Page 1
Revision A
$35.00
010803MS
Part No. MAN-CAYENNE
M&R Printing Equipment, Inc.
www.mrprint.com
Toll Free 1-800-736-6431
International 1-630-858-6101
Cayenne Flash
Operator’s Manual
Page 2
Revision A
IMPORTANT!
The product described in this publication may employ hazardous voltages or might create other conditions that could, through misuse, inattention, or lack of understanding,
result in personal injury, or damage to the product or to other equipment. It is imperative, therefore, that personnel involved in the installation, maintenance, or use of this
product understand the operation of the product and the contents of this publication.
This document is based on information available at the time of its publication. While
efforts have been made to be accurate, the information contained herein does not purport to cover all details or variations in hardware, software, features or specifications,
nor to provide for every possible contingency in connection with installation, operation
and maintenance. Features may be described herein which are not present in all variations of this product. M&R Printing Equipment, Inc. (M&R) assumes no obligation of
notice to holders of this document with respect to changes subsequently made.
M&R makes no representation or warranty, expr essed, implied or statutory with r espect
to, and assumes no responsibility for the accuracy, completeness, sufficiency or usefulness of the information contained herein. No warranties of merchantability or fitness
for purpose shall apply.
i
IMPORTANT!
A publication of M&R Printing Equipment, Inc. All information contained herein is derived in part from proprietary and
patent data of M&R Printing Equipment, Inc. This publication may not be reproduced, copied, or transmitted in any form
without prior permission from M&R Printing Equipment, Inc. Printed in the U.S.A. All Rights Reserved. 2002.
Page 3
Revision A
The information listed below will prove helpful when ordering replacement parts,
requesting service or repairs. Please fill in the following information. The Model No.,
Serial No., Schematic No. and Machine No. are all located on the Manufacturers
Rating Plate mounted to the equipment. Should you have any questions regarding
this information, please do not hesitate to contact our Equipment Service
Department at 1-800-736-6431 during normal business hours.
Product Name:
Model No.
Serial No.
Schematic No.
Machine No.
Date of Installation:
Installed By:
Page 4
Revision A
Page 5
Revision A
Valued Customer,
Thank you and congratulations on your purchase of your new Cayenne Flash unit.
The Cayenne Flash is the ultimate flash cure system and the perfect companion for most M&R’s auto-
matic textile presses. Designed to integrate flawlessly, Cayenne Flash uses state-of-the-art quartz
tubes for rapid flash curing during high-speed production. Cayenne Flash features digital temperature
controls, infrared substrate temperature monitoring, cooling fans, and instant-on technology. The unit
reverts to standby mode when the press is idle. The stand is sturdy, rugged, and fully portable, with
floor leveling pads for easy setup.
A thorough understanding of the operation and maintenance of your new Cayenne Flash will insure
maximum production rates and a long service life for your investment. This operator’s manual is provided to help guide you, and your employees, in the proper procedures for set-up, operation and preventive maintenance of your new Cayenne Flash unit.
Should you have any questions regarding the operation or maintenance of your new Cayenne Flash,
M&R’s world wide technical service and support network is available to you during regular business
hours (8:30 a.m. - 5:00 p.m. CST) at 1-800-736-6431, or, on weekends or holidays, call our 24-hour
Emergency Service Hotline at 1-630-462-4715 for technical support 24 hours a day, seven days a week.
On behalf of all of us here at M&R, thank you for selecting us as your equipment supplier.
Michael J. Sweers
Director of Technical Services
M&R Printing Equipment, Inc.
Page 6
Revision A
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Revision A
Table of Contents
Disclaimer
Model Description
Introduction
Safety Precautions . . . . . . . . . . . . . . . . . . . . . .1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .4
Views of Cayenne Flash . . . . . . . . . . . . . . . . . .5
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . .6
Installation Procedures . . . . . . . . . . . . . . . . . . .7
Controls and Operations . . . . . . . . . . . . . . . . . .13
Preventative Maintenance Procedures . . . . . . .16
Troubleshooting Procedures . . . . . . . . . . . . . . .17
Replacement Parts . . . . . . . . . . . . . . . . . . . . . .19
Electrical Schematics
Warranty Information
Safety Precautions and
Specifications
Installation Procedures
Maintenance and
Troubleshooting
Replacement Parts
Cayenne Flash Unit
Page 8
Revision A
Page 9
Safety Precautions
Glen Ellyn, Illinois
1
Cayenne Flash
Revision A
FUNDAMENTAL SAFETY INSTRUCTIONS
Please read all information regarding safety pr ecautions
as presented in the operator’s manual.
The fundamental requirement to assure safe and tr ouble-free
operation of this equipment, is a thorough understanding of
the safety information contained in this operator’s manual.
This operator’s manual includes important instructions to
assure safe operation of this equipment. This operator’s
manual, and especially the safety instructions as described
there-in, must be observed by everyone who will operate
this equipment. In addition to the safety instructions and
regulations described in this operator’s manual, rules and
regulations of the equipment owners place of business
must also be observed.
Obligation of the Equipment Operator
The equipment operator is obliged to guarantee that only
staff who are acquainted with the fundamental regulations
according to workers protection and accident prevention,
and, are completely knowledgeable in the operation of this
equipment have fully read the safety chapter and the
Warning Instructions of this manual, and understand the
instructions as they relate to operation of this equipment.
Equipment operators must be continually evaluated to
assure that they fully understand the operation of this
equipment.
Obligation of Personnel
Every person that will be engaged in the operation of this
equipment must comply with the following before operation
of the equipment is to begin.
1. Observe the fundamental regulations of worker’s protection and accident prevention.
2. Read the Safety Chapter and Warning Instructions of this
operator’s manual and confirm by signature that they
understand the instructions as described in the manual.
