USR8BX-Manual 12-05

D e s i g n e r s a n d M a n u f a c t u r e r s o f P r o d u c t D e c o r a t i n g E q u i p m e n t , Au t o m a t e d S ys t e m s , a n d S u p p l i e s
Operation and Maintenance Manual
Model R8BX
Roll-On Hot Stamping Machine
December 2005
About United Silicone Supplies
An ITW Decorating Company, United Silicone Our dedicated customer service team
specializes in the design and manufacture of hot understands—and responds with a sense of
stamp, and heat transfer decorating equipment. urgency to—the needs of our customers. Silicone
All standard machines and dedicated, custom- rubber sheets, rollers, and dies are all available at
designed systems are offered to the ever- low cost and with fast, friendly service. United
changing, continually expanding marketplace for Silicone’s creative art department meets customer
part decorating equipment. needs for accurate, meticulous quality in hot
In addition to our full line of equipment and design stamping dies. Our products include:
services, United Silicone offers a wide array of hot • Silicone rubber sheets
stamping and heat transfer tooling and supplies.
You have made a wise choice in selecting a • Silicone rubber rollers
United Silicone hot stamping machine. And to
help fill your future decorating needs, we want you • Stamping dies—flat and contoured
to know about our semi- and fully-automated
processing systems, and other products and • Part nesting fixtures
services. Details are provided in the following
paragraphs.
Semi- and Fully-Automated Systems • Part loading and unloading
From integrating two or more decorating
processes to developing fully automated part • Articulation
handling and production equipment, United
Silicone’s Automation Division offers • Sorting
comprehensive solutions to the demands of
today’s fast-paced manufacturing environment. • Part presence sensing
Our skilled engineers analyze needs, perform cost
analyses, consult with production engineers and • Optical inspection
decision makers, develop preliminary design
concepts, and create custom-designed systems, • Decorating (hot stamp, heat transfer)
which dramatically improve production efficiency
and quality control. • Pre- and post-treating, as required
• Robotics/interface to existing conveyor
• Sampling and testing
Engineering Services
When assistance is needed to solve a decorating
problem or plan future decorating systems, United
Silicone is ready to provide assistance when and
where needed. These services comprise:
• Feasibility studies
• Automation consulting
Typical Automated System • Cost analysis
Carefully designing, building, and testing • Design review

individual processing stations and integrating the
discrete assemblies into a unified, smooth- • Technical field support
functioning, reliable system are everyday events
at United Silicone’s Automation Division. And all
are directed at surpassing customer expectations!
Ready to Help
Contact United Silicone for assistance on all your
Automated systems employ combinations of part decorating requirements. We have the skill
various processing assemblies, a mechanism for and dedication to help you meet the needs of your
moving the parts through the various stations, and customers—today and tomorrow!
state-of-the-art digital controls that supervise the
entire system.
United Silicone’s innovative engineers develop

these custom systems by skillfully interfacing the
required processing stations to produce uniformly
high-quality finished products.
From transporting unfinished parts to the first

processing station, to dispensing the completed
components to the next manufacturing or
assembly process, our systems are conceived
and built to exacting customer standards and
specifications. Typical processing stations
currently in use on our automated systems are:
3
R8BX Roll-On Hot Stamping Machine
Contents
CONTENTS
1.0 Introduction
Why Hot Stamping ......................................................................................................1.0-1
Safety ..........................................................................................................................1.0-1
2.0 Warranty
3.0 Description
Roller Head .................................................................................................................3.0-1
Foil/Web Payout and Feed..........................................................................................3.0-1
Main Frame .................................................................................................................3.0-1
Head Height Adjuster ..................................................................................................3.0-1
Positive Stop ...............................................................................................................3.0-1
Control Panel ..............................................................................................................3.0-2
Message Screen ...................................................................................................3.0-2
Temperature Controller .........................................................................................3.0-2
Electrical Panel ...........................................................................................................3.0-2
4.0 Operation
The Roll-On Hot Stamping Process ............................................................................4.0-1
Equipment Operation ..................................................................................................4.0-1
Roll-On Stamping Cycle ........................................................................................4.0-1
Foil Feed ...............................................................................................................4.0-2
5.0 Installation
Shipping Inspection.....................................................................................................5.0-1
Machine Placement and Mounting..............................................................................5.0-1
Utility Requirements ....................................................................................................5.0-1
Electrical Power.....................................................................................................5.0-1
Air Supply ..............................................................................................................5.0-1
Air Connection.............................................................................................................5.0-1
Air Pressure Regulator................................................................................................5.0-1
Lubricator ....................................................................................................................5.0-2
Air Filter.......................................................................................................................5.0-2
6.0 Setup and Adjustment
Roller Head Height Adjustment...................................................................................6.0-1
Foil/Web Installation....................................................................................................6.0-2
Foil Stripper Bar Adjustments .....................................................................................6.0-3
Photocell Adjustments.................................................................................................6.0-4
Foil/Web Pulling Intervals............................................................................................6.0-5
Stamping Area Setup ..................................................................................................6.0-5
Temperature Setting ...................................................................................................6.0-6
Stamp Evaluation and Adjustment ..............................................................................6.0-7
Stamp Adhesion Testing and Adjustment ...................................................................6.0-8
Changing Temperature Scales ...................................................................................6.0-8
i
Contents
7.0 Troubleshooting
Error Messages...........................................................................................................7.0-1
Diagnostics..................................................................................................................7.0-2
Troubleshooting Chart.................................................................................................7.0-3
Battery Replacement...................................................................................................7.0-3
8.0 Maintenance
Lubrication...................................................................................................................8.0-1
Pneumatic System Lubricator ...............................................................................8.0-1
Head Height Adjusting Screw................................................................................8.0-1
Roller .....................................................................................................................8.0-1
Head Slide Assembly ............................................................................................8.0-1
Air Filter.......................................................................................................................8.0-1
Inspection and Cleaning..............................................................................................8.0-1
Adjustments ................................................................................................................8.0-1
Component Replacement ...........................................................................................8.0-1
Heater Shroud .......................................................................................................8.0-1
Up Limit Proximity Sensor .....................................................................................8.0-2
Solid State Relay...................................................................................................8.0-3
Palm or Opti-Touch Switch....................................................................................8.0-3
CYCLE START or EMERGENCY STOP Switch...................................................8.0-4
Air Cylinder............................................................................................................8.0-4
Head Slide Motor and Gearbelt.............................................................................8.0-5
Roller Drive Motor, Sprocket, and Chain...............................................................8.0-5
Roller Shaft Bearings ............................................................................................8.0-5
Foil Pinch Roller ....................................................................................................8.0-6
Foil Takeup Drive Belt ...........................................................................................8.0-7
9.0 Recommended Spare Parts
Ordering Parts.............................................................................................................9.0-1
10.0 Pneumatic Slide Table option
Description ................................................................................................................10.0-1
Operation ..................................................................................................................10.0-1
Troubleshooting ........................................................................................................10.0-1
Maintenance..............................................................................................................10.0-1
Air Cylinder..........................................................................................................10.0-1
Solenoid-Operated Air Valve...............................................................................10.0-2
10.1 Rotary Table Option
Description ................................................................................................................10.1-1
Operation ..................................................................................................................10.1-1
Station Alignment ................................................................................................10.1-1
Speed Control .....................................................................................................10.1-1
Table Index Cam Adjustment....................................................................................10.1-2
10.2 X-Y and X-Y-R Positioning Table Option
Description ........................................................................................................................10.2-1
Operation...........................................................................................................................10.2-1
ii
Contents
11.0 Semi-Automated Custom Hot Stamp Systems
Description ........................................................................................................................11.0-1
Documentation ..................................................................................................................11.0-1
12.0 Engineering Drawings
ILLUSTRATIONS
1.0-1 Model R8BX Roll-On Hot Stamping Machine .............................................................1-0-2
3.0-1 Control Panel ..............................................................................................................3.0-2
4.0-1 The Roll-On Hot Stamping Process ............................................................................4.0-2
5.0-1 Air Connection.............................................................................................................5.0-1
6.0-1 Setting Air Pressure ....................................................................................................6.0-1
6.0-2 Roller Head Height Adjustment...................................................................................6.0-2
6.0-3 Foil/Web Payout Assembly .........................................................................................6.0-2
6.0-4 Pinch Roller Camshaft ................................................................................................6.0-3
6.0-5 Foil Path ......................................................................................................................6.0-4
6.0-6 Foil/Web Front-to-Back Adjustments ..........................................................................6.0-4
6.0-7 Photocell X-Y Adjustments..........................................................................................6.0-4
6.0-8 Photocell Sensitivity Adjustment .................................................................................6.0-5
6.0-9 Temperature Controller Key Functions .......................................................................6.0-7
7.0-1 Controller Input and Output Cards ..............................................................................7.0-3
7.0-2 Controller Battery Location..........................................................................................7.0-3
8.0-1 Heater Shroud.............................................................................................................8.0-2
8.0-2 Roller Mounting Details ...............................................................................................8.0-2
8.0-3 Up Limit Proximity Sensor...........................................................................................8.0-3
8.0-4 Solid State Relay Location ..........................................................................................8.0-3
8.0-5 Panel Switch Installation .............................................................................................8.0-3
8.0-6 Air Cylinder Mounting Details ......................................................................................8.0-4
8.0-7 Head Slide Motor and Gearbelt...................................................................................8.0-4
8.0-8 Roller Drive Components ............................................................................................8.0-5
8.0-9 Rear Shaft Bearing Installation ...................................................................................8.0-5
8.0-10 Foil Takeup Components ............................................................................................8.0-6
10.0-1 Slide Table Cylinder Installation................................................................................10.0-2
10.0-2 Slide Table Air Valve.................................................................................................10.0-2
10.1-1 Rotary Table Option ..................................................................................................10.1-1
10.0-2 Rotary Table Index Drive Cam Adjustment ...............................................................10.1-2
iii
Contents
10.2-1 X-Y Positioning Table................................................................................................10.2-1
11.0-1 Pick and Place Station ..............................................................................................11.0-1
iv
1.0 Introduction
1.0 INTRODUCTION
The United Silicone Model R8BX roll-on hot • Dry process requiring no ink, allowing part
stamping machine (Figure 1.0-1) offers to be immediately ready for handling and
advanced capabilities for reduced installation packaging.
and setup time, consistent stamping force,
quiet operation, precision foil advance, and
operator convenience and ease of operation.
Its 20-inch lateral travel offers high versatility
in large-area decorating. Table 1.0-1 lists
technical specifications for the Model R8BX.
Your roll-on hot stamping machine is

designed for extended trouble-free operation.
Built-in diagnostics aid in fault analysis in
case of malfunction. United Silicone backs its
equipment with a strong customer service
organization. Telephone assistance is
provided at no charge to assist you in
troubleshooting, equipment installation,
setup, or other issues.
To gain the most from your equipment, you

are urged to read through this manual
completely before beginning your setup.
These instructions will minimize the
installation and setup time and assist you in
properly operating the machine following the
installation.
When selecting a location for the machine,

take into account the following concerns:
• Work area is adequately lighted.
• Required utilities (air and electricity) are

present.
• Sufficient space is available for receiving

and forwarding parts.
WHY HOT STAMPING

Following are some of the significant benefits
offered by the versatile hot stamp decorating
process:
1.0-1
Introduction
• Suitable for wide variety of materials SAFETY
including thermoplastics, thermoset The Model R8BX is designed for safe
plastics, wood, leather, cloth, paper, and operation and includes all required safety
pre-painted metals features to minimize possible injury to
personnel. However, you are responsible for
• Only method available for applying providing a safe environment for operating
permanent gold and silver metallic this machine and other equipment at your
graphics, as well as wood grain, gloss or facility. Do not remove any guards or defeat
matte pigment colors, brushed effects, safety devices. If any additional equipment is
chromium, and multi-colored graphics used or modifications made to the stamping
machine, be sure to provide suitable operator
• Applies to various surface geometries protection.
including flat, cylindrical, and spherical
Safety begins with permitting only properly
• Thermally bonds to substrate for excellent trained personnel to install and operate the
long-term durability equipment. All personnel involved in
installing and setting up the equipment must
• No hazardous vapors or solvents be fully trained in performing electrical,
requiring special storage or compliance pneumatic, and mechanical installations. All
with Environmental Protection Agency operators should be thoroughly trained in the
(EPA) rules safe and correct procedures described in this
manual. Do not permit untrained personnel
to perform, or assist in, installation of the
equipment or subsequent operation.
Table 1.0-1. Model R8BX Specifications

