Model US 25 Hot Stamping Machine Operation and Maintenance Manual October 2000

Designers and Manufacturers of Product Decorating Equipment, Automated Systems and Supplies

ABOUT UNITED SILICONE

SUPPLIES

An ITW Decorating Company, United Silicone specializes in the design and manufacture of hot stamp and heat transfer decorating equipment. All standard machines and dedicated, customdesigned systems are offered to the everchanging, continually expanding marketplace for part decorating equipment. In addition to our full line of equipment and design services, United Silicone offers a wide array of hot stamping and heat transfer tooling and supplies. You have made a wise choice in selecting a United Silicone hot stamping machine. And to help fill your future decorating needs, we want you to know about our semi- and fully-automated processing systems, and other products and services. Details are provided in the following paragraphs.

Our dedicated customer service team understands—and responds with a sense of urgency to—the needs of our customers. Silicone rubber sheets, rollers, and dies are all available at low cost and with fast, friendly service. United Silicone’s creative art department meets customer needs for accurate, meticulous quality in hot stamping dies. Our products include: • • • •

Silicone rubber sheets Silicone rubber rollers Stamping dies—flat and contoured Part nesting fixtures

Designers and Manufacturers of Product Decorating Equipment, Automated Systems and Supplies SEMI- AND FULLY-AUTOMATED SYSTEMS From integrating two or more decorating processes to developing fully automated part handling and production equipment, United Silicone’s Automation Division offers comprehensive solutions to the demands of today’s fast-paced manufacturing environment. Our skilled engineers analyze needs, perform cost analyses, consult with production engineers and decisionmakers, develop preliminary design concepts, and create custom-designed systems, which dramatically improve production efficiency and quality control.

United Silicone’s innovative engineers develop these custom systems by skillfully interfacing the required processing stations to produce uniformly high-quality finished products. From transporting unfinished parts to the first processing station, to dispensing the completed components to the next manufacturing or assembly process, our systems are conceived and built to exacting customer standards and specifications. Typical processing stations currently in use on our automated systems are: • • • • • • • • •

Part loading and unloading Articulation Sorting Part presence sensing Optical inspection Decorating (hot stamp, heat transfer) Pre- and post-treating, as required Robotics/interface to existing conveyor Sampling and testing

ENGINEERING SERVICES When assistance is needed to solve a decorating problem or plan future decorating systems, United Silicone is ready to provide assistance when and where needed. These services comprise: Typical Automated System Carefully designing, building, and testing individual processing stations. And integrating the discrete assemblies into a unified, smoothfunctioning, reliable system. All are everyday events at United Silicone’s Automation Division. And all are directed at surpassing customer expectations! Automated systems employ combinations of various processing assemblies, a mechanism for moving the parts through the various stations, and state-of-the-art digital controls that supervise the entire system.

• • • • •

Feasibility studies Automation consulting Cost analysis Design review Technical field support

READY TO HELP Contact United Silicone for assistance on all your part decorating requirements. We have the skill and dedication to help you meet the needs of your customers—today and tomorrow!

US 25 Hot Stamping Machine Contents

CONTENTS 1.0

INTRODUCTION Why Hot Stamping ........................................................................................................ 1.0-1 Safety ............................................................................................................................ 1.0-1

2.0

WARRANTY

3.0

DESCRIPTION Stamping Head.............................................................................................................. 3.0-1 Control Box.................................................................................................................... 3.0-1 Foil/Web Payout and Feed ........................................................................................... 3.0-2 Main Frame................................................................................................................... 3.0-2 Head Height Adjuster.................................................................................................... 3.0-2 Positive Stop ................................................................................................................. 3.0-2 Palm or Opti-Touch Switches ....................................................................................... 3.0-2

4.0

OPERATION The Hot Stamping Process........................................................................................... 4.0-1 Equipment Operation .................................................................................................... 4.0-2 Extension Cycle ...................................................................................................... 4.0-2 Retraction Cycle...................................................................................................... 4.0-2 Foil Feed.................................................................................................................. 4.0-2

5.0

INSTALLATION Shipping......................................................................................................................... 5.0-1 Machine Placement and Mounting ............................................................................... 5.0-1 Utility Requirements ...................................................................................................... 5.0-1 Air Connection............................................................................................................... 5.0-1 Air Pressure Regulator.................................................................................................. 5.0-1 Lubricator ...................................................................................................................... 5.0-2 Air Filter ......................................................................................................................... 5.0-2

6.0

SETUP AND ADJUSTMENT Stamping Die Mounting................................................................................................. 6.0-1 Head Height Coarse Adjustment .................................................................................. 6.0-1 Head Height Fine Adjustment....................................................................................... 6.0-3 Stamp Evaluation and Adjustment ............................................................................... 6.0-3 Stamp Adhesion Testing and Adjustment .................................................................... 6.0-4 Foil Installation .............................................................................................................. 6.0-4 Temperature and Dwell Relationship............................................................................ 6.0-7 Setting and Storing Job Parameters ............................................................................ 6.0-7

7.0

T ROUBLESHOOTING Configuration Display .................................................................................................... 7.0-1 Diagnostics ................................................................................................................... 7.0-1 Controller Inputs ............................................................................................................ 7.0-1 Troubleshooting Chart................................................................................................... 7.0-2 Battery Testing and Replacement ................................................................................ 7.0-3

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US 25 Hot Stamping Machine Contents 8.0

9.0 10.0

10.1

10.2

10.3

ii

M AINTENANCE Pneumatic System Lubricator....................................................................................... 8.0-1 Air Filter ......................................................................................................................... 8.0-1 Head Height Adjusting Screw ....................................................................................... 8.0-1 Inspection and Cleaning................................................................................................ 8.0-1 Adjustments .................................................................................................................. 8.0-1 Component Replacement............................................................................................. 8.0-1 Heater...................................................................................................................... 8.0-1 Thermocouple ......................................................................................................... 8.0-2 Down Limit Switch .................................................................................................. 8.0-2 Up Limit Switch ....................................................................................................... 8.0-3 Solid State Relay..................................................................................................... 8.0-3 Palm or Opti-Touch Switch..................................................................................... 8.0-4 Emergency Stop Switch ......................................................................................... 8.0-4 Air Cylinder.............................................................................................................. 8.0-4 Foil Pinch Roller ...................................................................................................... 8.0-5 Foil Takeup Drive Belt............................................................................................. 8.0-6 RECOMMENDED SPARE P ARTS Ordering Parts............................................................................................................... 9.0-1 PNEUMATIC S LIDE T ABLE OPTION Description .................................................................................................................. 10.0-1 Operation..................................................................................................................... 10.0-1 Troubleshooting........................................................................................................... 10.0-1 Maintenance................................................................................................................ 10.0-1 Air Cylinder............................................................................................................ 10.0-1 Solenoid-Operated Air Valve ................................................................................ 10.0-2 Engineering Drawings ................................................................................................. 10.0-2 X-Y AND X-Y-R POSITIONING T ABLE OPTION Description .................................................................................................................. 10.1-1 Operation..................................................................................................................... 10.1-1 WEBTRAK H EAT T RANSFER P HOTOCELL OPTION Description .................................................................................................................. 10.2-1 Web Feed.............................................................................................................. 10.2-1 Control Panel......................................................................................................... 10.2-1 Operation..................................................................................................................... 10.2-1 Heat Transfer Web or Foil Installation ........................................................................ 10.2-2 Diagnostics ................................................................................................................. 10.2-4 Maintenance................................................................................................................ 10.2-5 Web Takeup Drive Belt ......................................................................................... 10.2-5 Recommended Spare Parts ....................................................................................... 10.2-5 Engineering Drawings ................................................................................................. 10.2-6 WEBTRAK H EAT T RANSFER L ASER E YE OPTION Description .................................................................................................................. 10.3-1 Web Feed.............................................................................................................. 10.3-1 Control Panel......................................................................................................... 10.3-1 Operation..................................................................................................................... 10.3-1 Heat Transfer Web or Foil Installation ........................................................................ 10.3-2 Diagnostics ................................................................................................................. 10.3-4

US 25 Hot Stamping Machine Contents Maintenance................................................................................................................ 10.3-5 Web Takeup Drive Belt ......................................................................................... 10.3-5 Recommended Spare Parts ....................................................................................... 10.3-5 Engineering Drawings ................................................................................................. 10.3-5 10.4

ROTARY T ABLE OPTION Description .................................................................................................................. 10.4-1 Operation..................................................................................................................... 10.4-1 Station Alignment .................................................................................................. 10.4-1 Speed Control ....................................................................................................... 10.4-1 Table Index Cam Adjustment ..................................................................................... 10.4-2 Index Check .......................................................................................................... 10.4-2 Cam Adjustment ................................................................................................... 10.4-2 Engineering Drawings ................................................................................................. 10.4-2

10.5

LOCKOUT K EY SWITCH OPTION Description .................................................................................................................. 10.5-1 Operation..................................................................................................................... 10.5-1

11.0

12.0

SEMI-AUTOMATED CUSTOM HOT STAMP S YSTEMS Description .................................................................................................................. 11.0-1 Documentation ............................................................................................................ 11.0-1 ENGINEERING DRAWINGS

1.0-1 3.0-1 4.0-1 4.0-2 5.0-1 6.0-1 6.0-2 6.0-3 6.0-4 6.0-5 6.0-6 6.0-6 7.0-1 7.0-2 7.0-3 8.0-1 8.0-2 8.0-3 8.0-4 8.0-5 8.0-6 8.0-7 8.0-8 8.0-9

Model US 25 Two and One-Half-Ton Hot Stamping Machine ..................................... 1-0-2 Control Panel................................................................................................................. 3.0-5 Typical Vertical Hot Stamping Setup ............................................................................ 4.0-1 The Hot Stamping Process........................................................................................... 4.0-2 Air Connection............................................................................................................... 5.0-1 Stamping Die Mounting................................................................................................. 6.0-2 Setting Air Pressure...................................................................................................... 6.0-2 Vernier Positive Stop Preliminary Adjustment.............................................................. 6.0-3 Foil Payout Assembly ................................................................................................... 6.0-5 Stripper Bar Positioning ................................................................................................ 6.0-5 Pinch Roller Camshaft.................................................................................................. 6.0-5 Foil Path ........................................................................................................................ 6.0-6 Typical Controller Inputs ............................................................................................... 7.0-2 Battery Location ............................................................................................................ 7.0-3 Pin J8 Jumper Location................................................................................................. 7.0-4 Heater and Thermocouple Location ............................................................................. 8.0-2 Down Limit Switch Location.......................................................................................... 8.0-2 Up Limit Switch Location............................................................................................... 8.0-3 Solid State Relay Location............................................................................................ 8.0-4 Palm Switch Installation ................................................................................................ 8.0-4 Emergency Stop Switch Installation ............................................................................. 8.0-5 Air Cylinder Installation ................................................................................................. 8.0-5 Foil Pinch Roller ............................................................................................................ 8.0-6 Foil Takeup Drive Belt................................................................................................... 8.0-6

ILLUSTRATIONS

iii

US 25 Hot Stamping Machine Contents 10.0-1 10.1-1 10.2-1 10.2-2 10.2-3 10.2-4 10.2-5 10.3-1 10.3-2 10.3-3 10.3-4 10.4-1 10.4-2 10.5-1 11.0-1 11.0-2

iv

Pneumatic Slide Table Components .......................................................................... 10.0-2 X-Y and X-Y-R Positioning Table Option.................................................................... 10.1-1 Webtrak Heat Transfer Photocell Option.................................................................... 10.2-1 Heat Transfer Web Payout Assembly ........................................................................ 10.2-3 Photocell Heat Transfer Web Path............................................................................. 10.2-4 Photocell X-Y Adjustments ......................................................................................... 10.2-5 Photocell Adjustment .................................................................................................. 10.2-5 Webtrak Heat Transfer Laser Eye Option .................................................................. 10.3-1 Heat Transfer Web Payout Assembly ........................................................................ 10.3-3 Laser Eye Heat Transfer Web Path............................................................................ 10.3-4 Laser Eye Adjustment................................................................................................. 10.3-5 Rotary Table Option .................................................................................................... 10.4-1 Rotary Table Index Drive Cam Adjustment................................................................ 10.4-2 Lockout Key Switch Option......................................................................................... 10.5-1 Typical Semi-Automated Custom Hot Stamp System ............................................... 11.0-1 Pick and Place Station ................................................................................................ 11.0-1

US 25 Hot Stamping Machine 1.0 Introduction

1.0 INTRODUCTION The United Silicone Model US 25 vertical hot stamping machine (Figure 1.0-1) offers advanced capabilities for reduced installation and setup time, consistent stamping force, quiet operation, precision foil advance, and operator convenience and ease of operation. Its two and one half-ton maximum stamping force combined with available head sizes of 6” x 6”, 6” x 8”, and 6” x 10” ensure optimum quality and versatility in hot stamping operations. Table 1.0-1 lists technical specifications for the Model US 25. Your hot stamping machine is designed for extended trouble-free operation. Built-in diagnostics aid in fault analysis in case of malfunction. United Silicone backs its equipment with a strong customer service organization. Telephone assistance is provided at no charge to assist you in troubleshooting, equipment installation, setup, or other issue. To gain the most from your equipment, you are urged to read through this manual completely before beginning your setup. These instructions will minimize the installation and setup time and assist you in properly operating the machine following the installation. When selecting a location for the machine, take into account the following concerns: • Work area is adequately lighted. • Required utilities (air and electricity) are present. • Sufficient space is available for receiving and forwarding parts. WHY HOT STAMPING Following are some of the significant benefits offered by the versatile hot stamp decorating process: • Dry process requiring no ink, allowing part to be immediately ready for handling and packaging.

