PDF User Manual

MAXI PRESS AIR

OWNERS MANUAL

REV. 10-2010

BASIC INSTRUCTIONS

Geo. Knight offers a variety of machine options under the MAXI PRESS AIR line. There

are two standard sizes of 30” x 40” and 40” x 64” heat platens, both of which can be ordered as
twin stations and with top and bottom heat. The general operation and features of the MAXI
PRESS AIRes are basically the same regardless of the options included. These options can not be
added after the machine has been built. Please use the following information as a guide only. If
there are any detailed questions or issues with the press, please call the factory at 800-525-6766.

UNPACKING

Your MAXI PRESS AIR was shipped in a fully enclosed crate. Great care must be used

when uncrating the machine and removing all of the packaging material. The MAXI PRESS AIR
is lagged to the bottom of the crate. Depending on the model, the sidewalls of the wooden crate
may need to be dismantled in order to remove the air maxi from its crate.

It is recommended that a forklift be used to remove the AIR MAXI  PRESS from the

crate. 

CARE MUST BE USED TO POSITION THE FORKS IN AN AREA THAT WILL

NOT DAMAGE ANY OF THE LOWER AIR COMPONENTS OR AIR TUBING.
NEVER LIFT THE PRESS BY LIFTING UP UNDER THE TOP HEATER BLOCK.

 Only

lift up against the lower steel tubing structure.

Locate the MAXI PRESS AIR in an area that will allow for access around the entire

machine. On most machines the Main Power Disconnect is located in the rear of the press. Make
sure there is room to allow the operator to be able to reach the main disconnect on the machine.

IT IS RECOMMENDED THAT A TWIN STATION MAXI PRESS AIR BE
LAGGED/BOTLED TO THE FLOOR AFTER LEVELING THE MACHINE.

ELECTRICAL AND AIR SUPPLY REQUIREMENTS

ELECTRICAL:

30x40 (208-240 VAC) 1 phase 41 amps.
30x40  (208-240 VAC) 1 phase 81 amps (with bottom heat option)
40x64 (208-240 VAC) 1 phase 81 amps.
40x64 (208-240 VAC) 3 phase 95 amps (with bottom heat option)

AIR:

Regardless of the machine size, all of the MAXI PRESS AIR machines require
a 1/2” NPT AIR LINE with a maximum  supply pressure of 100psi.

BASIC MACHINE OPERATION

Regardless of what size or options the MAXI PRESS AIR has, the basic operation is the

same. Before turning the machine on, make sure all of the packaging materials have been
removed and that there are no protection packaging material between the heater block and the
lower table. A white soft nomex pad should be included and laid on the loading table before
operating the press.

TURNING ON THE MACHINE: 

Your MAXI PRESS AIR was shipped with a fused MAIN

disconnect mounted on the rear of the press. Switch this MAIN fused disconnect to the ON
position. Next, locate the on/off switch on the control console and switch to the ON position.

LCD TIME AND TEMPERATURE CONTROL:

 Please refer to the KNIGHT DIGITAL

CONTROLLER MANUAL for proper operation of the digital controller.

SETTING THE AIR PRESSURE:

 Set the pressure by pulling up on the regulator knob and

turning to the desired pressure. For most applications, (60-80) psi works best. You can lock in
the knob by simply pushing the knob into the locked position. It is recommended that while
adjusting the pressure, let set the gauge beyond the pressure desired pressure and then turn it
back to the desired pressure. PRESSURE MUST NOT EXCEED 100 PSI.

EMERGENCY RELEASE BUTTON: 

This red mushroom push-pull switch is used to release

the press in case of an emergency. Simply press the button in to release the press. You must pull
on the switch to reset it for operation. 

DO NOT USE THIS SWITCH ON A REGULAR

BASIS DURING NORMAL OPERATION.

CONTROL ON/OFF SWITCH

FRONT PANEL

REGULATOR

 AND

GAUGE

EMERGENCY
RELEASE

DIGITAL TIME &
TEMPERATURE
CONTROL

RIGHT SIDE
ACTIVATE PUSH
BUTTON

ACTIVATE THE PRESS: 

Regardless of the size or options of the MAXI PRESS AIR, all of

the MAXI PRESS AIRES require the following to take place in order for the machine to
activate.

•

Press BOTH the left & right activate buttons on the sides of the control console

•

The loading table index lever switch (a micro switch at the rear of the loading table mounted
on the machine frame) must be pressed in the closed position by the loading table. (see pic)

The most common reason for why the machine will not activate when the two black activate

buttons are pressed is either the Emergency Release button has been pressed or the lower table
index switch is not activated or closed.

