User Manual
Contents
1. Switch the main power switch to 1 position on the cooling fans in the dryer module will turn on Additionally all Status LED s are blinking red one after the other for a short time Turn on the mailbase or web transport thus supplying the proper control voltage to the NIR120 M module and allowing operation of the NIR emitters Slowly turn the power level selector clockwise until a steady glowing light is visible under the NIR dryer module Start the inkjet printing system printing and make test prints at the desired running speed Rotate the power level selector clockwise until the test prints reach the optimal drying quality Call 1 262 790 9100 US or 49 8061 395 0 GER for detailed information Version 3 0 Page 26 of 35 adpho 8 Maintenance A Danger Electric shock hazard Maintenance of electrical components to be performed only by trained electricians Before disconnect the mains connector at the NIR120 M in case of handling or maintenance the module must be switched off and physically disconnected from the main adphos NIR drying systems are designed to require minimal maintenance The following components as described in table 11 should be checked according to the specified service interval Table 11 Service intervals of components NIR oa oa EO system 1 Error alarm condition ma status LED s during operation 2 Reflector of the NIR dryer 2 weeks Visually inspect the reflector for2. 4 3 1 Fastening kit included adphos no 735 640 To attach the NIR120 M on the mount arm optional adphos no 735305 a special fastening kit is assembled The kit consists of two brackets with a sliding nut and a lock washer each Elongated holes in the brackets allow for adjusting of the mounting angle by up to 3 between the arm and NIR120 M x The fastening kit can be used to affix the module at the four fastening points described in chapter 3 3 see figure 3 Call 1 262 790 9100 US or 49 8061 395 0 GER for detailed information Figure 3 mounting the fastening kit at the NIR120 M module Version 3 0 Page 10 of 35 adpho 4 3 2 Mount arm optional adphos no 735 305 The optional mount arm is a modified Item profile size 8 with a length of 870mm and a frontal center thread M8 15mm M8 0 6 deep on one side for the handle gt 870 A gt lf needed the arm can be cut to a customized length Watch out for threaded side Call 1 262 790 9100 US or 49 8061 395 0 GER for detailed information 4 3 3 Light shield optional adphos no 735 294 The optional available light shield is shown in fig 6 and can be mounted at the base of the NIR120 M drying modules to avoid a possible blinding of the operator by the intensive light emission of the NIR Emitter The physical dimensions of the light shield are 11 5 292mm in width x 20 507 5mm in length To mount NIR120 M modules side by
3. IRS environment 40 C IRL CPU green 65 C IRL controller 85 C blinking green fast one or several emitters are not working power too low or too high blinking red fast device is locked an error occurred while the device was running or has been suspended the pushbutton must be pressed to unlock the device 4 10 USB interface The internal USB interface is only installed in the NIR120 M2 NIR120 M3 and NIR120 M4 version and will be used for parameterization and customizing the accordingly NIR120 M drying system Call 1 262 790 9100 US or 49 8061 395 0 GER for detailed information Version 3 0 Page 23 of 35 adpho gt 5 System installation Important During operation of the drying systems significant heat will be produced in the proximity of the dryer module The installation location of the dryer module must be selected in such a way that no damage will be caused to the production line or objects in the surrounding area by the thermal effects of the drying system s When mounting the dryer module on a web transport make sure no components may be damaged by the thermal effects both beneath and to the sides of the web When mounting the dryer module on a sheet feed transport make sure to use high temp transport belts and ensure that the top deck of the transport is suitable for high temperatures A Danger Electric shock hazard Installation of NIR drying systems to be performed by trained personne
4. module dust dirt and damage 3 NIR emitter Monthly Visually inspect the emitter s for dust dirt and damage 4 Wiring Monthly Visually inspect all wires and cables for damage 8 1 Cleaning of NIR emitter For cleaning the NIR emitter follow the instructions below step by step Before cleaning remove the dryer module s and place on a soft pad to avoid damage NIR emitters are only be touched or handled with A protective clean cotton gloves Sebaceous residues on the glass surface will reduce operation time dramatically Before cleaning the emitters remove them out of the dryer module To remove the emitters out of the dryer module with cotton gloves gently grab the emitter on both ends by the 90 degree bend in the emitter and pull the emitter straight out of the dryer module Avoid touching of the emitter contact to the reflector optional emitter extraction tool adphos part number 726 174 Version 3 0 Page 27 of 35 adpho Light contamination can be removed with water and or Isopropyl alcohol Persistent contamination can be removed with a gentle polishing paste See opposite figure If after cleaning the quartz glass bulb is still cloudy or damage is visible specifically by the contact area the emitter should be replaced To reinstall the emitters be sure that the connecting contacts at the ends of emitters are straight and not bent straighten them if bent Insert the clean NIR emitter into refl
