Fix Any Problem in Ten Minutes the Maintenance & Programming Manual for the digital EzPress & digital PopUpPress with EzWizard Software version 2.

Transcription

1 Fix Any Problem in Ten Minutes the Maintenance & Programming Manual for the digital EzPress & digital PopUpPress with EzWizard Software version 2.00 Patent Pending Revised: 6/1//2007 Manual Revised 3/21/2008 copyright 2007,2008 EzPi EzProducts International Inc 4686 W Main Street, Wauchula FL USA

2 Important Information The table below lists the computer parameters used to control the digital EzPress or digital PopUpPress with EzWizard Software. The factory value column indicates the value that was pre-set at the factory. If you customize these values, please record your custom values in the column customer value. computer status table description (not changeable in set-up) units factory value customer value Program Version P200 P200 Extended Dwell Time Count (cycles) Short Cycle Error Count (errors) Long Cycle Error Count (errors) Hot Cycle Error Count (errors) Cold Cycle Error Count (errors) computer setup parameter description (changeable in set-up) units factory value customer value Seconds of Dwell Time (seconds) Upper Platen Temperature (degrees F) Lower Platen Temperature (optional) (degrees F) Limit, Cold Cycle (degrees F) 10 Limit, Hot Cycle (degrees F) 5 First Temperature Drop Limit (degrees F) 3 First Temperature Drop Additional Dwell Time (seconds) 3 Second Temperature Drop Limit (degrees F) 6 Second Temperature Drop Additional Dwell Time (seconds) 6 Display Degrees (Fahrenheit /Celsius) F Number of Heated Platens (1 or 2) 1 Temperature Calibration Offset (Degrees Fahrenheit) I M P O R T A N T Your digital EzPress or digital PopUpPress contain a small digital computer. Its power cord should always be plugged into an AC Surge Protector just like your desktop computer. Power surges from large electric motors or lightning can damage computers. Damage to the Press due to a power surge is not covered by the warranty.

3 Technical Assistance Technical Assistance & Customer Service are available 9:00am 6:00pm Eastern Time. To return a Press for repair, you must call for a Return Machine Authorization number. From the US or Canada: call toll free From other countries: call Fax Web Site: New orders are shipped the same day, if they are received by 2:00pm Eastern time. We accept: American Express, Discover, MasterCard & Visa. Warranty The digital EzPress and digital PopUpPress are covered by a 1 year Return to Factory Warranty. The Rubber Pad on the Lower Platen and the Teflon Pad on the Upper Platen are consumable items not covered by this warranty. During the warranty period, you may choose to have your technician order parts at no cost and repair the digital EzPress or digital PopUpPress at your facility. However, damage caused by un-qualified personnel will void your warranty. To return a digital EzPress or digital PopUpPress for repair you must first call EzProducts toll free at to obtain a Return Authorization Number. Then ship the Press freight pre paid to EzProducts at 4686 W Main St, Wauchula FL Allow 5 business days for repair. Your company name, address and Return Authorization Number must be clearly written on the outside of the box. Contents Important Information (inside front cover) Initial Press Setup 2 EzWizard Software Control Parameters 4 Applying Labels 5 Optional Heated Lower Platen 5 Applying Labels to the Inside of Pockets 6 Determining the Software Version of your Press 6 Auditing Operator Errors 6 Digital Computer Display Modes 7 Theory of Operation 8 Mechanical Design & Operation 8 Electrical Design & Operation 11 Handle Backstop Screw Adjustment 12 EzWizard Software Parameters 14 Replacing the Upper Platen 16 Testing a Heated Platen 17 Testing the Air Cylinder 17 Replacing the Electronics Drawer 18 Cycle Control Photo Sensor Adjustment 19 Operator Errors 21 Machine Errors 21 Fix Any Problem in Ten Minutes 22 Technical Assistance 24 Shipping Address for Repairs & Returns Return Authorization Number (call for number before shipping) EzProducts [Always write your name, address, phone number 4686 W Main Street and return authorization number on the outside of Wauchula FL USA of the box.] - 1 -

