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Volume
STAR INNOVATIONS, L.C.
BALLSTARS ™ - Photo Sports Ball Heat Transfer System
AutomaticPress
OperatingGuide
BALLSTARS ™
Automatic Press Operating Guide
© Star Innovations, L.C.
100 Mission Woods Drive
New Century, KS 66031
Phone 913-764-7738 • Fax 913-254-7803
www.ballstars.com
Table of Contents
Un-Crating and Setting up the Automatic Press ...................................................................................................................... 1
Verifying Contents ................................................................................................................................................................ 1
Powering Up .......................................................................................................................................................................... 1
Turning on the Press ........................................................................................................................................................... 1
Heating up the Press............................................................................................................................................................ 2
Non-Contact Thermometer ................................................................................................................................................. 2
Attaching Air Pressure to the Press .................................................................................................................................... 2
Setting the Timer................................................................................................................................................................. 2
Printing Photo Sports Balls ....................................................................................................................................................... 3
Basic Press Setup ................................................................................................................................................................... 3
Adjusting Cradle Position ................................................................................................................................................... 3
Coating Area ....................................................................................................................................................................... 3
Inflating Sports Balls .......................................................................................................................................................... 4
Sports Ball Position............................................................................................................................................................. 4
Hockey Puck Setup ............................................................................................................................................................... 5
Attaching Flat Print Head ................................................................................................................................................... 5
Printing Hockey Puck ......................................................................................................................................................... 5
Making a Christmas Ornament .......................................................................................................................................... 6
Ornament Cradle Position ................................................................................................................................................... 6
Ornament Coating Area ...................................................................................................................................................... 6
Ornament Overcoat ...........................................................................................................Error! Bookmark not defined.
Troubleshooting ......................................................................................................................................................................... 7
Appendix A ............................................................................................................................................................................... 10
O P E R A T I N G
G U I D E
1
Chapter
Un-Crating and Setting up
the Automatic Press
Open the press crate & other boxes and verify contents.
Verifying Contents
1.
Remove the top of crate.
2.
Remove any unsecured contents out of the crate.
3.
Locate and remove the lock down block found on the inside of the crate.
4.
With two people, lift out the press and place in the location that you will
be operating the press.
Powering Up
Now plug the power cord into any regular 110v electrical outlet. Also check the
heating element cord to ensure it is connected to the control box. See Appendix A.
Turning on the Press
To turn on the power, twist and slightly pull the red
safety knob to the right. It will “Pop” on and the Amber
light appears to indicate that the unit has power. This
knob is also used as the emergency shut off. If at any
time you need to quickly stop the press, just press the
knob and the Amber light will go out indicating that all
the power to the press has been turned off.
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O P E R A T I N G
G U I D E
Heating up the Press
You will see the Red “LOAD” light appear whenever the print head
is heating up. Set the temperature dial to 195o and you will see the
Red “LOAD” light appear. When the “LOAD” light goes off, you
are at the desired temperature. If the press is cold it takes an estimated
15 - 20 minutes to heat up to 195o. We want the temperature to read
between 200 and 205 degrees on the laser gun. The temperature on
the front dial and the laser gun is not the same. Use the laser gun to find the correct
temperature. (See Settings Chart.)
Non-Contact Thermometer
This is your first source for measuring the temperature of your head, it is the most
accurate. Do not go by the read out on your press this is a starting
point. To use your temperature gun just point at the Teflon
directly under the center of the printing head, pull the trigger for 35 seconds, and read the temperature. Adjust the temperature knob
accordingly. If the reading on the thermometer seems to be off,
check to be sure it is set to Fahrenheit and/or check the batteries.
Attaching Air Pressure to the Press
Attach your incoming air supply to the air regulator jack located on the
right-hand side of the press. A good starting point is 75lbs. Turn the black
knob on the top of the air regulator clockwise to increase the air pressure,
and counter-clockwise to decrease the air pressure. You will need to adjust
the air pressure according to which sports ball you’re printing. (See Settings
Chart.)
