DR-T300B Multifunction Hot Air Welding Machine

Instruction Manual
Version: Rev.201708

Manufacturer: SHENZHEN DANREL INDUSTIAL CO., LTD

Tel: +86-15899697780

Website: www.danrel.com

Email: [email protected]

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 Forewords

Thank you very much for choosing DANREL Hot Air Seam Sealing

Machine, wishing you have a booming business, meanwhile, our company

sincerely hopes you can pay attention to the safety regulations during

operation.

DR-T300B Hot Air Machine produces airtight and waterproof seams for 2D

and 3D inflatables with curves or custom edges, for uses such as white-water

rafts, military attack boats, airplane escape chutes, inflatable bounce houses

and tents and more. The DR-T300B machine only requires one-man

operation and is adaptable to configure a variety of seams. This machine is

built for multiple-shift production, and with its solid-steel design, this

machine can last for multiple decades.

We have tested and debugged the machine before shipment. If there is any

failure or broken during the use or transportation, please contact our sales

team immediately, we are ready to assist.

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External View of the Machine

① Rollers ⑥ Electronic Cabinet

② Hot Air Nozzle ⑦ Swing Arm/Throat
③ Foot Pedal ⑧ Power SW.
④ Roller Pressure ⑨ Lamp
⑤ Hot Air Pressure ⑩ Tape Dispenser

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Principle characteristic performance parameters

2.1.Working principle

Hot air welders use very precise heat, speed and pressure to join thermoplastic industrial

fabrics and films. The correct combination of these three parameters will allow you to

achieve a complete weld. During the hot air welding process, heat is provided by

compressed air blowing across electrical heat elements and is injected at the welding

point. The tightly controlled temperature can range from 1000 F to 1,350F (400C to

750C).

Hot wedge welding uses a heated metal wedge to provide the required heat for melting

the thermoplastics. A heated wedge heats the materials prior to passing through rollers,

and the combination of pressure and heat forms a hermetic seal that is permanent and

tear-resistant. Compared with hot air welding, hot wedge welding has less noises(no

noise) and has very few fumes.

2.2.Features

2.2.1. PLC/HMI easy operation touch screen , English Interface.

2.2.2. Precise Temperature control, heating temperature up to 750 ' C

2.2.3. Suitable for wide range material seam sealing.

2.2.4. Quick, repeatable head adjustments for precision welding

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2.2.5. Quick, easy guide change for multiple seam configurations, overlap, hem, hem

with cord, butt seal with tape, etc

2.2.6. Available in hot wedge, hot air or equipped with both for optimal product

production.

2.2.7. High Quality Imported components, Japan PANASONIC PLC, OMRON,

AIRTAC Pneumatic Parts, etc

2.2.8. Arm length can be customized, 800 mm (standard), 1300 mm, 1500 mm

2.3 Performance parameters

Rated voltage: AC~220V; rated frequency:50／60Hz

The temperature of hot air: up to 700℃

The temperature of the hot wedge: up to 450’C(if applicable)

Hot Air Heater Power: 3500W

Hot Wedge Heater: 450W(if applicable)

Total air pressure: 0.5MPa

The pressure of upper roller: 0.01~0.5MPa

Speed: 1.1-18m/min(adjustable)

Width of pinch roller: 20/30/40/50mm

Diameter of roller: 75mm

Nozzle width: 20/30/45mm

Swing Arm Length: 800-1300-1500-1800MM(as request)

3. Introduction of structure and function

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3.1.Structure composition of the mechanical part
Framework assembly, transverse arm assembly, hot air gun nozzle, slide block assembly,
swing gun and adjusting component, the upper roller component

3.2 Composition of the circuit controlling section

3.2.1. Control panel and power switch
Human-computer interface touch screen is convenient for operation, setting parameters.
3.2.2. Function of dynamical part
(1) Fan: for the heater heating, fan must be normal before heating; outlet assembly with
a copper gate valve and a pressure gauge, according to the need to adjust the size of the
heater air volume.
(2) Stepper motor: used to provide power source for the upper and lower press wheels
through the driving system.
3.2.3. Function of the heating part
The heating part mainly consists of heating inner tube and outer tube, which is used for
heating the compressed air blown into the heating inner tube, and transferring the heat to
the fabric, so as to conduct bonding.

