Thermopatch HS3E User manual

HS3E-4EOperator’s Manual
47243-MAN - 1212

© 2011, Thermopatch, Syracuse, New York. No part of this publication may be
reproduced by any means without the prior written permission of Thermopatch,
Syracuse, New York. Thermopatch, Thermo-Seal, Alligator, Beaver, Cheetah,
Deco-Print, Penguin, TruFlex and the Thermopatch logo are ® trademarks of
Thermopatch, Syracuse, New York.
Copyright

Contents
1. Introduction
1.1 What Did You Receive?
1.2 Machine Specifications
2. Machine Settings
4. Troubleshooting
6. Drawings and Parts Listings
1.3 Safety Information
5. Maintenance
3. Operating Instructions
1.4 Conditions of Warranty
4.1 Common Problems and Causes
4.2 Temperature Controller Error Codes
1.5 Customer Service
1.6 Setting Up the Machine

The HS3E and HS4E heat seal machines provide the heat, time and pressure
required for the application of a wide variety of Thermopatch products including
mending materials, emblems, label tapes and transfers.
1.1 What Did You Receive?
HS3E or HS4E Heat-Seal Machine Quick Start Guide
Line Power Cord
CD-ROM with Instruction Manual
1.2 Machine Specifications
Width: 7.5" (19 cm)
Length: 20.4" (52 cm)
Height: (Opened): 19.3" (49 cm)
(Closed): 9.3" (24 cm)
Sealing Platen: 3.75" x 4.75" (9.5 cm x 12 cm)
Time: 0 to 30 seconds
Heat Range: 69 to 446°F (20 to 230°C)
Electrical Requirements: 5.6 Amps @ 110 VAC, 50/60 HZ
2.8 Amps @ 220 VAC, 50/60 HZ
1. Introduction

1.3 Safety Information
The HS3E and HS4E heat seal machines have a Power Saver energy feature.
The machine heater element will be de-energized after a preset time and cool
down to room temperature. This will occur when the preset “Power Saver Time”
has elapsed.
Re-activation of the HS3E or HS4E machine is achieved by lowering the Seal Arm
handle of the machine. Once the Seal Arm Handle is lowered into the “Locked”
position, the machine will exit the Power Saver Mode. The Heater Element of the
machine will become re-energized and increase in temperature to the preset
“Power Saver Temperature.” Upon achieving the preset Power Saver
Temperature, the Sealing Cycle Timer will begin counting down to zero seconds.
This machine is equipped with a fully grounded 3-wire cord and plug. It must be
used only in conjunction with a properly grounded outlet of the correct voltage.
WARNING: THE HEATER ELEMENT CAN CAUSE SKIN BURNS!
1.4 Conditions of Warranty
Thermopatch Corporation, Syracuse, New York (”Seller”) warrants this product to be free from
defects in material and workmanship under normal use and service. Any part which proves to be
defective in material or workmanship within one year of the date of original purpose for use will be
repaired or replaced, at Seller’s option, free of service or labor charges, with a new or functionally
operative part. Seller’s liability under the Warranty shall be limited to repairing or replacing at its own
factory or through an authorized service distributor or dealer, material which is determined by Seller
to have been defective in manufacture and upon which a claim has been made by the original
purchaser or user to Seller (or an authorized distributor or dealer) within the warranty period. An
authorized officer of Seller will honor claims under this Warranty only upon written approval.
Approved return of parts or products will be on a prepaid transportation charges basis only. Claims
under this Warranty will be honored only upon Seller’s determination that the claim is covered by this
Warranty, and Seller shall incur no obligation under this Warranty prior to such determination. This
Warranty does not apply: (1) To any machinery or equipment which has been altered or repaired,
except by Seller or its authorized representatives, or (2) to any machinery or equipment which has
been subject to misuse, negligence or accident, including, without limitation, use and operation of
such machinery or equipment while parts are loose, broken, out of order, or damaged by the
elements. Parts replaced under this Warranty are warranted only through the remainder of the
original Warranty. Any and all claims for warranty service must include such information as Seller
designates, and shall include specifically the serial number of each unit (if appropriate).
The foregoing shall constitute the sole and exclusive remedy of any using purchaser and the sole and
exclusive liability of Seller in connection with this product. THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS, IMPLIED OR STATUTORY, INCLUDING BUT NOT LIMITED TO, ANY WARRANT
OF MERCHANTABILITY OR FITNESS AND ALL OTHER OBLIGATIONS OR LIABILITIES OF SELLER,
INCLUDING ANY TORT LIABILITY, FOR NEGLIGENT DESIGN OR MANUFACTURE OF THIS PRODUCT,
OR OTHERWISE. It is expressly agreed that Buyer shall not be entitled to recover any incidental or
consequential damages, as those terms are defined in the Uniform Commercial Code, and that Buyer
shall have no right of rejection or of revocation of acceptance of any part or of the goods covered
hereby.