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Suitable for wide variety of materials including thermoplastics, thermoset plastics, wood, leather, cloth, paper, and pre-painted metals

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Only method available for applying permanent gold and silver metallic graphics, as well as wood grain, gloss or matte pigment colors, brushed effects, chromium, and multi-colored graphics

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Applies to various surface geometries including flat, cylindrical, and spherical

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Thermally bonds to substrate for excellent long-term durability

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No hazardous vapors or solvents requiring special storage or compliance with Environmental Protection Agency (EPA) rules

SAFETY The Model US 25 is designed for safe operation and includes all required safety features to minimize possible injury to personnel. However, you are responsible for providing a safe environment for operating this machine and other equipment at your facility. Do not remove any guards or defeat safety devices. If any additional equipment is used or modifications made to the stamping machine, be sure to provide suitable operator protection. Safety begins with permitting only properly trained personnel to install and operate the equipment. All personnel involved in installing and setting up the equipment must be fully trained in performing electrical, pneumatic, and mechanical installations. All operators should be thoroughly trained in the safe and correct procedures described in this manual. Do not permit untrained personnel to perform, or assist in, installation of the equipment or subsequent operation.

1.0-1

US 25 Hot Stamping Machine 1.0 Introduction Utility requirements Electrical Air Mounting Die dimensions Heaters 8”x8” heater block 8”x12” heater block 8”x16” heater block Stroke Working height Throat depth Overall dimensions Work table Weight Personnel safety

Table 1.0-1. Model US 25 Specifications Electrical and pneumatic Three heaters – 110 Vac, 60 Hz, 15 A Four or five heaters – 220 Vac, 60 Hz, 30 A 80 to 100 PSI (50 PSI min.) at 5 CFM, moisture-free, 3/8” NPT connections Bench or stand 8” x 8” (std); 8” x 12” or 8” x 16” (optional) Three 500 Watt each, 500° F max. Four 500 Watt each, 500° F max. Five 500 Watt each, 500° F max. 0-3” Up to 16” Up to 8” 40” H x 28” W x 23” D 16” x 18” 600 LBS Dual palm or Opti-Touch (optional) switches

Figure 1.0-1. Model US 25 2.5-Ton Hot Stamping Machine

1.0-2

US 25 Hot Stamping Machine 2.0 Warranty

2.0 WARRANTY United Silicone (Seller) warrants the Model US 25 to be free of any defects in material and workmanship. The Seller’s sole obligation under this warranty is limited to replacing or repairing (at the Seller’s discretion), FOB Lancaster, New York, any part of its product which, under normal and proper use and maintenance, is proven defective in material or workmanship within one year1 after delivery to Buyer, provided that notice of any such defect and satisfactory proof thereof is promptly provided to the Seller, and thereafter such part is returned to the Seller, with transportation charges prepaid, and the Seller’s examination confirms such part to have been defective. This warranty does not apply to any damage to the product, accessory, or attachment thereof caused by overloading or other misuse, neglect or accident, nor does this warranty apply to any product or accessory or attachment thereof, which has been repaired or altered by other than the Seller or its authorized representative in any way, which in the sole judgment of the Seller affects the performance or purpose for which the equipment was manufactured.

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This warranty applies to United Silicone-manufactured components only. If components made by other manufacturers are used, the original equipment manufacturer’s warranty applies, unless otherwise specified .

2.0-1

US 25 Hot Stamping Machine 3.0 Description

3.0 DESCRIPTION Principal components of the hot stamping machine are: Stamping head, control box, foil feed, main frame, head height adjuster, positive stop, and palm (or Opti-Touch) switches. The major components are described in the following paragraphs. STAMPING HEAD A double-acting pneumatic cylinder, the principal component of the stamping head, is enclosed within the cylinder mounting box. The cylinder provides the motive force needed to drive the stamping head downward onto the decorating surface. The cylinder mounting box also contains the required guides and supports to prevent rotation of the air cylinder piston and ensure precise control of the stamping head during extension and retraction. Provisions for mounting the stamping die are also included in the head. The heater block applies heat to the stamping die, which is mounted on the die mounting plate. An insulation plate prevents excessive heat transfer from the heater plate to the cylinder and other components. The up limit switch, which completes a circuit that signals the control box of the completion of the cylinder’s upward travel, is also installed in the cylinder mounting box, adjacent to the stamping head. CONTROL BOX Electrical components and circuitry, which control machine operation, are installed in the control box. Switches, indicators, and controls used to set up and operate the machine, are installed on the control panel. The control box contains internal connections for input power and distribution to various components of the machine. Terminal strips are provided to facilitate component replacement. Both front control panel and rear panel may be separated from the control box for maintenance accessibility to the internal components.

In addition to the power and emergency switches, the control panel (Figure 3.0-1) contains membrane switches and indicators that are used to set up and operate the equipment and display its operating status. Table 3.0-1 describes the function of each switch, control, and indicator on the control panel. FOIL/WEB PAYOUT AND FEED The foil/web payout and feed includes the components for mounting the unused foil roll and guiding its path under the stamping head. It also includes components for pulling and receiving the used foil after the stamping cycle, moving the foil from right to left. For heat transfer machines, web movement is from left to right. An electric motor, operated under controller timing, rotates the takeup shaft that receives the used foil after stamping, while the and knurled roller prevent the used foil from slipping. Stripper bars apply tension to the foil when in contact with the decorating surface. MAIN FRAME All necessary supports and brackets that facilitate mounting of other major components are included on the main frame. The work table, which has provisions for mounting the nesting fixture used to properly retain and position the part to be decorated, is also included on the main frame. HEAD HEIGHT ADJUSTER The head height adjuster permits vertical adjustment of the head in relation to the work table. The adjuster sets the head position to ensure proper contact with the part without excessive contact, which could damage the die. A handwheel is used to move the head up and down to obtain the required relationship. Slide clamps permit positive locking of the head in the desired vertical position after adjustment.

3.0-1

US 25 Hot Stamping Machine 3.0 Description POSITIVE STOP A locking vernier adjusting sleeve installed on the positive stop is used for making fine adjustments of the cylinder’s downward stroke. The adjusting sleeve actuates the down limit switch, which is mounted on a bracket adjacent to the positive stop. When actuated by the adjusting sleeve, the closed switch contacts complete a circuit that signals the controller of the completion of the cylinder’s downward travel. In case the down limit switch fails, a dead stop mechanically stops movement before the cylinder bottoms.

PALM OR OPTI-TOUCH SWITCHES Hot stamping machine operation is initiated by simultaneously pressing or touching the two switches at the sides of the machine. This safety feature ensures that the operator’s hands are clear of the machine when the stamping head descends. Two types of switch are available: Palm and optional Opti-Touch. The palm switch is a simple contactor, which is actuated by pressing a large button. The Opti-Touch switch is a heat-sensitive device, requiring only touching to close the circuit.

Figure 3.0-1. Control Panel

3.0-2

US 25 Hot Stamping Machine 3.0 Description

Table 3.0-1. Control Panel Switches, Controls, and Indicators Name Message display

Function Continuously shows function selected and its current setting or value. First line shows current die temperature regardless of option selected. Sets die temperature. Pressing switch repeatedly scrolls through available options. The selected option and current value are displayed on the second line of the display. The + and – keys are used to change settings. The following options are available: TEMP. SET POINT – Changes die set temperature

TEMP. switch (normal operation)

TEMP. OFFSET – Adjusts displayed die temperature to correspond with die surface temperature. Before changing offset, check die temperature with a pyrometer to ensure that die surface temperature has stabilized. Offset should be a negative number. TEMP. HIGH LIMIT – Sets maximum allowable temperature. Upon rising to limit, heaters are turned off, a fault message is displayed, FAULT light flashes, and machine will not operate. TEMP. LOW LIMIT – Sets minimum allowable temperature. Upon falling to limit, heaters are turned on, a fault message is displayed, FAULT light flashes, and machine will not operate. Displays several options relating to effects of RF interference on temperature control. Pressing switch repeatedly scrolls through available options. The selected option and current value are displayed on the second line of the display. The following options are available: TEMP. P – Factory setting; do not change TEMP. I – Factory setting; do not change TEMP. D – Factory setting; do not change

TEMP. switch (Setup mode)

SNDFILTR.CONST1 – Sets threshold value for software noise discrimination filter (SNDF), which helps reduce effects of radio frequency (RF) noise on temperature control. Recommended setting is 50 to 100. If not needed, SNDFILTR.CONST1 is set to 0. SNDFILTR.TIME – Sets time dwell to correspond with SNDF source such as an RF welder. The SNDF rejects thermocouple measurements if, in two consecutive cycles, the dwell varies more than SNDFILTR.CONST1. The filter then engages and remains engaged until either the RF falls within the defined value or SNDFILTR.TIME interval has elapsed. If it times out, the new SNDFILTR.CONST1 value will be accepted. If not needed, SNDFILTR.TIME is set to 0.

FOIL PULL (standard machine)

Sets allotted time for advancing foil between stampings (FOIL PULL TIME XX.XX). The + and – switches are used to raise and lower the interval.

3.0-3

US 25 Hot Stamping Machine 3.0 Description Table 3.0-1. Control Panel Switches, Controls, and Indicators Name

Function Sets allotted time for advancing web between stampings. The + and – switches are used to raise and lower the following options: FOIL PULL TIME XX.XX – Sets allotted time for high-speed advancing of heat transfer web.

FOIL PULL (heat transfer machine)

FOIL HIGH SPEED: XX – Sets speed of heat transfer advance during FOIL PULL TIME (high-speed pulling). FOIL LOW SPEED: XX – Sets low (creep) speed of heat transfer pulling. WEB LOW RANGE: XX – Sets the upper and lower limits for low (creep) speed of web pulling. This is a factory setting and should not be changed. MARKS/ONE STEP: XX – Sets number of marks to be counted before stopping heat transfer advancement (usually used for multiple part stamping).

COUNT

Displays total number of machine cycles. Reset to zero by pressing CLR switch.

DWELL TIME

Sets time that begins when down limit switch is actuated; when time expires, head leaves surface. Reset to zero by pressing CLR. Use + and – switches to raise or lower dwell time.

HEAD UP (optional)

Sets time between end of dwell and before head up delay starts. Head rises until head up time expires, thus setting a distance from part where head pauses for head up delay. Use + and 0 switches to raise and lower time. Press CLR to remove set value.

HEAD UP DELAY (optional)

Sets time that head pauses after head up time has expired and before head fully retracts. Use + and 0 switches to raise or lower time. Press CLR to remove set value.

HEAT OFF/ON

Turns heater on and off.

HEAT OFF/ON indicator

Lights when power is applied to heaters.

BEFORE AFTER

Sets timing of foil pulling cycle to either before or after stamping cycle.

BEFORE AFTER indicator

When lighted, machine is set to pull foil before stamping cycle; when off, foil is pulled after stamping cycle.

FUNC.

Toggles between foil or heat transfer operation.

FUNC. indicator

Lights when FUNC. switch has set machine in heat transfer mode; light is off when FUNC. switch has set machine in foil mode.

TABLE JOG

Moves slide table into or out of stamping position or turns rotary table one index position.

3.0-4

US 25 Hot Stamping Machine 3.0 Description Table 3.0-1. Control Panel Switches, Controls, and Indicators Name

Function

SET UP

Turns setup mode on and off. When on, pressing both palm switches simultaneously extends and keeps head down in stamping position. Pressing switch again cancels setup and retracts head. Also displays other options (see TEMP. switch in Setup mode).

FOIL JOG

Advances foil or heat transfer. Foil moves until switch is released; heat transfer moves to next mark detected by photocell each time switch is pressed. If no mark is detected, after 10 seconds the watchdog timer will stop the heat transfer and display an error message.

CLR +

Returns setting of selected function to zero or lowest limit.

0

Lowers setting of selected function.

JOB #

Permits storage and retrieval of stamping parameters for up to 10 different jobs. (Refer to Setup and Adjustment for procedure.)

OFF-ON

Turns power to control box on and off.

EMERGENCY STOP

When pressed, disables machine. For machine not having head up delay, head fully retracts. If rotary index table is installed, table stops immediately (either mid-station or at station where located). Power is restored by pulling out button.

Raises setting of selected function.

3.0-5

US 25 Hot Stamping Machine 4.0 Operation

4.0 OPERATION THE HOT STAMPING PROCESS Vertical hot stamping is used to apply foil resins to small areas of flat or slightly crowned parts and up to 90 degrees on the circumference of cylindrical- or sphericalshaped parts. Hot stamping is performed as follows: 1. Part is mounted on a nesting fixture (Figure 4.0-1) attached to the work table. 2. The stamping head is extended downward (Figure 4.0-2) by pressing both palm (or touching Opti-Touch) switches simultaneously, with the foil maintained at a consistent distance from the stamping die face. As the foil contacts the part, stripper bars on the head stretch the foil tightly over the decorating surface removing any wrinkles or bubbles. 3. With foil in contact with the surface, the die continues its downward travel, pressing the foil into intimate contact with the surface. The resilient silicone rubber die conforms the foil to surface irregularities and creates a parting line in the foil resins.

