Insta 204 User manual

MNL90008 Rev. L 07.21.2014
OPERATION AND MAINTENANCE MANUAL
MODEL 204

FOR USE BY QUALIFIED PERSONNEL ONLY
Safety Summary
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
Hot Surface. Avoid contact.
CAUTION
During normal operation, the
base of the machine needs to be
installed or placed above the wall
socket.
CAUTION
The machine is to be operated by
one person only.
CAUTION
To reduce the risk of electric
shock and injury to persons,
disconnect from power supply
before servicing and /or cleaning.
International Symbols
Power Off
Power On
Hot Surface
Risk of Electrical Shock
Protective Earth Terminal
Ground
Caution - Warning
1

FOR USE BY QUALIFIED PERSONNEL ONLY
Congratulations!
Your selection of the Insta Graphic Systems 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, insures the
continuing capability of delivering the best-decorated
substrates possible.
This manual describes installation, operation, and
maintenance procedures for your new 204 series
machine, as well as easy to use instructions for on-
the-spot maintenance.
Your 204 series machine will have a long, trouble
free life. Read this manual. Keep it with your
machine; it's your key to proper operation and lasting
service.
Limited Machine Warranty
Insta Graphic Systems warrants this heat seal
machine, when operated under normal conditions, to
be free from manufacturing defects in material and
workmanship for a period of one year on parts
(lifetime on the heating element) and 90 days on
labor from the invoice date.
This warranty will be effective only when Insta
authorizes the original purchaser to return the
product to the factory in Cerritos, California, freight
prepaid, and only when the product upon
examination has proven to be defective.
This warranty does not apply to any machine that
has been subjected to misuse, negligence or
accident.
Insta shall not be liable for the injury, loss or
damage, direct or consequential, arising out of the
use or the inability to use the product.
No claim of any kind shall be greater in amount than
the sale price of the product or part to which claim is
made.
This is the sole warranty given by the company, it is
in lieu of any other warranties, expressed or implied,
in law or in fact, including the warranties of
merchantability and fitness for a particular use, and
is accepted as such by the purchaser in taking
delivery of this product.
2

FOR USE BY QUALIFIED PERSONNEL ONLY
Installation
DOMESTIC
Use a separate 15 amp AC
circuit. Only industrial extension
cords with proper wire size should
be used: size 16/3 wire for
distances up to 25 feet, and size
14/3 for distances up to 50 feet.
INTERNATIONAL
Use a designated 16 amp AC
circuit. Only industrial extension
cords with proper wire size (2.5
sq. mm) shall be used.
IMPORTANT
The appliance must be plugged
into a proper receptacle of the
proper size and rating. Equally
important the line voltage must
be able to accommodate this
appliance as well as other
appliances operating on this
circuit.
Specifications
MODEL 204
Voltage 120 Volts AC 50/60 Hertz
Model 204 1750 Watts 14.6 Amps
Voltage 230 Volts AC 50/60 Hertz
Model 204 2200 Watts 9.6 Amps
Model 204
Machine Weight 93 Pounds (42.2 KG)
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
IP54=IP
1st Digit5
2nd Digit4
1st
Digit
Protection from
solid objects
2nd
Digit
Protection from
moisture
0 Non protected 0 Non protected
1Objects greater
than 50mm 1 Dripping water
2Objects greater
than 12mm 2
Dripping water
when tilted up to
15 deg.
3Objects greater
than 2.5mm 3 Spraying water
4Objects greater
than 1mm 4 Splashing water
5 Dust protected 5 Water jets
6 Dust tight 6 Heavy seas
-- --- 7 .15m – 1m
immersion
-- --- 8 1m + submersion
3

