User Manual for ADKINS models including: 120CMx170CM Flatbed Series 7 Transfer Press, 120CMx170CM, Flatbed Series 7 Transfer Press, Series 7 Transfer Press, 7 Transfer Press, Transfer Press
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DocumentDocumentHEAT PRESS TECHNOLOGY ALPHA INDUSTRIAL FLATBED SERIES 7 120 CM x 170 CM Operators Handbook All products within the ADKINS range are labelled with CE marking and are manufactured and tested to comply with EC safety regulations. ©Charterhouse Holdings PLC. All rights reserved. Preface Dear User Welcome to the growing group of Alpha Industrial Flatbed Series 7 Transfer Press users. The product you have purchased has been carefully designed and manufactured to ensure that you, the user, will gain the maximum benefit. All Charterhouse Holdings PLC products are specifically designed to ensure ease of use with particular attention to safety requirements. Should you discover any fault or damage upon receipt of this product, you should immediately contact your local supplier. Contents 1. Introduction Alpha Industrial Flatbed 1 Series 7 Transfer Press 1.1 Application 2 1.2 Features 2 1.3 Specifications of the Alpha Industrial Flatbed Series 7 3 Transfer Press 2. Installation 5 2.1 Step-by-step installation procedure 5 3. Maintenance and troubleshooting 9 3.1 Daily maintenance 9 3.2 Weekly maintenance 9 3.3 Cleaning 9 3.4 General maintenance 9 3.5 Troubleshooting 10 3.6 Heat Plate temperature measurement 11 4. Machine drawings and diagrams 12 4.1 General layout 13 4.2 PLC controller operation procedure 14 4.3 Exploded diagrams and parts list 15 4.4 Electrical diagram 16 4.5 Pneumatic diagram 20 5. Design change 21 6. Guarantee (limited warranty) 22 Declaration of conformity 23 1. Introduction Alpha Industrial Flatbed Series 7 Transfer Press The Alpha Industrial Flatbed Series 7 Transfer Press is a pneumatically operated heat press for transfer printing and material fusing and comes supplied in a dual reciprocating table configuration making it ideal for high volume production with low operator fatigue. The dual fusing areas for the Alpha Industrial Flatbed Series 7 Transfer Presse is 120 cm x 170 cm. The Alpha Industrial Flatbed Series 7 Transfer Press is operated such that in the normal 'stand by mode', the heat plate is retained in the elevated position by compressed air, applied to the appropriate ports of the acting cylinder. Pressing either of the green buttons on the control boxes (located on either side of the frame) will initiate an automatic pressing cycle. This is only possible when the sliding table is positioned correctly to align the work under the heat plate, at which time the guard flap is manually closed. Micro switches then detect the closure of the flap and apply power to the pneumatic driver board. The pneumatic driver board then applies power to the intermediate relay, which in turn provides power to both the pneumatic solenoid valve and the digital timer, which allows the solenoid valve to open the intake door. Air is then applied to the other cylinder ports, forcing the heat plate onto the table and initiating the automatic pressing sequence. After expiry of the pre-set time the digital controller sends a signal to the pneumatic driver board, the driver board then cuts the power for the downstream line, deactivating the solenoid valve, which in turn closes the intake door. The cylinder then returns the heat plate to its elevated position. The Alpha Industrial Flatbed Series 7 Transfer Press is produced nominally as 380 - 440 Volts AC - 3 phase (neutral + earth). Page 1 1.1 Application This machine is suitable for Textile, Leather, Metal, Ceramic, Glass and Organic glass transfer, with colourful transfer images and rich layers. 1.2 Features 1. This machine employs advanced electronic control technology: · Dual pressure plates take turns to work automatically. · Very accurate safety limit switch. · Higher reliability. · Longer service life. 2. PLC controller (programmable logic controller): · Higher control precision. · Extremely stable in opeartion. · Large PLC screen displaying all data clearly. 3. Heat platen uses newly developed pluggable heat elements: · The heat is more evenly spread, and the temperature is more balanced and stable. · If one of the heating tubes is faulty during usage, the customer can replace them individually instead of having to replacing the entire heating element, thereby saving costs. 