5. cleaning of NIR reflector by slightly damp micro fiber cloth Generally for each NIR reflector a clean soft und lint free cleaning tissue e g cotton tissue should be used Do not apply force during cleaning and do not try to remove insistent contaminations by using sharp objects as damage to the reflector surface will occur Version 3 0 Page 29 of 35 adpho 8 3 Replacement of NIR reflector s A BEUH Electric shock hazard Maintenance of electrical components to be performed only by trained electricians Before disconnect the Souriau UTS connector in case of handling or maintenance the module must be switched off and physically disconnected from the main Note Before cleaning remove the dryer module s and place on a soft pad to avoid damage Remove NIR emitter first see chapter 7 1 If contaminations cannot get removed from the surface the reflector must be replaced Therefore follow the instructions below step by step mnie NE reflector is fixed on the module by 4 screws inside the NIR120 M drying module The access is carried out by 4 holes in both long sides exterior plates see opposite fig To bold the screws use a Phillips recessed head screwdriver size PHX Turn the screwdriver counter clockwise and unscrew the screws up to the stop The opposite figures shows the position of the screws tighten a and bold b Version 3 0 Page 30 of 35 adpho Extract the refl
6. greater or equal than 1 Status LED pushbutton red green a start signal has been detected and the device is running now the requested power still may be 0 blinking red vs device is not ready an error condition holds green blinking red device is initialising blinking green device is suspended the button must be pressed to resume the device yellow temperature error temperature switch set blinking yellow vs temperature threshold reached IRS environment 40 C IRL CPU green 65 C IRL controller 85 C blinking green fast blinking red fast device is locked an error occurred while the device was running or has been suspended the pushbutton must be pressed to unlock the device Version 3 0 Page 34 of 35 adpho gt 11 2 Trouble shooting list Failure Cause Display status LED Action _ _ NIR emitter doesn t work Module not connect with main First plug Souriau connector into socket second connect power cable to main Main switch in 0 position off P Set main switch to 1 position on Main power out of range Al blinking red fast Check the main source AO blinking red fast Module not in horizontal position Pi red Set module in horizontal position Pb blinking red fast Press push button to unlocked the dryer Remote I O contact open Check the Remote I O signal AO red a control voltage gt 100 mV DC Control voltage more the 11VDC AI blinking red fast Check the control vo
7. of the NIR120 M drying module will permanently check the applied power voltage lf the power voltage is out of the specified range the module will be locked and the status LED of the analog input and output as well as the status LED near the push button will be blinking red fast If this error occurs check your main and connect the NIR120 M dryer to the correct main power 4 5 2 Emitter power monitoring NIR120 M dryers can be equipped with emitters of different power classes The installed power of the emitters must not exceed the total power of the dryer A permanent emitter power monitoring prevents damage to the NIR120 M1 NIR120 M2 and NIR120 M3 drying systems due to using NIR emitters out of the specified range If the system detects emitters with too much power the dryer will be locked and the LED near by the push button will blink green This fault cannot be reset by any function You will need to shut down the system and install a correct NIR emitter set 4 5 3 Input Output control signal monitoring An internal controller monitors the incoming and outgoing signal of the NIR120 M dryer The majority of incorrect signals will be detected and signalized with the status LEDs See troubleshooting Wrong polarity at input signal Too high at input signal voltage or resistance Too high current at output signal circuit Voltage at Remote on off _ Notice Three color LED combinations will inform the user when incorrect si
