DMS FR Series User manual

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FO OI IL L H HO OT T S ST TA AM MP PI IN NG G U UN NI IT T M MA AN NU UA AL L " "F FR R" "
"FR" MODEL SERIES
Generic Email Version
1155 Rose Road
Lake Zurich, IL 60047 US

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Corporate Headq arters
DMS, Incorporated
1155 Rose Road
Lake Z rich, IL 60047
Phone: [phone]
Fax: [phone]
Toll Free Sales and Technical S pport
800-655-7882
Foil Hot Stamp Unit Information
Hot Stamp Unit Model Number FRXXXYYY
Hot Stamp Unit Serial Number Generic
Foil Printing Controller Model Number HP-3002
Foil Printing Controller Serial Number C-XXXX
TorKit Die Pressure Gauge Serial Number T-XXXX
Factor Ship Date 1/20/06
Notes

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Contents
I. Introduction…………………………………………………………………………………………3
II. Unpacking and Inspection…………………………………………………………………………..4
III. Press Preparation……………………………………………………………………………………5
IV. S stem Assembl ………………………….………………………………………………………..6
V. S stem Startup and Adjustments………………………………………………………………...…8
VI. S stem Maintenance………………………………………………………………………………11
VII. Notes………………………………………………………………………………………………12
Appendix A: Illustrated Parts List…………………………………………………………………….……14
Appendix B: Hot Stamping Tips & Tricks…………………………………………………………………18
Appendix B: MSDS-Material Safet Data Sheet..…………………………………………………………21

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Section I: Introd ction
Thank ou for choosing the foil printing s stem b DMS, Incorporated. The s stem described in this manual is the result of
thousands of combined man-hours of practical experience, along with extensive research and development in foil printing
applications.
Please stud this instruction manual thoroughl before attempting to assemble or operate the s stem. Personal injur or
damage to s stem components could result from not following instructions completel .
Over the ears, the field of foil printing has grown in diversit and, in man cases, complexit . Due to this fact, we could not
possibl cover ever potential application with this manual. The manual has been written in ver basic, outline form, with an
attempt to cover as much ground as possible for the foil-printing newcomer. We encourage ou to call DMS with an
questions ou ma have concerning job set-ups, foil selection, job feasibilit , etc.
Foil printing newcomers ma wish to begin b reviewing APPENDIX B: HOT STAMPING TIPS & TRICKS, for an
overview of foil printing.
Veteran users of DMS foil printing s stems should note that several new features have been added to our s stem control unit
and die shaft assembl , which should be reviewed before set-up.
Thank ou for making DMS, Incorporated our source for foil printing equipment!

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Section II: Unpacking and Inspection
Upon receiving the s stem, please be sure to check all cartons and crates carefull for the following components:
Quantity
Description Shipped Part Number Serial Number
1. Temperature Control Unit 1 HP-3002 C-XXXX
• Unit comes with handle and locking knobs.
2. Die Assist Assembl 1 FRXXXYYY-DA XXXXXX
3. Upper Die Shaft Assembl 1 FRXXXYYY -U XXXXXX
4. Lower Base Roll Assembl 1 FRXXXYYY -L XXXXXX
5. Accessor Tool Box 1 FRXXXYYY -T N/A
6. Spare Parts Package 1 FRXXXYYY -SP N/A
7. TorKit Die Pressure Gauge 1 TK2000 T-XXXX
It is a good practice to keep the cartons and crates that the s stem is shipped in to reuse them if the s stem ever needs to be
returned for service. Please notif DMS upon arrival if there are an possible omissions or damage to the s stem during
shipping and handling.

