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Javelin
Javelin REV: 000 Table Of Contents Introduction Features and Specs Standard Operating Guide 3 3-4 5 External Layout 6 - 34 Internal Layout 35 - 47 Wiring/ Plumbing Diagrams 48 - 62 F.A.Q. 63 - 69 Screen Shots 70 - 71 Comprehensive Parts List 72 - 75 2 Introduction: The Javelin Pro offers durable construction, user-friendly set-up, an advanced controller, and with high index speeds, it is the workhorse of automatic printers. Combined with our patented Flashback, our presses are the only machines in the industry that can print and flash on all print heads without sacrificing a color. Javelin’s print heads and drive systems are smooth and dependable, enabling you to take on even the most demanding jobs! The Javelin Pro is available in 6, 8, and 10 color models. Features and Specs: Power Options: 110v Single Phase, 50-60hz, 10 amps Air Requirements: 4-8: 22cfm @ 120psi 6-8: 22cfm @ 120psi 610: 22cfm @ 120psi 8-10: 30cfm @ 120psi 8-12: 30cfm @120psi 10-12: 30cfm @ 120psi Construction: All steel construction. Polyurethane Airline Standard Print Size: 16” x 18” (41 x 46cm) Features: Fast squeegee and flood angle, pressure adjustment 99 count print stroke per screen for more opacity on dark garments Independent head control for easy job setup and registration Non-warping solid aluminum platen Double index, run two jobs simultaneously Adjustable print stroke Micro registration front & back for fast setups One knob quick change squeegee Precision milled Registration fork on every print head for exact registration Easy release platens Fast production rate - 70 doz./hr. Two year limited warranty 3 Dimensions: Javelin 4-8: 10.5ft (3.2m) Javelin 6-8: 10.5ft (4m) Javelin 6-10: 13.5ft (4.4m) Javelin 8-10: 13.5ft (3.2m) Javelin 8-12: 14.5ft (4m) Javelin 10-12: 14.5ft (4.4m) Weight: Javelin 4-8: 3000lbs built Javelin 6-8: 3200lbs built Javelin 6-10: 3400lbs built Javelin 8-10: 3600lbs built Javelin 8-12: 4100lbs built Javelin 10-12: 4300lbs built 4 Standard Operating Guide: 1 2 7 3 4 5 6 1. Print Head Selector Switch: Each print head has its own selection switch that is independent of all others and may be set in any one of the following positions; OFF - Single, Print Stroke & Double Stroke. During a print cycle those heads in the OFF position will remain at rest. The remaining head(s) will print after the pallet table has raised up, then upon completion the pallet table will lower and rotate to the next station while the flood stroke is occurring. If a double print stroke is required for any head(s), the pallet table will not rotate after lowering but will rise again in the same position for the second print cycle before continuing to the next station. 2. Manual Print Buttons: Each print head has its own numbered button, when one is depressed the pallet table will raise and the corresponding print head will print. The table will then lower but no table rotation will occur (used primarily to check registration). 3. Emergency Stop Button: When activated the air pump valve will cycle and release all air from the printer and cut power to all systems. (Note It is very important that the table be in alignment before reenergizing the emergency stop). 4. Auto Mode/ Manual Mode: Auto/Start: Will start the printer into production run (flood, rotate and print). The table will begin rotation within 3 seconds of switching to Auto/Start. Speed is controlled by the Delay Timer or the Foot Switch. Manual/Stop: In manual mode the table may be raised and lowered using the table up/down button in the job setup window. The table can be rotated manually by hand. To print a desired head, select the number of the appropriate head and push that number switch. The table must be in the down position and in location when manually printing a head. 5. Print On/Off: If a squeegee requires service , the activation of this switch will release the air to the print cylinders so that the squeegee may be removed for cleaning, revised, replaced or to be able to adjust the squeegee angle and pressure adjustment. Flipping the switch to the original position will again supply air to the heads allowing operations to continue. 6. Foot Pedal: in the on position, to begin the production cycle, push the foot pedal down. When each print cycle is completed, the foot pedal must again be depressed in order for the cycle to start. In the off position the delay timer will energize and control the start of the next cycle. 7. HMI: The HMI (Human Machine Interface) allows the user to access all of the Javelins features, functions and settings. Its various displays and touch screen feature will walk the user thru the process of production to machine diagnostics 5 External View Front Micro Assy. Part A Front Screen Hanger Screen Clamp Cyl. Part V Screen Clamp Part B Knob Part FA Screen Clamp Cyl. Part V Manual Screen Clamp Knob Part FA Hex Nut Part FB All Thread Part FC Rear Screen Hanger Screen Clamp Cyl. Foot Part W Rear Screen Part C Hanger Swivel Pad Part AW Screen Clamp Part B Screen Clamp Cyl. Foot Part W 6 Micro Adjustments (Left Side) Large Lever Part D Fitting Elbow Part E Flange Nut Fender Washer Part F Micro Lock Cap Part J Part I Knurled Knob Part G Micro Target Label Part H Micro Adjustments (Right Side) Large Lever Part