Model US 25

Hot Stamping Machine

Operation and Maintenance Manual

October 2000
 Designers and Manufacturers of Product Decorating Equipment, Automated Systems and Supplies
ABOUT UNITED SILICONE
An ITW Decorating Company, United Silicone
specializes in the design and manufacture of hot
stamp and heat transfer decorating equipment. All
standard machines and dedicated, custom-
designed systems are offered to the ever-
changing, continually expanding marketplace for
part decorating equipment.
In addition to our full line of equipment and design
services, United Silicone offers a wide array of hot
stamping and heat transfer tooling and supplies.
You have made a wise choice in selecting a
United Silicone hot stamping machine. And to
help fill your future decorating needs, we want you
to know about our semi- and fully-automated
processing systems, and other products and
services. Details are provided in the following
paragraphs.
SUPPLIES
Our dedicated customer service team
understands—and responds with a sense of
urgency to—the needs of our customers. Silicone
rubber sheets, rollers, and dies are all available at
low cost and with fast, friendly service. United
Silicone’s creative art department meets customer
needs for accurate, meticulous quality in hot
stamping dies. Our products include:
• Silicone rubber sheets
• Silicone rubber rollers
• Stamping dies—flat and contoured
• Part nesting fixtures
 Designers and Manufacturers of Product Decorating Equipment, Automated Systems and Supplies
SEMI- AND FULLY-AUTOMATED SYSTEMS
From integrating two or more decorating
processes to developing fully automated part
handling and production equipment, United
Silicone’s Automation Division offers
comprehensive solutions to the demands of
today’s fast-paced manufacturing environment.
Our skilled engineers analyze needs, perform cost
analyses, consult with production engineers and
decisionmakers, develop preliminary design
concepts, and create custom-designed systems,
which dramatically improve production efficiency
and quality control.
Typical Automated System
Carefully designing, building, and testing
individual processing stations. And integrating the
discrete assemblies into a unified, smooth-
functioning, reliable system. All are everyday
events at United Silicone’s Automation Division.
And all are directed at surpassing customer
expectations!
Automated systems employ combinations of
various processing assemblies, a mechanism for
moving the parts through the various stations, and
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:
• Part loading and unloading
• Articulation
• Sorting
• Part presence sensing
• Optical inspection
• Decorating (hot stamp, heat transfer)
• 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
• Cost analysis
• Design review
• Technical field support
READY TO HELP
Contact United Silicone for assistance on all your
part decorating requirements. We have the skill
and dedication to help you meet the needs of your
customers—today and tomorrow!
 US 25 Hot Stamping Machine
Contents

CONTENTS
1.0 INTRODUCTION
Why Hot Stamping ........................................................................................................ 1.0-1
Safety ............................................................................................................................ 1.0-1
2.0 WARRANTY
3.0 DESCRIPTION
Stamping Head.............................................................................................................. 3.0-1
Control Box.................................................................................................................... 3.0-1
Foil/Web Payout and Feed ........................................................................................... 3.0-2
Main Frame................................................................................................................... 3.0-2
Head Height Adjuster.................................................................................................... 3.0-2
Positive Stop ................................................................................................................. 3.0-2
Palm or Opti-Touch Switches ....................................................................................... 3.0-2
4.0 OPERATION
The Hot Stamping Process........................................................................................... 4.0-1
Equipment Operation .................................................................................................... 4.0-2
Extension Cycle ...................................................................................................... 4.0-2
Retraction Cycle...................................................................................................... 4.0-2
Foil Feed.................................................................................................................. 4.0-2
5.0 INSTALLATION
Shipping......................................................................................................................... 5.0-1
Machine Placement and Mounting ............................................................................... 5.0-1
Utility Requirements ...................................................................................................... 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
Stamping Die Mounting................................................................................................. 6.0-1
Head Height Coarse Adjustment .................................................................................. 6.0-1
Head Height Fine Adjustment....................................................................................... 6.0-3
Stamp Evaluation and Adjustment ............................................................................... 6.0-3
Stamp Adhesion Testing and Adjustment .................................................................... 6.0-4
Foil Installation .............................................................................................................. 6.0-4
Temperature and Dwell Relationship............................................................................ 6.0-7
Setting and Storing Job Parameters ............................................................................ 6.0-7
7.0 T ROUBLESHOOTING
Configuration Display .................................................................................................... 7.0-1
Diagnostics ................................................................................................................... 7.0-1
Controller Inputs ............................................................................................................ 7.0-1
Troubleshooting Chart................................................................................................... 7.0-2
Battery Testing and Replacement ................................................................................ 7.0-3

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US 25 Hot Stamping Machine
Contents
8.0 M AINTENANCE
Pneumatic System Lubricator....................................................................................... 8.0-1
Air Filter ......................................................................................................................... 8.0-1
Head Height Adjusting Screw ....................................................................................... 8.0-1
Inspection and Cleaning................................................................................................ 8.0-1
Adjustments .................................................................................................................. 8.0-1
Component Replacement............................................................................................. 8.0-1
Heater...................................................................................................................... 8.0-1
Thermocouple ......................................................................................................... 8.0-2
Down Limit Switch .................................................................................................. 8.0-2
Up Limit Switch ....................................................................................................... 8.0-3
Solid State Relay..................................................................................................... 8.0-3
Palm or Opti-Touch Switch..................................................................................... 8.0-4
Emergency Stop Switch ......................................................................................... 8.0-4
Air Cylinder.............................................................................................................. 8.0-4
Foil Pinch Roller ...................................................................................................... 8.0-5
Foil Takeup Drive Belt............................................................................................. 8.0-6
9.0 RECOMMENDED SPARE P ARTS
Ordering Parts............................................................................................................... 9.0-1
10.0 PNEUMATIC S LIDE T ABLE 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
Engineering Drawings ................................................................................................. 10.0-2
10.1 X-Y AND X-Y-R POSITIONING T ABLE OPTION
Description .................................................................................................................. 10.1-1
Operation..................................................................................................................... 10.1-1
10.2 WEBTRAK H EAT T RANSFER P HOTOCELL OPTION
Description .................................................................................................................. 10.2-1
Web Feed.............................................................................................................. 10.2-1
Control Panel......................................................................................................... 10.2-1
Operation..................................................................................................................... 10.2-1
Heat Transfer Web or Foil Installation ........................................................................ 10.2-2
Diagnostics ................................................................................................................. 10.2-4
Maintenance................................................................................................................ 10.2-5
Web Takeup Drive Belt ......................................................................................... 10.2-5
Recommended Spare Parts ....................................................................................... 10.2-5
Engineering Drawings ................................................................................................. 10.2-6
10.3 WEBTRAK H EAT T RANSFER L ASER E YE OPTION
Description .................................................................................................................. 10.3-1
Web Feed.............................................................................................................. 10.3-1
Control Panel......................................................................................................... 10.3-1
Operation..................................................................................................................... 10.3-1
Heat Transfer Web or Foil Installation ........................................................................ 10.3-2
Diagnostics ................................................................................................................. 10.3-4

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 US 25 Hot Stamping Machine
Contents
Maintenance................................................................................................................ 10.3-5
Web Takeup Drive Belt ......................................................................................... 10.3-5
Recommended Spare Parts ....................................................................................... 10.3-5
Engineering Drawings ................................................................................................. 10.3-5
10.4 ROTARY T ABLE OPTION
Description .................................................................................................................. 10.4-1
Operation..................................................................................................................... 10.4-1
Station Alignment .................................................................................................. 10.4-1
Speed Control ....................................................................................................... 10.4-1
Table Index Cam Adjustment ..................................................................................... 10.4-2
Index Check .......................................................................................................... 10.4-2
Cam Adjustment ................................................................................................... 10.4-2
Engineering Drawings ................................................................................................. 10.4-2
10.5 LOCKOUT K EY SWITCH OPTION
Description .................................................................................................................. 10.5-1
Operation..................................................................................................................... 10.5-1
11.0 SEMI-AUTOMATED CUSTOM HOT STAMP S YSTEMS
Description .................................................................................................................. 11.0-1
Documentation ............................................................................................................ 11.0-1
12.0 ENGINEERING DRAWINGS

ILLUSTRATIONS
1.0-1 Model US 25 Two and One-Half-Ton Hot Stamping Machine ..................................... 1-0-2
3.0-1 Control Panel................................................................................................................. 3.0-5
4.0-1 Typical Vertical Hot Stamping Setup ............................................................................ 4.0-1
4.0-2 The Hot Stamping Process........................................................................................... 4.0-2
5.0-1 Air Connection............................................................................................................... 5.0-1
6.0-1 Stamping Die Mounting................................................................................................. 6.0-2
6.0-2 Setting Air Pressure...................................................................................................... 6.0-2
6.0-3 Vernier Positive Stop Preliminary Adjustment.............................................................. 6.0-3
6.0-4 Foil Payout Assembly ................................................................................................... 6.0-5
6.0-5 Stripper Bar Positioning ................................................................................................ 6.0-5
6.0-6 Pinch Roller Camshaft.................................................................................................. 6.0-5
6.0-6 Foil Path ........................................................................................................................ 6.0-6
7.0-1 Typical Controller Inputs ............................................................................................... 7.0-2
7.0-2 Battery Location ............................................................................................................ 7.0-3
7.0-3 Pin J8 Jumper Location................................................................................................. 7.0-4
8.0-1 Heater and Thermocouple Location ............................................................................. 8.0-2
8.0-2 Down Limit Switch Location.......................................................................................... 8.0-2
8.0-3 Up Limit Switch Location............................................................................................... 8.0-3
8.0-4 Solid State Relay Location............................................................................................ 8.0-4
8.0-5 Palm Switch Installation ................................................................................................ 8.0-4
8.0-6 Emergency Stop Switch Installation ............................................................................. 8.0-5
8.0-7 Air Cylinder Installation ................................................................................................. 8.0-5
8.0-8 Foil Pinch Roller ............................................................................................................ 8.0-6
8.0-9 Foil Takeup Drive Belt................................................................................................... 8.0-6

iii
US 25 Hot Stamping Machine
Contents
10.0-1 Pneumatic Slide Table Components .......................................................................... 10.0-2
10.1-1 X-Y and X-Y-R Positioning Table Option.................................................................... 10.1-1
10.2-1 Webtrak Heat Transfer Photocell Option.................................................................... 10.2-1
10.2-2 Heat Transfer Web Payout Assembly ........................................................................ 10.2-3
10.2-3 Photocell Heat Transfer Web Path............................................................................. 10.2-4
10.2-4 Photocell X-Y Adjustments ......................................................................................... 10.2-5
10.2-5 Photocell Adjustment .................................................................................................. 10.2-5
10.3-1 Webtrak Heat Transfer Laser Eye Option .................................................................. 10.3-1
10.3-2 Heat Transfer Web Payout Assembly ........................................................................ 10.3-3
10.3-3 Laser Eye Heat Transfer Web Path............................................................................ 10.3-4
10.3-4 Laser Eye Adjustment................................................................................................. 10.3-5
10.4-1 Rotary Table Option .................................................................................................... 10.4-1
10.4-2 Rotary Table Index Drive Cam Adjustment................................................................ 10.4-2
10.5-1 Lockout Key Switch Option......................................................................................... 10.5-1
11.0-1 Typical Semi-Automated Custom Hot Stamp System ............................................... 11.0-1
11.0-2 Pick and Place Station ................................................................................................ 11.0-1

iv

1.0 INTRODUCTION
The United Silicone Model US 25 vertical hot
stamping machine (Figure 1.0-1) offers
advanced capabilities for reduced installation
and setup time, consistent stamping force,
quiet operation, precision foil advance, and
operator convenience and ease of operation.
Its two and one half-ton maximum stamping
force combined with available head sizes of
6” x 6”, 6” x 8”, and 6” x 10” ensure optimum
quality and versatility in hot stamping
operations. Table 1.0-1 lists technical
specifications for the Model US 25.
Your 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 issue.
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:
• Dry process requiring no ink, allowing part
to be immediately ready for handling and
packaging.
US 25 Hot Stamping Machine
1.0 Introduction
• Suitable for wide variety of materials
including thermoplastics, thermoset
plastics, wood, leather, cloth, paper, and
pre-painted metals
• Only method available for applying
permanent gold and silver metallic
graphics, as well as wood grain, gloss or
matte pigment colors, brushed effects,
chromium, and multi-colored graphics
• Applies to various surface geometries
including flat, cylindrical, and spherical
• Thermally bonds to substrate for excellent
long-term durability
• No hazardous vapors or solvents
requiring special storage or compliance
with Environmental Protection Agency
(EPA) rules
SAFETY
The Model US 25 is designed for safe
operation and includes all required safety
features to minimize possible injury to
personnel. However, you are responsible for
providing a safe environment for operating
this machine and other equipment at your
facility. Do not remove any guards or defeat
safety devices. If any additional equipment is
used or modifications made to the stamping
machine, be sure to provide suitable operator
protection.
Safety begins with permitting only properly
trained personnel to install and operate the
equipment. All personnel involved in installing
and setting up the equipment must be fully
trained in performing electrical, pneumatic,
and mechanical installations. All operators
should be thoroughly trained in the 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.
1.0-1
US 25 Hot Stamping Machine
1.0 Introduction

