ACE&EASTMAN Instagraphic 204 Parts & Instructions 204A Manual English 040819 User

2012-12-27

User Manual: ACE&EASTMAN Instagraphic 204 Parts & Instructions

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Operation and Maintenance Manual

MODEL 204.1

MNL90008
08/31/05 Rev. G

FOR USE BY QUALIFIED SERVICE PERSONNEL ONLY
Limited Machine Warranty
Congratulations!
Insta Graphic Systems (IGS) warrants this heat
seal machine, when operated under normal conditions, to be free from manufacturing defects in
material and workmanship for a period of one
year on parts (lifetime on the upper heating
element) and 90 days on labor from the invoice
date.

Your selection of the Insta Graphic Systems (IGS)
heat seal machine is a sound business decision.
IGS equipment is the result of the highest quality
engineering and time-tested design. Your new
machine combined with IGS's reputation of
innovation in the heat-sealing field, insures the
continuing capability of delivering the best
decorated substrates possible.

This warranty will be effective only when IGS
authorizes the original purchaser to return the
product to the factory in Cerritos, California
freight prepaid, and only when the product upon
examination has proven to be defective.

This manual describes installation, operation, and
maintenance procedures for your new model
machine, as well as easy to use instructions for
on-the-spot maintenance.

This warranty does not apply to any machine
that has been subjected to misuse, negligence or
accident.

Your machine will have a long trouble-free life.
Read this manual. Keep it with your machine; it's
your key to proper operation and lasting service.

IGS shall not be liable for the injury, loss or damage, direct or consequential, arising out of the use
or the inability to use the product.

Installation
DOMESTIC
Use a separate 15 amp AC circuit.
Only industrial extension cords with
proper wire size should be used: size
16/3 wire for distances up to 25 feet,
and size 14/3 for distances up to 50
feet.

No claim of any kind shall be greater in amount
than the sale price of the product or part to
which claim is made.
This is the sole warranty given by the company, it is
in lieu of any other warranties, expressed or implied,
in law or in fact, including the warranties of
merchantability and fitness for a particular use, and
is accepted as such by the purchaser in taking delivery
of this product.

INTERNATIONAL
Use a designated 16 amp AC circuit. Only industrial extension
cords with proper wire size (2.5 sq.
mm) shall be used.

Specifications
Voltage 115/120 Volts AC 50/60 Hertz
Model 204
14.6 Amps
1750 Watts
Voltage 230/240 Volts AC 50/60 Hertz
Model 204
9.6 Amps
2200 Watts
Weight Model 204

-3-

94 Pounds (42.7 KG)

FOR USE BY QUALIFIED SERVICE PERSONNEL ONLY
Operation

Operation Timer/Temperature Control

1. It is recommended that you review the "How
to Apply Instructions" (on our Product
Information Sheet) before beginning heat
sealing operations.
2. Turn the power on by pressing the POWER
button on the controller.
3. Set desired temperature and time then swing
the upper platen arm to its fully open
position, away from lower platen.

Solid State Controller

4. Allow the machine to warm up until the
selected temperature is reached.

This controller has three (3) control features:
1. Temperature - Temperature may be set from
225-450°F (107-232°C).

5. Set the desired pressure by adjusting the
pressure adjust handle on the top of the
machine. To increase pressure, rotate handle
counterclockwise.

2. Time - Time may be set from 1 second to 10
minutes.
3. Counter - Cycle counter counts the number
of applications from 1 to 9999 (see
additional Notes - Counter).

6. Place the substrate on lower platen,
smoothing out all wrinkles.
7. Position transfer or lettering on substrate.

Controller Operation

8. Swing the upper arm into position directly
over the lower platen.

1. If the temperature is not being displayed,
press the MODE button until temperature is
displayed.

9. Close machine by pulling handle down into
locked position.

2. Push and hold SET button and
simultaneously push UP (↑) or DOWN (↓)
arrow buttons to the desired temperature
setting.

10. The timer will start automatically and a
buzzer will beep at the end of the time cycle.
11. Lift safety lock and pull handle up slowly and
move upper platen handle to its full open
position. This technique will avoid transfer
paper (cover) from being pulled off
prematurely due to suction from the
separating platens.