D Flange Nut Part I Fitting Elbow Part E Fender Washer Part F Micro Lock Cap Part J Knurled Knob Part G Knurled Knob Part G Micro Target Label Part H 7 Micro Adjustments Disassembled (Front Screen Hanger Left Side) Flange Nut Hex Bolt Part I Part K Nylon Lock Nut Part L Micro Lock Cap Part J Close Up View (Picture Above) Micro Adjustments Disassembled (Front Screen Hanger Right Side) Flange Nut Part I Flat Washer Part M Wave Washer Part N Nylon Lock Nut Part L Micro Lock Cap Part J 8 Micro Adjustments (Front Screen Hanger Left Side) Jam Nut Jam Nut Part O Part O Spring Part P Wave Washer Part U Rod End (RH) Part Q Rod End (LH) Part T Hex Bolt Part R Knurled Knob Part G Shoulder Bolt Part S Micro Adjustments (Front Screen Hanger Right Side) Jam Nut Jam Nut Part O Part O Spring Wave Washer Part U Part P Rod End (RH) Part Q Rod End (LH) Part T Shoulder Bolt Part S Knurled Knob Part G Hex Bolt Part R 9 Micro Adjustments (Front Screen Hanger Left Side) Rod End (LH) Part T Shoulder Bolt Part S Knurled Knob Part G Rod End (RH) Part Q Hex Bolt Part R Hex Bolt Part X Micro Adjustments (Front Screen Hanger Right Side) Shoulder Bolt Part S Rod End (LH) Part T Rod End (LH) Part T Shoulder Bolt Part S Knurled Knob Part G Rod End (RH) Part Q Hex Bolt Hex Bolt Part X Part R 10 Micro Adjustments (Rear Screen Hanger Right Side) Flange Nut Part I Hex Bolt Part X Flange Nut Part Y 4 Prong Knob Part AB U-Bracket Part Z Hex Bolt Part AA Micro Adjustments (Front Screen Hanger Right Side) Bottom View U-Bracket Part Z Jam Nut Hex Bolt Part AC Part AA Spring Part AD All Thread Hex Nut Part FD Part FE Hex Nut Part FE 11 Micro Adjustments (Rear Screen Hanger Left Side) Lever Part AE Rear Screen Hanger Part C Flange Nut Part I Flange Nut Part I Hex Bolt Part X Flange Nut Part Y U-Bracket Stopper Part AF Kep Nut Part AG Micro Adjustments (Rear Screen Hanger, Left Side, Front View) Flange Nut Part I Hex Bolt Part X Flange Nut Part Y Shoulder Bolt Part AH Female Rod End Part AI 12 Print Head Control Panel (Top Half) Flow Plate Part AJ Plastic Snap Bushing Part AK Toggle Valve Part AL Toggle Valve Part AL 13 Print Head Control Panel (Bottom Half) Flow Plate Part AJ Flow Control Part AM Flow Control Part AM 14 Print Head Control Panel (Internal Top Half) Flow Plate Part AJ Branch Tee Part AN Fitting Elbow Part AP Toggle Valve Part AL Black Poly Air Line Part AO 5/32” Fitting Elbow Part AP Part AN Toggle Valve Part AL Print Head Control Panel (Internal Bottom Half) Flow Control Part AM Male Tube Fitting Part AQ Flow Control (old) Part FZ 15 Front Screen Hanger Plate (View From Underneath) Button Head Part AR Screw Rear Stroke Stops, Squeegee Rail Lever Part AE Rear Hanger Assy. Part C Alum. Squeegee Part AT Track Lever Part AE Sq. Stop Assy. Part AS 16 Rear Screen Hanger Lever Rear Hanger Assy. Part C Part AE Lever Part AE Rear Stroke Stop Lever Spring Part AE Part AU Vinyl Cap Part AV Swivel Pad Part AW Sq. Stop Assy. Part AS Spring Part AU Lever Part AE 17 Squeegee Carriage Squeegee Carriage Part AY Sq. Carriage Wheels, Replacement Hardware PEM Stud Part FW Carriage Wheels Part AX Lock Washer Part FX Hex Nut Part FY Stroke Cylinder (Mounted) Hex Bolt Part AZ Stroke Cyl. Mount Bracket Part BD Fitting Elbow Compact Part BC Stroke Cyl. 20” Part BA Hose Clamp Part BB 18 Stroke Cylinder to Squeegee, Shoulder Bolt Assy. Flat Washer Part M Shoulder Bolt Part EZ Female Rod End Part AI Spring Part BE Nylon Lock Nut Part BF Stroke Cylinder to Squeegee Carriage Mounting Shoulder Bolt Part EZ Flat Washer Part M Female Rod End Part AI Spring Part BE 19 Assembled Squeegee carriage (Front View) Male Rod End Part BJ Flipper Block Part BG Squeegee Pin Part BH Angle Stop Barrel Part BI Flip Cylinder, Clevis and Spade Bolt Hex Nut Part BK Clevis Kit Part BL Spade Bolt Part BM Jam Nut Part BN 20 Flip Cylinder (View from Below) Fitting Elbow Compact Part BC Flip Cylinder Part BO Fitting Elbow Compact Part BC Flange Nut Hex Bolt E -Clip Part BP Part FF Part BQ 21 Flipper Frame Assembled (Right View) 4 Prong Knob Part BU Lever X-Large Lever Part BV Part AE Lever Part AE Bronze Bushing 3/8” Part BR Shoulder Bolt Part BS Shoulder Bolt Part FI Squeegee Adj. Weldment Part BT Flipper Frame Assembled (Left View) Bronze Bushing Part BR 3/8” Bronze Bushing 5/16” Part FX Shoulder Bolt Part FI Squeegee Adj. Weldment Part BT Shoulder Bolt Part BS 22 Squeegee Pressure Assy. Sq. Pressure Adj. Part BW Assy. 4 Prong Knob Part BU Male Rode End Part BJ Jam Nut Part BX Shoulder Bolt Part BY X-Large Lever Part BV Disc Washer Part GA Lower Squeegee Pressure Assy. Lower Pressure Part GD 23 Complete Control Box Lamp Part CD Control Panel (Empty) Part CE Control Box (Empty) Part CF Part CG 24 Complete Control Box (Left Half) Toggle Switch Part CG Button Switch Part CH E-stop Switch Part CI Toggle Switch Part CG Complete Control Box (Right Half) HMI Part CJ 25 Complete Control Box (Rear View) Flange Bolt Part BZ Pan Head Screw Part CB Flat Washer Part CA Control Arm Inner Part CC 26 Table Up Switch Flat Washer Part CA Pan Head Screw Part CB Snap Action Part CK Switch Pork Chop Plate Assy. Roller Bearing Part CO Jam Nut Nylon Lock Nut Part CL Part O Hex Bolt Part CP Socket Head Part CM Screw Flange Bolt Part CN Pork Chop Swivel Part CQ Plate 27 Off Contact Assembly Off Contact Spacer Part FG Wave