Setting the Timer
The adjustable timer has an outside ring that rotates increasing
or decreasing the time in “Second” intervals. If you look closely
at the upper right corner on the face of the timer you will see a
little screw head and a setting set to 60s meaning 60 seconds. A
good starting point for the timer is 10 seconds. Twist the
outside ring and move the indicator lines parallel with the “1”
on the dial. When the press is activated you will see the dial
move as it counts down from 10 – 0. You will need to adjust the timer according to
which sports ball you’re printing. (See Settings Chart.).
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O P E R A T I N G
G U I D E
2
Chapter
Printing Photo Sports
Balls
Adjusting Cradle, Ball Position and Printing.
Basic Press Setup
Turn on the press; adjust the temperature, air pressure and the time to the appropriate
levels based on the type of sports ball you are printing. (See Settings Chart.).
Adjusting Cradle Position
There are 5 cradle positions available on the automatic press. The
top hole is for baseballs, softballs, mini-footballs, mini soccer
balls, mini volleyballs, ornaments, dog balls, golf balls, and hockey
pucks. The third hole down is for full size footballs. For all fullsized balls, put the pin in the last hole. To avoid excessive
machine stress, do not let the cradle rest directly on the
bottom mounting plate when pressing full-sized balls.
If you have an older model automatic press that does not have a hole near the
bottom of the cradle shaft, you should have received an anti-stress collar along with
your machine. This anti-stress collar attaches to the bottom of the cradle shaft. The
cradle then rests on this collar when printing full-sized balls to avoid excessive machine
stress. In order to change the level of the ball cradle, firmly grasp the cradle and gently
push up. Pull the cradle pin out and adjust up or down. See Appendix A.
Coating Area
Most of your sports balls have only one coated side for printing there are a couple that
have two or more sides coated, refer to the settings chart to see what sides of what
balls are coated. The baseball and softball can be coated on all sides for an extra fee.
Be sure to align and attach the transfer paper to the side of the ball with the coating.
(TIP: Use only one piece of heat tape to secure the transfer to the ball.) The side
O P E R A T I N G
G U I D E
that is coated will appear slightly smoother and have a dull finish. Set the cradle to the
appropriate level from the top then set your time, temperature and pressure to the
appropriate settings. If your sports balls are stored in a dusty environment, be sure to
wipe away any dust or debris from the surface before printing. (See Settings Chart.)
Inflating Sports Balls
Before attempting to print any sports balls, insure that they
have been inflated to the proper pressure. (See Settings
Chart.) After you have printed on the ball, be sure to
deflate the ball to 10 psi. For ornaments, pet balls, and golf
balls release all air or the ball will keep expanding and
distort the ball.
Sports Ball Position
Center the transfer on the correct panel and using one
thumbnail size piece of tape, tape down the image. Be sure
not to cover any of the image with the tape. If any is
covered with tape that area will not transfer to the ball.
Then slide the cradle under the print head. Be sure that the
ball and transfer are as close to the center of the press head
as possible. Push the two green buttons on the control box
at the same time to activate the press. The timer will start once you have pressed the
two green buttons and the print head will automatically rise when the time is expired.
When the print head returns to its original position, remove the ball from the cradle
and peel the transfer paper from the ball. Put the ball back in the cradle with the image
side up towards the print head and cycle the machine one more time for about 2 - 5
seconds. After pressing the Activation Buttons, count to two or so and then push and
twist the red Safety Button. The Print Head will rise to its original position. This step
“Locks in” or “Sets” the transfer into the ball and gives the image a glossy look.
Suggested ball positioning is shown below.
Figure 1. Baseball
Figure 3. Softball
Figure 4. Mini
Football
Figure 5. Full &
Mini Soccer Ball
Figure 6. Full &
Mini Basketball
(TIP: To make the image on the ball even more durable we
suggest waiting until the ball returns to room temperature
before pressing the ball the second time. This will allow you
to “Lock in” or “Set” the transfer for 5-8 seconds instead of 2
seconds.)
