Adkins Alpha Calender Roll-Master 1.2 Service manual

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.
©2022 A. Adkins & Sons Ltd. All rights reserved. E&OE. V1.0.
Operators Handbook
Rev A - 17/01/22Rev A - 17/01/22

Preface
Dear User
Welcome to the growing group of 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 A. Adkins & Sons Limited 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 Alpha Calender Roll-
Master 1.2
1
1.1
Specifications of the Alpha Calender Roll-Master
1.2
2
1.2
Safety Tips
3
1.3
Safety Parts
4
1.4
Warning Symbols
5
2.
Installation
6
2.1
Transport Instructions
6
2.2
Installing the Machine
6
2.3
Disassembly of the Shipping Crate
6
2.4
Installation of the Machine
6
2.5
Electrical Requirements
7
3.
How to operate the Alpha Calender
Roll-Master 1.2
8
3.1
Pre-shrinking of Felt Blanket
8
3.2
Horizontal Adjustment
9
3.3
Heating System
10
3.4
Noise
10
3.5
Cleaning
10
3.6
Lubricating
10
3.7
Heating System
11
3.8
Oil Drum Temperature Measurement
13
3.9
General Maintenance
13
4.
Machine Drawings & Diagrams
14
4.1
General Layout
15
4.2
Control Unit Operation
17
4.3
General Electrical Diagram
18
5.
Design Change
19
6.
Guarantee (Limited Warranty)
20
Declaration of Conformity
21

Page 1
1. Introduction Alpha Calender
Roll-Master 1.2
The Alpha Calender Roll-Master 1.2 is a manually operated Calender
press for transfer printing and material fusing with an oil heating system
dye sublimation onto knitted, synthetic, and non-cloth fabrics such as
polyester and nylon. It is capable of printing in piece-to-piece operation
and also roll-to-roll for polyester materials and spandex materials.
Features include:
•Automatic felt blanket alignment
•High capacity oil drum that can be filled to 100% capacity
•Hand cranked blanket tensioning system
•Blanket release system
•Auto power off feature
•A duplex Teflon® oil drum
•Piece-to-piece and roll-to-roll functionality
•Three Feed rollers and three take-up rollers
The auto felt blanket alignment feature avoids lost and spoiled production
due to the blanket tracking off alignment during setup and production,
and requiring less maintenance during day-to-day operation.
The high capacity oil drum can be filled to 100% capacity, which
increases the transfer speed substantially as the heat temperature is more
evenly spread across the drum, and more stable during operation.
The auto power off feature makes the machine more energy efficient and
economical, and guards against accidental damage due to overheating
should the machine be left on accidentally. This feature is fully
programmable from the PLC controller and the main power button,
saving the operator at least 3 hours a day over using a manual shut down
machine, as no user interaction is required when the machine is turned
off.
The Control panel is very user friendly and will aid in the rapid training
of operators due to its simplicity of useage and easy to read layout.

Page 2
1.1 Specifications of the Alpha Calender Roll-Master
1.2
Specifications:
Power consumption
6.5 kW
Power supply
220 Volts AC 1-Phase (N+E)
Fuse
28.1 A
Maximum Working Temperature
240oC (464°F)
Heating element (oil filled drum)
Ø-200 mm (Ø-8 in)
Display Timer Range
N/A
Machine height
147.3 cm (58 in)
Machine width
162.6 cm (64 in)
Machine depth
88.5 cm (27 in)
Packed Dimensions
194 (W)x 142.3 (H)x 88.5 (D)cm
(76 (W)x 56 (H)x 27 (D) in)
Working area required
xxx (W)x xx (H)x xxx (D) cm
(xx (W)x xx (H)x xx (D) in)
Gross weight
1000 Kg (2,205 lbs.)
Net weight
850 Kg (1,874 lbs.)
Maximum print width
120 cm (47 in)
Maximum tranfer speed
0.5 m/min (196.8 in/min)
Feed rollers
3
Take-up rollers
3
Control unit
PLC digital microprocessor unit