Washer Part FI Off Contact Spacer Part FG Hex Nut Wheel, and Print Arm Assembly Part FH Flange Bolt Part CR 28 Registration Fork Flat Washer Part CS Flange Bolt Part CT Registration Fork Part CU Flat Washer Part CS Flange Bolt Part CT 29 Registration Fork, Cam Bearing (Rear View) Flange Bolt Part CT Flat Washer Part CS Flange Nut Part BP Flange Bolt Part CT Flat Washer Part CS Flange Nut Part BP Hex Nut Part CV Flat Washer Part CW 30 Cam Bearing Assy. Square Head Bolt Part CX Square Head Bolt Part CX Jam Nut Jam Nut Part BX Part BX Number Label Part CY (1-12) Registration Bearing Part CZ 31 Cam Bearing Assy. (Top View of Arm) Square Head Bolt Part CX Square Head Bolt Part CX Jam Nut Jam Nut Part BX Part BX Vertical Mylar Part DA Ruler 32 Platen Bracket Hex Nut Hex Nut Part DB Part DB Hex Bolt Hex Bolt Part DC Part DC Flat Washer Part M Flat Washer Part M Hex Bolt Hex Bolt Part DD Part DD Cam Lever Left Part DE Cam Lever Right Part DF Flat Washer Part M Flat Washer Part M Hex Bolt Hex Bolt Part DD Part DD Cam Lever Left Part DE Cam Lever Right Part DF Flange Nut Part BP 33 Platen Bracket (Side View) Flat Washer Part M Flange Nut Nylon Lock Nut Part L Flange Nut Part BP Part BP Flange Nut Flat Washer Part M Part BP Flat Washer Part M Hex Bolt Part DC Hex Bolt Part DC 34 Internal View Communication Switch, Dummy Plug (Installed) Pan Head Screw Part CB Flat Washer Part CA Lift Lug Communicator Bracket Part DG Hex Nut Part DI Part DJ Dummy Plug Part DH Communication Switch (Rear View) Snap Action Part CK Switch Communicator Part DK Plug 35 Table Up Switch Flat Washer Part CA Pan Head Screw Part CB Snap Action Part CK Switch In Location Switch (Installed) Cam Bearing Part EZ Snap Action Part CK Switch Pan Head Screw Part CB Flat Washer Part CA 36 V Block (Flipper Block) Collar Clevis Kit Part FJ V Block Part BL Collar Part FK Part FJ V Block Cylinder, Mounting Elbow Fitting Part BC Flip Cylinder Part BO Shoulder Bolt Part FL E-Clip Flange Nut Part FF Part CR 37 Index Cylinder, Clevis (Installed) Clevis Kit Part DP Index Cylinder Part DL Index Rail Part DQ Red Air Line (3/8) Part DM Fitting, Elbow Part DN Button Head Part DO Screw Index Cylinder Rear Mount, Fork, and All thread (Installed) Index Cyl. Rear Part DR Mount All Thread Index Cylinder Part DL Part DS Hex Nut Part CV Index Cyl. Rear Part DT Clevis Fitting, Elbow Part DN 38 Index Carriage, Fork Pan Head Screw Part FN Index Fork Top Plate Part DX Snap Action Roller Part FM Flat Head Cap Screw Part DW Index Fork Part DV Female Rod End Part GB Flange Bolt Part GC Female Rod End Part GB Flat Washer Part CS Index Plate Assembly Index Cylinder Part BO Hex Bolt Part DC Flange Nut Part BP Index Plate Part DU Snap Action Roller Part FM Flat Washer Part CS Nylon Lock Nut Part CL 39 Index Shock (Installed) Button Head Part DO Screw Index Shock Javelin 3/4 x 2” Part DY Index Rail Part DQ Index Track Part EA Index Shock Javelin 3/4 x 3” Part DZ Slow Down Switch Assy. Flat Washer Part FO Snap Action Roller Part FM Pan Head Screw Part FP Slow Down Bracket Part FQ Uni Strut Nut Part FR Flat Washer Part FO Part FP 40 7 Stack Assembly Valve Part EG Flip Valve Flow Control Part EJ Fitting Flow Control Part EJ Fitting Valve Part EG 41 Lift Cylinder (Installed) Cork Gasket Part FS Fitting, Elbow Part DN Lift Cylinder Part ED Red Air Line (3/8) Part EB Connector, Male Part EC 42 Lift Valve, Fork/ Flip Valve (Installed) Flow Control (1/4) Part EJ Flow Control (3/8) Part EI Valve Single Part EG Connector, Male Part EE Valve Single Part EG Red Air Line (3/8) Part DM Red Air Line (3/8) Part DM Connector, Male Part EE Muffler Muffler Part EF Part EF Lift Valve, Index Valve (Installed, Overhead View) Black Air Line (1/4) Part EH Flow Control (1/4) Part EJ Flow Control (3/8) Part EI Red Air Line (1/4) Part DM Flow Control (1/4) Part EJ Flow Control (3/8) Part EI 43 Index Valve Valve (Red) Part FT Index Valve Valve (BLK) 1/4” Part EK Index Valve Valve (BLK) 1/8” Part FU Index Valve Valve (WHT) Part EL Muffler Part EF 44 Control Box (Internal View, Right Side) Kep Nut Part EM Pan Head Screw Part CB Fuse Holder Part EN Toggle Switch Part CG Control Box, Power Supply (Installed, Internal View) Din Rail Part FV Power Supply Part EO 45 Control Box, Relay (Installed, Internal View) Kep Nut Part EM Relay Part EP Kep Nut Part EM Control Box, PLC (Installed, Internal View) PLC Part EQ Input Part ER Input Part ER 46 Main Air Assy. (Installed) lockout Valve Part ES (Duplicate Image) Filter/ Regulator Part ET (1/4) Secondary Filter Part EU Fitting Elbow Part BC Dump Valve Part EV Reducer Part EX Regulator (1/8) Part EW Connector, Male Part EC Union (1/2) Part EY 47 WARNING! RISK OF ELECTRICAL SHOCK! Turn ALL power to unit OFF before service. All service should be done by or under the supervision of a trained technician Javelin Control Box, Non Touch Screen: 48 Javelin Control Box, Non Touch Screen: 49 Javelin Pro Wiring, Touch Screen: 50 50 Wire Cable, Wiring: 51 Festo PLC: 52 PLC, I/O: 53 Javelin Pro PLC: Note: See Page 55 for Input/ Output designations: 54 Javelin Pro PLC Input/ Output Designations: Wire Wire Location Color Device Cable Wire Wire Location Color Input Output #1 #1 S/S Red 24V Loop X0 Blue/Wht Index Foot Switch X1 Blk/Wht Missing Shirt Foot Switch X2 Wht/Red/Blue Printhead 1 On/Off Switch X3 