4. The heated die remains in contact for sufficient time (dwell time) to soften the release agents and resins in the foil. The decorating surface also softens, while die pressure drives the resins into the molten surface to promote thermal bonding. 5. When dwell time expires, the head retracts to the start position in the following sequence: a. The die lifts away from the foil, while foil remains in contact with the surface briefly to allow both foil and surface to cool. b. As the die continues retracting, the foil lifts from the surface, peeling away first from the edges and then working toward the center. Since adhesion between the foil coating and the surface is greater than the bond between the release agents in the coatings and the film carrier, a virtually complete deposition of foil coating is achieved.

HEATER HEAD

DIE MOUNTING PLATE

ALUMINUM BACKING

DIE MOUNTING BLOCK

SILICONE DIE 1/32" 1/2"

FILM CARRIER

FILM COATINGS

HEAT

STRIPPER BAR PART PART NESTING FIXTURE

Figure 4.0-1. Typical Vertical Hot Stamping Setup 4.0-1

US 25 Hot Stamping Machine 4.0 Operation 6. Once the head has fully retracted to the start position, the foil advances until an unused section is positioned under the die. The hot-stamped part is then removed from the fixture. The part may be handled without danger of smudging or removing the image from the surface. EQUIPMENT OPERATION Supervision of the cycle described in the following paragraphs is provided by the controller. The controller defines the dwell and head-up delay (optional), which determines timing of the cylinder’s retraction. Extension Cycle The stamping process is initiated by pressing both palm switches (or touching Opti-Touch switches) simultaneously. With both switches actuated, power is applied from the OFF-ON switch through the palm or Opti-Touch switches and the closed contacts of the head up limit switch, which is held in the closed position by the guide bar. Power flows to the air cylinder extension solenoid valve, which re-positions to direct air from the air regulator to the extension side of the cylinder’s piston.

downward stroke, the up limit switch is reopened as its actuator is released by the guide bar. The down limit switch is simultaneously closed by the positive stop adjusting sleeve. Upon sensing the closed contacts of the down limit switch, the controller energizes the retraction solenoid valve. Air is then directed to the retraction side of the air cylinder, forcing the piston upward. The foil or heat transfer web is pulled after cylinder retraction to prepare for the next stamping cycle. As the cylinder retracts to the start position, the up limit switch is closed once again, while the down limit switch is opened. Upon sensing the closed contacts of the up limit switch, the controller stops air flow to the retraction side of the cylinder, thereby completing the cycle. Foil Feed Under microcontroller direction, the foil feed motor is energized after cylinder retraction. The motor pulls the foil for the programmed interval set by the operator. The controller then terminates foil pulling.

Retraction Cycle As the cylinder reaches the end of its 1 - Head Descends

4 - Head Retracts

2 - Die Contacts Part

5 - Foil or Web Advances

3 - Die Dwells on Part

Figure 4.0-2. The Hot Stamping Process

4.0-2

US 25 Hot Stamping Machine 5.0 Installation

5.0 INSTALLATION The procedures in this section are designed to assist installation personnel in safely and properly placing the hot stamping machine in its work environment and connecting the required utilities. Be sure to follow all personnel safety requirements during the installation. Following installation, perform the procedures in Setup and Adjustment to correctly prepare the machine for safe, productive operation. SHIPPING INSPECTION Your machine has been thoroughly tested and inspected before shipment. You should not see any visible damage or loose or missing parts. Carefully inspect the equipment to ensure that there are no apparent defects. Any damage or missing or loose parts should be reported promptly to the carrier. MACHINE PLACEMENT AND MOUNTING Observe the following safety and operator precautions when placing the machine at its operating location: WARNING THE MACHINE WEIGHS 350 POUNDS. DO NOT ATTEMPT LIFTING WITHOUT SUFFICIENT PERSONNEL TO SAFELY LIFT AND PLACE MACHINE IN POSITION. •

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Place the machine in a safe area having adequate lighting, and space on all sides to permit convenient access for operation and maintenance. Install machine on a level, flat surface capable of supporting its weight. An optional floor stand is available from United Silicone for properly mounting the machine. Do not modify mounting provisions. Use mounting holes provided for securing machine to bench or floor stand.

•

For operator comfort, mount machine so that operator’s arms are parallel to floor when hands are placed on palm switches.

UTILITY REQUIREMENTS Electrical power and a pressurized air supply are required to operate the equipment. The following paragraphs describe the requirements for each utility. Electrical Power Electrical power must be properly connected to the machine for safety and satisfactory operation. Three-heater machines require electrical power at 110 to 120Vac. Power at 220 to 240Vac minimum is required to operate four-heater machines Strict conformance to all applicable National Fire Protection Institute (NFPA) standards and local electrical codes is required. United Silicone equipment must be properly grounded, and clean, noise-free power must be supplied within the following ranges: 110-120 Vac 50/60Hz 220-240Vac 50/60Hz For voltages outside these ranges, contact United Silicone for assistance. Air Supply A source of moisture-free air at 80 to 100PSI at 5CFM should be connected to the machine. A supply of less than 50PSI at 5CFM will cause the machine to malfunction. AIR CONNECTION Connect air source to inlet side of air filter located at rear of machine. Use 3/8” flexible neoprene tubing for the connection to minimize vibration transfer. Figure 5.0-1 shows the recommended air connection. Note that a 3/8” NPT drain valve is installed to permit removal of moisture when necessary.

5.0-1

US 25 Hot Stamping Machine 5.0 Installation AIR PRESSURE REGULATOR Inlet air pressure should be adjusted to 50 to 100PSI by means of the pressure regulator. Do not exceed the maximum inlet air pressure of 120PSI. Also, the machine cannot be operated properly with pressure

PLANT AIR SUPPLY

below 20PSI. During operation, pressure should not drop more than 10PSI. If greater pressure drop is noted, check for constriction in the incoming air line, which may cause insufficient air volume to the machine.

AIR REGULATOR

FILTERREGULATORLUBRICATOR UNIT

LUBRICATOR 3/8 NPT FEMALE TEE AIR FILTER 3/8 NPT MALE DRAIN VALVE

1/2" DIA. NEOPRENE TUBING 3/8 NPT x 1/2" DIA. MALE PRESTOLOCK CONNECTION Figure 5.0-1. Air Connection

LUBRICATOR Fill lubricator with Shell Tellus 68, Mobil DTE 26, or equivalent oil. Do not overfill, and do not change the factory-set drip rate. Refer to Maintenance for ongoing maintenance instructions for the lubricator.

5.0-2

AIR FILTER Following the first day of operation an oily residue, but no drops of oil, should be present on the air filter. Appearance of oil drops is an indication of excessive lubrication, which is to be avoided. Refer to Maintenance for assistance in correcting this problem and for routine maintenance of the air filter.

US 25 Hot Stamping Machine 6.0 Setup and Adjustment

6.0 SETUP AND ADJUSTMENT Procedures for preparing the hot stamping machine for operation are included in this section. The setup and adjustment procedures apply to initial setup, as well as for future needs when changing dies, following component replacement or repair, and to correct stamping errors. Extensive illustrations are included to facilitate accurate, precise adjustments and thereby ensure trouble-free operation. The adjustments should be performed in the sequence presented, as each setting depends on successful completion of the previous procedure. If an adjustment cannot be achieved, refer to the preceding setting(s) to confirm that they were completed properly. Correct any errors before proceeding with the next step in the adjustment process. The following procedures are included: • Stamping Die Mounting • Head Height Coarse Adjustment • Head Height Fine Adjustment • Foil Installation • Stamping Quality Evaluation and Adjustment • Stamp Adhesion and Adjustment • Setting and Storing Job Parameters STAMPING DIE MOUNTING Before installing the die, thoroughly clean front and rear surfaces of die mounting plate and back of stamping die. No dust, residue, or debris is permitted on any of the mating surfaces. Also, check that the nesting fixture for the part being decorated is clean and firm, so that no deflection of part or fixture will occur when stamping pressure is applied. After ensuring proper cleanliness and fixture security, proceed as follows to mount the stamping die: 1. Remove die mounting plate (Figure 6.0-1) from heater head, and place on work surface with clamps facing down.

2. Determine front of die by comparing position of graphic with orientation of part on nesting fixture. 3. Place die on mounting plate, oriented so that its front faces positive stop brackets. 4. Align holes in die (drill holes if not predrilled), with mounting plate holes, and secure die to plate with screws. Note: For dies having offset graphics the contact area—not the die—must be centered. 5. Stand mounting plate on end with clamps facing you, and loosen both clamps sufficiently to allow some play. 6. Loosen locknuts on both positive stops, and back off screws until they project about 1/8” from bottom of stop brackets. 7. Slide mounting plate onto heater head until plate is flush with front of heater head, and tighten bolts on both clamps. 8. Turn in positive stops until they just contact heater head, but do not tighten locknuts at this time, as further adjustment of mounting plate position may be required. HEAD HEIGHT COARSE ADJUSTMENT Before beginning this procedure, confirm that electrical power and air supply are connected and operating (refer to Installation). The machine’s air pressure gage (Figure 6.0-2) should read desired pressure. WARNING FOR PERSONNEL SAFETY, ONLY ONE PERSON SHOULD PERFORM ADJUSTMENTS. ALL OBSERVERS SHOULD BE IN FRONT OR AT SIDES OF MACHINE, BUT NOT BEHIND IT. The coarse adjustment will position the head at approximately the correct height to stamp the part, while allowing sufficient clearance to place and remove part from nesting fixture safely.

6.0-1

US 25 Hot Stamping Machine 6.0 Setup and Adjustment

Figure 6.0-1. Stamping Die Mounting

GAGE READS ABOUT 50PSI

Figure 6.0-2. Setting Air Pressure To perform the coarse adjustment, proceed as follows: 1. Check that OFF-ON switch on control panel is set to ON. 2. Loosen bolts on both vertical slide clamps. 3. Turn handwheel clockwise to move head up sufficiently to provide 3” space above part surface. 4. Place part nesting fixture on work table. 5. Place a part on fixture, and align decorating surface with stamping die. 6. Press Setup key on control panel. 6.0-2

7. Align fixture with mounting holes, and insert but do not tighten mounting screws. Note: Refer to Description for details of controls. 8. If slide table is installed, jog table under stamping head. 9. Loosen knurled nut on positive stop (Figure 6.0-3); then turn adjusting sleeve counterclockwise until bottom edge is between 2” and 2.5” marks on vernier scale. 10. Tighten knurled nut on positive stop. 11. Press both palm switches simultaneously to extend head downward. 12. Turn handwheel counterclockwise to move head downward to within 1/8” to 1/4” of decorating surface. 13. Viewing from front of machine, check that die contact surface is as centered as possible over the decorating surface. If not centered, adjust nesting fixture left to right and/or in and out, as required. Also, be sure that contour of die matches shape of part. 14. Retract head by pressing Setup key on control panel.

US 25 Hot Stamping Machine 6.0 Setup and Adjustment 15. Tighten bolts on both vertical slide clamps, tightening evenly by alternating from side to side. 16. Tighten screws to secure part nesting fixture to work table. KNURLED NUT

POSITIVE STOP

Figure 6.0-3. Vernier Positive Stop HEAD HEIGHT FINE ADJUSTMENT This procedure sets the precise relationship between the die and the decorating surface. It must be performed only after the preceding adjustment has been successfully completed. Throughout this procedure, refer to Description section for details of control panel. 1. Enter Setup mode on control panel, if not already done. 2. Press both palm switches simultaneously to extend head downward. Check if die face contacts decorating surface, and retract head. 3. If no contact occurs, loosen knurled nut on positive stop, and turn adjusting sleeve counterclockwise 1/4 to 1/2 turn. 4. Extend head, and re-check for contact with surface. If no contact is made, turn adjusting sleeve counterclockwise in 1/4to 1/2-turn increments until die contacts surface. Re-check after each adjustment. 5. Set dwell interval to .50 second. 6. Turn on heaters. 7. Set heater temperature based on foil and substrate requirements (about 375°F to 400°F).

8. When heater temperature has been reached, measure die’s surface temperature using a pyrometer having a right-angled tip. Note: Die will be about 75°F to 125°F cooler than set temperature. 9. Place a small piece of hot stamp foil on decorating surface, and press both palm switches simultaneously to extend head. 10. Proceed to Stamp Evaluation and Adjustment, below, to inspect stamp quality and make any required adjustments. STAMP EVALUATION AND ADJUSTMENT Evaluate test samples and make adjustments to correct defects as follows: 1. Check graphic position on part. Complete image should be present, and uniform contact should be apparent. 2. To correct left-to-right or front-to-back positioning, adjust part nesting fixture and/or die position as follows: a. Measure distance that stamping must be moved. b. Adjust left to right position by loosening screws securing fixture to work table, moving fixture as needed, and re-tightening screws. c. Adjust front-to-back position by loosening bolts securing die mounting plate clamps, moving die as needed, and re-tightening clamp bolts. Note: Positioning adjustment is facilitated by the optional X-Y or X-YR positioning table (section 11.1). 3. If stamping head and decorating surface are not parallel, one of the following conditions will occur: a. Image is incomplete. b. Image is complete, but bulges appear on one side. c. Image is complete, but die digs more deeply into one side than the other. 4. If bulges appear in some areas of stamp, increase stroke length as follows:

6.0-3

US 25 Hot Stamping Machine 6.0 Setup and Adjustment a. Loosen knurled nut on positive stop, and rotate adjusting sleeve counterclockwise 1/8 turn. b. Re-tighten knurled nut on positive stop. c. Re-check stamp quality. d. If quality is unacceptable, increase stamping pressure slightly, and recheck quality. e. Repeat stroke and pressure adjustments until desired results are obtained. 5. If voids appear in the stamping, the part nesting fixture must be altered as follows: a. Remove part from fixture. b. Place a small strip of masking tape the size of the void area directly beneath the affected area. c. Re-check stamping quality, and make any further adjustments required. d. Perform Stamp Adhesion Testing and Adjustment, below. STAMP ADHESION TESTING AND ADJUSTMENT This test confirms proper adhesion of stamp to decorating surface and provides corrective action. To test adhesion, proceed as follows: 1. After part surface has cooled, apply a piece of clear tape, 3M No. 610 or equivalent, over image and apply thumb pressure. 2. Pull tape off, with free end held at a 90degree angle to surface. If part of image lifts off surface, make the following adjustments one at a time, and re-check stamp quality before continuing to the next step: Note: Repeat any step, as necessary, until optimal results are obtained. a. Increase die face temperature 10°F. Wait for proper heat indication, and then verify increased die temperature using a pyrometer.