Electrical 220 Vac, 60 Hz, 20 A
80 to 100 PSI (50 PSI min.) at 3 CFM, moisture-free, 3/8” NPT
Air
connections
Heater 2800 W shroud
Roller pressure (max.) 980 Lbs at 100 PSI air pressure
Roller dimensions 6” D x 8” L
Roller slide travel Up to 20”
Roller vertical travel Up to 2”
Head cylinder stroke Up to 1”
Roller climb Up to 0.5”
Working height Up to 14”
Overall dimensions (approx.) 70” H x 68” W x 36” D
Weight (approx.) 1000 Lbs
Light curtains; dual palm or Opti-Touch (optional) switches on
Personnel safety slide table machines
1.0-2
1.0 Introduction
Figure 1.0-1. Model R8BX Roll-On Hot Stamping Machine
3
2.0 Warranty
2.0 WARRANTY
United Silicone (Seller) warrants the Model R8BX to be free of any defects in material and
workmanship. The Seller’s sole obligation under this warranty is limited to replacing or repairing
(at the Seller’s discretion), FOB Lancaster, New York, any part of its product which, under
normal and proper use and maintenance, is proven defective in material or workmanship within
one year1 after delivery to Buyer, provided that notice of any such defect and satisfactory proof
thereof is promptly provided to the Seller, and thereafter such part is returned to the Seller, with
transportation charges prepaid, and the Seller’s examination confirms such part to have been
defective.1
This warranty does not apply to any damage to the product, accessory, or attachment thereof
caused by overloading or other misuse, neglect or accident, nor does this warranty apply to any
product or accessory or attachment thereof, which has been repaired or altered by other than
the Seller or its authorized representative in any way, which in the sole judgment of the Seller
affects the performance or purpose for which the equipment was manufactured.
_________
1
This warranty applies to United Silicone-manufactured components only. If components made by other
manufacturers are used, the original equipment manufacturer’s warranty applies, unless otherwise
specified.
2.0-1
3.0 Description
3.0 DESCRIPTION
Principal components of the roll-on hot up as the heated roller transfers the web
stamping machine are: Roll-on head, control resins to the decorating surface.
box, main electrical enclosure, web payout
and takeup, foil stripper, main frame, and The takeup includes the components for
head slide assembly (see Figure 3.0-1). The pulling and receiving the used carrier after the
major components are described in the roll-on cycle. The web moves from left to
following paragraphs. right. An electric motor, operating under
timing by the controller, rotates the takeup
shaft that receives the used carrier after
ROLLER HEAD stamping, while the knurled roller prevents
A double-acting pneumatic cylinder, enclosed the used foil from slipping. The foil stripper
within the cylinder mounting box, provides the subassembly applies tension to the foil when
motive force needed to drive the head in contact with the decorating surface.
downward onto the decorating surface. The
cylinder mounting box also contains the down
limit switch and up limit proximity sensor, MAIN FRAME
which detect vertical position of the head All necessary supports and brackets that
during extension and retraction. facilitate mounting of other major components
are included on the main frame. The
Provisions for rotating and heating the roller worktable, which has provisions for mounting
are also included in the head. An electric the nesting fixture used to properly retain and
motor drives the roller through a sprocket and position the part to be decorated, is also
roller chain system. Heat is applied to the included on the main frame.
roller as it turns within the heated shroud. An
infrared sensor continuously detects roller
HEAD HEIGHT ADJUSTER
temperature and transmits information to the
controller, which maintains the temperature The head height adjuster permits vertical
setting. Rapid cooling of the roller is adjustment of the head in relation to the
facilitated by directing an air jet over the roller worktable. The adjuster sets the head
through an orifice mounted in the shroud. The position to ensure proper contact with the
down limit switch, which completes a circuit to part, while avoiding excessive pressure,
the control panel when the cylinder is fully which could damage the die. A handwheel is
extended, is mounted at the top of the used to move the head up and down to
cylinder mounting box, adjacent to the obtain the required relationship. Slide clamps
stamping head. permit positive locking of the head in the
desired vertical position after adjustment.
FOIL/WEB PAYOUT AND TAKEUP

POSITIVE STOP
The web payout retains the carrier roll and
properly aligns the web with the heated roller. A locking vernier adjusting sleeve installed on
A micrometer adjustment facilitates precise the positive stop is used for making fine
alignment. In addition, the payout contains a
pneumatic cylinder that clamps the web adjustments of the cylinder’s downward
during head movement on the slide stroke. The adjusting sleeve actuates the
assembly. The clamping action ensures that down limit switch, which is mounted on a
the web is positively restrained from backing bracket adjacent to the positive stop. When
actuated by the adjusting sleeve, the closed
3.0-1
3.0 Description
switch contacts complete a circuit that signals machine. Switch and control panel functions
the control panel of the completion of the are described in Table 3.0-1. Table 3.0-2 lists
cylinder’s downward travel. In case the down and describes system status messages.
limit switch fails, a dead stop mechanically
stops movement before the cylinder bottoms. Alarm messages are listed and described in
Table 3.0-3, which follows the normal
operating information.
CONTROL PANEL
The control panel (Figure 3.0-1) includes the Temperature Controller
operator interface for the Allen-Bradley PLC The temperature controller maintains the
controller. The panel contains four major roller temperature. The temperature in
control and display sections: degrees F is constantly displayed on the
controller display. The setpoint temperature is
• Main switches – POWER OFF/ON, raised and lowered using the double arrow
START, RESET, STAMPING SPEED, keys on the left. The setpoint adjustment
and EMERGENCY STOP procedure is described in Setup and
Adjustment.
• Keypad – Soft keys are used for setup
and adjustment of operating
characteristics ELECTRICAL PANEL
Electrical components and circuitry that
• Message Screen – Displays system control machine operation are installed in the
status, error messages, and setup and electrical panel.
operating information
The electrical panel contains internal
• Temperature controller – Set and control connections for input power and distribution
temperature of shroud heater to various components of the machine.
Terminal strips are provided to facilitate
Message Screen component replacement.
During system operation, the keyboard’s
message screen displays the following
information:
• First line - System status and error

messages
• Next line(s) – Current operating mode,

cycle timing, current number of cycles
completed, and other operating
information
Note: The cycle count may be zeroed by

pressing the F8 key when COUNTER
RESET is displayed at lower right corner
of screen.
When a manual or other function is selected,

the message changes to information relating Figure 3.0-1. Control Panel with Allen-
to the selected activity, e.g. DECAL PULL or Bradley Operator Interface
END DELAY. Figures 3.0-2 through 3.0-09
show the various screens used to operate the
3.0-2
3.0 Description
DISPLAY SCREENS
The operator-accessible display screens and menus that follow include descriptions of each
associated function key.
Main Menu
} System Status Message
Figure 3.0-2. Main Menu

Note: Reverse video appears when function is selected
Function Description
Pressing F1 moves roller to left for as long as F1 is pressed, or until
JOG LEFT
left proximity switch is reached.
Pressing F2 moves roller to right for as long as F2 is pressed, or until
JOG RIGHT
right proximity switch is reached.
F3 acts as a momentary contact switch to move the web only during
WEB ADVANCE
contact.
F4 toggles between clamped and released mode. (Reverse text as
WEB CLAMP
shown indicates released mode)
TABLE JOG Press F5 to cycle table only.
ACCESS Press F6 to navigate to the Security Login Screen.
COUNTER RESET Press F7 for at least three seconds to reset counter to Zero.
HEAT IS ON/OFF F8 toggles the print head thermal element On or Off.
3.0-3
3.0 Description
Login Screen
Figure 3.0-3. Login Screen

Note: Reverse video appears when function is selected.
Allows the operator to enter a password that permits access to
LOGIN
appropriate menus.
Pressing F2 logs out the current user and restores the system to its
LOGOUT
basic security level.
F5 MAIN Press to navigate back to Main Menu
Press F6 to navigate to Configuration Menu 1. The two Configuration
CONFIG MENU-1
Screens allow setting of various operating characteristics
CONFIG MENU-2 Press F7 to navigate to Configuration Menu 2.
Keys F3, F4, and F8 are non-functional in the Security Login Screen.
3.0-4
3.0 Description
Configuration Menus
Figure 3.0-4. Configuration Menu 1

F1 enables keypad entry of interval (0.01 to 9.99 seconds) following
EYE TIMER end of a cycle for the photo eye to ignore registration mark. Press
return key [] to save your setting.
Press F2 to enter the pull period (in seconds) for advancing web or
WEB TIMER
film. Press return key [] to save your setting.
Toggle switch determines which carriage location (left or right) is
PULL LEFT/RIGHT
necessary for foil advance.
Press F4 to enter maximum allowable time for machine to complete
its cycle (in seconds), at which time for machine to complete its cycle
MAX TIMER
an alarm condition occurs and system stops. Press return key [] to
save your setting.
Toggle switch selects roller location (left or up) necessary for carriage
RETURN LEFT UP
return to home position.
F8 Allows the operator to make parameter changes and manually
SETUP MODE
cycle individual system components.
3.0-5
3.0 Description
Figure 3.0-5. Configuration Menu 2