Loading table
index lever switch
found on all single
station front
loading machines

Loading table
index lever switch
found on rigid
table twin left-to-
right shuttle
machines

REPLACEMENT PARTS

ELECTRICAL COMPONENTS:
(2) 

ELN-MX1540  (MICA HEATERS- 30” X 40” PRESSES)

(4)

ELN-MX1540  (MICA HEATERS- 40” X 64” PRESSES)

(1)

DKA-CTRLC  (PROCESSOR BOARD)

(1)

DKA-CTRLP  (POWER BOARD-220V)

(1)

ELN-BAYKTC10  (BAYONET THERMOCOUPLE SENSOR)

(1)

ELN-HVYLVR  (TABLE INDEX LEVER SWITCH)

(1) 

ELN-2CT01  (HEATER CONTACTOR-SINGLE PHASE MACHINES)

(1) 

ELN-4A064  (DPDT OCTAL TIMER RELAY)

(2) 

ELN-6HK58  (BLACK ACTIVATE PUSH BUTTON SWITCHES)

(1) 

ELN-6HK81  (RED EMERGENCY RELEASE PUSH BUTTON SWITCH)

AIR COMPONENTS:
(1) 

ARN-R184FO  (FRONT PANEL REGULATOR)

(1)

ARN-55B240   (AIR MAC VALVE)

(1) 

ARN-1B14365  (AIRBAG-30” X 40” PRESSES)

(2) 

ARN-1B14365  (AIRBAG-40” X 64” PRESSES)

(1) 

ARN-NAQ3KN03 (QUICK EXHAUST VALVE-30” X 40” PRESSES)

(2) 

ARN-NAQ3KN03  (QUICK EXHAUST VALVE-40” X 64” PRESSES)

(1) 

ARN-4ZJ86 (ADJUSTABLE EXH.FLOW CONTROL-30” X 40” PRESSES)

(2) 

ARN-4ZJ86 (ADJUSTABLE EXH.FLOW CONTROL-40” X 64” PRESSES)

MECHANICAL COMPONENTS:
SINGLE STATION TOP HEAT ONLY PRESSES
(2)

MEN-C930136D  (36” LOWER SIDE TABLE SLIDE-30” X 40” PRESSES)

(3) 

MEN-C930142D  (42” LOWER SIDE TABLE SLIDE-40” X 64” PRESSES)

RIGID TWIN STATION PRESSES
(6)

MEN-9546K18  (ADJUSTABLE STOP BUMPERS)

(8) 

MEN-NEO2WHL (NEOPRENE ROLLER WHEEL)

TOP & BOTTOM HEATED TWIN STATION PRESSES
(#)

MEN-T575S (STAINLESS STEEL TEFLON BLANKET SPRINGS)

(#)

MEN-¼20SPRACN  (SPRING ANCHOR STUD)

PRESS PADDING MATERIAL:
TOP HEAT ONLY PRESSES
(1) 

RMN-½NOM54YD  (1/2”NOMEX PAD -30” X 40” PRESSES)

(2) 

RMN-½NOM54YD  (1/2”NOMEX PAD -40” X 64” PRESSES)

TOP AND BOTTOM HEATED PRESSES
(1)

HCR-183040  (1/8” GREEN HCR RUBBER - 30” X 40” PRESSES)

(1)

HCR-184064  (1/8” GREEN HCR RUBBER - 40” X 64” PRESSES)

TWIN STATION TEFLON BLANKETS
(1) 

MAX-4064TFTS  (STITCHED BLACK TEF. BLANKET- 40” X 64” PRESSES)

ASSEMBLY OF THE MAXI PRESS AIR

TWIN RIGID STATION SHUTTLE

The Twin Rigid Station Shuttle is designed to allow the operator to unload and reload one

table while another table is being pressed. The two tables are independent allowing indexing
only when needed. Indexing is performed by simply manually moving the station in the desired
direction. The assembly is basically made up of (5) major parts. They are:

•

MID RAIL SECTION

•

LEFT RAIL SECTION

•

RIGHT RAIL SECTION

•

LEFT LOADING TABLE

•

RIGHT LOADING TABLE

FULLY ASSEMBLED RIGHT SIDE SHUTTLE SECTION

UNPACKING:

 Your machine was shipped in two main crates. One crate has the main MAXI

PRESS AIR with one of the loading tables mounted under the heater block. The 2

nd

 crate

contains the other loading table with both the left and right rail sections. Completely unpack and
remove all components. !CAUTION! When removing 4” X 4” wood timbers use a clamp or
other person to prevent accidental movement and damage to the rolling loading table. Especially
when assembling the left & right rails or moving the machine, use caution that the first loading
table on the machine can not roll off the press.