6.0-4

CAUTION Do Not Exceed 100 PSI Air Pressure In The Following Step.

3.

4. 5. 6.

b. If not striking dead stop, increase air cylinder pressure 5 PSI by turning regulator adjustment clockwise while watching gage. c. If dead stop is being struck, increase stroke slightly by turning positive stop adjusting sleeve counterclockwise 1/8 turn. d. If machine has head up delay feature, increase HEAD UP setting until head retracts without foil stripping. Set HEAD UP DELAY pause to .2 second and then increase until foil resin is not lifted from part. e. Increase die-to-part contact time by re-setting the dwell time on the control panel. After completing adjustments, tighten knurled nut on positive stop and secure by tightening setscrew. Tighten locknuts on both positive stops on die mounting plate. Reset cycle counter on control panel to zero. After completing adjustments, install foil as described in Foil Installation, below. For heat transfer web installation, refer to either Webtrak Photocell Heat Transfer Web Option or Webtrak Laser Eye Heat Transfer Web Option, depending on option installed.

FOIL INSTALLATION The following instructions describe foil installation. For heat transfer web installation, refer to Webtrak Photocell Heat Transfer Web Option or Webtrak Laser Eye Heat Transfer Web Option. To install foil, proceed as follows: 1. Loosen collar lock handle, and remove collar, spring, and payout holder from shaft (Figure 6.0-4).

US 25 Hot Stamping Machine 6.0 Setup and Adjustment 2. Slide foil roll onto shaft with foil oriented so that foil end is at bottom, matte (coated) side facing down. COLLAR LOCK HANDLE

PAYOUT HOLDER

Note: Stripper bars must be parallel to work table to prevent foil from walking to one side.

INSIDE COLLAR

Figure 6.0-4. Foil Payout Assembly 3. Looking toward machine from payout side, align foil front to back with stamping die by loosening inside collar and moving collar, as necessary, to properly position roll in relation to die. When fully aligned, tighten inside collar. CAUTION Insufficient Tension Will Cause Foil To Become Snagged; Excessive Tension Will Cause Breakage. In The Following Step, Be Sure To Set Tension Properly.

STRIPPER BARS POSITIONED ABOUT 2” FROM STAMPING HEAD OR EDGE OF PART AND 1/2” BELOW DIE CONTACT SURFACE

Figure 6.0-5. Stripper Bar Positioning 6. Rotate pinch roller camshaft (Figure 6.06) until a gap is opened between knurled roller and pinch roller. PINCH ROLLER CAMSHAFT

4. Slide payout holder, spring, and collar and lock handle onto shaft. Push collar against spring until medium tension is felt. Avoid excessive or insufficient tension. Tighten lock handle after setting tension. 5. Loosen adjusting handles on stripper bars (Figure 6.0-5), and position bars so that bottom of each bar is about 2” from the stamping head or edge of the part (whichever is greater), parallel to work table, and 1/2” below the die contact surface. Depending on shape of part, further adjustments may be required for optimum stamping quality. Tighten adjusting handles after completing adjustment.

OPEN GAP BY TURNING KNOB

PINCH ROLLER

Figure 6.0-6. Pinch Roller Camshaft 7. Mount takeup shaft on foil pull frame as follows: a. Pull out spring-loaded knob. b. Insert shaft between side plates. 6.0-5

US 25 Hot Stamping Machine 6.0 Setup and Adjustment

Figure 6.0-7. Foil Path c. Align pin in shaft end with slot in drive its travel; adjust foil position on takeup pulley, and release spring-loaded shaft if necessary. knob. 15. Position foil guide rings on stripper bars 8. Thread foil over tensioning bar, under close to foil edges. both stripper bars (Figure 6.0-7), over 16. Set foil pulling interval as follows: pinch roller, and under knurled roller. a. Measure width of graphic on die face. 9. Wrap one full turn of foil around takeup b. Using appropriate switches or menu shaft from underside of shaft without selections, enter foil pull timing compressing spring-loaded foil clamping function. bar. c. Based on the width of the graphic Note: If used roll is on takeup shaft, insert determined in step a, and allowing end of new roll under existing roll. 1/4” to 1/2” between stampings, set 10. Manually turn takeup shaft two full turns foil pull time to desired interval. to tighten foil on shaft. Note: Foil moves about 2” for each 11. Inspect foil path, viewing from takeup second. side. If foil is not parallel with stamping 17. The tensioner should move between the head, press in foil clamping bar and slide fully relaxed and fully extended positions foil on takeup shaft left or right to obtain to maintain tension in the foil. As the foil is correct alignment. Release clamping bar pulled, the tensioner extends downward when foil is aligned. and then relaxes slightly upward when 12. Rotate pinch roller camshaft (Figure 6.0pulling stops. Check for proper movement 5) until knurled roller and pinch roller are of tensioner as follows: brought together. a. While foil is pulling, tensioner should 13. Using FOIL JOG, confirm that foil is not move downward (toward full slipping on takeup shaft. extension). 14. While observing foil movement, use foil b. When pulling stops, tensioner should jog function for sufficient time to confirm move upward toward relaxed position. that foil remains properly aligned during

6.0-6

US 25 Hot Stamping Machine 6.0 Setup and Adjustment c. When foil is installed, tensioner should not be at either no extension or full extension. TEMPERATURE AND DWELL RELATIONSHIP Proper balance of temperature and dwell produce optimal hot stamping results. Generally, these parameters should be set as low as possible—consistent with satisfactory foil adhesion—to maximize die life, minimize cycle time, and optimize graphic quality. The following paragraphs discuss the interdependency of these two settings and how to achieve optimal hot stamping results. Temperature and dwell interdependency is due to the thermal bonding that occurs between the foil resins and the substrate. Since the foil is typically formulated with resins matching the material being stamped, the die surface temperature must be slightly higher than the melting point of the material. Also, the dwell time must be sufficient to both soften and join the foil and substrate resins. Ideally, the dwell time should be set after temperature setting, using the following guidelines: 1. Contact foil manufacturer for recommended heat range for the foil installed or substrate melting temperature. Note: This information is important, as variations in foil color, formulation, and carrier thickness require changes in machine temperature settings. 2. Increase dwell time from initial setting until results are satisfactory, re-testing after each change. Further changes in dwell time may be required to enhance durability and quality of stamping. Normally, the image lies on the part surface where it is subject to scuffing or scratching; however, increasing the dwell time will cause the die to dig into the surface, thereby embedding the image slightly below the surface. This stamping method provides a natural protection because the image lies below the surface; however, image quality may be somewhat compromised.

For a textured surface, increasing the dwell time may be necessary to cause the die to flatten the surface for enhanced stamping quality. SETTING AND STORING JOB PARAMETERS Up to 10 sets of job parameters can be stored in the machine’s control box for instant recall. This feature increases productivity by eliminating the need for re-entering parameters every time a standard job is run. To store a job, proceed as follows: CAUTION After Entering Job Parameters, Record All Settings For Future Reference, In Case Machine’s Memory Is Cleared Or Modified. 1. Press JOB # switch, and then select a job number by pressing + and – keys until desired number is displayed. Note: If machine is being set up for first time, use sequential job numbers beginning with “1.” 2. Enter all desired parameters for the job number, if not previously entered. All information will be stored under the job number, eliminating the need to re-set parameters each time the job is run. 3. To recall a job number, simply press JOB # switch; all parameters will be recalled. Turn on heaters, allow temperature to stabilize, and run job. Note: When switching jobs, allow sufficient time for heat to stabilize before running new job. 4. To change a parameter, press JOB # switch and then the + or – keys until desired job number is displayed. Make desired changes; new information will be automatically stored.

6.0-7

US 25 Hot Stamping Machine 7.0 Troubleshooting

7.0 TROUBLESHOOTING This section contains diagnostics, troubleshooting, and other aids to assist in isolating and correcting machine malfunctions. Refer to the electrical schematic and pneumatic diagram in Engineering Drawings and to Setup and Adjustment and Maintenance sections for additional assistance in analyzing and correcting faults. CONFIGURATION DISPLAY The current operating parameters can be viewed on the message display. The configuration is shown by pressing the COUNT and DWELL TIME switches simultaneously. The parameters listed in Table 7.0-1 will then be shown on the message display: Note: Depending on machine options, additional parameters may be shown. Table 7.0-1 Configuration Messages PROGRAM VERSION

Version of program installed on machine

LIMIT SWITCH CONDITION

Current up and down limit switch settings

INSTALLED JUMPERS

Displays jumper configuration on main board (different jumpers are required for different options).

TOTAL COUNT

Total number of cycles completed by machine (cleared when machine is re-initialized).

DIAGNOSTICS As an additional aid to troubleshooting, the machine is equipped with built-in diagnostics. Upon detecting a failure, the control box stops operation of the equipment and displays an error message on the control panel to notify the operator of an equipment malfunction. Table 7.0-2 lists available

diagnostic messages, definitions, and corrective actions. CONTROLLER INPUTS Beginning with program version 3.02E, the present status of controller inputs may be displayed on the message screen. To view this information, press and hold the TEMP and COUNT keys simultaneously. To cancel the status mode and return to the normal display, press the CLR key. When the status mode is entered, all inputs that are currently “on” are shown on the screen. Missing numbers denote that the input is “off.” The diagnostic code numbers refer to the schematic diagrams included at the rear of this manual. For example, code 1 (IN1 on the schematic) is found to be the right palm button switch. The head up limit switch, shown as IN4 on the schematic, is represented as code number 4 on the screen. Depending on machine options, additional numbers will be shown. It is important to understand that the diagnostics are dynamic. The inputs shown in Figure 7.0-1 reveal current conditions at the time the diagnostic program was accessed. Under other conditions, the diagnostics would be different. Examples of using diagnostics in typical troubleshooting problems are described in the following paragraphs. Example 1 Problem – Stamping head goes down, but immediately returns up when palm buttons are released rather than pausing for dwell time. Test – Press SETUP and then press palm buttons simultaneously to move head fully down. Diagnostic Result – Diagnostic number 3 is shown on the screen when head is down, indicating that switch is supplying “down” input to controller.

7.0-1

US 25 Hot Stamping Machine 7.0 Troubleshooting Solution – Switch is not defective; check for correct dwell time setting and reset as needed.

Solution – Right palm button switch is likely defective. Examples 1 and 2, above, provide guidance for using the diagnostics. These examples should be used to aid in interpreting the diagnostics for other conditions and problems. However, if assistance is needed in understanding the machine diagnostics, contact United Silicone.

Example 2 Problem – Machine fails to operate when palm buttons are pressed simultaneously. Test – Press buttons one at a time to check switches independently. Diagnostic Result – Diagnostic number 1 is shown when left button is pressed; however, number 2 fails to go on when right button is pressed. This indicates that right switch is not supplying required input.

INPUTS:

4

7 8

10 Figure 7.0-1. Typical Controller Inputs

Table 7.0-2. Diagnostics Message

Definition

Corrective Action Check for consistent air pressure of 5PSI minimum, and check that deadstop adjusting sleeve operates down limit switch..

STAMPER ERROR

Current cycle was not completed

Confirm that air flow controls are open sufficiently for head to move. Test palm switches for proper and consistent operation.

HEAT CONTROL ERROR

Error in control of heater temperature

7.0-2

Check for blown main fuse; replace if blown. Verify that high and low temperature limits are at least 10°F from setpoint; change if required.

Cold die

CHECK WEBTRAK AND FOIL

If temperature was recently lowered, turn off heat, allow to cool completely, and then turn heat back on.

Photocell (or laser eye) did not detect registration mark on heat transfer.

Wait for die to fully heat. Inspect alignment of heat transfer through slot above photocell to ensure that registration mark passes through beam; adjust as required. Check and adjust photocell (or laser eye) sensitivity (refer to 10.2 Photocell Heat Transfer Web or 10.3 Laser Eye Heat Transfer Web).

US 25 Hot Stamping Machine 7.0 Troubleshooting Table 7.0-2. Diagnostics Message

CHECK WEBTRAK AND FOIL (cont’d)

Definition

Corrective Action

Jog foil and observe high-to-low speed transition to confirm that low-speed setting is sufficiently high to pull heat transfer web; if web stops, increase low speed by 1 or 2. If transfer was Photocell (or laser changed, photocell must be re-set (refer to eye) did not detect registration mark on Webtrak Photocell Heat Transfer Option or heat transfer (cont’d) Webtrak Laser Eye Heat Transfer Option). Increase foil pull time sufficiently to allow transfer registration mark to reach part before switching to low speed.

