Insta 1020 User manual

MNL1020 Rev. F 08.07.19
OPERATION AND MAINTENANCE MANUAL
MODEL 1020

FOR USE BY QUALIFIED PERSONNEL ONLY
WARNING
In case of power cord damage, do not
attempt to repair or replace the power cord.
Contact the manufacturer or the local
distributor.
WARNING
This machine uses two fuses to protect
against fire and electric shock. Use the same
type replacement fuse rated at 3A, 250V as
specified on the label next to the fuse.
WARNING
Hot Surface. Avoid contact.
CAUTION
To reduce the risk of electric shock and
injury, turn the machine off and disconnect
the machine from the power supply before
servicing and/or cleaning.
CAUTION
The recommended air pressure shall not
exceed 85 psi (5.8 Bar). The operating
pressure is from 75 –85 psi.
CAUTION
In case of emergency, use the Emergency
Stop switches to stop machine movement.
CAUTION
During normal operation, the machine
should have at least 40 inches of clearance
on all sides.
Safety Summary
Power Off
Power On
Hot Surface
Risk of Electrical Shock
Protective Earth Terminal
Ground
Start Action
Caution - Warning
International Symbols
1

FOR USE BY QUALIFIED PERSONNEL ONLY
Congratulations!
Your selection of the Insta heat seal machine is a sound business decision. Insta equipment is the
result of the highest quality engineering and time-tested design. Your new machine combined with
Insta’s reputation of innovation in the heat-sealing field, ensures the continuing capability of delivering
the best decorated substrates possible.
This manual describes installation, operation, and maintenance procedures for your 1020 machine, as
well as easy to use instructions for preventive and routine maintenance.
Your machine will have a long trouble-free life. Read this manual and keep it with your machine. It's
your key to proper operation and lasting service. Check the Insta website www.instagraph.com for the
current version of user manual.
General Description
The 1020 is a large format machine capable of pressing multiple and large articles all in one cycle
across a 47.2” x 39.4” platen. It is capable of generating and evenly distributing large pressure
throughout its platens. It features dual stations that consist of two alternating trays operating in either
manual or automatic mode for mass production. The heat platen features cast-in tubular heating
elements to deliver rapid heat recovery and uniform temperatures.
Please fill out the following for future use:
MODEL NO:
SERIAL NO:
MANUFACTURE DATE:
PURCHASE DATE:
PURCHASE VENDOR:
2

FOR USE BY QUALIFIED PERSONNEL ONLY
IP21 = IP
1st Digit 2
2nd Digit 1
Degree of Protection
IP (Ingress Protection) rating according to IEC
60529.
NOTE
IEC 60529 does not specify sealing
effectiveness against the following:
mechanical damage of the equipment;
the risk of explosion; certain types of
liquid conditions, e.g. those that are
produced by condensation; corrosive
vapours; funus; vermin
Installation
WARNING:
This machine must be installed by a
licensed electrician. DO NOT attempt
to install this machine by unqualified
personnel.
IIMPORTANT
This machine does not come with a
plug and must be wired into a proper
receptacle per local electrical codes.
Air Compressor
A minimum of 3HP air compressor
with a rating of 20 gallons or 9 CFM is
required to operate this machine.
Shop air is recommended.
Electrical Wiring
Minimum AWG #12 UL rated
electrical wires shall be used for
external power connection.
1st Digit
Protection
from solid
objects
2nd Digit
Protection
from
moisture
0
Not
protected
0
Not
protected
1
Objects
greater
than 50 mm
1
Dripping
water
2
Objects
greater
than 12 mm
2
Dripping
water when
tilted up to
15°
3
Objects
greater
than 2.5
mm
3
Spraying
water
4
Objects
greater
than 1 mm
4
Splashing
water
5
Dust
protected
5
Water jets
6
Dust tight
6
Heavy seas
--
---
7
0.15 m –1
m
immersion
--
---
8
+1 m
submersion
Specifications
Voltage
208~230 Volts AC, 3
Phases (+Ground)
60 Hertz
Model 1020
9000-10000 Watts
44~48 Amps *
Weight
1874 lbs
(850 kg)
Machine Placement
3
*The specifications above were determined by a third party
certifying agency.
For installation purposes Insta recommends the following:
Voltage Requirement 3 Phase 208~230 VAC @ 60 Hz
Fuse per Phase Rated 30 Amps