Figure 7. Full & Mid
Football Positions
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O P E R A T I N G
G U I D E
Remember to turn the press back on by twisting the Safety button to the right. Repeat
these steps for as many balls as you are printing.
Hockey Puck Setup
Attaching Flat Print Head
To print hockey pucks, you will need to change the print head by removing the
curved surface head and replacing it with the flat surfaced head.
Changing Press Heads
Follow the instructions below for changing press heads.
1. Turn off the ball press and let the press head cool down.
2. Using the small Allen wrench, remove the thermocouple wire from the
back of the press head being careful not to lose the small machine bolt.
3. Using the larger Allen wrench, remove the machine bolt and washer that
holds the press head in place.
4. Slide the press head off of the slotted carrier being careful not to pull the
heating element with the head.
5. Slide the next press head onto the slotted carrier while inserting the
heating element into back of the press head.
6. Slide the new press head all the way to the back of the carrier.
7. Attach the thermocouple wire back onto the press head.
8. Put the machine bolt and washer into the front of the carrier.
9. Move the ball cradle back to align exactly under the press head.
10. Find the 5" x 5" x ¼" aluminum plate.
11. Set plate on top of the ball cradle from hockey pucks and home plates.
WARNNG! The hockey head gets extremely hot and will cause injury if
touched. Make sure to let the hockey head cool down before attempting to
remove it from the press.
Printing Hockey Puck and Home Plate
Be sure to set the temperature dial to 350o. The temperature laser gun is not
necessary in this scenario, it will not read the temperature accurately as there is a layer
of rubber on the hockey puck head that blocks us from reading the temperature. We
are actually just trying to get the head around 300o for it to transfer properly. It has
been tested here that if you wait 25 – 30 minutes the press will heat-up to the
needed temperature. Once the temperature is reached, center hockey puck in the
cradle so that the print head will distribute the heat and pressure evenly over the
transfer. After you have centered the hockey puck and slide the cradle under the
print head, press the two green buttons on the control box at the same time to
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O P E R A T I N G
G U I D E
activate the press. The timer will start once you have pressed the two green
buttons and the print head will automatically rise when the time is expired.
When the print head returns to its original position leave the transfer on the hockey
puck and turn the hockey puck 90o in the cradle as shown in Figure 8 & 9. Press the
two green buttons again. Do this procedure three more times so that you press the
hockey puck a total of 4 times. Wait for the print head to rise, let the hockey puck
cool to luck warm, then peel the transfer paper from the puck. Repeat these steps for
as many hockey pucks as you are printing. Do not press hockey puck or home plate
after transfer is pulled off this step is not necessary on these two items.
Figure 8. - Hockey
Puck position #1
Figure 9. - Hockey
Puck position #2
Printing a Christmas Ornament
Turn on the press; adjust the temperature, and the time to the following:
Temp 200 Degrees using the laser gun. Time to 25 Seconds, cylinder air pressure set to
75 psi, Ornament Pressure to 25 psi.
Ornament Cradle Position
To position the cradle for pressing Christmas Ornaments first carefully remove the
cradle pin and position the cradle housing in the top hole position, the same height as
the baseball. Once everything is measured and in place, you’re ready to start printing.
Ornament Coating Area
There is only one side on the Ornament that the image will
print on. It is located on the opposite side of the valve opening.
Place or tape (taping is optional) the transfer paper to this side
of the ball that has the coating. Be sure to place the ornament
with the valve pointing down and the hanger pointing forward
as shown above. Be sure that the hanger is level, if the hanger is pointing too high or
too low the platen could be damaged and could pop off the hanger. Picture above
shows what the ornament will look like when pressed.
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O P E R A T I N G
G U I D E
3
Chapter
Troubleshooting
How To Correct Common Problems.