4 Install Power Cord & Power on Test Initial Press Setup Plug the Power Cord into the socket located on the back of the Electronics Drawer. (It is easier to plug the Power Cord into the socket if you turn the Press upside down.) Power Cord (Press upside down) key + key - key Power Switch Plug the Power Cord into a wall outlet with 120V AC power. Turn the Power Switch on. Verify that the computer display indicates and the Power Fault light is NOT on. If the Power Fault light is on, the wall outlet is NOT wired properly. Plug the press into a properly wired outlet before using the press. After 4 seconds, the press will remain in the Pre-Heat Mode (see page 6) until it has heated to within 10º of your pre-set application temperature. When the Press is ready to use the computer will enter the Ready Mode and display the actual platen temperature. The digital EzPress or digital PopUpPress with EzWizard Software is pre-set at the factory to apply EzLabels, TrackIt Labels and Computype Labels. To apply other manufacturers labels, emblems, mending patches or thermal transfers, consult the manufacturer to obtain their recommended time and temperature settings. Fix Any Problem in Ten Minutes Step 2 Fix or Replace the Defective Component 3.00 Bad Power Outlet. Plug Press into a working outlet. Go to Bad Electronics Drawer. Replace it.. See P18. Go to Bad Platen. Replace it. See P15. Go to Bad pins on Platen Connector. Can you fix pins with pliers? 3.31 Yes Fix pins, plug cable in & tighten retaining ring securely. Go to No Bad Platen. Go to Handle Backstop Screws out of adjustment. See P12. Go to Bad or weak PopUp Motor. Replace motor. See Go to Motor Shaft Lock Nuts loose. Tighten lock nuts firmly. See P. Go to Check Platen. See P19. Is Platen ok? 3.72 Yes Platen is good, Electronics Drawer is bad. Go to No Platen is bad. Go to Check the Pop Up Air Cylinder. See P17. Go to Test complete. The PopUpPress is working fine. Verify the Proper Application Time and Temperature Call your label, emblem, patch, or transfer manufacturer and obtain their recommended settings. If the manufacturer recommends heating their product from both the top and bottom, an optional Lower Heated Platen is available from EzProducts and can be installed by your service technician in about 10 minutes. To order an optional Lower Heated Platen, please call EzProducts at Obtain the Computer Set-up Codes If you need to change application time or temperature, retrieve your Set-up Mode Sequence Card. If they can not find it, have your supervisor call toll free or , Monday Friday, 9:00 to 6:00pm Eastern Time

5 Fix Any Problem in Ten Minutes Step 1 Diagnose the Problem 1.00 Plug in the Press & turn it on. Did the Computer Display indicate 8888 for 4 seconds? 1.20 Yes In 5 seconds does the display alternate between U### and =###? 1.21 Yes Pre-Heat Mode. Wait 5 minutes. Is Platen hot & display showing pre-set temp +/- 10ºF? 1.22 Yes Platen Temperature is ok. Go to No Is the Display still alternating between U### and =###? 1.24 Yes Computer still in Platen Pre-Heat Mode. Is Platen hot? 1.25 Yes Still in Pre-Heat Mode. Go to No Platen Cold. Bad Platen. Go to No Does Computer Display show Err3 or Err4? 1.28 Yes Verify Platen Cable Connector plugged in & tight? 1.29 Yes Unplug connector. Are all pins ok? 1.30 Yes Check Platen. Go to No Bad pins on Platen Cable. Go to No Tighten Platen Cable Connector. Go to No Check Platen. Go to No Bad Electronics Drawer. Go to No Did the Computer Display light up at all? 1.41 Yes But, it did not indicate 8888 for the first 4 seconds. Bad Electronics Drawer. Go to No Computer Display did not light up at all Is the Power Cord firmly plugged in at both ends? 1.45 Yes Verify wall outlet power with meter or Outlet Tester. Is the Outlet OK? 1.46 Yes Bad Electronics Drawer. Go to No Bad Power Outlet. Go to No Plug the power cord in properly. Go to Platen temperature is ok. Pull the handle down all the way. Does it handle latch down? 2.01 Yes Does the computer display time count down? 2.02 Yes When the computer display time counts down to 0 does the Handle pop up? 2.03 Yes Did the handle pop up gently? Yes The PopUpPress is working fine. Go to 9.00 No Check the Pop Up Air Cylinder. Go to No When the display counted to 0 did the black shuttle bar move foreword? 2.05 Yes Can the handle be lifted easily (less than 4 pounds of force)? 2.06 Yes Bad or Weak PopUp Motor. Go to /07 No Handle Backstop Screws out of adjustment Go to No Is the motor shaft lock nut tight against black plastic shuttle bar? 2.09 Yes Bad or weak PopUp Motor. Go to No Motor Shaft Lock Nuts loose. Go to No Handle Backstop out of adjustment. Go to Application Time (must have access codes) Initial Press Setup (continued) When the access sequence is entered, the display will indicate S200 indicating that the software program is version Press the key five times. The display will indicate S 06 or S 08 indicating that the pre-set Application Time is 6 seconds or 8 seconds. Press the +key to increase the time or the key to decrease the time. When the proper time is indicated in the display, press the key to change another setting or press and hold the key for 4 seconds and the display will return to the Pre-Heat Mode. Upper Platen Temperature (must have access codes) Press the Key 6 times or until the display indicates U360 or U380 indicating that the Upper Platen Temperature is pre-set to 360ºF or 380º (the default out of box setting). Then, each time you depress the +key or - key, the display will change by one degree. When the proper temperature is indicated in the display, press the key to change another setting or press and hold the key for 4 seconds and the display will return to the Pre-Heat Mode. Optional Lower Platen Temperature (must have access codes) Press the key seven times or until the display indicates L370 indicating that the Lower Platen Temperature is pre-set to 370ºF (the default out of box setting). Then, press the +key to increase the temperature or the - key to decrease the temperature. Each time you depress the +key or - key, the display will change by one degree. When the proper temperature is indicated in the display, press the key to change another setting or press and hold the key for 4 seconds and the display will return to the Initialization mode. Number of Heated Platens (must have access codes) Press the key twice times. The display will indicate P 1 indicating that press has only 1 platen. Press the + key to change to 2 platens (heated upper and lower) or the - key to change to 1 platen (heated upper platen only). You must purchase and install the optional Lower Heated Platen before selecting 2 heated platens. Temperature to Fahrenheit or Celsius (must have access codes) Press the key five times. The display will indicate T F indicating that the temperature is displayed in Fahrenheit. Press the +key to change the display to T C, indicating that the temperature is displayed in Celsius. Press the - key to change the display to T F, indicating that the temperature is displayed in Fahrenheit. Important: after changing the Fahrenheit or Celsius setting, turn the power off for 4 seconds to initialize the computer. Do not use the Press during the Pre-Heat Cycle! Always allow the Press to Warm Up or Cool Down to Your New Temperature. Once any of the pre-set conditions have been changed, the computer will return to the Pre-Heat Mode. It will remain in the Pre-Heat Mode until the platen temperature has stabilized within 10 degrees of the new pre-set temperature. When the pre-set temperature is achieved, the computer will sound the buzzer on an EzPress or cycle the motor on a PopUpPress then, it will display Ready Mode indicating the actual platen temperature. The press is now ready to apply labels

