User Guide

Document Version: 2.0

Document Reference: Dual-UG
Produced: OCT 2018
 User Guide [2]

Copyright

2018 Adelco Screen Process Ltd. All rights reserved.

No part of this publication may be reproduced, transcribed or translated into any

language or computer language, in any form or by any means, electronic, mechanical or
otherwise, without prior written permission of Adelco Screen Process Ltd.
 User Guide [3]

Dear Valued Customer

Thank you and congratulations on the purchase of your new Dual dryer.

The Adelco Dual dryer is a highly efficient and economical dryer for drying/curing a
wide range of screen and digitally printed substrates. The Dual is suitable for virtually
all types of screen-printing and digital inks from water based to Plastic textile inks,
solvent based and enamel inks and in other screen-printing and industrial applications.

This manual seeks to illustrate to you, the customer, in the operation of the dryer.

By understanding its operation it will help ensure your Dual dryer has a long and
productive life.

However, should you have any technical questions concerning your dryer, then please
do not hesitate to contact our Technical Sales Department for further information.

Meanwhile, may we assure you of our best attention at all times and inform you that
Adelco are always available to discuss any screen-printing, digital printing or drying
application that may arise.

Yours faithfully,
ADELCO SCREEN PROCESS LIMITED
 User Guide [4]

TABLE OF CONTENTS
CHAPTER 1: IMPORTANT NOTICES.................................................................................................. 5
1.1 IMPORTANT INFORMATION............................................................................................................... 5
1.2 IMPORTANT NOTICE.........................................................................................................................5
1.3 PRE-INSTALLATION NOTICE..............................................................................................................6
1.4 STANDARD FEATURES...................................................................................................................... 7
CHAPTER 2: UNDERSTANDING THE DUAL......................................................................................8
2.1 GAS TRAIN...................................................................................................................................... 9
2.2 MAIN MOTOR & AIRFLOW SWITCH...................................................................................................9
2.3 UV DETECTOR...............................................................................................................................10
2.4 EXHAUST VALVE............................................................................................................................10
2.5 CONVEYOR AUTO TENSIONER......................................................................................................... 11
2.7 TOUCHSCREEN OPERATION............................................................................................................ 12
CHAPTER 3: DRYER OPERATION....................................................................................................13
3.1 START UP PROCEDURE...................................................................................................................13
3.2 SHUTDOWN PROCEDURE................................................................................................................ 13
CHAPTER 4: MAINTENANCE............................................................................................................ 14
4.1 DAILY........................................................................................................................................... 14
4.1.1 CLEAN FILTERS...................................................................................................................... 14
4.1.2 CLEAN QUARTZ LENS............................................................................................................. 15
4.2 MONTHLY..................................................................................................................................... 16
4.2.1 CLEAN EXHAUST FANS............................................................................................................16
4.3 EVERY SIX MONTHS.......................................................................................................................17
4.3.1 CHECK V BELT........................................................................................................................... 17
4.3.2 CLEAN EXTRACTION FAN IMPELLER.............................................................................................18
4.3.3 CLEAN INSIDE JET DUCTS............................................................................................................19
4.3.4 CLEAN MAIN IMPELLER FAN........................................................................................................ 20
4.3.5 GREASE MAIN FAN BEARINGS..................................................................................................... 21
4.3.6 GREASE CONVEYOR BEARINGS.....................................................................................................21
4.3.7 GREASE SLIDING DOORS..............................................................................................................21
CHAPTER 5: SECTION FOR TROUBLE SHOOTING........................................................................22
5.1 CONVEYOR FAULT..........................................................................................................................22
5.2 EXTRACTION FAN INVERTER FAULT................................................................................................23
5.3 HIGH TEMPERATURE ALARM......................................................................................................... 24
5.4 TEMP DEVIATION ALARM................................................................................................................25
5.5 FLAME SIGNAL FAULT.....................................................................................................................26
5.6 FLAME FAULT................................................................................................................................ 27
CHAPTER 6: REGULATIONS............................................................................................................. 29
6.1 WEEE NOTICE..............................................................................................................................29
6.2 ENVIRONMENTAL NOTICE.............................................................................................................. 29
6.3 CE DECLARATION OF CONFORMITY................................................................................................ 30
6.4 ROHS2 CERTIFICATION OF COMPLIANCE.........................................................................................31
6.5 UL CERTIFICATION OF COMPLIANCE............................................................................................... 32
CHAPTER 7: ADELCO REGIONAL SUPPORT OFFICES.................................................................. 33
 User Guide [5]

Chapter 1: Important Notices

1.1 Important Information
1) Serial Number: DL-180G-3
Marked: C.E.: 2017

2) Circuit Diagram No: DL-CD-220V/V5.2

DL-CD-380V/V5.2

1.2 Important Notice

1) This machine is intended for curing screen and digitally printed inks on to textile
and other substrates requiring curing temperatures up to a maximum of 180°C
and should not be used for any other purpose without prior consultation with
Adelco’s technical department.

