Thermopatch Deco-Print DP2000T User manual

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Thermopatch
DP2000T
Deco-Print
Operator's Manual
Rev 1215

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Contents
WARRANTY.................................................................................................................................................. 6
Section 1...................................................................................................................................................... 7
Introduction to the Deco-Print, from Thermopatch ............................................................................... 7
Section 2.................................................................................................................................................... 11
DP2000T SETUP..................................................................................................................................... 11
Step 1 ................................................................................................................................................ 11
Step 2 ................................................................................................................................................ 13
Step 3 ................................................................................................................................................ 13
Step 4 ................................................................................................................................................ 14
Step 5 ................................................................................................................................................ 15
DP2000T Transfer Specifications........................................................................................................... 18
DP2000T Transfer Setup........................................................................................................................ 18
Ribbon Tape Setup Feed Adjustment ................................................................................................... 21
Adjusting the Printing Pressure and Platen Height printing Pressure.............................................. 22
Printing Platen Adjustment............................................................................................................... 22
Setup for (2) or More Ribbons.......................................................................................................... 22
INSERTING THE PRINTING PLATE .......................................................................................................... 23
Choosing The Platen ......................................................................................................................... 24
Testing The Transfer Roll Feed Set-Up.............................................................................................. 24
Testing the Ribbon Feed Roll Set-Up ................................................................................................ 24
Correcting Take-Up Problems........................................................................................................... 24
Section 3.................................................................................................................................................... 25
CONTROL BOX ....................................................................................................................................... 25
Machine Setup ...................................................................................................................................... 27
Section 4: Troubleshooting....................................................................................................................... 28
OPERATIONAL MESSAGES..................................................................................................................... 31
Section 5: Parts Identification and Location............................................................................................. 32
Section 6: Maintenance ............................................................................................................................ 51
Rubber Print Platen ............................................................................................................................... 51

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Compressed Air Supply ......................................................................................................................... 51
General .................................................................................................................................................. 51
Teflon/Fiberglass Shield (Used for Heat Sealing).................................................................................. 51
Shipping the DP2000T ........................................................................................................................... 51
Section 7: Customer Service ..................................................................................................................... 52
Thermopatch Customer Service............................................................................................................ 52

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Figures
Figure 1 — Control Box Bracket................................................................................................................ 11
Figure 2 — Display .................................................................................................................................... 12
Figure 3 — Electrical Plugs Connected ..................................................................................................... 12
Figure 4 — Heater Cover Assembly, Installation ...................................................................................... 13
Figure 5 — Air Filter/Regulator, Installation............................................................................................. 13
Figure 6 — Electrical Enclosure Assembly, Outside view ......................................................................... 14
Figure 7 — Head Assembly, no Flanges.................................................................................................... 15
Figure 8 — Head Assembly, with Flanges................................................................................................. 15
Figure 9 — Transfer Roll Threading .......................................................................................................... 16
Figure 10 — Ribbon Roll Threading .......................................................................................................... 17
Figure 11 — Sensor ................................................................................................................................... 19
Figure 12 — Sensor location ..................................................................................................................... 19
Figure 13 — Sensor Position ..................................................................................................................... 20
Figure 14 — DP2000T Machine Assembly................................................................................................ 32
Figure 15 — Platen Assembly ................................................................................................................... 33
Figure 16 — Press Arm Assembly............................................................................................................. 34
Figure 17 — Heater Assembly .................................................................................................................. 35
Figure 18 — Support & Switch Assembly ................................................................................................. 36
Figure 19 — Head Assembly ..................................................................................................................... 37
Figure 20 — Front Plate Assembly............................................................................................................ 38
Figure 21 — Rear Plate Assembly ............................................................................................................. 39
Figure 22 — Laser Assembly ..................................................................................................................... 40
Figure 23 — Dancer Roller Assembly........................................................................................................ 41
Figure 24 — Touch Guard Assembly......................................................................................................... 42
Figure 25 — Heater Cover Assembly ........................................................................................................ 43
Figure 26 — Pneumatic Diagram .............................................................................................................. 44
Figure 27 — Valve and Regulator Assembly............................................................................................. 45
Figure 28 — Electronics Module............................................................................................................... 46
Figure 29 — Main Electronics Module...................................................................................................... 47

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Figure 30 — AC Harness............................................................................................................................ 48
Figure 31 — DC Harness ........................................................................................................................... 49
Figure 32 — Head Cover Assembly........................................................................................................... 50

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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 purchase 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. Claims under this
Warranty will be honored only upon written approval by an authorized officer of Seller. 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 WARRANTY
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 revocation of
acceptance of any part or all of the goods covered hereby.