Table 1.0-1. Model US 25 Specifications

Utility requirements Electrical and pneumatic
Electrical Three heaters – 110 Vac, 60 Hz, 15 A
Four or five heaters – 220 Vac, 60 Hz, 30 A
Air 80 to 100 PSI (50 PSI min.) at 5 CFM, moisture-free, 3/8” NPT
connections
Mounting Bench or stand
Die dimensions 8” x 8” (std); 8” x 12” or 8” x 16” (optional)
Heaters
8”x8” heater block Three 500 Watt each, 500° F max.
8”x12” heater block Four 500 Watt each, 500° F max.
8”x16” heater block Five 500 Watt each, 500° F max.
Stroke 0-3”
Working height Up to 16”
Throat depth Up to 8”
Overall dimensions 40” H x 28” W x 23” D
Work table 16” x 18”
Weight 600 LBS
Personnel safety Dual palm or Opti-Touch (optional) switches

Figure 1.0-1. Model US 25 2.5-Ton Hot Stamping Machine

1.0-2
 US 25 Hot Stamping Machine
2.0 Warranty

2.0 WARRANTY
United Silicone (Seller) warrants the Model US 25 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.
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
Principal components of the hot stamping
machine are: Stamping head, control box, foil
feed, main frame, head height adjuster,
positive stop, and palm (or Opti-Touch)
switches. The major components are
described in the following paragraphs.
STAMPING HEAD
A double-acting pneumatic cylinder, the
principal component of the stamping head, is
enclosed within the cylinder mounting box.
The cylinder provides the motive force
needed to drive the stamping head downward
onto the decorating surface. The cylinder
mounting box also contains the required
guides and supports to prevent rotation of the
air cylinder piston and ensure precise control
of the stamping head during extension and
retraction.
Provisions for mounting the stamping die are
also included in the head. The heater block
applies heat to the stamping die, which is
mounted on the die mounting plate. An
insulation plate prevents excessive heat
transfer from the heater plate to the cylinder
and other components. The up limit switch,
which completes a circuit that signals the
control box of the completion of the cylinder’s
upward travel, is also installed in the cylinder
mounting box, adjacent to the stamping head.
CONTROL BOX
Electrical components and circuitry, which
control machine operation, are installed in the
control box. Switches, indicators, and controls
used to set up and operate the machine, are
installed on the control panel.
The control box contains internal connections
for input power and distribution to various
components of the machine. Terminal strips
are provided to facilitate component
replacement. Both front control panel and
rear panel may be separated from the control
box for maintenance accessibility to the
internal components.
US 25 Hot Stamping Machine
3.0 Description
In addition to the power and emergency
switches, the control panel (Figure 3.0-1)
contains membrane switches and indicators
that are used to set up and operate the
equipment and display its operating status.
Table 3.0-1 describes the function of each
switch, control, and indicator on the control
panel.
FOIL/WEB PAYOUT AND FEED
The foil/web payout and feed includes the
components for mounting the unused foil roll
and guiding its path under the stamping
head. It also includes components for pulling
and receiving the used foil after the stamping
cycle, moving the foil from right to left. For
heat transfer machines, web movement is
from left to right. An electric motor, operated
under controller timing, rotates the takeup
shaft that receives the used foil after
stamping, while the and knurled roller
prevent the used foil from slipping. Stripper
bars apply tension to the foil when in contact
with the decorating surface.
MAIN FRAME
All necessary supports and brackets that
facilitate mounting of other major components
are included on the main frame. The work
table, which has provisions for mounting the
nesting fixture used to properly retain and
position the part to be decorated, is also
included on the main frame.
HEAD HEIGHT ADJUSTER
The head height adjuster permits vertical
adjustment of the head in relation to the work
table. The adjuster sets the head position to
ensure proper contact with the part without
excessive contact, which could damage the
die. A handwheel is used to move the head
up and down to obtain the required
relationship. Slide clamps permit positive
locking of the head in the desired vertical
position after adjustment.
3.0-1
US 25 Hot Stamping Machine
3.0 Description
POSITIVE STOP
A locking vernier adjusting sleeve installed on
the positive stop is used for making fine
adjustments of the cylinder’s downward
stroke. The adjusting sleeve actuates the
down limit switch, which is mounted on a
bracket adjacent to the positive stop. When
actuated by the adjusting sleeve, the closed
switch contacts complete a circuit that signals
the controller of the completion of the
cylinder’s downward travel. In case the down
limit switch fails, a dead stop mechanically
stops movement before the cylinder bottoms.
Figure 3.0-1. Control Panel
3.0-2
PALM OR OPTI-TOUCH SWITCHES
Hot stamping machine operation is initiated
by simultaneously pressing or touching the
two switches at the sides of the machine.
This safety feature ensures that the
operator’s hands are clear of the machine
when the stamping head descends. Two
types of switch are available: Palm and
optional Opti-Touch. The palm switch is a
simple contactor, which is actuated by
pressing a large button. The Opti-Touch
switch is a heat-sensitive device, requiring
only touching to close the circuit.
 US 25 Hot Stamping Machine
3.0 Description

Table 3.0-1. Control Panel Switches, Controls, and Indicators

Name Function

Message display Continuously shows function selected and its current setting or value.
First line shows current die temperature regardless of option selected.
Sets die temperature. Pressing switch repeatedly scrolls through
available options. The selected option and current value are displayed on
the second line of the display. The + and – keys are used to change
settings. The following options are available:
TEMP. SET POINT – Changes die set temperature
TEMP. OFFSET – Adjusts displayed die temperature to correspond
with die surface temperature. Before changing offset, check die
TEMP. switch
(normal operation) temperature with a pyrometer to ensure that die surface temperature
has stabilized. Offset should be a negative number.
TEMP. HIGH LIMIT – Sets maximum allowable temperature. Upon
rising to limit, heaters are turned off, a fault message is displayed,
FAULT light flashes, and machine will not operate.
TEMP. LOW LIMIT – Sets minimum allowable temperature. Upon
falling to limit, heaters are turned on, a fault message is displayed,
FAULT light flashes, and machine will not operate.
Displays several options relating to effects of RF interference on
temperature control. Pressing switch repeatedly scrolls through available
options. The selected option and current value are displayed on the
second line of the display. The following options are available:
TEMP. P – Factory setting; do not change
TEMP. I – Factory setting; do not change
TEMP. D – Factory setting; do not change

TEMP. switch SNDFILTR.CONST1 – Sets threshold value for software noise

(Setup mode) discrimination filter (SNDF), which helps reduce effects of radio
frequency (RF) noise on temperature control. Recommended setting is
50 to 100. If not needed, SNDFILTR.CONST1 is set to 0.
SNDFILTR.TIME – Sets time dwell to correspond with SNDF source
such as an RF welder. The SNDF rejects thermocouple measurements
if, in two consecutive cycles, the dwell varies more than
SNDFILTR.CONST1. The filter then engages and remains engaged
until either the RF falls within the defined value or SNDFILTR.TIME
interval has elapsed. If it times out, the new SNDFILTR.CONST1 value
will be accepted. If not needed, SNDFILTR.TIME is set to 0.
FOIL PULL
Sets allotted time for advancing foil between stampings (FOIL PULL TIME
(standard XX.XX). The + and – switches are used to raise and lower the interval.
machine)

3.0-3
US 25 Hot Stamping Machine
3.0 Description

Table 3.0-1. Control Panel Switches, Controls, and Indicators

Name Function
Sets allotted time for advancing web between stampings. The + and –
switches are used to raise and lower the following options:
FOIL PULL TIME XX.XX – Sets allotted time for high-speed advancing
of heat transfer web.
FOIL HIGH SPEED: XX – Sets speed of heat transfer advance during
FOIL PULL TIME (high-speed pulling).
FOIL PULL (heat FOIL LOW SPEED: XX – Sets low (creep) speed of heat transfer
transfer machine) pulling.
WEB LOW RANGE: XX – Sets the upper and lower limits for low
(creep) speed of web pulling. This is a factory setting and should not
be changed.
MARKS/ONE STEP: XX – Sets number of marks to be counted before
stopping heat transfer advancement (usually used for multiple part
stamping).
Displays total number of machine cycles. Reset to zero by pressing CLR
COUNT
switch.
Sets time that begins when down limit switch is actuated; when time
DWELL
expires, head leaves surface. Reset to zero by pressing CLR. Use + and
TIME – switches to raise or lower dwell time.
Sets time between end of dwell and before head up delay starts. Head
HEAD UP rises until head up time expires, thus setting a distance from part where
(optional) head pauses for head up delay. Use + and 0 switches to raise and lower
time. Press CLR to remove set value.
Sets time that head pauses after head up time has expired and before
HEAD UP head fully retracts. Use + and 0 switches to raise or lower time. Press
DELAY (optional)
CLR to remove set value.
HEAT Turns heater on and off.
OFF/ON
HEAT Lights when power is applied to heaters.
OFF/ON indicator
BEFORE Sets timing of foil pulling cycle to either before or after stamping cycle.
AFTER
BEFORE When lighted, machine is set to pull foil before stamping cycle; when off,
AFTER indicator foil is pulled after stamping cycle.
FUNC. Toggles between foil or heat transfer operation.
Lights when FUNC. switch has set machine in heat transfer mode; light is
FUNC. indicator off when FUNC. switch has set machine in foil mode.
TABLE Moves slide table into or out of stamping position or turns rotary table one
JOG index position.

3.0-4
 US 25 Hot Stamping Machine
3.0 Description

Table 3.0-1. Control Panel Switches, Controls, and Indicators

Name Function
Turns setup mode on and off. When on, pressing both palm switches
SET simultaneously extends and keeps head down in stamping position.
UP Pressing switch again cancels setup and retracts head. Also displays
other options (see TEMP. switch in Setup mode).
Advances foil or heat transfer. Foil moves until switch is released; heat
FOIL transfer moves to next mark detected by photocell each time switch is
JOG pressed. If no mark is detected, after 10 seconds the watchdog timer will
stop the heat transfer and display an error message.
CLR Returns setting of selected function to zero or lowest limit.
+ Raises setting of selected function.
0 Lowers setting of selected function.
JOB Permits storage and retrieval of stamping parameters for up to 10
# different jobs. (Refer to Setup and Adjustment for procedure.)
OFF-ON Turns power to control box on and off.
When pressed, disables machine. For machine not having head up delay,
EMERGENCY head fully retracts. If rotary index table is installed, table stops
STOP immediately (either mid-station or at station where located). Power is
restored by pulling out button.

3.0-5

4.0 OPERATION
THE HOT STAMPING PROCESS
Vertical hot stamping is used to apply foil
resins to small areas of flat or slightly
crowned parts and up to 90 degrees on the
circumference of cylindrical- or spherical-
shaped parts. Hot stamping is performed as
follows:
1. Part is mounted on a nesting fixture
(Figure 4.0-1) attached to the work table.
2. The stamping head is extended
downward (Figure 4.0-2) by pressing both
palm (or touching Opti-Touch) switches
simultaneously, with the foil maintained at
a consistent distance from the stamping
die face. As the foil contacts the part,
stripper bars on the head stretch the foil
tightly over the decorating surface
removing any wrinkles or bubbles.
3. With foil in contact with the surface, the
die continues its downward travel,
pressing the foil into intimate contact with
the surface. The resilient silicone rubber
die conforms the foil to surface
irregularities and creates a parting line in
the foil resins.
HEATER HEAD
ALUMINUM
BACKING
SILICONE
DIE
1/2" HEAT
FILM CARRIER
FILM COATINGS
Figure 4.0-1. Typical Vertical Hot Stamping Setup
US 25 Hot Stamping Machine
4.0 Operation
4. The heated die remains in contact for
sufficient time (dwell time) to soften the
release agents and resins in the foil. The
decorating surface also softens, while die
pressure drives the resins into the molten
surface to promote thermal bonding.
5. When dwell time expires, the head
retracts to the start position in the
following sequence:
a. The die lifts away from the foil, while
foil remains in contact with the surface
briefly to allow both foil and surface to
cool.
b. As the die continues retracting, the foil
lifts from the surface, peeling away
first from the edges and then working
toward the center. Since adhesion
between the foil coating and the
surface is greater than the bond
between the release agents in the
coatings and the film carrier, a
virtually complete deposition of foil
coating is achieved.
DIE MOUNTING
PLATE
DIE
MOUNTING
BLOCK
1/32"
STRIPPER
BAR
PART
PART NESTING
FIXTURE
4.0-1
US 25 Hot Stamping Machine
4.0 Operation
6. Once the head has fully retracted to the
start position, the foil advances until an
unused section is positioned under the
die. The hot-stamped part is then
removed from the fixture. The part may
be handled without danger of smudging
or removing the image from the surface.
EQUIPMENT OPERATION
Supervision of the cycle described in the
following paragraphs is provided by the
controller. The controller defines the dwell
and head-up delay (optional), which
determines timing of the cylinder’s retraction.
Extension Cycle
The stamping process is initiated by pressing
both palm switches (or touching Opti-Touch
switches) simultaneously. With both switches
actuated, power is applied from the OFF-ON
switch through the palm or Opti-Touch
switches and the closed contacts of the head
up limit switch, which is held in the closed
position by the guide bar. Power flows to the
air cylinder extension solenoid valve, which
re-positions to direct air from the air regulator
to the extension side of the cylinder’s piston.
Retraction Cycle
As the cylinder reaches the end of its
1 - Head Descends
2 - Die Contacts Part
3 - Die Dwells on Part
Figure 4.0-2. The Hot Stamping Process
4.0-2
downward stroke, the up limit switch is re-
opened as its actuator is released by the
guide bar. The down limit switch is
simultaneously closed by the positive stop
adjusting sleeve. Upon sensing the closed
contacts of the down limit switch, the
controller energizes the retraction solenoid
valve. Air is then directed to the retraction
side of the air cylinder, forcing the piston
upward. The foil or heat transfer web is pulled
after cylinder retraction to prepare for the next
stamping cycle.
As the cylinder retracts to the start position,
the up limit switch is closed once again, while
the down limit switch is opened. Upon
sensing the closed contacts of the up limit
switch, the controller stops air flow to the
retraction side of the cylinder, thereby
completing the cycle.
Foil Feed
Under microcontroller direction, the foil feed
motor is energized after cylinder retraction.
The motor pulls the foil for the programmed
interval set by the operator. The controller
then terminates foil pulling.
4 - Head Retracts
5 - Foil or Web Advances