6 Special EzWizard Software Control Parameter Limit, Cold Cycle Limit, Hot Cycle First Temperature Drop Limit First Temperature Drop Additional Seconds Second Temperature Drop Limit Second Temperature Drop Additional Seconds Temperature Display Degrees error meaning corrective action E-CC Cold Cycle E-HC Hot Cycle E-SC Short Cycle E-LC Long Cycle Operator Errors Press the key & wait until the platen has heated to your preset temperature before using the Press Press the key & wait until the press has cooled to your pre-set temperature before using the press The handle was lifted before the pre-set time had elapsed. Press the key and wait for the buzzer on an EzPress or wait for the handle to pop up on a PopUpPress. The handle was not lifted within 10 seconds of the buzzer sounding on an EzPress or the pop up motor failed on a PopUpPress. Press the key & lift the handle immediately when the buzzer sounds on an EzPress or repair the pop-up circuit on a PopUpPress. When the Press displays an Operator Error, leave the Power on, press the key to clear the error and continue using the press. To observe the 4 flashing Operator Error Counts stored in permanent memory, press the key twice to display Cold Cycle Errors. Press again to display Hot Cycle Errors. Press again to display Long Cycle Errors and press again to display Short Cycle Errors. The Operator Error Counts are stored in permanent memory and can not be cleared. (Note: when the total count reaches 255, the next Error Count will be 0 then it will continue counting up again.) error meaning corrective action Machine Errors E-01 Memory read error Turn power off for 10 seconds. E-02 Memory write error Turn power off for 10 seconds E-03 Platen not heating Verify that all cables are plugged in. E-04 Temp control error Check cables, thermal fuse or Thermistor Power Fault Screen is blank = No Power AC Hot and AC Neutral wires are reversed in the wall outlet. Call an electrician. Do not use the EzPress or PopUpPress if the Power Fault Light is on. Verify that the Power Switch on the front of the EzPress or PopUpPress is turned on. Check that the AC Power Cord at the back of the EzPress or PopUpPress is plugged in all the way. Verify that you have power at the wall outlet where the Press is plugged in. If a Machine Error continues to occur, call EzProducts toll free

7 Cycle Control Photo Sensor Timing Adjustment General Operation (continued) When the handle is in the Down and Latched position, light shines through the notch in the disc and the Cycle Timer should be activated and the display counts down. When the Handle is lifted off the Handle Backstop Screws, the light is blocked to the Photo Sensor and the Cycle Timer is deactivated and the display stops counting down. Adjustment With power off, slightly loosen the Photo Cell Lock-down Screw described above. Position the press upside down with rear of press toward you. Turn the Photo Cell Calibration Screw clockwise until the aluminum Calibration Pin in the plastic mount is all the way toward the rear of the slot. Turn the Press right side up. Turn the power on. Lock the handle in the down and latched position and observe that the Cycle Timer does not count down because the disc is blocking the photo sensor light. Turn the Photo Sensor Adjustment Screw (described above) counter clockwise until the timer begins to count down. Be careful, on a PopUpPress, the handle will pop up soon. When the timer begins to count down, Lift the Handle slightly to stop the countdown. Then continue turning the Photo Sensor Adjustment Screw counter clockwise two full turns. This will position the Photo Sensor so that the light is near the center of the notch when the handle is latched down. Gently tighten the Lock Down Screw. (Be Careful, do not over tighten the Lock-down Screw. It is threaded into plastic which can be easily stripped.) Pull the Handle down and observe that the Press operates properly. If not, call EzProducts at Applying Labels Before applying labels to clothing, complete the following test: Apply at least 5 labels a swatch of cotton polyester and at least 5 labels to a swatch of silk. When the labels have cooled to room temperature, try to pick them off. Try very hard. If you can lift even a tiny corner of one label, the label is not applied properly. Call EzProducts toll free: If the labels are firmly attached, verify that they are easy to read. If using barcode labels, verify that all labels can be read with your barcode wand. Wash and dry the cotton polyester swatch at least 10 times and dry clean the silk swatch at least 10 times. Then, verify that the labels are still firmly attached and easy to read. If they are not, call EzProducts. The label Application Time and Platen Temperature for the exact labels, mending patches, emblems or thermal transfers that you are using must be obtained from your supplier. The table below should be used as a guide. --Mini Platen Platen Platen- Label Manufacturer Temp Time Temp Time Temp Time EzLabels EzProducts 380ºF 8 sec 380º 8 sec 390º 9 sec TrackIt Labels EzProducts 380ºF 8 sec 380º 8 sec 390º 9 sec EzPatch Mending Patches EzProducts 380ºF 8 sec 380º 8 sec 390º 9 sec EzTransfer Thermal Transfers EzProducts 360ºF 6 sec 380º 8 sec 390º 9 sec Computype Barcode Labels Computype Corp 380ºF 8 sec 380º 8 sec 390º 9 sec Thermopatch Barcode Labels Thermopatch Corp 400ºF 10 sec 400º 10 sec 400º 10sec Optional Heated Lower Platen If the label manufacturer recommends that the Press heats the label from both the top and bottom platens, you can purchase an optional Lower Heated Platen from EzProducts. Your Service Technician can install it in about 15 minutes