8. 9 Push button 4 10 USB interface System installation Operation 6 1 Tachometer operation Adjustment of the dryer 7 1 General 7 2 Adjustment procedure Maintenance 8 1 Cleaning of NIR emitter 8 2 Cleaning of NIR reflector 8 3 Replacement of NIR reflector s 8 4 Maintenance kit optional Component and spare part list 9 1 NIR120 M1 and NIR120 M2 9 2 NIR120 M3 9 3 NIR120 M4 Optional equipment and maintenance material Troubleshooting 11 1 Meaning of the status LED s 11 2 Trouble shooting list Version 3 0 Page 3 of 35 adpho O OOoOmiinnnt vn vn OD DWN WN WwW U U WwW WWW we wWwowns YN NY NNN NN NN NY N NN N e h FE U AA WwWWwWNN NN FP OO WON NN ODO DU UN RW WDN FP DD UE W Certificate of compliance CERTIFICATE OF COMPLIANCE ISO TYPE 3 CERTIFICATION SYSTEM Dryer System NIR120 Mx x stands for 1 2 3 or 4 Adphos Innovative Technologies GmbH Bruckmuehler Strasse 27 Bruckmuehl Germany 83052 Name and Address of Manulacturer Factory Adphos Innovative Technologies GmbH Bruckmuehler Strasse 27 Gruckmuehl 240 Vac 50 60 Hz 13 A for NIR120 M1 and NIR120 M2 25 A for NIR120 M3 36 A for NIR 20 M4 A sample of the Product was tested and CSA 22 2 No 00950 1 07 UL 60950 1 2007 found to 2 nd Edition for information Technology ba in compliance with Equipment Safety As shown in Certification Report No LR11417 6 5 Products in compliance with the
9. B Option to be configured e Power relation to output signal e g 0 10V DC 0 100 power Call 1 262 790 9100 US or 49 8061 395 0 GER for detailed information Damage of the module by connecting an input voltage Never connect input voltage to the control voltage out connector To use the external control voltage from the control voltage out connector of the NIR120 M drying module use a red standard industrial RCA plug The standard configuration of the RCA plug is Pin1 pin contact wire and pin 2 annular contact wire Table 6 meanings of status LED control voltage output Blinking red fast Supply voltage or output voltage are out of range Red Output value is less than 1 Output value is greater than or equal to 1 Version 3 0 Page 18 of 35 adpho 4 6 3 Remote I O yellow color Do not use the NIR120 M module with a jumpered Remote I O In case of an unforeseen belt or paper stop the NIR module will not shut down Damage of the module by using a control voltage for the Remote O Connect the Remote I O only to a non potential contact in the machine control Link the Remote I O signal with your paper web transport so that Remote I O signal is active only during working paper web transport By using the Remote I O the NIR emitters can be switched on and off by an external control signal from a conveyor system mailerbase or web system The Remote I O requires a potential free dry co
10. Certification Report are eligible to bear the QPS April 1 2011 Evaluation Services Inc Dete 81 Kelfield St Units 7 9 Toronto ON Canada EE aan TFT AARE iy Li Version 3 0 Page 4 of 35 adpho 1 Indented use The adphos NIR120 M series drying systems were developed for complete and secure drying of water based and soft solvent non flammable inks for continuous and drop on demand inkjet systems lt was designed for build in use in commercial printing devices Fire hazard The drying of hard solvent based flammable inks and the use in hazard areas are not permitted with this adphos NIR drying system configuration For solvent applications special available NIR systems are required Call 1 262 790 9100 US or 49 8061 395 0 GER for detailed information The standard mounting position of the NIR120 M x drying system is horizontal see chapter 3 3 As a result of the special design the modules can be mounted in any orientation parallel to the paper surface Depending on operating conditions the NIR drying power of the module is adjustable by varying the input signal and additionally the onboard power level selector 2 NIR120 M series The NIR 120 M series is available in four different versions They differ in the installed maximum NIR Emitter power and in the capability to control the drying system via USB interface see table 1 The version is listed on the type plate at the backsi
11. User Manual NIR120 M series Serial No gt 10240 Version 3 0 USA_UL adphos 6 August 2013 Innovation in thermal processing adpho Thank you for purchasing an adphos NIR drying system This manual will help to show the proper installation operation and maintenance of your NIR drying system and how it can be safely and efficiently operated with your inkjet printing system NIR drying systems were developed with regard to the highest safety standards Proper installation operation and maintenance of the system never places trained operators or maintenance personnel at risk For your own safety and the safety of others please read the following procedures in this manual and follow all safety instructions adphos Innovative Technologies GmbH Bruckmuehler Str 27 83062 Bruckmuehl Heufeld Germany Phone 49 8061 395 0 Fax 49 8061 395 395 Technically Trained Representation adphos North America Inc 3490 North 127 Street Brookfield WI 53005 USA info adphosna com Phone 1 262 790 9100 Fax 1 262 790 1132 Version 3 0 Page 2 of 35 N a 10 11 Indented use NIR120 M series General safety instructions 3 1 Symbols 3 2 Safety 3 3 High Temperature 3 4 Electrical voltage 3 5 NIR radiation System description 4 1 General 4 2 NIR Emitter 4 3 Mounting 4 4 Electrical connection 4 5 Monitoring functions 4 6 Control elements 4 7 Inclination sensor 4 8 Power level selector 4