Dangerous Situations during Operation of the
Equipment
The Cayenne Flash System has been designed and constructed in accordance with safety standards as described
by Nationally Recognized Testing Laboratories, such as
Underwriters Laboratories in the United States, and CENELEC and the European Economic Community (CE)
Standards and Directives. However, it is possible that dangerous conditions which can cause serious injury or loss of
life for the user or third persons, or damage to the equipment or property could occur. This equipment must be used
only for the defined purpose as described in the operator’s
manual, and must be maintained in perfect running condition in accordance with described safety regulations.
Conditions which may compromise operator safety must be
identified and corrected immediately.
Defined Purpose
The Cayenne Flash System is specifically designed to flash
cure textile inks on textile substrates screen printed on M&R
textile printing systems. Any other use of the equipment
which does not meet the defined purpose as described
above is not permitted.
In accordance with the defined purpose of this equipment,
it is necessary to observe all instructions as outlined in the
operator’s manual and to perform the preventive maintenance procedures as described in the manual.
Guarantee and Liability
In principle, our general terms of sale and delivery are valid
and these are at the operator’s disposal. Guarantee and liability claims for persons or property damage are excluded if
they originate for one or more of the following reasons.
1. A non-defined use of the equipment
2. Improper installation or use of the equipment
3. Operation of the equipment with defective safety devices
4. Non-observance of instructions as described in the operator’s manual for transportation, storage, installation,
operation, maintenance, set-up and take-down of the
equipment.
5. Modification of the equipment.
6. Failure to replace worn or defective parts of the equipment.
7. Defective repairs made to the equipment.
8. Dangerous conditions which are a result of the improper
use of the equipment
Description of Safety Symbols and
Instructions
This symbol signifies or alerts the
equipment operator of conditions or
areas of the equipment which present
imminent danger to the health of the
equipment operator. Non-observance
of these instructions has serious
health consequences, and can lead
to highly dangerous injuries.
This symbol signifies a possible imminent danger for life and health of persons and equipment operators. Non-
observance of these instructions
can have serious health consequences and can lead to highly dangerous injuries.
DANGER
!
WARNING!
Page 10
Safety Precautions
Glen Ellyn, Illinois
2
Cayenne Flash
Revision A
This symbol signifies a possible danger. Non-observance of these
instructions can lead to light
injuries or damage to the equipment or property.
This symbol gives important instructions
for the proper use of the equipment.
Non-observance of these instructions
can lead to equipment failure.
This symbol is used to describe operating tips or especially useful information. This information will enable the
operator to use all equipment functions for optimal performance.
Organizational Measures
Equipment operators are responsible to provide personal
protection when operating this equipment. All safety
devices must be checked each day before operation of the
equipment can begin.
Safety Devices
Before beginning operation of the equipment, all safety
appliances must be checked for proper operation. Safety
devices may only be removed after:
1. The equipment is shut down.
2. The electrical power has been disconnected from the
equipment.
3. In case of delivery of partial components, the operator must install safety devices in accordance with
regulations.
Exploratory Safety Measures
The operator’s manual must be kept on or near the equipment at all times. All safety and danger notices must be kept
in readable condition at all times.
Training of Equipment Operators
Only properly trained operators may run the equipment. The
competence of personnel who are to operate, maintain, setup and shut down the equipment must be confirmed.
Unskilled staff may work with the equipment only when
supervised by experienced equipment operators.
Equipment Control System
Never make any modifications to software. Only experienced operators may actuate the control system.
Safety Measures during Normal Operation
Operate the equipment only if all safety devices are fully
operational. Before starting the equipment, check to be sure
no-one will be endangered by the operation of the equipment. Check the equipment and safety devices at least
once per shift for external or visible damage.
Danger by Electrical Energy
Work on the electrical system must be carried out by qualified personnel only. Check the electrical equipment regularly for any sign of defect or loose connections. Electrical
enclosures must be kept securely locked at all times. Only
authorized personnel with a key are allowed access to
electrical enclosures.
Maintenance and Troubleshooting
Preventive maintenance must be
performed at regular intervals as
described in the operator’s manual.
Equipment operator’s must be
informed before any preventive
maintenance can be performed. All
electrical must be disconnected
and locked out before preventive
maintenance may begin.
Structural Modification of the Equipment
Modifications of equipment are specifically not allowed with
out written authorization from M&R.
Cleaning of the Equipment
Clean away all ink or other contaminants at the end of
each day.
CAUTION: The information contained in this operator’s manual has
been provided to eliminate problems from occurring. Be sure to
read through this operator’s manual
fully before operating your press.
There are numerous safety features utilized in the operation
of this equipment. Please be sure you know the location of
these safety devices and how they operate before attempting to operate this equipment.
DANGER!
OPERATING
TIP!
i
IMPORTANT!
CAUTION!
CAUTION!
Page 11
Safety Precautions
Glen Ellyn, Illinois
3
Cayenne Flash
Revision A
Safety Features
Safety guards have been provided to protect the operator from all moving and heat producing parts. Please do
not remove these safety guards any time the equipment
is in operation.
This operator’s manual includes information regarding the
proper preventative maintenance procedures. When ever
personnel are performing preventative maintenance procedures, be sure that all electrical power is disconnected
from the equipment, and that disconnects are locked in
the off position.
Operator Safety Instructions
All industrial equipment, including screen printing equipment, requires a combination of high electrical, pneumatic, hydraulic or mechanical power for operation. In addition, automatic screen printing equipment, by its nature,
exposes operators to parts and assemblies which operate
at high speeds and contain numerous moving parts. As
with all complex industrial equipment, care should be
exercised to carefully observe proper operating procedures and safety precautions.