5.0 INSTALLATION
The procedures in this section are designed
to assist installation personnel in safely and
properly placing the hot stamping machine in
its work environment and connecting the
required utilities. Be sure to follow all
personnel safety requirements during the
installation. Following installation, perform the
procedures in Setup and Adjustment to
correctly prepare the machine for safe,
productive operation.
SHIPPING INSPECTION
Your machine has been thoroughly tested
and inspected before shipment. You should
not see any visible damage or loose or
missing parts. Carefully inspect the
equipment to ensure that there are no
apparent defects. Any damage or missing or
loose parts should be reported promptly to
the carrier.
MACHINE PLACEMENT AND MOUNTING
Observe the following safety and operator
precautions when placing the machine at its
operating location:
WARNING
THE MACHINE WEIGHS 350 POUNDS.
DO NOT ATTEMPT LIFTING WITHOUT
SUFFICIENT PERSONNEL TO SAFELY
LIFT AND PLACE MACHINE IN
POSITION.
• Place the machine in a safe area having
adequate lighting, and space on all sides
to permit convenient access for operation
and maintenance.
• Install machine on a level, flat surface
capable of supporting its weight. An
optional floor stand is available from
United Silicone for properly mounting the
machine.
• Do not modify mounting provisions. Use
mounting holes provided for securing
machine to bench or floor stand.
US 25 Hot Stamping Machine
5.0 Installation
• For operator comfort, mount machine so
that operator’s arms are parallel to floor
when hands are placed on palm switches.
UTILITY REQUIREMENTS
Electrical power and a pressurized air supply
are required to operate the equipment. The
following paragraphs describe the
requirements for each utility.
Electrical Power
Electrical power must be properly connected
to the machine for safety and satisfactory
operation. Three-heater machines require
electrical power at 110 to 120Vac. Power at
220 to 240Vac minimum is required to
operate four-heater machines
Strict conformance to all applicable National
Fire Protection Institute (NFPA) standards
and local electrical codes is required. United
Silicone equipment must be properly
grounded, and clean, noise-free power must
be supplied within the following ranges:
110-120 Vac 50/60Hz
220-240Vac 50/60Hz
For voltages outside these ranges, contact
United Silicone for assistance.
Air Supply
A source of moisture-free air at 80 to 100PSI
at 5CFM should be connected to the
machine. A supply of less than 50PSI at
5CFM will cause the machine to malfunction.
AIR CONNECTION
Connect air source to inlet side of air filter
located at rear of machine. Use 3/8” flexible
neoprene tubing for the connection to
minimize vibration transfer. Figure 5.0-1
shows the recommended air connection.
Note that a 3/8” NPT drain valve is installed
to permit removal of moisture when
necessary.
5.0-1
US 25 Hot Stamping Machine
5.0 Installation
AIR PRESSURE REGULATOR
Inlet air pressure should be adjusted to 50 to
100PSI by means of the pressure regulator.
Do not exceed the maximum inlet air
pressure of 120PSI. Also, the machine
cannot be operated properly with pressure
below 20PSI. During operation, pressure
should not drop more than 10PSI. If greater
pressure drop is noted, check for constriction
in the incoming air line, which may cause
insufficient air volume to the machine.

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
Fill lubricator with Shell Tellus 68, Mobil DTE
26, or equivalent oil. Do not overfill, and do
not change the factory-set drip rate. Refer to
Maintenance for ongoing maintenance
instructions for the lubricator.
AIR FILTER
Following the first day of operation an oily
residue, but no drops of oil, should be
present on the air filter. Appearance of oil
drops is an indication of excessive lubrication,
which is to be avoided. 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 hot stamping
machine for operation are included in this
section. The setup and adjustment
procedures apply to initial setup, as well as
for future needs when changing dies,
following component replacement or repair,
and to correct stamping errors.
Extensive illustrations are included to
facilitate accurate, precise adjustments and
thereby ensure trouble-free operation. The
adjustments should be performed in the
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:
• Stamping Die Mounting
• Head Height Coarse Adjustment
• Head Height Fine Adjustment
• Foil Installation
• Stamping Quality Evaluation and
Adjustment
• Stamp Adhesion and Adjustment
• Setting and Storing Job Parameters
STAMPING DIE MOUNTING
Before installing the die, thoroughly clean
front and rear surfaces of die mounting plate
and back of stamping die. No dust, residue,
or debris is permitted on any of the mating
surfaces. Also, check that the nesting fixture
for the part being decorated is clean and firm,
so that no deflection of part or fixture will
occur when stamping pressure is applied.
After ensuring proper cleanliness and fixture
security, proceed as follows to mount the
stamping die:
1. Remove die mounting plate (Figure 6.0-1)
from heater head, and place on work
surface with clamps facing down.
US 25 Hot Stamping Machine
6.0 Setup and Adjustment
2. Determine front of die by comparing
position of graphic with orientation of part
on nesting fixture.
3. Place die on mounting plate, oriented so
that its front faces positive stop brackets.
4. Align holes in die (drill holes if not pre-
drilled), with mounting plate holes, and
secure die to plate with screws.
Note: For dies having offset graphics the
contact area—not the die—must be
centered.
5. Stand mounting plate on end with clamps
facing you, and loosen both clamps
sufficiently to allow some play.
6. Loosen locknuts on both positive stops,
and back off screws until they project
about 1/8” from bottom of stop brackets.
7. Slide mounting plate onto heater head
until plate is flush with front of heater
head, and tighten bolts on both clamps.
8. Turn in positive stops until they just
contact heater head, but do not tighten
locknuts at this time, as further
adjustment of mounting plate position
may be required.
HEAD HEIGHT COARSE ADJUSTMENT
Before beginning this procedure, confirm that
electrical power and air supply are connected
and operating (refer to Installation). The
machine’s air pressure gage (Figure 6.0-2)
should read desired pressure.
WARNING
FOR PERSONNEL SAFETY, ONLY ONE
PERSON SHOULD PERFORM
ADJUSTMENTS. ALL OBSERVERS
SHOULD BE IN FRONT OR AT SIDES OF
MACHINE, BUT NOT BEHIND IT.
The coarse adjustment will position the head
at approximately the correct height to stamp
the part, while allowing sufficient clearance to
place and remove part from nesting fixture
safely.
6.0-1
US 25 Hot Stamping Machine
6.0 Setup and Adjustment
Figure 6.0-1. Stamping Die Mounting
GAGE
READS
ABOUT
50PSI
Figure 6.0-2. Setting Air Pressure
To perform the coarse adjustment, proceed
as follows:
1. Check that OFF-ON switch on control
panel is set to ON.
2. Loosen bolts on both vertical slide
clamps.
3. Turn handwheel clockwise to move head
up sufficiently to provide 3” space above
part surface.
4. Place part nesting fixture on work table.
5. Place a part on fixture, and align
decorating surface with stamping die.
6. Press Setup key on control panel.
6.0-2
7. Align fixture with mounting holes, and
insert but do not tighten mounting screws.
Note: Refer to Description for details of
controls.
8. If slide table is installed, jog table under
stamping head.
9. Loosen knurled nut on positive stop
(Figure 6.0-3); then turn adjusting sleeve
counterclockwise until bottom edge is
between 2” and 2.5” marks on vernier
scale.
10. Tighten knurled nut on positive stop.
11. Press both palm switches simultaneously
to extend head downward.
12. Turn handwheel counterclockwise to
move head downward to within 1/8” to
1/4” of decorating surface.
13. Viewing from front of machine, check that
die contact surface is as centered as
possible over the decorating surface. If
not centered, adjust nesting fixture left to
right and/or in and out, as required. Also,
be sure that contour of die matches
shape of part.
14. Retract head by pressing Setup key on
control panel.

15. Tighten bolts on both vertical slide
clamps, tightening evenly by alternating
from side to side.
16. Tighten screws to secure part nesting
fixture to work table.
KNURLED
NUT
POSITIVE
STOP
Figure 6.0-3. Vernier Positive Stop
HEAD HEIGHT FINE ADJUSTMENT
This procedure sets the precise relationship
between the die and the decorating surface.
It must be performed only after the preceding
adjustment has been successfully completed.
Throughout this procedure, refer to
Description section for details of control
panel.
1. Enter Setup mode on control panel, if not
already done.
2. Press both palm switches simultaneously
to extend head downward. Check if die
face contacts decorating surface, and
retract head.
3. If no contact occurs, loosen knurled nut
on positive stop, and turn adjusting sleeve
counterclockwise 1/4 to 1/2 turn.
4. Extend head, and re-check for contact
with surface. If no contact is made, turn
adjusting sleeve counterclockwise in 1/4-
to 1/2-turn increments until die contacts
surface. Re-check after each adjustment.
5. Set dwell interval to .50 second.
6. Turn on heaters.
7. Set heater temperature based on foil and
substrate requirements (about 375°F to
400°F).
US 25 Hot Stamping Machine
6.0 Setup and Adjustment
8. When heater temperature has been
reached, measure die’s surface
temperature using a pyrometer having a
right-angled tip.
Note: Die will be about 75°F to 125°F
cooler than set temperature.
9. Place a small piece of hot stamp foil on
decorating surface, and press both palm
switches simultaneously to extend head.
10. Proceed to Stamp Evaluation and
Adjustment, below, to inspect stamp
quality and make any required
adjustments.
STAMP EVALUATION AND ADJUSTMENT
Evaluate test samples and make adjustments
to correct defects as follows:
1. Check graphic position on part. Complete
image should be present, and uniform
contact should be apparent.
2. To correct left-to-right or front-to-back
positioning, adjust part nesting fixture
and/or die position as follows:
a. Measure distance that stamping must
be moved.
b. Adjust left to right position by
loosening screws securing fixture to
work table, moving fixture as needed,
and re-tightening screws.
c. Adjust front-to-back position by
loosening bolts securing die mounting
plate clamps, moving die as needed,
and re-tightening clamp bolts.
Note: Positioning adjustment is
facilitated by the optional X-Y or X-Y-
R positioning table (section 11.1).
3. If stamping head and decorating surface
are not parallel, one of the following
conditions will occur:
a. Image is incomplete.
b. Image is complete, but bulges appear
on one side.
c. Image is complete, but die digs more
deeply into one side than the other.
4. If bulges appear in some areas of stamp,
increase stroke length as follows:
6.0-3
US 25 Hot Stamping Machine
6.0 Setup and Adjustment
a. Loosen knurled nut on positive stop,
and rotate adjusting sleeve
counterclockwise 1/8 turn.
b. Re-tighten knurled nut on positive
stop.
c. Re-check stamp quality.
d. If quality is unacceptable, increase
stamping pressure slightly, and re-
check quality.
e. Repeat stroke and pressure
adjustments until desired results are
obtained.
5. If voids appear in the stamping, the part
nesting fixture must be altered as follows:
a. Remove part from fixture.
b. Place a small strip of masking tape
the size of the void area directly
beneath the affected area.
c. Re-check stamping quality, and make
any further adjustments required.
d. Perform Stamp Adhesion Testing and
Adjustment, below.
STAMP ADHESION TESTING AND
ADJUSTMENT
This test confirms proper adhesion of stamp
to decorating surface and provides corrective
action. To test adhesion, proceed as follows:
1. After part surface has cooled, apply a
piece of clear tape, 3M No. 610 or
equivalent, over image and apply thumb
pressure.
2. Pull tape off, with free end held at a 90-
degree angle to surface. If part of image
lifts off surface, make the following
adjustments one at a time, and re-check
stamp quality before continuing to the
next step:
Note: Repeat any step, as necessary,
until optimal results are obtained.
a. Increase die face temperature 10°F.
Wait for proper heat indication, and
then verify increased die temperature
using a pyrometer.
6.0-4
CAUTION
Do Not Exceed 100 PSI Air
Pressure In The Following Step.
b. If not striking dead stop, increase air
cylinder pressure 5 PSI by turning
regulator adjustment clockwise while
watching gage.
c. If dead stop is being struck, increase
stroke slightly by turning positive stop
adjusting sleeve counterclockwise 1/8
turn.
d. If machine has head up delay feature,
increase HEAD UP setting until head
retracts without foil stripping. Set
HEAD UP DELAY pause to .2 second
and then increase until foil resin is not
lifted from part.
e. Increase die-to-part contact time by
re-setting the dwell time on the control
panel.
3. After completing adjustments, tighten
knurled nut on positive stop and secure
by tightening setscrew.
4. Tighten locknuts on both positive stops on
die mounting plate.
5. Reset cycle counter on control panel to
zero.
6. After completing adjustments, install foil
as described in Foil Installation, below.
For heat transfer web installation, refer to
either Webtrak Photocell Heat Transfer
Web Option or Webtrak Laser Eye Heat
Transfer Web Option, depending on
option installed.
FOIL INSTALLATION
The following instructions describe foil
installation. For heat transfer web installation,
refer to Webtrak Photocell Heat Transfer
Web Option or Webtrak Laser Eye Heat
Transfer Web Option.
To install foil, proceed as follows:
1. Loosen collar lock handle, and remove
collar, spring, and payout holder from
shaft (Figure 6.0-4).
 US 25 Hot Stamping Machine
6.0 Setup and Adjustment
2. Slide foil roll onto shaft with foil oriented Note: Stripper bars must be parallel to
so that foil end is at bottom, matte work table to prevent foil from walking to
(coated) side facing down. one side.
COLLAR PAYOUT
LOCK HOLDER INSIDE
HANDLE COLLAR