12. cates them to the user The USB interface allows updates diagnostics remote control parameterization and customizing of the NIR120 M2 3 4 drying systems An integrated inclination sensor senses the actual 3D position and reacts accordingly to avoid an accidental switch on of the drying system in a non operating position e g during maintenance 4 2 NIR Emitter The NIR radiation is generated by a special NIR emitter which includes a tungsten filament which is heated up to 3000K by an electrical voltage To increase the lifetime of the emitters a small amount of halogen gas is added All materials used to manufacture the emitters are environmentally friendly Burned out or broken emitters can be disposed of as part of regular household waste No special disposal is required The chemical compounds tungsten halides deposition of tungsten at the quartz glass which may build up during improper use are harmless in these concentrations Injuries can occur through the breakage of the quartz glass tube Wear protection gloves and eye protection when handling broken emitters or glass parts to avoid injuries Wear clean cotton gloves optional adphos no 403 166 when handling NIR emitters Greasy residues on the glass surface will reduce operation time dramatically Clean emitters with water and or Isopropyl alcohol before inserting into module Note Use original adphos emitters only Use correctly specified emitter Each adph
13. de of the dryer top Table 1 available NIR120 M versions Version Emitter power Total power USB adphos no class max interface module only NIR120 M1 LB 11 230V 3 kW 735 891 NIR120 M2 LB 11 230V 3 kW yes 735 892 NIR120 M3 NB 21 230V 5 8 kW yes 735 893 NIR120 M4 HB 31 230V 8 3 kW yes 735 894 Version 3 0 Page 5 of 35 adpho 3 General safety instructions 3 1 Symbols Different symbols are used in this user manual to point out potential risks during op eration or maintenance of NIR drying modules Table 1 shows the symbols used and their meanings These symbols are also placed on appropriate parts of the drying system Please adhere to the safety instructions and procedures described in this manual Table 1 Symbols and their meanings Attention Exclamation point This symbol is used for safety notes Attention hot surface do not touch Every attempt has been made to keep all surfaces as cool as possible However some surfaces such as emitters and reflectors can become very hot so that serious burns can occur by touching these areas Attention electrical voltage Only electrical trained personnel is allowed to work at current carrying parts Before starting work the complete drying system has to be strictly cut off from power and power cables have to be disconnected Attention NIR radiation This sign indicates a possible hazard by NIR radiation during the drying process Generally NIR radiation d
14. ector LWR 1 736 142 1 complete for NIR120 M3 oO 2 NIR Emitter LB 11 230V 1 1kW 735 679 2 NIR Emitter NB 21 230V 2 1kW 735 677 9 3 NIR120 M4 Description Quantity adphos Parts list order no position NIR120 M43 drying module without NIR 735 894 emitters 735 679 135 677 1 NIR Emitter LB 11 230V 1 1kW 2 NIR Emitter NB 21 230V 2 1kW 2 NIR Emitter HB 31 230V 3 1kKW Light Weight Reflector LWR pt meme complete for NIR120 M4 _ 2 _ 2 O Version 3 0 Page 32 of 35 adpho 10 Optional equipment and maintenance material Description Quantity adphos Maintenance materials Option order no NIR protective goggles 408 857 NIR emitter removal tool 126 174 cotton gloves 1 package 403 166 Complete maintenance set in a case includes 1 712 373 NIR protective goggles Emitter removal tool Cotton gloves Cleaning paste for NIR emitters 11 Troubleshooting A BEUH Electric shock hazard Maintenance of electrical components to be performed only by trained electricians Before disconnecting the Souriau UTS connector in case of handling or maintenance the module must be switched off and physically disconnected from the main If issues cannot be solved by using the troubleshooting matrix described below call the central adphos service point pohone 49 8061 395 0 or 1 262 790 9100 Version 3 0 Page 33 of 35 adpho 11 1 Meaning of the status LED s value is
15. ector aSSEmay upward green yellow grounding wire and two brown wires for the 2 thermo switch to the control unit First strip the ground cable from the contact tab at the edge the long side plate a Then strip both cables from the thermo switch in the middle of the reflector unit b Now the reflector unit can be replaced with a new one The assembly of the module i a Fa with the new reflector will be 2 carried out in the reverse order Make sure that the edges of the module housing see arrows in c are completely fitted in the framed notch of the reflector assembly d Finally tighten the four screws as described above 8 4 Maintenance kit optional Required tools and materials except liquid solvents and micro fiber cloth are arranged in an optional maintenance kit adphos no 712 373 Call 1 262 790 9100 US or 49 8061 395 0 GER for detailed information Version 3 0 Page 31 of 35 adpho 9 Component and spare part list 9 1 NIR120 M1 and NIR120 M2 Description Quantity adphos Parts list order no position NIR120 M1 drying module without NIR emitters NIR120 M2 drying module without NIR 735 892 emitters na Light Weight Reflector LWR 735 353 1 complete for NIR120 M1 or NIR120 M2 NIR Emitter LB 11 230V 1 1kW 9 2 NIR120 M3 Description Quantity adphos Parts list order no position NIR120 M3 drying module without NIR 735 893 emitters Light Weight Refl