FOR USE BY QUALIFIED PERSONNEL ONLY
Operation
1. Turn the power on by pressing the POWER
button on the controller.
2. Set desired temperature and time. Swing
the upper platen arm to its fully open
position, away from lower platen. (See Solid
State Controller section)
3. Allow the machine to warm up until the
selected temperature is reached.
4. Set the desired pressure by adjusting the
crank handle knob on the top of the
machine. To increase pressure, turn the
crank handle knob counter-clockwise.
5. Place the substrate on lower platen,
smoothing out all wrinkles.
6. Position transfer or lettering on substrate.
7. Swing the upper arm into position directly
over the lower platen.
8. Close machine by pulling handle down into
locked position.
9. The timer will start automatically and a
buzzer will beep at the end of the time cycle.
10. Lift safety lock and pull handle up slowly
and move upper platen handle to its full
open position. This technique will avoid
transfer paper (cover) from being pulled off
prematurely due to suction from the
separating platens.
Environmental Conditions
Only operate Insta heat seal machines under
suitable environmental conditions.
1. Placed on a even, non flammable surface.
2. Can support a minimum of 300 lbs. if
placed above a platform.
3. Do not restrict access to the main power
switch.
4. Maintain a clearance around any forms of
liquid.
5. Do not over extend the power cord.
6. The operational voltage should not be 10%
max/min of the rated value.
7. Avoid voltage spikes.
NOTE
For safety purposes, it is necessary to
push the handle into the locked
position after it is lifted. This will
eliminate the accidental lowering of
the heat platen handle.
11. Swing away arm to the extreme right hand
position and remove substrate.
4

FOR USE BY QUALIFIED PERSONNEL ONLY
Operation Timer/Temperature
Control
Solid State Controller
This controller has three (3) control features:
1. Temperature - Temperature may be set
from 225 - 450°F (107-232°C).
2. Time - Time may be set from 1 second to
99.59 minutes.
3. Counter – Cycle counter counts the number
of applications from 1 to 9999 (see
additional Notes – Counter).
Controller Operation
1. If the temperature is not being displayed,
press the MODE button until temperature is
displayed.
2. Push and hold SET button and
simultaneously push UP (↑) or DOWN (↓)
arrow buttons to the desired temperature
setting.
3. Press the MODE button until time is
displayed.
4. Push and hold SET button and
simultaneously push UP (↑) or DOWN (↓)
arrow buttons to the desired timer setting.
Timer
•The controller has a count down timer that
automatically activates a buzzer at the
completion of the application.
•Timer display is minutes:seconds. Range is
00:00 to 99:59, Colons (:) flash while timer is
running.
Counter
The controller has a built in cycle counter.
•Press MODE button until the counter is
displayed.
•Counter display range is 0000 to 9999.
•To reset the cycle counter, display the
counter reading, then push and hold UP (↑)
and DOWN (↓) arrow buttons for 3 seconds
until the counter resets to zero (0000) on the
display.
NOTE
The timer or buzzer may be stopped
while the handle is in the down
position by pressing the MODE button.
The timer will automatically reset after
the handle is raised.
5
Temperature

FOR USE BY QUALIFIED PERSONNEL ONLY
Model 204
(Controller P/N MPC90270 ; Rev. 6.27)
The Sleep Mode / Automatic Shut Off is
designed to save electrical consumption when
the user is not engaged in the usage of the
Insta heat seal machines.
During activation, any disturbances such as the
key press or heat press cycle will reset the
timers for both Sleep Mode and Automatic Shut
Off.
When the Automatic Shut Off is set to OFF, the
Sleep Mode will hold forever until it is
interrupted by any disturbances.
When the Sleep Mode is set to OFF, the timer
for Automatic Shut Off will begin after every key
press or heat press cycle.
•Sleep Time
(Level 1 – Menu 1)
•Set Back Temperature
(Level 1 – Menu 2)
•Automatic Shut Off Time
(Level 1 – Menu 3)
•Fahrenheit / Celsius
(Level 1 – Menu 4)
•User Offset
(Level 1 – Menu 5)
Sleep Time
1. Display the COUNTER . Enter the
Factory Mode by pressing MODE +
SET for 3 to 5 seconds.
2. Press SET + UP or DOWN Arrow to
set Sleep Mode Time.
1._XX ; XX = Minutes from OFF to 99
Set Back Temperature
3. Press MODE.
4. Press SET + UP or DOWN Arrow to
set Set Back Temperature.
2._XXX ; XXX = Temp. from 225F to
300F
+
+or
+or
Sleep Time, Set Back Temperature,
Automatic Shut Off, Temperature
Conversion, and Offset
6