4. Dual air cylinders: · Creates higher, more uniform pressure, allowing the transfer range to be much wider. 5. Installation and calibration is convenient and fast: · Easy to maintain and clean. 5 6 1 7 2 8 3 4 1. PLC control cox 2. Air filter 3. Over wire 5. Upper and lower tray 7. Emergency stop Explosion proof box button 4. Left and right supporting arms 6. Green start button 8. Power cable Page 2 1.3 Specifications of the Alpha Industrial Flatbed Series 7 Transfer Press Below is a list of the specifications of the Alpha Industrial Flatbed Series 7 Transfer Press: Specifications Power consumption Power supply Working temperature Display timer range Suggested compressed air supply Maximum compressed air supply Machine height Machine width Machine depth Working area Size export packed Gross weight Net weight Press pad dimensions (x2) Fuse(s) A-weighted noise level (120 cm x 170 cm - table size) 18 kW 380 - 440 Volts AC (3-Phase) N+E 70 - 225°C 0 - 999 sec 5 bar 6 bar 155 cm 211 cm 313 cm 211(W) x 155(H) x 313(D) cm 215(W) x 187(H) x 224(D) cm 1390 Kg 1114 Kg 120 cm x 170 cm 34 A <70 dB(A) Page 3 2,110 mm Specifications of the Alpha Industrial Flatbed Series 7 (Cont.) 3,130 mm Page 4 1,550 mm 2. Installation 1.2 Step-by-step installation procedure 1.2.1 Open the crate, the machine is as shown above. 1.2.2 Check and make sure that no part of the machine is missing or has been damaged during the shipping process. Demount the left and right upper panels [see above]. Page 5 Installation (Cont.) C D A B 1.2.3 Install the slide tracks. Fix A, B, C and D slide tracks to the machine frame [see above], fixing the screws hand-tight only. F E 1.2.4 Fix the slide tracks onto the machine. Installing the sliding frame E and F to the slide tracks [see above]. Page 6 Installation (Cont.) G H 1.2.5 Install the left front plate of slide track H and right front plate of slide track G [see above], locking the screws tightly. M K J L I 1.2.6 Fix I, J, K, L and M connectors to the movable frame [see above]. Page 7 Installation (Cont.) O N 1.2.7 To adjust tension of the synchronous belts rotate the adjusting screw N. Once the desired tension is achieved lock off using the locking screw O. 1.2.8 Remount the left and right upper panels [see above]. Machine assembley is now complete! N.B. Ensure adequate ventilation and then test machine functions and operations. Page 8 3. Maintenance and troubleshooting For good press results it is important to keep the press surfaces clean. Wipe the surface of the heat plate with a dry non-abrasive cloth before use when the plate is cold. When the heat plate is hot and not in use, keep in the open position away from the silicone pad. 3.1 Daily maintenance The heat plate should be examined and cleaned on a daily basis as required. CAUTION: Before attempting to clean the heat plate ensure that the machine is isolated from the power supply and that the heat plate is cool. Note: It may take several hours for the heat plate to cool to handling temperature. It is recommended to power off the machine for 12 hours after approx. 6-8 hours of continuous operation. 3.2 Weekly maintenance CHECK:a) Pressing pad cover b) Silicone pressing pad c) Pressing pad base Replace as necessary Note: If print quality deteriorates it may be necessary to change the silicone pressing pad and pressing pad base. 3.3 General maintenance The following checks should be carried out at regular intervals by a qualified and competent person:- · Pneumatic system for air leaks · Pneumatic system for lubrication · Electrical connections · Belt tension and condition · Mechanical moving parts Any enquiries to: enquiries@aadkins.com 3.4 Cleaning First unplug the machine. Clean the outside of the machine frequently with a clean, moist cloth. This may conveniently be carried out when the machine Page 9 3.4 Cleaning (cont.) is cold. To prevent soiling of substrate, periodic wiping of entire exterior machine, including platens, with a clean rag is recommended. If necessary, use mineral spirits for cleaning a cold machine. Since mineral spirits are flammable, use precautions at all times and keep away from sparks, flames or hot heat platen. 