Portafix Universal

Operation
Manual

rev 2.3, July 2004

 Portafix Universal Manual • TOC

Contents

Declaration of conformity 1

1 General 2

1.1 Safety Instructions 2

1.2 Description 3

1.3 Intent of use 3

1.4 Environment 3

1.5 Operator 4

2 Recommended process settings 5

3 Operation 6

3.1 General 6

3.2 Process settings: Temperature 7

3.3 Process settings: Dwell time 7

3.4 Process settings: Fixation medium 8

3.5 Process settings: Textile input and output 8

3.5.1 Continuous mode 8

3.5.2 Sample steaming 9

3.5.3 Sensors 10

3.6 Transport 11

3.6.1 Dwell time 11

3.6.2 Forward transport 11

3.6.3 Reverse transport 12

3.6.4 Fast forward transport 12

3.6.5 Fast reverse transport 12

3.6.6 Cloth Tension 12

3.7 Normal Temperature (NT) 13

3.7.1 Start-up 13

3.7.2 Fixation 14

3.7.3 Shutdown 15

3.8 High Temperature (HT) 15

3.8.1 Start-up 16

3.8.2 Fixation 17

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 Portafix Universal Manual • TOC

3.8.3 Shutdown 18

3.9 Hot-Air fixation (AF) 18

3.9.1 Start-up 18

3.9.2 Fixation 19

3.9.3 Shutdown 20

3.10 Autostart/stand-by (optional) 20

3.10.1 Autostart (optional) 20

3.10.2 Countdown timer (optional) 21

3.10.3 Stand-by (optional) 22

4 Maintenance 23

4.1 Decalcifying steam generator 23

4.1.1 Regular check 23

4.1.2 Decalcifying procedure 24

4.2 Decalcifying the spray water nozzle 24

4.2.1 Decalcifying procedure 25

5 Troubleshooting 26

5.1 No power 26

5.2 No transport 26

5.3 No circulation 26

5.4 No steam 27

5.5 No heating 27

5.6 No smooth transport 28

5.6.1 Opening the steam chamber 28

5.6.2 Closing the steam chamber 29

6 Warranty 30

Appendix A: Technical Specifications

Appendix B: Installation and Commissioning

Appendix C: Boilingpoint versus Pressure

Appendix D: Wiring diagram

Appendix E: Spare parts

© 2005 SETeMa B.V.

 Portafix Universal Manual • Page 1

Declaration of conformity

Manufacturer: SETeMa BV
Address: Kerkstraat 32
5843 AP Westerbeek
The Netherlands
Telephone: +31 485-385764
Telefax: +31 485-385751
Web: www.setema.com
e-mail: info@setema.com

Product designation: Portafix Universal steam ager

Type designation: PU3, PU6 and PU9

SETeMa BV hereby confirms that the designated product is in

conformity with the essential health and safety requirements and
technical construction file requirements of the Machinery Directive
98/37/EC relating to machinery.

Westerbeek, June 1st 2004

N.F.J. Elemans
Managing director

© 2005 SETeMa B.V.

 Portafix Universal Manual • Page 2

1 General
This instruction manual will help you to learn the safe and
comfortable operation of the Portafix Universal.

Please read these operating instructions before putting the machine

into operation and observe the safety regulations.

Correct assembly and careful operation and maintenance are

essential in ensuring safe and reliable operation of the Portafix
Universal.

1.1 Safety Instructions

This manual uses the following signals to mark safety precautions for
the use of the Portafix Universal. Be sure to follow the instructions
provided in all safety precautions.

WARNING indicates a potentially hazardous

situation which, if not avoided, could result
in death or serious injury.

CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in
minor or moderate injury. Non-compliance with
the instructions may cause damage to the
machine.

The operating instructions must always be available to the operator

and other personnel involved with the Repair and Maintenance.

Make sure the Portafix Universal is only used for its intended purpose
as described in the operating instructions!

Only personnel that has received appropriate training should operate

this device or work in its immediate vicinity. The personnel must be
fully familiar with all of the warnings and maintenance measures in
these operating instructions.

Turn off main switch and secure against tampering, before starting
with Repair or Maintenance work.

After using the steamer, observe a cool down period of at least two
hours, before opening the steamer for any Repair or Maintenance to

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the steamer inside.

All work done on electrical parts of the Portafix Universal is to be

carried out by trained, qualified electricians or service technicians.

1.2 Description
The Portafix Universal (PU) is a steam/air fixation unit with
integrated steam generator. It is designed for fixation of dyes and
pigments into a variety of textile fabrics. These dyestuffs can be
applied by either conventional printing processes, for instance screen
printing, or by digital printing methods, such as Ink-jet.
The PU can be used for the fixation of small samples up to
continuous, roll-to-roll fixation. Due to the use of clamping frames no
lead-in or lead-out is necessary.
All rollers are driven by the transport belts ensuring a stress-free
fabric transport.
The fixation temperature can be adjusted continuously between 100
and 180 °C and the dwell-time can be set from 2 to 30 minutes. With
this combination of temperatures and dwell-times all dye-fabric
combinations can be fixed.
The content of the fixation chamber is recirculated by a fan. The
temperature in the chamber is controlled by an electronic PID
controller coupled to heating and cooling elements.
All necessary modules for operation are integrated in the machine. It
is suitable for use in office environments.