Press F1 to display current status of all machine inputs (refer to
INPUT SCREEN
Troubleshooting for details).
Press F2 to display the first page of Outputs to view current status of
OUTPUT SCREEN
all machine outputs (refer to Troubleshooting for details).
NO SLIDE F3 establishes whether or not machine has a slide table. (NO SLIDE
/SLIDE PRESENT mode ignores all resident programming for slide option)
DECAL/FOIL MODE Pressing F4 toggles between decal and foil modes as displayed.
Press F7 to toggle slide on/off. (Note: In OFF mode, slide table must
SLIDE OFF/ON
be at its position under the web for machine to cycle)
Corresponding functions of this key are accessible only to factory
DISPLAY SETUP
authorized service technicians.
3.0-6
3.0 Description
Inputs Display Screen
Figure 3.0-6. Inputs Display Screen
INPUTS SCREEN This screen is dynamic and emulates the LED status lamps within the
PLC and displays the current status of all machine inputs. (refer to
Troubleshooting for details).
OUTPUT SCREEN Pressing F8 displays the first page of Outputs to show current status
of all machine outputs (refer to Troubleshooting for details).
SINGLE SCREEN Pressing F5 returns Single Cycle Mode Screen.
MANUAL SCREEN Pressing F6 displays Manual Screen.
Outputs Display Screens
Figure 3.0-7. Outputs Display Screens 1 and 2
OUTPUTS The Outputs screens are dynamic and emulate the LED status lamps
within the PLC and displays the current status of all machine outputs.
(refer to Troubleshooting for details).
Pressing F7 from either of the two Output screens toggles the display
OUTPUT PAGE-1/-2
to the other Outputs Display page.
INPUT SCREEN Press F8 to navigate to the Inputs Display.
3.0-7
3.0 Description
Alarm Banner
Whenever an alarm or fault occurs within the machine, an associated fault message appears in
a alarm banner. The alarm banner obscures all other screens immediately upon detection of the
fault. See Troubleshooting (Section 7.0) for a complete list of system alarm messages.
Figure 3.0-9. Alarm Display (typical)

Refer to Troubleshooting (Section 7.0) for other common alarms
Press F1 to acknowledge fault condition and return to previous screen.

F1 ACK
Acknowledgement does not clear or correct the condition.
3.0-8
3.0 Description
System Status Messages
During normal operation the status messages listed below report the current operating status,
These messages appear only on the Main Menu and Configuration Menu screens.
• EMERGENCY STOP
• AUTO CYCLE RUNNING
• READY TO CYCLE WITH SLIDE TABLE
• READY TO CYCLE WITHOUT SLIDE TABLE
• MANUAL SLIDE TABLE MODE ACTIVE
• ROLLER HEAD NOT HOME

PRESS RESET BUTTON
• WEB ADVANCE IN PROGRESS
• STAMP SETUP MODE

PRESS RESET TO EXIT
• ROLLER OVER TEMPERATURE
• SLIDE TABLE IS NOT IN POSITION
• LIGHT CURTAIN BLOCKED
• GUARD DOOR IS OPEN
3.0-9
3.0 Description
OTHER PANEL CONTROLS AND INDICATORS

Allen Bradley Keypad
In the appropriate Configuration mode, enter numerical values for
Numbered Keys 0 – 9 parameters for: photo eye delay (EYE TIMER), maximum cycle time
(MAX TIMER), and web or foil pull time (WEB TIMER).
Backspace key [] Use this key to clear the digit to the left of the cursor.
Return/Enter key [] Press the return key to set the numerical value entered.
Panel Switches
Turns electric power to system on and off; when set to OFF, power
POWER ON-OFF
remains applied to solenoid valve for cooling roller head.
When no faults are present, initiates roll-on stamping cycle.
START
Note: The START button may not be present for some systems.
ROLLER TEMP Refer to supplied Temperature Controller literature. See Fig. 3.0-9.
STAMPING SPEED Adjusts speed of roller head movement across decorating surface.
Used to acknowledge error message and return message screen to
main display. After EMERGENCY STOP button is pressed, pressing
RESET
RESET button twice prepares system to resume operation by
acknowledging fault and returning roller head to home position.
When pushed, halts motion of slide table and roller head. Knob lights
EMERGENCY STOP when actuated. Clear fault(s) before pulling button out fully to restore
system operation.
3.0-10
4.0 Operation
4.0 OPERATION
THE ROLL-ON HOT STAMPING EQUIPMENT OPERATION
PROCESS Supervision of the cycle described in the
Roll-on hot stamping is used to apply foil following paragraphs is provided by the
resins to large areas of flat or slightly controller. The control panel is used to define
crowned parts. Roll-on hot stamping is the roller spin rate, travel speed, temperature,
performed as follows: and foil pull time.
1. Part is mounted on a nesting fixture Roll-On Stamping Cycle

attached to the worktable. For machine equipped with slide table, the
roll-on stamping process is initiated by
2. With the foil held slightly above the part, pressing both palm switches (or touching
the roller head extends downward both Opti-Touch switches) simultaneously.
pressing the foil into intimate contact with For machine without slide table, the process
the surface. is begun by pressing the CYCLE START
switch.
3. With the foil held in intimate contact with
the surface, the roller moves across the Power is then applied from the OFF-ON
decorating surface from right to left. The switch through the palm (or CYCLE START)
foil clamp restrains the foil from backing switches and the closed contacts of the head
up as the roller moves across the part. up right slide proximity switches. Power flows
The resilient silicone rubber roller through contacts of the slide proximity switch,
conforms the foil to surface irregularities energizing the slide motor through control
and creates a parting line in the foil relay CR531, which drives the head left.
resins.
As the head moves left, the slide proximity
4. When its travel is completed, the roller switch contacts are re-positioned as the head
head retracts from the surface and passes the roller down proximity switch
returns to the start position. target. Power then flows through the closed
slide switch contacts to the roller down
5. As the head rises and moves from left to solenoid valve. The valve re-positions to
right, the left stripper lifts the foil from the direct air to the extension side of the
surface, peeling away the left edge and cylinder’s piston, moving the head down onto
then working toward the right. Since the decorating surface.
adhesion between the foil coating and the
surface is greater than the bond between As the roller turns, foil resins are applied to
the release agents in the coatings and the the decorating surface until the head reaches
film carrier, a virtually complete deposition the head up proximity switch target near the
of foil coating is achieved. left end of the slide. The switch contacts are
returned to their original position, directing air
6. Once the head has fully retracted to the into the retraction side of the head up-down
start position, the foil clamp releases the cylinder to return the head upward and
foil, and foil advances until an unused deenergize slide motor relay CR531.
section is positioned under the roller. The
hot-stamped part is then removed from When the head is fully retracted, the head up
the fixture. The part may be handled proximity switch closes, applying power
without danger of smudging or removing through control relay CR532 to energize the
the image from the surface. slide motor in the reverse direction. The head
then moves right until the slide proximity
4.0-1
4.0 Operation
switch reaches the right slide target, which re- either before or after the head has returned
positions the switch and deenergizes control fully to its home position, depending on user
relay CR531 to terminate head movement. preference.
Foil Feed When energized, the motor pulls the foil for
Under controller direction, the foil clamp the programmed interval set by the user. The
cylinder releases the foil, in preparation for controller then terminates foil pulling.
foil pulling. After head cylinder retraction, the
foil feed motor is energized. This will occur
Figure 4.0-1. The Roll-On Hot Stamping Process
4.0-2
5.0 Installation
5.0 INSTALLATION
The procedures in this section are designed • Do not modify mounting provisions. Use
to assist installation personnel in safely and mounting holes provided for securing
properly placing the roll-on hot stamping machine to bench or floor stand.
machine in its work environment and
connecting the required utilities. Be sure to • For operator comfort, mount machine so
follow all personnel safety requirements that operator’s arms are parallel to floor
during the installation. Following installation, when hands are placed on palm switches.
perform the procedures in Setup and
Adjustment to correctly prepare the machine
for safe, productive operation. UTILITY REQUIREMENTS
Electrical power and a pressurized air supply
are required to operate the equipment. The
SHIPPING INSPECTION following paragraphs describe the
Your machine has been thoroughly tested requirements for each utility.
and inspected before shipment. No visible
damage or loose or missing parts should be Electrical Power
seen. Carefully inspect the equipment to Electrical power must be properly connected
ensure that there are no apparent defects. to the machine for safety and satisfactory
Any damage or missing or loose parts should operation. Power at 220 to 240 Vac minimum
be reported promptly to the carrier. is required to operate the machine.
Strict conformance to all applicable National

MACHINE PLACEMENT AND
Fire Protection Institute (NFPA) standards
MOUNTING and local electrical codes is required. United
Observe the following safety and operator Silicone equipment must be properly
precautions when placing the machine at its grounded, and clean, noise-free 220-240 Vac
operating location: 50/60 Hz single-phase power must be
supplied.
WARNING
THE MACHINE WEIGHS 1000 POUNDS. For voltages outside this range, contact
DO NOT ATTEMPT LIFTING WITHOUT United Silicone for assistance.
PROPER HOISTING EQUIPMENT TO
SAFELY LIFT AND PLACE MACHINE IN Air Supply
POSITION. A source of moisture-free air at 80 to 100 PSI
at 3 CFM should be connected to the
machine. A supply of less than 50 PSI at
• Place the machine in a safe area having 3 CFM will cause the machine to malfunction.
adequate lighting and space on all sides
to permit convenient access for operation
AIR CONNECTION
and maintenance.
Connect air source to inlet side of air filter
• Install machine on a level, flat surface located beneath machine stand. Use 3/8”
capable of supporting its weight. An flexible neoprene tubing for the connection to
optional floor stand is available from minimize vibration transfer. Figure 5.0-1
United Silicone for properly mounting the shows the recommended air connection.
machine. Note that a 3/8” NPT drain valve is installed
to permit removal of moisture when
necessary.
5.0-1
5.0 Installation
AIR PRESSURE REGULATOR below 20 PSI. During operation, pressure
Inlet air pressure should be adjusted to 50 to should not drop more than 10 PSI. If greater
100 PSI by means of the pressure regulator. pressure drop is noted, check for constriction
Do not exceed the maximum inlet air in the incoming airline, which may cause
pressure of 120 PSI. Also, the machine insufficient air volume to the machine.
cannot be operated properly with pressure
PLANT AIR REGULATOR

AIR
SUPPLY
FILTER-
REGULATOR-
LUBRICATOR UNIT
LUBRICATOR
3/8 NPT
FEMALE TEE
AIR FILTER
3/8 NPT MALE 1/2" DIA. NEOPRENE TUBING
DRAIN VALVE
3/8 NPT x 1/2" DIA. MALE
PRESTOLOCK CONNECTION
FIGURE 5.0-1. AIR CONNECTION

LUBRICATOR AIR FILTER
Fill lubricator with Shell Tellus 68, Mobil DTE Following the first day of operation an oily
26, or equivalent oil. Do not overfill, and do residue, but no drops of oil, should be
not change the factory-set drip rate. present on the air filter. Appearance of oil
drops is an indication of excessive lubrication,
Refer to Maintenance for ongoing which is to be avoided.
maintenance instructions for the lubricator.
Refer to Maintenance for assistance in
correcting this problem and for routine
maintenance of the air filter.
5.0-2
6.0 SETUP AND ADJUSTMENT