8 Applying Labels to the Inside of Pockets Use a mini-5 interchangeable lower platen. Fold jacket pocket over the end side of the platen with the inside of the pocket facing up and apply the label as usual. For additional information, repair parts or assistance of any kind, please call toll free: If calling from a foreign country, please call Telephone assistance is available Monday through Friday from 9:00am to 6:00pm Eastern Time. Additional information is available online at: or Determining the Software Version of your Press When the EzWizard Software is in the Pre-Heat Mode or the Ready Mode, press the key once and the computer display will indicate the Program Version. Such as: P200 = EzWizard Software Version 2.00 Important Cycle Start Photo Sensor Timing Adjustment This adjustment is pre-set at the factory and under normal operating conditions it should not be changed. However, if the Press is dropped or the Electronics Drawer is replaced, perform the following procedure. General Operation Attached to the lower end of the Left Handle near the bushing where the handle pivots on the Axle is a Cycle Timing Disc (see diagram below). This Disc is attached to the handle and it rotates with the handle. This Disc has a notch in the bottom edge. When the handle is latched down, this notch will rotate down and line up with the black Photo Sensor (mounted on the back of the Electronics Drawer). Auditing Operator Errors The total of each of the 4Operator Errors is stored in permanent memory. You can observe the Total Error Count for each of the 4 Operator Errors by pressing the Key. The first depression of the Key will display the Program Version. The second depression of the Key will display the number of times the Press detected a Cool Cycle and extended the dwell time. The next four depressions will display each of the four flashing Operator Error Totals. computer status table description (not changeable in set-up) units factory value customer value Extended Dwell Time Count (cycles) Short Cycle Error Count (errors) Long Cycle Error Count (errors) Hot Cycle Error Count (errors) Cold Cycle Error Count (errors) Located directly under the Timing Disc is a black Photo Sensor which is mounted on a small green Circuit Board. When the light on the left of the Photo Sensor shines through the notch in the Timing Disc, the Photo Sensor is enabled and an Application Cycle begins. The Photo Sensor Circuit Board is attached to its Mounting Bracket with two Phillips Head Screws. The rear screw under the timing disc attaches the circuit board to a Calibration Pin. DO NOT loosen this screw! The Lock-down Screw near the back of the Electronics Drawer is in an elongated hole in the Photo Sensor Circuit board and is used to lock the circuit board down when properly adjusted. If you loosen the Lock-down Screw, the elongated hole in the Circuit Board allows the Photo Sensor Circuit Board to be moved forward or backward when the calibration screw is turned. The Calibration Screw is located on the back of the black plastic mount under the circuit board