Although every effort has been made to design and construct safe, dependable equipment, it is impossible to foresee all circumstances under which this equipment may be
utilized, or to anticipate all possible combinations of factors
which may cause a hazardous condition or situation. It is
therefore imperative that the equipment operator, as well as
all other personnel engaged in any phase of the set-up,
operation or preventative maintenance of this equipment
consider safety first an important part of their job.
The following general safety considerations are offered
as an aid to users of M&R equipment to assist them in
becoming safety conscience.
1. Read the operator’s manual before attempting to lift,
move, operate or perform maintenance on any piece of
machinery. Become intimately familiar with all equipment
controls, their locations, their operation and their effect on
equipment function. Keep this operator’s manual in a clean
location immediately adjacent to the equipment for a quick
and handy reference.
2. Before attempting to start the equipment inspect all areas
around and adjacent to moving parts for possible obstructions: tools, rags, crating remnants etc. Be certain that all
safety guards, covers, access doors etc., are properly
installed prior to starting operation.
3. Do not attempt to operate this equipment if you are sick,
excessively fatigued or under the influence of alcohol or
prescription drugs. Shut off the equipment immediately if
any malfunction occurs or appears imminent. Report any
unsafe equipment or condition promptly in order that correction can be made as soon as possible.
4. When changing setup performing maintenance work,
cleaning the equipment etc., it is imperative that the main
electrical power supply be disconnected to avoid accidental operation and possible resultant injury. This is particularly important in the event more than one person is involved
in such duties.
Page 12
Specifications
Glen Ellyn, Illinois
4
Cayenne Flash
Revision A
The electrical specifications indicated are based on mathematical calculations which assume ideal conditions
exist for electrical supply line values, material used in the installation of electrical service and site preparation.
Although every effort has been made to provide accurate electrical specifications, M&R does not assume any liability for damages, whether consequential or incidental, that may result from the use of the indicated electrical
specifications. M&R encourages the use of a licensed Electrician for the installation of electrical service to this
equipment. The equipment when installed must be electrically grounded in accordance with local codes, or in the
absence of local codes, with the National Electrical Code ANSI/NFPA 70- Latest Edition.
M&R reserves the right to alter specifications in the manufacture of its products.
IMPORTANT
i
NOTE: Indicated wattage represents total electrical consumption in kw.
Size Electrical Requirements
18” x 18” 208/230VAC, 3 phase, 31/34 amps, 11.1 watts
240VAC, 3 phase, 35 amps, 12.8 watts
380VAC, 3 phase, 18 amps, 12.5 watts
415VAC, 3 phase, 20 amps, 14.3 watts
480VAC, 3 phase, 16 amps, 16.6 watts
18” x 22” 208/230VAC, 3 phase, 31/34 amps, 11.1 watts
240VAC, 3 phase, 35 amps, 12.8 watts
380VAC, 3 phase, 18 amps, 12.5 watts
415VAC, 3 phase, 20 amps, 14.3 watts
480VAC, 3 phase, 18 amps, 16.6 watts
22” x 24” 208/230VAC, 3 phase, 31/34 amps, 11.1 watts
240VAC, 3 phase, 35 amps, 12.8 watts
380VAC, 3 phase, 18 amps, 12.5 watts
415VAC, 3 phase, 20 amps, 14.3 watts
480VAC, 3 phase, 16 amps, 16.6 watts
22” x 24” 208/230VAC, 3 phase, 34/37 amps, 11.1 watts
240VAC, 3 phase, 38 amps, 12.8 watts
380VAC, 3 phase, 20 amps, 12.5 watts
415VAC, 3 phase, 22 amps, 14.3 watts
480VAC, 3 phase, 19 amps, 16.6 watts
22” x 30” 208/230VAC, 3 phase, 39/43 amps, 11.1 watts
240VAC, 3 phase, 45 amps, 12.8 watts
380VAC, 3 phase, 24 amps, 12.5 watts
415VAC, 3 phase, 26 amps, 14.3 watts
480VAC, 3 phase, 23 amps, 16.6 watts
22” x 36” 208/230VAC, 3 phase, 50/56 amps, 11.1 watts
240VAC, 3 phase, 58 amps, 12.8 watts
380VAC, 3 phase, 30 amps, 12.5 watts
415VAC, 3 phase, 33 amps, 14.3 watts
480VAC, 3 phase, 28 amps, 16.6 watts
Size Electrical Requirements
24” x 30” 208/230VAC, 3 phase, 42/43 amps, 11.1 watts
240VAC, 3 phase, 48 amps, 12.8 watts
380VAC, 3 phase, 25 amps, 12.5 watts
415VAC, 3 phase, 27 amps, 14.3 watts
480VAC, 3 phase, 23 amps, 16.6 watts
24” x 36” 208/230VAC, 3 phase, 50/53 amps, 11.1 watts
240VAC, 3 phase, 55 amps, 12.8 watts
380VAC, 3 phase, 28 amps, 12.5 watts
415VAC, 3 phase, 31 amps, 14.3 watts
480VAC, 3 phase, 27 amps, 16.6 watts
38”x48”T 208/230VAC, 3 phase, 85/94 amps, 11.1 watts
240VAC, 3 phase, 97 amps, 12.8 watts
380VAC, 3 phase, 52 amps, 12.5 watts
415VAC, 3 phase, 56 amps, 14.3 watts
480VAC, 3 phase, 49 amps, 16.6 watts
40” x 32” 208/230VAC, 3 phase, 86/94 amps, 11.1 watts
240VAC, 3 phase, 98 amps, 12.8 watts
380VAC, 3 phase, 52 amps, 12.5 watts
415VAC, 3 phase, 57 amps, 14.3 watts
480VAC, 3 phase, 50 amps, 16.6 watts
40”x36”T 208/230VAC, 3 phase, 74/82 amps, 11.1 watts
240VAC, 3 phase, 85 amps, 12.8 watts
380VAC, 3 phase, 47 amps, 12.5 watts
415VAC, 3 phase, 51 amps, 14.3 watts
480VAC, 3 phase, 43 amps, 16.6 watts
40” x 36” 208/230VAC, 3 phase, 87/94 amps, 11.1 watts
240VAC, 3 phase, 99 amps, 12.8 watts
380VAC, 3 phase, 53 amps, 12.5 watts
415VAC, 3 phase, 58 amps, 14.3 watts
480VAC, 3 phase, 50 amps, 16.6 watts
Page 13
Side Views of Unit
Glen Ellyn, Illinois
5
Cayenne Flash
Revision A
Front of unit. Back of unit.