Procedures for preparing the roll-on hot The height adjustment will position the roller
stamping machine for operation are included at the correct height to contact the part, while
in this section. The setup and adjustment allowing sufficient clearance to place and
procedures apply to initial setup, as well as remove part from nesting fixture safely.
for future needs when changing dies,
following component replacement or repair,
and to correct stamping errors.
Extensive illustrations are included to GAGE

facilitate accurate, precise adjustments and READS
thereby ensure trouble-free operation. The ABOUT
adjustments should be performed in the 50 PSI
sequence presented, as each setting
depends on successful completion of the
previous procedure. If an adjustment cannot
be achieved, refer to the preceding setting(s)
to confirm that they were completed properly.
Correct any errors before proceeding with the
next step in the adjustment process.
The following procedures are included: Figure 6.0-1. Setting Air Pressure
• Roller Height Coarse Adjustment To adjust roller height, proceed as follows:
• Foil/Transfer Web Installation
WARNING
• Foil Stripper Bar Adjustments FOR PERSONNEL SAFETY, ONLY
ONE PERSON SHOULD PERFORM
• Photocell Adjustments ADJUSTMENTS. ALL OBSERVERS
SHOULD BE IN FRONT OR AT SIDES
• Foil/Web Pulling Intervals OF MACHINE, BUT NOT BEHIND IT.
• Stamping Area Setup 1. Check that OFF-ON switch on control
panel is set to ON.
• Temperature Setting
2. Loosen bolts on both vertical slide
• Stamping Quality Evaluation and clamps.
Adjustment
3. Place part-nesting fixture on worktable,
• Stamp Adhesion and Adjustment align mounting holes, and secure with
mounting screws.
ROLLER HEAD HEIGHT ADJUSTMENT 4. Place a part on fixture, and press F6
Before beginning this procedure, confirm that MANUAL SCREEN and then F3 JOG
electrical power and air supply are connected LEFT to position roller directly above
and operating (refer to Installation). The decorating surface.
machine’s air pressure gage (Figure 6.0-1)
should read desired pressure. 5. Press F8 SETUP to enter setup mode.
6.0-1
6. If sliding table is installed, move table 1. Loosen collar lock handle, and remove
under roller head. collar, spring, and payout holder from
shaft (Figure 6.0-3).
7. Press START button, and then press both
palm switches simultaneously to extend 2. Slide foil roll onto shaft with foil oriented
roller head downward. so that foil end is at top, matte (coated)
side facing down.
8. Turn handwheel at top of machine
counterclockwise to move roller head 3. Looking toward machine from payout
down until roller contacts part surface. side, align foil front to back with roller by
loosening inside collar and moving collar,
9. Loosen knurled nut on positive stop as necessary, to properly position roll in
(Figure 6.0-2); and then turn adjusting relation to roller. When properly aligned,
sleeve until bottom edge of sleeve is tighten inside collar.
about 1/4” above deadstop.
10. Tighten knurled nut on positive stop.

INSIDE
11. Retract head by pressing F8 SETUP or COLLAR
RESET button.
12. Tighten bolts on both vertical slide

clamps, tightening evenly by alternating
from side to side.
COLLAR
HEIGHT ADJUSTING
LOCK
HANDWHEEL
HANDLE
PAYOUT HOLDER
LOCKING NUT
Figure 6.0-3. Foil/Web Payout Assembly

POSITIVE STOP
ADJUSTING
SLEEVE
CAUTION
INSUFFICIENT TENSION WILL
CAUSE FOIL TO SNAG.
Figure 6.0-2. Roller Head Height EXCESSIVE TENSION WILL
Adjustments CAUSE BREAKAGE. IN THE
FOLLOWING STEP, BE SURE TO
FOIL/TRANSFER WEB INSTALLATION SET TENSION PROPERLY.
The following instructions describe foil or web 4. Slide payout holder, spring, and collar
installation. To install foil or web, proceed as and lock handle onto shaft. Push collar
follows: against spring until medium tension is felt.
Avoid excessive or insufficient tension.
Tighten lock handle after setting tension.
6.0-2
5. With MODE:MANUAL displayed, press 10. Manually turn takeup shaft two full turns
F6 CLAMP TOGGLE to open foil clamp. to tighten foil on shaft.
6. Rotate pinch roller camshaft (Figure 6.0- 11. Press F6 CLAMP TOGGLE to close foil
4) until a gap is opened between knurled clamp.
roller and pinch roller.
7. Mount takeup shaft on foil pull frame as

FOIL STRIPPER BAR ADJUSTMENTS
follows: In this procedure, the payout stripper bars,
foil clamp, and roller head stripper bars are
a. Pull out spring-loaded knob. adjusted. To adjust stripper bars, proceed as
follows:
b. Insert shaft between side plates.
1. Place a part into nesting fixture.
c. Align pin in shaft end with slot in drive
pulley, and release spring-loaded Note: Part is used to facilitate
knob. adjustments of stripper bars.
2. Position stripper bar on left side of roller

head vertical and with bottom of bar about
1/4” to 1/2” above the decorating and 1”
below the roller surface. Set right stripper
bar vertical and about 1/8” above
decorating surface. Tighten retaining
screws after completing adjustments.
PINCH
ROLLER
3. Set payout subassembly stripper bar
approximately at midpoint of its adjusting
slot and angled about as shown in Figure
6.0-5.
4. Set foil clamp approximately at midpoint

of its adjusting slot and about parallel to
work table.
OPEN GAP
BY TURNING 5. Inspect foil path, viewing from takeup
KNOB side. If foil is not parallel with roller, press
in foil clamping bar and slide foil on
takeup shaft left or right to obtain correct
alignment. Release clamping bar when
Figure 6.0-4. Pinch Roller Camshaft
foil is aligned.
8. Thread foil or web as shown in Figure
6.0-5. 6. Viewing from side of machine, check that
roller contact surface is as centered as
9. Wrap one full turn of foil around takeup possible over the decorating surface. If
shaft from underside of shaft without not centered, adjust foil/web position
compressing spring-loaded foil clamping using vernier adjusting knobs at payout
bar. and foil pull (Figure 6.0-6), as required.
Note: If used roll is on takeup shaft, insert 7. If heat transfer web is installed, check that
end of new roll under existing roll. registration mark is about at vertical
6.0-3
midpoint of background. If not, re-position that foil remains properly aligned during
payout subassembly stripper bar to move its travel; adjust web or foil position on
mark into center. takeup shaft if necessary.
8. Turn takeup shaft manually until 11. Position foil guide rings on stripper bars
foil/transfer web is taught, and rotate close to foil edges.
pinch roller camshaft (Figure 6.0-4) until
pinch roller is brought together with
knurled roller.
9. With MODE:MANUAL displayed, press

F2 DECAL ADVANCE and confirm that
web or foil is not slipping on takeup shaft.
10. While observing foil movement, press F2

DECAL ADVANCE sufficiently to confirm
FOIL PATTERN
Figure 6.0-5. Foil Path
Figure 6.0-6. Foil/Web Front-to-Back

Position Adjustments
LEFT VERNIER RIGHT VERNIER PHOTOCELL ADJUSTMENTS

ADJUSTMENT ADJUSTMENT
If heat transfer web is installed, the photocell
must be adjusted in the X and Y directions to
align with the web registration marks. In
addition, the sensitivity must be set to read
the registration mark. Adjustments are
performed as follows:
6.0-4
1. Loosen locking knobs on both Note: No further setup is normally
adjustments (Figure 6.0-7). Move web required. However, if the contrast meter
until registration mark is in view. fails to move full scale, re-set the offset
adjustment so that contrast deviation
2. Move photocell horizontally until aligned straddles the switchpoint of “5.” Rarely, it
with mark, and tighten locking knob. may be desirable to re-adjust contrast
meter under dynamic conditions, as the
web marks pass under the photocell
beam.
VERTICAL BACKGROUND
ADJUSTING
HANDLE
VERTICAL
HORIZONTAL ADJUSTMENT
ADJUSTMENT LOCKING KNOB LEDs
LOCKING KNOB
OFFSET
CONTROL
KNOB
Figure 6.0-7. Photocell X-Y Adjustments

Figure 6.0-8. Photocell Sensitivity
3. Turn handle at top of photocell mounting
Adjustment
bracket to align photocell vertically with
registration mark. Tighten locking knob
after completing adjustment. FOIL/WEB PULLING INTERVALS
The factory-set interval for foil pull time
4. To adjust photocell sensitivity, place the should be adjusted for the application. The
appropriate background (Figure 6.0-8)— other parameters apply to heat transfer web
light or dark—that contrasts with the operation and normally do not require
web’s registration mark under photocell adjustment. If adjustment is desired, refer to
beam. Step a, below, describes light Description for explanations of settings and
background adjustment, and step b proceed as follows:
explains adjustment for dark background.
Using appropriate procedure, adjust 1. If foil is installed, check foil pulling interval
machine’s contrast meter as follows: as follows:
a. For light-state adjustment, turn
OFFSET control knob to obtain a a. Measure width of decorating surface.
reading of 10; then rotate adjustment
knob an additional 1/4 turn clockwise. b. With MODE:SINGLE displayed, press
b. For dark-state adjustment, adjust F7 CONFIG SCREEN to enter
OFFSET control knob to obtain a configuration mode.
reading of zero (all LEDs off); then
rotate adjustment knob an additional c. Press F7 NEXT CONFIG two times,
1/4 turn counterclockwise. and then press F4 FOIL PULL to enter
foil pull timing function.
6.0-5
d. Based on the width of the decorating 4. Jog roller farther to left until it reaches the
surface determined in step a, and end of the area to be stamped, and move
allowing 1/4” to 1/2” between the left target to this location.
stampings, use number keypad to set
foil pull time to desired interval. Press 5. Confirm that the proximity sensor on the
enter (return) to save new setting. slide has an unobstructed view of targets.
Note: Foil moves about 2” for each second. TEMPERATURE SETTING

This procedure should be performed to
2. For heat transfer web, only the high-
confirm temperature settings before the
speed web pull time is changed. Factory
settings for other parameters normally do machine is placed in service. The factory-set
not require re-setting. If necessary to roller temperature should produce
satisfactory stamping results. However, the
change web high-speed pull interval,
temperature may be changed to meet the
proceed as follows:
web or foil manufacturer’s recommendations
a. With MODE:SINGLE displayed, press or user’s preferences. In addition, it is useful
F7 CONFIG SCREEN to enter to become familiar with temperature setting,
configuration mode. as in-service changes may warrant
temperature adjustment in the future.
b. Press F7 NEXT CONFIG and then
press F4 DECAL TOGGLE to switch To set temperature, proceed as follows:
to WEBTRAK.
Note: The large red LED display shows
a. Press F7 once again, and then press the current heater temperature, and the
F4 FOIL PULL to enter foil pull timing small green display shows the current
function. temperature setting.
b. Use number keypad to set web pull 1. With power applied to system and MODE:
time to desired interval. Press enter SINGLE screen displayed, press F8
(return) to save new setting. HEAT TOGGLE to turn on heater. Wait
for temperature to rise.
STAMPING AREA SETUP Note: Steps 2, 3, and 4 are only necessary if