9 Remove the old Electronics Drawer Replacing the Electronics Drawer Turn the Press up side down and un-plug the Power Cable. Unscrew the blue locking ring on the Platen Cable Connector and un-plug the Platen Cable Connector. Using a 3/8 Nut Driver and a pair of Pliers, remove the nut from the back of the Pop Up Motor Drive Shaft that secures it to the black plastic Pop Up Shuttle Bar (Hold the Shaft firmly with the Pliers and turn the Lock Nut counter clockwise. Using a Phillips Screwdriver, remove the two front Feet, the two screws near the back edge of the Electronics Drawer and the one screw in the back edge of the Electronics Drawer near the Pop Up Motor. Slide the Electronics Drawer out of the base. Test the new Electronics Drawer Plug the female end of the Power Cord into the Power Cord Socket in the back of the Electronics Drawer. Plug the male end of the Power Cord into a working 120V AC Outlet. Place a piece of folded paper in the black Photo Sensor on the back edge of the Electronics Drawer to block the light from the Photo Sensor. Turn the Power Switch on. Did the Display indicate 8888 for 4 seconds? Yes Computer Self Test in process. Did Display indicate alternating U### & =####? Yes Pre-Heat Mode. Remove paper blocking Photo Sensor. Display = E-CC? Yes Photo Sensor is working. Did Pop Up Motor run forward & backward? Yes The Electronics Drawer is Working. Turn it OFF. No The Pop Up Motor is defective or the CPU Board is defective. No Wait 4 Seconds for Self Test No No AC Power. Try another Outlet. (Could be bad Power Switch but very rare.) Insert the new Electronics Drawer Remove the AC Power Cord from the connector on the Electronics Drawer. Turn the Motor Shaft clockwise until there is about ½ inch of Motor Shaft on the inside edge of the Motor. Verify that there is a Nut screwed all the way onto the back of the Pop Up Motor Shaft. (Replace Nut if necessary.) Insert the Electronics Drawer into the upside down PopUpPress Chassis. Guide the Motor Shaft into the hole in the black plastic Pop Up Shuttle Bar. Using a Phillips Screw Driver, install the screw in the back edge of the Electronics Drawer near the Pop Up Motor. Install the two screws in the bottom of the Electronics Drawer near the back edge. Install the two rubber Feet. Turn the Pop Up Motor Shaft counter clockwise until the nut is flush against the inside edge of the black plastic Pop Up Shuttle Bar. Using a pair of Pliers and a 3/8 Nut Driver, install the Lock Nut on the Pop Up Motor Shaft. Tighten the Lock Nut firmly against the black Pop Up Motor Shaft. Turn the PopUpPress right side up and perform the Cycle Start Photo Sensor Timing Adjustment on page Self Test Mode Digital Computer Display Modes When power is first turned on, the computer runs a Self Test. It will first display all 8 s in the four display positions to show the operator that all segments of the display are operating. Then it will display the program version number ie: P200 (or the current Program version number) for 4 seconds. When the computer has finished its self test, it will cycle the pop up motor or sound the buzzer, indicating that everything is operating fine. Then the computer will enter the Pre-Heat Mode. Pre-Heat Mode Then the display will show U380 (or your pre-set temperature) indicating that the upper platen is pre-set to 380º then it will show =321 or the actual platen temperature. (If the actual platen temperature is below 300ºF the display will show = - - -, indicating the platen temperature is too low to be displayed. It must be over 300º F to be displayed.) When platen has heated to at least 300ºF the display will alternate between the pre-set temperature and the actual temperature. Then, when the platen has heated to within 10º of your pre-set value, the buzzer will sound on an EzPress or the pop up motor will cycle on a PopUpPress indicating that the press is now ready to use. At this time it will display the actual platen temperature and will remain in the Ready Mode until you pull the handle down to the latched position. Ready Mode Once the platen has heated to within 10 degrees of the pre-set temperature, the display will indicate the actual platen temperature. The press is ready to use. Application Mode As soon as the handle is pulled down to the latched position, the display will indicate the pre-set application time. It will then count down from the pre-set time to 0 at which time the buzzer will sound or the pop up motor will be activated. When the handle is lifted or pops up, the display will return to the Ready Mode. If an Error is detected, the display will indicate E and one of the Error Codes listed on page 11. To clear the Error Display and return to normal press operation, press the key. Error Mode When an error has been detected, the buzzer will sound on an EzPress or the pop up motor will be activated on a PopUpPress and the Error Code will be locked into the display until the operator presses the key. The computer detects two types of errors Operator Errors and Machine Errors. These error codes are described in detail on page 11. Operator errors cause labels, emblems, etc to fall off! Regularly audit the 4 Operator Error Counts by following the instructions on page 5. The Operator Error Counts are stored in permanent memory and can not be cleared. Write the Press Serial Number and the 4 Operator Error Counts down on a piece of paper, then observe the Error Counts again in a few days. If the Error Counts increase, you will know if your operators are making these errors and corrective action can be taken

10 Theory of Operation The digital EzPress and digital PopUpPress with EzWizard Software were design with consultation from 7 of the largest drycleaners in America. We asked the drycleaners, If you had a magic wand and could create your ideal press for applying labels to personal clothing, what features would you want? They responded, We want a press that is: Reliable & easy to repair (repair any problem in 10 minutes) Light weight & easy to transport to drop stores Small footprint for counter top use Use conventional 120V AC power (no compressed air) Reliable solid state technology Tamper proof time & temperature settings (no knobs) Small Mini-platen for applying tiny barcode labels on delicate fabric High platen pressure to decrease temperature & dwell time Detect & alarm when common operator errors occur Count & store operator error count in permanent memory for supervisor auditing & training. Detect cooling of hot platen when labeling denim & other heavy fabric & automatically increase the dwell time to insure perfect label application, every time. Out-of-box set up correct for applying their labels. (No set-up required.) Immediate availability of all spare parts. Drycleaners asked for these features and EzProducts delivered them in the digital EzPress and digital PopUpPress with EzWizard Software version Mechanical Design & Operation The digital EzPress and digital PopUpPress are manufactured from durable powder coated steel with all stainless steel axles and fasteners. Permanently lubricated Bronze bushings are used on all pivot points to eliminate wear. A comfortable foam rubber grip is attached to the Handle that is to use to raise and lower the hot platen. With only 15 pounds of pressure on the handle, 100 pounds of pressure is applied to the label when the handle is pulled down to it s latching position. The exact position of the handle when it is pulled all the way down and the Hot Platen is compressed down onto the garment is very important. If the handle pivots down too far, the platen pressure will make it difficult to lift the handle up. If the handle does not pivot down far enough, it will not latch and will pop up when you release it. The downward pivoting motion of the handle is controlled very precisely with two harden steel back-stop screws attached to levers on lower edge of the handle near the pivot point. (See Figure 1) The heads of these two back-stop screws hit bushings on each end of the rear axle when the handle is pulled all of the way down (See Figure 2). These bushings prevent the heads of the screws from being damaged and the sides of the axle from being damaged when the screw hits it. Turning these screws inward (clockwise) allows the handle to pivot down farther and turning these screws outward (counter-clockwise) prevents the handle from pivoting down as far. The adjustment is correct if it requires 4 pounds of pressure to lift the handle when it is pulled all of the way down until the screws hit the bushings and the handle latches. Care must be taken to insure that both screws hit the bushings with equal pressure Unplug the Platen from the Press. Testing a Heated Platen Plug the Platen Cable Connector into a Platen Test Cable. Using an Ohm Meter, verify the following: 1. On the lowest Ohms Scale of the Meter, measure between each pin on the Test Cable and one of the screws in the Platen. There should be no resistance. If so, a component or a wire inside the Platen is shorted to the Aluminum Platen. If the 4 wires test ok, proceed to the next test. 2. Measure the resistance between the Red and White wires on the Test Cable. They should read 50 ohms for a Standard Platen or 75 ohms for a Mini Platen. No resistance indicates a broken wire or a blown Thermal Fuse. 3. Change the Ohm Meter to two higher scales and measure the resistance between the Red and White Wires. They should read about 9000 ohms when the Platen is at room temperature (about 70º F). If the Red and White wires are ok, the Platen is good. No resistance indicates a broken wire or a broken Thermistor. Does the Handle pop up gently? Yes The Air Cylinder is ok. Testing an Air Cylinder No Is the nut securing the Air Cylinder to the Mounting Bracket tight? Yes Is the lock nut securing the Air Cylinder Shaft to the Axle in the Link tight? Turn the Press upside down and remove the red plug in the bottom of the Air Cylinder. Squirt WD 40 into the hole in the bottom of the Air Cylinder. Then pump the Air Cylinder 4 times by moving the front edge of the Press up and down while holding the handle down against the table. Then firmly insert the red plug into the bottom of the Air Cylinder. Turn the Press right side up and test it again. If the problem persists, replace the Air Cylinder