3. Press the MODE button until time is
displayed.
4. Push and hold SET button and
simultaneously push UP (↑) or DOWN (↓)
arrow buttons to the desired timer setting.

NOTE
For safety purposes, it is necessary to
push the handle into the locked position
after it is lifted. This will eliminate the
accidental lowering of the heat platen
handle.
12. Swing away arm to the extreme right hand
position and remove substrate.

-4-

FOR USE BY QUALIFIED SERVICE PERSONNEL ONLY
ADDITIONAL NOTES:
Temperature
NOTE
Fahrenheit/Centigrade (Celsius)
Conversion
The temperature controller can be
programmed to display either °F or °C.
To change:
Press the MODE button until the
temperature is displayed, then push and
hold the SET button for 10 seconds.

Timer
•
•

The controller has a count down timer that
automatically activates a buzzer at the
completion of the application.
Timer display is minutes:seconds. Range is
00:00 to 10:00, Colons (:) flash while timer is
running.
NOTE
The timer or buzzer may be stopped
while the handle is in the down
position by pressing both the DOWN
(↓) arrow button and the UP (↑) arrow
button simultaneously. The timer will
automatically reset after the handle is
raised.

Counter
The controller has a built in cycle counter.
• Press MODE button until the counter is
displayed.
• Counter display range is 0000 to 9999.
• To reset the cycle counter, display the counter
reading, then push and hold both UP (↑) and
DOWN (↓) arrow buttons for 3 seconds until
the counter resets to zero (0000) on the
display.

-5-

FOR USE BY QUALIFIED SERVICE PERSONNEL ONLY
International Symbols

Safety Summary
WARNING
In case of power cord damage, do
not attempt to repair or replace the
power cord. Contact the manufacturer or the local distributor.

Power Off

WARNING
Avoid touching hot surfaces while
operating the machine.

Power On

CAUTION
During normal operation, the base
of the machine needs to be installed
or placed above the wall socket.

Hot Surface

CAUTION
When servicing or cleaning the
machine, make sure that the power
cord is removed from the wall
socket.

Risk of Electrical Shock

Protective Earth Terminal

Ground

Caution - Warning

-6-

FOR USE BY QUALIFIED SERVICE PERSONNEL ONLY
Preventive Maintenance Suggestions
General Maintenance

The IGS heat seal machines are relatively
maintenance free. For long trouble-free life, the
following preventive maintenance should be
followed:

It is recommended that you have the following
items available:
A. Regular screw driver
B. Phillips head screw driver
C. Small adjustable wrench
D. Needle nose pliers with insulated
handle
E. Set of Allen wrenches
F. Grease gun
G. Special high temperature grease
(MPPL023)
With the above items you should be able to
accomplish most repairs.

1. Do not heat seal items such as buttons, pins,
snaps, or zippers that tend to cut the silicone
rubber pad or scratch the Teflon heat platen.
2. Periodically clean the Teflon-coated heat
platen with a non-abrasive piece of cloth.
Stubborn stains may be cleaned, when
platen is cool, with mineral spirits.
3. When the heat platen is hot and not in use,
keep in open position (away from the silicone
rubber pad).

WARNING
Power cord replacement should be from
the manufacturer only (because it
requires a specially prepared cord).

4. To prevent soiling of substrate, periodic
wiping of the entire exterior machine,
including platens, with a clean rag is
recommended. If necessary, use mineral
spirits for cleaning a cold machine. Since
mineral spirits are flammable, use precautions
and keep away from sparks, flame, or hot heat
platen.

Replacement of Silicone Rubber Pads
1. Make sure heat platen is cool.
2. Use tube of MPPC006 adhesive to bond
silicone rubber pad to metal platen.
NOTE: Read instructions on the tube package.