FOR USE BY QUALIFIED PERSONNEL ONLY
Automatic Shut Off
5. Press MODE.
6. Press SET + UP or DOWN Arrow to
set Auto Shut Off Time.
3._XX ; XX = Minutes from OFF to 99
Fahrenheit / Celsius
7. Press MODE.
8. Press SET + UP or DOWN Arrow to
set Fahrenheit or Celsius.
4._X ; X = F or C
+or
+or
User Offset
9. Press MODE.
10. Press SET + UP or DOWN Arrow to
set the Offset.
5._XX ; XX = Offset Number
Exit
11. Press MODE + SET for 3 to 5
seconds to Exit.
+or
+
7

FOR USE BY QUALIFIED PERSONNEL ONLY
Preventive Maintenance
Suggestions
The Insta heat seal machines are relatively
maintenance free. For long, trouble-free life,
the following preventive maintenance should be
followed:
1. Do not heat seal items such as buttons,
pins, snaps, or zippers that tend to cut the
silicone rubber pad or scratch the Teflon
heat platen.
2. Periodically clean the Teflon-coated heat
platen with a non-abrasive piece of cloth.
Stubborn stains may be cleaned, when
platen is cool, with mineral spirits.
3. When the heat platen is hot and not in use,
keep in open position (away from the
silicone rubber pad).
4. To prevent soiling of substrate, periodic
wiping of the entire exterior machine,
including platens, with a clean rag is
recommended. If necessary, use mineral
spirits for cleaning a cold machine. Since
mineral spirits are flammable, use
precautions and keep away from sparks,
flame, or hot heat platen.
5. The Model 204 machine requires periodic
lubrication with a high-temperature, non-
melting grease (MPPL023).
A. Lubricate the post, handle and cam
assembly depending upon usage. (Once
every month if used continuously.)
B. There are four (4) points of lubrication:
a) Post
b) Lower Cam
c) Guide Post
d) Upper Pin Area
In addition, occasionally apply a few drops of
heavy machine oil to the upper portion of the
cam assembly.
WARNING
Power cord replacement should be
from the manufacturer only (because it
requires a special prepared cord.)
Replacement of Silicone Rubber
Pads
1. Make sure heat platen is cool.
2. Use tube of MPPC006 silicone adhesive
sealant to bond the silicone rubber pad to
metal platen. NOTE: Read instructions on
the tube package.
3. Be sure that the surface of the silicone
platen is clean. Use a mild solvent such as
mineral spirits.
4. The pad and metal must be thoroughly dry
and clean, before starting the bonding
operation.
5. Apply adhesive sealant to the metal platen.
Spread a thin even coat and apply pad
immediately. Apply pressure and position
pad making sure that there is no air
entrapment.
NOTE: A serrated blade such as used for
laying down rubber floor tiles would be
helpful.
6. Allow to cure overnight under low pressure
at normal room temperature.
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 Allen wrenches
F. Grease gun
G. Special high temperature grease MPPL023
8

Safety and Danger Zone Diagram
Hot Surface.
Avoid contact
with Upper
Platen Shroud
and Aluminum
Casting
Keep hands clear
Do not handle
the machinery
with wet hands
Machinery
should be
operated under a
secure flat
surface
9