Figure 6.0-4. Foil Payout Assembly

STRIPPER BARS POSITIONED ABOUT 2”
3. Looking toward machine from payout FROM STAMPING HEAD OR EDGE OF PART
side, align foil front to back with stamping AND 1/2” BELOW DIE CONTACT SURFACE
die by loosening inside collar and moving
collar, as necessary, to properly position
roll in relation to die. When fully aligned,
tighten inside collar.
CAUTION Figure 6.0-5. Stripper Bar Positioning
Insufficient Tension Will Cause Foil
To Become Snagged; Excessive 6. Rotate pinch roller camshaft (Figure 6.0-
Tension Will Cause Breakage. In The 6) until a gap is opened between knurled
Following Step, Be Sure To Set roller and pinch roller.
Tension Properly.
PINCH ROLLER
4. Slide payout holder, spring, and collar CAMSHAFT
and lock handle onto shaft. Push collar
against spring until medium tension is felt.
Avoid excessive or insufficient tension.
Tighten lock handle after setting tension. OPEN GAP BY
TURNING KNOB
5. Loosen adjusting handles on stripper bars
(Figure 6.0-5), and position bars so that
bottom of each bar is about 2” from the
stamping head or edge of the part
(whichever is greater), parallel to work PINCH ROLLER
table, and 1/2” below the die contact
surface. Depending on shape of part,
further adjustments may be required for Figure 6.0-6. Pinch Roller Camshaft
optimum stamping quality. Tighten 7. Mount takeup shaft on foil pull frame as
adjusting handles after completing follows:
adjustment.
a. Pull out spring-loaded knob.
b. Insert shaft between side plates.

6.0-5
US 25 Hot Stamping Machine
6.0 Setup and Adjustment

Figure 6.0-7. Foil Path

c. Align pin in shaft end with slot in drive
pulley, and release spring-loaded
knob.
8. Thread foil over tensioning bar, under
both stripper bars (Figure 6.0-7), over
pinch roller, and under knurled roller.
9. Wrap one full turn of foil around takeup
shaft from underside of shaft without
compressing spring-loaded foil clamping
bar.
Note: If used roll is on takeup shaft, insert
end of new roll under existing roll.
10. Manually turn takeup shaft two full turns
to tighten foil on shaft.
11. Inspect foil path, viewing from takeup
side. If foil is not parallel with stamping
head, press in foil clamping bar and slide
foil on takeup shaft left or right to obtain
correct alignment. Release clamping bar
when foil is aligned.
12. Rotate pinch roller camshaft (Figure 6.0-
5) until knurled roller and pinch roller are
brought together.
13. Using FOIL JOG, confirm that foil is not
slipping on takeup shaft.
14. While observing foil movement, use foil
jog function for sufficient time to confirm
that foil remains properly aligned during
its travel; adjust foil position on takeup
shaft if necessary.
15. Position foil guide rings on stripper bars
close to foil edges.
16. Set foil pulling interval as follows:
a. Measure width of graphic on die face.
b. Using appropriate switches or menu
selections, enter foil pull timing
function.
c. Based on the width of the graphic
determined in step a, and allowing
1/4” to 1/2” between stampings, set
foil pull time to desired interval.
Note: Foil moves about 2” for each
second.
17. The tensioner should move between the
fully relaxed and fully extended positions
to maintain tension in the foil. As the foil is
pulled, the tensioner extends downward
and then relaxes slightly upward when
pulling stops. Check for proper movement
of tensioner as follows:
a. While foil is pulling, tensioner should
move downward (toward full
extension).
b. When pulling stops, tensioner should
move upward toward relaxed position.

6.0-6

c. When foil is installed, tensioner should
not be at either no extension or full
extension.
TEMPERATURE AND DWELL
RELATIONSHIP
Proper balance of temperature and dwell
produce optimal hot stamping results.
Generally, these parameters should be set as
low as possible—consistent with satisfactory
foil adhesion—to maximize die life, minimize
cycle time, and optimize graphic quality. The
following paragraphs discuss the
interdependency of these two settings and
how to achieve optimal hot stamping results.
Temperature and dwell interdependency is
due to the thermal bonding that occurs
between the foil resins and the substrate.
Since the foil is typically formulated with
resins matching the material being stamped,
the die surface temperature must be slightly
higher than the melting point of the material.
Also, the dwell time must be sufficient to both
soften and join the foil and substrate resins.
Ideally, the dwell time should be set after
temperature setting, using the following
guidelines:
1. Contact foil manufacturer for
recommended heat range for the foil
installed or substrate melting
temperature.
Note: This information is important, as
variations in foil color, formulation, and
carrier thickness require changes in
machine temperature settings.
2. Increase dwell time from initial setting
until results are satisfactory, re-testing
after each change.
Further changes in dwell time may be
required to enhance durability and quality of
stamping. Normally, the image lies on the
part surface where it is subject to scuffing or
scratching; however, increasing the dwell
time will cause the die to dig into the surface,
thereby embedding the image slightly below
the surface. This stamping method provides a
natural protection because the image lies
below the surface; however, image quality
may be somewhat compromised.
US 25 Hot Stamping Machine
6.0 Setup and Adjustment
For a textured surface, increasing the dwell
time may be necessary to cause the die to
flatten the surface for enhanced stamping
quality.
SETTING AND STORING JOB
PARAMETERS
Up to 10 sets of job parameters can be stored
in the machine’s control box for instant recall.
This feature increases productivity by
eliminating the need for re-entering
parameters every time a standard job is run.
To store a job, proceed as follows:
CAUTION
After Entering Job Parameters, Record
All Settings For Future Reference, In
Case Machine’s Memory Is Cleared Or
Modified.
1. Press JOB # switch, and then select a job
number by pressing + and – keys until
desired number is displayed.
Note: If machine is being set up for first
time, use sequential job numbers
beginning with “1.”
2. Enter all desired parameters for the job
number, if not previously entered. All
information will be stored under the job
number, eliminating the need to re-set
parameters each time the job is run.
3. To recall a job number, simply press JOB
# switch; all parameters will be recalled.
Turn on heaters, allow temperature to
stabilize, and run job.
Note: When switching jobs, allow
sufficient time for heat to stabilize before
running new job.
4. To change a parameter, press JOB #
switch and then the + or – keys until
desired job number is displayed. Make
desired changes; new information will be
automatically stored.
6.0-7

7.0 TROUBLESHOOTING
This section contains diagnostics,
troubleshooting, and other aids to assist in
isolating and correcting machine
malfunctions. Refer to the electrical
schematic and pneumatic diagram in
Engineering Drawings and to Setup and
Adjustment and Maintenance sections for
additional assistance in analyzing and
correcting faults.
CONFIGURATION DISPLAY
The current operating parameters can be
viewed on the message display. The
configuration is shown by pressing the
COUNT and DWELL TIME switches
simultaneously. The parameters listed in
Table 7.0-1 will then be shown on the
message display:
Note: Depending on machine options,
additional parameters may be shown.
Table 7.0-1 Configuration Messages
PROGRAM Version of program
VERSION installed on machine
LIMIT SWITCH Current up and down
CONDITION limit switch settings
Displays jumper
configuration on main
INSTALLED
board (different jumpers
JUMPERS
are required for different
options).
Total number of cycles
completed by machine
TOTAL COUNT
(cleared when machine
is re-initialized).
DIAGNOSTICS
As an additional aid to troubleshooting, the
machine is equipped with built-in diagnostics.
Upon detecting a failure, the control box
stops operation of the equipment and
displays an error message on the control
panel to notify the operator of an equipment
malfunction. Table 7.0-2 lists available
US 25 Hot Stamping Machine
7.0 Troubleshooting
diagnostic messages, definitions, and
corrective actions.
CONTROLLER INPUTS
Beginning with program version 3.02E, the
present status of controller inputs may be
displayed on the message screen. To view
this information, press and hold the TEMP
and COUNT keys simultaneously. To cancel
the status mode and return to the normal
display, press the CLR key.
When the status mode is entered, all inputs
that are currently “on” are shown on the
screen. Missing numbers denote that the
input is “off.” The diagnostic code numbers
refer to the schematic diagrams included at
the rear of this manual. For example, code 1
(IN1 on the schematic) is found to be the right
palm button switch. The head up limit switch,
shown as IN4 on the schematic, is
represented as code number 4 on the screen.
Depending on machine options, additional
numbers will be shown.
It is important to understand that the
diagnostics are dynamic. The inputs shown in
Figure 7.0-1 reveal current conditions at the
time the diagnostic program was accessed.
Under other conditions, the diagnostics would
be different.
Examples of using diagnostics in typical
troubleshooting problems are described in the
following paragraphs.
Example 1
Problem – Stamping head goes down, but
immediately returns up when palm buttons
are released rather than pausing for dwell
time.
Test – Press SETUP and then press palm
buttons simultaneously to move head fully
down.
Diagnostic Result – Diagnostic number 3 is
shown on the screen when head is down,
indicating that switch is supplying “down”
input to controller.
7.0-1
US 25 Hot Stamping Machine
7.0 Troubleshooting
Solution – Switch is not defective; check for Solution – Right palm button switch is likely
correct dwell time setting and reset as defective.
needed. Examples 1 and 2, above, provide guidance
Example 2 for using the diagnostics. These examples
should be used to aid in interpreting the
Problem – Machine fails to operate when
diagnostics for other conditions and
palm buttons are pressed simultaneously.
problems. However, if assistance is needed
Test – Press buttons one at a time to check in understanding the machine diagnostics,
switches independently. contact United Silicone.
Diagnostic Result – Diagnostic number 1 is INPUTS: 4 7 8
shown when left button is pressed; however,
number 2 fails to go on when right button is 10
pressed. This indicates that right switch is not
Figure 7.0-1. Typical Controller Inputs
supplying required input.
Table 7.0-2. Diagnostics
Message Definition Corrective Action
Check for consistent air pressure of 5PSI
minimum, and check that deadstop adjusting
sleeve operates down limit switch..
STAMPER Current cycle was
Confirm that air flow controls are open sufficiently
ERROR not completed
for head to move.
Test palm switches for proper and consistent
operation.
If temperature was recently lowered, turn off
heat, allow to cool completely, and then turn heat
Error in control of back on.
HEAT CONTROL heater temperature Check for blown main fuse; replace if blown.
ERROR
Verify that high and low temperature limits are at
least 10°F from setpoint; change if required.
Cold die Wait for die to fully heat.
Inspect alignment of heat transfer through slot
above photocell to ensure that registration mark
passes through beam; adjust as required.
Photocell (or laser
CHECK Check and adjust photocell (or laser eye)
eye) did not detect
WEBTRAK AND sensitivity (refer to 10.2 Photocell Heat Transfer
FOIL registration mark on
heat transfer. Web or 10.3 Laser Eye Heat Transfer Web).

7.0-2
 US 25 Hot Stamping Machine
7.0 Troubleshooting

Table 7.0-2. Diagnostics

Message Definition Corrective Action
Jog foil and observe high-to-low speed transition
to confirm that low-speed setting is sufficiently
high to pull heat transfer web; if web stops,
Photocell (or laser increase low speed by 1 or 2. If transfer was
CHECK eye) did not detect changed, photocell must be re-set (refer to
WEBTRAK AND
registration mark on Webtrak Photocell Heat Transfer Option or
FOIL (cont’d)
heat transfer (cont’d) Webtrak Laser Eye Heat Transfer Option).
Increase foil pull time sufficiently to allow transfer
registration mark to reach part before switching
to low speed.
CHECK BATTERY Either battery dead Check and replace battery, if defective (refer to
INITIALIZE CPU or error in CPU Battery Testing and Replacement, below).

TROUBLESHOOTING CHART 3. Grasp EMERGENCY STOP button, and

Table 7.0-3 lists possible troubles and their
causes and corrective actions. The
troubleshooting chart contains the most
common problems, but cannot include all
possibilities. For additional assistance, refer
to the Description, Operation, Installation,
and Engineering Drawings sections.
BATTERY TESTING AND REPLACEMENT
CAUTION
This Procedure Will Clear The Memory.
All Variables Must Be Reset After
Battery Is Removed And Re-Installed.
To remove, test, and replace battery, proceed
as follows:
1. Shut down and disconnect power from
machine.
2. Remove four screws securing control
panel.
pull panel outward at bottom and then
swing down top of panel until separated
from control box. Be careful to avoid
pulling out electrical leads.
4. While an assistant supports control panel,
remove battery from middle of circuit
board near bottom (Figure 7.0-2).
5. Check for battery voltage of 2.5 Vdc. If
less than 2.5 Vdc, replace battery with a
Panasonic P-186 or equivalent.
6. Re-install battery at lower middle of circuit
board.
7. Locate pins J8 in upper left corner of
circuit board (see Figure 7.0-3).
8. Connect a jumper across pins J8, and
then turn power on and off again.
9. Remove jumper from pins J8.
10. Turn on power.
11. Re-install and secure control panel.