3.3 Composition of the gas circuit controlling section

Water filter, pressure governor valve, solenoid valve, muffler, pressure gauge, current
limiter, cylinder, quick connecting and air tube.
3.3.1. The water filter, pressure governor valve are generally connected as a whole, the
main function is to filter the moisture in the air, to add a proper amount of lubricating oil
to the gas circuit controlling section and adjust the total gas pressure.
3.3.2. pressure governor valve.
(1) Pressure governor valve of air gun pressure: used for pressure adjustment of the upper
pressure wheel. Pull the handle up, adjust leftwards and rightwards, it can be increased in
a clockwise direction, or decreased.
(2) Pressure governor valve of upper wheel pressure: used for air gun pressure regulation.
Pull the handle up, adjust leftwards and rightwards, it can be increased in a clockwise
direction, or decreased.
3.3.3. Solenoid valve: Used to control the movements of each cylinder.
3.3.4. Muffler: used for electromagnetic exhaust and noise elimination.
3.3.5. Pressure gauge:

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(1) The pressure gauge of the air gun is used to display the pressure value of the air gun.
(2) The upper wheel pressure gauge is used to display the pressure value of the upper
wheel.
3.3.6. Current limiter:
a. Upper roller cylinder current limiter is used to adjust the lifting speed of the upper
roller, and to make it stable and smooth.
b. Posing gun cylinder current limiter is used to adjust the speed of the posing gun, and
to make it stable and smooth.
3.3.7. Cylinder
(1). Upper roller cylinder is used for the lifting control of the upper roller(upper pressure
wheel)
(2). Swing gun cylinder is used to control the putting in or out of the hot air nozzle
(heating external tube).
3.3.8. The quick connecting and air tube are used for connecting various pneumatic
control components.
3.3.9. Functions of other switches
(1) Air switch for electric leakage: used for the protection and control of the total power
supply
(2) Left pedal switch: control the hot gun posing and the start of press wheel
(3) Right pedal switch: control the lift of the upper roller press wheel.
Note : If you only step down the left pedal, then the press wheel will turn, while
the hot air nozzle will not pose in.

4. Operation guide
4.1 Preparation before operation
4.1.1 The hot air seam sealing machine must be placed in a place of a fixed position to
prevent it moving and sliding to the floor.
4.1.2 The operation condition of this machine is shown in the following:
the power supply should be 220V, the air pressure should reach to 0.35
～0.5MPa, the cable for the input power shall be capable of bearing the
overload of voltage and current, and check whether the ground
protection is good or not.
4.1.3 Before heating up this machine, check that there are any inflammable and
explosive articles existing in the ambient environment, if yes, clean up the site, and
store those inflammable and explosive articles in a safe place.
4.1.4 When heating with the hot air gun, clothes, human body or other objects can not be
in contact with the hot outer hot air gun tube in order to avoid burning or scalding.
4.1.5 When using adhesive tape, be careful of hands burnt by hot air gun and injured by
scissors.
4.1.6 When heating up adhesive substances, it is necessary to wear protective gloves (half
gloves with five figures exposed to outside) in order to avoid burning of hands.
4.1.7.Please take a safety lesson and basic training operation for the worker at least one
hour in the first time operation.
4.1.8 The worker without training should not open and operate this machine in case of
abnormal usage to cause machine damage and work-piece failure and hurt workers.
4.1.9 Please do not play fun and games during working to keep from dangers

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4.2 Operation instructions of the whole machine
A.English and Chinese language selection screen:

Chinese and English language selection page: can choose to enter Chinese or English
interface.

B.Main picture:

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Speed Setting: to set the rotation speed of the rollers, also known as welding speed.
Ranges from 1.1-18 meters/min; Please change the value gradually according to the
welding result.
Current temperature: shows the hot air temperature which comes out from a hot air
nozzle, also known as heating temperature.
Set Temperature: to set the temperature of the hot air, also known as welding
temperature/heating temperature. Click the button and enter the value. Ranges from 0-
700’C; Please increase the value gradually according to the welding result.
Heating key: press the "Heating" button for 3 seconds to display the "heating ON"(the
button changes to green button), the heater element starts heating; Press the "heating"
button to display the red "heating" and the heater element stops heating. When the
heating is ON, you can see the [Current Temperature] value is increasing.
Upper Roller Speed Tolerance(Speed Tolerance): its function is to adjust the rotation
speed difference between the upper seam roller and lower seam roller, to make the up and
down roller synchronous or asynchronous, such as: the synchronous speed value is
100%;
* When the value is bigger than 100% , the upper roller is faster than the lower roller; *
When the value is smaller than Smaller than 100% the upper roller rotation speed is
slower than bottom roller. (For example, when the value is 105%, the upper roller is
faster than the lower roller).
Note: the standard value of the machine is 100 %, the two rollers are rotating at the same
speed.
Puller Roller Speed Tolerance: Its function is to adjust the speed difference between the
puller rollers and front seam rollers. When the valve is bigger than 100%, the puller roller
rotation speed is faster than the front seam rollers. For example, when the fabric wrinkles
after welding, we can set a bigger than 100% value to make the pullers run faster to
eliminate the wrinkles.
Remark: Please change the value gradually.
Reversal: press this button to reverse the rollers rotating direction.
Set parameter: press the [Set Parameter] button to enter parameters setting page and to
adjust the parameters setting. The picture jumps out the password box option, enters the
password "2222" and then clicks the "ENTER" key to enter the setting page. If the
password is wrong, please re-enter the password.

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 Function Selection Page.

Function Selection Page description: can choose to enter each function page according to

the actual operation.

Order Parameters(Password: 2222)

Attention: Be cautious when modifying these parameters.

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Delay of Crosswise Gun Swing in: to adjust the “Synchronous Start-up” between [Hot air

nozzle/gun’s right and left swing(in "Y-axis direction")] and [Rollers], in order to achieve

synchronous start-up for Hot Air Gun and Rollers. Such as when the swinging Hot-air

gun caused fabric burning or tape burning off at work, the numerical value must be

reduced; And increase the numerical value when there is welding blank(No welding)

when pausing. The adjusting ranges from 0.01-1 S.

Delay of Lengthwise of Gun Swing in: to adjust the “Synchronous Start-up” between

[Hot air nozzle/gun’s Front and Back swing(in "X-axis direction")] and [Rollers], in

order to achieve synchronous start-up for Hot Air Gun and Rollers. Such as when the

swinging Hot-air gun caused fabric burning or tape burning off at work, the numerical

value must be reduced; And increase the numerical value when there is welding blank(No

welding) when pausing. The adjusting ranges from 0.01-1 S.

Delay of Lengthwise of Gun Swing Out: In order to achieve synchronous stop for Hot

Air Gun and Rollers. Function: When the hot air gun leaves the rollers, the pressure

roller should stop immediately. If the fabric burns during welding stop, the numerical

value must be increased. If there is a welding blank, the value needs to be reduced. The

value adjustment range is 0.01-1.0 seconds.

Delay of the Pull Roller: To delay the start-up of the pulling rollers, the pullers start

rotating after the front rollers.

Roller Back Length: The rollers reversely rotate for a small distance before stop rotating,

this delay is to avoid blank-welding(a small gap is not welded).

Roller Stop Delayed Length: The rollers continue to rotate after the hot air nozzle goes

out, to avoid burning the fabric caused by the delay of the hot air gun out.

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Switch OFF Delay: To set the Auto-shutdown time. Turn off the [heating Key] on the

main screen, then turn off the power switch of the machine, and the whole machine will

enter the automatic shutdown state. The time set by the delay will automatically shut

down afterwards. If not used for a long time, please turn off the main power supply.

Adjusting ranges from 1-10 minutes.

Temperature Parameters(Password: 1010)

Current temperature: shows the temperature of the hot air which comes out from the
nozzle.
Set temperature: to set the temperature of the hot air, also known as welding
temperature/heating temperature.
Temperature alarm value: when the temperature reaches the set value, it starts alarming.
Max Temp.: maximum temperature value.
Heating key: press the "Heating" button for 3 seconds to display the "heating ON" of
green, heater element starts heating; Press the "heating" button to display the red "heating
OFF" and the heater element stops heating.
Auto Adjust: The [auto adjust] function automatically measures, calculates, and sets the
most appropriate P, I, and D values, and automatically adjusts the internal parameters of
the temperature controller to make the temperature more stable. Firstly, turn on the heat,
then click the "Auto-adjust" button, the button is turned on the green "Auto Adjust",
waiting for the self-tuning button to turn red, the auto-tuning is automatically adjusted.
Back: return to the previous menu.