2) This machine is designed to operate within a maximum of 40˚C difference

between top and bottom conveyor levels.

3) This machine must be installed correctly according to installation document DP-

IM

4) The weight of the machine and its dimensions are as shown on the appropriate
layout drawings. Care should be given in lifting, transporting and siting the
machine with approved lifting machinery.

5) Adjustments for the correct operation of this dryer are contained in the
“Operation Section “ hereafter and users should familiarize themselves with the
controls and these instructions prior to operation.

6) Drawings, circuit diagrams and controller details are enclosed to assist

maintenance. Only a competent engineer who has the additional back up of a full
technical service department available from Adelco should carry out work.

7) Care should be exercised at all times when using this conveyorised heating
appliance to ensure correct time and temperature for inks, solvents and
substrates do not provide a fire or toxic fume hazard. For such guidance it is
essential that operators refer to their suppliers Material Safety Data Sheet
(MSDS).

8) It is important that all operators familiarize themselves with the safe and rapid
“Shut Down/Switch off” of this equipment, at the control panel.

9) Wash tests should always be carried out to ensure substrates are fully cured
prior to production runs.
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1.3 Pre-Installation Notice

For all information regarding gas, electric and exhaust supplies please refer to the
document: “Dual-Site Prep”.

For all information regarding Unpacking and Installation guides please refer to the
document: “Dual-Installation”

Adelco reserves the rights to change, update and modify any manual/guide with immediate
affect and without prior notice.
 User Guide [7]

1.4 Standard Features

 Two dryers in one footprint for 20ft of curing in a 10ft oven.

 Independent heat control for each level

 Over 10,000 CFM of airflow

 Low energy consumption with only 7Kw of maximum power consumption.

 Cure 6 lines of XL T-Shirts

 Place garment in any position on the belt

 Integrated hood extraction for smoke free working environment

 Precise independent belt speeds automatically set to minutes and seconds

 Dual control airflow technology for even heat distribution across belt width,
length and both levels

 Triple insulation with air curtain for the coolest exterior skin

 Reduced energy consumption for the lowest running costs

 Adjustable exhaust outlet valve

 Lint filter removable from either side of dryer for clean recycled airflow (No
replacement filters required)

 Designed for easy and accessible maintenance

 Siemens PLC controlled touchscreen

 Auto Tension and tracking belts

 User Guide [8]

Chapter 2: Understanding The Dual

Outfeed Extraction Hood

Cleaning
extraction Duct.
(Same on
Touchscree 10” Exhaust
Infeed Extraction Hood touchscreen Conveyor
Pulleys

Top
Conveyor

Bottom
Conveyor

Exhaust
Valve

Filter (Same on
Opposite side)

Main Motor and Airflow

Switch, (Gas Train on
opposite side)

Main Isolator

UV Detector
Cleaning
extraction Duct.
Extraction Fans (Same on

Control Box, Also

on opposite side
 User Guide [9]

2.1 Gas Train

Incoming
pressure Outgoing Modulating
Ball Solenoid valve pressure gauge
gauge valve
valve

Ignition
transformer

2.2 Main Motor & Airflow Switch

Double air flow switches connect two burner controller respectively, the third airflow
switch is for warning filter cleaning.

Fan Shaft
bearing 2
Main Fan
Motor V-Belt

Air Flow Air Flow Pipe

warning filter Switches Main Fan
cleaning Motor
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2.3 UV Detector

Quartz Lens
Holder

UV Tube

Quartz Lens
UV Detector
Removal system

2.4 Exhaust Valve

Exhaust in Open
Position
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2.5 Conveyor Auto Tensioner

2.6 Burner Controller

The double burner controllers are used for control the purge, ignition, UV signal and all fail safety.
systems and interlocks.

Combustion
Burner Controller
Controller
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2.7 Touchscreen Operation

Emergency Stop Power On Button

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Chapter 3: Dryer Operation

3.1 Start Up Procedure
1) Open the Ball Valve to each gas train (Section 2.1) and ensure the incoming
pressure gauge is at the correct pressure. (Refer to document: “Dual-Site Prep”
for pressure details).

2) Turn the main isolator on and press the power On Button, when pressed the
following will happen:
a) The power on button will illuminate green.
b) The Touchscreen will start up.
TIME c) The main fan will start.
d) The Conveyor belts will start.

3) Input your specified set temperatures and conveyor Speeds for each level.