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Section 1
Introduction to the Deco-Print, from Thermopatch
The DECO-PRINT Model DP2000T machine is shipped with the printing platen assembly (hard rubber)
installed onto the machine. The printing plate is not included and must be ordered separately.
The machine cannot be used for direct printing without a printing plate installed into the machine.
New features on this machine include:
•A transfer sensor used to precisely align each transfer on the sealing platen as the transfer
moves through the machine.
•An adjustable laser target dot to assist the operator in positioning the garment for print /
transfer.
The DECO-PRINT Model DP2000T machine prints the customer’s logo or text directly onto the garment
using the hard rubber platen, “C” tape, and a printing plate (not included).
The printing plate is ordered separately in one of three configurations.
1. With the customer’s logo,
2. With a plate with tracks, or
3. With a combination of a logo and tracks for individual lettering.
When using individual lettering, the type font kit, (not included), will need to be ordered separately.
With the sealing kit installed, the Deco-Print Model DP2000T machine can be used for heat sealing
individual labels, mending patches and for applying hot paper transfers.
PLEASE NOTE: The time, temperature, and pressure settings needed to seal these products
with the DP2000T may differ from the settings needed by other Thermopatch heat seal
equipment. Contact a Thermopatch representative with any questions.
The DECO-PRINT model DP2000T prints a permanent mark directly onto most natural or synthetic
fabrics by means of a printing plate, briefly striking the inked ribbon against the material to be marked.
The machine is an air operated machine that uses a foot pedal, (included), to initiate the printing cycle.
The transfer roll or “C” tape roll advances by means of a motor drive. The transfer sensor is used to
accurately locate the transfer in the correct position for each application.
The heater is made from cast aluminum for durability. The electronic temperature control maintains
the temperature within 5 degrees of the temperature setting for accurate printing / sealing conditions.
The printing plate and sealing plate slide into guides mounted onto the sides of the heater. The plate
can be easily changed by pulling the plate out and inserting another plate, using the plate holder
(included).

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ACCESSORIES INCLUDED:
•45658 — Sealing kit. Use for sealing labels, mending materials and applying hot paper transfers
•46780 — (3) Separator discs. Used between different colored ribbon rolls (C-TAPE) on supply
side. See page 21.
•46007 — Plate holder.
•47312 — the Standard (SAE) Tool Kit (after January 2015)
•47309 — 1.5 M of 6 mm tubing (after May 2015)
•47310 — 6 mm OD Connection (after May 2015)
PRINTING OPTIONS:
•45957 — Special adapter plate to mount narrow plates previously used in the Model PAP304
machine.
•PM-1330 — TYPE FONT KIT, 94 pieces, ¼” high to fit standard print plates listed below.
•PP0500-01 — Print plate with (1) track.
•PP0500-02 — Print plate with (2) tracks.
•PP0500-03 — Print plate with (3) tracks.
•PP0500-04 — Print plate with (4) tracks.
•PP0600-01 — Print plate with (1) extended track, up to 14 characters.
•PP0600-02 — Print plate with (2) extended track, up to 14 characters.
•PP0600-03 — Print plate with (3) extended track, up to 14 characters.
CUSTOM PRINT PLATES
Depending on a customer’s requirements, the printing plate may be an engraved plate, changeable
type slugs, or a combination. This will allow you to:
•Print property marks, logos, and other information on sheets and the inside layers of pants,
jackets, and other garments.
•Print company logos directly on suit bags, hospital linen, table linen, or shop wear.
•Print any of the above with different colors - up to four, 1” wide ribbons or any combination up
to 4” total width.
Print plates can be fabricated to fit individual requirements using customer supplied artwork. Design
can include tracks for individual type fonts or full phrase slugs. Maximum printing area is 4 ¾” x 3 ¾”.
To print with (2) or more different colored ribbons, a relief or space between adjacent fonts or
engravings should be 7/32”.
The “C” tape ink ribbons are available in 13 standard colors, in 1”, 2”, 3”, and 4” widths.
Custom colors are available. Contact customer service for information and pricing for custom colors.

