Adkins Alpha Calender Roll-Master 1.2 Manuel de service
HEAT PRESS TECHNOLOGY
All products within the ADKINS range are labelled with CE marking and are manufactured and tested to comply with EC safety regulations.
ALPHA CALENDER ROLL-MASTER 1.2
©2018 A. Adkins & Sons Ltd. All rights reserved. E&OE. V1.0.
All products within the ADKINS range are labelled with CE marking and are manufactured and tested to comply with EC safety regulations.
©2019 A. Adkins & Sons Ltd. All rights reserved. E&OE. V1.0.
Operators Handbook
Rev C - 07/02/19Rev C - 07/02/19
Copyrights
©2019 A. Adkins & Sons Limited,
High Cross, Lancaster Road, Hinckley,
Leicestershire LE10 0AW
http://www.aadkins.com/
No part of this publication may be reproduced by any means without
the prior written permissions of A. Adkins & Sons Limited.
Alpha Calender Roll-Master 1.2 is a trademark of A. Adkins & Sons
Limited.
Please read this manual carefully and keep it with your machine at all
times for reference.
Preface
Dear User
Welcome to the growing group of Adkins Alpha Calender Roll-
Master 1.2 users! The product you have purchased has been carefully
designed and manufactured to ensure that you, the user, will gain the
maximum benefit.
All Adkins products are specifically designed to ensure ease of use,
with particular attention to safety requirements.
Should you discover any fault or damage upon receipt of this product,
you should immediately contact your supplier.
Contents
1. Introduction 1
1.1 Machine Benefits 2
1.2 Specifications 3
1.3 Safety Instructions 4
1.4 Safety Tips 4
1.5 Warning Signs 5
2. Installation 6
2.1 Unpacking 6
2.2 Installation of Worktable 6
2.3 Installation Notice 7
3. Operation Guide 8
3.1 Operation Notice 8
4. Maintenance 10
4.1 Cleaning 10
4.2 Lubrication 10
4.3 Blanket Care 10
4.4 Heating Oil Replacement 10
5. Machine Drawings and Diagrams 11
5.1 General layout 12
5.2 Roller configurations 13
5.3 Control Panel operations 14
5.4 LH Cabinet layout 17
5.5 RH Cabinet layout 18
5.6 Electrical diagram 19
6. Troubleshooting 20
7. Design Change 21
8. Guarantee (limited warranty) 22
9. Declaration of Conformity 23
Page 1
1. Introduction
The Alpha Calender Roll-Master 1.2 has been developed after
continuous feedback from end users and aims to provide market
leading specifications with ease of operation and economical running
costs.
It is capable of thermal transfer from roll-to-roll, roll-to-pieces and
pieces-to-pieces and for any type of cotton, polyester or polyester mix.
Moreover, the machine footprint and energy usage make it ideal for
smaller workplaces where both are critical factors to successful
production runs.
Being simple in operation it can be operated by as few as two
personnel and training overhead is low.
Page 2
1.1 Machine Benefits
Below is a brief list of the many benefits of the Alpha Calender Roll-
Master 1.2:
i. Most of the machine rollers are precisely cut using computer
operated CNC cutting machines to provide a completely
parallel shaft. This allows for very long material transfers
without any tracking.
ii. The heating roller is constructed from stainless steel and is
also CNC cut, providing a very smooth surface which allows
for uniform heat distribution. Approximately 70% of the
roller surface is covered by a felt blanket, enabling it to
reduce the emission of radiated heat to the environment and
thereby ensuring a good transfer result.
iii. The CNC cut balance (tensioning) rollers have a diameter of
8.7 cm (3.42 in) which prevents any deformation in the
substrate thereby completely eliminating curls and ripples
which could possibly transfer onto the printed media.
iv. The machine is designed in such a way that the materials are
fed into the rollers from an elevated position, allowing for
precise fabric feed and lowering the fault rate in production.
v. A high-quality blanket with outstanding torsional stability at
temperatures of up to 250°C (482°F) provides a stable
transfer of substrates and with less than 1% thermal
shrinkage will last the lifetime of the machine.
Page 3
1.2 Specifications
Below are the specifications for the Alpha Calender Roll-
Master 1.2
Heating Media Oil
Voltage Single Phase 230 Volts AC
Power (Heater - 4.5 kW) (Motor - 0.5 kW)
N
o. of Heating Elements 1
N
o. of Feed Rollers 3
N
o. of Collection Rollers 3
Machine Size 152.5(L) x 40(W) x 124(H) cm
60(L) x 15.7(W) x 48.8(H) in
Worktable size 60(L) x 112(W) x 90(H) cm
23.6(L) x 44(W) x 35.4(H) in
Drum Diameter 16.8 cm (6.6 in)
Transfer Speed up to 1.3 m/min (40.5 in/min)
Transfer Blanket Width 115 cm (45 in)
Maximum Temperature 265°C (509°F)
Maximum Transfer width 120 cm (47 in)
Gross Weight 216 Kg (476 lbs.)
