rail-insulating strip on top of the rail. 15. Reinstall the five (5) rail mounting screws in the tabletop and loosely tighten 16. Tighten the rail mounting screws starting with the center screws and working outwards. 17. Using a straight edge align the outside flanges of the drive and driven pulley and tighten the locking screws. 18. Loosen the drive motor adjusting bolts and set the correct belt tension. See Section 3.2.1 Rail Mounting Screws (5) Roller Drum Shaft Locking Collar Drive Motor Adjusting Bolts (4) Drive Pulley Figure 3.2.2 XPS-ProDry Drive Belt Removal 16 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 3 Adjustments and Maintenance Maintenance The drive motor is accessed by removing the end panel. The drive motor is a ball or roller bearing motor. The bearings have been lubricated at the factory. The motor does not have any regrease capability and is lubricated for the normal life of the bearings. • Check the timing cog belt annually for wear and replace as needed. • Check the drive and driven pulley locking screws annually and tighten as needed. • Check the drive motor adjusting bolts annually and tighten as needed 17 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 3 Adjustments and Maintenance 3.3 Mailpiece Transport Belts The XPS-ProDry is equipped with three (3) high temperature mailpiece transport belts. One (1) 3” center vacuum belt and two (2) 1” adjustable outer belts. Belt Adjustment Transport Belt Roller Shaft Transport Belt Adjustment Screw Fig 3.3.1 Mailpiece Transport Belt Adjusting Screw 1” Belt Play Figure 3.3.2 Mailpiece Transport Belt Tension Adjustment 18 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 3 Adjustments and Maintenance Belt Adjustment The correct belt tension is measured at the mid point of the tabletop. The center vacuum and two outer belts should have a distance of 1” of play measured from the tabletop to the bottom of the belt surface. See figure 3.3.2 NOTE: Do Not Over Tighten the Transport Belts. This Will Lead to Premature Belt Failure Tension Adjustment If the mailpiece transport belts need a tension adjustment: 1. Adjust the transport belt adjustment screw to allow for 1” of belt play measured from the mid point of the tabletop. Turn the belt adjusting screw clockwise to tighten the belt and counter clockwise to loosen the belt. See Figure 3.3.1 NOTE: Do Not Over Tighten the Transport Belts. This Will Lead to Premature Belt Failure. Outer Belt Width Adjustment 1. 2. 3. 4. The two 1” outer belts are adjustable to allow for varying mailpiece widths. If the two outer mailpiece belts need width adjustment: Loosen the two (2) locking collar set screws in each of the two outer belt pulleys. Adjust the outer edge of the belts to align with the outer edge of the mailpiece. Tighten the two (2) locking collar set screws in each of the two outer belt pulleys. Turn on the mailpiece transport belts (START) for 15 seconds to auto-align the outer belts on the roller drum shaft. Locking Collar Set Screws (2) Figure 3.3.3 Transport Belt Adjustment Graphic 19 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 3 Adjustments and Maintenance Belt Replacement If the mailpiece transport belts require replacement: 1. Remove the front cover 2. Loosen the two (2) belt adjustment screws to allow the full amount of travel to the transport belt roller shaft assembly. See figure 3.3.1 3. Remove the vacuum feed hose from the barbed brass fitting. 4. Unscrew the ¾” x10” black steel vacuum feed pipe from the 90 elbow. 5. Remove the Exit Wheel mounting bar. 6. Remove the six (6) tabletop to dryer base attaching screws. 7. Move the tabletop to the left to allow slack in the drive motor belt, remove the drive motor timing cog belt from the drive pulley. 8. Remove the belt(s) and replace as necessary. 9. Assemble in the reverse order. Move Tabletop to Remove Drive Belt Figure 3.3.4 Transport Base Belt Replacement Graphic Maintenance • • • Blow off dirt and debris from belts daily. Remove any ink, as needed using an approved solvent. (i.e. Simple Green) Check belt tension every six months and adjust as needed. Check belts for wear every six months and replace as needed. 