CHECK BATTERY Either battery dead INITIALIZE CPU or error in CPU

Check and replace battery, if defective (refer to Battery Testing and Replacement, below).

TROUBLESHOOTING CHART Table 7.0-3 lists possible troubles and their causes and corrective actions. The troubleshooting chart contains the most common problems, but cannot include all possibilities. For additional assistance, refer to the Description, Operation, Installation, and Engineering Drawings sections. BATTERY TESTING AND REPLACEMENT CAUTION This Procedure Will Clear The Memory. All Variables Must Be Reset After Battery Is Removed And Re-Installed. To remove, test, and replace battery, proceed as follows: 1. Shut down and disconnect power from machine. 2. Remove four screws securing control panel.

3. Grasp EMERGENCY STOP button, and pull panel outward at bottom and then swing down top of panel until separated from control box. Be careful to avoid pulling out electrical leads. 4. While an assistant supports control panel, remove battery from middle of circuit board near bottom (Figure 7.0-2). 5. Check for battery voltage of 2.5 Vdc. If less than 2.5 Vdc, replace battery with a Panasonic P-186 or equivalent. 6. Re-install battery at lower middle of circuit board. 7. Locate pins J8 in upper left corner of circuit board (see Figure 7.0-3). 8. Connect a jumper across pins J8, and then turn power on and off again. 9. Remove jumper from pins J8. 10. Turn on power. 11. Re-install and secure control panel.

7.0-3

US 25 Hot Stamping Machine 7.0 Troubleshooting

BATTERY

CLIP

TEMPORARY JUMPER

Figure 7.0-2. Battery Location Figure 7.0-3. Pin J8 Jumper Location

7.0-4

US 25 Hot Stamping Machine 7.0 Troubleshooting Table 7.0-3. Troubleshooting Trouble Possible Cause Corrective Action Uneven die-to-part Reposition fixture so that decorating surface contact is in proper relationship to die. Surface contamination from flow agent, antiDiscontinue use of all contaminating agents. static solution, or siliconebased mold releases Wipe surface using a clean cotton cloth or Incomplete stamped Foreign particles on image surface glove. Fixture support Modify or re-design fixture to increase inadequate, permitting rigidity under decorating surface and/or part to flex under ensure that mandrel-type designs do not machine pressure permit deflection of part. Air trapped between foil Re-design die face to include convex crown. and surface Uneven die-to-part Reposition fixture so that decorating surface contact is in proper relationship to die. Reduce stroke length or reduce air pressure Excessive stamping force (refer to Setup and Adjustment). Die surface temperature Reduce temperature setting (refer to Setup too high and Adjustment). Rollover in image Reduce dwell time setting (refer to Setup Excessive dwell time and Adjustment). Build up support fixture beneath part in light Sinks (low areas) in areas, and reduce stamping pressure (refer decorating surface to Setup and Adjustment). Part wall thickness Switch to a dual durometer silicone-part variations rubber die. Insufficient stamping Increase stroke length and/or increase air pressure pressure (refer to Setup and Adjustment). Surface contamination from flow agent, antiDiscontinue use of all contaminating agents. static solution, or siliconebased mold releases Die surface temperature Increase temperature setting (refer to Setup and Adjustment). Edges of image are too low ragged or not sharp Increase dwell time setting (refer to Setup Insufficient dwell time and Adjustment). Reduce head retraction speed and/or Resin not fully released introduce head-up delay (refer to Setup and from carrier (foil stripping) Adjustment). Resin adversely affected Select BEFORE foil pulling cycle to advance by heat exposure prior to foil just before head extends downward. stamping cycle

7.0-5

US 25 Hot Stamping Machine 7.0 Troubleshooting Table 7.0-3. Troubleshooting Trouble Possible Cause Corrective Action Increase temperature setting (refer to Setup Insufficient die heat and Adjustment). Poor image adhesion Resin-to-part Change foil to compatible resin. incompatibility Check resistance across each heater or use an inductive ammeter to check current flow Die does not heat or Defective heater(s) through heater. If open circuit, high heats slowly resistance, or low current is found, replace heater (refer to Maintenance). Adjust software noise discrimination filter Display temperature (SNDF) as described in Description Table rises quickly and Interference from RF 3.0-1. then heat shuts off; welder or similar Re-locate machine and re-try. HEAT CONTROL equipment Contact United Silicone for assistance, if ERROR appears unable to clear problem. Check for infinite resistance between each thermocouple lead and ground; if low Temperature Thermocouple grounded resistance is found, replace thermocouple fluctuates 5°F-10°F (refer to Maintenance). during cycles Contact United Silicone for assistance in reTEMP. P value incorrect setting value. Replace thermocouple (refer to Defective thermocouple Maintenance). Check AC voltage across relay terminals 1 and 2 and DC voltage across terminals 3 Stamping head and 4 (refer to Maintenance for relay overheats Defective heater relay location). With heat off, line voltage should be present across 1 and 2; 0Vdc should be present across 3 and 4. Replace relay if readings are incorrect. Blown fuse Check and replace fuse if open. Check that adjustable deadstop is operating Foil does not move Down limit switch not limit switch, and adjust if necessary (refer to closing Setup and Adjustment). Stamping head extends down Clean/replace palm switches, as required Defective palm switches slightly and then (refer to Maintenance). retracts

7.0-6

US 25 Hot Stamping Machine 8.0 Maintenance

8.0 M AINTENANCE Your United Silicone hot stamping machine is designed for trouble-free operation and requires minimal maintenance. Periodic maintenance instructions included in this section consist of lubrication and cleaning. Component replacement procedures are included to assist technicians in replacing parts found to be defective. Use the information in Troubleshooting for assistance in fault isolation before replacing components. PNEUMATIC SYSTEM LUBRICATOR Check lubricator oil level once a month, and replenish as needed. Shell Tellus 68 and Mobil DTE are approved by United Silicone; however, other equivalent oil may be used. Change oil immediately if it becomes contaminated or emulsified, as indicated by loss of clarity. AIR FILTER Drain air filter daily to remove moisture from the pneumatic system. Always check for moisture before and after machine operation. HEAD HEIGHT ADJUSTING SCREW Apply a good grade of Lithium grease to screw threads once a year. INSPECTION AND CLEANING Occasionally inspect machine for obvious defects, and perform required maintenance. Cleaning is not normally required. Remove any dust, debris, or other contaminants from machine surfaces. ADJUSTMENTS After setup, the machine does not normally require further adjustment. However, if die is changed, or stamping defects are observed, adjustment may be required. Refer to Setup and Adjustment for assistance in checking and re-adjusting machine.

COMPONENT REPLACEMENT The following paragraphs describe removal and replacement procedures for components that may be replaced or repaired. Obvious procedures are not included. Before replacing any part, refer to Troubleshooting for assistance in fault isolation. A complete list of recommended spares is included in Recommended Spare Parts. Heater Any one of the heaters may be replaced independently. The heaters are installed in wells at the rear of the heater block. To replace a heater (Figure 8.0-1), proceed as follows: Removal 1. Unplug machine power cord, and lockout/tagout electrical power. 2. Operate air dump valve, and lockout/tagout air supply. 3. Remove heater retaining screw at front of heater block. 4. Cut leads of heater to be removed at rear of heater block, and withdraw heater from front of heater block. 5. Remove two screws securing cover to small junction box below control panel, and remove cover. 6. Trace leads from removed heater back to the small junction box, and disconnect leads. 7. Unscrew and separate electrical lead retaining nut from strain relief, and pass out heater leads. 8. Carefully cut tie wraps securing heater leads to power cable and discard leads. Installation Installation is basically the reverse of removal. Insert new heater from front of heater block, passing leads out through rear. Connect new leads at junction box. Be sure to replace all tie wraps cut during removal.

8.0-1

US 25 Hot Stamping Machine 8.0 Maintenance HEATER

THERMOCOUPLE

Figure 8.0-1. Heater and Thermocouple Locations Thermocouple The thermocouple is inserted into a well at the back of the heater block. To replace thermocouple (Figure 8.0-1), proceed as follows: Removal 1. Unplug machine power cord, and lockout/tagout electrical power. 2. Operate air dump valve, and lockout/tagout air supply. 3. Remove screws securing rear cover to control box or junction box, and remove or swing out cover. 4. Trace leads from thermocouple back to their source, and disconnect leads. 5. Unscrew and separate electrical lead retaining cap from cable strain relief, and pass out leads. 6. Carefully cut tie wraps securing thermocouple leads to power cable. 7. Remove screws securing two thermocouple cable clamps to connecting plate, and separate cable clamps; remove thermocouple leads from clamps. 8. Twist thermocouple retaining cap 1/4 turn counterclockwise, and slide thermocouple out rear of heater block. Installation Installation is the reverse of removal. Be sure to replace all tie wraps cut during removal. 8.0-2

Down Limit Switch The down limit switch is installed on a bracket adjacent to the positive stop. The switch begins the head dwell time when actuated by the positive stop adjusting sleeve, as the stamping head reaches the bottom of its stroke. To replace the down limit switch (Figure 8.0-2), proceed as follows: Removal 1. Unplug machine power cord, and lockout/tagout electrical power. 2. Operate air dump valve, and lockout/tagout air supply. 3. Remove cover, and disconnect electrical leads from down limit switch. 4. Remove two socket head screws securing limit switch to mounting bracket, and remove switch. Installation Installation is the reverse of removal. DOWN LIMIT SWITCH

Figure 8.0-2. Down Limit Switch Location Adjustment After replacing down limit switch, adjust as follows: 1. Set vernier positive stop adjustment to 0. 2. Loosen screws securing mounting bracket to top cover. 3. Slide bracket toward adjusting sleeve until switch clicks, and hold in position while tightening screws.

US 25 Hot Stamping Machine 8.0 Maintenance Up Limit Switch The up limit switch is mounted on a bracket adjacent to the left rear guide shaft inside the cylinder mounting box. The switch transmits a signal to the controller when actuated by the guide shaft, as the stamping head reaches the top of its stroke. To replace the up limit switch (Figure 8.0-3), proceed as follows: Removal 1. Unplug machine power cord, and lock out/tagout electrical power. 2. Operate air dump valve, and lockout/tagout air supply. 3. Remove two socket head screws securing down limit switch mounting bracket to head cover, and separate bracket with switch from cover. 4. Remove socket head screws securing head cover to cylinder mounting box, and remove cover. 5. Remove cover, and disconnect electrical leads from up limit switch. 6. Remove two socket head screws securing up limit switch to mounting bracket, and remove switch. Installation Installation is the reverse of removal; however, leave screws loose to permit adjustment. Adjustment 1. With stamping head fully retracted, loosen bracket mounting screw if not already loose. 2. Slide bracket into contact with tapered guide shaft until switch just clicks. 3. Slide switch in about 1/16” further, and tighten bracket mounting screw.

GUIDE SHAFT

UP LIMIT SWITCH

Figure 8.0-3. Up Limit Switch Location Solid State Relay The relay is mounted on the bottom inside of the control box. To replace the solid state relay (Figure 8.0-4), proceed as follows: Removal 1. Unplug machine power cord, and lockout/tagout electrical power. 2. Operate air dump valve, and lockout/tagout air supply. 3. Tag and disconnect four electrical leads from relay. 4. Remove two screws securing relay (and plastic cover if installed) to control box, and remove relay. Installation Installation is the reverse of removal. Palm or Opti-Touch Switch The switches are installed in housings on the left and right sides of the main frame. To replace either switch, proceed as follows: Removal 1. Unplug machine power cord, and lockout/tagout electrical power. 2. Operate air dump valve, and lockout/tagout air supply. 3. Disconnect electrical lead from solenoid valve corresponding to switch being replaced.

8.0-3

US 25 Hot Stamping Machine 8.0 Maintenance

SOLIDSTATE RELAY

Figure 8.0-4. Solid State Relay Location 4. For palm switch, unscrew and remove switch bezel. 5. Working from underside of switch base plate, remove four screws securing switch housing to base plate, and separate switch housing from plate. Note: If access to underside of switch housing is hindered by machine mount, remove base plate from main frame and invert plate to remove switch housing. 6. For palm switch, carefully lift locking tabs and separate switch from actuator. For Opti-Touch switch, remove nut securing switch to housing, and slide switch out from front of housing. 7. Disconnect electrical leads from switch terminals, and remove switch. Installation Installation is the reverse of removal. When installing palm switch, be sure to insert locking tabs into proper slot. If not installed properly, button will not operate switch (Figure 8.0-5). LOCKING TAB

OPEN SLOT

Figure 8.0-5. Palm Switch Installation

8.0-4

Emergency Stop Switch The emergency stop switch is installed on the rear of the control panel. The switch is attached to its actuator by a bayonet-type mount. To replace the emergency stop switch (Figure 8.0-6), proceed as follows: Removal 1. Unplug machine power cord, and lockout/tagout electrical power. 2. Operate air dump valve, and lockout/tagout air supply. 3. Remove four screws securing front panel to control box, and separate panel from box. 4. Disconnect leads from screw terminals at rear of switch. 5. Loosen screw securing switch to actuator, and remove switch. Installation Installation is the reverse of removal. MOUNTING SCREW

ELECTRICAL TERMINALS

Figure 8.0-6. Emergency Stop Switch Installation Air Cylinder The air cylinder drives the stamping head and applies the required pressure to apply the image to the decorating surface. Following removal, the cylinder should be either replaced or inspected, cleaned, and repaired. To replace the cylinder (Figure 8.0-7), proceed as follows:

US 25 Hot Stamping Machine 8.0 Maintenance Removal 1. If cylinder is not already extended, set machine to Setup mode and extend piston to facilitate access to cylinder mounting hardware. 2. Unplug machine power cord, and lockout/tagout electrical power. 3. Operate air dump valve, and lockout/tagout air supply. 4. Disconnect both air lines at left side of cylinder mounting box, and unscrew and remove elbows. 5. Unscrew and remove knurled nut, adjusting sleeve, and dead stop from top of cylinder. 6. Remove two socket head screws securing guide bar to stamping head, and remove guide bar. Note: Removing guide bar facilitates access to hardware securing flanged coupling and cylinder to mounting box. 7. Restrain piston rod using an open-end wrench, while using a suitable wrench applied to screws in flanged coupling to break coupling free from cylinder. 8. Remove four screws securing flanged coupling to connecting plate, and separate plate from coupling. 9. Unscrew and remove flanged coupling from cylinder. 10. Working from underside of cylinder, remove four nuts, lockwashers, and flat washers securing cylinder to mounting box, and lift and remove cylinder. Installation Installation is the reverse of removal.

