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.
©2019 A. Adkins & Sons Ltd. All rights reserved. E&OE. V1.0.
Operators Handbook
Rev C - 07/02/19Rev C - 07/02/19

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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.
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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.

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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

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Page 1
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1. Introduction
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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.
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Page 2
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1.1 Machine Benefits
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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.
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Page 3
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1.2 Specifications
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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
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Page 4
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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.
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Page 5
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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.
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Page 6
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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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Page 7
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Installation of Work Table (cont.)
Step 4 Installation of Work Table (20)
Place the metal table onto the installed holder and fasten with
four screws.
Step 5 Installation of the Tension Shaft (17), including the
installation of the Gear Reducer (3).
Install similarly to the Tension Shaft at the top of the machine
but please note that you will need to install the metal plates
on the left and right cabinets first.
Step 6 Install Guide Shaft (19).
Step 7 Adjust the height of the Table with the adjustable feet (8).
Step 8 Check all of the screws and nuts on the machine and
fasten where needed.
NB The Rewind Shafts (15, 16 and 21) can be
removed by pulling on one end and removing
from the other.
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2.3 Installation Notice
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i. Check whether all screws in the machine are loose or not,
tighten them if loose.
ii. As the equipment is heating machinery, the machine should
be used in an environment that is well ventilated, dry and
noncorrosive. Make sure no flammable and/or explosive
materials are located near to the machine.
iii. The machine must be earthed separately.
iv. The main power lead must be of sufficient quality with at
least a 6 mm thickness.
v. While installing the machine every effort should be taken to
keep the machine level. Ideally the machine should be finally
installed with the aid of a spirit level.
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Page 8
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3. Operation Guide
i. Before switching on the machine, make sure that all of the
electrical wires are connected correctly. The body of the
machine must be connected to ground. Press the main power
switch and transform start switch. Then, adjust the rotary
speed on the Speed Adjustor (2) to optimum values. When
the heated roller starts to revolve, press “heating” button (5)
and adjust the temperature to optimum values. (Default
temperature is 220℃ (428°F).
ii. When the machine reaches the pre-set temperature, allow the
thermostat to stabilize the temperature for a while. Check the
transfer results with a small piece of printed transfer paper
and substrate. Adjust the temperature with reference to the
testing result of the transfer.
iii. Place the printed transfer paper and tissue paper in the correct
position (to prevent contamination of the blanket), onto the
working table and main machine. Feed the tissue paper in
first and then the printed transfer paper, taking care to keep
them flat. Then feed the textiles into the machine evenly.
iv. When the tissue paper and the transfer paper exit the rear of
the machine, attach them to their respective collecting rollers.
Then attach the transfer paper to the collection roller at the
front of the machine, under the table so that all materials can
be collected automatically. The speed of collection of the
transfer paper can be adjusted using the controller (7).
v. During the working process, the transfer speed can be
adjusted (by “2”) according to the vividness of the final
sublimated print.
vi. When the transfer cycle is completed, switch off the heating
button to let the machine cool down. The operator should
monitor the machine until the temperature drops to below
80℃ (176°F), at which point the machine can be switched
off. Under special circumstances (including an emergency),
the operator may switch off the main power supply and
heater simultaneously. The machine will cool down
automatically and stop running after approximately 2 hours.
Although this is not recommended during normal use, due to
the potential for damage and/or fire risk.
3.1 Operation Notice
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3.11 Adjustment of Blanket tracking
When working at high temperatures a small amount of
shrinkage is to be expected from a new blanket. To avoid
damaging your new blanket by improper operation, do not
adjust the location of the Tracking Adjusting Roller (45)
within the first two weeks, or the first 100 hours of operation,
whichever is quickest; To adjust the new blanket, reverse the

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Page 9
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Operation Notice (Cont.)
direction of revolution using the Blanket Reverse Switch (18)
until the blanket moves back to the central of the oil drum.
During use the blanket may track to either side, this is a nor-
mal operation and should not be a cause for concern. As men-
tioned above there is a tracking adjusting roller (45) on the
machine.
When the blanket is tracking to the right hand side, increase
the tension of the blanket on the right hand side by a small
amount, or if the opposite is the case, decrease the tension of
the blanket on the left hand side by a small amount.
To control the tension – insert the supplied spanner onto the
end of the Adjusting Rod. Increase the tension by revolving
anti-clockwise, decrease the tension by revolving clockwise.
Please be patient as this adjustment process can take some
time.
3.12 Operation Noise
While heating the rollers and bearing may expand and emit
noise. This is normal and should not be a cause for concern.
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Page 10
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4. Maintenance
4.1 Cleaning
Care should be taken to keep the machine clean and tidy and
to keep the electric circuit box and transducer free from dirt
and dust that may accumulate over time.
NB Do not open the Transformers protective shield
to avoid electric shock.
When cleaning the rollers care should be taken not to scratch
them or use harsh or acidic chemicals.
4.2 Lubrication
All bearings should be lubricated with lithium based, heat
proof grease, with a flash point of not less than 240℃
(464°F).
4.3 Blanket Care
As the blanket is not a warranty part care should be taken in
operation to use best practise.
If there is a power failure or at the end of each working day,
stop the heating and use the separate Hand Wheel to move
the blanket well clear of the oil drum. Insert soft paper board
or individual papers to approximately 2 to 4 mm in thickness
between the blanket and the oil drum; this method should
protect the blanket from burning.
When restarting the machine, care should be taken to remove
the paper board or paper and re-tighten the blanket again us-
ing the separate Hand Wheel.
4.4 Heating Oil Replacement
The Oil Drum is filled with temperature resistant oil which is
rated up to 320℃ (608°F). Replacement should be with
equivalently rated good quality oil.
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Page 11
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5. Machine Drawings and
Diagrams
5.1 General Layout.…………………………………….. 12
5.2 Roller Configurations……………………………… 13
5.3 Control Panel Operation...…………………………. 14
5.4 LH Cabinet Layout.………………………………… 17
5.5 RH Cabinet Layout.………………………………... 18
5.6 Electrical Diagram.………………………………… 19