16. ector by taking the emitter in both hands wearing protective cotton gloves and plug the contacts completely into the jackets of both ends of the reflector until the contacts are securely in place be sure not to force or jam the contacts into the jackets Important New emitters should always be cleaned with alcohol to remove any possible contaminants which may have been deposited during the manufacturing shipment and storage of the emitters 8 2 Cleaning of NIR reflector Electric shock hazard Maintenance of electrical components to be performed only by trained electricians Before disconnect the NIR20 M main connector in case of handling or maintenance the module must be switched off and physically disconnected from the main Note Before cleaning remove the dryer module s and place on a soft pad to avoid damage Remove NIR emitter first see chapter 7 1 Note Avoid any flow or contamination of water or cleaning agents into the module A damage of the module will occur NIR reflectors are manufactured out of specially coated aluminum sheets Contamination of the reflectors results in a reduction of reflectivity which under certain circumstances can damage the reflectors or cause over temperature emergency stop Version 3 0 Page 28 of 35 adpho Clean NIR reflectors only with a slightly damp micro fiber cloth see fig 13 to prevent any damages on the electrical components of the module Figure 13
17. ed via USB Option to be configured e Enable disable e Function Call 1 262 790 9100 US or 49 8061 395 0 GER for detailed information Table 9 meanings of the different indicators for the power level selector Potentiometer disabled Value is greater than or equal to 1 Version 3 0 Page 22 of 35 adpho 4 9 Push button The push button is located below the power level selector see figure 11 The push button will be used to unlock the NIR120 M dryer after any system error It can also be used by the operator to lock the operating NIR120 M dryer manually remote I O closed To restart the dryer push the button again remote I O closed Note for NIR120 M2 NIR120 M3 NIR120 M4 These models can be configured via USB Option to be configured e Enable disable e function Call 1 262 790 9100 US or 49 8061 395 0 GER for detailed information Table 10 meanings of the different indicators for the power level selector Status LED pushbutton red device is ready and is waiting for a start signal green a Start signal has been detected and the device is running now the requested power may still be 0 blinking red vs device is not ready an error condition remains green blinking red device is initializing blinking green device is suspended the button must be pressed to resume the device yellow temperature error temperature switch set blinking yellow vs temperature threshold reached
18. gnals are detected Damage cannot be ruled out Follow manual instructions for the control elements Version 3 0 Page 15 of 35 adpho 4 6 Control elements All control elements of the NIR120 M drying modules are located on the top right of the NIR120 M drying modules The control elements include RCA connectors for control voltage in and output an RCA connector for the remote I O a potentiometer a start push bottom and finally the USB plug socket There are also six multi LED indicator lamps for indicating the module status An overview of the control elements is shown in fig 11 The connectors for the control voltage input and output and remote I O are RCA connectors RCA jack Figure 11 control elements of the NIR120 M drying module Status LED D control input control input Status LED control voltage output control voltage output Status LED e I O remote I O Status LED inclination sensor power level selector Status LED power level selector push button Status LED push button on off USB interface 4 6 1 Input connector white color Damage of the module by using input voltage higher of 15 VDC or using AC voltage Use only a control voltage of less than 15 VDC In default configuration an external control input signal of 0 10 VDC 0 100 is required for operating the NIR120 M drying module The power of the emitters can also be aligned with the power level selector poten
19. l only Only a qualified electrician may connect the module to the main Remove packaging and check that the contents are complete and undamaged Check proper position of all three inserted emitters Attach the light shield at the module optional Check proper torque of all screws that are accessible from outside the module Mount the NIR dryer module on the line Make sure that the dryer module is parallel to the paper in a horizontal position and the distance to the paper surface complies with the specifications Mount the tachometer on the line according to the manual optional 7 Wire all cables as described in sections 3 4 and 3 5 Input signal Output signal Remote I O signal 8 Double check Remote I O function safety related function 9 Make sure the main power switch is in the Off position 10 Set the power level selector to the 0 position turn left as far as it will go 11 Plug the power cable into the NIR120 M before connecting the cable to the mains Mains line breakers must be open for connection 12 Close breakers to power mains connection 13 Switch the main power switch to 1 position on The cooling fans in the dryer module will turn on 14 Self test procedure of status LEDs 15 Turn on the mailbase or web transport thus supplying the proper Remote I O signal to the NIR120 M drying module and allowing operation of the NIR emitters 16 Be sure that a proper control voltage is applied c