3.5 Troubleshooting Phenomenon Reason Solution 1. No display on the controller panel when the machine is on and heat plates cannot be reciprocated in both Manual/ Auto modes 1. Lack of electrical power 2. Fuse is burned out 3. Controller is damaged 4. Reciprocating motor has failed Check the power source Check and replace the fuse Replace the controller Replace the motor 2. No display on the controller panel when the machine is on but the heat plates can be reciprocated in both Manual/ Auto modes 1. Solid state relay is broken 2. Controller is damaged 3. Temperature value was set too high 4. Temperature switch (inside heating plate) broken Replace the solid state relay Replace the controller Reset the temperature after a cold reboot Replace the temperature switch 3. Display works fine but the heat plates cannot be reciprocated in either Manual/ Auto modes 1. Motor speed controller damaged 2. The synchronisation belt is broken 3. The synchronisation wheel sprocket slips 4. The sensor is broken Replace the motor speed controller Replace the synchronisation belt Tighten the synchronisation wheel sprocket Replace the sensor 4. Occasional stops during Auto mode whilst transferring 1. The limit switch is loose Tighten the limit switch 2. The distance between the Adjust the distance sensor and sensor shim is too large 5. Machine will not heat 1. The solid state relay Replace the solid state relay is broken 2. The heat platen is broken Replace the heat platen 3. The sensor is broken Replace the sensor 6. Switch trips when the machine is opened 1. The sold state relay Replace the solid state relay is broken 2. The heat platen is broken Replace the heat platen 3. Circuits go to earth Check the circuits for leakage Page 10 3.6 Heat Plate temperature measurement Testing of the Heat Plate for temperature consistency or fault condition should only be undertaken after consulting Charterhouse Holdings PLC, and then only using a wired Digital Thermometer (*please see note below). *Please Note: The Digital Thermometer with external probe is suitable for surface, air and immersion/penetration measurement, which is required for all Adkins heat presses. Laser Thermometers only measure air surfaces which can be misleading due to currents of hot air floating on the surface of the heat plate. Page 11 4. Machine drawings and diagrams On the following pages are the schematic diagrams for the Alpha Industrial Flatbed Series 7 Transfer Press. 4.1 General Layout.........................................................Page 13 4.2 PLC Controller Operation Instructions............................Page 14 4.3 Exploded Diagrams and Parts List..................................Page 16 4.4 Electrical Diagram.........................................................Page 19 4.5 Pneumatic Diagram.....................................................Page 20 Page 12 4.1 General layout Machine body Cooling fan fixture Pneumac controllers Foam pad Emergency stop buons PLC controller box Moving frame Start/ Stop buons Page 13 4.2 PLC controller operation instructions 4.2.1 Step-by-step controller operation procedure a). Turn on the machine to display the PLC main interface: · The top row displays heating zones, 1# to 7# showing the actual temperature. · The second row displays the transfer temperature, from 1# to 7#. · The third row is for setting the dwell time, countdown time, press counter, and heating start and stop. · The fourth row indicates auto mode, semi auto mode, manual mode, °F and °C. · The fifth row indicates manual start, lower plate movement, upper plate movement and setup mode. TEMPERATURE 1# 2# 3# pv 195 195 195 2018.10.23 9:29:30 4# 5# 6# 7# 195 195 195 195 sv 200 200 200 200 200 200 200 TIME SV 10 PV 7 Counter Reset Heat Start 2495 OFF ON Auto Manual Start Semi auto Bottom Plate Manual Up Plate °F °C Setup b). Press 1# to set the SV position, enter the #1 to the heating zone temperature setting, press ENT to save and then exit, CLR to clear the setting, ESC to reset; The same procedure is used for setting 2# to 7#; Then press °F or °C; After setting, press `Heat Start' to open the heating switch, the machine will enter into heating mode. (Adjustable temperature range is 50 - 225°C (50 - 437°F), adjustable time range is 0 - 999 sec) c). When the set temperature is achieved, press the `Manual' button to enter operation mode, then press the `Bottom Plate' button until it reaches the lower limit and stops. Then press the `Manual Start' button to begin the heat transfer cycle and countdown cycle. When the countdown reaches three seconds to go, the buzzer will sound for one second, the upper platen will then return to the upper limit and the heat transfer cycle will be complete. Page 14 PLC