1.5 Customer Service
Thermopatch Corporation’s U.S. and International network of Sales
Representatives, as well as its internal Customer Service Department, offer their
assistance in the development of effective heat-seal mending, marking and
identification programs.
Thermopatch markets a complete line of heat-seal and marking machines, as
well as a complete line of materials and supplies.
Label Print Machines – Manual, automatic and computer controlled.
Marking Machines – High speed permanent imprinting of decorative or
informative marks on most woven fabrics.
Heat-Seal Machines – Manual, semi-automatic and completely automatic, with
high inter-platen pressure to assure excellent adhesion of label tapes and
mending materials.
Label Tapes – Specially woven 100% cotton and blends with adhesives to
match specific processing requirements.
The Deco-Print line of products has been specifically designed to offer
alternative solutions to sewn-in labeling and other methods of decorative
trimming. An assortment of heat-sealable applications are available including
hot paper transfers, screen printed transfers, direct printing, application
equipment and supplies and digital printed transfers.
When ordering machine parts, please include the model and serial numbers of
your equipment.
United States :
Thermopatch Corporation
P.O. Box 8007
Syracuse, New York 13217-8007
Telephone: [phone]
Fax: [phone]
Toll Free: 800-252-6555
(in the US only)
Canada :Thermopatch (Canada)
Incorporated
25 Groff Place, Unit No. 5
Kitchener, Ontario N2E 2L6
Telephone: [phone]
Fax: [phone]
Toll Free: 800-265-6416
(in Canada only)
Australia :
Thermo
p
atch
(
Australia
)
Pt
y
. Ltd.
477 Warrigal Road, Unit No. 9
Moorabbin, Victoria 3189
Telephone:
011-61-3-9532-5722
Fax:
011-61-3-9532-5652
Netherlands :Thermopatch BV
P.O. Box 50052
1305 AB Almere
Netherlands
Telephone: [phone]
Fax: [phone]
Germany :Thermopatch Deutschland
Grunteweg 33
26127 Oldenburg
Deutschland
Telephone: [phone]
Fax: [phone]
E-mail:
[e-mail]
France :Thermo
p
atch France
7 Rue Chappe-Z.I. Des Garennes
B.P. 1011
Les Mureaux Cedex 78131
France
Telephone: [phone]
Fax: [phone]
Internet Address :http://www.thermopatch.com
E-mail Address :[e-mail]

1.6 Setting Up the Machine
1. Set the machine on the worktable in a desired location.
2. Raise the Seal Arm Handle to the upright position.
3. Plug the line power cord into the back of the machine.
4. Plug the line power cord into a properly grounded outlet of correct voltage.
5. Switch the machine to the “ON” position.

During the heat-up phase and when the machine has achieved “Set
Temperature,” changes to the machine settings for Set Temperature,
Temperature Display in Celsius or Fahrenheit, Sealing Cycle Time, Power Saver
Time and Power Saver Temperature can be made.
Changes cannot be made to the settings during an active Sealing Cycle.
LCD Panel Functions
The following describes the LCD Display functions:
The Celsius or Fahrenheit LED will light up
continuously once the temperature is
within range of the setting. Range is
+/- 15°F and +/- 7°C.
When not in a sealing cycle, the actual
temperature of the Heater Element is displayed.
During the sealing cycle, the LCD will display a countdown of the time in seconds
from the preset Sealing Cycle Time.
The machine has been factory preset to:
Temperature: 400°F (204°C)
Sealing Time: 12 seconds
Power Saver Timer: 30 minutes
Power Saver Temperature: 302°F (150°C)
1. To adjust settings, press the select/save button:
1 time to adjust Temperature.
2 times to adjust Sealing Cycle Time.
3 times to adjust Preset Power Saver Time. Setting the Power Saver Time to
“0” disables the Power Saver.
4 times to change Power Saver Temperature. Thermopatch does not
recommend changing the default setting.
2. Press +or
- to adjust to your desired setting.
3. Press select/save immediately to save the setting.
4. To change display between Celsius and Fahrenheit, hold the + and
- buttons
until the LED changes.
2. Machine Settings

