Model 6040 User’s Manual Dry-IR Infrared Dryers Publication #: 107103-002 Rev. 1 March, 2004 Another quality product from: 7128 Shady Oak Road, Eden Prairie, MN 55344 Phone: (952)949-9009 Fax: (952)949-9559 E-mail: sales@researchinc.com www.researchinc.
Dry-IR MODEL 6040-16 USER’S MANUAL 107103-002 REV. 1 REVISION HISTORY REV 1 ECN NO xxxxx DESCRIPTION Initial Release DRAFT CHKR ENG. JAR JAR JAR Copyright © 2003 by Research, Inc. All rights reserved. Under copyright laws, neither the documentation nor the software may be copied, photocopied, reproduced, translated, or reduced to any electronic medium or machine-readable form, in whole or in part, without the prior written consent of Research, Inc.
Dear Valued Customer: Thank you for purchasing a Model 6040 Dry-IR infrared dryer. We believe it is the finest heating system of its type and are confident you will think so also. This instruction manual has been carefully prepared to ensure you will be able to easily install and operate the Model 6040 dryer and to fully realize all its inherent capabilities. We invite your comments as well as any issues you may have regarding this manual or the Model 6040.
Model 6040 Dry IR Drying System Instruction Manual Table of Contents Section 1 – Introduction…………………………….…… 1 Section 2 – Safety………………………………………… 2 Section 3 – Installation……………………………………5 Section 4 – Operation Instructions……………………..11 Section 5 – Maintenance………………………………….13 Appendix A – Dimensions and Specifications………..15 Appendix B – Spare & Replacement Parts…………….17 Appendix C – Optional Tachometer Kit……………….. 20 Appendix D – Schematic Drawings……………………..
Model 6040 Dry IR Drying System Instruction Manual Section 1 - Introduction The Model 6040 Dry-IR Drying System is specifically designed to dry ink-jet printing. On many types of coated stock, the water or solvent base of the ink is not easily absorbed by the material. Instead, it remains on the surface in a liquid state and is easily smeared if touched. The Dry-IR heater module provides the heat and air flow necessary to convert the liquid to vapor, and quickly remove it from the surface of the paper.
Model 6040 Dry IR Drying System Instruction Manual Section 2 – Safety General The Model 6040 Dry-IR Drying System is designed for safe operation. Nevertheless, installation, maintenance and operation of the system can be dangerous for a careless operator or maintenance person. For your safety and the safety of others, please read the instructions in this INSTRUCTION MANUAL and follow these safety practices, which will help to prevent accident or injury.
Model 6040 Dry IR Drying System Instruction Manual Fire Safety . CAUTION! • • • • Jams or stoppages in the transport may cause a FIRE HAZARD. NEVER operate the system unless an operator is present at all times. NEVER operate the system without a FIRE EXTINGUISHER in the immediate area. REMOVE all paper from under heater module IMMEDIATELY if the transport stops or jams. Even though the lamps are turned off, RESIDUAL HEAT may still ignite paper.
Model 6040 Dry IR Drying System Instruction Manual The HIGH VOLTAGE label is a yellow label indicating a potentially hazardous situation that could result in injury. The international “lighting bolt” symbol is used on the 6040 to indicate that high voltage is present inside the enclosure. All power cords to the product must be disconnected before servicing the product or replacing the lamps.
Model 6040 Dry IR Drying System Instruction Manual Section 3 - Installation CAUTION! • Please read the installation instructions carefully. It is important that the Model 6040 is installed correctly or important safety features will not be operational. Tools Required 1. Phillips screwdriver 2. Straight blade screwdriver Mechanical Installation There are 4 - 5mm (10-32) mounting holes on each end of the heater for mounting the unit. See Appendix A for dimensions.