Figure 8.0-7. Air Cylinder Installation Foil Pinch Roller The silicone rubber pinch roller presses the used foil against the knurled roller to prevent the foil from slipping as it is pulled onto the takeup shaft. To replace the pinch roller (Figure 8.0-8), proceed as follows: Removal 1. Unplug machine power cord, and lockout/tagout electrical power. 2. Operate air dump valve, and lockout/tagout air supply. 3. Carefully unhook extension springs on front and rear pinch roller levers. 4. Remove socket head screw from each pinch roller lever, and remove pinch roller and levers. 5. Separate pinch roller from front and rear levers. Installation Installation is the reverse of removal. Replace extension springs, if they have taken a set or are obviously deformed.

8.0-5

US 25 Hot Stamping Machine 8.0 Maintenance EXTENSION SPRING

PINCH ROLLER

Figure 8.0-8. Foil Pinch Roller Foil Takeup Drive Belt The foil takeup drive belt transfers the foil motor’s rotation to the takeup shaft and pinch roller. The belt material is supplied in 2-foot lengths with two attachment couplings. To replace the drive belt (Figure 8.0-9), proceed as follows: 1. Unplug machine power cord, and lockout/tagout electrical power. 2. Operate air dump valve, and lockout/tagout air supply. 3. Cut and remove existing belt; discard belt. 4. Insert new coupling halfway into one end of new belt material, leaving opposite pointed end exposed.

5. Run belt material around knurled roller and takeup shaft grooves. Note: Only one coupling is needed for attaching ends of belt; for heat transfer web machine, entire length of belt is required (refer to Photocell Heat Transfer Web Option or Laser Eye Heat Transfer Web Option for applicable procedure). 6. Pull belt until taut, and cut off excess material. Attach belt ends together by pushing into coupling previously inserted into opposite end. 7. Rotate takeup shaft manually to confirm proper tension, as evidenced by rotation of knurled roller.

TAKEUP SHAFT

BELT

Figure 8.0-9. Foil Takeup Drive Belt

8.0-6

US 25 Hot Stamping Machine 9.0 Recommended Spare Parts

9.0 RECOMMENDED SPARE P ARTS While your hot stamping machine is highly reliable and trouble-free, occasional parts replacement may be required due to normal wear and aging. This section contains a listing of parts, which have been determined to be most likely requiring possible future replacement. By stocking these parts, minimal downtime should be experienced in case of equipment malfunction. Table 9.0-1 lists the recommended spare parts for standard and heat transfer machines. For unique parts used only on heat transfer machines, refer to Webtrak Photocell Heat Transfer Web Option or Webtrak Laser Eye Heat Transfer Web Option. Required ordering information is listed for each part. The recommended quantities listed in the table are not

necessarily the total installed on your machine. The list is keyed by component index numbers to Engineering Drawings, which follows this section. Where no item number is shown, the part is not shown on the engineering drawings. ORDERING PARTS When ordering parts, please fill out the Parts Order Form on the following page. The form should be duplicated so that additional copies will be available if needed. When filling out the form, be sure to enter all required information, which includes item number, part number, and complete description. To expedite delivery, parts orders may be phoned or faxed. Your parts will be shipped within two days following receipt of order.

Table 9.0-1. Recommended Spare Parts Item No.

Part No.

Description

Qty

33

722135-99

Foil Pinch Roller, Standard Machine

1

40

725061-1-99

Foil Guide Ring

2

50 54

41242018 41215004

Extension Spring Foil Drive Belt (Includes 2 Connectors)

66

41242006

Compression Spring

1

176

41401028

Solenoid Valve (for standard machine)

1

183

41401052

Solenoid Valve (for machine with head up delay option)

1

—

41111004

Heater,1/2 x 8, 120V

2

—

41111002

Heater,1/2 x 8, 240V

2

— —

41113007 41122033

Thermocouple Solid State Relay

1 1

—

41121016

Emergency Stop Contact

1

—

41121083

Palm Switch Contact

2

2 2 Ft

9.0-1

PARTS ORDER FORM US Hot Stamping/Pad Printing Machine Mail, Fax, or Phone Your Order to: UNITED SILICONE 4471 Walden Avenue Lancaster, New York 14086 Phone 716/681-8222 Fax 716/681-8789 Date: __________________________ Invoice to: Company Name: ________________________ Address: ______________________________ City, State: ____________________________ Zip Code: ______________ Phone No.: ____________________________

Ship to: (If different) Company Name: _____________________ Address: ___________________________ City, State: __________________________ Zip Code: ______________ Phone No.: _________________________ Ship: o Partial

Purchase Order No.: ____________________ Price and Delivery Quotation Required Before Shipment?

o Yes

o No

Machine Model & Serial No.: _________________ Drawing No.: Part Number

Ship Via:

o Complete o UPS o UPS Next Day Air o Motor Freight o Overnight Air o Other (Specify)

Title: Description

Item No.

Qty

Price

9.0-3

US 25 Hot Stamping Machine 10.1 X-Y and X-Y-R Positioning Table Option

10.0 PNEUMATIC SLIDE T ABLE OPTION The pneumatic slide table option enhances stamping productivity by facilitating the transfer of parts under the nesting fixture. The unit does this by moving the work table well out from under the stamping head for loading and removal of parts, thereby eliminating the need for the operator to position the part under the stamping head, where space is often limited. The sliding work table is driven by an air cylinder that automatically moves the work table under the stamping head as the stamping cycle begins and then slides out toward the operator after the part is stamped. Description, operation, troubleshooting, and maintenance information for the pneumatic slide table is provided in this section. DESCRIPTION The slide table option consists of a sliding work table, base plate, air cylinder, solenoidoperated air valve, and associated wiring. The base plate is secured to the machine’s side supports in place of the standard stationary table. The slide table is guided by tubular slides on each side and by the air cylinder piston in the center for precise positioning during in and out travel. The double-acting air cylinder is mounted horizontally beneath the base plate. A solenoid-operated air valve installed beside the cylinder directs air to the extension and retraction cylinder ports to move the table. Electric power to energize the air valve solenoid is supervised by the controller, which coordinates valve operation with stamping head travel. OPERATION The slide table remains out (home position) when the stamping head is retracted following completion of a stamping cycle. With air and electric power supplied to the machine, pressing both palm switches simultaneously directs electric power to the solenoidoperated air valve. Air supplied from the inlet air regulator flows to the retraction port of the air cylinder, driving the piston inward, and

moving the table directly under the stamping head. The stamping head then extends downward, stamping the part. After stamping is completed and the head retracted, the air valve is re-positioned, exhausting air from the retraction port and directing air to the extension port. The cylinder extends, moving the table back to its home position. TROUBLESHOOTING The pneumatic slide table is highly reliable and virtually trouble-free. Usually, failure of the slide table to operate is a symptom of a general malfunction of the machine. Table 10.0-1 contains troubles, possible causes, and corrective actions specifically related to the slide table. Use this information to assist in fault analysis if a malfunction appears to be isolated to the slide table. MAINTENANCE Maintenance consists of replacement of defective parts. The following paragraphs describe replacement procedures for slide table components. Air Cylinder The air cylinder is mounted on the underside of the slide table. To replace the cylinder (Figure 10.0-1), proceed as follows: Removal 1. Unplug machine power cord, and lockout/tagout electrical power. 2. Operate air dump valve, and lockout/tagout air supply. 3. Remove four screws securing slide table to side supports, and remove table. 4. Disconnect air lines from cylinder elbows. 5. Prevent piston rod from turning while loosening locknut, and unscrew piston rod from table coupling until completely free of coupling. 6. Remove two screws securing cylinder to mounting bracket, and remove cylinder.

10.1-1

US 25 Hot Stamping Machine 10.0 Pneumatic Slide Table Option Installation Installation is the reverse of removal.

PNEUMATIC LINES

2. Operate air dump valve, and lockout/tagout air supply. 3. Disconnect electrical leads from air valve. 4. Disconnect two outlet air lines and inlet airline from valve. 5. Remove two screws securing valve to mounting bracket, and remove air valve. Installation Installation is the reverse of removal.

TABLE COUPLING

VALVE

Figure 10.0-1. Slide Table Cylinder Installation Solenoid-Operated Air Valve The air valve is mounted on the underside of the table adjacent to the air cylinder. To ELECTRICAL replace the air valve (Figure 10.0-2), proceed LEADS as follows: 1. Unplug machine power cord, and Figure 10.0-2. Slide Table Air Valve lockout/tagout electrical power. Table 10.0-1. Troubleshooting Trouble

Possible Cause

Corrective Action Run machine diagnostics, and check for a “1” at diagnostic number 8. If a “0” is shown, controller is not supplying power to solenoid valve (refer to Troubleshooting section).

Slide table remains No input from controller under head after stamping Defective solenoid valve Replace valve. Table moves slowly or hesitates

Defective air cylinder

ENGINEERING DRAWINGS Drawings for slide table machines are identical with standard machines, except for

10.0-2

Repair or replace cylinder. drawings related specifically to the slide table. These drawings are included in the Engineering Drawings section at the rear of this manual.

US 25 Hot Stamping Machine 10.1 X-Y and X-Y-R Positioning Table Option

10.1 X-Y

AND X-Y-R

POSITIONING TABLE OPTION

The X-Y and X-Y-R positioning table option simplifies and improves accuracy of nesting fixture positioning by allowing precise movement of the table both horizontally and vertically. The table is a precision device having micrometer adjustments for movement on both axes. The X-Y-R table has an additional adjustment, which provides rotational movement. This additional adjustment allows compensation for minor discrepancies in die or heat transfer positioning. Description and operation information for the positioning table is provided in this section. DESCRIPTION The positioning table consists of a base plate, movable work table, micrometer adjustments, and locking collars. Mounting holes are provided for securing the X-Y or X-Y-R table to the work table. Several threaded holes in the X-Y or X-Y-R table surface are used to mount the part nesting fixture in the desired location. The table permits a total travel of 3” on both axes. When centered, approximately 1.5” is available in all directions for nesting fixture alignment. The table’s micrometer adjustments permit movement in 0.001” increments in both directions. However, a backlash of 0.005” is present in adjusting knobs on both axes. Locking collars on both axes lock the table in its settings after adjustments are completed and prevent inadvertent movement or re-positioning due to vibration. Once the locking collars are securely tightened, only the backlash movement should be possible. OPERATION Proper alignment of the decorating surface in relation to the stamping head ensures even distribution of stamping force, which will

produce the highest quality image. The table should be set up as follows: 1. Turn micrometer knobs until both axes are about at their centers. 2. Mount the nesting fixture on the X-Y or X-Y-R table so that the part decorating surface is as close as possible to directly below the stamping head. 3. Turn the micrometer knobs until the decorating surface is precisely aligned with the stamping head. Note: Do not make major adjustments with the micrometer knobs. If a major offset of either axis is required, the nesting fixture or the die mounting plate should be moved. 4. If using an X-Y-R table, the third adjustment is performed by loosening screws in slotted holes on top of table and then turning stop screws at left and right to rotate the table. 5. After completing adjustments, the locking collars should be tightened on both axes to prevent accidental movement. If using an X-Y-R table, tighten locking screws in slotted holes, as well.

Figure 10.1-1. X-Y Positioning Table

10.1-1

US 25 Hot Stamping Machine 10.2 Webtrak Heat Transfer Photocell Option

10.2 WEBTRAK HEAT TRANSFER P HOTOCELL OPTION Stamping heat transfer decals requires specialized features. The Webtrak heat transfer photocell option (Figure 10.2-1) is designed to hold, transport, and precisely position the heat transfer for accurate, highquality stamping. This section provides description, operation, setup and adjustment, troubleshooting, maintenance, spare parts, and drawings for the heat transfer photocell option. Only unique information is included. Where information or procedures are identical to standard machines, references are included to the applicable sections of this manual.

transfer web controls, switches, and indicators. OPERATION As directed by the controller, the heat transfer feed motor is energized either before cylinder extension or during retraction. The motor pulls the web rapidly for the programmed interval set by the operator and then switches to the slow speed. After the inactive photocell time has expired, the photocell is enabled by the controller, allowing the web registration mark to be detected. The photocell signal is relayed to the controller, which then terminates pulling of the web.

