Stahls Hotronix Fusion XF

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Replacement Manual4 pages

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Summary

Preparation and Initial Disassembly

Safety Precaution: Power Cord

Detach power cord before proceeding with any adjustments or replacements.

Prepare Heat Press and Remove Adjustment Knob

Lower heater gently and remove pressure adjustment knob by loosening its set screw.

Remove Control Housing Screws

Remove four thumb screws from the underside of the control housing using a 9/32" Allen wrench.

Disconnect Power and Remove Control Housing

Lift off control housing, then unplug ground, black, and white wires from the power connections.

Disconnect Controller Connectors

Unplug the 9-pin, 3-pin TRIAC, and 4-pin Strain Gauge connectors from the controller.

Remove TRIAC and Ground Wire

Unscrew two screws to remove the TRIAC and ground wire from the casting.

Prepare Strain Gauge Wires

Cut strain gauge wires, loosen a screw, and remove wires from the sheathe and clamp.

Remove Heat Press Handles

Unscrew four bolts to remove the handles from the press.

Remove Shoulder Bolts and Hub Caps

Remove shoulder bolts using specified wrenches and pry off hub caps with a flathead screwdriver.

Remove Pressure Adjustment Spindle and Casting

Remove the rear pin, unthread the spindle, and remove the old adjustment casting.

Reassembly and Installation

Re-insert Rear Pin and Attach Hub Cap

Re-insert the rear pin and secure the provided hub cap onto it.

Reattach Pressure Link Hardware

Attach pressure links using bearing housings, shoulder screws, washers, and locknuts.

Attach Handles and Secure Strain Gauge Cable

Screw in handles and use zip ties to secure the strain gauge cable, allowing for movement.

Install TRIAC and Ground Wire

Install the TRIAC and ground wire flat side down using provided screws, orienting wires correctly.

Reconnect Controller Connectors

Plug in the 9-pin, 3-pin TRIAC, 4-pin Strain Gauge, and 10-pin I/O connectors to the controller.

Reconnect Power Wires

Plug in white and black wires into the ON/OFF switch and the green wire into the IEC outlet.

Final Assembly and Calibration

Replace Control Housing

Replace the control housing onto the press and secure it with four thumb screws.

Replace Pressure Adjustment Knob

Align the set screw with the flat on the shaft and tighten the pressure adjustment knob.

Verify Operation

Raise the handle, plug in the press, and turn it ON to verify proper operation.

Access Calibration Menu

Navigate the control panel by pressing the 'GEAR' icon, then 'SET UP', and entering the password.

Initiate Platen Pressure Calibration

Press 'PLATEN PRESSURE CALIBRATION', then 'CALIBRATE' to begin the calibration process.

Set Minimum and Maximum Points

Adjust the knob to achieve target voltages (2.5V, 2.7V, 3.1V/3.2V) and press 'SET MIN POINT'/'SET MAX POINT'.

Save Calibration Settings

Press 'SAVE' to store the calibration settings and then press 'BACK' to return to the main screen.

Overview

Technical Specifications (Inferred from the manual and general knowledge of such devices)
Usage Features
Maintenance Features (as detailed in the replacement procedure)

This document outlines the procedure for replacing the adjustment casting on a Stahls' Hotronix Fusion (Model XF) heat press, dated March 11, 2015. The Fusion heat press is a professional-grade machine designed for applying heat transfers to various materials, such as garments, bags, and other flat items. It utilizes heat and pressure to bond designs onto substrates, making it a crucial tool in the custom apparel and promotional product industries.

The Fusion (Model XF) is characterized by its dual-functionality, offering both swing-away and draw-style operation. This versatility allows users to choose the most convenient and safe method for loading and unloading garments, minimizing the risk of burns and improving workflow efficiency. The swing-away motion provides a clear workspace above the lower platen, while the draw-style motion pulls the lower platen out towards the operator.

Key components of the Fusion (Model XF) include an upper heating platen, a lower platen, a control housing with a digital interface, and an adjustment casting assembly that manages pressure. The digital controller, as seen in the manual, features a touchscreen interface for setting temperature, time, and pressure, and includes functions like override, setup, lock, and back. It also displays real-time temperature readings for both the upper and lower platens, a countdown timer, and a counter for completed presses. The controller allows for preset setup, date and time adjustments, display settings, auto on/off, calibration, password protection, language selection, and statistics tracking.