Grn/Red/Org Printhead 2 On/Off Switch X4 Red/Blk/Grn Printhead 3 On/Off Switch X5 Blue/Wht/Org Printhead 4 On/Off Switch X6 X7 C0 White BLK 0 Y0 Wht/Blk BLK 3 C1 White Y1 ` White Y2 Red/Grn C3 White Org/Blk/Grn Printhead 5 On/Off Switch Y3 Grn/Blk Wht/Blk/Blue Printhead 6 On/Off Switch C4 White Input Y4 #2 C5 White Y5 Org/Blk S/S Red 24V Loop 0V Loop Printhead 1 Stroke Valve 0V Loop 0V Loop Printhead 3 Stroke Valve 0V Loop Printhead 4 Stroke Valve 0V Loop Org/Blk/Wht Printhead 5 Stroke Valve 0V Loop Printhead 6 Stroke Valve X0 Blue/Red/Org Printhead 1 Manual Switch C6 X1 Wht/Blk/Grn Printhead 2 Manual Switch Y6 X2 Blk/Blue/Wht Printhead 3 Manual Switch C7 X3 Grn/Blk/Org Printhead 4 Manual Switch Y7 X4 Blk/Org/Red Printhead 5 Manual Switch Output X5 Red/Grn/Wht Printhead 6 Manual Switch #2 X6 Blk/Org/Wht Print On/Off Switch C0 White X7 Org/Blue/Wht Foot Pedal On/Off Switch Y0 Org/Red Brown Wire to F/B Switch Input Y1 Org/Grn Blue Wire to Index Valve #3 Y2 S/S Red X0 Blue/Blk X1 24V Loop Y3 Table Up Switch Blk 1 Y4 Blue In Location Switch Blk 2 Y5 X2 Orange Slow Down Switch Blk 4 Y6 X3 Wht/Red Fork Switch Blk 5 Y7 X4 Wht/Org/Red Auto Manual Switch Cable Grn/Blk/Wht Printhead 2 Stroke Valve C2 ` Device 0V Loop Red/Blk/Wht Red Wire to Fork Valve Black Wire to Relay Coil White 0V Loop Output #3 C0 Y0 Blk/Red/Grn Black Wire to Dump Valve Y1 Blue/Blk/Wht To the Flip Valve Y2 Y3 Y4 Y5 Y6 Y7 55 Javelin Base Wiring 6/8/10 color: 56 Javelin Pro Base Wiring: 57 7/10 Stack Wiring: 58 Head Plumbing/ Wiring: 59 Screen Clamp Plumbing: 60 Flip Cylinder Plumbing: 61 Print Arm Plumbing: 62 WARNING! RISK OF ELECTRICAL SHOCK! Turn ALL power to unit OFF before service. FAQ: All service should be done by or under the supervision of a trained technician 1. My Javelin will not turn on. If there is no air, the press will give the appearance that there is no power, but actually there is no air. Turn the Main Power switch on. The emergency stop button should be in the out position, on newer machines the light should be off when it is set correctly Make sure the safety cable is plugged in correctly Make sure the power cable is plugged in, you can check that the machine has Image 1 power by turning the registration lamp on. Check the fuse to the left of the power switch (Image 1) Check the Fuse at the power supply on earlier models, Located in the base, attached to the frame. If all of these things are good we can begin to trouble shoot. Start with bypassing the safety cable for the first test. On newer machines you will need to pull the flow plate off the top of the print arm and find the connection point for the cables. Use wire nuts and connect the wires together this will close the circuit. If this fixes the problem you will need to figure out what is wrong with the cables, on older machines the safety cable makes the main connection near the center of the machine. You will need to pull the hole plugs off the top of the print arms and pull the wires through, remove the blue wire nuts and twist the wires together. Image 2 Output Input If this does not correct the problem will need to get a digital volt meter. Using a digital Volt/Ohm meter in the ACV setting (500700) verify there is 110 volts AC going to into the power supply. If the power supply is getting the correct input voltage next check for 24VDC coming on the out of the power supply. If the correct voltage is coming from the power supply we need to go the PLC where the connections are and see if we have 24vdc there, On older Javelins the -24vdc is connected direct to the PLC and the +24 vdc goes through safety circuit. On javelin pro the +24vdc is connected direct to PLC and the -24 vdc goes through safety circuit. 63 Note: Most of information contained in the FAQ section concerning timers, and viewing external lights of the PLC may not pertain to the newer Javelin Pro series presses. As the same symptoms may appear on both older and newer presses, the solutions are the same. But, all timers on the newer Pro series presses are internal of the HMI and the PLC Input /Outputs can be viewed from there as well. Any further testing of switches, valves, connections, voltage readings and indexing adjustments are the same. Delay times, print times and slow down timing is all controlled using the HMI and internal programming. 2. The Press tables up but will not print. The normal sequence for this process is the table raises then just sits there waiting to print and nothing happens until you turn the power off. Then you start all over and it still just sits there again. The machine will not print if the table up sensor is not making a connection to the PLC, on older javelins and on Freedoms this sensor will register under green lights #1 This is in the first bank of Green lights in the E16A The input is #1 to the PLC showing it has made Contact and it is ok to begin the print stroke. ON The Javelin Pro you can see if the switch is being made by hitting the F1 key and go to diagnostics, at diagnostics you can then select sensors and see if contact is being made or PLC and see if the X30 is being made On either PLC if the connections are not being made, the table up switch will need to be adjusted or replaced. With machine off locate the table up switch, note the location of the current position of the black and white wires, remove the wires. Next using a digital Volt/Ohm meter in the resistance setting (Upside down omega symbol) to test the switch for continuity place one probe on “COM” terminal of the switch and the other probe on the “NO” terminal. With the probes in place depress the switch, the meter should have a low reading or produce a beep, if the meter reads zero or does not produce a beep the switch will need to be replaced. If the switch is functioning properly a simple adjustment may be needed. To adjust the switch, with your thumb on the base of the tab where it connects to the switch body, bend the tab down towards the floor just enough that it makes adequate contact with surface of the carousel when the press tables up. Adjust as needed until press functions properly. 