controller operation instructions (Cont.) d). When the lower platen has moved to the lower limit or when the upper platen has moved to the upper limit, press the `Semi auto' button, the machine will then enter into semi auto mode (single transfer mode). e). When the bottom platen has moved to the lower limit or when the upper platen move to the upper limit, press the `Auto open' button the machine will enter into auto mode (mutiple transfer mode). For operation procedure please refer to step c). f). Press the `Reset' button and the counter value will flash and return to 0. g). When one or more thermocouples are malfunctioning `Abnormal' appears between the current temperature and the set temperature [see below], and the heating is turned off. 1# 2# 3# 4# 5# 6# 7# pv 195 195 195 195 195 195 195 Abnormal sv 200 200 200 200 200 200 200 h). Pressing `Setup' enters into machine engineering mode. · The top row displays heating zones, 1# to 7# showing the actual temperature. · The second row shows temperature calibration values 1# to 7#, the calibration range is -99 to +99; Please contact Adkins Technical Support for guidance when updating settings in the above mode. Setup pv 1# 2# 3# 4# 5# 6# 7# 195 195 195 195 195 195 195 Compensate -5 -5 -5 Operation range 55 5 03 30 Counter Reset Heat Start 55 55 Tray in Floor place delay rise time 1.0 1.0 Delayed operation 1.0 Return Page 15 4.3 Exploded diagrams and parts list 14 45 1 16 30 39 12 56 13 25 26 2 17 18 41 15 43 5 19 48 4 28 11 29 27 38 37 24 10 31 3 9 40 6 20 21 42 37 44 33 32 34 7 8 35 23 22 36 46 9 47 49 Page 16 Exploded diagrams and parts list (Cont.) Control panel 50 51 52 53 No. Parts Description 1 Top cover plate 2 Side plate 3 Black silicon pad 4 Air cylinder 5 Air system lubricator 6 Drive rod 7 Rear rail fixing plate 8 Front rail fixing plate 9 Solenoid valve 10 Front plate 11 Iron pipe 12 Back plate 13 Electric box 14 Fixture for cooling fan 15 Electric box 16 Shield for drive shaft 17 Power cord 18 Unite box 19 Caster 20 Slide rail 21 Fall board for the frame 54 55 Qty. Part No. 1 2 4 AIP/SIL100x170 4 1 1 2 2 2 1 12 1 2 1 1 1 1 1 4 4 1 - Page 17 Exploded diagrams and parts list (Cont.) 22 Start control box 23 Moving frame 24 Lifting board 25 Machine frame 26 Lower electric control box 27 Cover plate for heat platen 28 Fixing bolt 29 Upper adaptor plate 30 Governor 31 Synchronous belt 32 Synchronizing wheel 33 Fixed flange 34 Gear 35 Emergency stop button 36 Start button 37 Slide block 38 Heat plater 39 Shim plate for heat plater 40 Tee piece 41 PLC Display 42 Foam pad (30mm thick) 43 Air flow filter/ regulator 44 Proximity switch 45 Silicone stop 46 16 mm Fixules nut 47 16 mm Threaded bar 48 Pneumatic restrictor 49 Pneumatic silencer 50 Solid state relay 51 Relays 52 Circuit breaker (MCB) 53 PLC power supply 54 PLC controller board 55 PLC external controller board 56 Thermal Cut-Out 2 2 1 1 1 1 6 1 1 4 4 2 1 2 2 8 1 4 3 1 2 AIP7FOAM120x170 1 1 2 12 4 4 2 1 4 1 1 1 1 1 BM338 Page 18 L1 L2 L3 L4 G 380V 3-Phase ©2018 a. adkins and sons limited. all rights reserved 4.4 Electrical diagram GND ©2018 a. adkins and sons limited. all rights reserved Page 19 Switching Power 3 Phase Power Switch with fuses (380V 40A) 3 Phase Contactor New Addon (KM1--40A) FU 250V 3A N1 L1 FU 250V 3A 03 K0 (POWER SWITCH) (250V/15A) LN DC24V +24V DL a COM DN a N SR3 SR2 SR1 KA1 L (OUT) 01 URGENT PAUSE START LCD operation panel FG 0v 24v L N FG 0 COM COM X0 X1 X2 X3 X4 X5 X6 X7 X10 X11 X12 X13 Data link XC3-32T-E 24v 0v XC-6PT-P-H 24V+ 0V 24v 0v XC-6PT-P-H (RELAY: SSR-80DA) L N Relay Solenoid 7pcs M T.P. Speed Adjusting Motor L (OUT) _ A0 A1 A2 A3 A4 A5 COM0 Y0 COM1 Y1 COM2 Y2 Y3 Y4 Y5 COM3 Y6 Y7 Y10 Y11 COM4 Y12 Y13 Y14 + C0 C1 C2 C3 C4 C5 _ A0 A1 A2 A3 A4 A5 + C0 C1 C2 C3 C4 C5 0V 24V+ SSR SSR CONNECTOR SSR 7pcs BUZZER KA3 KA4 KA2 KA1 1 2 3 4 5 6 7 SSR7 Sensor 7pcs Heat 2 240°C THERMO SWITCH (1) Cap L (OUT) N YA2 240°C THERMO SWITCH (2) L Heat 1 Heat 3 t + Sensor _ 7pcs HEATER PLATEN SR1 - Under Limit Sensor SR2 - Bottom Working Station Sensor SR3 - Upper Working Plate Station Sensor FG AC AC CCW CV COM 28 43 KA33 09 07 KA43 05 Motor Speed Adjusting Device Down Up 26 a 28 a KA21 26 KA11 28 YA1 38 30 M 41 Electromagnetic coil working program 43 Speed regulator AC port 45 FAN TERMINAL BLOCK (BND24W) N1 N2 DL a DL DL DL DL DL DL DL DL DL DL DL DL DL DL DL AL AL AL AL AL AL 01 03 02 D14 D12 D10 D08 D06 D04 D02 04 06 08 10 12 14 16 18 20 22 24 26 a 28 a 30 DN