Right side of unit. Left side of unit.
Page 14
Required Tools
Glen Ellyn, Illinois
6
Cayenne Flash
Revision A
Quantity Description Part No.
3 Quartz heating elements Order by model
4 Air filter elements 1009012
1 2-Position toggle switch 1010011
1 2-Pole toggle switch 1010007
2 Red neon indictor lights 1013000
1 Temperature controller 1012178
1 Idec timer 1022016A
1 2-Pole Idec relay 24VAC 1011084
1 2-Pole Idec relay socket 1011006
1 4-Pole Idec relay 24VAC 1011079A
1 SCR power controller 1011061
2 Current sensor 1024000
1 Solid State Relay 75 amp 1011205
Recommended Spare Parts
1 - Set standard size Allen wrenches
1 - Standard blade screw driver
1 - Standard Phillips screw driver
1 - 10” adjustable wrench
1 - Set open end wrenches
1 - Volt/Ohm meter (multi-tester)
1 - Wire stripper/solderless terminal crimping tool
1 - 9” torpedo level
Recommended Hand Tools
Page 15
Installation Procedures
Glen Ellyn, Illinois
7
Cayenne Flash
Revision A
The Cayenne Flash unit is shipped in one crate, ready for
installation. Carefully uncrate the Cayenne Flash unit and
examine it for any signs of damage which may have occurred
in transit. M&R is not responsible for any damage which
occurs in transit. Should you discover any damage to the
unit after delivery to you, contact the freight forwarder immediately to file a damaged goods claim. Additionally, contact
M&R’s Customer Service department at 1-630-858-6101 so
that replacement parts may be identified and ordered.
The crate contains the Cayenne Flash unit, one carton which
contains the quartz heating elements, and one carton which
contains the signal cable and required assembly hardwar e. If
the Cayenne Flash unit is to be installed on an M&R press
which is not pre-wired for integration into the presses PLC
system, then an additional carton will be enclosed which
contains the remote control box, floor stand with sensor
assembly and associated communication cables.
After removing the unit from the crate, install the two rear
leveling legs with plastic adjustment handles and leveling
pads as shown in the illustration below. The threaded studs
with adjustment handle are screwed into the threaded hole
on the lower leveling angle brackets on the chassis, and
then into the metal leveling pad which rests on the floor.
Determine which print station you will use for the location
of the Cayenne Flash. Place that print station in the rear
position by using the “Front/Rear” toggle switch on the
control panel.
Leveling pad.
Adjustment handle with threaded stud.
Unlock the front frame holder assembly on the print head
and secure it in the locked upright position.
Move the Cayenne Flash into position using the chassis
mounted casters provided for this purpose.
Leveling the Cayenne Flash
The Cayenne Flash will produce excellent curing results
when leveled properly. It is imperative that the heating element assembly be parallel to the pallet surface. The preferred dimension between the surface of the heating elements and the pallet surface is 2-1/4” at all four corners.
Dimension is 2-1/4” from heating element to pallet surface.
Page 16
Installation Procedures
Glen Ellyn, Illinois
8
Cayenne Flash
Revision A
Leveling the Cayenne Flash is easily accomplished by use
of the two rear leveling legs and the front to rear pivoting
adjustment for the heating element assembly. Once the
Cayenne Flash is parallel to the pallet, the height or distance
from the pallet is easily adjusted by use of the hand wheel
located at the top of the unit.
To level the Cayenne Flash:
1. Place a carpenter's level on top of the quartz heating
element assembly to check level both front to back and
side to side.
2. To adjust the front to rear angle of the heating element
assembly, loosen the 3/4” hex head bolt located on either
side of the chassis.
3. Adjust the front to rear angle by using a 3/4” socket
wrench to adjust the hex head bolt located at the bottom
center of the chassis. Additional leveling adjustments are
made by alternately adjusting the two rear leveling legs
located at the rear bottom of the chassis.
4. When leveling adjustments are completed, tighten the 3/4”
pivot hex head bolts and the rear leveling leg adjustments.
Heating Element Installation
The Cayenne Flash uses a spring-loaded type heating element. The most common type used in the small to midsized units is the spring loaded lamp connection. The
mechanical type is used on the larger size units.
Note: The quartz lamp envelope
(glass tube) must always be clean of
any dirt, oils, or other contaminants
which will lead to reduced curing
efficiency. Always handle heating
elements while wearing lintless
gloves. Lintless gloves will prevent
the natural oils present on your
hands from contaminating the quartz
envelope. Before installation, lightly wipe the quartz
envelope surface with a lintless cloth dampened in
Isopropyl Alcohol to remove dirt, oils and contaminates.
i
IMPORTANT!
Page 17
The following will explain how to install the spring-loaded
heating elements:
1. While wearing lintless gloves, gently grasp the heating
element at both ends at the electrical connector.
2. The heating element has a female electrical connection at
both ends. This connector is designed to fit over the corresponding male connector located in the heating element
mounting socket located on the reflector assembly.
Position one end of the heating element over the spring
loaded male pin connector on the reflector assembly and
carefully push the female electrical connector onto the male
pin connector. Compression of the spring-loaded male fixture will require only light (1-2 pounds) pressure to properly
position the heating element.