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Section III: Press Preparation
1. In order to automaticall raise the base roll when the press runs, the HP-3002 temperature control unit needs to be
supplied with a source of power when the press is in “RUN” mode only. This source of power is referred to as the slave
line. Power for the slave line ma be 90-280 volts A/C. There is no appreciable load on the slave line and #16/2 wire
ma be used for this connection. A mini twist-lock connector is included for proper connection to the temperature
control unit.
2. Main s stem power supplied to the control unit must be rated at 30 amps, 208-240 volts, single phase, A/C. The suppl
circuit must be fused for 30 amp service, and #12/3 wire is recommended for this connection. The control unit must be
properl grounded to reduce the risk of electric shock hazard. A 30 amp twist-lock connector is included for proper
connection to the control unit.
3. Air supplied to the control unit must be clean, dry, and reg lated to 80-100 p.s.i. Air/line connectors are included for
proper connection to the unit.
4. The base roll assembl supplied with the s stem should be test-fitted in the intended die station. Position the base roll
assembl in the station and check for interference and proper alignment with the die station drive-gear. Proper fit and
drive gear mesh are critical elements in the s stem. The base roll should sit level in the station, and the drive gear should
not bottom out into the base roll gear.

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Section IV: System Assembly
A. Assembling Roll Die to Die Shaft:
(applies only to 13” systems and above, for 10” systems see “Ill strated Parts” section).
1. On a clean, level bench; prepare the die for assembl b gentl placing it in the “V” blocks provided. Ensuring the
blocks are located under the bearers of the die and not on the image.
2. Remove the bearing block from the press side of the die shaft assembl and set the block aside.
3. Slide the shaft assembl into the die and align slots in the die bearer and hot stamp journal.
4. Install the three (3) or four (4) 10-24 socket head cap screws supplied and tighten thoroughl .
5. Re-assemble the bearing block onto the end of the die shaft.
B. Assembling Components in Die Station:
1. Install the base roll assembl into the station to be used, and check for proper drive gear mesh.
2. Install the die shaft assembl in the station, making sure the proper gear mesh is achieved.
3. Install the die assist assembl in the station checking for the correct bearing alignment with the hot stamp die.
4. The lateral register adjusting plates have been left at their outermost (loosest) position to facilitate an eas first time
fitting in the station. To adjust these plates, appl slight outward pressure to the shaft assembl and adjust the plates
for a snug slide fit on the side frame. Be sure retaining screws are tight.
5. Install pressure screws in the usual manner. Do NOT attempt to tighten the pressure screws until the hot stamp die
has reached its operating temperature. The hot stamp die operating temperature will be specific to each run job and
die.
NOTE: No more than 300 lbs./side of pressure should be applied at an given time. Excessive pressure will result in
premature bearing failure and possible tooling damage.

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Section IV: System Assembly
C. Connections:
1. Position the HP-3002 temperature control unit on a flat, level surface near the intended station and within eas reach
of the operator.
2. Connect power cord to die shaft assembl b inserting plug into receptacle and turning clockwise to lock. Repeat
procedure at control unit.
3. Connect air lines labeled “A” and “B” to their corresponding outputs on the control unit b pushing line squarel
and firml into fitting. Repeat procedure at respective fittings on base roll actuator.
4. Connect air line labeled “C” to the cooling output on the temperature control unit. And to the air inlet on the die
shaft assembl .
5. Connect the infrared thermocouple lead to the socket on the control unit, aligning the wide and narrow blades of the
plug with their corresponding slots in the socket.
NOTE: Please be sure to route all cables and air lines carefull ! Personal injur and/or damage to the equipment could
result from lines or cables becoming caught in moving parts!
D. Thermoco ple Positioning:
1. Gentl insert thermocouple into mounting block b rotating the block around the thermocouple until it is full
threaded into the block.
2. Carefull snap the mounting block into the die assist assembl b inserting the “C” channel end of the block around
one die assist shaft, then rotate the block down to lock into place against the opposite shaft.
3. Once the thermocouple has been properl mounted on the die assist assembl , it should slide smoothl along the die
assist bar.
4. Position the thermocouple as far at an angle that the brackets will allow with the tip of the sensor targeted at the
black stripe located on the hot stamp die. If the thermocouple is not targeted at the black stripe on the die it will not
accuratel read the die temperature which will result in poor print qualit .
NOTE: This is an extremel important element in overall print qualit ! An improperl positioned thermocouple can, and
will, cancel all attempts to attain print qualit and consistenc ! Please remember that the thermoco ple m st be pointed
directly at the black stripe on the die to work properly.