120V AC 230V AC
1 SHROUD, HEAT MPS90174 MPS90174
2 SCREW, BUTTON HD 5/16-18 X .50 LG " MHSB5161812 MHSB5161812
3 INSULATION, FIBERGLASS 15X20 MPSP254 MPSP254
4 SCREW, SOCKET HD 1/4-20 X 4 LG MHSSH14204 MHSSH14204
5 TUBING, SHRINK TFE AWG7 MPPS131 MPPS131
6 INSULATORS, SPACER (4/SET) MPI90156 MPI90156
7 PLUG, BUTTON 7/8 IN MHPB78 MHPB78
8 SENSOR, TEMP. REPLACEMENT KIT MPPS210 MPPS210
9 POST, GUIDE MPSP084 MPSP084
10 DECAL PRESSURE ADJUSTMENT MPPL010 MPPL010
11 LUG PIN MPP0139 MPP0139
13 CLEVIS, UPPER PLATEN MPSP221 MPSP221
14 PAD, SILICONE 15 X 20 BLK MPPP031 MPPP031
15 SCREW, PAN 10-24 X .50 LG MHSP102412 MHSP102412
16 HOUSING, INSTRUMENT MPSH015 MPSH015
17 WIRE, HEATER 14GA TGGT MPPW700 MPPW700
18 LABEL, CONTROLLER OVERLAY MPL90346 MPL90346
19 BOLT, HEX 5/16-18 X 1 LG STAINLESS MPBH14201S MPBH14201S
20 SCREW, BUT HD 1/4-20 X .75 LG " MHSB142034 MHSB142034
21 HANDLE, PRESSURE ADJUST F/204 MPSP014 MPSP014
22 SCREW, PAN HD 6-32 x 0.25 IN MHSP63214 MHSP63214
23 CONTROLLER, DIGITAL W/SWITCH MPC90003 MPC90003
25 HANDLE, SWINGAWAY 200 MPH90002 MPH90002
26 WASHER, SAE 1/4 " MHWSAE14 MHWSAE14
27 SWITCH, MICRO MPPS043 MPPS043
29 NUT, HEX 3/8-16 LOCKING MHNH3816 MHNH3816
30 PLUNGER SPRING DETENT 500 MPSP134 MPSP134
32 SCREW, SOCKET HD 1/4-20 X .50 HD MHSSH142012 MHSSH142012
33 KNOB, HANDLE (MUSHROOM) MPPK017 MPPK017
34 CAP, VINYL BLK 5/16X.281 LG MPC90006 MPC90006
35 RELAY MPPR200 MPPR200
36 SCREW, BTN HD 1/4-20 X .875LG MHSB142078 MHSB142078
37 BLOCK, TERMINAL MPB90006 MPB90006
38 CLAMP, CABLE 5/16 IN. MHCC516 MHCC516
39 TRANSFORMER MPT90001 MPT90001
40 SCREW, RD HD 4-40X.625 LG " MHSR44058 MHSR44058
41 SCREW, PRESSURE ADJUSTMENT MPSS070 MPSS070
42 POST, ARM ASSY MPSP204 MPSP204
43 PLATE, POST STOP MPSP20450 MPSP20450
45 WASHER, SAE 1/2 " MHWSAE12 MHWSAE12
47 NUT, JAM SELF LOCKING 1/2-20 MHNHJSL1220 MHNHJSL1220
48 E-CLIPS MPSC240 MPSC240
49 PIN, CAM PIVOT (UPPER) MPSP262 MPSP262
50 SCREW, PAN HD 8-32 X 1.00 LG " MHSP8321 MHSP8321
52 SAFETY LOCK MPSL241 MPSL241
53 WASHER, #8 SAE MHWSAE8 MHWSAE8
54 FITTING, GREASE (SHORT) MPSF145 MPSF145
MODEL VOLTAGE
PART NAME
P/N
MODEL 204 0721