Page 3
1.2 Safety Tips
♦Our customer service department has its own service
engineers and, if required, maintenance is available.
♦The Alpha Calender Roll-Master 1.2 meets the European
Legislation standard. Under normal conditions accidents are
rare. However listed below are some practical points to ensure
your safety.
•Make sure there is sufficient space around the machine
for the heat to dissipate from the drum, without interference.
Only persons fully trained should operate this machine.
•Always switch off the current (and pull plug out of the
socket) when undertaking maintenance work or when
cleaning the machine.
•Ensure that there is sufficient space around the machine.
Cables and connections must not get jammed. Although the
heat radiation of the press is low, there should be enough
space for cooling down.
•Avoid contact with the heating drum.
♦DO NOT REMOVE ANY INSTRUMENT COVERS
UNLESS QUALIFIED TO DO SO - touching internal parts is
dangerous and may cause shock hazard. All electrical
connections inside covers are live. Never operate Press with any
covers and/or guards removed.
♦PROTECT THE MAINS CABLE - damage to the mains cable
may cause fire or shock hazard. When unplugging, hold by the
plug only and remove carefully. Take care that the mains cable
does not come into contact with the heating drum (or moving
parts of the machine) during operation of the machine.
♦OPERATING AMBIENT TEMPERATURE RANGE- the
operating ambient temperature range is 0oC - 35oC, (32oF -
104oF) and humidity of 20 - 80%.
♦MACHINE FUSE(S) – 28.1 Amps.
♦WARNING - THIS APPARATUS MUST BE EARTHED
(GROUNDED)
♦CAUTION
This machine gets hot whilst operating. Take care not to touch
any surfaces that are labelled “HOT”.
♦MACHINE OPERATION
Only persons trained to do so should operate this machine.
1.2.1 Before switching on the machine, make sure that all
electrical wires are connected correctly. The body of the

Page 4
Safety Tips (cont.)
machine must be connected to ground. Press the power
switch and belt start rotary switch. Then adjust the rotary
speed on speed adjuster (6) to the optimum value. When the
heating roller starts revolving press the ‘heating’ button (5)
and adjust the temperature to the optimum value (Default
temperature is 220°C (428°F).
1.2.2 When the machine reaches the preset temperature, let
the thermostat stabilize the temperature for a while. Check
the transfer result with a small sample piece of printed
transfer paper and substrate. Adjust the temperature with
reference to the testing result of the transfer.
1.2.3 Place the printed transfer paper and exhaust tissue
paper (to preventcontamination of the felt blanket) in the
correct position on the working tableand main
machine.Feed the tissue paper firstly onto the collection
roller at the rear. Secondly feed the textile, taking care to
keep as flat and wrinkle free as possible. Thirdly, and lastly,
feed the printed transfer paper evenly onto the machine.
1.2.4 When the fsbric transfer paper comes out, attach the
fabric to the collecting rollers at the rear of the machine, or
alternatively just drop onto the textile collector (19). Then
attach the transfer paper to the collection roller at the front
of the machine, under the work table, allowing the finished
work to be collected automatically. The transfer collecting
speed can be adjusted by using the controller (8).
1.2.5 During the working process the transfer speed can be
adjusted by 6 speeds according to the required vividness of
the finished printed result.
1.2.6 When the transfer process is completed switch off the
heating button to let the machine cool down. The operator
will have to monitor the machine until the temperature
drops to less than 80°C (176°F). Only then can the
operator switch off the machine.
1.2.7 If there is a sudden loss of electrical supply during
machine operation at high temperature, the felt should be
immediately separated from the hot oil drum, using soft
board or paper, to prevent permanent damage to the felt.
1.3 Safety Parts
Heat button and power button:
Both the power button and heat button are on the control panel; Press
the heat button to immediately stop the heating of the oil filled drum;
Turning off the power button will isolate the oil filled drum from the
supply, and thus stop all heating but does provide power for the motor to
revolve.
Felt blanket maintenance:
When the transfer run is completed turning off the heat will allow the
motor to continue revolving until the temperature reaches 80°C (176°F),
to prevent the blanket from burning.

Page 5
Safety Parts (cont.)
N.B. The machine can also be set to automatically shut down from the
PLC controller.
Oil filled heated roller:
Following heating the surface temperature of the oil filled roller can
be in excess of 240°C (464°F). While it is heating do not touch the roller
surface withany part of the body, to avoid crushing and/or burning. When
the machine is heating and/or operating, operators should always be
present to avoid roller damage or accidental fire, due to overheating.
1.4 Warning Symbols
Please pay attention to the following warning symbols, to reduce the
instance of serious injury and/or death during machine operation
and maintenance.
Anti Grinding
This sign is diplayed at the junction of the
upper and lower drive rollers on both sides, at
the front of the machine.
The rubber roller is dangerous in operation, so
care must be taken to keep hands, hair, clothing or
other parts of the body clear.
High Voltage
This sign is displayed at the inner flank of the
power box.
Do not touch to avoid burns and/or electric shock,
which can result in serious injury or death.
Chain
This sign is displayed on the inner flank of the
left box.
The chain is dangerous in operation, so care must
be taken to keep hands, hair, clothing or other
parts of the body clear.
Burning Prevention
This sign is displayed at the front of the
cabinet near the heated oil drum.
The oil drum coated with black Teflon™ is hot
during operation and cool down of the machine so
care must be taken to keep hands, hair, clothing or
other parts of the body clear until the machine has
fully cooled down.