20. ltage control voltage AO red max 10 VDC ee Pb blinking red fast Press push button to unlocked the dryer Power level selector O position Ps red Turn the knob clockwise until the emitter work correctly NIR emitters work but shut Temperature switch set Pb yellow Check the position of the module regarding down after a present time accessibility cooling air check the reflector regarding pollution Internal temperature threshold Pb blinking yellow vs Check the position of the module regarding reached green accessibility cooling air and environmental temperature Installed emitters out of the allowed Pb blinking green Install the correct emitter types range Pi Inclination sensor lO Remote I O Pb Push button Ps Power level selector Al Analog input PAO Analog output Page 35 of 35
21. ntact only For operation of the emitters the remote I O contact must be closed Do not attach AC or DC voltage directly to remote I O use Interface box Remote I O Table 7 meanings of status LED Remote I O Locked contact closed Version 3 0 Page 19 of 35 adpho 4 6 3 1 Interface Box Remote I O optional adphos no 736022 If a potential free contact dry contact is not available in the machine control a control voltage can be used in combination with the Interface box Remote I O see figure 12 The optional Interface box Remote I O consists of an electronic relay for control voltages in a range of 24 120 VDC VAC The relay is integrated in a plastic box A 16 feet 4 9 m long 2x 0 75 mm AWG 19 cable with cable end sleeves is available to connect the relay to the machine control A 4 5 feed 1 4 m long coaxial cable with a yellow RCA connector is provided as a connection to the NIR120 M drying module Figure 12 optional Interface box Remote I O Only a certified electrician may connect electric voltages in a range of 24 120 VDC VAC Version 3 0 Page 20 of 35 adpho 4 7 Inclination sensor An inclination sensor on the control board of the NIR120 M drying module watches the operating position of the module default configuration horizontal alignment If the positional deviates more than 10 from the horizontal the module will be locked The status LED turns red and the push button status LED
22. oes not damage human tissue However at close distances to the radiation source burns to the skin can occur Very close and direct view of the radiation source without eye protection can cause damages to the eyes Version 3 0 Page 6 of 35 adpho 3 2 Safety The adphos NIR drying systems are designed to be safe and effective when operated according to the guidelines outlined in this user manual As with other industrial systems there is a risk of personal injury if the products are not used according to the guidelines outlined in this manual Warning There is a risk of personal injury by improper use of this equipment The following sections include information regarding operational safety for different aspects of the dryer system Important To ensure safe operation of this unit personnel must be trained regarding the proper use of this equipment Installation and operation of the system according to the instructions as outlined in this user manual by properly trained personal will avoid unforeseeable safety risks 3 3 High Temperature In spite of the cooling of the high temperature NIR emitters the tem perature of the reflector system and parts of the housing will exceed 49 C 120 F Therefore do not touch the NIR drying module and assembled parts during and within five minutes after operation 3 4 Electrical voltage NIR emitters operate at a voltage of 230 VAC Do not replace NIR emitters or at
23. orrectly at the input control voltage connector 17 Slowly turn the power level selector clockwise until a glowing light is visible under the NIR dryer module Raising the power the visible light will turn from orange glowing up to bright white shinning at 100 power a ae a gt Version 3 0 Page 24 of 35 adpho 6 Operation 6 1 Tachometer operation Tacho or Speed signal Remote As described above the NIR dryer system can operate with an external control voltage To control the drying system proportional to the paper speed in an open loop control a control voltage in the range of 0 VDC and 10 VDC must be available If the control voltage is not available from the central controlling system now base or web transport an external tachometer must be mounted e g on a roller or conveyor Optional adphos tacho s Speed adphos item Adphos No m min ft min 15 246 Tachometerkit 75 m min 557153 100 328 Tachometerkit 100 m min 557155 150 492 Tachometerkit 150 m min 557156 Version 3 0 Page 25 of 35 adpho 7 Adjustment of the dryer 7 1 General Turn the power level selector and the main switch to the 0 position to avoid any damages of the paper Be sure that the module is mounted to the mailerbase or paper feeder properly 7 2 Adjustment procedure After successful installation the next step is to adjust the degree of dryness Therefore follow the next instructions step by step 1