PROBLEM:
I’ve plugged the Ball Press into an outlet and the Print Head is not warming up.
SOLUTION:
•
The Heating Element is not plugged into the Short Power Cord
•
The red Safety Knob (on/off) needs to be twisted to the right to turn on the
Ball Press.
•
The Temperature Dial is turned all the way down to “0”.
•
Heating Element is burned out (very rare).
•
Fuse is burned out.
PROBLEM:
Everything is plugged in and the Print Head will not go up or down.
SOLUTION:
•
The air pressure hose is not connected.
•
Both Activation Buttons have not been pushed simultaneously.
•
Twist red Safety Button to the right.
PROBLEM:
I cannot get the ball in the cradle because the Print Head is all the way down.
SOLUTION:
•
There is no air pressure to the Ball Press. Check, Air Compressor, air lines,
and connections.
PROBLEM:
The whole image is not transferring onto the ball.
SOLUTION:
•
Not enough air pressure.
•
•
•
•
The Cradle Base is positioned too low for the ball being printed. Remove
Cradle Pin and slide the Cradle Base up one Adjustment Hole and reinsert
the Cradle Pin.
The Ball is not positioned correctly in the Cradle and the Print Head is not
making contact with the whole surface of the ball.
The temperature may be set too low.
Try increasing the print time in two-second intervals until desired results.
PROBLEM:
Parts of the image are not transferring onto the ball.
SOLUTION:
•
Not enough air pressure
•
Not enough heat
•
The surface of the ball may be cool which would require that you:
•
Preheat the ball for a few seconds.
•
Increase the time by a few seconds.
PROBLEM:
The image seems to be bubbling off the Ball. The surface of the Ball appears to be
melted.
SOLUTION:
•
The temperature is set too high
•
The Timer is set too long.
•
The surface temperature of the Ball may be high in the summer or from
setting in the sun. Reduce the Temperature setting and/or reduce the
printing time.
PROBLEM:
The top of the image on the Baseball is not transferring correctly.
SOLUTION:
•
The top of the image is too close to the Strings of the Baseball.
•
The baseball is not properly sitting on the Cradle. Rotate the Baseball to the
right.
•
Not enough Air Pressure.
PROBLEM:
Everything worked once but now nothing is working.
SOLUTION:
•
The red Safety Button may have been pushed in, shutting off the Press.
Twist the red Button to the right and wait for the temperature to rise to the
proper setting.
PROBLEM:
8
I’ve made a mistake. The image is upside down or the image did not transfer
correctly.
SOLUTION:
•
Get Acetone from the Plunger Can provided by pushing down on the top of
the plunger surface with a cotton pad. Clean off the image using as little
Acetone as possible and within 24 hours. Let dry another 24 hours before
attempting transfer.
•
If too much Acetone is used, the surface treatment may be damaged. Save
up the damaged balls and return them to us for re-treatment.
PROBLEM:
The image is not coming off onto the Ball.
SOLUTION:
•
You have plain paper in the Printer.
•
You have the wrong type Transfer Paper in the Printer.
•
The heat is not turned on.
PROBLEM:
The image is backwards on the Ball.
SOLUTION:
•
This is a software issue. If you are using a Postscript driver, you need to
“Flip the page Horizontally.”
•
If you are printing from Adobe PhotoShop, or any picture program, you
may need to “Mirror” each image before printing.
PROBLEM:
Inflatable balls such as soccer, basketball and football, don’t seem to print as easy as
baseballs
SOLUTION:
•
The key to printing inflatable balls is the air pressure both inside the ball and
in the Air Cylinder. Refer to Time/Temp charts for correct settings.
PROBLEM:
Heat dial is set to one setting but the laser guns reads a different temperature.
SOLUTION:
•
Set the temperature to the correct setting using the laser gun, It is more
accurate.
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A
Appendix
Appendix A
Automatic Press Diagram.
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