DL 44 05 07 09 DN DN DN DN DN DN DN DN DN DN DN DN AN AN AN AN AN AN 47 46 05 07 09 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 4.5 Pneumatic diagram CYLINDER 1 CYLINDER 2 BACK VALVE BACK VALVE SOLENOID VALVE COMPRESSOR GAS PROCESSING COMPONENTS Page 20 5. Design change With the policy of constant improvement and/or modification to meet changing conditions, the right is reserved to change the design and/or specifications at any time without prior notification, and therefore specifications may vary and not be in accordance with this manual. Page 21 6. Guarantee (limited warranty) Charterhouse Holdings PLC warrants that the press is free from defects in material and workmanship (excluding Pressing Pad Assembly) for a period of 12 months from the date of supply. The machine comes with a 12 month warranty on the heating element, one year warranty on parts and 90 days labour. This warranty covers all parts to repair the defects, except when damage results from misuse or abuse, accident, alteration or negligence or when a machine has been improperly installed. If a press covered by warranty should need to be returned to the factory for examination and repair, if on-site component replacement is not possible, Charterhouse Holdings PLC will make every effort to repair the customers press. The warranty will only be effective when Charterhouse Holdings PLC author-ises the original purchaser to return the machine to the factory and only when the product upon examination has proven to be defective. Should in our opinion any part of this press be defective in materials or workmanship, it will be replaced or repaired free of charge, provided that the press has been installed and operated in the correct manner and not subjected to misuse. If Charterhouse Holdings PLC authorise a replacement press, the warranty of the replacement press shall expire on the anniversary date of the original machines invoice to the customer. In order for this warranty to be effective, no return of machine or parts may be made without prior factory authorisation. (This will exclude any travelling and/or carriage costs which will be charged at our discretion). This is the sole warranty given by the company; there are no warranties, which extend beyond the description on the face hereof. The seller disclaims any implied warranty of merchantability and/or any implied warranty of fitness for a particular purpose; the buyer agrees that the goods are sold "as is". Charterhouse Holdings PLC does not warrant that the functions of the press will meet the customer's requirements or expectations. The entire risk as to use, quality and performance of the press lies with the customer. (No claim of any kind shall be greater than the sale price of the product or part to which the claim is made). In no event will Charterhouse Holdings PLC be liable for any injury, loss or damage, including loss of profits, destruction of goods or any special, incidental, consequential or indirect damages arising from the use of the press or accompanying materials. This limitation will apply even if Charterhouse Holdings PLC or its authorised agent had been advised of the possibility of such damage. Page 22 A. ADKINS AND SONS LIMITED DECLARATION OF CONFORMITY Application of Council Directives: European Low Voltage Directive (LVD), European Machinery Directive (MD), Electro Magnetic Conformity (EMC) Standards to which Conformity is Declared: (LVD): EN 60204-1:2018 (MD): EN ISO 12100:2010 2006/42/EC Annex1 (EMC): EN 61000-6-2:2019 Manufacturer's Name: A. Adkins and Sons Limited Manufacturer's Address: High Cross, 18 Lancaster Road, Hinckley, Leicestershire LE10 0AW United Kingdom. Type of Equipment: Standards Compliance: Alpha Industrial Flatbed Series 7 (120 cm x 170 cm) RoHS COMPLIANT Model Number: ..A..I..P..R..T..1..7..0.................................................................................. Serial Number: .................................................................................................. Year of Manufacture: .................................................................................................. I, the undersigned, hereby declare that the equipment specified above conforms to the above directives and standards. Place: Hinckley, United Kingdom Signature: ..................................... Date: ................... Full Name: Marie McMahon Position: General Manager Page 23Acrobat Distiller 21.0 (Windows)