7.0-3
US 25 Hot Stamping Machine
7.0 Troubleshooting

BATTERY

CLIP

TEMPORARY
JUMPER
Figure 7.0-2. Battery Location
Figure 7.0-3. Pin J8 Jumper Location

7.0-4

Table 7.0-3. Troubleshooting
Trouble Possible Cause
Uneven die-to-part
contact
Surface contamination
from flow agent, anti-
static solution, or silicone-
based mold releases
Incomplete stamped Foreign particles on
image surface
Fixture support
inadequate, permitting
part to flex under
machine pressure
Air trapped between foil
and surface
Uneven die-to-part
contact
Excessive stamping force
Die surface temperature Reduce temperature setting (refer to Setup
too high
Rollover in image
Excessive dwell time
Sinks (low areas) in
decorating surface
Part wall thickness
variations
Insufficient stamping
pressure
Surface contamination
from flow agent, anti-
static solution, or silicone-
based mold releases
Die surface temperature Increase temperature setting (refer to Setup
Edges of image are too low
ragged or not sharp
Insufficient dwell time
Resin not fully released
from carrier (foil stripping)
Resin adversely affected Select BEFORE foil pulling cycle to advance
by heat exposure prior to
stamping cycle
US 25 Hot Stamping Machine
7.0 Troubleshooting
Corrective Action
Reposition fixture so that decorating surface
is in proper relationship to die.
Discontinue use of all contaminating agents.
Wipe surface using a clean cotton cloth or
glove.
Modify or re-design fixture to increase
rigidity under decorating surface and/or
ensure that mandrel-type designs do not
permit deflection of part.
Re-design die face to include convex crown.
Reposition fixture so that decorating surface
is in proper relationship to die.
Reduce stroke length or reduce air pressure
(refer to Setup and Adjustment).
and Adjustment).
Reduce dwell time setting (refer to Setup
and Adjustment).
Build up support fixture beneath part in light
areas, and reduce stamping pressure (refer
to Setup and Adjustment).
Switch to a dual durometer silicone-part
rubber die.
Increase stroke length and/or increase air
pressure (refer to Setup and Adjustment).
Discontinue use of all contaminating agents.
and Adjustment).
Increase dwell time setting (refer to Setup
and Adjustment).
Reduce head retraction speed and/or
introduce head-up delay (refer to Setup and
Adjustment).
foil just before head extends downward.
7.0-5
US 25 Hot Stamping Machine
7.0 Troubleshooting
Table 7.0-3. Troubleshooting
Trouble Possible Cause Corrective Action
Increase temperature setting (refer to Setup
Insufficient die heat
Poor image and Adjustment).
adhesion Resin-to-part
Change foil to compatible resin.
incompatibility
Check resistance across each heater or use
an inductive ammeter to check current flow
Die does not heat or
Defective heater(s) through heater. If open circuit, high
heats slowly
resistance, or low current is found, replace
heater (refer to Maintenance).
Adjust software noise discrimination filter
Display temperature (SNDF) as described in Description Table
rises quickly and Interference from RF 3.0-1.
then heat shuts off; welder or similar
HEAT CONTROL equipment Re-locate machine and re-try.
ERROR appears Contact United Silicone for assistance, if
unable to clear problem.
Check for infinite resistance between each
thermocouple lead and ground; if low
Temperature Thermocouple grounded
resistance is found, replace thermocouple
fluctuates 5°F-10°F
(refer to Maintenance).
during cycles
Contact United Silicone for assistance in re-
TEMP. P value incorrect
setting value.
Replace thermocouple (refer to
Defective thermocouple
Maintenance).
Check AC voltage across relay terminals 1
Stamping head and 2 and DC voltage across terminals 3
overheats and 4 (refer to Maintenance for relay
Defective heater relay location). With heat off, line voltage should
be present across 1 and 2; 0Vdc should be
present across 3 and 4. Replace relay if
readings are incorrect.
Blown fuse Check and replace fuse if open.
Foil does not move Down limit switch not Check that adjustable deadstop is operating
limit switch, and adjust if necessary (refer to
closing
Setup and Adjustment).
Stamping head
extends down Clean/replace palm switches, as required
Defective palm switches
slightly and then (refer to Maintenance).
retracts

7.0-6

8.0 M AINTENANCE
Your United Silicone hot stamping machine is
designed for trouble-free operation and
requires minimal maintenance. Periodic
maintenance instructions included in this
section consist of lubrication and cleaning.
Component replacement procedures are
included to assist technicians in replacing
parts found to be defective. Use the
information in Troubleshooting for
assistance in fault isolation before replacing
components.
PNEUMATIC SYSTEM LUBRICATOR
Check lubricator oil level once a month, and
replenish as needed. Shell Tellus 68 and
Mobil DTE are approved by United Silicone;
however, other equivalent oil may be used.
Change oil immediately if it becomes
contaminated or emulsified, as indicated by
loss of clarity.
AIR FILTER
Drain air filter daily to remove moisture from
the pneumatic system. Always check for
moisture before and after machine operation.
HEAD HEIGHT ADJUSTING SCREW
Apply a good grade of Lithium grease to
screw threads once a year.
INSPECTION AND CLEANING
Occasionally inspect machine for obvious
defects, and perform required maintenance.
Cleaning is not normally required. Remove
any dust, debris, or other contaminants from
machine surfaces.
ADJUSTMENTS
After setup, the machine does not normally
require further adjustment. However, if die is
changed, or stamping defects are observed,
adjustment may be required. Refer to Setup
and Adjustment for assistance in checking
and re-adjusting machine.
US 25 Hot Stamping Machine
8.0 Maintenance
COMPONENT REPLACEMENT
The following paragraphs describe removal
and replacement procedures for components
that may be replaced or repaired. Obvious
procedures are not included. Before replacing
any part, refer to Troubleshooting for
assistance in fault isolation. A complete list of
recommended spares is included in
Recommended Spare Parts.
Heater
Any one of the heaters may be replaced
independently. The heaters are installed in
wells at the rear of the heater block. To
replace a heater (Figure 8.0-1), proceed as
follows:
Removal
1. Unplug machine power cord, and
lockout/tagout electrical power.
2. Operate air dump valve, and
lockout/tagout air supply.
3. Remove heater retaining screw at front of
heater block.
4. Cut leads of heater to be removed at rear
of heater block, and withdraw heater from
front of heater block.
5. Remove two screws securing cover to
small junction box below control panel,
and remove cover.
6. Trace leads from removed heater back to
the small junction box, and disconnect
leads.
7. Unscrew and separate electrical lead
retaining nut from strain relief, and pass
out heater leads.
8. Carefully cut tie wraps securing heater
leads to power cable and discard leads.
Installation
Installation is basically the reverse of
removal. Insert new heater from front of
heater block, passing leads out through rear.
Connect new leads at junction box. Be sure
to replace all tie wraps cut during removal.
8.0-1
US 25 Hot Stamping Machine
8.0 Maintenance
Down Limit Switch
HEATER
The down limit switch is installed on a bracket
adjacent to the positive stop. The switch
begins the head dwell time when actuated by
the positive stop adjusting sleeve, as the
stamping head reaches the bottom of its
stroke. To replace the down limit switch
(Figure 8.0-2), proceed as follows:
Removal
1. Unplug machine power cord, and
THERMOCOUPLE lockout/tagout electrical power.
2. Operate air dump valve, and
lockout/tagout air supply.
Figure 8.0-1. Heater and Thermocouple
Locations 3. Remove cover, and disconnect electrical
leads from down limit switch.
Thermocouple 4. Remove two socket head screws
The thermocouple is inserted into a well at securing limit switch to mounting bracket,
the back of the heater block. To replace and remove switch.
thermocouple (Figure 8.0-1), proceed as
Installation
follows:
Installation is the reverse of removal.
Removal
DOWN LIMIT
1. Unplug machine power cord, and SWITCH
lockout/tagout electrical power.
2. Operate air dump valve, and
lockout/tagout air supply.
3. Remove screws securing rear cover to
control box or junction box, and remove
or swing out cover.
4. Trace leads from thermocouple back to
their source, and disconnect leads.
5. Unscrew and separate electrical lead
retaining cap from cable strain relief, and
pass out leads. Figure 8.0-2. Down Limit Switch Location
6. Carefully cut tie wraps securing Adjustment
thermocouple leads to power cable.
After replacing down limit switch, adjust as
7. Remove screws securing two follows:
thermocouple cable clamps to connecting
1. Set vernier positive stop adjustment to 0.
plate, and separate cable clamps; remove
thermocouple leads from clamps. 2. Loosen screws securing mounting
bracket to top cover.
8. Twist thermocouple retaining cap 1/4 turn
counterclockwise, and slide thermocouple 3. Slide bracket toward adjusting sleeve until
out rear of heater block. switch clicks, and hold in position while
tightening screws.
Installation
Installation is the reverse of removal. Be sure
to replace all tie wraps cut during removal.

8.0-2

Up Limit Switch
The up limit switch is mounted on a bracket
adjacent to the left rear guide shaft inside the
cylinder mounting box. The switch transmits a
signal to the controller when actuated by the
guide shaft, as the stamping head reaches
the top of its stroke. To replace the up limit
switch (Figure 8.0-3), proceed as follows:
Removal
1. Unplug machine power cord, and lock
out/tagout electrical power.
2. Operate air dump valve, and
lockout/tagout air supply.
3. Remove two socket head screws
securing down limit switch mounting
bracket to head cover, and separate
bracket with switch from cover.
4. Remove socket head screws securing
head cover to cylinder mounting box, and
remove cover.
5. Remove cover, and disconnect electrical
leads from up limit switch.
6. Remove two socket head screws
securing up limit switch to mounting
bracket, and remove switch.
Installation
Installation is the reverse of removal;
however, leave screws loose to permit
adjustment.
Adjustment
1. With stamping head fully retracted, loosen
bracket mounting screw if not already
loose.
2. Slide bracket into contact with tapered
guide shaft until switch just clicks.
3. Slide switch in about 1/16” further, and
tighten bracket mounting screw.
US 25 Hot Stamping Machine
8.0 Maintenance
UP LIMIT
SWITCH
GUIDE
SHAFT
Figure 8.0-3. Up Limit Switch Location
Solid State Relay
The relay is mounted on the bottom inside of
the control box. To replace the solid state
relay (Figure 8.0-4), proceed as follows:
Removal
1. Unplug machine power cord, and
lockout/tagout electrical power.
2. Operate air dump valve, and
lockout/tagout air supply.
3. Tag and disconnect four electrical leads
from relay.
4. Remove two screws securing relay (and
plastic cover if installed) to control box,
and remove relay.
Installation
Installation is the reverse of removal.
Palm or Opti-Touch Switch
The switches are installed in housings on the
left and right sides of the main frame. To
replace either switch, proceed as follows:
Removal
1. Unplug machine power cord, and
lockout/tagout electrical power.
2. Operate air dump valve, and
lockout/tagout air supply.
3. Disconnect electrical lead from solenoid
valve corresponding to switch being
replaced.
8.0-3
US 25 Hot Stamping Machine
8.0 Maintenance
SOLID-
STATE
RELAY
Figure 8.0-4. Solid State Relay Location
4. For palm switch, unscrew and remove
switch bezel.
5. Working from underside of switch base
plate, remove four screws securing switch
housing to base plate, and separate
switch housing from plate.
Note: If access to underside of switch
housing is hindered by machine mount,
remove base plate from main frame and
invert plate to remove switch housing.
6. For palm switch, carefully lift locking tabs
and separate switch from actuator. For
Opti-Touch switch, remove nut securing
switch to housing, and slide switch out
from front of housing.
7. Disconnect electrical leads from switch
terminals, and remove switch.
Installation
Installation is the reverse of removal. When
installing palm switch, be sure to insert
locking tabs into proper slot. If not installed
properly, button will not operate switch
(Figure 8.0-5).
LOCKING TAB
OPEN
SLOT
Figure 8.0-5. Palm Switch Installation
8.0-4
Emergency Stop Switch
The emergency stop switch is installed on the
rear of the control panel. The switch is
attached to its actuator by a bayonet-type
mount. To replace the emergency stop switch
(Figure 8.0-6), proceed as follows:
Removal
1. Unplug machine power cord, and
lockout/tagout electrical power.
2. Operate air dump valve, and
lockout/tagout air supply.
3. Remove four screws securing front panel
to control box, and separate panel from
box.
4. Disconnect leads from screw terminals at
rear of switch.
5. Loosen screw securing switch to actuator,
and remove switch.
Installation
Installation is the reverse of removal.
MOUNTING
SCREW
ELECTRICAL
TERMINALS
Figure 8.0-6. Emergency Stop Switch
Installation
Air Cylinder
The air cylinder drives the stamping head and
applies the required pressure to apply the
image to the decorating surface. Following
removal, the cylinder should be either
replaced or inspected, cleaned, and repaired.
To replace the cylinder (Figure 8.0-7),
proceed as follows:
 US 25 Hot Stamping Machine
8.0 Maintenance
Removal
1. If cylinder is not already extended, set
machine to Setup mode and extend
piston to facilitate access to cylinder
mounting hardware.
2. Unplug machine power cord, and
lockout/tagout electrical power.
3. Operate air dump valve, and
lockout/tagout air supply.
4. Disconnect both air lines at left side of
cylinder mounting box, and unscrew and
remove elbows.
5. Unscrew and remove knurled nut,
adjusting sleeve, and dead stop from top Figure 8.0-7. Air Cylinder Installation
of cylinder.
Foil Pinch Roller
6. Remove two socket head screws
securing guide bar to stamping head, and The silicone rubber pinch roller presses the
remove guide bar. used foil against the knurled roller to prevent
the foil from slipping as it is pulled onto the
Note: Removing guide bar facilitates
takeup shaft. To replace the pinch roller
access to hardware securing flanged
(Figure 8.0-8), proceed as follows:
coupling and cylinder to mounting box.
7. Restrain piston rod using an open-end Removal
wrench, while using a suitable wrench 1. Unplug machine power cord, and
applied to screws in flanged coupling to lockout/tagout electrical power.
break coupling free from cylinder. 2. Operate air dump valve, and
8. Remove four screws securing flanged lockout/tagout air supply.
coupling to connecting plate, and 3. Carefully unhook extension springs on
separate plate from coupling. front and rear pinch roller levers.
9. Unscrew and remove flanged coupling
4. Remove socket head screw from each
from cylinder.
pinch roller lever, and remove pinch roller
10. Working from underside of cylinder, and levers.
remove four nuts, lockwashers, and flat
5. Separate pinch roller from front and rear
washers securing cylinder to mounting
levers.
box, and lift and remove cylinder.
Installation
Installation Installation is the reverse of removal. Replace
Installation is the reverse of removal. extension springs, if they have taken a set or
are obviously deformed.