24. os emitter is labeled on the left hand front side immediately after the 90 bend The label shows the power class and charge number underneath the adphos logo e g NIR LB 11 230V y1 1100W 230V production charge y1 Version 3 0 Page 8 of 35 adpho 4 3 Mounting Four fastening points with an M4 thread with screws are placed on the top side of the NIR module see figure 1 The distance between the threads is 4 13 105mm Note Use original screws with a thread length of maximum 0 3 8 mm only to avoid contact with built in components The maximum torque to fasten the screws is 2 Nm 1 5 ft lb Figure 1 Fastening points on the upper side of the NIR120 M module Befestigungsschrauben M4x10 Bedienpane Mounting screws M4xi0 Control pane To ensure proper operation of the dryer the distance between paper and bottom edge of the module must be a minimum of 0 2 5 mm Due to NIR radiation the surface temperature opposite the modules could exceed 120 F 49 C Do not touch the surfaces during operation Ensure that no thermally sensitive devices are present in the heating area For the drying of large scale papers two NIR120 M can be mounted side by side Do not place the modules directly side by side since this will result in cooling problems Instead stagger them as shown in figure 2 for a proper cooling Version 3 0 Page 9 of 35 adpho Figure 2 Two drying modules mounted side by side
25. rth America Inc 3490 North 127 Street Brookfield WI 53005 The connection of the power cord to the NIR120 M module is carried out by a Souriau UTS connector 3 Pin Note The module may only be connected to the main power supply by using a 3x 6 mm AWG 10 UL approved cable National standards and regulations on ampacities must be observed Call 1 262 790 9100 US or 49 8061 395 0 GER for detailed information Version 3 0 Page 13 of 35 adpho 4 4 3 Main power connector The main power connector is located on the left side of the upper edge of the NIR120M module Figure 8 main connector of NIR120 M dying modules 4 e src in assignment see fig 9 b DF h ai Read manual before use Figure 9 pin assignment of Souriau UTS connector plan view of the mounted male connector aH o Electric shock hazard Before handling connecting or disconnecting the Souriau UTS connector in case of service or maintenance the module must be switched off and physically disconnected from the main electrical supply 4 4 4 Main power switch The main power switch is located on the left side of the upper edge of the NIR120 M module see figure 8 and serves for connecting the power to the drying system Two conditions are available Table 3 Conditions of the main switch poson contin Version 3 0 Page 14 of 35 adpho 4 5 Monitoring functions 4 5 1 Power supply monitoring The controller
26. side both shields on the side can be folded up as shown in fig 6 Figure 6 optional light shield To mount the light shield on the lower edge of the NIR120 M drying module unscrew the mounting screws on the long side until the screws latch into the four supports of the shield see fig 7 Then tighten the four screws evenly with a maximum torque of 2 Nm 1 5 ft Ib Figure 7 fastening of the light shield on a NIR120 M module tre IOI Note e If a customized light shield is used the light shield must not prevent the cooling air from exiting the dryer module This may cause overheating Call 1 262 790 9100 US or 49 8061 395 0 GER for detailed information Version 3 0 Page 11 of 35 adpho 4 3 4 Mount optional adphos no 735 294 The optional available mount is designed for a safe and quick on site positioning of the NIR120 M with the mount arm 735305 The mount has a total height of 16 5 419 mm and a square base of 4 6 117mm To fix the mount on the machine base four mounting holes with 0 33 8 5mm in diameter are integrated in the square base Figure 4 mount 5 cg S oe LA oA The mount consists of a tie bar 1 with a movable attachment 2 for the mount arm 735305 The mount arm will be fixed to the attachment with four sliding nuts Cables will be fixed with cable ties at the 3 fixing points 4 on top of the arm To adjust the correct distance to the paper the a