DESCRIPTION Web Feed The heat transfer web feed operates similarly to the foil feed on standard machines. In addition to the components needed for pulling and taking up the used transfer carrier material, the web feed contains a photocell which detects the registration marks on the transfer web carrier. The transport direction is left to right (opposite foil feed). Control Panel Webtrak photocell machines use the same control panel. Refer to Description for control panel information. Table 10.2-1 describes only unique features of heat Name

FOIL PULL

Figure 10.2-1. Webtrak Heat Transfer Photocell Option

Table 10.2-1. Control Panel Webtrak Features Function The following options are available on heat transfer web machines: FOIL PULL TIME XX.XX – Sets time allotted for high-speed advancing of web. FOIL LOW SPEED: XX – Sets creep speed of web. WEB LOW RANGE: XX – Sets the upper and lower limits for low (creep) speed of web pulling. This is a factory setting and should not be changed. FOIL HIGH SPEED: XX – Sets speed at which web advances during FOIL PULL TIME. MARKS/ONE STEP: XX – Sets number of marks to be counted before stopping web advancement (usually used for multiple part stamping).

10.2-1

US 25 Hot Stamping Machine 10.2 Webtrak Heat Transfer Photocell Option

Name FUNC. FOIL JOG

Table 10.2-1. Control Panel Webtrak Features Function Selects heat transfer web operation. Advances web to next mark detected by photocell each time switch is pressed.

HEAT TRANSFER WEB OR FOIL INSTALLATION The Webtrak photocell option moves the web or foil in the opposite direction from the standard machine. The feed path through the machine and adjustments are also different. To install heat transfer web or foil, proceed as follows: 1. Loosen front collar lock handle (Figure 10.2-2), and remove collar, spring, and payout holder from shaft. 2. Slide web or foil onto shaft with material oriented so that end is at top, matte (coated) side faces down.

PAYOUT HOLDER

INSIDE COLLAR

COLLAR LOCK HANDLE

Figure 10.2-2. Heat Transfer Web Payout Assembly 3. Center web or foil on shaft by loosening inside collar and moving collar, if necessary, to properly position web or foil in center of shaft. When fully aligned, tighten inside collar.

10.2-2

CAUTION Insufficient Tension Will Cause Material To Become Snagged; Excessive Tension Will Cause Breakage. In The Following Step, Be Sure To Set Tension Correctly. 4. Slide payout holder, spring, and collar and lock handle onto shaft. Push collar against spring until medium tension is felt. Avoid excessive or insufficient tension. Tighten lock handle after setting tension. 5. Loosen adjusting screws securing stripper bars, and position bars so that bottom of each bar is about 2” from the stamping head or edge of the part whichever is greater, parallel to work table, and 1/2” below the die surface. Tighten adjusting screws after completing adjustment. Note: Stripper bars must be parallel to work table to prevent web from walking to one side. 6. Rotate pinch roller camshaft until a gap is opened between knurled roller and pinch roller. 7. Mount takeup shaft on web pull frame as follows: a. Pull out spring-loaded knob. b. Insert shaft between side plates. c. Align pin in shaft end with slot in drive pulley, and release spring-loaded knob. 9. Thread web or foil from payout roller as shown in Figure 10.2-3. 10. After threading web or foil around rollers, past photocell, under stripper bars, and between pinch roller and knurled roller, wrap web one full turn around takeup shaft from underside of shaft without

US 25 Hot Stamping Machine 10.2 Webtrak Heat Transfer Photocell Option compressing spring-loaded foil clamping bar. 11. Manually rotate takeup shaft two full turns to tighten web on shaft. 12. Inspect web path, viewing from takeup side. If web or foil is not parallel with stamping head, press in web clamping bar and slide web or foil on takeup shaft left or right to obtain correct alignment. Release clamping bar when web is aligned. 13. Rotate pinch roller camshaft to bring knurled roller and pinch roller together. 14. Manually rotate knob on knurled roller at least two full turns to confirm that foil is not slipping on takeup shaft. 15. While observing movement, use foil jog function to confirm that web or foil remains properly aligned during its travel; adjust position on takeup shaft if necessary. After web has settled in

position, move guides on stripper bars close to edges of web. Note: These guides help prevent web from walking to one side. 16. The photocell can be moved in the X and Y directions to align with the web registration marks (Figure 10.2-4). Adjustment is performed as follows: a. Loosen locking knobs on both adjustments. b. Move web until registration mark is in view. c. Move photocell horizontally until aligned horizontally with mark, and tighten locking knob. d. Turn handle at top of photocell mounting bracket to align photocell vertically with registration mark. Tighten locking knob after completing adjustment.

Figure 10.2-3. Photocell Heat Transfer Web Path

10.2-3

US 25 Hot Stamping Machine 10.2 Webtrak Heat Transfer Photocell Option

VERTICAL ADJUSTING HANDLE HORIZONTAL ADJUSTMENT LOCKING KNOB

VERTICAL ADJUSTMENT LOCKING KNOB

Figure 10.2-4. Photocell X-Y Adjustments 17. To adjust photocell sensitivity, place the appropriate background (Figure 10.2-5)— light or dark—which contrasts with the web’s registration mark under photocell beam. Step a, below, describes light background adjustment, and step b explains adjustment for dark background. Using appropriate procedure, adjust machine’s contrast meter as follows: a. For light-state adjustment, turn OFFSET control knob to obtain a reading of 10; then rotate adjustment knob an additional 1/4 turn clockwise. b. For dark-state adjustment, adjust OFFSET control knob to obtain a reading of zero (all LEDs off); then rotate adjustment knob an additional 1/4 turn counterclockwise. Message

CHECK WEBTRAK AND FOIL

10.2-4

Definition

Note: No further setup is normally required. However, if the contrast meter fails to move full scale, re-set the offset adjustment so that contrast deviation straddles the switchpoint of “5.” Rarely, it may be desirable to re-adjust contrast meter under dynamic conditions, as the web marks pass under the photocell beam. 18. Run test samples, and check quality in accordance with Foil Stamp Evaluation and Adjustment and Stamp Adhesion and Testing procedures in Setup and Adjustment. Make any required adjustments before placing machine in service.

BACKGROUND

LEDs

OFFSET CONTROL KNOB

Figure 10.2-5. Photocell Adjustment DIAGNOSTICS The following diagnostic message and its definition and corrective actions apply to Webtrak photocell machines:

Corrective Action Inspect alignment of heat transfer through slot above photocell to ensure that registration mark Photocell did not detect passes through beam; adjust as required. registration mark on Press FOIL JOG switch and observe high-to-low heat transfer. speed transition to confirm that low-speed setting is sufficiently high to pull heat transfer; if heat transfers stop, increase low speed by 1 or 2.

US 25 Hot Stamping Machine 10.2 Webtrak Heat Transfer Photocell Option MAINTENANCE Procedures included in Maintenance section apply to Webtrak photocell machines except for the drive belt procedure, which is included below. Web Takeup Drive Belt To replace the drive belt, proceed as follows: 1. Lockout/tagout electrical power, and unplug machine power cord. 2. Operate air dump valve, and lockout/tagout air supply. 3. Cut and remove existing belt; discard belt. 4. Insert new coupling halfway into one end of new belt material, leaving opposite pointed end exposed. 5. Run belt material around knurled roller and takeup shaft pulleys. 6. Pull belt until taut, and attach its ends together by pushing into coupling previously inserted into opposite end. 7. Rotate takeup shaft manually to confirm proper belt tension, as evidenced by rotation of knurled roller.

RECOMMENDED SPARE PARTS Recommended spare parts for Webtrak photocell machines are mostly identical with standard machines. Following is the only unique spare part: Item No. Part No. Description 17 7WT033-8-99 Foil Pinch Roller, Heat Transfer Machine For ordering information, refer to the Recommended Spare Parts section of this manual. ENGINEERING DRAWINGS Drawings for Webtrak photocell machines are identical with standard machines, except for Webtrak drive and electrical schematic. These drawings are included in the Engineering Drawings section at the rear of this manual.

10.2-5

US 25 Hot Stamping Machine 10.3 Webtrak Heat Transfer Laser Eye Option

10.3 WEBTRAK HEAT TRANSFER L ASER EYE OPTION Relying on the pinpoint accuracy of laser positioning, the Webtrak heat transfer laser eye option (Figure 10.3-1) offers a high level of precision for stamping heat transfer decals. By detecting the registration mark for the transfer directly under the stamping head just before stamping onto the decorating surface, a high degree of precision is assured. Description, operation, setup and adjustment, troubleshooting, maintenance, spare parts, and drawings for the Webtrak laser eye option are included in this section. Only unique laser eye information is included. Where information or procedures are identical to standard machines, references are included to the applicable sections of this manual. DESCRIPTION Web Feed The heat transfer web feed operates similarly to the foil feed on standard machines. As on standard machines, a dancer bar is used to apply light tension to the web during transport. In addition to the components needed for pulling and taking up the used heat transfer carrier the web feed contains the laser eye, which detects the image registration marks on the heat transfer web. The transport direction is left to right (opposite foil feed).

Control Panel Webtrak laser eye machines use the same control panel as standard machines. Refer to Description for control panel switch and indicator information. Table 10.3-1 describes only unique features of laser eye controls, switches, and indicators.

Figure 10.3-1. Webtrak Heat Transfer Laser Eye Option

Table 10.3-1. Laser Eye Webtrak Control Panel Features Name

Function The following options are available on Webtrak machines:

FOIL PULL

FOIL PULL TIME XX.XX – Sets time allotted for high-speed advancing of heat transfer web. FOIL LOW SPEED: XX – Sets creep speed of heat transfer web. WEB LOW RANGE: XX – Sets the upper and lower limits for low (creep) speed of web pulling. This is a factory setting and should not be changed. FOIL HIGH SPEED: XX – Sets speed at which heat transfer web advances during FOIL PULL TIME.

10.3-1

US 25 Hot Stamping Machine 10.3 Webtrak Heat Transfer Laser Eye Option Table 10.3-1. Laser Eye Webtrak Control Panel Features Name FOIL PULL (cont’d)

Function MARKS/ONE STEP: XX – Sets number of images to be counted before stopping heat transfer web advancement (usually used for multiple-part stamping).

FUNC.

Selects heat transfer web operation.

FOIL JOG

Advances web to next mark detected by laser eye each time switch is pressed.

OPERATION According to control panel settings, the heat transfer feed motor is energized either before cylinder extension or after the head is fully retracted. The motor pulls the web rapidly for the programmed interval set by the operator and then switches to the slow speed. After the inactive eye time has expired, the laser eye is enabled by the controller, allowing the registration mark directly under the stamping head to be detected. The laser eye signal is relayed to the controller, which then terminates pulling of the web. HEAT TRANSFER WEB OR FOIL INSTALLATION The Webtrak option moves the web or foil in the opposite direction from the standard machine. The feed path through the machine and adjustments are also different. Install the heat transfer web as follows: 1. Loosen front collar retaining screw (Figure 10.3-2), and remove collar, spring, and payout holder from shaft. 2. Slide heat transfer web onto shaft with material oriented so that end is at top, matte (coated) side faces down. 3. Center web on shaft by loosening inside collar and moving collar, if necessary, to properly position web. When fully aligned, tighten inside collar. CAUTION Insufficient Tension Will Cause Material To Become Snagged; Excessive Tension Will Cause Breakage. In The Following Step, Be Sure To Set Tension Correctly.

10.3-2

4. Slide payout holder, spring, and collar onto shaft. Push collar against spring until medium tension is felt, avoiding excessive or insufficient tension. Tighten collar retaining screw after setting tension. 5. Loosen adjusting screws on stripper bars, and position bars so that bottom of each bar is about 2” from the stamping head or edge of the part, whichever is greater, parallel to work table, and1/2” below the pad surface. Tighten adjusting screws after completing adjustment. Note: Stripper bars must be parallel to work table to prevent web from walking to one side. 6. Rotate pinch roller camshaft until gap is opened between knurled roller and pinch roller.

INSIDE COLLAR

FRONT COLLAR

PAYOUT ASSEMBLY

Figure 10.3-2. Heat Transfer Web Payout Assembly

US 25 Hot Stamping Machine 10.3 Webtrak Heat Transfer Laser Eye Option 7. Mount takeup shaft on web pull frame as follows: d. Pull out spring-loaded knob. e. Insert shaft between side plates. f. Align pin in shaft end with slot in drive pulley, and release spring-loaded knob. 8. Thread web from payout roller as shown in Figure 10.3-3. 9. After threading web around rollers and dancer bar, through stripper bars, past laser eye, and between pinch roller and knurled roller, wrap web one full turn around takeup shaft from underside of shaft without compressing spring-loaded foil clamping bar. 10. Manually rotate takeup shaft two full turns to tighten web on shaft. 11. Inspect web path, viewing from takeup side. If web is not parallel with stamping head, press in web clamping bar and

slide web on takeup shaft left or right to obtain correct alignment. Release clamping bar when web is aligned. 12. Rotate pinch roller camshaft to bring knurled roller and pinch roller together. 13. Manually rotate knob on knurled roller at least two full turns to confirm that web is not slipping on takeup shaft. 14. Set OFF-ON switch to ON. 15. While observing web movement, use foil jog function to confirm that web remains properly aligned during its travel; adjust position on takeup shaft if necessary. After web has settled in position, move guides on stripper bars close to edges of web. Note: These guides help prevent web from walking to one side.

