Bob's Automatic Installation Cheat Sheet

By Bob Drake

Getting it off the Truck

An automatic is a pretty big piece of equipment. The truck is going to pull up and open its back door. Unloading the freight is then your responsibility. A hand pallet jack and a forklift (customer supplied) are the only two things you will usually need to get the equipment into your shop. The factory recommends a 5,000 lb capacity forklift with 6 foot blades. Once off the truck, you will usually be able to move the printer base (the heaviest part) with just the pallet jack. This will come in handy when moving the printer into exact position at the time of install. Before signing the truck drivers bill of lading inspect the crate for damage. Note any damage on the bill of lading and report it to us so we can assist with any freight claims and arrange for replacement parts.

Door Clearance

A special 34 in. door clearance machine is available for a $500 cost and must be preordered with the machine. Otherwise, we need a path 84 in. (7 ft.) wide from the entrance of the building to the machine’s final location. Machines larger than six colors may require additional clearance, so if your space is tight, let us know so we can get you exact measurements.

Clear Span

A six color machine requires a minimum of a 10.5 ft. diameter circle to fit. There can be no obstructions (i.e. columns) within this circle. Ideally you’ll add a 2 to 3 ft. walking space all the way around the machine. Many installations save on space by pushing one side of the machine against a wall. This will save space, but you’ll have to walk part way around the machine in each direction when setting up a job.

Floor

A concrete floor is preferred for installation. If you have a wood floor and are in a commercial building, we need to talk first. A wood floor installation may require an extra piece of plywood or a metal plate placed on the floor to spread out the weight of the equipment.

Electrical

You must supply the electrical connections to your building.

Tuf Freedom or Javelin Automatic Printer

Drop cords from the ceiling, directly over the center of machine. Make the cords long enough to fall to the floor. Extra wire can be cable tied out of the way during installation.

1. 110 VAC 5 amp three-prong. The machine comes with the male plug, you provide just the female plug on the end of drop cord.
2. 220/115VAC single phase 20 amp (Flashback) has four wires (requires neutral). That means two hots, one ground and one neutral. Again, go with heavy duty twist locks and make cord long enough to fall to floor. Please consider using a little lower gauge (heavier, fatter) wire than the electrical books say, as this flash draws 100% load when operating. If you ordered more than one Flashback then run a separate 20 amp drop cord for each one. The Flashback just has a pigtail and you supply the male twist lock plug. This works out nicely because your electrician can provide the matching twist lock plug and receptacle.

Air Compressor and Air Dehumidifier/Chiller

1. 230 volt, single phase 34 amps (7.5 hp compressor). You'll need to hard wire into the compressor.
2. 115 volt, 15 amp (chiller). Chiller has a standard three-prong plug, so you just need an outlet nearby.

Note: The factory will call and ask to hear your air compressor run before they will schedule the technician to fly in for the install. Getting electric run to the compressor is the first thing you should do.

Air Compressor Hose and Fittings

You supply the hose and fittings.

I recommend heavy-duty 300 p.s.i., ¾-in. i.d. rubber air hose. Add swivel connections on both ends if you are having the hoses made. If you are using the Grainger parts list (below) then swivels are not required if the last thing you do is press the hose onto the hose barb fittings and secure with hose clamps. (1 in. hose is required for runs over 50 ft.)

The equipment will have the following air outlet specifications:

• ½-in. NPT female out of 6/8 auto (requires ½-in. NPT male on your hose)
• ½-in. NPT female out of compressor (requires ½-in. NPT male on your hose)
• 2 x 3/4-in. NPT male in and out of chiller

Usually you can source air hose locally at Grainger (www.grainger.com), an industrial supply house or plumbing store. Home Depot usually doesn’t stock large enough or long enough hose.

A sample shopping list for hose and fittings at Grainger looks like this:

• Qty 1 -- Stock #4XR60 50 feet x ¾-in 300 p.s.i. hose @ $82.30 each
• Qty 1 -- Stock #5X584 tape sealant, size 3/4 x 520 in. @ $2.29 each
• Qty 2 -- Stock #6JM72 reducing coupler, pipe size 3/4 x 1/2 in. @ $4.87 each
• Qty 2 -- Stock #3LZ74 boss fitting, male NPT size 3/4-in., 3/4-in hose barb @ $5.82 each
• Qty 2 -- Stock #6KV41 nipple, size 1/2 x 2-in., 316 stainless steel @ $2.58 each
• Qty 2 -- Stock #5P920 coupling, pipe size 3/4-in., galvanized pipe, class 150 @ $1.67 each
• Qty 1 -- Stock #4XZ77 10-pack hose clamp stainless @ $16.22 each

For a Tuf Javelin printer the best way to run the hose is up the ceiling and then drop it down the middle of the machine. The center shaft of the machine is hollow, so the hose will run right through it and the final connection will be made under the machine. 

For a Tuf Freedom printer there is no hollow center shaft. The hose would typically be run from floor to ceiling just outside the diameter of the machine so that it doesn’t interfere with the load and unload stations. The hose would then run along the floor underneath the Tuf Freedom printer where it will get connected to the air inlet of the printer. Your town’s codes may require a small rubber “ramp” (or something similar) to go on the floor over the hose (to prevent a trip hazard).

Be sure to properly secure all air hoses (clamp down a minimum of every 36 in.), as a broken air hose can cause bodily injury if it whips around and hits someone. Some customers use steel threaded pipe instead of hose. A short length of hose is still required to make the connection to the equipment and the compressor/chiller to isolate vibration. I am not a big fan of pipe installations because they are more expensive and can foul your printer if their rust ends up in your printer's cylinders.

It is preferable to put the chiller closer to the automatic press than the compressor. This gives the air some distance to cool down before it hits the chiller. If the only available location for the chiller is right next to the compressor, that will be OK, but not preferred.

If you use the Grainger hose #4XR60 in the above list, it comes with 3/4-in. male NPT fitting on both ends. These ends will both go into the chiller (with #6JM72 reducing couplers in between). Then cut the hose to allow appropriate lengths going to the compressor and the automatic press.

Uncrating

Don’t uncrate the printer, flash or accessories. The tech will uncrate and put the entire printer together. 

Installation and Training

This typically takes between 12 and 16 working hours. The tech will require the assistance of one of your employees for about an hour to help him install the print heads. 

For operator training, you should have a couple of multicolor jobs burned on 23x31-in. o.d. screens. Manual sized screens will not work on the automatic printer. You need to get some 23x31-in. o.d. screens coated and burned before the technician arrives.

A full front image burns 6.5 in. down from the top outside edge of the screen. It’s important on a multi color design that the image on each screen be burned at the correct height. You have only about an inch of “up and down” adjustment on press and maybe 2 in. “left and right.” Burn your “tallest” film positive first at 6.5 in. down from the top outside edge of the screen. Make a note of how far down and over from the inside of the screen one of the registration marks is. When you burn the rest of the screens, make sure that same registration mark is “down and over” the same distances as on the first screen.

If you purchased a flash, it would be a good idea to run a job on darks so you learn how to operate the Flashback. 

The technician will go over all the operating features of the press. His job is not to burn screens or to do the actual printing for you. A basic understanding of screen printing is a prerequisite. The technician does not teach basic screen printing. He does teach you how to setup and operate every feature of the automatic printer and flash. He also covers any required maintenance (which is minimal).

Final Payment

Please pay the technician your balance due in the form of a certified or cashiers check when the installation is complete. Please make the check payable to “Performance Screen Supply, LLC.” The technician is not allowed to leave the installation without payment. Please take weekends and holidays into account and don’t wait until the last minute to run to the bank.