5.1 General Layout
Page 12
No. Part Name
1 Shaft Pin and Chain
2 Barrier Paper Shaft
3 Gear Reducer
4 Cabinet Door
5 Name Plate
6 Cooling Fan
7 Castor Wheel
8 Adjustable Foot
9 Shaft Pin and Chain
10 Transfer Paper Loading Shaft
11 Table Leg
12 Structural Bar
13 Fabric Loading Shaft
14 Tensioner
15 Transfer Paper Rewind Shaft
16 Fabric Rewind Shaft
17 Fabric Tension Shaft
18 Drum Direction Switch
19 Guide Shaft
20 Work Table
21 Barrier Paper Rewind Shaft
22 Drum Speed Controller
23 Roller Speed Controller
24 Temperature Controller
25 Main Power Button
26 Temperature Start Button
27 Structural Bar
28 Blanket
29 Transfer Paper Guide Bar
30 Separation Shaft
31 Emergency Stop Button
1
25
18
28
4
22
30
23
24
26
6
15
21
7
8
9
10
12
13
14
17
19
20
29
11
2
27
16 331
5

5.2 Roller Configurations
Page 13
4
3
8
2
1
5
6
7
No. Part Name
1 Barrier Paper Charge Roller
2 Tensioning Bar
3 Work Table
4 Fabric Charge Roller
5 Transfer Paper Charge Roller
6 Transfer Paper Exhaust Roller
7 Fabric Exhaust Roller
8 Barrier Paper Exhaust Roller

5.3 Control Panel Operations
Page 14
PV
°C
SV
CHB402
°C
AT OUT1
ALM
OUT2
SET
TEMPERATURE CONTROLLER
Operation Procedure
1. Power up the machine at the mains supply switch.
2. The controller displays the set temperature SV (set value) in green
digits 0 in red digits PV.
3. To change the SV (set value) press the SET button displays Su in
red. Use the up and down buttons to change the set temperature,
once correct value is shown press SET to update controller.
4. Press HEAT button to switch heating elements on.
5. Press POWER button.
6. Press transform button.
NB.
IT IS VERY IMPORTANT THAT THE DRUM IS REVOLVING ONCE
THE HEATERS ARE SWITCHED ON.
WITH THE TEMPERATURE ABOVE 100°C AND THE DRUM NOT
TURNING THE FELT BELT WILL BE DAMAGED BEYOND REPAIR.
This is located at the front of the left hand cabinet and controls the temperature of
the drum.

Control Panel Operations (Cont.)
Page 15
Operation Procedure
1. On powering up the machine at the mains supply switch the
controller displays the last speed setting used.
2. To change the speed setting turn the knob shown clockwise to
increase speed and anti-clockwise to reduce speed.
3. To start the roller press the FWD button.
4. To stop the roller press the red STOP button.
5. To reverse the roller press the REV button.
* The MODE and ENTER buttons should not be used as these are
factory set.
Conveyor belt speed controllers
This is located at the rear of the left hand cabinet and controls the speed of the
conveyor belt.
It is operated in the same way as the fabric charge roll controller.
The Fabric charge speed controller is located at the front of the left hand cabinet
and controls the speed of the fabric charge roller.
Fabric Charge Speed Controller
REV STOP FWD
MODE ENTER
MCU
Inside
Digital Technology
0
2
46
8
10
ROLLER SPEED
REV STOP FWD
MODE ENTER
MCU
Inside
Digital Technology
0
2
46
8
10
DRUM SPEED
STOP FWDREV
MCU inside
JSCC
®
MODE ENTER
Digital Technology
0
28
10
46
Digital Technology

Control Panel Operations (Cont.)
Page 16
DRUM START
TEMPERATURE START
POWER START
Operation Procedure
1. On powering up the machine at the mains supply switch the
controller displays the last speed setting used.
2. To change the speed setting turn the knob shown clockwise to
increase speed and anti-clockwise to reduce speed.
3. To start the roller press the FWD button.
4. To stop the roller press the red STOP button.
5. To reverse the roller press the REV button.
* The MODE and ENTER buttons should not be used as these are
factory set.
Xxxxxxxx x xxxxxx xx xxxxx xxxxx xxxx xxx xxxxxxx xxxx. Xxxxxxxx x
xxxxxx xx xxxxx xxxxx xxxx xxx xxxxxxx xxxx.
Power Start, Temperature Start and Drum Start Buttons