4) Press the “Start” button. The dryer will start its safety check procedures and the
following sequence will happen:
a) The main fan will stop running.
b) Dryer will check airflow (Air flow Comparison Check)
c) Main fan will turn on (Purging)
d) The Dryer will Spark the bottom burner first,
(whilst igniting, one UV Signal bar will show up on the Lower flame signal
on the touchscreen)
e) The Bottom level Solenoid valve will open (Section 2.1) and the bottom
level burner will flame on.
TIME f) The Bottom Level UV detector will inspect flame and give full UV signal
35 s on touchscreen.
g) The Dryer will now Spark the Top burner,
(whilst igniting, one UV Signal bar will show up on the Upper flame signal
on the touchscreen)
h) The Top level Solenoid valve will open (Section 2.1) and the Top level
burner will flame on.
i) The Top Level UV detector will inspect flame and give full UV signal on
touchscreen.

5) Wait for the dryer to reach the set temperature on both top and bottom levels.
(Approximately 15-20 mins)

3.2 Shutdown Procedure

1) Press the “Shutdown” button on the touchscreen.
2) The flames will automatically cut out.
3) When dryer cools to 80˚C(176˚F) it will automatically shut off.
4) Turn off the main isolator and ball valve.
 User Guide [14]

Chapter 4: Maintenance
4.1 Daily
4.1.1 Clean Filters
Remove and clean lint filter, if the filter is getting blocked with lint daily then clean
twice a day. The filter should never be fully blocked, for best curing results ensure a
clean filter.

Reason Explained- If the main filter is blocked it will reduce the recirculation of the
exhaust which will cause the following:

1) Lint to get through the filter and in to the fan and UV tube.
2) Over heating the dryer
3) Uneven temperatures
4) Blue carbon free flame will turn to yellow

NOTE: when cleaning filters, one filter should always be left in whilst cleaning
the other.
 User Guide [15]

4.1.2 Clean Quartz Lens

Ensure you clean the UV Quartz Lens daily.

Reason Explained-A dirty UV lens will cause the UV signal to be blocked, which will
result in a flame failure.

Adelco’s Top Tip

Keep the spare lens inside a jar of Denatured Alcohol and do as follows:
1) Remove dirty lens from UV detector.
2) Clean dirty lens with Lint Free Cloth and place in jar of Denatured Alcohol.
3) Remove spare lens from jar of denatured alcohol and Clean with lint free cloth.
4) Place clean spare lens in UV detector.

Note: Never run the dryer with out the quartz lens, as this will damage the UV detector!

1 2

To release the UV lens turn the cylinder To remove the UV lens push the pin up.
Anti-clockwise to release the clamp on the
lens

3 4

Drop the lens back in to the slot ensuring it To re-clamp the UV lens tighten cylinder by
is fully inserted. hand. (Do not over tighten)
 User Guide [16]

4.2 Monthly
4.2.1 Clean Exhaust Fans
Clean the lint from the FOUR exhaust fans.

Important: Ensure the mains power is isolated and dryer is cool before cleaning.

Reason Explained- If the fans block with lint they may overheat and cease up causing
the dryer to overheat.

Clean lint on filter

Lift the End Hoods

Note: if the lint has got

inside fan remove mesh
guard and clean inside
impellers

Clean
Cleanlint
lintoff
offthe
the
outside
other covers
cover

Clean lint off the

outside cover
 User Guide [17]

4.3 Every Six Months

4.3.1 Check V Belt
1) Check and adjust V belt tension, if loose, undo main motor bolts and push back until
belt is tight but make sure belt is straight and aligned with the impeller pulley.
2) Check V belt for any cracks or splits. If need replacement belt please contact Adelco.

Reason Explained-If the V belt is loose it may damage the belt, come off the pulleys or it
will not turn the main motor all of which will cause no airflow.

4.3.2 Clean Extraction Fan Impeller

Reason Explained- If the fans block with lint they may overheat and get damaged, this
will result in cooling failures and cause damage to further components.
 User Guide [18]

4.3.3 Clean Inside Extraction Ducts

Clean the inside of the extraction ducts with an air gun and vacuum on both sides of the
dryer.

Reason Explained- If the jet holes are blocked then you will get uneven airflow across
the width and length of the dryer, this will cause uneven temperatures and cause
uneven curing.

1 2

Remove the Side covers from both sides of Remove the inner access panel from both
dryer sides of dryer

Remove the 6x covers from both sides of

the dryer and then remove the Cleaning
access panels.
 User Guide [19]

4.3.4 Clean Inside Jet Ducts

Clean the inside of the Jet ducts using an air gun and vacuum on both sides of the dryer.

Reason Explained- If the jet holes are blocked then you will get uneven airflow across
the width and length of the dryer, this will cause uneven temperatures and cause
uneven curing.

Hot
Jet jet cleaning
panel cleaning Suction
The panel
suction cleaning
plate is clean
 User Guide [20]

4.3.5 Clean main Impeller fan

Use a flat head screwdriver to remove the lint from each fan blade. Ensure you remove
all lint and the lint does not drop inside the impeller.