3. Bring the opposite end of the heating element into contact with the male pin contact on the other side of the reflector assembly. Allow the spring-loaded pressure from the
opposite contact to hold the heating element in position.
4. Install the remaining heating elements as described above.
Installation Procedures
Glen Ellyn, Illinois
9
Cayenne Flash
Revision A
Reflector mounted Male pin contact.
Gently push female lamp contact onto spring loaded male contact.
When replacing the spring-loaded lamp:
1. Disconnect electrical power from the Cayenne Flash.
2. Remove the old lamp by grasping the lamp connection at
each end of the lamp. Gently move/push the lamp either to
the right or left to compress the spring loaded female fixture
in the reflector assembly. Light pressure is needed to disengage the lamp. Slightly lower the lamp 2-3 inches and
disengage the lamp from the opposite male fixture to completely remove the lamp from the reflector assembly.
3. Using a lintless cloth dampened with Isopropyl Alcohol,
gently wipe the reflector surface to remove any dirt or contamination which may reduce reflector efficiency.
4. Check the replacement lamp to be sure both contact
retaining clips are properly seated. If either of the retainer
clips are loose when the lamp is installed in the reflector
connections, the lamp may create an electrical arc during
operation destroying the connector and lamp.
5. Lightly wipe the surface of the replacement lamp with
Isopropyl Alcohol to remove any dirt or contamination which
may reduce lamp efficiency.
6. Position the female connector on one end of the lamp with
the spring loaded male connector on the reflector assembly,
and lightly push the lamp onto the connector. Now, position
the other end of the lamp so that the female contact aligns
with the male contact in the reflector assembly, and gently
move the lamp onto the contact. The spring loaded contacts
will now hold the lamp in place. Check to be sure the lamp
is secure in the connector. If the lamp is loose, check the
connectors on both the lamp and the reflector to be sure
they are not loose or damaged in their mounting.
Page 18
Installation Procedures
Glen Ellyn, Illinois
10
Cayenne Flash
Revision A
The larger size quartz heating elements employ a mechanical type electrical connection for mounting of the heating
elements. Heating elements are held in place by means of
a threaded post and nut. Close examination of these type
of heating elements will reveal an internal material which is
used to increase element efficiency by providing an additional reflective surface. When properly mounted, this
reflective material will be at the top of the element next to
the reflector assembly.
While wearing lintless gloves, position the heating element
so that the internal white reflective material is positioned at
the top towards the reflector assembly. Install the heating
element so that the slots on each end of the heating element engage and fit over the threaded posts. Install the
8/32” stainless steel nuts on each mounting post and tighten the nuts securely.
To replace the mechanical type lamp:
1. Disconnect the electrical power from the Cayenne Flash.
2. Remove the old lamp/lamps by loosening 8/32” nut at
either end of lamp connection. Slightly lower the lamp 2-3
inches until the ends clear the threaded mounting post, then
completely remove the lamp from the reflector assembly.
3. Using a lintless cloth dampened in Isopropyl Alcohol,
gently wipe the reflector surface and replacement lamp to
remove any dirt or contamination which may reduce reflector efficiency.
4. While wearing lintless gloves, position the replacement
lamp so that the white reflective material on the inside of the
lamp envelope is positioned at the top, towards the reflector assembly. Install the lamp so the slots on each side of
the lamp engage and fit over the threaded posts. Install the
8/32” nut on each post and tighten securely. Torque to 25
lbs/inches. The replacement lamp is now properly installed.
White reflective material.
To facilitate the installation of the quartz heating elements,
the chassis of the Cayenne Flash may be carefully placed
and supported on its side.
NEVER POWER UP THE CAYENNE
FLASH WITH THE QUARTZ HEA TING
ELEMENTS IN THE VERTICAL POSITION. IN THE VERTICAL POSITION,
THE QUARTZ HEATING ELEMENTS
ARE EXPOSED TO EXCESSIVE
STRESSES WHICH WILL RESULT IN
ELEMENT FAILURE. ALWAYS MAKE
SURE THE QUARTZ HEATING ELEMENTS ARE IN THE NORMAL HORIZONTAL POSITION
BEFORE POWERING UP THE CAYENNE FLASH.
Double check to be sure all heating elements are securely
installed in their respective terminals.
WARNING!
Page 19
Installation Procedures
Glen Ellyn, Illinois
11
Cayenne Flash
Revision A
Signal Cable Installation
PLC controlled models
The Cayenne Flash unit is designed to receive operational
signals from either the on-board programmable logic controller (PLC) to your M&R press control system, or from an
independent remote control box in conjunction with a
remotely located sensor assembly.
In the case of the PLC signal method, you need only install
the signal cable from the plug marked “PLC Signal” on the
Cayenne Flash unit, to the plug socket located on the presses lower electrical enclosure provided for this purpose. You
will note that there are four plug sockets located on the
press. Plug the signal cable into any of the sockets on the
left. The remaining plugs are provided for futur e units. Note:
The Sportsman press is only available with two sockets.
The signal toggle switch located on the Cayenne Flash unit
must be set to “PLC Signal”. If this switch is in any other
position, the Cayenne Flash unit will not operate.
Remote Control Box and Sensor Models
When used in conjunction with a M&R press which does not
include the prewired plug sockets located on the presses
lower electrical enclosure, the Cayenne Flash unit is operated and controlled through the use of a remote mounted
control box (located at main control console of the press)
and a remote located sensor assembly.
The control box is mounted to the presses existing operator
control panel and is connected via a communication cable
to the Cayenne Flash unit. The control box includes a red
indicator light which illuminates whenever electrical power
is supplied to the Cayenne Flash unit. The
“Preheat/Work/Stand By” toggle switch operates in the
same manner.