64 3. Table will not lower after printing This normally only on older Javelins and Freedoms, Not so much on the Javelin Pro as the timers are built in to the program After the Press has made the print stroke the PLC is looking for the print timer to finish, once this happens it sends a signal to the input labeled 0 in the E16A if the #2 yellow light is on under the A12C this is output to the print timer. If that light is still on your print timer has not cycled. You should open the control box and make sure the connections are secure at the timer and the speed pot. If all the connections look good will need to get a VOM and check for the 24vdc going to the timer and through the timer back to base. On the orange power lamp, there are 2 purple wires one is the -24vdc leg this is normally connected with a White blue red wire. Expose this connection by removing the blue wire nut. Then with the machine still in the middle of the cycle we can to see if there is +24vdc going to the delay timer and coming out of the timer. If this all test good then we need to test the wire that comes from the timer and runs to the input #0 under the E16A If it test bad we can switch the timer around with one of the other timers in the control box, I would use the delay timer so we are able to get past the flood time with a manual stroke. If this still does not correct your problem or at least move it the it is most likely a bad wire 65 4. My Javelin will not table up Depending on the command we give, the machine will direct us on where to start trouble shooting. Say we hit manual print and the squeegee does not move it just sits there and the press does nothing, then we should check that the press is in location and that the PLC is showing location light is on. Freedom’s and older Javelin will have Green light #2 on under the E16A and the Javelin Pro will be able to be checked by going to diagnostics and checking the sensor is made Table in location. If the sensor is not made the machine will not perform. Say we hit the manual print and the squeegee moves forward and then the table just sits there, then we should then check if we turn the machine off and back on will it table up? If so, then we need to check on the PLC is the orange light #1 on and the flood timer not timing out? This will be on older javelins and Freedoms. If the light is on then the flood timer has not cycled, and we need to diagnose the flood timer and see if we have a loose connection. You should open the control box and make sure the connections are secure at the timer and the speed pot. If all the connections look good will need to get a VOM and check for the 24vdc going to the timer and through the timer back to base. On the orange power lamp, there are 2 purple wires one is the -24vdc leg this is normally connected with a White blue red wire. Expose this connection by removing the blue wire nut. Then with the machine still in the middle of the cycle we can see if there is +24vdc going to the Flood timer and coming out of the timer. If this all test good then we need to test the wire that comes from the timer and runs to the input #0 under the E16A Another Scenario is you just hit table up and nothing happens machine will do other functions but just will not table up, Then we start looking at other items for example Flashbacks on the machine interfering with the output, first step is to check the simplest thing. Are the air supplies turned on to the flashbacks, if not turn them on as this allows the element tray to drift forward. Are all the Flashback cables plugged in and Dummy plug in the last Flashback? If this is correct is the #5 orange light on? If yes at this point put the dummy plug in to the base of the machine and then try to table up again if this corrects the problem then we know it is somewhere in the flashbacks if not then we need to go directly to the valve and check it for 24vdc. If the valve has 24vdc then we have a bad valve. If the Dummy plug in the base solved the problem we need to go to the Flashback trouble shooting for more in depth testing of the Flashbacks. Refer to the Flashback Tech Guide for further testing. 