Uninet iColor User manual

www.icolorprint.com [email protected]om
ICDS 10”(254mm) Digital UV
Coating System with Auto Pump
User Manual

Table of Contents
Chapter 1
Symbology 1
Introduction & Technical Assistance 2
Equipment Specications 3
Safety & Precautions 4
Chapter 2
Features, Advantages & Benets 7
Operator Do’s 8
Operator Don’ts 9
Chapter 3
10
11
12
Unpacking your iColor coater
Installing Your iColor coater - Electrical
Installing Your iColor coater - Drip Pan
Installing/Replacing Your - UV Lamp 13
Chapter 4
15
16
20
21
22
23
24
25
26
27
28
30
Make Ready & Operating Instructions
Digital Control Panel
Establishing iColor Coating Unit Settings Testing the
iColor Coating Unit Calibration Calibrating the iColor
Coating Unit
Setting Form to Impression Roller Pressure
Power ON the Coater
Make Ready the Coating Pump & Unit
Setting the “Optional” Automatic UV Coating Sensor
Coating Information
Production Considerations
Testing & Evaluating the Coating Finish
Five Kwik & EZ Ways to Perfect the Coating Finish 31

Table of Contents (continued)
Chapter 5
32
33
35
36
37
49
40
43
44
45
Troubleshooting & Maintenance
Troubleshooting Guidelines
Daily UV Cleanup Procedure
Weekly or Holiday UV Cleanup Procedure
Aqueous Coating & Primer Cleanup Procedure
Lubrication Schedule
Replacing the Doctor Blade Procedure
Tracking the Conveyor Belt
Replacing the Conveyor Belt
Decimal & Millimeter Conversion Table

1
Chapter 1
Symbology:
Notes, Caution, Remarks, Warnings
Below is a guide to the symbols used throughout this manual.
NOTE:
A NOTE symbol indicates important information that helps you in your install / operation.
CAUTION:
A CAUTION symbol indicates that special attention and care should be taken to avoid
injury or damage.
REMARKS:
A REMARK symbol provides you with additional information such as options that are
available.
WARNING:
UV Light – Avoid looking directly at UV Light. Use only with shielding in place.
Protect eyes & skin from exposure to UV Light.
WARNING:
HOT / WARM metal surface
WARNING:
HIGH VOLTAGE
WARNING:
Keep hands and ngers clear. Sever injury may occur. Do Not operate without guards in
place.
WARNING:
EXPLOSIVE HAZARD

2
Introduction
Your New iColor Coating and Curing System
Uninet thanks you for the purchase of the iColor coater. The iColor coater is a unique offline UV
coating & curing system. In this manual we will discuss the following topics:
• Introduction
•Equipment Specications
•Unpacking
•Installing
•iColor Coater
• Safety & Precautions
• Operation
•Maintenance & Troubleshooting
• Coating & Consumables
Please familiarize yourself with the content of this manual before unpacking, installing and operating
the iColor coater. In an effort to ensure safety, please read and pay close attention to all safety relat-ed
comments.
I
UNITED STATES

3
Equipment Specications
SPECIFICATIONS STANDARD METRIC
Maximum Sheet Size 10” x Virtually Any Length 254mm x Virtually Any Length
Minimum Sheet Size Business Card Business Card
Speed up to 80 feet/minute up to 24 meter/minute
Stock Weight 7pt. to 30pt. 150 up to 600 g/m²
UV Lamp - Solid State UV 70 watts to ~200 watts
(Innitely Variable)
70 watts to ~200 watts
(Innitely Variable)
Total Weight Approx. 200 lbs. Approx. 91 kgs.
Electrical 208-230v/1Φ/50-60Hz/25amps 208-230v/1Φ/50-60Hz/25amps
Noise Level < 60 dB < 60 dB

4
Safety & Precautions
Before unpacking, installing and operating the iColor Coater, please make sure you read and follow
these safety instructions.
The iColor coater can be installed by the customer after reading and following the detailed
directions provided in this manual.
CAUTION: The operator of the iColor coater must take extreme caution during the running of
the machine to prevent the possibility of a Fire!
When feeding stock you must make sure it is exiting the machine, i.e. not getting jammed in
the delivery area or it will catch on Fire!
CAUTION: AClass A,B,C fire extinguisher and a metal garbage can with a metal lid should be
located in close proximity to the iColor coater system in case a coated sheet gets caught under
the lamp and catches fire.
Class A extinguishers are for ordinary combustible materials such as paper, wood,
cardboard and most plastics.
Class B res involve ammable or combustible liquids such as gasoline, kerosene,
grease and oil.
Class C res involve electrical equipment, such as appliances, wiring, circuit breakers
and outlets. Never use water to extinguish class C res - the risk of electrical shock is
far too great!
CAUTION: Those coatings cannot be used which build an explosive atmosphere when being
heated up under the UV Dryer.
CAUTION: A licensed / certified electrician MUST connect iColor coater to the plant pow-er.
CAUTION: Do not connect or disconnect any power cables or perform any maintenance to
the iColor coater while the system is powered on.
WARNING: Some of the components (i.e. UV lamp housing, bulb and duct) of the iColor
coater system may become hot during normal operation. Use care when handling or touching
these components.