8.0-5
US 25 Hot Stamping Machine
8.0 Maintenance
5. Run belt material around knurled roller
EXTENSION SPRING and takeup shaft grooves.
Note: Only one coupling is needed for
attaching ends of belt; for heat transfer
web machine, entire length of belt is
required (refer to Photocell Heat Transfer
Web Option or Laser Eye Heat Transfer
Web Option for applicable procedure).
6. Pull belt until taut, and cut off excess
material. Attach belt ends together by
PINCH ROLLER pushing into coupling previously inserted
into opposite end.

Figure 8.0-8. Foil Pinch Roller 7. Rotate takeup shaft manually to confirm
proper tension, as evidenced by rotation
Foil Takeup Drive Belt of knurled roller.
The foil takeup drive belt transfers the foil
motor’s rotation to the takeup shaft and pinch
roller. The belt material is supplied in 2-foot
lengths with two attachment couplings. To
replace the drive belt (Figure 8.0-9), proceed
as follows:
1. Unplug machine power cord, and
lockout/tagout electrical power. TAKEUP
SHAFT
2. Operate air dump valve, and
lockout/tagout air supply.
3. Cut and remove existing belt; discard belt.
4. Insert new coupling halfway into one end BELT
of new belt material, leaving opposite
pointed end exposed.
Figure 8.0-9. Foil Takeup Drive Belt

8.0-6
 US 25 Hot Stamping Machine
9.0 Recommended Spare Parts

9.0 RECOMMENDED SPARE P ARTS

While your hot stamping machine is highly
reliable and trouble-free, occasional parts
replacement may be required due to normal
wear and aging. This section contains a
listing of parts, which have been determined
to be most likely requiring possible future
replacement. By stocking these parts,
minimal downtime should be experienced in
case of equipment malfunction.
Table 9.0-1 lists the recommended spare
parts for standard and heat transfer
machines. For unique parts used only on heat
transfer machines, refer to Webtrak
Photocell Heat Transfer Web Option or
Webtrak Laser Eye Heat Transfer Web
Option. Required ordering information is
listed for each part. The recommended
quantities listed in the table are not
necessarily the total installed on your
machine. The list is keyed by component
index numbers to Engineering Drawings,
which follows this section. Where no item
number is shown, the part is not shown on
the engineering drawings.
ORDERING PARTS
When ordering parts, please fill out the Parts
Order Form on the following page. The form
should be duplicated so that additional copies
will be available if needed. When filling out
the form, be sure to enter all required
information, which includes item number, part
number, and complete description.
To expedite delivery, parts orders may be
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
33 722135-99 Foil Pinch Roller, Standard Machine 1
40 725061-1-99 Foil Guide Ring 2
50 41242018 Extension Spring 2
54 41215004 Foil Drive Belt (Includes 2 Connectors) 2 Ft
66 41242006 Compression Spring 1
176 41401028 Solenoid Valve (for standard machine) 1
183 41401052 Solenoid Valve (for machine with head up delay option) 1
— 41111004 Heater,1/2 x 8, 120V 2
— 41111002 Heater,1/2 x 8, 240V 2
— 41113007 Thermocouple 1
— 41122033 Solid State Relay 1
— 41121016 Emergency Stop Contact 1
— 41121083 Palm Switch Contact 2

9.0-1
 PARTS ORDER FORM
US Hot Stamping/Pad Printing 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.: ____________________________ Phone No.: _________________________
Ship: o Partial o Complete
Purchase Order No.: ____________________ Ship Via: o UPS
Price and Delivery Quotation Required o UPS Next Day Air
Before Shipment? o Yes o No o Motor Freight
Machine Model & Serial No.: _________________ o Overnight Air
o Other (Specify)
Drawing No.: Title:
Part Number Description Item No. Qty Price

9.0-3

10.1 X-Y and X-Y-R Positioning Table Option
10.0 PNEUMATIC SLIDE T ABLE OPTION
The pneumatic slide table option enhances
stamping productivity by facilitating the
transfer of parts under the nesting fixture. The
unit does this by moving the work table well
out from under the stamping head for loading
and removal of parts, thereby eliminating the
need for the operator to position the part
under the stamping head, where space is
often limited. The sliding work table is driven
by an air cylinder that automatically moves
the work table under the stamping head as
the stamping cycle begins and then slides out
toward the operator after the part is stamped.
Description, operation, troubleshooting, and
maintenance information for the pneumatic
slide table is provided in this section.
DESCRIPTION
The slide table option consists of a sliding
work table, base plate, air cylinder, solenoid-
operated air valve, and associated wiring.
The base plate is secured to the machine’s
side supports in place of the standard
stationary table. The slide table is guided by
tubular slides on each side and by the air
cylinder piston in the center for precise
positioning during in and out travel.
The double-acting air cylinder is mounted
horizontally beneath the base plate. A
solenoid-operated air valve installed beside
the cylinder directs air to the extension and
retraction cylinder ports to move the table.
Electric power to energize the air valve
solenoid is supervised by the controller,
which coordinates valve operation with
stamping head travel.
OPERATION
The slide table remains out (home position)
when the stamping head is retracted following
completion of a stamping cycle. With air and
electric power supplied to the machine,
pressing both palm switches simultaneously
directs electric power to the solenoid-
operated air valve. Air supplied from the inlet
air regulator flows to the retraction port of the
air cylinder, driving the piston inward, and
US 25 Hot Stamping Machine
moving the table directly under the stamping
head. The stamping head then extends
downward, stamping the part. After stamping
is completed and the head retracted, the air
valve is re-positioned, exhausting air from the
retraction port and directing air to the
extension port. The cylinder extends, moving
the table back to its home position.
TROUBLESHOOTING
The pneumatic slide table is highly reliable
and virtually trouble-free. Usually, failure of
the slide table to operate is a symptom of a
general malfunction of the machine. Table
10.0-1 contains troubles, possible causes,
and corrective actions specifically related to
the slide table. Use this information to assist
in fault analysis if a malfunction appears to be
isolated to the slide table.
MAINTENANCE
Maintenance consists of replacement of
defective parts. The following paragraphs
describe replacement procedures for slide
table components.
Air Cylinder
The air cylinder is mounted on the underside
of the slide table. To replace the cylinder
(Figure 10.0-1), proceed as follows:
Removal
1. Unplug machine power cord, and
lockout/tagout electrical power.
2. Operate air dump valve, and
lockout/tagout air supply.
3. Remove four screws securing slide table
to side supports, and remove table.
4. Disconnect air lines from cylinder elbows.
5. Prevent piston rod from turning while
loosening locknut, and unscrew piston rod
from table coupling until completely free
of coupling.
6. Remove two screws securing cylinder to
mounting bracket, and remove cylinder.
10.1-1
US 25 Hot Stamping Machine
10.0 Pneumatic Slide Table Option
Installation 2. Operate air dump valve, and
Installation is the reverse of removal. lockout/tagout air supply.
3. Disconnect electrical leads from air valve.
4. Disconnect two outlet air lines and inlet
airline from valve.
PNEUMATIC
LINES
5. Remove two screws securing valve to
mounting bracket, and remove air valve.
Installation
Installation is the reverse of removal.
TABLE
COUPLING VALVE

Figure 10.0-1. Slide Table Cylinder Installation

Solenoid-Operated Air Valve
The air valve is mounted on the underside of
the table adjacent to the air cylinder. To
replace the air valve (Figure 10.0-2), proceed ELECTRICAL
LEADS
as follows:
1. Unplug machine power cord, and Figure 10.0-2. Slide Table Air Valve
lockout/tagout electrical power.
Table 10.0-1. Troubleshooting
Trouble Possible Cause Corrective Action
Run machine diagnostics, and check for a “1”
Slide table remains No input from controller at diagnostic number 8. If a “0” is shown,
under head after controller is not supplying power to solenoid
stamping valve (refer to Troubleshooting section).
Defective solenoid valve Replace valve.
Table moves
Defective air cylinder Repair or replace cylinder.
slowly or hesitates
ENGINEERING DRAWINGS drawings related specifically to the slide table.
Drawings for slide table machines are These drawings are included in the
identical with standard machines, except for Engineering Drawings section at the rear of
this manual.

10.0-2
 US 25 Hot Stamping Machine
10.1 X-Y and X-Y-R Positioning Table Option

10.1 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
1. Turn micrometer knobs until both axes
movement of the table both horizontally and
are about at their centers.
vertically. The table is a precision device
having micrometer adjustments for movement 2. Mount the nesting fixture on the X-Y or
on both axes. The X-Y-R table has an X-Y-R table so that the part decorating
additional adjustment, which provides surface is as close as possible to directly
rotational movement. This additional below the stamping head.
adjustment allows compensation for minor 3. Turn the micrometer knobs until the
discrepancies in die or heat transfer decorating surface is precisely aligned
positioning. with the stamping head.
Description and operation information for the Note: Do not make major adjustments
positioning table is provided in this section. with the micrometer knobs. If a major
offset of either axis is required, the
DESCRIPTION nesting fixture or the die mounting plate
The positioning table consists of a base plate, should be moved.
movable work table, micrometer adjustments,
4. If using an X-Y-R table, the third
and locking collars. Mounting holes are
adjustment is performed by loosening
provided for securing the X-Y or X-Y-R table
screws in slotted holes on top of table and
to the work table. Several threaded holes in
then turning stop screws at left and right
the X-Y or X-Y-R table surface are used to
to rotate the table.
mount the part nesting fixture in the desired
location. 5. After completing adjustments, the locking
The table permits a total travel of 3” on both collars should be tightened on both axes
axes. When centered, approximately 1.5” is to prevent accidental movement. If using
available in all directions for nesting fixture an X-Y-R table, tighten locking screws in
alignment. The table’s micrometer slotted holes, as well.
adjustments permit movement in 0.001”
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 10.1-1. X-Y Positioning Table

10.1-1
 US 25 Hot Stamping Machine
10.2 Webtrak Heat Transfer Photocell Option

10.2 WEBTRAK HEAT TRANSFER P HOTOCELL OPTION

Stamping heat transfer decals requires transfer web controls, switches, and
specialized features. The Webtrak heat indicators.
transfer photocell option (Figure 10.2-1) is OPERATION
designed to hold, transport, and precisely
position the heat transfer for accurate, high- As directed by the controller, the heat transfer
quality stamping. feed motor is energized either before cylinder
extension or during retraction. The motor
This section provides description, operation,
pulls the web rapidly for the programmed
setup and adjustment, troubleshooting,
interval set by the operator and then switches
maintenance, spare parts, and drawings for
to the slow speed. After the inactive photocell
the heat transfer photocell option. Only
time has expired, the photocell is enabled by
unique information is included. Where
the controller, allowing the web registration
information or procedures are identical to
mark to be detected. The photocell signal is
standard machines, references are included
relayed to the controller, which then
to the applicable sections of this manual.
terminates pulling of the web.
DESCRIPTION
Web Feed
The heat transfer web feed operates similarly
to the foil feed on standard machines. In
addition to the components needed for pulling
and taking up the used transfer carrier
material, the web feed contains a photocell
which detects the registration marks on the
transfer web carrier. The transport direction is
left to right (opposite foil feed).