N
et Weigh
t
166 Kg (366 lbs.)
Roll-to-roll Functionality Yes
Piece-to-piece Functionality Yes
Roll-to-piece Functionality Yes
Work Table Included Yes
Air Cylinder Required No
Page 4
1.3 Safety Instructions
Before operating the Alpha Calender Roll-Master 1.2, please read
the safety instruction carefully to fully understand the machine’s
primary structure, function, and operation method. Training in
machine operation and maintenance procedures is also required, for all
personnel involved in the day-to-day use of the Alpha Calender Roll-
Master 1.2.
During operation and maintenance, personnel should pay particular
attention to any warning signs, or stickers, to guarantee all operators
personal safety.
1.4 Safety Tips
i. The electrical power source used for the equipment must be
in line with the type displayed on the nameplate. The earthing
must be accurate and reliable (equipment with three-terminal
polarized plus plug not allowed to change the function of the
earth electrode freely).
ii. When the equipment is operating normally, the surface
temperature of the heating roller is very high and care should
be taken never to touch it with your hand.
iii. When opening the box to examine and fix any equipment, the
power must be shut off, to avoid electric shock or mechanical
wounding incidents. When transfer work has been finished
the power should be cut off too.
iv. Don’t place the power lead onto the walkway, or leave the
cord wrapped in a pile, to prevent tripping accidents. Care
should also be taken to prevent the power lead from rolling
depressions caused by vehicles or trollies, possibly causing a
short circuit and or fire/electrical shock.
v. Mounting card and transducer in the box should be kept clean
and dry to avoid conductive material such as dust etc. Don’t
open the protective covering to avoid electric shock injuries.
vi. The working area should be kept dry and well ventilated.
Also care should be taken to prevent water spillage and
protect from damp when using the equipment. Don’t store or
stack any flammable or explosive materials close to the
machine.
vii. Don’t put tools or other items, such as screwdrivers, nails,
screws and/or nuts etc. onto part(s) of the machine to avoid
them from falling into the rotating rollers, thereby causing
damage to the machine.
viii Do not wash the machine with water to avoid short circuits,
electric shock and corrosion.
Page 5
Safety Tips (cont.)
1.4.1 Heat and Power Switches
Both the Heat and Power switches are located on the Control
Panel. To immediately stop the machine from heating, turn
off the Power Button. This will stop the power for heating,
but will still allow power to pass to the motor.
1.4.2 Blanket Maintenance
When the heat transferring is completed, turn off the heater
(as above) but allow the motor to rotate the blanket until the
temperature falls below 80℃ (176°F), this will prevent the
blanket from scorching/burning on the hot roller.
1.4.3 Heat Roller
Following heating, the surface temperature of the heating
roller could be over 240°C (464°F). While the machine is
heating, special care should be taken not to touch the roller
surface with any part of the body, to avoid crushing or
burning injuries. In addition, when the machine is heating
and/or operating, the operators should be present to avoid the
roller from overheating, thereby causing a fire.
1.5 Warning Signs
Please pay close attention to any and all warning signs
displayed on the machine. The injuries displayed on the signs
may death or permanent disablement to operators and/or
general bystanders. Serious machine damage will likely also
occur if the warnings are ignored.
NB Under no circumstances should any attempt to remove,
modify or bypass safety equipment be undertaken, as this
could lead to serious personal injury, including death and
seriously damage the machine, which will invalidate your
warranty.
Page 6
2. Installation
The Alpha Calender Roll-Master 1.2 should be sited in a secure, flat
and dry location with good ventilation and enough space for safe and
efficient operation.
A safe and adequate electrical supply should be provided with
sufficient protection for the rating of the machine and with easy access
to a trip/safety switch.
It is also good practise to provide close and easy access to emergency
medical equipment and firefighting equipment.
2.1 Unpacking
i. Remove the pin
ii. Loosen all of the screws on the packaging
iii. Remove the crate cover with a hammer and/or crowbar
iv. Lower the crate side covers
v. Remove the Work table and shafts
vi. Using a forklift transport the Alpha Calender Roll-Master
1.2 to the correct position
2.2 Installation of Work table
NB Two people are required for installation
Step 1 Installation of the main structure
a. Fix the two angled horizontal table support arms to the left
and right cabinets (please refer to the exploded diagram on
page 12).
b. Using two people connect the angled table legs (11) to the
two angled horizontal table supports.
Step 2 Installation of the lower structural bar (12)
Care should be taken not to fasten the bar too tightly at this
stage.
Step 3 Installation of the Material Loading Shaft (10, 13)
a. Screw the four metal plates onto the left and right angled
table legs (11), making sure the screws are only hand tight at
this stage.
b. Connect the Transfer Paper Loading Shaft (10) and the Fabric
Loading Shaft (13) onto the angled table legs. So the
installation of the Guide Bar for transfer paper (30) is the
same.
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