5
Safety & Precautions (continued)
WARNING: The UV bulb is extremely hot during use. Never touch this bulb as a severe
burn/injury could result.
WARNING: DO NOT touch the UV light bulb with your hands as it will shorten the life of the
bulb. If the bulb is touched immediately wipe the area with isopropyl alcohol (IPA). DO NOT
wipe the bulb with IPA unless the bulb is cool.
WARNING: When working around the UV unit with the power on you must wear the UV Safety
Glasses (provided) to protect your eyes from direct or indirect (reection from paper) exposure
to the UV rays. UV rays can severely damage your eyes.
CAUTION: When handling the UV Coating, please use safety gloves (provided) for skin protec-
tion.
CAUTION: Please read and observe the UV coating Material Safety Data Sheets (MSDS) for
the various personal, work and environmental recommendations. The MSDS sheets should be
easily accessible in the event of an emergency.
CAUTION: Keep UV coating away from heat and/or open ame. Keep UV containers in a cool
and dry location. Do not allow UV coating to freeze.
CLEAN, CLEAN, CLEAN!
It is extremely important to clean and maintain your iColor coater
properly in order to produce the outstanding coating output that your
customers expect.
If you do not properly clean and maintain your iColor coater, it will
not perform properly.
Also, failure to clean and maintain your iColor coater will void your
warranty.

6
Safety & Precautions (continued)
At Uninet, Safety is our number one priority!
Interlocking Guards, Fixed Guards and Warning Labels are used when necessary and are clearly
visible, to protect all operators. If a safety sticker becomes damaged, please contact Uninet to
purchase a replacement!
Please nd below a visual representation of our Safety Guards. If the front safety guard is opened, the
conveyor will shut down immediately, the UV light will drop to the lowest setting and the reector hous-
ing will rotate to the idle position. The fan will continue to operate. If the rear safety guard is opened
the UV lamp, conveyor & fans will instantly shut down. Upon closing the rear guard, the fan will begin
to operate and begin running the cooling cycle. You may turn on the UV at this time, however note it
could take up to 2 minutes for the lamp to engage.
Figure - Front Safety Guard Figure - UV Chamber Access Panel
(Rear Safety Guard)

7
Chapter 2
Features, Advantages & Benets
Uninet’s coating and curing systems offer digital, offset and hybrid printers a quick and easy way to
apply and cure UV, aqueous, specialty coatings and primers on a variety of substrates. The versatile
iColor coater system offers features and benefits that result in high quality output and increased
productivity in an ever-increasing competitive market.
This unique system provides:
• Ease of operation and maintenance
•A rub resistant nish to every printed piece
• Durability and protection of the printed sheet for repeated handling and mailing
This system is also able to:
• Apply aqueous coatings as well as water based primers ,such as Sapphire, to papers and
plastics to be printed with the HP Indigo
•Flood coat a 10” (254mm) x unlimited length product
• Provide faster job turnaround
• Reduce time to bindery
•Apply various nishes: (gloss, satin, specialty and primer)
• Handle a variety of substrates and thicknesses
NOTE: The iColor coater is rated to handle a minimum stock weight of 100# text (150 gsm),
but some lighter stocks may work depending on grain direction and surface finish when running
sheets, when running roll to roll, (50# text (75 gsm)) stocks may be run.
•Coat product at a competitive rate (typically less than one penny per side)
•Control coating thickness on the fly with the patented Uninet Coating Unit
•Less than 2 minute coating change and clean up with the patented Uninet Vac