Technical Specifications (Inferred from the manual and general knowledge of such devices):

Pressure Adjustment: The device features a pressure adjustment knob, which, in conjunction with a strain gauge, allows for precise digital pressure readings. This is a significant advantage over manual pressure adjustments, as it ensures consistent and repeatable results, crucial for quality heat transfer applications. The calibration process detailed in the manual highlights the importance of setting minimum and maximum pressure points based on voltage readings (2.7V for minimum and 3.1V or 3.2V for maximum when locked down), indicating a sophisticated electronic pressure sensing system.
Temperature Control: While specific temperature ranges are not detailed, the controller displays temperatures up to 350°F, suggesting a capability for a wide range of heat transfer materials. The presence of a "Temperature Calibration" option in the setup menu indicates precise temperature management.
Electrical Connections: The device uses a 9-pin connector, a 3-pin TRIAC connector, a 4-pin Strain Gauge connector, and a 10-pin I/O connector for its internal electronics. Older versions (V2 and prior) may use a 25-pin D-sub connector. It also includes a ground wire (green with yellow stripe) for safety, connected to an IEC inlet. Power is supplied via black and white wires to an ON/OFF switch.
Construction: The adjustment casting, the focus of this replacement guide, is a critical structural component, likely made of a durable metal alloy to withstand constant pressure and heat. The handles are attached with 1/4"-20 x 5/8" bolts, suggesting robust construction.

Usage Features:

Digital Control: The touchscreen controller provides intuitive access to all operational parameters, enhancing ease of use and precision.
Versatile Operation: The Fusion (Model XF) offers both swing-away and draw-style platen movement, catering to different user preferences and workspace configurations.
Pressure Readout: The digital pressure display, enabled by the strain gauge, allows operators to achieve consistent pressure settings for various materials and transfer types, which is vital for preventing transfer failures or damage to garments.
Calibration: The ability to calibrate temperature and platen pressure ensures accuracy and optimal performance over time, compensating for wear and tear or environmental factors.
Safety Features: The manual emphasizes detaching the power cord before maintenance, and the design includes a ground wire, indicating attention to electrical safety. The swing-away/draw-style design also inherently improves safety by moving the hot platen away from the loading area.

Maintenance Features (as detailed in the replacement procedure):

Modular Design: The adjustment casting, control housing, and other components are designed to be replaceable, facilitating repairs and extending the lifespan of the machine.
Standard Tools: The replacement procedure primarily requires common tools such as Allen wrenches (3/32", 5/32", 3/16", 9/32"), scissors, Phillips screwdriver (#2), flathead screwdriver, and combination wrenches (1/2", 5/16"). This makes maintenance accessible without specialized equipment.
Clear Instructions: The manual provides step-by-step instructions with accompanying images, making complex procedures manageable for technicians or experienced users.
Wiring Management: The use of zip ties to secure cables and the specific orientation instructions for the TRIAC wires (to direct them around the adjustment spindle) highlight the importance of proper cable management for functionality and longevity.
Pressure System Maintenance: The detailed steps for loosening and re-tightening the set screw in the pressure adjustment knob, and the re-assembly of the pressure link with specific washer order, indicate that the pressure system is designed for serviceability and precise adjustment.
Calibration Post-Maintenance: The requirement to recalibrate the platen pressure after replacing the adjustment casting is a critical maintenance step to ensure the machine operates within specified parameters, maintaining accuracy and quality of transfers. This involves entering a password ("JAGUAR2" or "JAGUAR" for older models) to access calibration settings, underscoring the importance of authorized and correct calibration.

In summary, the Stahls' Hotronix Fusion (Model XF) is a robust and versatile heat press, designed for professional use with an emphasis on precise digital control, operational flexibility, and user-friendly maintenance. Its modular construction and detailed service instructions ensure that critical components like the adjustment casting can be replaced, prolonging the machine's operational life and maintaining its high performance standards.