20 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 3 Adjustments and Maintenance 3.4 IR Drying System Overview The IR Drying Assembly is a source of high intensity light in the short to medium infrared spectrum. The IR lamp transfers its energy to the stock in the form of heat. The increased temperature causes the ink to “set” at a faster rate than normal. The Intensity control provides IR lamp intensities, enabling the operator to compensate for such variables as imaging speed, paper stock, ink coverage, ink color etc. The effectiveness of the infrared drying will vary from job to job based on these variables. Safety Precautions • Note the label on the lamp housing. Do not drop flammable liquids on a hot lamp housing. • Do not jar or vibrate the IR lamp housing while the IR lamps are still hot. • Do not operate the IR lamps unless they are in a horizontal position. • When the IR lamps turn off, allow the cooling fans to operate for at least 5 minutes before turning the power switch off. • Adjust the height of the IR lamp to maintain a minimum of 2 inches above the stock passing underneath. 21 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 3 Adjustments and Maintenance Infrared Lamp Replacement CAUTION: Read and follow these instructions carefully. Failure to do so will result in premature failure of the IR lamp, damage to the control box, and create a shock and burn hazard that may result in personal injury…. ** Please Note: Use care NOT to touch the replacement bulbs with bare hands. The natural oils from your skin WILL shorten the usable life of the bulbs. Lamp Replacement procedure – • Unplug the (3) connectors for the Heat Lamp Head from the rear panel of the Dryer Base. • Remove the bolts that secure the Dryer Lamp Assembly to the support cross bar and carefully remove the lamp assembly from the base. Support Cross Bar Remove bolts 22 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 3 Adjustments and Maintenance • Set the Lamp head on a clean, flat work surface. • Remove the (4) Philips head screws located on both sides of the cooling fans (2 per side). Remove 2 Screws Remove 2 Screws • Carefully turn the lamp head over so that the bulbs are facing you. Grab the aluminum lamp housing (to the outside of the ceramic lamp sockets) and gently pull the entire lamp housing from the frame. With the lamp head cords to your right, roll the lamp housing towards you exposing the lamp wiring. • Locate and disconnect the (4) quick connect lamp wires by spreading the locking clips outward while pulling the wires away from each other. • Carefully guide the disconnected wires through the holes in the lamp housing so that the wires are on the same side of the housing as the bulbs. 23 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 3 Adjustments and Maintenance • Remove the (4) Philips head screws from (1) end of the lamp housing, releasing the ceramic lamp holders. Remove 4 Screws • Remove the U-shaped aluminum lamp holders from the end of the fixture. This will loosen the bulbs and allow them to be slid off the opposite side bulb holders. • Replace the bulbs with the new set, again being careful not to expose them to direct contact with your skin. Note: The ceramic insulators must be removed and reused with your new lamps. • Reassemble the fixture in the reverse order that is described above. Be careful to make sure that no wires are pinched during this assembly. • Place repaired Lamp head back onto the Dryer Base. Plug in the (3) connectors and the Dryer Base should be ready for use. 24 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 3 Adjustments and Maintenance Preventive Maintenance Do not allow lubricants or solvents to drip onto the IR lamp housing If any substance (including fingerprints) should come in contact with the glass infrared lamp, carefully wipe the lamp WHEN IT IS COLD, with a lint free cloth and isopropyl alcohol NOTE: Fingerprints on the IR lamp WILL decrease the lamp life. Periodically clean the IR lamp WHEN IT IS COLD, and the parabolic reflector to remove any dust or materials, which may collect over time. Always use a lint free cloth and isopropyl alcohol. NOTE: To increase lamp and drive belt life, on initial setup set the IR intensity adjuster to between 50 and 60% capacity. Drying Assembly Graphics Minimum 2” Clearance Figure 3.4.1 Heater Assembly 25 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 3 Adjustments and Maintenance IR Heater Intensity Adjuster Figure 3.4.2 Rear View Showing Intensity Adjuster (Original revision) Figure 3.4.2a Rear View Showing Connectors - Current Revision (Intensity Control Front Panel Mounted) 26 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 3 Adjustments and Maintenance 3.5 XPS-ProDry Covers Removal Removal of the cover panels is accomplished by turning the Zeus fasteners one-half turn counter clockwise. Installation Installation of the cover panels is accomplished by turning the Zeus fasteners one-half turn clockwise. Maintenance The front and rear covers are coated with a high quality, durable powder coating. Remove ink, grease and dirt using an approved solvent (i.e. Simple Green) as needed. 