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System Parameter(Password: 1010)
Attention: Be cautious when modifying these parameters.

Reverse speed: the running speed of the roller reversely rotates.

Back speed: the running speed of the rollers rotates back when welding stops.

Motor Speed Up time: the developer sets internal parameters and is consistent with the

main operation page. Attention: Please do not change

Motor deceleration time: the developer sets internal parameters, which is consistent with

the main operation page. Attention: Please do not change

Test start: consistent with the main operation page.

Test stop: consistent with the main operation page.

Back: return to the previous page.

Speed Parameters(Password: 2222)

Attention: Please do not change the parameters of this page!

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1. Up roller diameter: the diameter of the upper roller.
2. Middle roller diameter value: the diameter of the rear roller(Pull Roller).
3. Down roller diameter: the diameter of the lower roller.
4. Step motor pulse count(Step Motor Subdivision Value): the developer sets internal
parameters and is consistent with the main operation page.
5. Upper Motor Speed Contrast: To adjust the upper roller motor parameter(please don’t
change the value).
6. Down motor speed Contrast: To adjust the lower roller motor parameter(please don’t
change the value).
7. Up Roller speed contrast: To control the upper and lower rollers speed
synchronization, consistent with the main page.
8. Max Speed: consistent with the main operation page.
9. Rear Wheel(When machine is equipped with Pull Rollers): to switch ON & OFF the
pulling rollers.
10. Left pedal manual Model: Also known as Self-lock mode. The left foot can leave the
pedal in the welding process (no need to keep pressing the pedal all the time).
11. Back: return to the previous menu.

Device shutdown screen

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Auto Shutdown Page: display device shutdown the remaining shutdown time.

5. PART MANUAL
5.1. Introduction to frame welding

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5.2.Upper bracket transmission parts

5.3. Tool mould parts

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5.4.Tool mould parts

5.5.Hot air gun assembly parts

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Technical Requirement after Adjustment
6.1. Total pressure should be 0.35-0.5 MPa
6.2. Upper roller pressure should be 0.1-0.5 MPa.
6.3. The oil volume of the oil sprayer should be between the minimum and the maximum
oil value(if applicable).
6.4. The lifting of the upper roller flows freely, without large shock, no rapid collision
noise.
6.5. The two rollers edges should be aligned in parallel while the two rollers are
pressing.
6.6. Requirements for micro-back: After depressing the up-pressure-roller, press the
right foot pedal to swing in the hot air gun to conduct synchronized operation. Then
release the right foot, the hot air gun will swing out and you can see two rollers micro-
back rotate. The range of micro-back can be adjusted according to tested results. Micro-
back is necessary to avoid blank welding.
6.7. Requirements for swing air pressure gun: The swinging of the heat gun shall be
smooth with regulated speed and without rapid impact sound.
6.8. Technical requirements for transmission:
Checking and minimizing the “phantom distance”(one hand grasp the one roller, while
the other hand turn the other pressure roller, the moving distance between of the two
pressure rollers is the phantom), (Notes: there shall not be a 1.5mm2 phantom while
swinging the pressure roller). More phantoms will lead to welding blank. Check if the
transmission chains of the machine have simultaneous loose-tight properties, if there is
loose fastening screw of necklace gear, chain wheel, and candan universal joint.
6.9. The heater element (inner pipe) and thermal outer pipe shall not loose, and the air
intakes of inner pipe and thermal outer pipe shall be aligned.
6.10. All gas lines shall be sealed without air leaking.
6.11. Normal forward swinging angle between Hot Air Gun and Rollers
shall be 20°, and shall be regulated above 4～6 mm for the tangent line
of the pushing connection of the pressure rollers and within 2 ～ 4 mm
between muzzle and side of up roller. The distance between air
pressure gun and the two pressure rollers also can be regulated
according to different production of anti-water material and hot sealing
tape, the regulation shall be subject to the requirements of pasting.
6.13. The gun nozzle shall be transverse parallel to the edges of up and down pressure
rollers, otherwise one side cannot be pasted while pressuring the belt.
Notes: The different thickness of materials, different hot sealing tape, different
proficiency of operators, different environment and season, and other changes may
directly influence the effect of products. The scheduler shall note mainly changing factors
of the machine as follow:
A. the heating temperature can be regulated
B. the overall air pressure and the pressure of up roller can be regulated
C. The hot air pressure can be regulated
D. the separation distance between hot air gun and up and down rollers can be regulated