5. This machine requires periodic lubrication
with a high-temperature, non-melting grease
(MPPL023).
A. Lubricate the post, handle and cam
assembly depending upon usage.
(Once every month if used
continuously.)
B. There are four (4) points of
lubrication:
a) Post
b) Lower Cam
c) Guide Post
d) Upper Pin Area
In addition, occasionally apply a few drops of
heavy machine oil to the upper portion of the
cam assembly. To lubricate the pressure
adjustment, raise cover put some hightemperature grease MPPL023 grease on the
treaded section of the adjustment screw.
NOTE
Wipe off any excess oil or grease.
Replace cover, screw, and knob.

3. Be sure that the surface of the silicone platen
is clean. Use a mild solvent such as
mineral spirits.
4. The pad and metal must be thoroughly dry
and clean, before starting the bonding
operation.
5. Apply adhesive sealant to the metal platen.
Spread a thin even coat and apply pad
immediately. Apply pressure and position
pad making sure that there is no air
entrapment.
NOTE: A serrated blade such as used for laying down
rubber floor tiles would be helpful.
6. Allow to cure overnight under low pressure at
normal room temperature.

-7-

TAN

BLACK

RELAY

GN/YEL

2
12 Vac
INPUT
1

3
OP-2
N/C

TEMPERATURE
CONTROL

YELLOW

WHITE

GREEN/YELLOW

BLUE

5
+12V

TIMER
START
7
6

GREEN
(GN/YEL-EUROPE)
5

4
OP-1

SENSOR

C
NO
MICRO
SW\ITCH

GN/YEL

RTD

BROWN

WHITE

7
12 Vac
8

RED

TRANSFORMER

BLACK

WHITE

WHITE
(BLUE-EUROPE)

WHITE

BLACK
(BROWN-EUROPE)

PURPLE

TERMINAL
BLOCK

GRAY

COIL

TAN
GREEN

GND

HEAT PLATEN

BROWN

BROWN
1

8 GN/YEL

BLUE

12 Vac

230 Vac

BLUE

TRANSFORMER

204.1 Wiring Diagram - 10/08/04

NO
1
2
3
4
5
6
7
8
9
11
13
14
15
16
17
18
19
20
21
22
23
25
26
27
29
30
32
33
34
35
36
37
38
39
40
41
42
43
45
47
48
49
50
52
53
54
55

DESCRIPTION
SHROUD, HEAT
SCREW, PAN HD #10 X 1.00" LG
INSULATION, FIBERGLASS 15X20
SCREW, SOCKET HD 1/4-20 X 4 LG
TUBING, SHRINK TFE AWG7
INSULATORS, SPACER (4/SET)
PLUG, BUTTON 7/8 IN
SENSOR, TEMP. REPLACEMENT KIT
POST, GUIDE
PIN, PIVOT PLATEN
CLEVIS, UPPER PLATEN
PAD, SILICONE 15 X 20 BLK
SCREW, PAN 10-24 X .50 LG
HOUSING, INSTRUMENT
WIRE, HEATER 14GA TGGT
LABEL, CONTROLLER OVERLAY
BOLT, HEX 5/16-18 X 1 LG STAINLESS
SCREW, BUT HD 1/4-20 X .75" LG
HANDLE, PREASURE ADJUST F/204
SCREW, PAN HD 6-32 x 0.25 IN
CONTROLLER, DIGITAL W/SWITCH
HANDLE, SWINGAWAY 218A 228A
WASHER, SAE 1/4"
SWITCH, MICRO
NUT, HEX 3/8-16 LOCKING
PLUNGER SPRING DETENT 500
SCREW, SKT. HD 1/4-20 X.625 HD
KNOB, HANDLE (MUSHROOM)
CAP, VINYL BLK 5/16X.281 LG
RELAY
SCREW, BTN HD 1/4-20 X .875LG
BLOCK, TERMINAL
CLAMP, CABLE 5/16 IN.
TRANSFORMER
SCREW, RD HD 4-40X.625" LG
SCREW, PRESSURE ADJUSTMENT
POST, ARM ASSY
PLATE, POST STOP
WASHER, SAE 1/2"
NUT, JAM SELF LOCKING 1/2-20
CLIPS, "E"
PIN, CAM PIVOT (UPPER)
SCREW, PAN HD 8-32 X .375" LG
SAFETY LOCK
WASHER, #8 SAE
FITTING, GREASE (SHORT)
PIN, ROLL (SAFETY LOCK)