Page 6
2. Installation
2.1 Transport Instructions
The Alpha Calender Roll-Master 1.2 comes to you in a wooden
shipping crate. If you have to transport the machine at any time it is
recommended that you use a similar crate and packing method.
2.2 Installing the Machine
The machine must be place on a flat stable hard standing, a concrete
floor is ideal for this. The ideal area should be twice the length of the
machine and twice the width to allow for easy access and maintenance,
and the room should be dry and well ventilated with a mechanical
extractor where possible.
2.3 Disassembly of the Shipping Crate
•Unscrew the bolts on all edges and remove all nails on the top
cover of the crate.
•Use a hammer and crowbar to remove the upper cover of the
crate.
•Remove the four crate walls.
•Move the machine to its desired position, using a forklift truck
rated for at least the gross weight of the machine.
2.4 Installation of the Machine
Install the working table (referring to the numbered stickers as a guide)

Page 7
Installation of the Machine (cont.)
Use a good quality spirit level of at least 3 m length to aid in leveling
of the machine.
2.5 Electrical Requirements
2.5.1 Power input point
Release the screw on the main terminal, connect the three live
wires to terminals L1, L2 and L3 one-by-one and then connect
the neutral wire to the terminal marked N
The ground wire should be connected to the grounding point
N.B. The wiring used should be rated for the power value on the
machine dataplate

Page 8
3How to operate the Alpha
Calender Roll-Master 1.2
3.1 Pre-Shrinking of Felt Blanket
If you need to replace your felt blanket then the new part should be pre-
stabilized to resist high temperatures.
Please perform the following procedures:
1. Ensure the actuator is located at the centre position as shown
in image No.1.
2. Remove No.3 and No.4 relays to disconnect the felt blanket
auto-aligning system.
3. To keep the blanket under the correct tension status a
pressure reading on the pressure regulator should be 0.2. You
should then turn the ‘felt tension/release’ crank handle to its
maximum and then turn back by half a turn.
4. The procedures for pre-shrinking the felt blanket should be
based on the following table:
Temperature
Working time
120°C
248°F
3 hours
140°C
284°F
3 hours
170°C
338°F
4 hours
200°C
392°F
4 hours (very important)
230°C
446°F
4 hours
N.B. During the pre-shrink period adjust the tracking of the felt
blanket manually or reverse the rotation direction of the felt.
After the pre-shrink period is completed the machine should be run
for 6 hours at 220°C (428°F),then the No.3 and No.4 relays should be
replaced to activate the auto aligning system. The white sensor rods on
either side of the felt blanket should then be closed to touch the edge of
the felt blanket.

Page 9
Pre-Shrinking of Felt Blanket (cont.)
Caution:
If there is a sudden loss of power whilst the machine is operating
at high temperature use the hand wheel immediately to move the
felt blanket backwards, and then insert soft paper board orpapers
(around 2 mm to 4 mm in thickness) between the oil drum and
the felt blanket, to prevent burning of the felt.
3.2 Horizontal Adjustment
When transfer working is finished please turn the heating off and
keep the blanket running until the temperature reduces to 80°C
(176°F). Or activate the ‘auto-off’ function by switching off the ‘heating
‘on/off’ button and the power ‘on/off’ button, and the machine will auto-
off after several hours running, to cool down.
When you restart the machine after a prolonged period of inactivity
it is suggested to pre-heat the felt blanket at a temperature of 200°C
(392°F) for 3 hours, especially during the colder winter months.
Please use a spirit level of at least 3m to perfom initial levelling of the
machine at its new location using the adjustable feet to perform the
changes.
Precise measurements should be taken both horizontally and vertically to
ensure all parts of the machine are perfectly level.