FOR USE BY QUALIFIED PERSONNEL ONLY
Operating Environment
To maximize user safety, ensure that the
following operating conditions are met:
3. The machine has enough clearance, at least 40 inches on
all sides and 60 inches between machines.
4. The workspace does not restrict access to the main power
switch or power cord.
5. The workspace is free of any forms of liquid.
6. The power cord is not over-extended. Taking these steps is
crucial in maximizing user safety and ensuring a long,
trouble-free life for your machine!
1. The machine is placed on a flat, even, and
non-flammable surface.
2. The machine shall be located in a dry
working environment.
Hot Surface. Avoid
contact with upper platen
and housing. Keep
hands clear from this
area when in use.
Hot surfaces- do not
touch or place any
objects on top
Emergency Stop
Machine should
operate on a solid and
leveled surface.
Moving stations. Keep
hands clear between
moving parts when the
machine is in operation.
Electronic access panel is
located in the rear of the
machine. Do not open when
the machine is power on.
Safety and Danger Zone Diagram
4

FOR USE BY QUALIFIED PERSONNEL ONLY
Air Source Connection
Connect air source hose to the inlet port of the
pressure regulator. The machine comes with
standard industrial ¼” quick connection male
coupling.
Machine installation requires at least two (2)
persons. Do not attempt to install machine alone.
Installation requires a Phillips head screwdriver and
a set of metric Allen wrenches.
In order to be able to move the machine with the
casters, the stand legs must be retracted. Use a
forklift to raise machine 6 inches off the floor, and
use a wrench to retract all four stands. Then slowly
lower the machine so is sitting on all four (4)
casters. Using at least two persons push the
machine to the desired location. Use caster locks to
keep the machine from further moving. Extend the
stand legs to secure the machine in place.
Electrical connections must be made by a
licensed electrician. DO NOT attempt to install
this machine with unqualified personnel.
Factory Electrical Requirements
Voltage
Requirement
3 Phase 208~230 VAC @60 Hz
Wiring
Requirement
Minimum AWG #12 Gauge
Fuse or
Breaker per
Phase
Minimum 25 Amp Rating
Wiring Declaration
Blue/Red/Black
Phase Line (Live)
Green
Ground Line
Machine Installation Instructions
5

FOR USE BY QUALIFIED PERSONNEL ONLY
Emergency Stop Buttons
There are two (2) Emergency Stop buttons. They are
located at each end of the front console. In case of
emergency, buttons stop all machine movement and release
air pressure inside the cylinders. When the emergency stop
button is pressed;
1. Manual, Auto, and Start buttons are disabled.
2. Motor stops and so does all shuttle movement.
3. Air directional valve is disabled. Air pressure will bleed
off from the two air cylinders. The lower and upper
platens gradually return to the full open positions.
4. To cutoff all electrical power, turn off the power switch
located in the front control panel or turn off the main
power disconnect from the factory.
To disengage the emergency mode:
1. To prevent accidental movement of the machine, it is
important that the machine control is configured to the
manual mode before the emergency stop is released.
2. Switch Manual/ Auto to Manual.
Auto Start is up for “Once”.
3. Press and turn the emergency stop button clockwise until
the button is completely released from the lock position.
Use either Up Platen or Bottom Platen button to move
the platens back to ready position.
Note
The emergency stop switches do not
cutoff the electrical power to the
control panel and heaters.
Note
Auto Start “Repeat” mode enables
machine to resume the last incomplete
cycle when the emergency stop button
is unlocked.
Hi Temperature Shut Off
The MS1020 is protected from the platen overheating
to temperature above 482°F (250°C). Beyond this
safety temperature, the machine will automatically
cutoff all electrical power to the heaters and the Heat
button on the control panel will no longer light up.
When this happens, turn the power switch to the Off
position, and allow the machine to cool down below
200°C.
Then turn the power switch back to the On position and
press the Heat button.This should reset the overheat
protection switch and the heating function resumes.
If the overheat issue continues, stop the machine and
contact Insta Service Department for assistance.
Machine Safety Features
6