A remotely located sensor mounted to a floor stand assembly is utilized to supply the trigger on signal to the Cayenne
Flash unit in this application. The following provides information on how to configure this type system.
1. Locate the small control box with indicator light and
toggle switch on top of the presses main control panel.
The control box is mounted using the two sheet metal
screws provided.
2. Connect one end of the communication cable to the
adapter at the rear of the control box.
After installation of all quartz heating elements, carefully
place the Cayenne Flash upright in its normal operating
position. Supply electrical power to the unit to confirm
element operation.
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Installation Procedures
Glen Ellyn, Illinois
12
Cayenne Flash
Revision A
6. Place the signal toggle switch in the “Sensor Signal”
position. If this switch is placed in any other position, the
Cayenne Flash unit will not operate.
Multiple Cayenne Flash unit installations, which incorporate
the remote control box/sensor control system, may be controlled from the one small control box located at the main
control panel. A communication cable is installed between
units for transmission of the control signals from one unit to
the next. Although multiple units may be controlled in this
manner, each individual unit will still require a floor stand
mounted sensor to receive the power on signal for operation.
Multiple Unit Plug Jack
3. Connect the other end of the communication cable to the
plug located on the side of the Cayenne Flash unit.
4. Locate the sensor and floor stand assembly , and position
the floor stand and sensor underneath the index table pallet at the print station just before the print station where the
Cayenne Flash unit is located. The sensor should be adjusted to read the lower pallet support arm just as it starts to
make an index cycle. This provides sufficient time for the
Cayenne Flash unit to start its preheat cycle.
5. Connect the communication
cable from the sensor floor stand
assembly to the plug marked
“Sensor Signal” on the side of the
Cayenne Flash unit.
Direction of index rotation
Sensor reads pallet support arm
Plug in control box communication cable here.
Page 21
Controls and Operations
Glen Ellyn, Illinois
13
Cayenne Flash
Revision A
The following will assist you in correctly operating the
Cayenne Flash unit.
Control Panel
The Cayenne Flash features a user-friendly control panel
which provides at-a-glance monitoring of all operational
parameters.
On/Off/Reset Toggle Switch
Located in the upper left corner of the control panel is the
three position “On/Off/Reset” toggle switch. To supply electrical power to the Cayenne Flash unit, place the toggle
switch in the on position. When the toggle switch is in the off
position, the Cayenne Flash unit will not operate. The “Reset”
position on the switch is provided to deactivate the audible
alarm after the initial power up of the Cayenne Flash unit.
Preheat On/Off Toggle Switch
This switch is used to preheat the quartz heater elements
when the Cayenne Flash unit is initially turned on. Upon initial operation, move the spring loaded toggle switch to
“Preheat” position. The unit will go through an on cycle.
Repeat this procedure for two or three cycles. After holding
the toggle switch in “Preheat”, the spring loaded toggle
switch will automatically move to the “Work” position upon
release. When this toggle switch is in the off position, the
quartz flash unit will not operate.
Be sure that none of the pallets or
pallets with garments are positioned under the Cayenne Flash unit
for an excessive time while the unit
is on as the extreme heat can cause
damage to pallets, garments and/or
possible fire.
Lamps “On” Timer
The setting of this adjustable timer control determines the
on cycle time when using the Cayenne Flash integrated with
an M&R automatic textile printing press. The control may be
set for a maximum on cycle time of 10 seconds or a minimum on cycle time of 1 second.
Power Level
The “Power Level” control is used to adjust the intensity of
the Cayenne heater elements. The range is a minimum of 1
and a maximum of 10.
Outside Section
Located in the middle left area of the control panel, this red
indicator light, when illuminated, indicates that the outside
bank of quartz heater elements are on and functioning.
When this indicator light is extinguished, the outside bank
of elements are not operating.
Center Section
This indicator light, when illuminated, indicates that the
center bank of quartz heater elements are operating. When
extinguished, the center bank of quartz heater elements are
not operating.
Inside Section
As described previously with the outside and center section, this indicator light is illuminated the inside bank of
quartz heater elements are operating. When extinguished,
the inside bank of heater elements are not operating.
On/Off Toggle Switch
Located under each of the Cayenne section indicator lights,
this toggle switch, when placed in the on position, will command that particular section of quartz heater elements to
operate. When this toggle switch is placed in the off position, the quartz heater elements will not operate.
WARNING!
Page 22
Revision A
Glen Ellyn, Illinois
14
Cayenne Flash
Controls and Operation
Temperature Controller
The following information describes how to use the Fuji
temperature controller Model No. PXR4-REY1-5V for setting the process temperature on Cayenne Flash units. The
temperature controller provides a means of regulating the
maximum temperature that the quartz heating elements will
attain after the unit is commanded to cycle. The controller
is adjustable to a maximum of 350°F.
To operate the temperature controller, proceed as follows:
1. Turn electrical power on to the Cayenne Flash unit.
2. The lower “SV” display indicates the set value. The upper
“PV” (red) display indicates the process temperature. In the
example below, the process value is displayed as 345°F.
3. To set the desired pr ocess temperature, pr ess the arrow up
key to increase the process temperature (green) indication.
Press the arrow down key to decrease the process value by
one digit. Pressing and holding the arrow up or arrow down
keys will rapidly increase or decrease the indication.
Once the Cayenne Flash unit is installed, you are ready to
use it with your M&R textile press. To operate the Cayenne,
proceed as follows:
1. Connect main power to the flash unit using the 230 volt
power cord using the supplied cord.
2. Plug the PLC signal cord from the base of the press to the
flash unit PLC connector (see page 10 for proper installation).
Please note some models are not equipped with PLC plugs.
You will need to use a sensor stand for these units.