Control Panel Figure 10.2-1. Webtrak Heat Transfer

Webtrak photocell machines use the same Photocell Option
control panel. Refer to Description for
control panel information. Table 10.2-1
describes only unique features of heat
Table 10.2-1. Control Panel Webtrak Features
Name Function
The following options are available on heat transfer web machines:
FOIL PULL TIME XX.XX – Sets time allotted for high-speed advancing
of web.
FOIL LOW SPEED: XX – Sets creep speed of web.
WEB LOW RANGE: XX – Sets the upper and lower limits for low
FOIL PULL (creep) speed of web pulling. This is a factory setting and should not
be changed.
FOIL HIGH SPEED: XX – Sets speed at which web advances during
FOIL PULL TIME.
MARKS/ONE STEP: XX – Sets number of marks to be counted before
stopping web advancement (usually used for multiple part stamping).

10.2-1
US 25 Hot Stamping Machine
10.2 Webtrak Heat Transfer Photocell Option
Table 10.2-1. Control Panel Webtrak Features
Name
FUNC. Selects heat transfer web operation.
FOIL Advances web to next mark detected by photocell each time switch is
JOG pressed.
HEAT TRANSFER WEB OR FOIL
INSTALLATION
The Webtrak photocell option moves the web
or foil in the opposite direction from the
standard machine. The feed path through the
machine and adjustments are also different.
To install heat transfer web or foil, proceed as
follows:
1. Loosen front collar lock handle (Figure
10.2-2), and remove collar, spring, and
payout holder from shaft.
2. Slide web or foil onto shaft with material
oriented so that end is at top, matte
(coated) side faces down.
PAYOUT
HOLDER
COLLAR
LOCK
HANDLE
INSIDE COLLAR
Figure 10.2-2. Heat Transfer Web Payout
Assembly
3. Center web or foil on shaft by loosening
inside collar and moving collar, if
necessary, to properly position web or foil
in center of shaft. When fully aligned,
tighten inside collar.
10.2-2
Function
CAUTION
Insufficient Tension Will Cause
Material To Become Snagged;
Excessive Tension Will Cause
Breakage. In The Following Step, Be
Sure To Set Tension Correctly.
4. Slide payout holder, spring, and collar
and lock handle onto shaft. Push collar
against spring until medium tension is felt.
Avoid excessive or insufficient tension.
Tighten lock handle after setting tension.
5. Loosen adjusting screws securing stripper
bars, and position bars so that bottom of
each bar is about 2” from the stamping
head or edge of the part whichever is
greater, parallel to work table, and 1/2”
below the die surface. Tighten adjusting
screws after completing adjustment.
Note: Stripper bars must be parallel to
work table to prevent web from walking to
one side.
6. Rotate pinch roller camshaft until a gap is
opened between knurled roller and pinch
roller.
7. Mount takeup shaft on web pull frame as
follows:
a. Pull out spring-loaded knob.
b. Insert shaft between side plates.
c. Align pin in shaft end with slot in drive
pulley, and release spring-loaded
knob.
9. Thread web or foil from payout roller as
shown in Figure 10.2-3.
10. After threading web or foil around rollers,
past photocell, under stripper bars, and
between pinch roller and knurled roller,
wrap web one full turn around takeup
shaft from underside of shaft without

10.2 Webtrak Heat Transfer Photocell Option
compressing spring-loaded foil clamping
bar.
11. Manually rotate takeup shaft two full turns
to tighten web on shaft.
12. Inspect web path, viewing from takeup
side. If web or foil is not parallel with
stamping head, press in web clamping
bar and slide web or foil on takeup shaft
left or right to obtain correct alignment.
Release clamping bar when web is
aligned.
13. Rotate pinch roller camshaft to bring
knurled roller and pinch roller together.
14. Manually rotate knob on knurled roller at
least two full turns to confirm that foil is
not slipping on takeup shaft.
15. While observing movement, use foil jog
function to confirm that web or foil
remains properly aligned during its travel;
adjust position on takeup shaft if
necessary. After web has settled in
Figure 10.2-3. Photocell Heat Transfer Web Path
US 25 Hot Stamping Machine
position, move guides on stripper bars
close to edges of web.
Note: These guides help prevent web
from walking to one side.
16. The photocell can be moved in the X and
Y directions to align with the web
registration marks (Figure 10.2-4).
Adjustment is performed as follows:
a. Loosen locking knobs on both
adjustments.
b. Move web until registration mark is in
view.
c. Move photocell horizontally until
aligned horizontally with mark, and
tighten locking knob.
d. Turn handle at top of photocell
mounting bracket to align photocell
vertically with registration mark.
Tighten locking knob after completing
adjustment.
10.2-3
US 25 Hot Stamping Machine
10.2 Webtrak Heat Transfer Photocell Option
Note: No further setup is normally
required. However, if the contrast meter
fails to move full scale, re-set the offset
adjustment so that contrast deviation
VERTICAL straddles the switchpoint of “5.” Rarely, it
ADJUSTING may be desirable to re-adjust contrast
HANDLE meter under dynamic conditions, as the
VERTICAL web marks pass under the photocell
HORIZONTAL ADJUSTMENT beam.
ADJUSTMENT LOCKING KNOB
18. Run test samples, and check quality in
LOCKING KNOB
accordance with Foil Stamp Evaluation
and Adjustment and Stamp Adhesion and
Testing procedures in Setup and
Adjustment. Make any required
adjustments before placing machine in
service.

Figure 10.2-4. Photocell X-Y Adjustments

BACKGROUND
17. To adjust photocell sensitivity, place the
appropriate background (Figure 10.2-5)—
light or dark—which contrasts with the
web’s registration mark under photocell
beam. Step a, below, describes light LEDs
background adjustment, and step b
explains adjustment for dark background.
Using appropriate procedure, adjust OFFSET
CONTROL
machine’s contrast meter as follows:
KNOB
a. For light-state adjustment, turn
OFFSET control knob to obtain a
reading of 10; then rotate adjustment
knob an additional 1/4 turn clockwise.
b. For dark-state adjustment, adjust Figure 10.2-5. Photocell Adjustment
OFFSET control knob to obtain a
DIAGNOSTICS
reading of zero (all LEDs off); then
rotate adjustment knob an additional The following diagnostic message and its
1/4 turn counterclockwise. definition and corrective actions apply to
Webtrak photocell machines:
Message Definition Corrective Action
Inspect alignment of heat transfer through slot
above photocell to ensure that registration mark
CHECK Photocell did not detect passes through beam; adjust as required.
WEBTRAK registration mark on Press FOIL JOG switch and observe high-to-low
AND FOIL heat transfer. speed transition to confirm that low-speed setting
is sufficiently high to pull heat transfer; if heat
transfers stop, increase low speed by 1 or 2.

10.2-4
 US 25 Hot Stamping Machine
10.2 Webtrak Heat Transfer Photocell Option

MAINTENANCE RECOMMENDED SPARE PARTS

Procedures included in Maintenance section Recommended spare parts for Webtrak
apply to Webtrak photocell machines except photocell machines are mostly identical with
for the drive belt procedure, which is included standard machines.
below. Following is the only unique spare part:
Web Takeup Drive Belt Item
No. Part No. Description
To replace the drive belt, proceed as follows:
17 7WT033-8-99 Foil Pinch Roller, Heat
1. Lockout/tagout electrical power, and
Transfer Machine
unplug machine power cord.
For ordering information, refer to the
2. Operate air dump valve, and
Recommended Spare Parts section of this
lockout/tagout air supply.
manual.
3. Cut and remove existing belt; discard belt.
4. Insert new coupling halfway into one end ENGINEERING DRAWINGS
of new belt material, leaving opposite Drawings for Webtrak photocell machines are
pointed end exposed. identical with standard machines, except for
5. Run belt material around knurled roller Webtrak drive and electrical schematic.
and takeup shaft pulleys. These drawings are included in the
Engineering Drawings section at the rear of
6. Pull belt until taut, and attach its ends
this manual.
together by pushing into coupling
previously inserted into opposite end.
7. Rotate takeup shaft manually to confirm
proper belt tension, as evidenced by
rotation of knurled roller.

10.2-5
 US 25 Hot Stamping Machine
10.3 Webtrak Heat Transfer Laser Eye Option

10.3 WEBTRAK HEAT TRANSFER L ASER EYE OPTION

Relying on the pinpoint accuracy of laser Control Panel
positioning, the Webtrak heat transfer laser Webtrak laser eye machines use the same
eye option (Figure 10.3-1) offers a high level control panel as standard machines. Refer to
of precision for stamping heat transfer decals. Description for control panel switch and
By detecting the registration mark for the indicator information. Table 10.3-1 describes
transfer directly under the stamping head just only unique features of laser eye controls,
before stamping onto the decorating surface, switches, and indicators.
a high degree of precision is assured.
Description, operation, setup and adjustment,
troubleshooting, maintenance, spare parts,
and drawings for the Webtrak laser eye
option are included in this section. Only
unique laser eye information is included.
Where information or procedures are identical
to standard machines, references are
included to the applicable sections of this
manual.
DESCRIPTION
Web Feed
The heat transfer web feed operates similarly
to the foil feed on standard machines. As on
standard machines, a dancer bar is used to
apply light tension to the web during
transport. In addition to the components
needed for pulling and taking up the used
heat transfer carrier the web feed contains Figure 10.3-1. Webtrak Heat Transfer
the laser eye, which detects the image Laser Eye Option
registration marks on the heat transfer web.
The transport direction is left to right
(opposite foil feed).
Table 10.3-1. Laser Eye Webtrak Control Panel Features
Name Function
The following options are available on Webtrak machines:
FOIL PULL TIME XX.XX – Sets time allotted for high-speed advancing of
heat transfer web.
FOIL LOW SPEED: XX – Sets creep speed of heat transfer web.
FOIL PULL
WEB LOW RANGE: XX – Sets the upper and lower limits for low (creep)
speed of web pulling. This is a factory setting and should not be changed.
FOIL HIGH SPEED: XX – Sets speed at which heat transfer web advances
during FOIL PULL TIME.

10.3-1
US 25 Hot Stamping Machine
10.3 Webtrak Heat Transfer Laser Eye Option

Table 10.3-1. Laser Eye Webtrak Control Panel Features

Name Function
MARKS/ONE STEP: XX – Sets number of images to be counted before
FOIL PULL
(cont’d) stopping heat transfer web advancement (usually used for multiple-part
stamping).
FUNC. Selects heat transfer web operation.
FOIL JOG Advances web to next mark detected by laser eye each time switch is pressed.

OPERATION 4. Slide payout holder, spring, and collar

According to control panel settings, the heat onto shaft. Push collar against spring until
transfer feed motor is energized either before medium tension is felt, avoiding excessive
cylinder extension or after the head is fully or insufficient tension. Tighten collar
retracted. The motor pulls the web rapidly for retaining screw after setting tension.
the programmed interval set by the operator 5. Loosen adjusting screws on stripper bars,
and then switches to the slow speed. After and position bars so that bottom of each
the inactive eye time has expired, the laser bar is about 2” from the stamping head or
eye is enabled by the controller, allowing the edge of the part, whichever is greater,
registration mark directly under the stamping parallel to work table, and1/2” below the
head to be detected. The laser eye signal is pad surface. Tighten adjusting screws
relayed to the controller, which then after completing adjustment.
terminates pulling of the web. Note: Stripper bars must be parallel to
HEAT TRANSFER WEB OR FOIL work table to prevent web from walking to
INSTALLATION one side.
6. Rotate pinch roller camshaft until gap is
The Webtrak option moves the web or foil in
opened between knurled roller and pinch
the opposite direction from the standard
roller.
machine. The feed path through the machine
and adjustments are also different. Install the
heat transfer web as follows: FRONT
INSIDE COLLAR COLLAR
1. Loosen front collar retaining screw
(Figure 10.3-2), and remove collar,
spring, and payout holder from shaft.
2. Slide heat transfer web onto shaft with
material oriented so that end is at top,
matte (coated) side faces down.
3. Center web on shaft by loosening inside
collar and moving collar, if necessary, to
properly position web. When fully aligned,
PAYOUT
tighten inside collar. ASSEMBLY
CAUTION
Insufficient Tension Will Cause
Material To Become Snagged;
Excessive Tension Will Cause
Breakage. In The Following Step, Be Figure 10.3-2. Heat Transfer Web Payout
Sure To Set Tension Correctly. Assembly