Page 10
Horizontal Adjustment (cont.)
Once all measurements confirm that the machine is level then the
adjustable feet should be locked in their positions.
3.3 Heating System
The oil drum was filled with heat tranfer oil (mineral based, suggested
brand name: Total™) with specifications:
•Density: 0.83-0.87 g/cm³ at 20°C
•Viscosity: 21-31 mm²/s at 50°C
•Flash point (open to air): 173°C
•Distillation range (2% v/v): 340°C
•Maximum temperture during use: 320°C
Under normal usage the heating oil can be used for up to 3 years before
replacement, although it may be necessary to ‘top-up’ the drum via the
oil tank from time to time.
N.B.
Replacement of parts/heating oil should not be undertaken by the
end user without firstly consulting an Adkins engineer. All parts
should be supplied and or approved by A Adkins and Sons Limited.
3.4 Noise
The rollers and bearings may expand and become noisey in operation
when they are heated to certain temperatures. This is a normal
phenomenon and does not impare operation.
3.5 Cleaning
Keep clean and tidy so that there is no dirt falling into the electric
circuit box and transducer. Always keep the electrical coverings in
place to avoid electrical shok and/or death.
There is a Teflon™ coating on the oil drum roller that should not be
scratched or cleaned with acidic chemicals, this is important as the oil
drum is a non-warranty part.
3.6 Lubricating
All bearings should be lubricated with lithium based grease with a
temperature flash point of not less than 240°C (464°F).

Page 11
3.7 Heating System
The oil drum was filled with heat transfer oil (mineral base, suggested
brand name: Total)
Oil specification:
•Density: 0.83-0.87 g/cm³at 20°C (68°F)
•Viscosity: 21-31 mm² at 50°C (122°F)
•Flash point (open to air): 173°C (343.4°F)
•Distillation range (2% v/v): 340°C (644°F)
•Maximum temperature at use: 320°C (608°F)
The heating oil can be used for up to 3 years and canbe topped up from
the top oil tank
3.7.1 Oil drum
(1) Inspection window
(2) Bearing (6019)
(3) End cap, for sealing
1
2 3

Page 12
Heating System (cont.)
Front view of oil drum
(4) Release bolt to drain oil
(5) Release bolt to refil oil
(6) Thermo sensor to detect surface temperature
(7) Heating element
(8) Heating oil (green)
(9) Present temperature
(10)Preset temperature (default value: 204°C (400°F))
(11)Increase setting value
(12)Reduce setting value
N.B. Collected leaked oil can be recycled back into the oil tank on the top
right hand side of the cabinet.

Page 13
Heating System (cont.)
Do not replace the heating oil or any of the oil roller parts yourself
without consulting our engineers. Parts must be provided and approved
by A. Adkins and Sons Limited
3.8 Oil Drum Temperature Measurement
Testing of the Oil Drum for temperature consistency or fault condition
should only be undertaken after consulting A. Adkins and Sons, and then
only using a wired Digital Thermometer (*please see note below).
*Please Note:
The Digital Thermometer with external probe is suitable for
surface, air and immersion/penetration measurement, which is
required for all Adkins heat presses.
Laser Thermometers only measure air surfaces which can be
misleading due to currents of hot air floating on the surface of
the Oil Drum.
3.9 General Maintenance
The following checks should be carried out at regular intervals by a
qualified and competent person:-
•Pneumatic system for air leaks
•Pneumatic system for lubrication
•Electrical connections
•Belt tension and condition
•Mechanical moving parts
Any enquiries to: [email protected]

Page 14
4. Machine Drawings and
Diagrams
On the following pages are the schematic diagrams for the Alpha
Calender Roll-Master 1.2.
4.1 General Layout………………..…………… Page 15
4.2 Control Units Operation…………………... Page 17
4.3 General Electrical Diagram...…………...… Page 18

4.1 General Layout
Page 15
Tensioner
Power on/off
Heat on/off
Speed
controller
Temperature
controller
Front View
Blanket rotation
Fabric shaft
Emergency
stop
Drivetrain
(hidden)
Core plug
Core plug
Fabric piece catcher
Fabric
unwind shaft
Tension shaft for
fabric unwind
Gearbox for
tension adjustment
Exhaust barrier paper
tensioning shafts
Castor wheel
Fan
Fan
Core plug
Barrier paper
shaft
Barrier paper
exhaust shaft
Barrier paper
shaft
Fan
Tension
adjusting handle
Height
adjustable foot
Printing paper
guide
Glass working table
Rear View
Emergency
stop
Crank for belt
tension/release
Compressed air
input and output
Fabric exhaust
shaft
Guide shaft Fabric shaft

4.1 General Layout (cont.)
Page 16
Right Cabinet
Left Cabinet
Gearbox for felt tension and release
Rotory power for drum heaters
Electrical box
Pressure piston for belt
Belt actuator
Roller tensioners

4.2 Control Panel
Page 17