Page 23
Controls and Operation
Glen Ellyn, Illinois
15
Cayenne Flash
Revision A
3. Turn power on. Adjust the power level to the desired
setting. The higher the number, the quicker the flash time.
The power level is equivalent to how much power the
bulbs receive.
4. Adjust the desired setting for the lamps using the
temperature controller.
5. Access the Timers menu on the control panel. Set the
flash time to the quartz time.
Page 24
Revision A
Glen Ellyn, Illinois
16
Cayenne Flash
Daily
D1. Remove any dirt or spray tac which may have accumu-
lated on the surface of the Cayenne Flash unit.
D2. Check and clean as needed the filter elements located
at the bottom of the control panel enclosure door.
D3. Check the operation of the quartz heating elements.
D4. Clean quartz bulbs with lintless cloth and Isopropyl
Alcohol.
Every Two Weeks
ETW1. Vacuum away any lint or dirt which may have accu-
mulated in the two squirrel cage blower wheels located
inside the control panel enclosure.
ETW2. Vacuum away any lint or dirt which may have accumulated inside the control panel enclosure.
BE SURE TO DISCONNECT THE
ELECTRICAL POWER TO THE
CAYENNE FLASH UNIT BEFORE
WORKING INSIDE THE ELECTRICAL ENCLOSURE PANEL!
ETW3. Clean quartz tubes using Isopropyl Alcohol. Do not
touch quartz tubes with your bare hands. Wear lintless
gloves whenever handling quartz tubes as the natural oils
present on your hands can leave stains on the quartz surface which will burn into the quartz surface, decreasing element efficiency.
Every Three Months
ESM1. Clean reflector surface with Isopropyl Alcohol.
ESM2. Apply white lithium grease to the guide rails for the
Cayenne flash unit height adjustment mechanism inside the
electrical control enclosure.
ESM3. Vacuum away any dirt or lint which may have
accumulated in the air jet plenum above the quartz element reflector assembly.
Preventative Maintenance
ETW1
ESM3
ETW1
Air Jet Plenum
i
IMPORTANT!
Page 25
Revision A
Glen Ellyn, Illinois
17
Cayenne Flash
Troubleshooting Procedures
PROBLEM A: Indexer operates, however Cayenne Flash does not operate.
SOLUTION:
Signal toggle switch is not set for proper operation, or signal cable in plugged into the wrong jack. Check position of signal toggle switch. When the Cayenne Flash unit is operating, this toggle switch must be set for either “PLC SIGNAL” or
“SENSOR SIGNAL”. If the toggle switch is set in its middle position, then it cannot receive a signal from either the on-board
PLC on the press, or the sensor mounted on the floor stand. In this case, the systems internal safety programming prevents the Cayenne Flash unit from operating. If the signal cable is plugged into the correct jack, however the signal toggle switch is incorrectly positioned in “PLC SIGNAL”, the Cayenne Flash unit will not operate. Always be sure that the signal cable is plugged into the correct jack, and that the signal toggle switch is positioned for proper operation.
PROBLEM B: The Cayenne Flash unit is operating, however you notice that the first 2 or 3 garments are not curing properly.
SOLUTION:
1. The pre-heat time must be increased to allow the heating elements sufficient time to come up to operating temperature.
When first starting production, or whenever the Cayenne Flash unit has been inoperative for 10 minutes or more, an
increased pre-heat time interval is requir ed to bring the heating elements up to proper operating temperature. The pre-heat
function is an important part of the overall control and performance of the quartz heating elements.
2. On systems using multiple quartz flash units, one of the communication cables between units may be disconnected. In
multiple units installations, check to be sure that the communication cable between quartz flash units is properly connected.
PROBLEM C: The Cayenne Flash unit operates, however you notice that garments exhibit an uneven cure across the
printed image.
SOLUTION:
1. The quartz heating element assembly is not parallel to the printing pallets. In order to achieve optimum curing results,
the quartz flash heating elements must be parallel to the printing pallet/garment surface. The ideal dimension is 2-1/4” from
the surface of the heating element to the surface of the printing pallet. Instructions on how to properly level the quartz heating element assembly can be found on page 7 of this manual.
2. The quartz heating element assembly reflector is dirty. Clean the reflector assembly using a lintless cloth dampened in
Isopropyl Alcohol. Residues from spray tac, or inks as they cure on the garment can produce airborne compounds which
will dull the reflector assembly decreasing cure efficiency. When this happens, some areas of the printed image will exhibit incomplete cure of the ink film.
The following information is provided as a guide for troubleshooting in the event a problem may occur during the operation of your Cayenne Flash unit. Should you have any questions regarding the installation, operation or preventive maintenance procedures for this equipment, we strongly encourage you to contact our Equipment Service Department at 1-630858-6101 during normal business hours, or our 24 hour Emergency Service hotline at 1-630-462-4715 in the evening,
weekends or holidays.
It is further recommended that persons using this troubleshooting guide have a working knowledge of electrical power and
control systems, and in addition are thoroughly familiar with the operation and adjustment of the components and control
devices used on this equipment before attempting to replace or adjust components of this equipment.
Experience has shown that many problems can be Operator induced. It is important to check that the main electrical power
lines to the equipment are on and that the manual power “On/Off” switch is on. Check condition of main power plug, look
for any burnt marks or broken wire connections.
Page 26
Revision A
Glen Ellyn, Illinois
18
Cayenne Flash
Troubleshooting Procedures
PROBLEM D: The Cayenne Flash unit operates, however you notice that some garments are showing signs of scorching.
SOLUTION:
1. The control box cooling fan filters are clogged restricting air flow through the electrical enclosure and across the heating element reflector assembly. Clean or replace cooling fan filters as required in Preventive Maintenance Schedule.
Clogged cooling fan filters restrict air circulation in both the electrical enclosure and at the heating element assembly creating hot spots which can result in scorched garments.