RIGHT SIDE

LOAD VEHICLE

RIGHT SIDE

STOP END

TUBE

RIGHT SIDE

RAIL

SECTION

RIGHT SIDE

FRONT HANDLE

ASSEMBLY INSTRUCTIONS

The first step is to attach the Left and Right rail sections to the Mid rail section already

attached to the main press frame. Each side is attached to the Mid rail section by union plates.
Carefully position the left or right rail section to the union plate (already attached) on the Mid
rail section. Adjust the feet on the rail section so the aluminum bars mounted to the inside of the
Mid rail section and the left or right rail section are level.

Attach the lower cross channels on each section and tighten. Make sure that the

adjustable leg locking nut is tightened to prevent movement of the foot. Before tightening all
hardware, make sure of the following:

•

All aluminum bars are level & straight with each other.

•

The center distance between the front and rear aluminum bars are the same on the left, right
& mid rail sections.

•

Lower cross channels are attached.

•

Adjustable feet are locked by tightening the nut on the threaded stud up against the black leg.

Note: All of the hardware needed was shipped either in the hole used for or in a separate

package.

RIGHT RAIL SECTION ATTACHED TO MID RAIL SECTION

UNION
PLATE

MID RAIL
SECTION

RIGHT
RAIL
SECTION

Once the Left and Right rail sections have been attached, the next step is to attach the

LEFT AND RIGHT stop end tubes. These 1” x 3” black aluminum tubes attach to the very end
of each side rail section. The hardware needed should already be screwed into the tapped holes
for attachment.

LEFT SIDE RAIL SECTION SHOWING THE END TUBE AND CROSS CHANNELS

With both the Left and Right rail sections attached and level, position the loading table

that was shipped separately from the press. This is done by rolling the loading table into the rail
section from the proper end. This is determined by the loading table that was already on the press
when shipped.

•

Remove the end stop tube from the side that the loading table must be rolled in from.

•

Lift the loading table using a fork lift to the height needed to feed and roll the loading table
onto the rail assembly.

•

Carefully roll the loading table onto the aluminum rails. Lift the opposite side it is entering
from to prevent the handle brackets from making contact with the rail.

•

Once the entire loading table is in place, re-attach the end stop tubes.

•

Proceed with attaching the handle to the front of the loading table using hardware supplied.

With both loading tables on the rail sections and the end stop tubes in place, roll each

table carefully back and forth to test the motion. If it is difficult to manually move the loading
table, adjust the lower neoprene roller bracket on the loading tables to reduce the amount of
friction against the rails.

In order for the MAXI PRESS to activate, there is a safety lever switch that must be

depressed with the loading table under the heater block. In the event that the machine does not
activate properly, inspect this lever switch and hardware to adjust for proper operation.

LEFT SIDE
STOP END
TUBE

LOWER LEG
CROSS CHANNELS

ASSEMBLY OF THE MAXI PRESS AIR

TWIN STATION TEFLON SHUTTLE

The Teflon Shuttle System for certain Maxi Press Air models is made up of 4 major assemblies:

•

BASE ROLLER FRAME ASSEMBLY:

 This is an aluminum rectangle frame assembly

that is attached to the base of the Maxi-Press Air. The assembly has multiple cam rollers and
is the foundation of the shuttle system. It is made of Front, Rear, Left & Right tubes. The
Front and Rear tubes attach to the maxi press by (6) threaded studs attached to holes in the
tubes welded to the lower stand of the Maxi Press Air. The Front and Rear tubes are shipped
in place on the machine stand.

FRONT BASE
TUBE ON ROLLER
FRAME ASSEMBLY

MOUNTING STUDS
ATTACH TO
LOWER 2” 4”
STEEL TUBING

FRONT LEFT SIDE
OF ROLLER 1” X 3”
TUBE

LOWER LEFT SIDE 1” X 3” TUBE FOR ROLLER
FRAME ASSEMBLY

NOTE: THE LEFT AND RIGHT SIDE 1” X 3” TUBES
FOR THE ROLLER FRAME ASSEMBLY IS ATTACHED
ON THE BOTTOM SIDE OF THE FRONT AND REAR
ROLLER TUBES

•

MAIN TEFLON SHUTTLE FRAME:

 This is the large aluminum rectangle frame that

shuttles back and forth on the Base Roller Frame Assembly. The Teflon blanket is attached to
this moving shuttle frame. The assembly is made up of 2 long Front & Rear Aluminum
Angles and 2 shorter Right & Left End Tubes. The long Front and Rear angles have 1” x 1”
aluminum bars attached. It is these aluminum rail bars that will roll between the cam rollers
on the Roller Frame assembly (see picture below). First roll the long front and rear angles
into the front and rear Roller Frame, then attach the left and right end tubes. 

NOTE: The left

and right end tubes that are attached to the front and rear angles are attached to the
TOP SIDE of the angles.

  Once this assembly is attached properly, this Teflon Shuttle

Frame will roll freely left and right on the lower Base Roller Frame Assembly.

.