FOR USE BY QUALIFIED PERSONNEL ONLY
Belt Tension
1. Locate the two bolts on the front and the side of each
rail enclosure. These bolts control the belt tension.
2. To adjust belt tension, first slightly loose the side bolt
until it is free to move. Do not take the bolt out of its
seat.
3. Next, turn the front bolt using an Allen wrench to
adjust the belt tension.
4. Turn clockwise to tighten the belt and
counterclockwise to relax.
5. Once adjustment is made, tighten the side bolt.
Pressure Setting
1. Locate the air regulator assembly on the left side of the
machine.
2. Pull the air regulator knob up.
3. Turn the air regulator knob clockwise to increase
pressure, or counterclockwise to decrease pressure.
4. The pressure setting is displayed on the pressure gauge.
5. When the operating pressure is set, push the air
regulator knob down until it locks.
Motor Speed Setting
The motor speed control panel is located at the rear of the
machine. Use the On/Off switch to turn on the motor.
1. Use the speed control knob to adjust the motor speed.
An increase motor speed means a faster platen travel.
NOTE
The suggested operating pressure ranges
between 75 –85 psi.
Low pressure setting may result in poor
printing and longer cycle times.
Do not operate the machine at more then
100 psi.
Machine Setting
Upper Platen Teflon Sheet*
1. Remove both side panels.
2. Locate the four (4) screws that are used to increase
or decrease the slack of the upper platen Teflon
cover.
3. Turning clockwise makes the sheet tighter and vice
versa.
*not available on all models
7

FOR USE BY QUALIFIED PERSONNEL ONLY
Digital Controller
This controller has five (5) control features:
1. Temperature Scale
•User can choose to read temperature in °C or °F
2. Temperature Setting
•User can set heater temperature up to 225°C or 437°F.
3. Timer
•User can set cycle time from 001 to 999 seconds.
4. Cycle Counter
•Cycle counter can count up to 999 cycles. To reset,
press and hold the Reset button for 10 seconds.
5. Optional Offset Setting
•There are two levels of temperature offset settings. Both
settings are pre-calibrated in factory. Do not alter these
settings unless otherwise directed by the manufacturer
service personnel.
Machine Control Setting
Controller Readout
•OK: Main button to scroll through 3 control
settings.
Temperature Scale ►Temperature Setting ►Timer
►Confirm
•▲and ▼: Increase or decrease number.
•Reset: Reset cycle counter to zero.
•PV: Present Value
•SV: Set Value
•COUNTER: Number of press cycles since last reset.
Controller Setting
•Temperature Scale
a) Press the OK button, either the “°C” or “°F”
icon starts blinking.
b) Press ▲or ▼to change to “°C” or “°F”.
•Temperature Setting
c) Press OK again to set the transfer
temperature. Press ▲or ▼to increase or
decrease the temperature. Hold ▲or ▼for
faster change.
•Timer
d) After setting the temperature, press OK to set
the transfer time. Press ▲or ▼to increase
or reduce time.
NOTE:
The cycle time shall be added an additional 5
seconds to compensate the time required to
raise the platen upward before the substrate
seeing any temperature and pressure.
8

FOR USE BY QUALIFIED PERSONNEL ONLY
Optional Temperature Offset Adjustment
1. To adjust the temperature offset, press and
hold the OK button for 2 seconds until the
screen displays P-1 and the current
temperature. The bottom row displays the
current offset setting in green color.
1. If the display temperature is lower than the
measured temperature, increase the offset
by the same amount. This is done by
pressing the ▲to increase the display
temperature.
2. If the display temperature is greater than the
measured temperature, decrease the offset.
This is done by pressing the ▼to decrease
the display temperature.
Machine Setting
Optional Temperature Control Adjustment
1. Press the OK button and scroll to the next P-
2 screen. The default setting of P-2 is 003.
This setting allows factory personnel to fine
tune the heater temperature accuracy
pending on user’s heating requirements. Do
not attempt to alter the default setting without
consulting with Insta Service Department
personnel.
9

FOR USE BY QUALIFIED PERSONNEL ONLY
6. Press the Manual Start button to activate the pistons
and raise the work station. The timer then starts its
countdown and beeps 3 seconds before completion.
7. After the press is complete, the work station is
automatically lowered. Press/hold either Up Plate or
Bottom Plate button to retrieve the work station in
ready position.
Machine Operation Mode
Make sure the machine is properly installed before use. The machine will not operate without air
pressure and correct power source (3 Phase + Ground). Make sure the electric motor is turned on.
Manual Mode Operation
1. Turn ON/OFF switch to ON position.
2. Turn the Auto/Manual switch to Manual. When in
Manual mode, the two green start buttons in the front
console are de-activated.
3. Allow the machine to warm up to the set temperature.
A buzzer will sound when the temperature reaches to
the set temperature. The buzzer will continue until a
press cycle is initiated.
4. Place the substrate on the working station and smooth
out all wrinkles.
5. Press either the Up Plate or the Bottom Plate button
to feed the external work station into the heat press
chamber. Press and hold the button until the moving
work station has completely stopped.
NOTE:
Heating may take anywhere from 45 –60
minutes depending on the set temperature.
Do not leave the machine unattended at
anytime.
CAUTION
Keep hands clear of gaps when the machine
is in operation. See Pg. 4 for Machine Safety.
Note:
During the press cycle, you may hear sounds
of springs compressing. This is normal since
the upper platen is attached with springs that
produce a squeaking sound when they are
compressed.
10