Important: Read this entire section before operating the machine.
1. Set the heat and time settings to your recommended levels. See Control Panel
Instructions. Double-check settings have been saved.
2. Individual HS3E and HS4E machines vary slightly. To achieve the optimum
pressure setting, adjust the lower platen such that when the Sealing Arm Handle
is down, it depresses 1/16th of an inch (1.5mm).
3. Place the garment to be labeled on the sealing platen.
4. Place the repair patch, emblem or label tape adhesive shiny side down
(Transfers should be placed ink side down).
5. Lower the Seal Arm Handle to its locked position.
6. At the end of the Sealing Cycle an alarm buzzer will sound. The HS3E Series
Machine requires a manual release. The HS4E Series Machine will automatically
release.
WARNING: THE HEATER ELEMENT CAN CAUSE SKIN BURNS! HEAT-
SEALED MATERIALS ARE VERY HOT. ALL HEAT-SEALED MATERIALS
SHOULD BE ALLOWED TO COOL DOWN BEFORE HANDLING.
Pressure adjustment may be necessary. Normally, higher pressures will produce
more effective heat seals. However, the use of excess pressure may force
adhesive through the fabric, with an unsightly result.
THE DATUM HEIGHT OF THE LOWER SEAL PLATEN IS (4) TURNS UP
FROM THE BASE OF THE MACHINE. ANY LESS WILL DAMAGE MACHINE.
A label to indicate the direction in which to turn the Lower Press Platen is
mounted directly below the Lower Press Platen. To increase inter-platen pressure,
turn the Lower Press Platen counterclockwise. To decrease the inter-platen
pressure, turn the Lower Press Platen clockwise.
Caution: Use of excess pressure can cause the HS3E and HS4E machines
to become locked in a closed position and difficult to open. Extreme
pressure may severely damage your machine and your garment.
Difficulty locking the Seal Arm Handle of the HS3E or HS4E machines in a closed
position is an indication of too much inter-platen pressure. To prevent excess
pressure when sealing thick garments, turn the Lower Press Platen down.
A Lower Press Platen that is worn from use can cause insufficient inter-platen
pressure. The Lower Press Platen (P/N 43941) can be replaced.
3. Operating Instructions

4.1 Common Problems and Causes
Head will not come down. The most common causes are:
1. Mechanical binding
2. Broken links
3. Broken link pivot shaft
Head will not lock down. The most common causes are:
1. Sealing platen is adjusted too low
2. Release motor switch out of adjustment (HS4E)
3. Release motor faulty (HS4E)
4. Mechanical binding
5. Worn gears
6. Broken or stretched links
7. Broken link pivot shaft
Head will not release (HS4E only). The most common causes are:
1. Incorrect machine setup
2. Sealing platen adjusted too high
3. Release motor microswitch out of adjustment
4. Cam on release motor loose or out of position
5. Faulty release motor switch
6. Broken return spring
7. Broken rod end
8. Faulty start switch
9. Faulty control board
10. Faulty release motor
Head will only raise 1-2”. The most common causes are:
1. Broken spring
2. Faulty gas spring
Head will only come up halfway. The most common causes are:
1. Broken rod end
2. Faulty gas spring
Heating problems (No heat or low heat). The most common causes are:
1. Temperature settings incorrect
2. Machine in “Sleep Mode”
3. Faulty temperature sensor
4. Broken wiring to sensor
5. Faulty relay
6. Faulty temperature controller
7. Faulty heater
4. Troubleshooting

4.2 Temperature Controller Error Codes
Error 1 (Sensor Shorted) The most common causes are:
1. Faulty temperature sensor
2. Shorted wiring to sensor
3. Faulty temperature controller
Error 2 (Sensor Broken) The most common causes are:
1. Faulty temperature sensor
2. Broken wiring to sensor
3. Faulty temperature controller
Error 3 (Control Board Problems) The most common cause is:
1. Faulty temperature controller
Error 4 (Release Problems- HS4E only) The most common cause is:
1. Release motor microswitch shorted or faulty