120V AC 230V AC
55 PIN, ROLL (SAFETY LOCK) MPSR141 MPSR141
57 CAM MPSC220 MPSC220
58 SCREW, BUTTON HD 5/16-18 X1 LG MHSB516181 MHSB516181
59 NUT, HEX JAM 5/16-18 MHNHJ51618 MHNHJ51618
60 RING, O" POST " MPSS273 MPSS273
63 FEET,RUBBER (6/SET) MPF90004 MPF90004
66 BASE MPSB204 MPSB204
68 BRACKET, POWER CORD MPSS163 MPSS163
69 STRAIN RELIEF 14/3 MPSS168 MPSS168
70 SCREW, PAN HD 10-24 X .375 LG MHSP102438 MHSP102438
71 CORD, POWER (USA) MPPW141 MPPW142
71A CORD, POWER (EUROPEAN) 230V N/A MPPW202
71B CORD, POWER (U.K) 240V N/A MPPW203
72 WIRE, HARNESS MPW90320 MPW90320
73 FUSE (1 AMP, 250V) MPPF701R MPPF701R
74 FUSE HOLDER MPPF708 MPPF708
75 SCREW, PHILLIP PAN HEAD 2-56 x .25 LONG MHSP25614 MHSP25614
76 SPRING, CAM MPSS201 MPSS201
78 INSULATION, MICRO SWITCH MH700214 MH700214
79 WASHER, CUT 5/16 " MHWC516 MHWC516
80 SCREW, SKT HD 5/16-18 X .50 LG MHSSH5161812 MHSSH5161812
82 CLAMP, CABLE 3/8" (STEEL) MH8863T2 MH8863T2
84 SCREW, PAN HD 8-32 X 1/4 LG MHSP83214 MHSP83214
87 SCREW, PAN HD 8-32 X 1/2 LG MHSP83212 MHSP83212
88 SCREW, SOCKET HD 1/4-20 0.5 LG MHSSH142012 MHSSH142012
89 NUT, HEX 6-32 MHNH632 MHNH632
90 NUT, JAM 1/2-20 MHNHJ1220 MHNHJ1220
91 SCREW, SET 3/8-16 X .500 LG MHSST516184 MHSST516184
92 BUSHING, GUIDE POST MPSB074 MPSB074
93 WASHER, SHIM #6 (.031) MH311150019 MH311150019
94 SPACER, NYLON 0.166 ID X1/4 LG MH110969111 MH110969111
95 PLATE, CONTROLLER MPP90011 MPP90011
96 WIRE, GROUND ASS'Y MPW90125 MPW90125
97 LABEL, ROHS/WEE MPL90175 MPL90175
98 WASHER INT LOCK #8 MHWLIT8 MHWLIT8
99 NUT HEX 8-32 MHNH832 MHNH832
A1 PLATEN, HEAT ASS'Y MPP2041A MPP2042A
A2 HANDLE, PRESSURE ASS'Y MPSH515 MPSH515
A3 CAM ASS'Y MPSC213 MPSC213
A4 BASE ASSEMBLY MPSB204A MPSB204A
A5 PLATEN, LOWER ASSY MASP007 MASP007
A6 PLATEN, HEAT W/WIRING MPP2041W MPP2042W
A7 LUG PIN ASS'Y MPP90141 MPP90141
P/N
PART NAME
MODEL VOLTAGE
MODEL 204 0721

FOR USE BY QUALIFIED PERSONNEL ONLY
14
Notes:

FOR USE BY QUALIFIED PERSONNEL ONLY
15

FOR USE BY QUALIFIED PERSONNEL ONLY
16

FOR USE BY QUALIFIED PERSONNEL ONLY
13925 E. 166th St. • Cerritos, CA USA 90702 • [phone] • Fax [phone]
Parts Orders • (800) 426
-
3609 • (562) 404
-
3000 Ext 215
Parts
Orders
•
(800)
426
-
3609
•
(562)
404
-
3000
Ext
.
215
Technical Support • [phone] • [phone] Ext. 208
In House Repair • [phone]