In this procedure, the positions of the protection has been engaged. Skip to step 5,
proximity switch targets is set. The targets if temperature protection is not enabled.
define the roller’s horizontal range of
movement. To set the target positions, 2. Press and hold Level and Mode keys on
proceed as follows: temperature controller (Figure 6.0-9) for 3
seconds to enter Protect level.
1. Locate two adjustable targets at left and
right on top of slide assembly. 3. Press down arrow key to turn off
protection.
2. Place a part in the nesting fixture to locate
targets over decorating area. 4. Press and hold Level and Mode keys for
1 second to enter Operation level.
3. With MODE:MANUAL screen displayed,
press F3 JOG LEFT key to jog roller to 5. Press up and down arrow keys to adjust
the beginning of area to be stamped temperature as desired (normally
move right target to this location. corresponds with heat transfer or foil
manufacturer’s recommendations).
6.0-6
6. Check or reset high temperature alarm 2. Cycle machine to produce test samples.
setting as follows:
3. Check graphic position on part. Complete
a. Press Level key to display AL-1. application of resins and uniform contact
of roller should be apparent.
b. Press up and down arrow keys to
adjust alarm setting. 4. To correct front-to-back positioning,
adjust payout (at left) and takeup (at right)
Note: Alarm setpoint is the desired vernier adjustments (Figure 6.0-6) until
number of degrees above the foil/web is properly aligned and complete
temperature setpoint, not upper deposition of resins is achieved.
temperature limit.
Note: Coarse adjustment can be made by re-
7. If desired, protection may be reset as positioning payout and takeup subassemblies
follows: in their mounting slots.
a. Press and hold Level and Mode keys 5. If roller and decorating surface are not
for 3 seconds to return to Protect parallel, one of the following conditions
level. will occur:
b. Press up arrow key to reset a. Image is incomplete.
protection.
b. Image is complete, but bulges appear
STAMP EVALUATION AND on one side.
ADJUSTMENT
c. Image is complete, but roller presses
Run test samples, evaluate samples, and more deeply into one side than the
make adjustments to correct defects as other.
follows:
1. Turn on heater, and set temperature in

accordance with foil/web manufacturer’s
recommendations.
6.0-7
Figure 6.0-9. Temperature Controller Key Functions

6. If voids appear in some areas of stamp, e. Repeat stroke and pressure
increase stroke length as follows: adjustments until desired results are
obtained.
a. Loosen knurled nut on positive stop,
and rotate adjusting sleeve 7. If bulges appear in the image after
counterclockwise 1/8 turn. correcting the void problem, the part
nesting fixture must be altered as follows:
b. Re-tighten knurled nut on positive
stop. a. Remove part from fixture.
c. Re-check image quality. b. Place a small strip of masking tape

the size of the void area directly
d. If quality is unacceptable, increase beneath the affected area.
roller head pressure slightly, and re-
check quality. c. Re-check image quality, and make
any further adjustments required.
6.0-8
d. Perform Stamp Adhesion Testing and b. If not striking dead stop, increase air
Adjustment, below. cylinder pressure 5 PSI by turning
regulator adjustment clockwise while
STAMP ADHESION TESTING AND watching gage.
ADJUSTMENT
c. If dead stop is being struck, increase
This test confirms proper adhesion of resins stroke slightly by turning positive stop
to decorating surface and provides corrective adjusting sleeve counterclockwise 1/8
action. To test adhesion, proceed as follows: turn.
1. After part surface has cooled, apply a 3. After completing adjustments, tighten
piece of clear tape, 3M No. 810 or knurled nut on positive stop and secure
equivalent, over image and apply thumb by tightening setscrew.
pressure.
4. Reset cycle counter on control panel to
2. Pull tape off, with free end held at a 90- zero as follows:
degree angle to surface. If part of image
lifts off surface, make the following a. With MODE:SINGLE screen
adjustments one at a time, and re-check displayed, press F7 three times.
image quality before continuing to the
next step: b. Press F8 RESET to reset counter to
zero.
Note: Repeat any step, as necessary, until
optimal results are obtained.
CHANGING TEMPERATURE SCALES
a. Increase roller face temperature 10°F. The machine’s temperature scale is factory-
Wait for proper heat indication, and set and normally is not changed. Switching
then verify increased die temperature the temperature scale may be required,
using a pyrometer. however, if the machine is located outside the
United States. To change this setting, contact
United Silicone for assistance.
CAUTION
Do Not Exceed 100 PSI Air
Pressure In The Following Step.
6.0-9
7.0 Troubleshooting
7.0 TROUBLESHOOTING
This section contains diagnostics,
troubleshooting, and other aids to assist in
ERROR MESSAGES
isolating and correcting machine As an aid to troubleshooting, the system
malfunctions. Refer to the electrical includes built-in diagnostics. Upon detecting a
schematic and pneumatic diagram in failure, the controller stops machine operation
Engineering Drawings and to Setup and and displays an error message on the control
Adjustment and Maintenance sections for panel specifying the area of the detected
additional assistance in analyzing and condition. Table 7.0-1 lists error messages
correcting faults. and suggested corrective actions.
Table 7.0-1. Error Messages, Definitions, and Corrective Actions
Alarm Code Message Displayed/Corrective Action

FAULT #1 CPU BATTERY LOW CONDITION
Replace battery (refer to Battery Replacement below).
FAULT #2 EMERGENCY STOP PUSHBUTTON PRESSED
Check that EMERGENCY STOP button was pushed and has been
pulled out; reset system by pressing RESET button.
Note: EMERGENCY STOP internal lamp goes out when
EMERGENCY STOP circuit is reset.
FAULT #3 ROLLER UP SWITCH FAULT
CHECK PX407 & INPUT I:0/3
FAULT #4 ROLLER RIGHT SWITCH FAULT
FAULT #5 ROLLER LEFT SWITCH FAULT
FAULT #6 MAXIMUM CYCLE TIME EXCEEDED
Determine cause, correct and Reset system to resume operation.
FAULT #7 ROLLER OVER TEMPERATURE
CHECK PRESETS & INPUT I:0/6
FAULT #8 ROLLER SPIN DETECT FAULT
FAULT #9 DECAL REGISTRATION DETECT FAULT
CHECK PE419 & INPUT I:0/13
FAULT #10 SLIDE TABLE AT LOAD SWITCH FAULT
CHECK HE414 & I:0/8
FAULT #11 SLIDE TABLE AT STAMP SWITCH FAULT
CHECK HE415 & I:0/9
FAULT #12 SLIDE TABLE FAULT
Reset system to resume operation.
7.0-1
7.0 Troubleshooting
Consequently, if roller heat is not on, a defect
DIAGNOSTICS is present in the heater, control relay CR437,
Input and output (I/O) diagnostics are or other component. The conditions needed
displayed on the control panel to reveal the to turn on the heater are present in the
current status of machine operation. These controller.
diagnostics are displayed by pressing F1
INPUT SCREEN or F2 OUTPUT SCREEN on
any Configuration Screen. Each item is BATTERY REPLACEMENT
numbered to correspond with a notation on If the BATTERY LOW message appears on
the electrical schematic (refer to Engineering the control panel, the battery should be
Drawings). The screens list all diagnostics as replaced. To replace battery, proceed as
either ON or OFF. The following examples follows:
assist in understanding the practical use of
the diagnostics. All I/O items are numbered
on the controller (Figure 7.0-1) to assist in
determining their physical location. Note that BATTERY
two output cards are present in the controller.
Be sure to check the correct output location
on the schematic when diagnosing a
malfunction.
Example 1
The INPUTS screen shows I:0/10 – ON.
Referring to the schematic, note that the roller
spin proximity switch supplies this input to the
controller. Therefore, if the roller is not
spinning, it must be due to some cause other
than a defective proximity switch.
Figure 7.0-2. Controller Battery Location
Example 2
The OUTPUTS screen shows O:0/4 – ON. Removal
Once again, by referring to the schematic, it 1. Lockout/tagout electrical power, and
can be seen that the roller heat circuit is unplug machine power cord.
enabled (turned on) by this output.
2. Operate air dump valve, and
lockout/tagout air supply.
INPUT CARD
3. Open electrical panel door, and locate
controller at bottom of panel (Figure 7.0-
2).
4. Remove cover from battery compartment
at left end of controller by depressing
latch.
5. Remove battery.
Installation
Installation is the reverse of removal.
OUTPUT
CARDS
TROUBLESHOOTING CHART
Figure 7.0-1. Controller Input and Output
7.0-2
7.0 Troubleshooting
Table 7.0-2 lists possible troubles and their all possibilities. For additional assistance,
causes and corrective actions. The refer to the Description, Operation,
troubleshooting chart below contains the Installation, and Engineering Drawings
most common problems, but cannot include sections.
Table 7.0-3. Troubleshooting
Trouble Possible Cause Corrective Action

Incomplete stamped Uneven roller-to-part Reposition fixture so that decorating
image contact surface is in proper relationship to roller.
Surface contamination Discontinue use of all contaminating
from flow agent, anti-static agents.
solution, or silicone-based
mold releases
Foreign particles on Wipe surface using a clean cotton cloth or
surface glove.
Fixture support Modify or re-design fixture to increase
inadequate, permitting part rigidity under decorating surface and/or
to flex under machine ensure that mandrel-type designs do not
pressure permit deflection of part.
Rollover in image Uneven roller-to-part Reposition fixture so that decorating
contact surface is in proper relationship to die.
Excessive roller force Reduce stroke length or reduce air
pressure (refer to Setup and Adjustment).
Rollover in image Roller surface temperature Reduce temperature setting (refer to Setup
(cont’d) too high and Adjustment).
Sinks (low areas) in Build up support fixture beneath part in
decorating surface light areas, and reduce roller pressure
(refer to Setup and Adjustment).
Part wall thickness Switch to a dual durometer silicone rubber
variations die.
Edges of image are Insufficient roller pressure Increase stroke length and/or increase air
ragged or not sharp pressure (refer to Setup and Adjustment).
Surface contamination Discontinue use of all contaminating
from flow agent, anti-static agents.
solution, or silicone-based
mold releases
Roller surface temperature Increase temperature setting and/or spin
too low causing incomplete rate (refer to Setup and Adjustment).
release of resin
Resin adversely affected Select HOME foil pulling cycle to advance
by heat exposure prior to foil just before head extends downward.
stamping cycle
7.0-3
7.0 Troubleshooting