FOR USE BY QUALIFIED PERSONNEL ONLY
Auto Start- Repeat (Fully Auto Mode, continuous cycle)
1. If the machine is at the Manual mode, make sure both
work stations are in their full stop positions on both
ends. Use Up Plate or Bottom Plate button to move
them to their full stop positions if needed.
2. Select Auto Start button to Once. The button shall be
in the up position.
3. Turn the Auto/Manual switch to Auto.
4. Select the Auto Start button to Repeat. The button
shall be in the down position. The auto cycle starts
immediately.
5. If the machine is at the Semi Auto mode, select the
Auto Start button to Repeat. The auto cycle starts
immediately.
6. To come out of the Auto Start- Repeat Mode, do any
of the followings:
a. Turn Auto/Manual to Manual
b. Select Auto Start to Once
c. Use Emergency Stop buttons
Machine Operation Mode
Auto Start Mode Operations
Auto Start- Once (Semi Auto Mode, one cycle at a time)
1. Turn ON/OFF switch to ON position.
2. Select the Auto Start button to Once. The button
shall be in the up position.
3. Turn the Auto/Manual switch to Auto. The two Start
buttons at the front console are now activated.
4. Press the two (2) Start buttons on the console to start
one (1) press cycle. The external work station will
shuttle into the chamber while the other station is
coming out simultaneously. The heat press then starts
automatically. When the press cycle is complete, the
work station is lowered and stays inside the chamber.
Press the two Start buttons again to repeat the press
cycle.
CAUTION
Keep hands clear of gaps when the machine
is in operation. See Pg. 4 for Machine Safety.
NOTE
In the situation of an emergency, press the
Emergency Stop buttons on the front console
of the machine.
NOTE
The shuttle trays must fully retract before
Auto Mode can be activate. If the trays is not
fully retracted put the machine back to
Manual mode. Then fully feed either the top
or button tray into position. Restart Auto Start
Process.
11

FOR USE BY QUALIFIED PERSONNEL ONLY
Preventive Maintenance
1. To prevent the substrates from becoming soiled,
periodically wipe the entire exterior of the machine,
including the platens, with a clean rag. If necessary, use
mineral spirits for cleaning a cooled down machine.
Since mineral spirits are flammable, do not clean with
mineral spirits while the machine is hot.
2. Avoid pressing items such as buttons, pins, snaps, or
zippers that tend to cut the pad or scratch the heat platen
and Teflon cover.
3. Periodically lubricate the transmission, joints, bearings,
and air regulator with a high-temperature, non-melting
grease (MPPL023).
4. Periodically check the level of the air pressure regulator
lubricant. If there is an insufficient level, add more. This
will help lubricate the piston and solenoid. Oil rated IS0-
VG68 or ISO-VG32 is recommended.
5. Air pressure regulator: Avoid area with direct sunlight;
impact blow or temperature outside of the rated range.
6. Do not expose or clean filter bowls with detergents,
chlorinated hydro-carbons, keytones, esters, or certain
alcohols.
7. Do not expose the bowls or air pressure regulator in air
systems where compressors are lubricated with fire
resistant fluids such as phosphate ester and di-ester
lubricants.
8. Remove excessive dirt, grime, and clutter from work
area.
9. Periodically check for leaks from the pistons, air
regulators, and hoses.
10. Periodically check the tension of the synchronous belt.
11. Turn off air pressure when machine is not being used.
12. Once a week check the air regulator for moisture and
drain if needed. To drain the water, first place container
under the bowl and disconnect the air as indicated in the
picture. Make sure to have the container in place before
disconnecting air; the water will drain as soon as air is
disconnected.
Make sure water does not get onto electrical
wires/connectors.
NOTE
Wipe off any excess oil or grease.
General Maintenance
It is recommended that you have the following
items available:
a) Regular screw driver
b) Phillips head screw driver
c) Small adjustable wrench
d) Needle nose pliers with insulated handle
e) Set of metric Allen wrenches
f) Grease gun
g) Special high temperature grease MPPL023
Machine Maintenance
WARNING:
Do not attempt to remove the upper
platen without proper equipment.
WARNING:
Do not attempt to service or repair
machine while it is still hot and
powered.
12