MODEL
204.1
120V AC

MODEL
204.1
230V AC

MPSS228
MPSS143
MPSP254
MHSSH14204
MPPS131
MPSI089
MHPB78
MPPS210
MPSP084
MPP0139
MPSP221
MPPP031
MHSP102412
MPSH015
MPPW700
MPSL128
MHBH516181S
MHSB142034
MPSP014
MHSP63214
MPC90003
MPH90002
MHWSAE14
MPPS043
MHNH3816
MPSP134
MHSSH142058
MPPK017
MPC90006
MPPR200
MHSB142078
MH11096914
MHCC516
MPPT700
MHSR44058
MPSS070
MPSP204
MPSP20450
MHWSAE12
MHNHJSL1220
MPSC240
MPSP262
MHSP83238
MPSL241
MHWSAE8
MPSF145
MPSR141

57
58
59
60
63
68
69
70
71
71A
71B
72
76
78
79
80
82
84
87
88
89
90
91
92
93
94
95
96
A1
A2
A3
A4
A5
A6

CAM
SCREW, BUTTON HD 5/16-18 X1 LG
NUT, HEX JAM 5/16-18
RING, "O" POST
FEET,RUBBER (6/SET)
BRACKET, POWER CORD
STRAIN RELIEF 14/3
SCREW, PAN HD 10-24 X .375 LG
CORD, POWER (USA)
CORD, POWER (EUROPEAN) 230V
CORD, POWER (U.K) 240V
WIRE, HARNESS
SPRING, CAM
INSULATION, MICRO SWITCH
WASHER, CUT 5/16"
SCREW, SKT HD 5/16-18 X .50 LG
CLAMP, CABLE 3/8" (STEEL)
SCREW, PAN HD 8-32 X 1/4 LG
SCREW, PAN HD 8-32 X 1/2 LG
SCREW, SOCKET HD 1/4-20 0.5 LG
NUT, HEX 6-32
NUT, JAM 1/2-20
SCREW, SET 3/8-16 X .500 LG
BUSHING, GUIDE POST
WASHER, SHIM #6 (.031)
SPACER, NYLON 0.166 ID X1/4 LG
PLATE, CONTROLLER
WIRE, GROUND ASS'Y

MPSC220
MHSB516181
MHNHJ51618
MPSS273
MPF90004
MPSS163
MPSS168
MHSP102438
MPPW141
N/A
N/A
MPW90011
MPSS201
MH700214
MHWC516
MHSSH5161812
MH8863T2
MHSP83214
MHSP83212
MHSSH142012
MHNH632
MHNHJ1220
MHSST381612
MPSB074
MH311150019
MH110969111
MPP90011
MPW90125

MPSC220
MHSB516181
MHNHJ51618
MPSS273
MPF90004
MPSS163
MPSS168
MHSP102438
MPPW142
MPPW202
MPPW203
MPW90011
MPSS201
MH700214
MHWC516
MHSSH5161812
MH8863T2
MHSP83214
MHSP83212
MHSSH142012
MHNH632
MHNHJ1220
MHSST381612
MPSB074
MH311150019
MH110969111
MPP90011
MPW90125

PLATEN, HEAT ASS'Y
HANDLE, PRESSURE ASS'Y
CAM ASS'Y
BASE ASSEMBLY
PLATEN, LOWER ASSY
PLATEN, HEAT W/WIRNG

MPP2041A
MPSH515
MPSC213
MPSB204A
MASP007
MPP2041W

MPP2042A
MPSH515
MPSC213
MPSB204A
MASP007
MPP2042W

13925 E. 166th Street • Cerritos CA USA 90702-7900
Service: (800) 426-3609 • Fax: (562) 861-1519 • (562) 861-2566 • Sales: (800) 421-6971 (562) 404-3000 • Fax: (562) 404-3010
http://www.instagraph.com

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