Poor image Insufficient roller heat Increase temperature setting (refer to
adhesion Setup and Adjustment).
Resin-to-part Change foil to compatible resin.
incompatibility
Roller does not heat Defective heater Check resistance across heater or use an
or heats slowly inductive ammeter to check current flow
through heater. If open circuit, high
resistance, or low current is found, replace
heater (refer to Maintenance).
Temperature Thermocouple grounded Check for infinite resistance between each
fluctuates 5°F-10°F thermocouple lead and ground; if low
during cycles resistance is found, replace thermocouple
(refer to Maintenance).
Stamping head Temperature controller Reduce upper temperature limit setting
overheats alarm setting incorrect. (refer to Setup and Adjustment).
Defective thermocouple Replace thermocouple (refer to
Maintenance).
Defective heater relay Check AC voltage across relay terminals 1
and 2 and DC voltage across terminals 3
and 4 (refer to Maintenance for relay
location). With heat off, line voltage should
be present across 1 and 2; 0 Vdc should
be present across 3 and 4. Replace relay if
readings are incorrect.
Foil does not move Blown fuse Check and replace fuse if open.
Stamping head Defective palm switches Clean/replace palm switches as required
extends down (refer to Maintenance).
slightly and then
retracts
7.0-4
8.0 Maintenance
8.0 MAINTENANCE
Your United Silicone roll-on hot stamping
machine is designed for trouble-free
INSPECTION AND CLEANING
operation and requires minimal maintenance. Occasionally inspect machine for obvious
Periodic maintenance instructions included in defects, and perform required maintenance.
this section consist of lubrication and Cleaning is not normally required. Remove
cleaning. Component replacement any dust, debris, or other contaminants from
procedures are included to assist technicians machine surfaces.
in replacing parts found to be defective. Use
the information in Troubleshooting for ADJUSTMENTS
assistance in fault isolation before replacing
After setup, the machine does not normally
components.
require further adjustment. However, if roller
is changed, or stamping defects are
LUBRICATION observed, adjustment may be required.
Proper lubrication contributes to extended life Refer to Setup and Adjustment for
and trouble-free operation. The following assistance in checking and re-adjusting
paragraphs describe lubrication machine.
requirements.
COMPONENT REPLACEMENT
Pneumatic System Lubricator
The following paragraphs describe removal
Check lubricator oil level once a month, and
and replacement procedures for components
replenish as needed. Shell Tellus 68 and
that may be replaced or repaired. Obvious
Mobil DTE are approved by United Silicone;
procedures are not included. Before
however, other equivalent oil may be used.
replacing any part, refer to Troubleshooting
Change oil immediately if it becomes
for assistance in fault isolation. A complete
contaminated or emulsified, as indicated by
list of recommended spares is included in
loss of clarity.
Recommended Spare Parts.
Head Height Adjusting Screw
Heater Shroud
Apply a good grade of Lithium grease to
To replace heater shroud (Figure 8.0-1),
screw threads once a year.
proceed as follows:
Roller
The silicone roller bearings should be Removal
lubricated daily with A-TEMP high- 1. Unplug machine power cord, and
temperature grease. Pump grease into both lockout/tagout electrical power.
front and rear grease fittings.
Head Slide Assembly lockout/tagout air supply.
Apply lithium soap-base grease number 2 to
linear bearings at each end of head slide 3. Trace leads from shroud back to junction
assembly. Also, brush lubricant onto head box, and disconnect and pass out leads.
slide ball screw monthly.
4. Disconnect pneumatic line from heater
cooler.
AIR FILTER
Drain air filter daily to remove moisture from 5. Remove four screws securing right
the pneumatic system. Always check for stripper bar lower mounting bar to
moisture before and after machine operation.
8.0-1
8.0 Maintenance
horizontal bar, and remove lower top halves of collars from front and rear of
mounting bar with stripper bar attached. roller.
6. Remove eight screws securing shroud to 6. Slide roller off roller shaft and remove.
roller head, and rotate and remove
shroud and insulators. Installation
Installation
JUNCTION
BOX
PNEUMATIC
LINE
SHROUD
ATTACHMENT
POINT STRIPPER BAR
LOWER MOUNTING
BAR
Figure 8.0-1. Heater Shroud
Roller
Replacement of the roller requires partial
disassembly of the roller head. To replace
roller, proceed as follows:
Removal
1. Unplug machine power cord, and
lockout/tagout electrical power.

3. Remove shroud as described in

preceding paragraph.
4. Remove two screws securing front arm to

arm connector (Figure 8.0-2), and remove
front arm with bearing cover attached.
5. Turn roller until collar screws are

accessible, and remove collar screws and
8.0-2
8.0 Maintenance
FRONT ARM
UP LIMIT
SENSOR ACTUATOR
ARM CONNECTOR
COLLAR
Figure 8.0-3. Up Limit Proximity Sensor
Solid State Relay

Figure 8.0-2. Roller Mounting Details The relay is mounted in the upper right corner
of the electrical panel. To replace the solid
Up Limit Proximity Sensor state relay (Figure 8.0-4), proceed as follows:
The up limit proximity sensor is mounted on
the bottom of the cylinder mounting box. The Removal
sensor completes a circuit to the controller as 1. Unplug machine power cord, and
the stamping head reaches the top of its lockout/tagout electrical power.
stroke. To replace the up limit proximity
sensor (Figure 8.0-3), proceed as follows: 2. Operate air dump valve, and
Removal
1. Unplug machine power cord, and 3. Open electrical panel doors.
4. Tag and disconnect four electrical leads
2. Operate air dump valve, and from relay.
5. Remove two screws securing relay to
3. Remove socket head screws securing electrical panel, and remove relay.
head cover to cylinder mounting box, and
remove cover. Installation
4. Disconnect electrical leads from up limit
proximity sensor.
5. Remove nut on outside of cylinder

mounting box securing up limit sensor to
mounting box, and remove sensor from
inside box.
Installation
8.0-3
8.0 Maintenance
Removal
1. If cylinder is not already extended, with
Manual Screen displayed press F8
SETUP to extend piston to facilitate
access to cylinder mounting hardware.
MOUNTING
SOLID SCREW
STATE
RELAY
Figure 8.0-4. Solid State Relay Location
START or EMERGENCY STOP Switch

ELECTRICAL
The switches are mounted on actuators on TERMINALS
the rear of the control panel. To replace either
switch (Figure 8.0-5), proceed as follows:
Figure 8.0-5. Panel Switch Installation
Removal
1. Unplug machine power cord, and lockout/tagout electrical power.
2. Operate air dump valve, and lockout/tagout air supply.
4. Remove screws securing cover to
3. Remove four screws securing front panel cylinder mounting box, and remove cover.
to control box, and separate panel from
box. 5. Disconnect both airlines at right side of
cylinder mounting box, and unscrew and
4. Disconnect leads from screw terminals at remove elbows.
rear of switch.
6. Unscrew and remove knurled nut and
5. Loosen screw securing switch to switch adjusting sleeve from top of cylinder.
actuator, and remove switch. 7. Remove two screws each at front and
rear cam retainers, and remove retainers.
Installation 8. Working from underside of cylinder,
remove four nuts, lockwashers, and flat
Installation is the reverse of removal. washers securing cylinder to mounting
box, and lift and remove cylinder.
Air Cylinder
9. Restrain piston rod using an open-end
The air cylinder drives the roller head and
wrench, while using a suitable wrench to
applies the required pressure to the
break coupling free from cylinder.
decorating surface. Following removal, the
cylinder should be replaced or inspected, 10. Unscrew and remove coupling (with cam
cleaned, and repaired. To replace the rollers installed) from cylinder.
cylinder (Figure 8.0-6), proceed as follows: Installation
8.0-4
8.0 Maintenance
system. The roller sprocket is partly
concealed by the proximity switch target. To
replace any roller drive component (Figure
8.0-8), proceed as follows:
Removal

3. Loosen setscrew securing sprocket to

motor.
4. Separate sprocket from motor, and

Figure 8.0-6. Air Cylinder Mounting Details disengage from chain to remove.
Head Slide Motor and Gearbelt 5. Remove screws securing cable clamps to
The drive motor must be separated from the motor, and separate clamps from motor.
head slide assembly to permit removal of the
gearbelt. Removal of both components is 6. Cut tie wrap on electrical connector,
covered in the following procedure. To disengage clips, and unplug connector.
remove motor and gearbelt (Figure 8.0-7),
proceed as follows: 7. Remove four screws securing motor to
rear arm, and remove motor.
lockout/tagout electrical power. 8. If necessary to remove chain, disengage
from sprocket.
Installation
3. Remove ten screws securing left side Installation is the reverse of removal.
plate to slide assembly (four on front, two
on end, and four on rear), and remove
side plate.
GEARBELT
4. While supporting motor, remove four
screws securing motor to slide assembly.
5. Separate motor and spacer from slide

assembly.
6. Disengage drive belt from motor pulley,

and remove motor and belt.
MOTOR
ROLLER DRIVE MOTOR, SPROCKET,
AND CHAIN SIDE PLATE
The roller drive motor rotates the roller
through a sprocket and roller chain drive
8.0-5
8.0 Maintenance
Figure 8.0-7. Head Slide Motor and Figure 8.0-8. Roller Drive Components
Gearbelt
7. Disconnect pneumatic line from heater
Roller Shaft Bearings cooler.
Two bearings support the roller shaft at the
rear, and a single bearing supports the front 8. Remove two screws securing rear arm to
of the shaft. All bearings are pressed in place arm connector, and remove arm.
and should be replaced as a set.
9. Disassemble bearings from bearing
housing as follows:
Removal
To remove the bearings (Figure 8.0-9), a. Remove screws retaining roller drive
proceed as follows: shaft in bearing housing.
1. Unplug machine power cord, and b. Press out and remove roller drive
lockout/tagout electrical power. shaft and two bearings.
2. Operate air dump valve, and 10. While supporting silicone roller, remove
lockout/tagout air supply. two screws securing front arm to arm
connector, and remove arm and roller.
3. Remove screw securing proximity switch
target, and remove target. 11. Remove six screws securing bearing
housing to front arm, and remove housing
4. Remove screw securing cable clamp to with bearings installed.
rear arm, and separate clamp from arm.
12. Press out bearing from bearing housing.
5. Remove two screws securing proximity
switch to rear arm, and separate switch
from arm. Installation
Installation is basically the reverse of
6. Remove sprocket from roller shaft by removal. However, extreme care must be
carefully prying evenly against bearing taken when installing bearings. Be sure to
housing, and disengage chain from apply pressure only to the outer race of each
sprocket. bearing to prevent damage. Also, replace all
bearings as a set, and pump A-TEMP grease
into front and rear bearings after assembly.
ROLLER CHAIN AND
SPROCKET
REAR ARM PNEUMATIC
LINE
REAR ARM
BEARING
HOUSING
PROXIMITY
SWITCH TARGET
ELECTRICAL
CONNECTOR
8.0-6
8.0 Maintenance
Figure 8.0-9. Rear Bearing Installation Figure 8.0-10. Foil Takeup Components
Foil Pinch Roller Foil Takeup Drive Belt