66 5. The press will not print. Press tables up then just sits there until you turn the power off. When the machine raises it hits a switch that then sends a signal to a PLC that the table is up. If the switch is not making contact, the machine will not finish it needs the switch to continue on. Normally just lowering the switch or fixing a loose connection will cure the problem however you may need to change the switch if it is damaged or covered in spray adhesive. On some machines it is in between the #3 and #4 print heads on others it is in front of the on Load and un-load stations. With machine off locate the table up switch, note the location of the current position of the black and white wires, remove the wires. Next using a digital Volt/Ohm meter in the resistance setting (Upside down omega symbol) to test the switch for continuity place one probe on “COM” terminal of the switch and the other probe on the “NO” terminal. With the probes in place depress the switch, the meter should have a low reading or produce a beep, if the meter reads zero or does not produce a beep the switch will need to be replaced. If the switch is functioning properly a simple adjustment may be needed. To adjust the switch, with your thumb on the base of the tab where it connects to the switch body, bend the tab down towards the floor just enough that it makes adequate contact with surface of the carousel when the press tables up. Adjust as needed until press functions properly. 6. My machine spins before I am ready for it to. This requires you to add more Delay time, turn the delay time up for longer flash times especially if your using Flashback. You can also turn the foot pedal on and step on the pedal when ready for the machine to turn 7. The Press tables down before completing the print. Adjust the print timer on the control box to a higher number to increase print dwell time. Pull the base panel off the press an locate the PLC. With the press powered on, and the pallet table down check the PLC for green light 1.1 If the 1.1 light is on the table up switch is stuck in the on position. Check the condition of the switch and replace if required. With machine off locate the table up switch, note the location of the current position of the black and white wires, remove the wires. Next using a digital Volt/Ohm meter in the resistance setting (Upside down omega symbol) to test the switch for continuity place one probe on “COM” terminal of the switch and the other probe on the “NO” terminal. With the probes in place depress the switch, the meter should have a low reading or produce a beep, if the meter reads zero or does not produce a beep the switch will need to be replaced. If the switch is functioning properly a simple adjustment may be needed. To adjust the switch, with your thumb on the base of the tab where it connects to the switch body, bend the tab down towards the floor just enough that it makes adequate contact with surface of the carousel when the press tables up. Adjust as needed until press functions properly. (Older Javelins) If the switch is working properly, you may have a defective print timer. Locate the print timer inside the control box by following the two wires from the print timer control to the print timer. Replace the print timer. The print timer may be timing out early also from static discharge and it may need to be grounded out with a resistor to drain any left over power in the line. See wiring diagrams section for resistor wiring specs. 67 8. The Squeegee’s Flip to hard or not fast enough When the squeegee flips it is controlled by the flip valve it the valve is set to fast it can cause the squeegee to snap over to fast slinging the ink forward (make sure print head is not running to fast forward causing the ink to fly forward) Adjust the flow controls on the flip valve to make squeegee flip at a controlled speed, by turning clockwise it will slow the flip. Counter clock wise will speed it up To test the flipping motion put the machine in automatic with 2 strokes and make sure the flip is fast enough on the table down after the first print stroke and when the table raises for second print stroke. Remember though that the motion does not need to be super fast, a nice and controlled motion is ideal. 9. The Squeegee’s lose pressure before completing the print stroke. This condition is usually a defective flip cylinder. It is usually worse on one head, but can affect other heads as well. You may hear an unusual flow of air. The head with a defective flip cylinder may not even be one of the heads you are using, but it can still affect other heads ability to hold pressure. If you can hear air leaking when you have the print toggle switch in the on position we will need to find what is causing the leak. A weak cylinder can cause loss of pressure on a print stroke excessive pressure can cause it and ink that is really thick will give the same result as well. Printing with white ink is usually the biggest culprit for loss of pressure if this is the case we need to make sure the ink has been mixed really well before adding it to the screen. If a leak has been heard we need to check the flip cylinders to see if one or two are causing a exhaust of air. The reason for this is all the flip cylinders are branched together off the same valve and one being bad can cause issues at all the others. The best way to test is to raise the tables with the print on and if you have excessive air loss turn the print off and see if that stops the leak of air. If it does, turn the print back on and see if it continues to leak. If it does not, lower the tables and then raise the tables again. At this point if it begins to leak air start by kinking the red and black airlines that come out of the top of the flow plates and wrap with masking tape. Until you stop the leak, then open the airlines one at a time and see which one causes the leak keeping in mind more than one could be bad. Once you have found the bad cylinder it will need to be replaced. You could have a weak cylinder also and you can test for a weak one by just putting a ¾” wrench on the flip block and rotate the block back and forth and compare the weak ones with heads that are printing well you may see some variance in the pressure from head to head using your best judgment on which one is stronger you will want to change the weaker cylinder. 