10.3-2

10.3 Webtrak Heat Transfer Laser Eye Option
7. Mount takeup shaft on web pull frame as
follows:
d. Pull out spring-loaded knob.
e. Insert shaft between side plates.
f. Align pin in shaft end with slot in drive
pulley, and release spring-loaded
knob.
8. Thread web from payout roller as shown
in Figure 10.3-3.
9. After threading web around rollers and
dancer bar, through stripper bars, past
laser eye, and between pinch roller and
knurled roller, wrap web one full turn
around takeup shaft from underside of
shaft without compressing spring-loaded
foil clamping bar.
10. Manually rotate takeup shaft two full turns
to tighten web on shaft.
11. Inspect web path, viewing from takeup
side. If web is not parallel with stamping
head, press in web clamping bar and
Figure 10.3-3. Laser Eye Heat Transfer Web Path
US 25 Hot Stamping Machine
slide web on takeup shaft left or right to
obtain correct alignment. Release
clamping bar when web is aligned.
12. Rotate pinch roller camshaft to bring
knurled roller and pinch roller together.
13. Manually rotate knob on knurled roller at
least two full turns to confirm that web is
not slipping on takeup shaft.
14. Set OFF-ON switch to ON.
15. While observing web movement, use foil
jog function to confirm that web remains
properly aligned during its travel; adjust
position on takeup shaft if necessary.
After web has settled in position, move
guides on stripper bars close to edges of
web.
Note: These guides help prevent web
from walking to one side.
10.3-3
US 25 Hot Stamping Machine
10.3 Webtrak Heat Transfer Laser Eye Option
16. When precisely adjusted, the laser eye’s
yellow indicator will glow steadily.
Adjustment is achieved by moving the
laser eye in any combination of directions
until the laser beam strikes the
registration mark. To adjust laser eye,
proceed as follows:
Note: For proper operation, laser eye
must be within 3-3/4” to 4” from web and
positioned at no greater than a 45-degree
angle.
a. Sufficiently loosen all retaining screws
in slotted laser eye support brackets
(Figure 10.3-4) to allow movement,
and center each bracket slot on its
retaining screw.
b. Locate registration marks, and
manually move the web until a
registration mark is under the
stamping head.
c. Using the available adjustments,
move laser eye until beam is
projected as close as possible to the
registration mark beside image under
pad.
Note: Beam will pass through a clear
or translucent mark and be seen on
surface above web.
d. Make final adjustment by turning
micrometer adjusting knobs to focus
laser beam on registration mark, and
then tighten all mounting bolts.
Note: In the following steps, the laser
eye’s sensitivity is adjusted. The
adjustment is correct if the yellow
indicator changes state (switches on
or off) when the registration mark
moves off the beam.
18. With the laser beam focused on the
registration mark, check state of laser
eye’s yellow indicator (on or off).
19. Manually move web until registration
mark is off laser beam. The yellow
indicator should switch to the opposite
condition. If indicator did not change, use
a screwdriver to turn laser eye adjusting
screw until light switches on or off.
10.3-4
20. Using Foil Jog function, move web past
laser eye, while watching yellow indicator.
Light should switch on and off as
registration marks pass under beam.
21. If light does not go on and off as
described above, repeat steps 18 through
20 until indicator responds properly.
Contact United Silicone for assistance, if
unable to achieve adjustment.
22. Run test samples, and check quality in
accordance with Foil Stamp Evaluation
and Adjustment and Stamp Adhesion and
Testing procedures in Setup and
Adjustment. Make any required
adjustments before placing machine in
service.
DIAGNOSTICS
The diagnostic message and its definition and
corrective actions (Table 10.3-2) apply to
Webtrak heat transfer laser eye machines.
MICROMETER
ADJUSTING KNOBS
ADJUSTING
SLOTS
Figure 10.3-4. Laser Eye Adjustment
MAINTENANCE
Procedures included in Maintenance section
apply to Webtrak heat transfer laser eye
machines except for the drive belt procedure,
which is included below.
Web Takeup Drive Belt
To replace the drive belt, proceed as follows:
1. Lockout/tagout electrical power, and
unplug machine power cord.
2. Operate air dump valve, and
lockout/tagout air supply.

10.3 Webtrak Heat Transfer Laser Eye Option
3. Cut and remove existing belt; discard belt.
4. Insert new coupling halfway into one end
of new belt material, leaving opposite
pointed end exposed.
5. Run belt material around knurled roller
and takeup shaft pulleys.
6. Pull belt until taut, cut off excess material,
and attach ends together by pushing into
coupling previously inserted into opposite
end.
7. Rotate takeup shaft manually to confirm
proper tension, as evidenced by rotation
of knurled roller.
US 25 Hot Stamping Machine
RECOMMENDED SPARE PARTS
Recommended spare parts for Webtrak laser
eye machines are mostly identical with
standard machines. The only unique spare
part is as follows:
Item
No. Part No. Description
17 7WT033-8-99 Foil Pinch Roller, Hot
Transfer Machine
For ordering information, refer to the
Recommended Spare Parts section of this
manual.
ENGINEERING DRAWINGS
Drawings for Webtrak laser eye machines are
identical with standard machines, except for
Webtrak drive and electrical schematic.
Drawings are at the rear of this manual in the
Engineering Drawings section.
10.3-5
US 25 Hot Stamping Machine
10.3 Webtrak Heat Transfer Laser Eye Option

Table 10.3-2. Webtrak Laser Eye Diagnostics

Message Definition Corrective Action
Check alignment of laser beam with registration
mark on heat transfer web; adjust as required.
Check for flickering ambient lighting that may be
interfering with laser eye sensitivity.
CHECK Laser eye did not
Check for fluttering of web caused by vibration or
WEBTRAK AND detect registration
other source; eliminate vibration source.
FOIL mark on web.
Press FOIL JOG switch and observe high-to-low
speed transition to confirm that low-speed setting
is sufficiently high to pull web; if web stops,
increase low speed by 1 or 2.

10.3-6

10.4 ROTARY TABLE OPTION
Increased productivity is offered by the rotary
table, which automatically indexes each part
under the stamping head. The rotary table
replaces the standard single-station work
table.
The rotary table is available in four-, six-, and
eight-station models to accommodate various
production requirements and part
dimensions.
Description and operation information for the
rotary table is provided in this section.
Maintenance and servicing instructions are
provided in the CAMCO service manual.
DESCRIPTION
The rotary table consists of a motor-driven
index drive, rotating work table, and speed
control. Its operation is supervised by the
control box, which automatically coordinates
table rotation with stamping head extension
and retraction. The drive rotates the table
through four, six, or eight stations depending
on model, pausing at each station for the
operator to place and remove parts. The
speed control permits setting an appropriate
speed to match the operator’s parts-handling
speed. If machine has a shot pin for station
indexing, the speed control is disabled.
OPERATION
Station Alignment
The rotary table is factory set to index at the
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 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. This
adjustment is performed by loosening the
index drive mounting bolts, re-positioning the
table as required until the part is brought into
US 25 Hot Stamping Machine
10.4 Rotary Table Option
precise alignment with the head, and
tightening the index drive mounting bolts after
completing the adjustment.
This adjustment is not suitable for making
major adjustments. If a major offset is
required, the holding fixture or die mounting
plate should be moved. The remaining
stations are automatically aligned by
positioning any one station.
Guard Door Interlock
For personnel safety, all motion stops if a
safety guard door is opened during a cycle.
After closing the door, the stamping head will
not descend until the table is indexed one
station. This step resets the machine’s
controller to resume operation. The one-
station index is required even if the
interruption occurred while the table was at a
station.
Speed Control
The speed control permits a wide range of
adjustment for rotation speed to match the
operator’s pace. The speed setting is
dependent on the operator’s ease of placing
and removing the parts. For example, a rapid
speed is appropriate for small parts that rest
lightly on the holding fixture and can be
removed and placed quickly. However, large
or complex parts may require a slower speed
to permit sufficient time for the operator to
remove the stamped part and place the next
part on the fixture.
The numbered increments on the dial provide
a reference between the fastest speed
(rotated fully clockwise) and slowest speed
(fully counterclockwise); they do not specify
time intervals. Generally, the control is set
initially at its midpoint and then turned left or
right to accommodate production
requirements and the operator’s needs.
10.4-1
Hot Stamping Machine
10.4 Rotary Table Option
INDEX
DRIVE
Figure 10.4-1. Rotary Table Option
TABLE INDEX CAM ADJUSTMENT
Due to table inertia, a change in the rotary
table speed setting may cause the table to
either undershoot or overshoot the index
position. This may cause misalignment of the
part nesting fixture and/or a brief jerking
movement as the table indexes. Therefore,
whenever table speed is altered, the
relationship between the index drive cam lobe
and the index drive shaft keyway should be
checked and adjusted, if required. These
instructions will assist in checking and
adjusting rotary table indexing following
speed setting changes.
Index Check
To check table indexing, proceed as follows:
1. Turn on electrical power.
2. Index table to next station, while
observing its movement as it arrives at
the station.
3. From underside of table, check the
following:
a. Limit switch roller should be on cam
lobe (Figure 10.4-2).
b. Shaft keyway should be about parallel
to table at the 3:00 o’clock position.
4. If cam is not at 3:00 o’clock, adjust cam
as described in the following paragraph.
Cam Adjustment
1. If keyway is below 3:00 position, e.g. 2:00
o’clock, adjust as follows:
10.4-2
a. Loosen two setscrews on cam.
b. Rotate cam counterclockwise
approximately the same amount of
displacement from 3:00 o’clock.
2. Tighten setscrews. If keyway is past 3:00
o’clock, e.g. 4:00 o’clock, adjust as
follows:
a. Loosen two setscrews on cam.
b. Rotate cam clockwise approximately
the same amount of displacement
from 3:00 o’clock.
c. Tighten setscrews.
3. Operate table once again, while
observing its movement. Table should
move to next index position and stop
smoothly. If any jerking, undershooting, or
overshooting of cam lobe is seen,
readjust cam lob, and repeat check.
4. Adjustment is completed when table
moves and stops smoothly at each index
station. If correct operation is not
achieved through this adjustment, contact
United Silicone for assistance.
LIMIT SWITCH
ROLLER
KEYWAY
CAM LOBE
Figure 10.4-2. Rotary Table Index Drive
Cam Adjustment
ENGINEERING DRAWINGS
Drawings for rotary table machines are
identical with standard machines, except for
the electrical schematics. Drawings are
included in the Engineering Drawings
section at the rear of this manual.
 US 25 Hot Stamping Machine
10.5 Lockout Key Switch Option

10.5 LOCKOUT KEY S WITCH OPTION

The lockout key switch option prevents OPERATION
accidental or unauthorized changing of When the control panel is “locked,” most
stamping machine operating parameters. functions cannot be changed. By setting the
Description and operation information for the lockout key switch in the “off” position, only
lockout key switch option is provided in this the foil pull time can be modified. To permit
section. changing of all parameters, set the lockout
key switch in the “on” position.
DESCRIPTION
The lockout key switch is installed on the
front of the control panel between the power
ON-OFF switch and EMERGENCY STOP
switch (Figure 10.5-1). It is supplied with two
keys that operate a simple lock. The key may
duplicated, but keys should only be given to
personnel requiring full access to machine
operating parameters.

Figure 10.5-1. Lockout Key Switch Option

10.5-1
 US 25 Hot Stamping Machine
11.0 Semi-Automated Custom Hot Stamp Systems

11.0 SEMI-AUTOMATED CUSTOM HOT STAMP SYSTEMS

DESCRIPTION needed for system operation,
Semi-automated hot stamp systems (Figure troubleshooting, and maintenance.
11.0-1) are custom-designed and built to
meet unique customer requirements. The
systems integrate one or more hot stamping
machines with a rotary table and other
accessories. For example, a photocell or HOT
STAMPING
laser eye heat transfer web option, pick and MACHINE
place station (Figure 11.0-2), shuttle table,
and/or articulating nest 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
ROTARY
shielding and wire terminations. TABLE
Each semi-automated system is enclosed
within a protective cabinet for optimum safety CONTROL
of the operator and other personnel in the PANEL
system’s vicinity. All doors and swing guards
have safety interlock switches that stop the Figure 11.0-1. Typical Semi-Automated
system whenever any door or guard is moved Custom Hot Stamp System
out of its closed position. Non-interlocked
light curtains are also installed on some
custom systems.
DOCUMENTATION
Basic information on semi-automated custom
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.
Description and operation instructions for the
rotary table are included in Rotary Table
Option. In addition, where applicable, the
documentation package shipped with each
system includes electrical and pneumatic
schematic diagrams, control panel
description, and any other pertinent data Figure 11.0-2. Pick and Place Station

11.0-1
 US 25 Hot Stamping Machine
12.0 Engineering Drawings

12.0 ENGINEERING DRAWINGS

This section contains manufacturing 12.0-1 lists all drawings for both standard and
drawings, which should be used to assist in optional equipment; however, only drawings
troubleshooting, parts replacement, and applicable to your equipment configuration
understanding machine operation. Table are included in this manual.
Table 12.0-1. Engineering Drawings
Drawing No. Description
Standard Mechanical, Electrical, and Pneumatic Drawings
722001 Two & One-Half Ton Hot Stamp Assembly
722002 Foil Feed Subassembly
722003 Foil Payout Subassembly
724004 Main Frame Subassembly
724005 Head Subassembly
722006 Positive Stop Subassembly
722200 Pneumatic Diagram, Hot Stamp Model US 25
722201 Pneumatic Diagram, Hot Stamp Model US 25 With Head-Up Delay
HS-B-100 Electrical Schematic, 110 Volt Hot Stamp
HS-B-101 Electrical Schematic, 110 Volt Hot Stamp With Head-Up Delay
HS-B-110 Electrical Schematic, 220 Volt Hot Stamp
HS-B-111 Electrical Schematic, 220 Volt Hot Stamp With Head-Up Delay
Slide Table Electrical and Pneumatic Drawings
HSST-B-100 Electrical Schematic, Hot Stamp Slide Table
HSST-B-200 Pneumatic Schematic, Slide Table
Webtrak Heat Transfer Web Drawings
WT-D-001-2 US 25 Webtrak for up to 8”x16” Head Assembly
WT-C-050 Webtrak Drive Subassembly
WT700-B-100 Electrical Schematic, Webtrak Control
HS-B-104 Electrical Schematic, 110 Volt Hot Stamp With Webtrak Headup Delay
HS-B-112 Electrical Schematic, 220 Volt Hot Stamp With Webtrak Headup Delay
Rotary Table Drawings
HSSRT-B-100 Electrical Schematic, Hot Stamp Smart Rotary Table
HSSRT-B-102 Electrical Schematic, Hot Stamp Smart Rotary Table With Webtrak

12.0-1