FOR USE BY QUALIFIED PERSONNEL ONLY
1020 Explosion View
ITEM NO.
PART/ASSY. NO.
DESCRIPTION
QTY.
A1
MACHINE COVER ASSEMBLY
1
A2
CONTROLLER BOX ASSEMBLY
1
A3
UPPER PLATEN ASSEMBLY
1
A4
SHUTTLE TRAY ASSEMBLY
2
A5
PISTON ASSEMBLY
2
A6
SHUTTLE ARM ASSEMBLY
2
1
MH004-008
EMERGENCY BUTTON
2
2
MH004-009
MOMENTARILY BUTTON
6
3
MP1020-002
AIR REGULATOR ASSY
1
15

FOR USE BY QUALIFIED PERSONNEL ONLY
1020 Explosion View
16
ITEM NO.
PART/ASSY. NO.
DESCRIPTION
QTY.
A7
ELECTRICAL BOX ASSEMBLY
1
A8
MH007-035
AUTOMATIC SOLENOID ASSEMBLY
1
A9
MB1020-001
MOTOR ASSEMBLY
1
4
MP1020-007-011
TRAY BUMPER
4
5
MH009-004
PROXIMITY SWITCH
3

FOR USE BY QUALIFIED PERSONNEL ONLY
A2 –Controller Box Assembly
ITEM NO.
PART/ASSY. NO.
DESCRIPTION
QTY.
6
MH004-010
AUTO/MANUAL KNOB
1
7
MH004-011
HEAT START BUTTON
1
8
MH004-019
ON/OFF SWITCH ,240V
1
9
MP1020-001
DIGITIAL CONTROL OVERLAY
1
10
MH006-005
DIGITIAL CONTROLLER
1
11
MH008-003
TRANSFORMER
1
12
MH008-002
CONTROLLER POWER ADPATER
1
17

FOR USE BY QUALIFIED PERSONNEL ONLY
A3 –UPPER PLATEN Assembly
ITEM NO.
PART/ASSY. NO.
DESCRIPTION
QTY.
13
MTTP046
HIGH TEMP LIMITER
2
14
MH009-005
THERMOCOUPLE, TYPE-K
1
15
MAPT1020U
TELFON SHEET, UPPER PLATEN
1
18

FOR USE BY QUALIFIED PERSONNEL ONLY
A4 –Shuttle Tray Assembly
ITEM NO.
PART/ASSY. NO.
DESCRIPTION
QTY.
16
MPT1020-008*
48 X 40 TELFON COVER
2
17
MP1020-006
47 X 38, SILICONE TOP PAD
2
18
MP1020-004**
47 X 38, 1” COTTON BASE PAD
2
19
MH007-039
TIMING BELT
2
20
MH007-041
SLIDER ROD
4
21
MH007-040
BALL BEARING ASSY
8
A6 –Shuttle Arm Assembly
19 * Optional –Order separately **Consumable –Not covered by warranty

FOR USE BY QUALIFIED PERSONNEL ONLY
A8 –Automatic Solenoid Assembly
ITEM NO.
PART/ASSY. NO.
DESCRIPTION
QTY.
22
MH007-035
5/2 AIR SOLENOID ASSY
1
23
MH007-042
½” COPPER MUFFLER
2
24
PISTON
2
25
MH007-036
½” SAFETLY RELIEF VALVE
2
26
MH007-046
RIGHT ANGLE ½” HOSE FITTING
4
A6 –Shuttle Arm Assembly
A5 –Piston Assembly
20

FOR USE BY QUALIFIED PERSONNEL ONLY
A7 –ELECTRICAL BOX
21
ITEM NO.
PART/ASSY. NO.
DESCRIPTION
QTY.
27
MH004-012
THREE PHASE GFCI
1
28
MP1020-007
MAGNETIC CONTACTOR ASSY
1
29
MH005-004
THREE PHASE SSR
1
30
MH004-013
SSR COOLING FAN
1
31
MH004-014
LINE CONTACT BANK
1
32
MH007-034
FUSE HOLDER
2
33
MH004-015
FUSE
2
34
MH005-005
INTERMEDITATE RELAY 12V
1
35
MH005-006
INTERMEDITATE RELAY 220V-240V
4
36
MH005-007
INTERMEDITATE RELAY RR2P-U 220V
2
37
MP1020-004-001
MOTOR SPEED CONTROLLER
1