Figure 10.3-3. Laser Eye Heat Transfer Web Path

10.3-3

US 25 Hot Stamping Machine 10.3 Webtrak Heat Transfer Laser Eye Option 16. When precisely adjusted, the laser eye’s yellow indicator will glow steadily. Adjustment is achieved by moving the laser eye in any combination of directions until the laser beam strikes the registration mark. To adjust laser eye, proceed as follows: Note: For proper operation, laser eye must be within 3-3/4” to 4” from web and positioned at no greater than a 45-degree angle. a. Sufficiently loosen all retaining screws in slotted laser eye support brackets (Figure 10.3-4) to allow movement, and center each bracket slot on its retaining screw. b. Locate registration marks, and manually move the web until a registration mark is under the stamping head. c. Using the available adjustments, move laser eye until beam is projected as close as possible to the registration mark beside image under pad. Note: Beam will pass through a clear or translucent mark and be seen on surface above web. d. Make final adjustment by turning micrometer adjusting knobs to focus laser beam on registration mark, and then tighten all mounting bolts. Note: In the following steps, the laser eye’s sensitivity is adjusted. The adjustment is correct if the yellow indicator changes state (switches on or off) when the registration mark moves off the beam. 18. With the laser beam focused on the registration mark, check state of laser eye’s yellow indicator (on or off). 19. Manually move web until registration mark is off laser beam. The yellow indicator should switch to the opposite condition. If indicator did not change, use a screwdriver to turn laser eye adjusting screw until light switches on or off.

10.3-4

20. Using Foil Jog function, move web past laser eye, while watching yellow indicator. Light should switch on and off as registration marks pass under beam. 21. If light does not go on and off as described above, repeat steps 18 through 20 until indicator responds properly. Contact United Silicone for assistance, if unable to achieve adjustment. 22. Run test samples, and check quality in accordance with Foil Stamp Evaluation and Adjustment and Stamp Adhesion and Testing procedures in Setup and Adjustment. Make any required adjustments before placing machine in service. DIAGNOSTICS The diagnostic message and its definition and corrective actions (Table 10.3-2) apply to Webtrak heat transfer laser eye machines. MICROMETER ADJUSTING KNOBS

ADJUSTING SLOTS

Figure 10.3-4. Laser Eye Adjustment MAINTENANCE Procedures included in Maintenance section apply to Webtrak heat transfer laser eye machines except for the drive belt procedure, which is included below. Web Takeup Drive Belt To replace the drive belt, proceed as follows: 1. Lockout/tagout electrical power, and unplug machine power cord. 2. Operate air dump valve, and lockout/tagout air supply.

US 25 Hot Stamping Machine 10.3 Webtrak Heat Transfer Laser Eye Option 3. Cut and remove existing belt; discard belt. 4. Insert new coupling halfway into one end of new belt material, leaving opposite pointed end exposed. 5. Run belt material around knurled roller and takeup shaft pulleys. 6. Pull belt until taut, cut off excess material, and attach ends together by pushing into coupling previously inserted into opposite end. 7. Rotate takeup shaft manually to confirm proper tension, as evidenced by rotation of knurled roller.

RECOMMENDED SPARE PARTS Recommended spare parts for Webtrak laser eye machines are mostly identical with standard machines. The only unique spare part is as follows: Item No. Part No. Description 17 7WT033-8-99 Foil Pinch Roller, Hot Transfer Machine For ordering information, refer to the Recommended Spare Parts section of this manual. ENGINEERING DRAWINGS Drawings for Webtrak laser eye machines are identical with standard machines, except for Webtrak drive and electrical schematic. Drawings are at the rear of this manual in the Engineering Drawings section.

10.3-5

US 25 Hot Stamping Machine 10.3 Webtrak Heat Transfer Laser Eye Option Table 10.3-2. Webtrak Laser Eye Diagnostics Message

Definition

Corrective Action Check alignment of laser beam with registration mark on heat transfer web; adjust as required. Check for flickering ambient lighting that may be interfering with laser eye sensitivity.

CHECK WEBTRAK AND FOIL

Laser eye did not detect registration mark on web.

Check for fluttering of web caused by vibration or other source; eliminate vibration source. Press FOIL JOG switch and observe high-to-low speed transition to confirm that low-speed setting is sufficiently high to pull web; if web stops, increase low speed by 1 or 2.

10.3-6

US 25 Hot Stamping Machine 10.4 Rotary Table Option

10.4 ROTARY TABLE OPTION Increased productivity is offered by the rotary table, which automatically indexes each part under the stamping head. The rotary table replaces the standard single-station work table. The rotary table is available in four-, six-, and eight-station models to accommodate various production requirements and part dimensions. Description and operation information for the rotary table is provided in this section. Maintenance and servicing instructions are provided in the CAMCO service manual. DESCRIPTION The rotary table consists of a motor-driven index drive, rotating work table, and speed control. Its operation is supervised by the control box, which automatically coordinates table rotation with stamping head extension and retraction. The drive rotates the table through four, six, or eight stations depending on model, pausing at each station for the operator to place and remove parts. The speed control permits setting an appropriate speed to match the operator’s parts-handling speed. If machine has a shot pin for station indexing, the speed control is disabled. OPERATION Station Alignment The rotary table is factory set to index at the center of each station. For optimum precision, an optional pneumatic shot pin is available to lock the table at each station. Accurate station alignment ensures uniform distribution of stamping force when the stamping head contacts the decorating surface. In most cases, the factory index setting will accurately position each part directly under the stamping head. However, minor adjustments may be required to accommodate fixture and part variations. This adjustment is performed by loosening the index drive mounting bolts, re-positioning the table as required until the part is brought into

precise alignment with the head, and tightening the index drive mounting bolts after completing the adjustment. This adjustment is not suitable for making major adjustments. If a major offset is required, the holding fixture or die mounting plate should be moved. The remaining stations are automatically aligned by positioning any one station. Guard Door Interlock For personnel safety, all motion stops if a safety guard door is opened during a cycle. After closing the door, the stamping head will not descend until the table is indexed one station. This step resets the machine’s controller to resume operation. The onestation index is required even if the interruption occurred while the table was at a station. Speed Control The speed control permits a wide range of adjustment for rotation speed to match the operator’s pace. The speed setting is dependent on the operator’s ease of placing and removing the parts. For example, a rapid speed is appropriate for small parts that rest lightly on the holding fixture and can be removed and placed quickly. However, large or complex parts may require a slower speed to permit sufficient time for the operator to remove the stamped part and place the next part on the fixture. The numbered increments on the dial provide a reference between the fastest speed (rotated fully clockwise) and slowest speed (fully counterclockwise); they do not specify time intervals. Generally, the control is set initially at its midpoint and then turned left or right to accommodate production requirements and the operator’s needs.

10.4-1

Hot Stamping Machine 10.4 Rotary Table Option

INDEX DRIVE

Figure 10.4-1. Rotary Table Option TABLE INDEX CAM ADJUSTMENT Due to table inertia, a change in the rotary table speed setting may cause the table to either undershoot or overshoot the index position. This may cause misalignment of the part nesting fixture and/or a brief jerking movement as the table indexes. Therefore, whenever table speed is altered, the relationship between the index drive cam lobe and the index drive shaft keyway should be checked and adjusted, if required. These instructions will assist in checking and adjusting rotary table indexing following speed setting changes. Index Check To check table indexing, proceed as follows: 1. Turn on electrical power. 2. Index table to next station, while observing its movement as it arrives at the station. 3. From underside of table, check the following: a. Limit switch roller should be on cam lobe (Figure 10.4-2). b. Shaft keyway should be about parallel to table at the 3:00 o’clock position. 4. If cam is not at 3:00 o’clock, adjust cam as described in the following paragraph. Cam Adjustment 1. If keyway is below 3:00 position, e.g. 2:00 o’clock, adjust as follows:

10.4-2

a. Loosen two setscrews on cam. b. Rotate cam counterclockwise approximately the same amount of displacement from 3:00 o’clock. 2. Tighten setscrews. If keyway is past 3:00 o’clock, e.g. 4:00 o’clock, adjust as follows: a. Loosen two setscrews on cam. b. Rotate cam clockwise approximately the same amount of displacement from 3:00 o’clock. c. Tighten setscrews. 3. Operate table once again, while observing its movement. Table should move to next index position and stop smoothly. If any jerking, undershooting, or overshooting of cam lobe is seen, readjust cam lob, and repeat check. 4. Adjustment is completed when table moves and stops smoothly at each index station. If correct operation is not achieved through this adjustment, contact United Silicone for assistance.

LIMIT SWITCH ROLLER

KEYWAY

CAM LOBE

Figure 10.4-2. Rotary Table Index Drive Cam Adjustment ENGINEERING DRAWINGS Drawings for rotary table machines are identical with standard machines, except for the electrical schematics. Drawings are included in the Engineering Drawings section at the rear of this manual.

US 25 Hot Stamping Machine 10.5 Lockout Key Switch Option

10.5 LOCKOUT KEY S WITCH OPTION The lockout key switch option prevents accidental or unauthorized changing of stamping machine operating parameters. Description and operation information for the lockout key switch option is provided in this section. DESCRIPTION The lockout key switch is installed on the front of the control panel between the power ON-OFF switch and EMERGENCY STOP switch (Figure 10.5-1). It is supplied with two keys that operate a simple lock. The key may duplicated, but keys should only be given to personnel requiring full access to machine operating parameters.

OPERATION When the control panel is “locked,” most functions cannot be changed. By setting the lockout key switch in the “off” position, only the foil pull time can be modified. To permit changing of all parameters, set the lockout key switch in the “on” position.

Figure 10.5-1. Lockout Key Switch Option

10.5-1

US 25 Hot Stamping Machine 11.0 Semi-Automated Custom Hot Stamp Systems

11.0 SEMI-AUTOMATED CUSTOM HOT STAMP SYSTEMS DESCRIPTION Semi-automated hot stamp systems (Figure 11.0-1) are custom-designed and built to meet unique customer requirements. The systems integrate one or more hot stamping machines with a rotary table and other accessories. For example, a photocell or laser eye heat transfer web option, pick and place station (Figure 11.0-2), shuttle table, and/or articulating nest may be included to meet customer specifications. Systems may also include other equipment, as requested by the customer. To meet European Union requirements, United Silicone designs and builds custom systems to meet CE wiring standards for shielding and wire terminations. Each semi-automated system is enclosed within a protective cabinet for optimum safety of the operator and other personnel in the system’s vicinity. All doors and swing guards have safety interlock switches that stop the system whenever any door or guard is moved out of its closed position. Non-interlocked light curtains are also installed on some custom systems. DOCUMENTATION Basic information on semi-automated custom systems is included in this section. Detailed instructions and procedures contained in other sections of this manual form the major part of system documentation. Refer to the Description, Installation, Setup and Adjustment, Troubleshooting, and Maintenance, Recommended Spare Parts, Engineering Drawings, and other sections for information that applies to your system. Description and operation instructions for the rotary table are included in Rotary Table Option. In addition, where applicable, the documentation package shipped with each system includes electrical and pneumatic schematic diagrams, control panel description, and any other pertinent data

needed for system operation, troubleshooting, and maintenance.

HOT STAMPING MACHINE

ROTARY TABLE CONTROL PANEL

Figure 11.0-1. Typical Semi-Automated Custom Hot Stamp System

Figure 11.0-2. Pick and Place Station

11.0-1

US 25 Hot Stamping Machine 12.0 Engineering Drawings

12.0 ENGINEERING DRAWINGS This section contains manufacturing drawings, which should be used to assist in troubleshooting, parts replacement, and understanding machine operation. Table

12.0-1 lists all drawings for both standard and optional equipment; however, only drawings applicable to your equipment configuration are included in this manual.

Table 12.0-1. Engineering Drawings Drawing No.

Description

Standard Mechanical, Electrical, and Pneumatic Drawings 722001

Two & One-Half Ton Hot Stamp Assembly

722002

Foil Feed Subassembly

722003 724004

Foil Payout Subassembly Main Frame Subassembly

724005

Head Subassembly

722006

Positive Stop Subassembly

722200

Pneumatic Diagram, Hot Stamp Model US 25

722201

Pneumatic Diagram, Hot Stamp Model US 25 With Head-Up Delay

HS-B-100

Electrical Schematic, 110 Volt Hot Stamp

HS-B-101 HS-B-110

Electrical Schematic, 110 Volt Hot Stamp With Head-Up Delay Electrical Schematic, 220 Volt Hot Stamp

HS-B-111

Electrical Schematic, 220 Volt Hot Stamp With Head-Up Delay Slide Table Electrical and Pneumatic Drawings

HSST-B-100

Electrical Schematic, Hot Stamp Slide Table

HSST-B-200

Pneumatic Schematic, Slide Table Webtrak Heat Transfer Web Drawings

WT-D-001-2 WT-C-050

US 25 Webtrak for up to 8”x16” Head Assembly Webtrak Drive Subassembly

WT700-B-100

Electrical Schematic, Webtrak Control

HS-B-104

Electrical Schematic, 110 Volt Hot Stamp With Webtrak Headup Delay

HS-B-112

Electrical Schematic, 220 Volt Hot Stamp With Webtrak Headup Delay Rotary Table Drawings

HSSRT-B-100

Electrical Schematic, Hot Stamp Smart Rotary Table

HSSRT-B-102

Electrical Schematic, Hot Stamp Smart Rotary Table With Webtrak

12.0-1