Teflon Cover
Clean the Teflon Cover frequently by wiping with a soft clean rag. A
non-flammable cleaner such as “Ez-Off,” (P/N DH-6873), may be used according
to the manufacturer’s instructions. NEVER USE A FLAMMABLE SOLVENT OR
ABRASIVE CLEANER. To ensure the best heat-sealing results, replace the Teflon
Cover whenever it becomes torn or too soiled to clean.
Procedure to Replace Teflon Cover
1. Turn the machine off, unplug it and allow it to cool down.
2. Turn the machine upside down.
3. Peel the old Teflon cover off of the surface of the heater.
4. Use a razor blade to scrape all of the old adhesive off of the heater. All old
adhesive must be removed.
Do not use any liquid cleaners on the heater.
5. Peel the yellow backing off of the Teflon to expose the adhesive. Discard the
yellow backing.
6. Stick the Teflon onto the heater and rub out any air bubbles.
7. If necessary, trim off any excess Teflon.
8. Turn the machine over, back to its proper position.
9. Plug in the machine and turn the power “ON.” Allow it to warm up.
The machine is now ready to use.
Lower Press Platen
Clean frequently by wiping with a soft, clean rag. Replace the pad whenever it
becomes deteriorated. To replace the Lower Press Platen:
1. Switch the Heat Sealing machine to the “Off” position and allow the Heater
Element to cool down to room temperature.
2. From the side, gently wedge a screwdriver between the aluminum base and
aluminum backing plate of the platen assembly. The Lower Press Platen can now
be removed from the base.
Lubrication
The HS3E and HS4E machines do not require lubrication.
5. Maintenance

Drawings and Parts Listing
On the following pages, the reader will find technical drawings and corresponding
parts listings of the HS3E and HS4E machines. The technical drawing illustrating
a particular sub-assembly or area of the machine provides the individual parts for
that sub-assembly or area. A complete listing of available parts is provided at
the end of this chapter.
The reader will find that the technical drawings and corresponding parts listings
are arranged by category. Those categories in order are:
1. Electrical
2. Mechanical
3. Parts listing

N
E
P
E
N
P
Line Side
Chassis Gnd
18
GRN/YEL
L1 BLK
L2 WHT
J1
J2
18
Power Entry Module
Fuses: [2] 6.3 Amp
Controller
Board
+
Solid State
Relay
5 BLK
2 RED
1 RED
6 WHT
5 BLK
6 WHT
L1 WHT
L2 WHT
AC Input
HTR
MTR
Wire Harness
Plug
Heater Unit
High Limit
Thermostat
GRN/YEL
Wire Harness
Plug
7 BLK
8 WHT
7 BLK
8 WHT
7 BLU
GRN
3 GRY 4 GRY
Seal Switch
LS1 LS2
Motor Control
Switch
8 BLU
Wire Harness
Plug
5 YEL
6 YEL
RED
YEL
Thermocouple,
Type K
hs3e Series
Electrical Schematic
115 Volt
CN2 CN1
SSR
HTR
Press Arm
Gnd
LEGEND:
HTR - Heater
LS1 - Limit Switch 1
LS2 - Limit Switch 2
MTR - AC Motor
SSR - Solid State Relay
TS - Temperature Sensor
Plug to AC Motor
hs4e series only
SSR
LS1
TS
LS2

N
E
P
E
N
P
Line Side
Chassis Gnd
18
GRN/YEL
L1 BLK
L2 WHT
J1
J2
18
Power Entry Module
Fuses: [2] 6.3 Amp
Controller
Board
+
Solid State
Relay
5 BLK
2 RED
1 RED
6 WHT
5 BLK
6 WHT
L1 WHT
L2 WHT
AC Input
HTR
MTR
Wire Harness
Plug
Heater Unit
High Limit
Thermostat
GRN/YEL
Wire Harness
Plug
7 BLK
8 WHT
7 BLK
8 WHT
AC
GRN/YEL
7 BLK
8 WHT
7 BLU
GRN
3 GRY 4 GRY
Seal Switch
LS1 LS2
Motor Control
Switch
8 BLU
Wire Harness
Plug
5 YEL
6 YEL
RED
YEL
Thermocouple,
Type K
hs4e Series
Electrical Schematic
115 Volt
CN2 CN1
SSR
MTR
HTR
Press Arm
Gnd
LEGEND:
HTR - Heater
LS1 - Limit Switch 1
LS2 - Limit Switch 2
MTR - AC Motor
SSR - Solid State Relay
TS - Temperature Sensor
LS2
TS
LS1
SSR

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