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Section V: System Start p and Adj stments
NOTE: Foil positioning, tension, and process temperature will all var somewhat depending on differences in print patterns,
substrates, press speeds, foil performance, etc. Some experimentation ma be necessar to obtain the best results with our
application. For the reasons listed above, the following instructions have been left intentionall brief.
1. Web press as usual, then web the foil from the unwind through a web idler approximatel 3-5 inches ahead of the station,
then along the web through the die and base roll. Strip the foil about 2-3 inches after the die and to the waste wind-up.
The foil should lie flat against the web as it enters the die, with little or no wrinkling during operation. The distance
from the die where the foil joins and leaves the web will var according to the actual application, but the foil needs to be
“paced” with the web at some point, to keep the foil from traveling faster than the web. See Figure 1 and Figure 2 on the
following pages for a basic webbing diagram.
2. Make sure the MAIN POWER switch is in the “OFF” position. Connect the power to the control unit and turn the
MAIN POWER switch to the “ON” position. After an initial diagnostic check, the temperature control module will
displa the current set point in the middle displa and the current die temperature in the upper displa .
3. Set the desired process temperature (consult our foil manufacturer) b pressing the UP or DOWN buttons until the
desired temperature appears in the “SET” displa . Press the ENTER ke to lock in the new set point. If ou do not press
the ENTER ke within 5-10 seconds after ke ing in a change, the control module will return to the previous set point.
4. As the die nears the set point, run the press at 50-75 FPM. Turn the impression mode switch on the control unit to the
“AUTO” position and observe the action of the base roll to be sure it rises to the print position.
5. Bring the die into contact with the web and appl slight pressure with the pressure adjusting screws. Note print qualit
and current die temperature. Lock pressure-adjusting screws, but do not over tighten.
6. Adjust an other press operations as necessar , in accordance with standard operating procedures.
7. After all other press operations have been adjusted for qualit and register, graduall increase press speed, adjusting
pressure and temperature to maintain foil print qualit .

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Section VI: System Maintenance
A. Base Roll Assembly
1. Dail
a. Inspect base roll for damage or excessive wear. Clean an foil adhesive build-up with solvent on a soft cloth.
b. Inspect die drive gear for proper lubrication and excessive wear.
B. Die Shaft Assembly
1. Dail
a. Inspect the die mounting screws for loose connections and tighten if necessar .
b. Inspect drive gears for excessive or abnormal wear.
2. Weekl
a. Inspect shaft bushings for excessive wear or cracks due to shock. The shaft assembl needs to be returned to
DMS to have new bushings installed, as special tools and fixtures are required for this procedure to ensure
proper operation.
b. Inspect connections for loose or damaged parts.
c. Inspect lateral register assembl for proper fit in the press.
d. Inspect operator side bearing block for oil once a month, block takes 1 oz of Mobile # 1 oil , do not add more
than the 1 oz. required limit for the block.
C. Die Assist Assembly
1. Dail
a. Inspect cam followers for proper lubrication and excessive wear.
b. Add high temperature grease (+550 °F) to cam followers after ever 4-6 hours of run time. Use ONLY DuPont
Kr tox® GPL-407 high temperature grease. Failure to do so will void warrant , damage cam followers, and
degrade performance. DMS includes one cartridge in the accessor box.
c. Check infrared thermocouple sensor for proper position or possible damage.
d. Make sure infrared thermocouple sensor is clean and free of dirt and grease.
D. Control Unit, Hoses and Cables
1. Weekl
a. Inspect hoses and cables for damage.
b. Make sure all connections are secured and locked.

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APPENDIX A
Illustrated Parts List

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APPENDIX B
Hot Stamping Tips & Tricks