11 Replacing the Upper Platen Remove the old Upper Platen Turn the Press up side down and un-plug the Power Cable. Unscrew the blue locking ring on the Platen Cable Connector and un-plug the Platen Cable Connector. Turn the Press right side up and using a Phillips Screw Driver, un-screw the four screws securing the Upper Platen to the Arm. If the old Platen does not drop down and off of the Arm, pry it down a little with a Standard Screwdriver. Then slide the Platen Cable toward the back of the Arm until the Teflon Cable Cover is behind the edge of the Arm. Then the wires can be slid down through the slot in the back edge of the Arm and the Platen removed. Install the new Upper Platen Remove the four mounting screws from the new Upper Platen. Remove the Teflon Sleeves from the two back Screws. Place the two back screws into the two back mounting holes in the Arm and slip the two Teflon Sleeves over the two Screws. If the Teflon Sleeves fall off, crease them before you slip them over the Screws. Slip the Platen Cable Wires up through the slot in the back edge of the Arm. Then, pull the cable forward until the Teflon Sleeve on the Platen Cable is protruding past the edge of the Arm about ½ inch. Route the wires from the Teflon Sleeve left and right around the two Screws with the Teflon Sleeves and position the platen approximately in the center of the Arm. Pull the Handle down until it latches. This will hold the platen in place. Insert a Phillips Screwdriver down through the front left front hole in the Arm and into the screw hole in the Platen. Use the Screwdriver as a lever, pry the Platen into a position until the shaft of the Screwdriver is perpendicular with the top surface of the Arm. This will insure that the Platen is correctly aligned with the screw hole. Remove the Screwdriver and insert the screw into the left front hole and screw it down but do not tighten it firmly. Use the Phillips Screwdriver to align the right front screw hole and insert a screw into this hole but do not tighten it firmly. Align the two back screws until they fit into the holes in the Platen and tighten them firmly. Insure that the wires inside the Platen Arm are routed around the back of the Screws. Tighten all four Screws. Turn the Press upside down and install the Platen Cable Connector into the Socket on the back of the Electronics Drawer. Notice that there is a slot on the edge of the Socket and there is a bump on the outside edge of the Platen Cable Connector. The bump and the notch must line up to plug the Connector into the Socket. Figure - 1 The procedure for adjusting the Handle Back-stop Screws is explained on page 7. This adjustment is made at the factory and it should not be necessary to change it unless the Press is mechanically damaged. When you pull the Handle down until it latches, the Upper Platen press down onto the Lower Platen with great force. This force is obtained by compressing the Rubber Pad on top of the lower platen and the Rubber Mounts under the lower platen. The distance that the Upper Platen compresses the pad and the rubber mounts is controlled by Platen Spacers which are inserted between the Aluminum Lower Platen and the Rubber Mounts. Removing a Platen Spacer will decrease the Platen Pressure and inserting additional Platen Spacers will increase the Platen Pressure. The Platen Pressure is calibrated to 100 pounds at the factory. Additional Platen Spacers can be purchased from EzProducts if you wish to increase the Platen Pressure. When the Handle is pulled down to the latching position and the label is pressed between the hot platen and the rubber pad, a photo sensor is activated and starts the cycle count down. A round Cycle Timing Disc (see Figure 1) is attached to the lower edge of the left handle (see Figure 1). As the handle is pulled down, the Cycle Timing Disc rotates through a photo sensor. When the notch on the Cycle Timing Disc rotates down as the Handle is latched, light shines through the notch and activates the Photo Sensor. When the Photo Sensor detects the light, the computer starts the cycle count down