27. tempt to repair drying systems with electrical power running to the units Before replacing NIR emitters opening the power cabinet or removing any protection plates make certain there is no electrical current going to the power cabinet 3 5 NIR radiation NIR emitters send out an electromagnetic spectrum with a wavelength around 1um Because of the high yield of visible light during operation do not look directly into the radiation source without eye protection Looking directly at the radiation source may cause eye damage lf direct exposure of the light to the eyes occurs please seek medical attention immediately For further protection wear class 4 protective goggles optional adphos no 008857 To minimize the NIR radiation to the surrounding area use optional light shield Version 3 0 Page 7 of 35 adpho 4 System description 4 1 General The NIR120 M is a high power drying system with intelligent dryer control The module has a drying width of 4 7 120mm and a drying length of 9 8 250mm Each module is 5 6 143mm wide x 14 6 370mm long x 9 5 241mm high It consists of the housing with the control power unit a high efficiency reflector and three adphos NIR emitters The module is cooled by an internal fan and additionally monitored by a thermostat and three temperature sensors An integrated onboard CPU supervises most drying functions reacts to operating situations and reports indi
28. tiometer To connect your external control voltage to the NIR120 M drying module use a white standard industrial RCA plug The standard configuration of the RCA plug is Pin pin contact wire and pin 2 annular contact wire lf the maximum external control voltage signal is higher than 10 VDC the status LED near by the input connector will be blinking red fast Version 3 0 Page 16 of 35 adpho Note At the output connector red color a constant voltage of 10 VDC is applied If external control voltage is not available this constant control voltage output of the module can be used for the input voltage signal Use a cable with two standard industrial RCA plugs and connect the control input connector white to the internal output connector red To adjust the power of the dryer dependent upon print speed an external control voltage from a tachometer or other device can be also applied Table 4 meanings of status LED control voltage input Blinking red fast Supply voltage or input voltage are out of range Input value is less than 1 Input value is greater than or equal to 1 Version 3 0 Page 17 of 35 adpho 4 6 2 Control voltage output connector red color The control voltage output is a voltage signal Use a minimum resistance of 10kKOhm At the control voltage output connector a constant voltage of 10 VDC is applied Note for model NIR120 M2 NIR120 M3 NIR120 M4 These models can be configured via US
29. ttachment can be adjusted over a range of 2 4 60 mm in height with the crank handle 3 on the top of the tie bar To get easy access to the paper the position of the module to the substrate can be changed and fixed in three positions see fig 5 To do so the latching bolt 6 on the side of the tie bar must be pulled and then the mount arm can be tilted by lifting the handle 5 to the designated position see fig 5 Call 1 262 790 9100 US or 49 8061 395 0 GER for detailed information Figure 5 operating and two maintenance positions of the mount 0 operating position 45 maintenance position 80 maintenance position Version 3 0 Page 12 of 35 adpho gt 4 4 Electrical connection A Danger Electric shock hazard Only a certified electrician may connect the NIR120 M system to the main electrical panel It is only allowed to terminate the NIR drying system to mains specified on the type plate max voltage current frequency 4 4 1 Main power supply The NIR120 M drying modules are designed for use with 230 VAC 2 phase 5OHZ 60Hz mains 1PE Depending on the NIR dryer type the following fuse rates for external line breakers both lines are required table 2 Table 2 Required voltages and fuse rates for the different NIR120 M versions 2 phase NIR120 M4 230 VAC 50 or 60Hz 10 2 phase 4 4 2 Main power cord cable To order your customized main power cord get in contact with adphos No
30. will blink red To unlock put the device in the operating position and push the push button both status LEDs will turn green Note for NIR120 M2 NIR120 M3 NIR120 M4 These models can be configured via USB Option to be configured e Operating position e Tolerance of inclination angle Call 1 262 790 9100 US or 49 8061 395 0 GER for detailed information Table 8 meanings of status LED Inclination sensor Blinking red fast Signal from sensor is invalid e g not calibrated Red Out of operating position module ready In operating position module is ready or running Version 3 0 Page 21 of 35 adpho 4 8 Power level selector The power level selector is a potentiometer located below the Remote I O connector see figure 11 By rotating the knob of the potentiometer the power of the drying system will be adjusted The effect of adjustment depends on the kind of external control voltage default lf a constant external power control of 10 VDC is used the power of the NIR dryer continuously varies between 0 and 100 of the possible drying power default lf a variable external control device e g tachometer signal is used the potentiometer is used to tune the power for the external control voltage for the drying power Detailed information can be found in chapter 3 5 1 Optimal adjustment of the dryer is described in chapter 7 Note for NIR120 M2 NIR120 M3 NIR120 M4 These models can be configur
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