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Appendix B: Hot Stamping Tips & Tricks
A. Abo t Foil Printing
Rotar foil printing is accomplished b laminating a roll leaf material to the web. B running the two materials through a
station that has a heated, engraved impression die and a suitable base roll, and then stripping the roll leaf material from the
web; leaving the transferred image on the substrate and rewinding the waste foil.
In the DMS Foil Printing S stem, the die is a CNC and/or photo engraved hand-finished brass roll. The die is mounted on a
custom-engineered shaft/heater assembl .
The base roll assembl uses a hard (90-100 durometer) base roll mounted on an eccentric shaft within the intended die station
and a pneumatic rotar actuator outside the station, connected to the shaft. The base roll is rotated up into print position onl
when the press and the HP-3002 control unit are in “RUN” mode.
The s stem control unit, using a microprocessor based temperature control module and solid state rela , controls the
temperature and base roll actions.
Signals are received b the control unit from an infrared thermocouple mounted on the die assist and from the “RUN” circuit
of the press run rela through a “slave line”.
B. Abo t Roll Leaf (foil)
The foil used in hot stamping toda is usuall an extruded film carrier with several la ers coated on one side. These la ers
consist of a release agent, a pigment (or pattern of pigments), and an adhesive agent (often referred to as “sizing”). The
formulation of these la ers varies depending on the application.
During the foil printing process, heat from the die travels through the foil la ers, activating the release agent and sizing
simultaneousl , which causes the transfer of material from carrier to substrate. The performance of these two la ers together
give the foil it’s specific traits, such as how long the foil needs to be left on the web before it is stripped and where the
stripping idler is placed.
The three factors that affect foil transfer the most are: heat, dwell, and pressure.
Below a certain heat threshold, the reactions necessar for proper release will not occur consistentl , and poor print qualit
will result.
Dwell is the amount of time the transfer has to occur between the die and base roll. The greater the web speed, the less time
(dwell) the transfer has to take place. Increasing die temperature will compensate for reduced dwell, to a point, but there are
ph sical limits to how fast heat can travel from the surface of the die through the foil. Foils that will accept a short dwell are
considered “loose”, while foils that require a long dwell (or high heat) are considered “tight”.
A certain amount of pressure is needed to aid the release action of the foil, but generall not enough to deform the substrate
substantiall . Image size and configuration will affect pressure requirements almost as much as foil sizing and release
properties.

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Appendix B: Hot Stamping Tips & Tricks…contin ed
C. Abo t Temperat re Control
Rotar foil printing is a fairl demanding application for temperature control. Most temperature control applications are
much more “stable” in that the don’t have as man s stem variables. Die size, web speed, substrate used, and impression
size all affect how quickl heat is dissipated from the die surface.
In the DMS Foil Printing S stem an infrared thermocouple is used to sense the die temperature. It is important to note that
the thermocouple sensor must be located directl over the black stripe on the surface of the hot stamp die.
If ou notice a rapid change in the indicated temperature while running a job, immediatel check the thermocouple sensor for
proper position, insulation from ambient air, etc., as it is impossible for the die itself to change temperature ver quickl .
D. Abo t Handling Foil
It is most common to use the existing laminating unwind and waste rewind for controlling the foil web. Naturall , ou will
want to match the length of the foil rolls to the substrate rolls whenever practical, to help cut down on press down time and
make the job run as economicall as possible. Your own requirements will determine which set-up is best for ou.
• Foil build-up (from burning the foil) is hard material. If left on the surface of the die during a run, this build-up can dent
the surface of the die, causing permanent damage. Build-up can be removed b using the supplied cleaning brush, wood,
or lead to scrape the surface of the die. Return the die to DMS if there is an fear of damaging the die.
• Foil tension should be kept fairl light, compared with web tension. Foil tension affects release action. Excessive foil
tension will adversel affect release action of the foil, while too little tension will cause wrinkling.
• If ou’re having problems with foil release, tr stripping the foil a little closer or farther awa from the die. Some
substrates require as much as 8-10” of cooling area before stripping the foil.
• Foil strips better (cleaner) when a small diameter roller strips it. Knife-edges are also sometimes used.
• Depending on the size of the roll, side plates ma be desirable on the foil to prevent telescoping while unwinding and to
provide better tension control.
E. Abo t Handling Dies
• Alwa s use the wooden “V” blocks to temporaril store or assemble dies.
• Use the shipping crate to store dies and prevent damage.
• Never use abrasive cleaners on dies.
• If die becomes tight on shaft, warm the die to 150-200 °F, then tr disassembling. Have the die resized ASAP.
• If the die is brushed periodicall during a job (ever 15-20 min.), print qualit and consistenc will be improved.
• Remember to keep the black stripe on the die clean.
• Insulated welding gloves are great if ou plan to handle hot dies regularl .