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Maintenance and maintenance
7.1 Catalog of repair and maintenance
(1) Check of air channel
A. Check that the total air pressure should be kept above 0.35MPa.
B. Check the total air pressure regulating valve and pull out the total pressure regulating
valve handle. After adjusting one turn(360’), if the pointer of the total pressure gauge has
not changed, the dirt in the water filter cup should be cleaned.
C. Check for looseness of each cylinder restrictor valve.
D. Check if the air pipe is aging, damaged, loose or leaking.

(2) Circuit check

A.All installation, maintenance and overhaul of the electrical control system of the
machine must meet the requirements of relevant national safety criteria for fear of
equipment and personal injury.
B.When you replace the parts and components, you must use the parts or components of
the same type as the original type or equivalent to the original type.
C. Periodically stop the machine to clean the inner of the electrical control cabinet (as per
the field situation).
D.Periodically stop the machine to fasten the wiring terminals of the electrical control
system.
E.To avoid damaging the PLC, display and operating panel, never plug or unplug the
cables connecting the PLC, display and operating panel while the power is on.
F.If there is any fault that cannot be removed, please immediately contact the service net
of the Company.
G.The Company will not be responsible for the results caused by violence of any criteria
on safe operation.

(3) Overhaul of the mechanical section

A.Check if the driving sprockets are dislocated or loosened, if yes, the forcing off screw
on the chain gear shall be aligned or fixed
B.Check if the chain is too loose and too long, and adjust the holding strain of the chain
or adjust the distance from the bearing seat; if the phenomenon remains the same after
adjustment, just shorten the chain.
C.Check if the nozzle of the hot air gun is parallel with the rubber wheel of the upper
column, and at the center; if not, it shall be adjusted as per the above-mentioned
adjustment method.
D.Check if the up and down of the upper column is smooth or if the blank is too large.
Notice:
Though the machinery is fairly durable, abrasion of different degrees will happen after
long-term operation, leading to the abnormal action of the machinery operation. If it is
not overhauled or repaired in time, some parts of a certain section will surely be severely
damaged and cannot be repaired. So all maintainers shall be familiar with the machine,
and get done with the routine maintenance and periodical services, perform the
adjustment and maintenance strictly as per the technical requirements so as to increase
the service life of the equipment.

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7.2. Fault inquiry schedule;

Failure Analysis Solution

The touch screen Hot Air Pressure is not enough Press the [heating]button for three
shows air pressure is seconds to green”Heating ON” ,
not enough then rotate the hot air pressure
gauge until the message
disappears.
Welding is not OK A.The distance between the hot air A.Adjust the position of the hot
nozzle and the rollers (too far, too air nozzle;
high or too low); B.Clean the hot air nozzle;
B.The debris in the nozzle is blocked C.Reset the speed;
C.The rotation speed of the roller is D.Reset the temperature;
too fast; E.Adjust the hot air volume.
D.The hot air temperature is too low;
E.The hot air volume is small;
Phantom A. The drive chain is too loose or A. Tighten each chain.
distance(virtual wears out. B. Replace gears and universal
Position) is big and B. Gears and universal joints wear. joints.
there is blank welding C. The upper and lower roller shafts C. Replace the pressure roller and
and the pressure roller generate a fit tightly with the pressure roller
virtual position in the radial direction. shaft.
The upper column A. The air pressure is not enough or A. Adjust the air pressure,
lifts and slides are the restrictor valve is not adjusted. eliminate air leaks or readjust the
not in place or are B. The three top screws next to the restrictor valve.
not smooth and slider seat are not adjusted (too tight). B. Add the lubricate oil to the
stable. C. The exhaust anechoic net is dirty. sliding position of the slider.
C. Clean the muffler net dirt.
The temperature A. The temperature sensing A. Replace a new thermocouple
control value line(thermocouple) is damaged or the B. Reset the thermometer.
deviation is too large compensation wire is disconnected
or shows flickering. from a certain position.
B. The internal parameter settings of
the thermometer are modified.

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