Reason explained- Over time a build up of lint will get stuck to the main fan blades, this
will reduce airflow, which will affect the curing.

Remove screws to release the cover

Vacuum all the lint from the duct. Remove the filters to access the main
impeller, clean all lint off fan blades
 User Guide [21]

4.3.6 Grease Main Fan Bearings

Use grease gun to grease fan bearings with high temperature grease.
(See section 2.1 & 2.2)

Reason Explained- If the Bearing is not greased it will cause the main fan to cease which
will result in no airflow.

4.3.7 Grease Conveyor Bearings

Use grease gun to grease conveyor bearing nipples with high temperature grease.

Reason Explained-If the bearings are not greased they will cease up and the conveyors
will not turn.

4.3.8 Grease Sliding Doors

Apply grease to both the infeed and outfeed sliding door shafts.
 User Guide [22]

Chapter 5: Section For Trouble Shooting

5.1 Conveyor Fault

Reason Analysis : 1) The conveyor motor power on switch off.

2) The connecting cable/fitting of the conveyor motor is not connected.

Conveyor motor switch Conveyor motor cable/fitting

 User Guide [23]

5.2 Extraction Fan Inverter Fault

Reason Analysis ：1) Extraction fan faulty.

2) The extraction fan power on switch off.

Extraction fan power on switch Extraction fan

 User Guide [24]

5.3 High Temperature Alarm

Reason Analysis:
1) The temp inside the machine is higher than the setting alarm temp.
2) The modulation valve is not working .
3) Relay is not working (The relay is not installed or the relay is damaged).

Relay HT reset button

Modulation Valve
 User Guide [25]

5.4 Temp deviation alarm

Temp
deviation
alarm

Reason Analysis: 1) Thermocouple damaged

2) PLC temperature module damaged

PLC
Temp
Module

Clean
filter

Reason Analysis: Need clean the filter if it’s too dirty

 User Guide [26]

5.5 Flame signal fault

Flame
signal
fault

Reason Analysis：
1) Quartz lenses too dirty (Clean the lenses with a clean cloth and alcohol)
2) The UV tube is not in horizontal position.

Cleaning quartz lenses

 User Guide [27]

5.6 Flame fault

Reason Analysis：

1. Air flow switch fault

1) Check the main fan running direction.

2) Check the filter mesh, make sure no block.

3) Check the air flow copper tube & air tube, make sure no block.

air
airflow
flowcopper
coppertube
tube&&air
airtube
tube filter
filtermesh
mesh
 User Guide [28]

2. UV flame detector fault.

1) Cleaning quartz lenses
2) Check if the flame detector is damaged
3) Check the gas pressure.
4) Check the ignition transformer.
5) Check whether the ignition spark is working.（ If the ignition spark touch the
burner, the ignition spark will not work ）

The ignition spark is not accessible Ignition Transformer

to the burner

3. Check whether the solenoid valve is damaged.

Check
Checkthethe
Check
gas
gas
the gas
pressure &
pressur
solenoid
&
e, the
solenoid
valve&
solenoid
ignition
valve＆
valve is
tranformer
ignition
normal
HTHTwire
wire
 User Guide [29]

Chapter 6: Regulations
6.1 WEEE Notice

WEEE Notice

 Disposal of Waste Electrical and Electronic Equipment and/or Battery by users

in private households in the European Union.

 This symbol on the product or on the packaging indicates that when the last user
wishes to discard of a product, it must be sent to appropriate facilities for
recovery and recycling. For more information about recycling of this equipment
and/or battery, please contact the equipment supplier.

 The recycling of materials will help to conserve natural resources and ensure
that it is recycled in a manner that protects human health and environment.

6.2 Environmental Notice

 Service personnel should dispose of replaced machine parts and waste materials
according to the laws and regulations of the local authority and recycled, where
applicable.

 For more detailed information regarding these recommended procedures, refer

to your regional Adelco Support office or distributor.
 User Guide [30]

6.3 CE Declaration Of Conformity

 User Guide [31]

6.4 RoHS2 Certification of Compliance

 User Guide [32]

6.5 UL Certification of Compliance

 User Guide [33]

Chapter 7: Adelco Regional Support Offices

Adelco China
Office Hours: 08.30 – 17.30 Mon-Sat
Address: No. 1019, Huang Pu Rd, Qiandeng Town, Kunshan 21500,
China
Tel: +86 (512) 5747 0786
Fax: +86 (512) 5747 0776
Email: shipping.cn@adelco.cn & aftersales.cn@adelco.cn

Adelco UK
Office Hours: 08.00 – 17.00 Mon-Fri
Address: HighView, High Street, Bordon, Hants, England, GU35 0AX
Tel: +44 (0) 1420 488388
Fax: +44 (0) 1420 476445
Email: service@adelco.co.uk