68 9. (Continued) It is not a bad idea to change out all flip cylinders at one time when pressure problems arise. If you had a leak with the print on and table up and you kinked all the airlines at every head and left them taped and the leak continued you may have a bad air valve that needs replacing. Locate the flip valve and kink the red and black coming off the top of it and see if that does not stop the leak before deciding to replace the valve. 10. The heads flood but will not print. This condition usually indicates a defective stroke cylinder. While this head is hung in the flooded position, after other heads have completed there print stroke. You will usually here air leaking. If you hear air leaking, turn both flow controls on top of the print head all the way clockwise. if this stops the air leak you more than likely have a defective stroke cylinder and will need to replace it. But you may also have a valve that is causing it and the easiest method to test that is move airlines blue and green from valve with bad head to valve with good head remembering to open the flow controls that we had closed previously if the problem stays on the effected head it is a bad cylinder, but if the problem then moves to a different head it is a bad valve. If you do not hear any airflow when the print head is hung in the flooded position after all other heads have finished printing and table has come down. You may have a stuck valve and you can test this also by moving the airlines from known working head and the bad one and if you do move the problem you will know for sure the valve is bad. You may also be able to add to tool oil into the valve and get it to function, this may loosen the valve up and keep it running to get through a job. But this is not a permanent fix the valve will need to be replaced Javelin presses with an index timer and an index pressure regulator. If the pallet table had a sudden change in the way it indexes that makes it hit hard at the end of the index you may not be depressing the slow down switch enough to activate it. With the press turned on push down on the slow down switch. As you press the switch the red light on the slow down timer that is marked ”up” will come on for a second then go back off. If this does not happen you may need to replace the slow down switch. Index the press in auto mode and watch the red light on the index timer. It should cycle on for a second as the pallet table turns. If it does not, you need to adjust the slow down switch up. After adjusting the switch, turn the press off and push the index carriage over the switch by hand to insure it is adjusted to let the switch activate in both directions. Check the setting on the index timer, it may have been unintentionally moved. The normal setting for most presses is about .2 check the “T” and “F” dip switches on the index timer. T = 00, f = 01 these get bumped all the time from just rotating the control box out of your way Make sure your compressor is delivering 110 psi to the main regulator, and can maintain 110 psi while the press is running. The pressure will drop during the print cycle but should recover to 110 psi after each index. Check the pressure setting on the index regulator The pressure should be around: 8 pallet press = 40 psi 12 pallet press = 60 psi 10 pallet press = 50 psi 14 pallet press = 70 psi. This will very from press to press, if you have the older version indexer with the nylotron block, it will require more air pressure to cycle. The Linear wheels and tracks will require less air pressure to cycle the machine. 69 Screen Shot Reference 70 Screen Shot Reference 71 Comprehensive Parts List Description P/N Description Description P/N P/N A. Front Micro Assembly SA-0060 AH. Shoulder Bolt (5/16 x 1.75 ) B. Screen Clamp I-0003 AI. Female Rod End (5/16-24) B-0004 C. Rear Screen Clamp Hanger T-0210 AJ. Flow Plate I-0139-SCR D. Large Lever (5/16-18 THD) K-0006 AK. Plastic Snap Bushing 1" F-0154 E. Fitting Elbow 5/32T X 1/8 NPT 20-02-024 AL. Toggle Valve 20-07-019 F. Fender Washer AM. Flow Control A-0971 G. Knurled Knob SA-0103 AN. Branch Tee (5/32 T x 10-32) A-0003 H. Micro Target Label 68-1610 AO. Black Poly Air Line (5/32) PER FT A-0301 I. Flange Nut 42-FLG-500-15 AP. Fitting Elbow (10-32 NPT x 5/32TUBE ) 20-07-017-1 J. Micro Lock Cap AQ. Male Tube Fitting (1/4 x 1/4) A-0032 K. Hex Bolt (5/16-18 x 2) 41-HTB-3125-15 AR. Button Head Screw (5/16-18 X 1) L. Nylon Lock Nut 42-NYL-3125-10 AS. Squeegee Stop Assy. SA-0025 M. Flat Washer 43-FLT-250-20 AT. Aluminum Squeegee Track T-0167 N. Wave Washer 43-WAV-M8-10 