8
Operator Do’s & Don’ts
Do’s:
1. Follow safety rules.
2. Take great care to prevent fires .
3. Read the manual and follow the instructions.
4. Clean the Coating Station regularly and for each job setting.
5. Keep the rollers clean.
6. Lubricate Uninet Coating Unit Gears once a week.
7. Use the correct size Allen key for the corresponding size bolts.
8. Follow daily wash up procedures.
9. Follow end of the day procedures.
WARNING: Use only coatings that do not build up an explosive atmosphere when being heated
(for example: “Flammable Limit” mentioned in the MSDS sheet as “Not Usable”).
10. Prior to running a job make sure of the following:
a. The lamp system is up and running and set to the suggested wattage
b. Conveyor speed is set to suggested speed
c. Coating unit pressure is properly set
d. There is ample coating in the nip of the coating unit - if using optional UV automatic sensor,
make sure sensor light is on
e. The correct coating is being used for your job
f. You have a supply of lint free rags and cleaner available
g. When feeding stock be sure it is existing the UV chamber...stock that does not exit the UV
chamber will result in a FIRE
11. Always mix your coating prior to use.
12. UV coating has a shelf life of approximately 6 months, so always use the oldest coating rst.
13. UV Coating is temperature sensitive, store in a climate controlled area. Cold coating may result in a
less than adequate gloss level and/or nish.
CAUTION: VERY IMPORTANT - When shutting the system down for the day, it is VERY
IMPORTANT that you completely clean the coating unit and set the metering controls to the
“END OF DAY POSITION”. Failure to set the roller pressure to the “END OF DAY POSITION”
may result in a form roller at spot which is NOT covered by our warranty!

9
Operator Do’s & Don’ts (continued)
Do’s: Cont...
15. In case of re, open UV Chamber Access Panel (this will automatically turn off the lamp) and care-
fully remove the paper to a near by metal trash can. A Class A, B, C fire extinguisher and metal
gar-bage can with a metal lid should be located in close proximity to the iColor Coater.
See Safety & Precautions section for re extinguisher details.
Don’ts:
1. DO NOT service the machine with the power on.
2. DO NOT run the coating unit without the safety covers in place.
3. DO NOT make any adjustments while the coating unit is running.
4. DO NOT make any repair work while the coating unit is running.
5. DO NOT run the coating unit with excessive pressures on the impression roller.
6. DO NOT run the coater unit without the seals in place. The rollers will be damaged. (This damage
will not be covered by the warranty)
7. DO NOT forget to perform the end of day procedure.
WARNING: Do not use Flammable Non-Approved coatings.
8. NEVER leave the coating unit in the ON position, when running light weight stocks, without paper
going through the system. This will continue to apply coating to the impression roller. The excess
coating that builds up will be scraped off by the doctor blade resulting in extra waste and
unnecessary wear of the doctor blade.
9. NEVER attempt to clean the machine while it is running. You can advance the impression roller by
using jog button on the touch screen. DO NOT use the Jog button with the Coating Unit ON Impres-
sion as this will dump the contents of the coating unit.
Figure - UV Chamber Access Panel
UV Chamber Access Panel

10
Chapter 3
Unpacking your iColor UV Coater
Your iColor coater has been inspected prior to delivery. Please take note if any items are missing or
damaged.
Once your iColor coater has been placed in your facility you can begin unpacking the equipment
and supplies.
NOTE: It is the responsibility of the customer to provide any and all the necessary
rigging equipment needed to off load the iColor coater and/or position the equipment.
1. Carefully remove the strapping, plastic & protective padding. If reusable, nylon ratchet tie downs
have been used, remove by using the release handle. If plastic strapping, please cut with a razor
blade. Take care not to damage your iColor coater when cutting with a razor.
2. Remove the boxes or packages that may have been included and place them in safe keeping until
needed.
3. With a minimum of two people, carefully lift the iColor coater from the wooden weight support
bracket and place clear of the skid.
WARNING: The approximate weight of the iColor coater is 200lbs. (91kgs). Take care when
lifting or positioning the equipment as bodily injuries or damage to the equipment could occur.
4. Position the iColor coater in your desired location.

11
Installing your iColor coater - Electrical
Once you have placed your iColor coater it is time to install the equipment. The iColor coater can be
installed by Certified iColorTechnician / iColor Dealer or by the customer after reading and following
the detailed directions provided in this manual.
CAUTION: A licensed / certified electrician MUST connect the iColor coater to the plant power.
1. Place the iColor coater in the desired operating location. Remember to provide at least 3 feet (1
meter) of space around the iColor coater for operation and service.
2. The iColor coater is equipped with approximately 8ft of electrical cord.
3. Have the Electrician connect the iColor coater cord to the existing plant power.
4. If it is necessary to hardwire the equipment, it is very important that it is completed by a licensed /
certied electrician.
WARNING: Once the power is connected, be sure to have the Electrician check with an electri-
cal meter prior to turning the system on. Too much power will blow the breaker or cause severe
damage to the equipment. Too little power and the system will not power up.
Figure - Electrical cord