The silicone rubber pinch roller presses the The foil takeup drive belt transfers the foil
used foil against the knurled roller to prevent motor’s rotation to the takeup shaft and pinch
the foil from slipping as it is pulled onto the roller. The belt material is supplied in 2-foot
takeup shaft. To replace the pinch roller lengths with two attachment couplings. To
(Figure 8.0-10), proceed as follows: replace the drive belt (Figure 8.0-10),
proceed as follows:
Removal
3. Cut and remove existing belt; discard belt.
3. Carefully unhook extension springs on
front and rear pinch roller levers. 4. Insert new coupling halfway into one end
of new belt material, leaving opposite
4. Remove socket head screw from each pointed end exposed.
pinch roller lever, and remove pinch roller
and levers. 5. Run belt material around knurled roller
and takeup shaft pulleys.
5. Separate pinch roller from front and rear
levers. Note: Only one coupling is needed for
attaching ends of belt.
Installation 6. Pull belt until taut, and cut off excess
Installation is the reverse of removal. material. Attach belt ends together by
Replace extension springs, if they have taken pushing into coupling previously inserted
a set or are obviously deformed. into opposite end.
7. Rotate takeup shaft manually to confirm

TAKEUP DRIVE BELT proper tension, as evidenced by rotation
of knurled roller.
TAKEUP
SHAFT
PINCH ROLLER
EXTENSION
KNURLED ROLLER SPRING
PULLEY
8.0-7
9.0 RECOMMENDED SPARE PARTS

While your hot stamping machine is highly item numbers, where available, to the
reliable and trouble-free, occasional parts Engineering Drawings section. Where no
replacement may be required due to normal item number is shown, the part is not shown
wear and aging. This section contains a on the engineering drawings.
listing of parts, which have been determined
to be most likely requiring possible future
ORDERING PARTS
replacement. By stocking these parts,
minimal downtime should be experienced in When ordering parts, please fill out the Parts
case of equipment malfunction. Order Form on the following page. The form
should be duplicated so that additional copies
Table 9.0-1 lists the recommended spare will be available if needed. When filling out
parts for standard and heat transfer the form, be sure to enter all required
machines. Required ordering information is information, which includes item number, part
listed for each part. The recommended number, and complete description.
quantities listed in the table are not
necessarily the total installed on your To expedite delivery, parts orders may be
machine. The list is keyed by component phoned or faxed. Your parts will be shipped
within two days following receipt of order.
Table 9.0-1. Recommended Spare Parts

Item No. Part No. Description Qty
41122033 IDEC Solid State Relay 1
41122028 IDEC Single-Pole Relay 1
41122025 IDEC Double-Pole Relay 1
41112003 Snap Disk Thermostat 1
41113021 Exergen Infrared Thermostat 1
41124001 T.E. Proximity Switch, Roller Spin 2
41124021 ACI Proximity Switch, Head Up 1
41126014 Tri-Tronics Photoeye 1
41042006 KB DC Drive Motor, Head Slide 1
41102056 KB Braking Resistor, Head Slide 1
41127016 Clarostat 5K Potentiometer, Slide Speed 1
41121102 A-B Contactor, Main Power Switch 1
Heater Shroud Assembly, 220 Vac, 2800 W 1
41401034 MAC Valve, Heater Cooler 1
41401028 Norgren Valve, Roller Up-Down 1
18 7WT033-8-99 Foil Pinch Roller With Bearings 1
26 41259005 Gear Belt, Head Slide 1
9.0-1
Table 9.0-1. Recommended Spare Parts

Item No. Part No. Description Qty
11 41242018 Extension Spring 2
24 41215004 Foil Drive Belt (Includes 1 Connector) 2 Ft
39 41201010 Ball Bearing, Roller 2
41 USR8BX-A-044 Roller Shaft With Pin 1
36 41201012 Cam Clutch, Roller 1
33 41211008 Sprocket Gear, Roller 1
35 USR8BX-A-042 Sprocket Gear, Roller Motor 1
41302011 Cylinder Repair Kit 1
Silicone Roller, 6” x 8” 1
— 41121015 Emergency Stop Contact 1
9.0-2
PARTS ORDER FORM
US Hot Stamping/Thermal Transfer Machine
MAIL, FAX, OR PHONE YOUR ORDER TO:

UNITED SILICONE
4471 Walden Avenue
Lancaster, New York 14086
Phone 716/681-8222
Fax 716/681-8789
Date: __________________________
Invoice to: Ship to: (If different)
Company Name: ________________________ Company Name: _____________________
Address: ______________________________ Address: ___________________________
City, State: ____________________________ City, State: __________________________
Zip Code: ______________ Zip Code: ______________
Phone No.: ____________________________ Attention: _________________________
Ship: R Partial R Complete
Purchase Order No.: ____________________ Ship Via: F UPS F UPS Next Day Air
Price and Delivery Quotation Required F Motor Freight
Before Shipment? R Yes R No F Overnight Air
Machine Model No.: F Other (Specify)
Machine Serial No.: _________________
Drawing No.: Title:
Part Number Description Item No. Qty Price
9.0-3
10.0 Pneumatic Slide Table Option
10.0 PNEUMATIC SLIDE TABLE OPTION

The pneumatic slide table option enhances operated air valve. Air supplied from the inlet
stamping productivity by facilitating the air regulator flows to the retraction port of the
placement of parts into the nesting fixture. air cylinder, driving the piston inward, and
The unit does this by moving the work table moving the table directly under the roller
well out from under the roller head for head. The roller head then extends
convenient loading and removal of parts, downward and moves from right to left,
thereby eliminating the need for the operator applying the heat transfer or foil resins to the
to position the part under the roller head, part. After the roller head has retracted, the
where space is often limited. The sliding air valve is re-positioned, exhausting air from
worktable is driven by an air cylinder that the retraction port and directing air to the
automatically moves the worktable under the extension port. The cylinder extends, moving
roller head as the stamping cycle begins and the table out to the load position, and the
then slides out toward the operator after the head moves right to its home position.
part is stamped.
Description, operation, troubleshooting, and

TROUBLESHOOTING
maintenance information for the pneumatic The pneumatic slide table is highly reliable
slide table is provided in this section. and virtually trouble-free. Usually, failure of
the slide table to operate is a symptom of a
general malfunction of the machine. Table
DESCRIPTION 10.0-1 contains troubles, possible causes,
The slide table option consists of a sliding and corrective actions specifically related to
worktable, base plate, air cylinder, solenoid- the slide table. Use this information to assist
operated air valve, and associated wiring. in fault analysis if a malfunction appears to be
The base plate is secured to the machine’s isolated to the slide table.
side supports in place of the standard
stationary table. The sliding table is guided
by tubular slides on each side and by the air
MAINTENANCE
cylinder piston in the center for precise Maintenance consists of replacement of
positioning during in and out travel. defective parts. The following paragraphs
describe replacement procedures for slide
The double-acting air cylinder is mounted table components.
horizontally beneath the base plate. A
solenoid-operated air valve installed beside AIR CYLINDER
the cylinder directs air to the extension and
retraction cylinder ports to move the table. The air cylinder is mounted on the underside
Electric power to energize the air valve of the slide table. To replace the cylinder
solenoid is supervised by the controller, (Figure 10.0-1), proceed as follows:
which coordinates valve operation with roller
head travel. Removal
OPERATION
The slide table remains out (home position) 2. Operate air dump valve, and
when the roller head is retracted following lockout/tagout air supply.
completion of a stamping cycle. With air and
electric power supplied to the machine, 3. Remove screws securing piston
pressing both palm switches simultaneously attachment fitting at front of table, and
directs electric power to the solenoid-
10.0-1
10.0 Pneumatic Slide Table Option
draw fitting out from under table with ATTACHMENT
attached piston. FITTING SCREWS
Note: Manually move table to facilitate

access to air lines and proximity switches
in steps 4 and 5, below.
4. Disconnect air lines from cylinder.
5. Loosen setscrew securing each proximity

switch to cylinder, and separate switches
from cylinder.
6. Remove two screws securing piston to

PISTON ATTACHMENT
attachment fitting, and separate fitting FITTING
from piston.
7. Remove screws securing rear of cylinder

to mounting bracket, and remove cylinder. Figure 10.0-1. Slide Table Cylinder
Installation
Installation
AIR LINES
SOLENOID-OPERATED AIR VALVE
The air valve is mounted beneath the
machine behind the electrical panel. To
replace the air valve (Figure 10.0-2), proceed
as follows:

lockout/tagout air supply. ELECTRICAL
LEADS
3. Disconnect electrical leads from air valve.
4. Disconnect two outlet air lines and inlet

Figure 10.0-2. Slide Table Air Valve
airline from valve.
5. Remove two screws securing valve to

mounting bracket, and remove air valve.
Installation
10.0-2
Check for signal at mainboard connector

H11 pin IN10. If no signal is present,
Slide table remains No input from controller
controller is not energizing solenoid valve
under head after
(refer to Troubleshooting section).
cycle
Defective solenoid valve Replace valve.
Table moves slowly

Defective air cylinder Repair or replace cylinder.
or hesitates
10.1-1
10.0 ROTARY TABLE OPTION

Increased productivity is offered by the rotary This adjustment is performed by loosening
table (Figure 10.1-1), which automatically the index drive mounting bolts, re-positioning
indexes each part under the stamping head. the table as required until the part is brought
The rotary table replaces the standard single- into precise alignment with the head, and
station worktable. tightening the index drive mounting bolts after
completing the adjustment.
The rotary table is available in four-, six-, and
eight-station models to accommodate various This adjustment is not suitable for making
production requirements and part major adjustments. If a major offset is
dimensions. required, the holding fixture or die mounting
plate should be moved. The remaining
Description and operation information for the stations are automatically aligned by
rotary table is provided in this section. positioning any one station.
Maintenance and servicing instructions are
provided in the CAMCO service manual.
SPEED CONTROL
The speed control permits a wide range of
DESCRIPTION adjustment for rotation speed to match the
The rotary table consists of a motor-driven operator’s pace. The speed setting is
index drive, rotating worktable, and speed dependent on the operator’s ease of placing
control. Its operation is supervised by the and removing the parts. For example, a rapid
control box, which automatically coordinates speed is appropriate for small parts that rest
table rotation with stamping head extension lightly on the holding fixture and can be
and retraction. The drive rotates the table removed and placed quickly. However, large
through four, six, or eight stations depending or complex parts may require a slower speed
on model, pausing at each station for the to permit sufficient time for the operator to
operator to place and remove parts. The remove the stamped part and place the next
speed control permits setting an appropriate part on the fixture.
speed to match the operator’s parts-handling
The numbered increments on the dial provide
speed. If machine has a shot pin for station
a reference between the fastest speed
indexing, the speed control is disabled.
(rotated fully clockwise) and slowest speed
(fully counterclockwise); they do not specify
OPERATION time intervals. Generally, the control is set
STATION ALIGNMENT initially at its midpoint and then turned left or
right to accommodate production
The rotary table is factory set to index at the
requirements and the operator’s needs.
center of each station. For optimum
precision, an optional pneumatic shot pin is
available to lock the table at each station.
Accurate station alignment ensures uniform
distribution of stamping force when the
stamping head contacts the decorating Photo to be Supplied
surface.
In most cases, the factory index setting will