AU. Spring, Squeegee Stop M-0045 O. Jam Nut 42-JAM-375-10 AV. Vinyl Cap F-0904 P. Spring 49-1280 AW. Swivel Pad F-0902 Q. Rod End (RH) I-0265 AX. Squeegee Carriage Wheel B-0101 R. Hex Bolt (3/8-16 x 1.5) AY. Squeegee Carriage WA-0153 S. Shoulder Bolt T-1977 AZ. Hex Bolt (1/4-20 x 1/2”) T. Rod End, (LH) I-0266 BA. Stroke Cylinder 20" A-0140 U. Wave Washer BB. Hose Clamp A-0910 V. Screen Clamp Cylinder A-0119 BC. Fitting Elbow Compact (1/4 T x 1/8) A-0015 W. Screen Clamp Cylinder Foot F-0106Z BD. Stroke Cylinder Mount I-0294 X. Hex Bolt (1/2-13 x 3") 41-HTB-500-10 BE. Spring, Stroke Cylinder M-0402 Y. Flange Nut 42-FLG-500-10 BF. Nylon Lock Nut Z. U-Bracket Weldment WA-0128 BG. Flipper Block T-0201 AA. Hex Bolt (1/4 - 20 x 1) 41-HTB-250-50 BH. Squeegee Pin SA-0004 AB. 4 Prong Knob (5/16-24 THD) BI. Squeegee Angle Stop Barrel T-0095 AC. Jam Nut BJ. Male Rod End (1/2-20) B-0006 AD. Spring M-0319 BK. Hex Nut AE Lever ( 5/16-18 x 1-9/16 STD) K-0005 BL. Clevis Kit A-0916 AF. U-Bracket, Stopper I-0302 BM. Spade Bolt I-0022 AG. Kep Nut (1/4 - 20) BN. Jam Nut 43-FND-3125-10 I-0514 41-HB-375-55 43-WAV-10-10 K-0002 42-JAM-250-10 42-KEPS-250-10 41-SB-3125-05 41-BHCS-3125-40 41-HB-250-15 42-NYL-250-10 42-HEX-500-30 42-JAM-375-15 72 Comprehensive Parts List Description BO. Flip Cylinder BP. P/N Description Description P/N P/N A-0102 CU. Registration Forks Flange Nut 42-FLG-375-10 CV. Hex Nut 42-HEX-437-20 BQ. Hex Bolt (3/8-16 x 4) 42-HB-375-100 CW. Flat Washer 43-FLT-375-20 BR. Bronze Bushing, Flanged (3/8) CX. Square Head Bolt (5/16-18 x 2) 41-SQH-3125-10 BS. Shoulder Bolt (3/8 x 3/4) CY. Number Label (1-12) 35-33-007-(1-12) BT. Squeegee Angle Adj. Weldment WA-0101 CZ. Registration Bearing B-0012 BU. 4 Prong Knob (1/2-20 THD) K-0017 DA. Vertical Mylar Ruler 35-33-006 BV. X-Large Lever (3/8 - 16 THD) K-0014 DB. Hex Nut 42-HEX-375-20 BW. Squeegee Pressure Adj. Assy. SA-0005 DC. Hex Bolt (3/8-16 x 2-1/2) 41-HTB-375-10 BX. Jam Nut DD. Hex Bolt (5/16-18 x 2) 41-HB-3125-30 BY. Shoulder Bolt T-0913 DE. Cam Lever (Left) 34-41-002 BZ. Flange Bolt (5/16-18 x 1) 41-FLG-312-10 DF. Cam Lever (Right) 43-41-001 CA. Flat Washer 43-FLT-8-10 DG. Communicator Bracket I-0025 CB Pan Head Screw (#6-32 x 1-1/4) 41-PHMS-6-50 DH. Dummy Plug EA-0007 CC. Control Arm (Inner) WA-0129 DI. Lift Lug WA-0121 CD. Lamp 390698 DJ. Hex Nut CE. Control Panel Javelin (Empty) I-0017-SCRJ DK. Communicator Plug 390692 CF. Control Box Javelin (Empty) WA-0089-1 DL. Index Cylinder A-0104 CG. Toggle Switch (SP/ST) E-0106 DM. Red Poly Air line (3/8) A-0306 CH. Button Switch (Red) E-0991 DN. Fitting Elbow (3/8T x 3/8P) 20-02-029 CI. Illuminated E-Stop Switch CJ. Delta HMI 30-1612 DP. Clevis Kit A-0905 CK. Snap Action Switch E-0982 DQ. Index Rail T-1999 CL. Nylon Lock Nut 42-NYL-375-10 DR. Index Cyl. Rear Mount A-0902 CM. Socket Head Screw (3/8-16 x 2) 41-SHCS-375-50 DS. All Thread T-0904 CN. Flange Bolt (3/8-16 x 1-1/2) 41-FLG-375-20 DT. Index Cyl. Rear Clevis A-0904 CO. Roller Bearing (1 3/8 ) B-0018 DU. Index Plate WA-0195 CP. Hex Bolt (3/8-16 x 1-1/2) DV. Index Fork WA-0194 CQ. Pork Chop Bearing Swivel T-0525 DW. Flat Head Cap Screw (1/4-20 x 3/4) 41-FHCS-250-10 CR. Flange Bolt (3/8-16 x 3/4) 41-FLG-375-10 DX. Index Fork Top Rails T-0275 CS. Flat Washer 43-FLT-375-10 DY. Index Shock (3/4 x 2") M-0401 CT. Flange Bolt (3/8-16 x 3/4) 41-FLG-375-10 DZ. Index Shock (3/4 x 3") M-0400 B-0022 41-SB-375-30 42-JAM-3125-10 10-11-024-2 DO. 41-HTB-375-30 Button Head Screw (1/4-20 x 1/2) T-0059 42-HEX-625-20 41-BHCS-250-10 73 Comprehensive Parts List Description P/N Description Description P/N P/N EA. Index Track T-0205 FG. Off Contact Spacer I-0023 EB. Black Poly Air Line (3/8) A-0056 FH. Hex Nut 42-HEX-625-10 EC. Connector, Male (3/8 Tube x 3/8 NPT) A-0029 FI. Wave Washer 43-WAV-250-10 ED. Lift Cylinder (3” New Style) A-0106 FJ. Collar B-0103 EE. Connector, Male (3/8 Tube X 1/4 NPT) A-0022 FK. V-Block T-0301 EF. Muffler A-0030 FL. Shoulder Bolt EG. Valve Single (Top Ported) A-0126-1 FM. Snap Action Roller Switch EH. Black Poly Air Line (1/4) A-0056 FN. Pan Head Screw 41-PHMS-6-70 EI. Flow Control Fitting (3/8) A-0043 FO. Flat Washer 43-FLT-250-10 EJ. Flow Control Fitting (1/4) A-0042 FP. Pan Head Screw 41-PHMS-250-20 EK. Index Valve (black) A-0126 (REV A) FQ. Slow Down Bracket I-0568 EL. Index Valve (White) A-0126 (REV B) FR. Uni-Strut Nut F-0079 EM. Keps Nut 42-KEPS-6-10 FS. Cork Gasket M-0705 EN. Fuse Holder E-0912 FT. Index Valve (VERSA) A-0127 EO. Power Supply 30-1615 FU. Index Valve (Parker 1/8") A-126(REV A) EP. Relay 10-06-008 FV. Din Rail 10-08-017-04 EQ. Delta PLC, 14 Point 30-1600 FW. PEM Stud 44-FH-0420-16 ER. Input Module, 16 Point 30-1605 FX. Lock Washer 43-LOK-250-30 ES. Lock-Out Valve A-0097 FY. Hex Nut 42-HEX-250-30 ET. Filter/ Regulator (1/4) W/ Gauge A-0143 FZ. Flow Control (Old Style) EU. Secondary Filter A-0142 GA. Disc Washer EV. Dump Valve A-0210 GB. Female Rod End EW. Regulator (1/8) W/ Gauge A-0219 GC. Flange Bolt EX. Reducer (5/32 TUBE x 1/4 TUBE) A-0012 GD. Lower Sq. Adj. Assy. SA-0008 EY. Union (1/2) 20-03-005 GE. Red Poly Air Line (1/4) A-0054 EZ. Shoulder Bolt FA. Knob FB. Hex Nut FC. All Thread T-0915 FD. All Thread T-0901 FE. Hex Nut FF. E-Clip 41-SHCS-375-75 E-0101 A-0201 43-DIS-375-10 B-0005 41-FLG-375-15 41-SB-3125-10 K-0008 42-HEX-3125-20 42-HEX-3125-40 F-0957 74