12
Installing your iColor coater - Drip Pan
1. Turn the Main Power disconnect to the OFF position!
2. Make sure the Drip Pan Plug is securely installed in the Drip Pan. If not, do so by pulling the rubber
plug through the drain hole until secure.
3. Install the Drip Pan in the mounting bracket below the impression roller by tilting the rear of the pan
(high back), insert the high back behind the impression roller, level off the drip pan and place in the
mounting bracket . Be sure the Drip Pan is facing the correct direction.
Figure - Drip Pan Close UpFigure - Drip Pan Plug Figure - Drip Pan
Drip Pan Plug Drip Pan Installed Correctly

13
Installing / Replacing your iColor coater - UV Lamp
1. Turn the Main Power disconnect to the OFF position.
2. Remove Control Panel mount and unplug control panel (OP Side).
3. Remove both side covers using a 3mm Allen key.
4. Take care to unplug the Coating Pump (OP Side).
5. Lift the rear UV chamber safety cover to access the UV reector & bulb.
6. It is recommended that you also remove the black heat sink for additional access to the UV bulb.
7. Disconnect the bulb wires from the terminal block, on each side, using a Flat Head screwdriver.
8. Using a 4mm Allen key, remove UV bulb access cover on both OP & NOP side.
Figure - Remove OP Side CoverFigure - Remove NOP Side Cover
Side Cover Side Cover
Figure - Bulb Disconnect
(UV bulb access cover)
Figure - Bulb Disconnect
(UV bulb access cover removed
Bulb Disconnect
Figure - Rotated UV Reector /
UV Bulb
Rotated UV Reector Bulb Access Cover UV Bulb Access Hole
UV Bulb

14
Installing / Replacing your iColor coater - UV Lamp (continued)
9. With the UV bulb access covers and heat sink removed. Taking care not to touch the UV bulb, gen-
tly pull UV bulb by the white end cap through either the OP or NOP side UV bulb access hole.
10. Carefully unwrap the New bulb. Take care NOT to touch the glass surface with your ngers as it
will cause the bulb life to decrease. Gently slide the bulb through the access hole and place ends in
mounts.
NOTE: If you accidentally touch the bulb with your ngers or hands be sure to clean the bulb
with Isopropyl Alcohol (IPA) as soon as possible
11. Reinstall Bulb Access Covers making sure the tab is on top of the bulb end caps. This will ensure
the bulb remains properly seated in the mounts. (Failure to do so will result in bulb breakage when
the shutter is activated).
12. Connect the wires to the terminal blocks. Make sure to place the wire into the terminal block above
the incoming wire.
13. Replace the Heat Sink and close the UV chamber safety cover.
14. Plug in Coating Pump.
15. Replace the Side Covers, plug in Control Panel, reinstall Control Panel Mount.
Figure - Bulb Connect
(Operators Side )
Figure - Bulb Connect
(Non- Operators Side)
Bulb Connect
Figure - Rotated UV Reector with Heat Sink
Removed
Figure - UV Bulb Access Hole
Bulb Access
Hole

15
Make Ready & Operating Instructions
You will soon be on your way to coating and curing!
Once the iColor coater is installed by you or your iColor certified technician and connected by a
licensed electrician you will be able to start coating and curing. Please follow the step-by-step instruc-
tions on the operation of the iColor coater to guarantee success.
Chapter 4
Digital Control Panel
Cooling Filters
Coating Unit
UV Lamp
Housing
Figure - iColor coater System
Coating Pump

16
iColor Coater - Digital Control Panel
The iColor coater Digital Control Panel:
•Provides quick & easy control of the
iColor coater at the touch of a button
• Adjust UV bulb intensity & belt speed on-
the-y
• Manually pump coating to the coating unit
when needed
• Jog forward / reverse
• Alerts when rear guard is open
CAUTION: DO NOT use the Jog button with the Coating Unit ON Impression as this will dump
the contents of the coating unit.
Figure - Digital Control Panel

17
iColor Coater - Digital Control Panel (continued)
NOTE: The Control Panel is “NOT” a touchscreen and is only controlled by the function keys.
HOME SCREEN
Get to this screen by pressing the “F0” Function Key in any screen
F1 = Belt Screen
F2 = UV Lamp Screen
F3 = Coating Pump Screen
F4 = Forward / Reverse Job Screen
BELT SCREEN
Get to this screen by pressing “F1” Function Key from the Home Screen
• The speed is controlled by the Left & Right Arrow Keys, whether the belt is ON or OFF
•Press “F5” Function Key to Turn ON Belt (The belt will not turn on if the Front Guard is “OPEN”)
• Press “F6” Function Key to Turn OFF Belt
• Press “F0” Function Key to return to the Home Screen
Belt Speed Scale
(Shown in percentage
of machine speed)