12 The precise alignment of the Cycle Timing Disc and the Photo Sensor is required to start the Computer Count Down exactly when the Handle is in the down and latched position. To accomplish this precise alignment, a Micro Positioning Screw is inserted in the back of the Photo Sensor Mounting Bracket (See Figure 1). When this screw is turned clockwise, it moves the Photo Sensor toward the back of the Press and when it is turned counter-clockwise, it moves the Photo Sensor toward the front of the press. A Locking Screw on the top of the Photo Sensor is securely tightened when the Photo Sensor is in the correct position, which prevents it from accidentally moving. This adjustment is made at the factory and it should not be necessary to change it unless the Electronics Drawer of the Photo Sensor is replaced or the Press is mechanically damaged. EzWizard Software Parameters (continued) 2d Second Temperature Drop Limit 0 20 If the platen temperature drops more than 2dº during an application cycle, 6 std add 2A more seconds of dwell time. 2A Second Temperature Drop Additional Dwell Time 0 20 If the platen temperature drops more than 2dº during an application cycle, 6 std add 2A more seconds of dwell time. Dd F Display Degrees F C The temperature is displayed in degrees: F=Fahrenheit or C=Celsius F std H 1 Number of Heated Platens 1 2 1=Upper heated platen only, 2=Both upper and lower platens are heated 1 std with independent temperature control. O ## Temperature Calibration Offset (degrees F) -30 to +30 At the factory, the Platen temperature, is measured using a precision Fluke Digital Thermometer. A special small flat Temperature Probe (the size of a small barcode label is placed ½ inch in from the front center edger of the platen. The Fluke then accurately measures the temperature at the exact spot on the Platen where most labels are applied. The display is then calibrated to match the Fluke Digital Thermometer. This 2-digit number (displayed only in the (Operating Mode) represents the difference between the Fluke and the displayed value at the time of calibration. The Fluke Digital Thermometer used for this Calibration is expensive, extremely accurate and has been verified to be within 1º accuracy by the Bureau of Standards. WARNING: Do not change this Calibration Offset Value unless you have an extremely accurate digital thermometer. When in the Set-up Mode, insert the temperature probe of your digital thermometer between the platens, lock the handle down. Press the key several times, until the display indicates c###. Then, allow the platen temperature to stabilize until the displayed value changes about once every 30 seconds or more on both the display and the digital thermometer. Then, adjust the displayed value on the Press to be equal to the digital Thermometer value. Pressing the +key will increase the displayed value and pressing the key will decrease the displayed value. When the displayed value matches your digital thermometer, press and hold the key for 4 seconds or turn the Press off. This will save your settings and exit the Set-up Mode. Remember, the Calibration Offset Value can be displayed in the Normal Operation Mode but it can not be changed unless in the Set-up Mode