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Safety Information
Each DECO-PRINT machine is equipped with a Safety Guard feature for the protection of the operator.
The Safety Guard is activated in two ways:
1. The metal bar senses the touch of your hand.
2. There are switches that sense any obstruction.
Once the safety guard is activated, the downward movement of the print will be interrupted and the
“CLEAR” button must be pressed before the next print cycle. If an obstruction is met before this point,
the power print cycle will not occur.
There is an Emergency Stop switch, on the front of the machine that will immediately interrupt the
machine at any point in the power printing cycle, and return to the normal positions. The switch must
be reset before resuming operation.
The electrical system is isolated and fully grounded. The electrical power cord must always be plugged
into a properly grounded outlet.
THE USE OF POWER STRIPS AND EXTENTION CORDS IS NOT RECOMMENDED
CAUTION: PRESSURE READING ON AIR GAUGE MUST NOT EXCEED 100 PSI (7.0 BAR)
CAUTION: THE PRINTING HEAD AND PLATE MAY REACH TEMPERATURES AS HIGH AS
550
°
F (288
°
C) DURING NORMAL OPERATION. ALWAYS KEEP HANDS CLEAR OF THE
PRINTING HEAD WHEN OPERATING MACHINE.
IF POWER IS ON, DO NOT LEAVE MACHINE UNATTENDED. IF A LOSS OF AIR PRESSURE
OCCURS, AND IF A GARMENT IS RESTING ON THE PLATEN, THE HEAD CAN LOWER AND
COULD CAUSE A FIRE. A CHECK VALVE IS BUILT INTO THE MACHINE TO PREVENT THIS,
BUT WITH A LOSS OF AIR PRESSURE, THE HEAD WILL COME DOWN AT SOME POINT.
WARNING: BEFORE OPERATING THE MACHINE, MAKE SURE ALL COVERS ARE IN
PLACE, AND KEEP LOOSE JEWELRY AND CLOTHING CLEAR OF THE MACHINE DURING
OPERATION.
BEFORE SERVICING THE MACHINE, UNPLUG THE ELECTRICAL CORD, DISCONNECT THE
AIR SUPPLY, AND LET THE PRINTING HEAD COOL DOWN TO ROOM TEMPERATURE
CLEAN MACHINE PARTS WITH NON-FLAMMABLE CLEANING FLUIDS ONLY.

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MACHINE SPECIFICATIONS
Electrical Requirements: 5 Amps @ 110 VAC 50/60 HZ
Or
2.5 Amps @ 220 VAC, 50/60 HZ
Operating Air Pressure: 25 PSI (1.8 BAR) Minimum to
70 PSI (4.8 BAR) Maximum
1.3 CFM (0.6 Liters/sec)
Dwell Time Setting:
0.1 Seconds to 99.9 Seconds
Heat Range: 200°-500°F (93° - 260°C)
Maximum Print Area:
4-3/4” wide x 3-3/4” deep
Transfer Advance (Roll) Sensor controlled stop is adjustable from 7 ½” to
13 ½”from the centerline of the platen
Ribbon Advance:
0.1” to 6.0” (2.5mm to 152mm)
Ink Ribbon Width:
4, 3, 2, and 1 inch (102, 76, 51, and 25 mm)
Multiple colors and widths
any combinations up to 4” total width
Opening Height:
(Between Printing Plate and Platen)
5.0” (127 mm)
Clearance:
(From Back of Platen to Machine)
1-3/4” (44 mm)
Weight:
115 lbs. 52 kg.
FACTORY SETTINGS
Temperature: 500°F (260°C)
Transfer time:
2.0 seconds
Label seal time:
12.0 seconds
Printing time:
0.5 seconds
Air Pressure:
50 PSI (3.5 BAR)
Transfer (Roll) Advance:
5.0in (126-128mm)
Ribbon Advance:
5.0 in (126-128 mm)