The bolts attaching the Left & Right end tubes lower roller frame may need to be

loosened & then tightened while spreading the angles to insure a smooth & tight rolling fit of the
Main Teflon Shuttle Frame on the Base Roller Frame Assembly.

2” X 4” STEEL
STAND FRAME
TUBING

SHUTTLE FRAME
LONG ALUMINUM
ANGLE

1” X 1” ALUMINUM
ROLLER BAR

BASE ROLLER FRAME
ASSEMBLY-LEFT SIDE

TEFLON BLANKET SUPPORT OUT-RIGGER TABLES:

 The Teflon blanket support out-

riggers are welded assemblies that are attached to the left side and the right side of the Maxi
Press Air. These assemblies support the Teflon blanket and materials being loaded & unloaded
on it when it is shuttled to the left or right. It is made of (2) components, the welded structure
with adjustable legs and the top aluminum tray. The out-riggers are attached to the left side of the
lower roller frame assembly. Three screws are used to screw up from under the “left” side tube
too the 3 tapped standoffs welded to the end of the out-rigger. On ce attached, adjust the feet so
the assembly is level.

LEFT SIDE OUT-
RIGGER SUPPORT
TABLE WELDED

ATTACHMENT
POINTS TO LEFT
SIDE LOWER
ROLLER FRAME

ADJUSTABLE FEET
TO LEVEL ASSEMBLY

ALUMINUM  SHEETS ATTACHED
TO THE OUT-RIGGERS ONCE
ATTACHED. SCREWS FASTEN
THE ALUMINUM SHEET TO EACH
OUT-RIGGER VIA ALUMINUM
ANGLES WELDED TO THE TIN
AND SCREWS THAT SCREW
INTO THE 1” X 1” STEEL

TEFLON SHUTTLE BLANKET: 

The stitched Teflon stitched that will support and carry

materials in and out of the press is attached to the shuttle frame using springs. The springs pinch
through the Teflon, wrapping around brass rods that are slid inside the stitched seams along the
short and long sides of the Teflon blanket. The other side of the spring will hook into threaded
studs with eyelets on the Main Teflon Shuttle Frame. Follow these 4 steps to attach the Teflon
blanket to the Teflon shuttle frame:

1.

Attach 1 spring to all the spring studs around the shuttle frame. (The machine may have
been shipped with the springs already attached)

2.

Position the Teflon blanket within the shuttle frame resting on the aluminum support
trays so the Teflon blanket is centered within the Teflon Shuttle Frame.

3.

Slide in the long and short brass rods into the stitched seams of the Teflon blanket.

4.

From the center out, hook the Teflon springs to the brass rods hidden in the Teflon
pockets, then hook them to the eyelets on the studs of the Teflon Shuttle Frame. Start
along the rear long edge of the machine first attaching all springs to corresponding
eyelets & threaded studs. Pull forward on the Teflon blanket when attaching springs to
the front edge of the frame. Again - rememb er to start from the center and work out
towards the ends. Once the rear and front sides are attached, then attach the shorter left
and right side of the Teflon blanket.

Once the Teflon blanket is attached, it should be supported evenly & flat without waves

or wrinkles tightly around the entire Main Teflon Shuttle Frame Assembly.

TEFLON SPRING

SPRING STUD

TEFLON SHUTTLE BLANKET
LAID INTO POSITION

With the Teflon blanket now secured, shuttle the assembly to the left and right. Make

sure that the Teflon slides smoothly without risk of abrasion against edges or surfaces. In most
cases the bottom heater block will have a layer of 1/8” green heat conductive rubber laying on
top of the heater block surface. The Teflon blanket needs to be above this green heat conductive
rubber/semi porous Teflon by approximately ¼”.

 The Teflon shuttle frame is equipped with Stop Blocks. These stop blocks will insure

that the shuttle is fully shifted to the left and to the right for proper operation. They are located
on the rear long aluminum angle. When properly adjusted, the heat platen will not make contact
with the left or right side tubes of the shuttle assembly when the machine is activated. The
machine is designed to allow activation of the machine anywhere with in the Teflon blanket for
long multiple pressing applications. Make sure the Main Teflon Shuttle Frame can not be pressed
by the heat platen.

It is recommended that a cover sheet of tissue or craft paper be used above and below the

work piece when pressing. This added protection will prevent excessive water vapor or inks from
collecting on the stitched Teflon shuttle blanket

It is normal to have the bottom heat adjusted higher than the top heat to compensate for

temperature loss through the green heat conductive rubber and Teflon blanket. Under normal
applications, the bottom heat should be set (20-30 deg F) higher than the top heat.

Geo Knight & Co Inc

52 Perkins St

Brockton MA 02302

800-525-6766 / 508-588-0186 / fax 508-587-5108

www.heatpress.com