Model 6040 Dry IR Drying System Instruction Manual 4. Insert the lamp lead wire into terminal blocks 1TB1-4 and 2TB1-4 and tighten the screw terminal. Make sure that the terminal block is not tightened on the insulation of the wire. 5. When all of the lamps have been installed, check for electrical shorts to the heater’s metal chassis and then replace the air deflectors and front cover. Figure 3-1. Model 6040 Spring Clip and Terminal Block locations.
Model 6040 Dry IR Drying System Instruction Manual Note: The Model 6040 will not operate unless a transport signal is supplied to the interlock circuit. Typically, an interlock cable is supplied from the transport and is connected on top of the blower housing, near the ON/OFF switch. WARNING! • Disconnect the power to the heater module before proceeding. To connect the interlock to the transport: 1. Remove the gray connector from the top of the unit. 2.
Model 6040 Dry IR Drying System Instruction Manual Section 4 - Operation Instructions Note: The lamps in the heater module will respond very quickly when turned on, but the most effective drying results will occur after the heater module has been on for about 45 to 60 seconds. This allows the heater module enough time to start producing hot air. Once the Dry-IR Drying System has been properly installed, it is very easy to operate.
Model 6040 Dry IR Drying System Instruction Manual Auto Mode (Closed Loop Control) The process controller comes with default settings for 0-10 vdc (user set 1) and a type K thermocouple (user set 2). The controller allows a large variety of inputs that can be used to control the process. If you are using something other than a 0-10 vdc or type K thermocouple input as the process control, see the Watlow users manual for details on how to set up the controller for different types of input.
Model 6040 Dry IR Drying System Instruction Manual Section 5 – Maintenance In dusty environments the lamps and impeller blades should be inspected occasionally for a cloudy buildup. When this occurs it is recommended that they be cleaned. Doing so will extend the life of the lamp and improve the system’s overall performance. Use the following procedure: WARNING! • Disconnect all power cords from the power sources and allow the heater to cool at least 15 minutes before continuing.
Model 6040 Dry IR Drying System Instruction Manual Troubleshooting PROBLEM Lamps do not come on SOLUTION Make sure the fan is spinning. Check that the supply voltage is 240 VAC. Check the Interlock connection. Power must be applied to the interlock before the lamps will turn on. Make sure that the proper relay is installed. Make sure that the heater is in the heating position. Check the tach signal. The tach signal should be 0-10 VDC, 0 is lamps off 10 V is maximum power. Set the heater to manual mode.
Model 6040 Dry IR Drying System Instruction Manual Appendix A Dimensions and Specifications 12
Model 6040 Dry IR Drying System Instruction Manual Figure A-1. Model 6040 Dimensions. Maximum Drying Width Overall Length Heated Length Lamps (4 Total) Lamp Rated Voltage Applied Lamp Voltage Amps at Applied Voltage KW at Applied Voltage Blower Air Volume Interlock Relays Mounting Hardware Operator Controls Operation Interrupts Site Requirements 4 inches (102 mm) 15 inches (381 mm) 10 inches (254mm) 1000W-Rapido-COLL-14OAL 240 volts 240 volts 18.0 amps 4.0 KW 75 CFM (2.
Model 6040 Dry IR Drying System Instruction Manual Appendix B Spare & Replacement Parts 14
Model 6040 Dry IR Drying System Instruction Manual 15
Model 6040 Dry IR Drying System Instruction Manual Figure B-1. Model 6040 Spare & Replacement Parts.
Model 6040 Dry IR Drying System Instruction Manual COMPONENT NO.
Model 6040 Dry IR Drying System Instruction Manual Appendix C Installing the Optional Tachometer Kit The dryer may be mounted on a variety of equipment configurations. If the tachometer supplied with the Dry-IR system is used (Fig. C-1), it must be properly installed so that it will send a “speed signal” to the control box ranging from zero volts when the conveyor is stopped to 10 volts when the conveyor is at full speed.
Model 6040 Dry IR Drying System Instruction Manual Appendix D Schematic Drawings 19