13 EzWizard Software Parameters display parameter description factory value P200 Program Version (factory pre-set not changeable) P200 d### Extended Dwell Time Count (reference only, this is not an error) 0 This value is incremented each time that the EzWizard extends the dwell time because the platen cooled more than 3º F during a heavy garment labeling cycle. S### Short Cycle Error Count (automatically saved, not changeable) The number of times that the operator lifted the handle before the timer counted down to zero. L### Long Cycle Error Count (automatically saved, not changeable) The number of times that the operator failed to lift the handle within 10 seconds of the buzzer sounding on a digital EzPress. H### Hot Cycle Error Count (automatically saved, not changeable) The number of time the operator applied a label before the Platen cooled to within 5º of the pre-set temperature. This error will occur only if a technician changed the pre-set temperature to a lower value and the operator applied a a label before the Platen cooled to the new lower pre-set temperature. C### Cold Cycle Error Count (automatically saved, not changeable) The number of times the operator applied a label before the Platen heated to within 10º of the pre-set temperature. S 6 Seconds of Dwell Time (mini Platen) The digital computer compares the actual platen temperature it obtains from the Thermistor The time that the computer will count down before sounding the buzzer 8 (std Platen) with your pre-set platen temperature. When the platen is cold, the digital computer applies or popping up the handle. 6(mini Platen) full power to the platen heater. However, as the platen heats to the pre-set temperature, the U360 Upper Platen Temperature (mini Platen) digital computer gradually reduces the power to the platen heater until the exact pre-set 380 (std Platen) temperature is obtained. By micro adjusting the heater power, the platen temperature can be controlled to within 1º of your pre-set value. L340 Lower Platen Temperature (optional heated lower platen only) (mini Platen) 360 (std Platen) LC10 Limit, Cold Cycle Allowable limit of temperature drop during a cycle. If the temperature drops 10 std more than 10º below the pre-set temperature, a Cold Cycle Error will occur. LH 5 Limit, Hot Cycle Allowable limit of temperature increase during a cycle. If the platen 5 std temperature increases more than 5º above the pre-set temperature, a Hot Cycle Error will occur. 1d First Temperature Drop Limit If the platen temperature drops more than 1dº during an application cycle, 3 std add 1A more seconds of dwell time. 1A First Temperature Drop Additional Dwell Time If the platen temperature drops more than 1dº during an application cycle, 3 std add 1A more seconds of dwell time Electrical Design & Operation Application Cycle Control The digital computer starts an application cycle when the handle is pulled down to its latched position. An optical sensor monitors the location of a notch in the Cycle Timing Disk which is attached to the bottom of the left handle side (see diagram page 4). This notch allows light to the sensor and begins the application cycle when the handle has pivoted down to its latched position. The Photo Sensor is adjusted so that the light source is blocked until the handle is within.010 of the down and latched position. This insures that the cycle will never start until the handle is all the way down and latched. When the application cycle begins, the pre-set application time is displayed, it counts down to 0 seconds and the buzzer sounds on an EzPress or the pop-up motor is activated on a PopUpPress. When the handle is lifted, the display returns to the Ready Mode. If you use the EzPress or PopUpPress in a dusty environment, occasionally (once a month) blow the dust off the photo sensor. Platen Temperature Control A digital Computer with EzWizard Software monitors the Platen Temperature using a small precision Thermistor. This Thermistor is mounted in a notch in the top of the platen near the center. The Thermistor is insulated from the outside air with a small Teflon mounting block. This Teflon mounting block also houses a Thermal Fuse which is used to prevent the platen from overheating in the event of a computer or Thermistor malfunction. It should be noted that the temperature will drop 3 or 4 degrees when you first start applying labels. I takes the computer 5 or 6 cycles to micro adjust the power for label application after remaining in the Idle Mode for a few minutes. Do not be alarmed if you see this slight temperature drop. The EzWizard Software will extend the dwell time if needed to insure that the labels are always properly applied. Also, if the temperature drops more than 10º below your pre-set value, the EzWizard Software will stop the Press operation and declare a Cold Cycle Error. Platen Temperature Calibration The Platen Temperature is calibrated at the factory using a precision Fluke Digital Thermometer with 1º accuracy. The temperature probe is placed in the center of the platen, about 1 in from the front edge. Then, with the Handle down and latched, the temperature measured with the Fluke Digital Thermometer and compared to the Computer Display. The Display Temperature is then adjusted to be within 1º of the Fluke. The temperature difference is permanently stored into the Temperature Calibration Offset which insures that the Computer displays the actual temperature at the label application surface with a 1º accuracy. Do not attempt to re-calibrate the platen temperature unless you use an extremely accurate digital Thermometer such as the Fluke. - 11

14 General Operation Handle Backstop Screw Adjustment Both the Left and Right sides of the handle pivot on the lower front axle that attaches the Handle to the Chassis. There is a Backstop Lever that is part of the handle and this lever protrudes slightly down and back under the Rear Axle that attaches the Arm to the Chassis. Observing from the rear of the Press, notice that there are two black screws in the ends of this Backstop Levers. These are the Handle Backstop Screws. The heads of these Backstop Screws hit a brass bushing on the Rear Axle when the Handle is pulled all the way down to the latching position. General Operation (continued) Handle Backstop Screw Adjustment The ideal position of the Handle Backstop Screws is when the Handle latches down easily and requires approximately 4 pounds of pressure to lift. At the factory, we use a small Fish Scale to measure the lifting pressure. However, without the scale, just press the handle down firmly and verify that it latches. Then lift it without pressing down on the Press. If it lifts easily, it is about 4 pounds. Care must be taken to insure that both Backstop Screws are hitting the Rear Axle with equal force. This can be done by latching the Handle down and trying to rotate both of the bushings on the rear axle above the Backstop screws. If either bushing can be rotated, that Backstop Screw must be turned counter-clockwise slightly. Adjustment Important: Before adjusting the Handle Backstop Screws on a PopUpPress, insure that the black Pop-up Shuttle Bar moves forward when the Cycle Countdown is complete and insure that the Black Shuttle Bar is all the way back in the groves when the Handle is up. If the Black Shuttle Bar is not all the way back when the handle is up, turn the power off and back on to re-initialize the Press. When performing the Handle Backstop Screw adjustment, always loosen the Backstop Screw Lock Nuts, adjust the Backstop Screw only ½ of a turn, or less, then re-tighten the Locknuts. If the Handle will not latch down, adjust both Backstop Screws Clockwise. If the Handle will latch down but will not Pop Up on a PopUpPress or is difficult to lift up on an EzPress, adjust the Backstop Screws Counter Clockwise. As the Handle pivots down toward it s Latched Position, it moves the top of the Link forward and downward, pressing the Arm and Hot Platen downward. This downward movement of the Platen compresses the Rubber Pad on the lower platen and the rubber mounts under the Lower Platen. When the Handle is in the Down and Latched position, the Upper Axle of the Link has pivoted into vertical alignment with the Handle Axle In this exact position, the Upper Platen has compressed the Lower Platen with 120 pounds of force. However the platen can not move up when the handle is released because the three axles are in direct alignment. This is the Down and Latched position. To obtain this exact alignment when the Handle is all the way down, the Handle Backstop screws must be adjusted. Shorten the Backstop Screws by turning them clockwise, so that they stop the handle after the axles are in exact vertical alignment. If they are too short, the handle be very difficult to lift. Lengthen the Backstop Screws by turning them counter clockwise. If the screws are too long, the axles will not reach the exact vertical alignment and the handle will not latch