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Section 2
DP2000T SETUP
Step 1
Refer to Figure 1
Loosen the two screws on the top of the case in the back and install the control box bracket, Item 4.
Figure 1 — Control Box Bracket

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Plug one side of the display cable, Item A, into the control box, Item B, connector.
Figure 2 — Display
Plug the other end of the display cable, Item C, into the connector on the side of the machine.
Figure 3 — Electrical Plugs Connected

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Step 2
Refer to Figure 4.
Turn the “Emergency Stop” switch, Item A, in the direction of the arrow to make sure it is out.
Figure 4 — Heater Cover Assembly, Installation
Step 3
Refer to Figure 5
Attach the air filter/regulator, with fittings to the bulkhead fitting, Item A, on the back of the machine.
Orient as shown with the gauge facing forward.
Connect the air supply to the male hose adaptor, Item C.
Figure 5 — Air Filter/Regulator, Installation

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Step 4
Refer to Figure 6. This is the Electrical Enclosure Assembly, found on the right side of your machine
Connect the foot pedal plug into the FOOTSWITCH Plug, Item A.
Connect the power line cord to power entry module, Item B, and to the power outlet. Turn on the
machine by pressing the on/off switch, Item D.
Item C depicts the display cable plugged in, previously discussed in connection on page 14
Figure 6 — Electrical Enclosure Assembly, Outside view

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Step 5
Refer to Figures 7 & 8
Place flange assemblies, Item A, on supply and take-up shafts, Item B.
Figure 7 — Head Assembly, no Flanges
Figure 8 — Head Assembly, with Flanges

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Figure 9 — Transfer Roll Threading

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Figure 10 — Ribbon Roll Threading

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DP2000T Transfer Specifications
DP2000T Transfer Setup
1. Select the transfer for use and measure the distance from the leading edge of one image to the
leading edge of the next transfer as shown.
A special platen is required if this measurement is less than 2-1/2 inches ( 64 mm )
2. Install the transfers onto the machine.
3. Use the JOG button to feed the transfer image until the image is in the center of the sealing platen.
4. Press the MENU button.
5. Press the ENTER button until the display reads “ SET FEED LENGTH: “.
6. Subtract 2 tenths of an inch, (5 mm) from the transfer measurement in step 1 and use the UP or
DOWN ARROW button to enter this number into the machine.
Example – The transfer measures 3 inches, (76 mm) from leading edge to leading edge. Subtract 2
tenths of an inch, (5 mm) from 3 inches. The number entered into the machine should be 2.8
inches, (71 mm).

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7. Press the ENTER button until the display reads “PATTERN MARKER: “.
Use the UP or DOWN ARROW button to select YES.
8. Press the MENU button to exit the menu.
9. Loosen the clamp screw, move the transfer sensor onto the space between the transfer images and
tighten the clamp screw.
10. Press the TRANSLUCENT button and hold it until the lights on the sensor stop blinking.
NOTE: If green and red output lights are on and an * is displayed on the control box, push both
(normal) and (translucent) buttons simultaneously. This procedure inverts the output to
the correct status, green light on.
Figure 11 — Sensor
Figure 12 — Sensor location

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11. Loosen the clamp screw and move the transfer sensor towards the leading edge of the transfer
image closest to the sealing iron. When the edge of the image is detected by the transfer sensor, an
asterisk ( * ) will appear on the display next to the feed length.
When you see the asterisk ( * ), on the display, tighten the clamp screw.
Test the machine. The transfer image should be centered on the sealing platen. If the image is
moving after each cycle, re-adjust the position of the transfer sensor.
If the image is not centered, repeat the setup procedure.
Figure 13 — Sensor Position