accurately position each part directly under
the stamping head. However, minor
adjustments may be required to
accommodate fixture and part variations.
10.1-1
Figure 10.1-1. Rotary Table Option b. Rotate cam counterclockwise
approximately the same amount of
displacement from 3:00 o’clock.
TABLE INDEX CAM ADJUSTMENT
Due to table inertia, a change in the rotary c. Tighten setscrews. If keyway is past 3:00
table speed setting may cause the table to o’clock, e.g. 4:00 o’clock, adjust as
either undershoot or overshoot the index follows:
position. This may cause misalignment of the
part nesting fixture and/or a brief jerking a. Loosen two setscrews on cam.
movement as the table indexes. Therefore,
whenever table speed is altered, the b. Rotate cam clockwise approximately the
relationship between the index drive cam lobe same amount of displacement from 3:00
and the index drive shaft keyway should be o’clock.
checked and adjusted, if required. These
instructions will assist in checking and c. Tighten setscrews.
adjusting rotary table indexing following
speed-setting changes. d. Operate table once again, while
observing its movement. Table should
move to next index position and stop
INDEX CHECK
smoothly. If any jerking, undershooting,
To check table indexing, proceed as follows: or overshooting of cam lobe is seen,
readjust cam lob, and repeat check.
1. Turn on electrical power.
e. Adjustment is completed when table
2. Index table to next station, while moves and stops smoothly at each index
observing its movement as it arrives at station. If correct operation is not
the station. achieved through this adjustment, contact
United Silicone for assistance.
3. From underside of table, check the
following:
a. Limit switch roller should be on cam lobe

(Figure 10.1-2). LIMIT SWITCH
ROLLER
b. Shaft keyway should be about parallel to
table at the 3:00 o’clock position.
KEYWAY
4. If cam is not at 3:00 o’clock, adjust cam

as described in the following paragraph.
CAM LOBE
CAM ADJUSTMENT
1. If keyway is below 3:00 position, e.g. 2:00
o’clock, adjust as follows:
Figure 10.1-2. Rotary Table Index Drive
a. Loosen two setscrews on cam. Cam Adjustment
10.0-2
10.2 X-Y and X-Y-R Positioning Table
10.0 X-Y AND X-Y-R POSITIONING TABLE OPTION

The X-Y and X-Y-R positioning table option produce the highest quality image. The table
simplifies and improves accuracy of nesting should be set up as follows:
fixture positioning by allowing precise
movement of the table both horizontally and 1. Turn micrometer knobs until both axes
vertically. The table is a precision device are about at their centers.
having micrometer adjustments for movement
on both axes. The X-Y-R table has an 2. Mount the nesting fixture on the X-Y or
additional adjustment, which provides X-Y-R table so that the part-decorating
rotational movement. This additional surface is as close as possible to directly
adjustment allows compensation for minor below the roller head.
discrepancies in roller or heat transfer
positioning. 3. Turn the micrometer knobs until the
decorating surface is precisely aligned
Description and operation information for the with the roller head.
positioning table is provided in this section.
Note: Do not make major adjustments
with the micrometer knobs. If a major
DESCRIPTION offset of either axis is required, the
The positioning table consists of a base plate, nesting fixture or the die mounting plate
movable worktable, micrometer adjustments, should be moved.
and locking collars. Mounting holes are
provided for securing the X-Y or X-Y-R table 4. If using an X-Y-R table, the third
to the worktable. Several threaded holes in adjustment is performed by loosening
the X-Y or X-Y-R table surface are used to screws in slotted holes on top of table and
mount the part-nesting fixture in the desired then turning stop screws at left and right
location. to rotate the table.
The table permits a total travel of 3” on both 5. After completing adjustments, the locking
axes. When centered, approximately 1.5” is collars should be tightened on both axes
available in all directions for nesting fixture to prevent accidental movement. If using
alignment. The table’s micrometer an X-Y-R table, tighten locking screws in
adjustments permit movement in 0.001” slotted holes, as well.
increments in both directions. However, a
backlash of 0.005” is present in adjusting
knobs on both axes. Locking collars on both
axes lock the table in its settings after
adjustments are completed and prevent
inadvertent movement or re-positioning due
to vibration. Once the locking collars are
securely tightened, only the backlash
movement should be possible.
OPERATION
Proper alignment of the decorating surface in
relation to the stamping head ensures even
distribution of stamping force, which will
Figure 10.2-1. X-Y Positioning Table
10.2-1
Hot Stamping Machine
11.1 X-Y Table Option
11.1-2
R8BX Hot Stamping Machine
11.0 Semi-Automated Systems
11.0 SEMI-AUTOMATED CUSTOM ROLL-ON HOT STAMP

SYSTEMS
Description and operation instructions for the
DESCRIPTION rotary table are included in Rotary Table
Semi-automated roll-on hot stamp systems Option. In addition, where applicable, the
are custom-designed and built to meet unique documentation package shipped with each
customer requirements. The systems system includes electrical and pneumatic
integrate the roll-on hot stamping machine schematic diagrams, control panel
with a rotary table and other accessories. For descriptions, and any other pertinent data
example, a pick and place station (Figure needed for system operation,
11.0-1), shuttle table, and/or articulating nest troubleshooting, and maintenance.
may be included to meet customer
specifications. Systems may also include
other equipment, as requested by the
customer.
To meet European Union requirements,

United Silicone designs and builds custom
systems to meet CE wiring standards for
shielding and wire terminations.
Each semi-automated system is enclosed

within a protective cabinet for optimum safety
of the operator and other personnel in the
system’s vicinity. All doors and swing guards
have safety interlock switches that stop the
system whenever any door or guard is moved
out of its closed position. Non-interlocked
light curtains are also installed on some
custom systems.
DOCUMENTATION
Basic information on semi-automated custom Figure 11.0-1. Pick and Place Station
systems is included in this section. Detailed
instructions and procedures contained in
other sections of this manual form the major
part of system documentation. Refer to the
Description, Installation, Setup and
Adjustment, Troubleshooting, and
Maintenance, Recommended Spare Parts,
Engineering Drawings, and other sections
for information that applies to your system.
11.0-1
R8BX Hot Stamping Machine
12.0 Engineering Drawings
12.0 ENGINEERING DRAWINGS

Table 12.0-1 lists all drawings available for Note that Table 12.0-1 is an all-inclusive list,
troubleshooting and maintenance of your but that only drawings specifically relating to
equipment. This list comprises mechanical your equipment configuration are included in
assemblies, electrical and pneumatic this manual. For a custom machine or
diagrams, and optional equipment drawings. system, additional system drawings are
The applicable drawings for your machine or inserted after the standard and optional
system are inserted after the drawing list. equipment drawings.
Table 12.0-1. R8BX Engineering Drawings for Standard and Optional Equipment
Drawing No. Description

348187-001C Box Motion with Dial Table
USR8BX-D-001 Reciprocating Roll-On Machine General Assembly
USR8BX-D-002 Head Slide Assembly
SR8BX-D-004 Head Slide Subassembly
USR8BX-D-005 Webtrak Take-Up Subassembly
USR8BX-D-006-1 Webtrak Pay-Out Subassembly
USR8BX-D-054 Foil Clamp Subassembly
SR8BX-D-085 Decal Position Adjustable Sensor Bracket
USR8BX-D-315 Stripper Assembly
353947-100 Main Power Wiring
353947-101 E-Stop / Roller / Webtrak Control
353947-102 Operator Interface / Heat Control / PLC Power
353947-103 PLC Inputs
353947-104 PLC Outputs
353947-105 Robot Interface Wiring
353947-106 Main Panel Layout
353947-107 Operator interface
353947-200 Pneumatic Diagram
12.0-1

USR8BX-Manual 12-05

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USR8BX-Manual 12-05

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D e s i g n e r s a n d M a n u f a c t u r e r s o f P r o d u c t D e c o r a t i n g E q u i p m e n t , Au t o m a t e d S ys t e m s , a n d S u p p l i e s

Operation and Maintenance Manual

Roll-On Hot Stamping Machine

• Robotics/interface to existing conveyor

• Sampling and testing

Typical Automated System • Cost analysis

Carefully designing, building, and testing • Design review

United Silicone’s innovative engineers develop

From transporting unfinished parts to the first

Your roll-on hot stamping machine is

To gain the most from your equipment, you

When selecting a location for the machine,

• Work area is adequately lighted.

• Required utilities (air and electricity) are

• Sufficient space is available for receiving

WHY HOT STAMPING

Table 1.0-1. Model R8BX Specifications

Figure 1.0-1. Model R8BX Roll-On Hot Stamping Machine

FOIL/WEB PAYOUT AND TAKEUP

• First line - System status and error

• Next line(s) – Current operating mode,

Note: The cycle count may be zeroed by

When a manual or other function is selected,

} System Status Message

Figure 3.0-2. Main Menu

Figure 3.0-3. Login Screen

Figure 3.0-4. Configuration Menu 1

Figure 3.0-5. Configuration Menu 2

Figure 3.0-6. Inputs Display Screen

Outputs Display Screens

Figure 3.0-7. Outputs Display Screens 1 and 2

Figure 3.0-9. Alarm Display (typical)

Press F1 to acknowledge fault condition and return to previous screen.

• AUTO CYCLE RUNNING

• READY TO CYCLE WITH SLIDE TABLE

• READY TO CYCLE WITHOUT SLIDE TABLE

• MANUAL SLIDE TABLE MODE ACTIVE

• ROLLER HEAD NOT HOME

• WEB ADVANCE IN PROGRESS

• STAMP SETUP MODE

• ROLLER OVER TEMPERATURE

• SLIDE TABLE IS NOT IN POSITION

• LIGHT CURTAIN BLOCKED

• GUARD DOOR IS OPEN

OTHER PANEL CONTROLS AND INDICATORS

1. Part is mounted on a nesting fixture Roll-On Stamping Cycle

Figure 4.0-1. The Roll-On Hot Stamping Process

Strict conformance to all applicable National

PLANT AIR REGULATOR

FIGURE 5.0-1. AIR CONNECTION

6.0 SETUP AND ADJUSTMENT

Extensive illustrations are included to GAGE

10. Tighten knurled nut on positive stop.

12. Tighten bolts on both vertical slide

Figure 6.0-3. Foil/Web Payout Assembly

7. Mount takeup shaft on foil pull frame as

2. Position stripper bar on left side of roller

4. Set foil clamp approximately at midpoint

9. With MODE:MANUAL displayed, press

10. While observing foil movement, press F2

Figure 6.0-5. Foil Path

Figure 6.0-6. Foil/Web Front-to-Back

LEFT VERNIER RIGHT VERNIER PHOTOCELL ADJUSTMENTS

Figure 6.0-7. Photocell X-Y Adjustments