27 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 2 Troubleshooting 3.6 General Troubleshooting Electrical The Dryer Base Main circuit breaker, Vacuum Pump fuse and Dryer Base drive motor circuit is located in the Dryer Base wiring cabinet. The Dryer Base speed potentiometer control box is also located in the Dryer Base wiring cabinet. The wiring cabinet is accessed by removing the front cover Main Heater L1 Heater L2 Vacuum Base Contactor Circuit 15A 15A Pump Power for Heater Breaker 5A 15A Control Relay for Heater Cam Switch Contactor for Base and Accessories Field Replaceable Resistor IR Heater Control Box Motor Control Line Fuse 25A Motor Control Armature Fuse 5A Figure 3.6.1 Wiring Cabinet Detail (Original Revision) 28 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 2 Troubleshooting Figure 3.6.1a Wiring Cabinet Detail (Current Revision) 29 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 2 Troubleshooting Relay for Heater Cam Switch Heater Control Fuses 20 A Figure 3.6.1b Internal Dryer Control Wiring Cabinet Detail (Current Revision) 30 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 2 Troubleshooting Dryer Control Indicator Lights Dryer Controller PC Board P/N D0013-03 Figure 3.6.1c Dryer Controller Detail (Current Revision) 31 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 2 Troubleshooting Electrical Troubleshooting Guide Symptom Solution No Power to Any Selector or Pushbutton Switch on the Control Panel • Vacuum Pump Does Not Start • Dryer Base Belts Do Not Move or Drive Motor Does Not Run • • • • IR Lamps Do Not Turn On • • • • • • Ink on the Mailpieces is Not Drying After Passing Under the IR Lamps • • • Verify the Correct Power is Supplied to the Transport Base Check Main Circuit Breaker and Reset as Needed Check 5A Vacuum Pump Fuse and Replace as Needed Verify Speed Control is Not Set to Zero (0) Check 15A Drive Motor Fuse and Replace as Needed Check Motor Control Line and Armature Fuse and Replace as Needed Lamps Will Not Power On Unless The Drive Belts Are Moving Check the 20Amp Fuse Located in the IR Control Box and Replace as Needed Check and Replace IR Lamps as Needed Verify proper operation of the drive shaft mounted cam activated Proximity Switch. Red light should flash on Proximity Switch on every rotation of shaft. Verify that the Heater Control relay is operating. Listen for the switching action of the relay as the drive shaft rotates. Check that the signal from the relay is getting to the Heater Control Board by checking the Red and Green Status Lights. Green indicates power is at control board and flashing Red indicates signal from the relay is being received. Increase IR Intensity Switch Until Sufficient Drying Is Achieved Adjust IR Lamps to a Minimum of 2 Inches Above the Stock Reduce Belt Speed 32 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Chapter 2 Troubleshooting Vacuum Pump Troubleshooting Guide Symptom Solution Vacuum Pump Does Not Start When the Selector Switch is ON • Check 5A Vacuum Pump Fuse and Replace as Needed Inconsistent or Low Vacuum Condition • Clean or Replace Vacuum Pump Intake and Exhaust Filters as Needed XPS-ProDry Drive Motor Troubleshooting Guide Symptom Solution Dryer Base Belts Do Not Move or Drive Motor Does Not Run • • • Verify Speed Control is Not Set to Zero (0) Check 15A Drive Motor Fuse and Replace as Needed Check Motor Control Line and Armature Fuse and Replace as Needed Mailpiece Transport Belts Troubleshooting Guide Symptom Belts are Moving Too Slowly to Transport Mailpiece Belts Slipping on the Roller Drum Shaft Solution • Increase Speed Control Setting • Tighten Belts to Recommended Specifications. See Section 2.5 33 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Replacement Parts 3.7 Replacement Parts DESCRIPTION PART NUMBER 5 AMP Armature Fuse for Speed Control AC Line Fuse for Speed Control 1/3 HP Plug-in Resistor for Speed Control 5 AMP Fuse for Vacuum Pump Circuit 15 AMP Fuse for Drive Motor Circuit IR Heater Assembly 2000 Watt IR Lamp (Two Required) 20 AMP Ceramic Fuse for IR Lamp Controller Dryer Lamp Control Board 1” High Temperature Belt (36” Base) 3” High Temperature Center Belt (36” Base) 2” Swivel Casters Zeus Button (Cover Fasteners) Zeus Retainer Spring Drive Motor Drive Motor Belt Vacuum Pump Vacuum Pump Filters Vacuum Pump Supply Hose D0007-01 D007-02 D0021 D0036 D0037 D0013 D0013-01 D0013-02 D0013-03 D0014 D0015 D0020 D0079 D0016 D0006 D0010 D0070 D0070-01 D0071 34 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician! Dryer Base Notes NOTES: 35 Rena Systems, Inc. Rev. 8/05 XPS-ProDry Dryer Base NOTE: To be performed ONLY by a qualified field service technician!