2. The squirrel cage blower fans are clogged reducing air circulation across the quartz heating element assembly. Check
and clean the squirrel cage blower fans as required in the Preventive Maintenance section of this manual. Clogged squirrel cage blowers will reduce the volume of circulated air in the system, resulting in hot spots in the heating element reflector assembly. This will result is scorching of garments.
PROBLEM E: Power on light comes on and the Fuji temperature controller display “LLLL” or “UUUU”.
SOLUTION:
1. “UUUU” display - Thermocouple has burn out, thermo resistance (thermocouple) disconnection, or signal from thermocouple has exceeded by 5% from P-SU value.
2. “LLLL” display - Thermo resistance (thermocouple) disconnection, thermocouple in short circuit, or signal from thermocouple is under 5% below P-SL value.
3. “ERR” display - incorrect range setting (P-SL/P-SU).
4. “FALT” display - fault in the temperature controller.
5. Replace thermocouple. Make sure you use a thermocouple type “K” (part no. 1014001) for this unit, and that you
connect the yellow wire from the thermocouple to terminal 17 on temperature controller and the red wire from the thermocouple to terminal 18 on the temperature controller.
Page 27
Revision A
Glen Ellyn, Illinois
19
Cayenne Flash
Replacement Parts
1 Toggle Switch 1010007
2 Cycle Timer 1022016A
3 Fuji Temperature Controller 1012178A
4 Potentiometer 1K 2 watt 1029001
5 Red Neon Indictor Lamp (115 volt) 1013000
6 2-Position Toggle Switch 1010011
Part Name Part Number
1
2
3
4
5
6
Page 28
Revision A
Replacement Parts
Glen Ellyn, Illinois
20
Cayenne Flash
1 Terminal Block (2 position) 1003001
2 Magnetic Contactor 60 Amp 1011483
3 Idec Timer 0-180 Seconds 1011523
4 Idec Relay 2-Pole 24 volt 1011084
5 Idec Relay 2-Pole Plug Socket 1011006
6 *Idec Relay 4-Pole 24 volt 1011079A
7 *Idec Relay 4-Pole Plug Socket 1011022
8 75 Amp Solid State Relay - 220V 1011205
75 Amp Solid State Relay - 480V 1011207
9 SCR Power Controller 1011061
10 Control Transformer - 1019052A
24 volt Secondary
11 Optional - Transformer 480V 1019071
Part Name Part Number
*Note: #6 and #7 are for 220V unit only.
When ordering fuses, please specify model and fuse size.
1
2
3
4
5
8
9
10
11
Page 29
Revision A
Glen Ellyn, Illinois
21
Cayenne Flash
NOTE: M&R incorporates the use of two different quartz lamp types for the electrical connection of the
quartz tube, a spring loaded type, and a mechanical connection type. The spring loaded type uses a spring
loaded socket connection at each end of the lamp, while the mechanical type employs a mechanical connection with slot at each end. Further, spring loaded lamps are color coded as to operating voltage as indicated below. Indicated lamp lengths as listed above ar e obtained from end to end measur ement of the internal lamp heating element for the spring loaded type, and overall length for the mechanical type. Mechanical
connection lamps are identified by the letter “P” in the part number. The spring loaded lamp type color code
is as follows:
Black = 208 volts Yellow = 220 volts
18” Quartz Tube 240VAC 1007210
22” Quartz Tube 240VAC 1007252
24” Quartz Tube 240VAC 1007257
18” Quartz Tube 415VAC 1007251
22” Quartz Tube 415VAC 1007255
24” Quartz Tube 415VAC 1007258
30” Quartz Tube 415VAC 1007259
22” Quartz Tube 480VAC 1007256
24” Quartz Tube 480VAC 1007253
Part Name Part Number
Replacement Parts
Page 30
Revision A
Replacement Parts
Glen Ellyn, Illinois
22
Cayenne Flash
1 Multi-Con Connector 3S 1020035
2 3-Position Toggle Switch SPDT 1010013
3 Multi-Con Connector 4S 1020174
4 Not Shown: Multi-Con Cable 1020034
Connector
5 Not Shown: Multi-Con Cable 1020173
Connector
Part Name Part Number
1
2
3
Page 31
Revision A
Glen Ellyn, Illinois
23
Cayenne Flash
1 Connector Multi-Con 2S 1020039
2 Sonalert Sensor 24 VAC 1024004B
3 Not Shown: Multi-Con Cable 1020038
Connector
Part Name Part Number
1
2
Replacement Parts
Page 32
Revision A
Replacement Parts
Glen Ellyn, Illinois
24
Cayenne Flash
1 Spring Socket for Quartz Tube (Soneko) 1007101A
2 Infrared Sensor 1012041
3 14 Gauge Hi-Temp Wire 1002013
Part Name Part Number
1
2
3
Page 33
Revision A
Glen Ellyn, Illinois
25
Cayenne Flash
1 Infrared Sensor 1012041
2 Thermo Switch 400°F 1012022
3 14-Gauge Hi-Temp Wire 1002013
Part Name Part Number
1
2
3
Replacement Parts
Page 34
Revision A
Glen Ellyn, Illinois
26
Cayenne Flash
1 Blower Shaded Pole 230V 1016000
Part Name Part Number
Replacement Parts
1
Page 35
Replacement Parts
Glen Ellyn, Illinois
27
Cayenne Flash
Revision A
1 Remote Mounted Control Box 8090064
2 Control Box Communication Cable 8080161
3 Sensor 1010095
4 Communication Cable (PLC system) 8080162
5 Sensor Floor Stand 9P10713
6 Sensor Extension Cord 8080163
7 Not Shown: Communication Cable 8080164
multiple units
Part Name Part Number
1
2
3
5
4
6
Page 36
Revision A
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