1.3 Intent of use

The Portafix Universal is designed for the fixation of dyes and
pigments into textile fabrics. The intended purpose of the device is
restricted to this application.

1.4 Environment
The Portafix Universal is intended to be used indoors. The steamer
should be placed on a flat surface during operation. The Portafix
Universal should be used only in environments that are clean and
certainly not too dusty.
The environment should be adequately lighted, complying with
normal office and workshop lightning requirements.

The Portafix Universal requires a power connection of at least 3

phase 25A at 230/380 VAC for its operation.
The steamer has to be connected to a fresh water supply within a
pressure range of 0.5 to 6 bar (7-94 psi). To minimize the problems
due to mineral deposition on heating elements, one should use soft
water for the steamer; a water softener is supplied as an option.
The waste water gathered in the bottom part of the Portafix
Universal has to be removed via a waste water outlet. The water can
be drained naturally, but if this is not feasible, one should employ a
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 Portafix Universal Manual • Page 4

water pump; a waste water pump is supplied as an option.

The steamer requires a gas exhaust system to remove the used
steam/air. This exhaust system is part of the standard package. The
connection between the Portafix Universal and the outside has to be
installed by the customer.
The gas exhaust is not necessary if one uses the optional condenser.
The condenser configuration does, however, lead to large amounts of
clean lukewarm waste water that one has to remove.
Optionally a flange and control valve, for use of an external steam
net, can be supplied. The electrical heating of the steam generator is
redundant in this case reducing the electrical requirement by 17 A
per phase.

1.5 Operator
Only personnel that has received appropriate training should operate
the Portafix Universal. The operator should at least be fully familiar
with all the warnings and all maintenance measures in these
operating instructions.

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2 Recommended process settings

The most common fixation process settings for combinations of

substrate and dyestuff-group.

Reactive Disperse Acid Pigment

steam steam steam air
101 °C 150-160 °C
Cotton
8-10 min. 4-8 min.

101 °C 150-160 °C
Rayon
8-10 min. 4-8 min.

101 °C 150-160 °C
Linnen
8-10 min. 4-8 min.

101 °C 101 °C
Wool
10-15 min. up to 30 min.

101 °C 101 °C
Silk
10-15 min. up to 30 min.

160-180 °C 150-160 °C
Polyester
4-8 min. 4-8 min.

101 °C 101 °C 150-160 °C

Polyamid (Nylon)
up to 30 min. 15-30 min. 4-8 min.

101 °C
Tri-Acetate
up to 30 min.

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3 Operation
3.1 General
The user-definable settings are the fixation temperature and
duration, and furthermore the type of fixation, that is fixation with
steam or with hot-air.

The text in the following chapters

refers to the operation switch
board buttons as shown in
adjacent figure (also see fold-out
leaflet at the end of the manual)

legend for switchboard

 main power ON/OFF switch

 control power ON/OFF key-switch
 control power ON/OFF blue indicator light
 circulation OFF push-button
 circulation ON push-button
 heater OFF push-button
 heater ON push-button
 steam generator OFF push-button
 steam generator ON push-button
 transport OFF push-button
 transport ON push-button
 emergency stop lock-button
 temperature control unit
upper display present value (PV)
lower display set value (SV)
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 temperature UP push-button
 temperature DOWN push-button
 switchboard door latches
 transport reverse push-button
 transport fast push-button
 sensor selection knob with three positions
left position: no sensors active
middle position: end-of-roll and clamping frame detection
right position: clamping frame detection only
 dwell time selection knob with dwell time scale in minutes
 frequency drive fault indicator light
 fault audible sound
 steam generator fault indicator light

 start count down button (optional)

 count down selection unit (optional)
 stand-by button/indicator (optional)
 autostart button/indicator (optional)

The operation of the Portafix Universal requires that the electrical

and water supplies are present and switched on.

3.2 Process settings: Temperature

The temperature for the fixation process can be set with the
selection buttons on the temperature control unit . Press the
temperature up  and temperature down  buttons to either
increase or decrease the process temperature setting. The user
selected process temperature is displayed on the temperature
control unit in the lower display SV. The actual temperature inside
the steamer is also shown on the temperature control unit in the
upper display PV.

Changing the temperature setting

Before proceeding with the fixation for a new process temperature
one has to wait until the actual temperature PV has reached the
value of the selected process temperature SV.
The fixation temperature for normal steam fixation lies between
100 °C and 110 °C, for high temperature fixation it falls in the range
160 °C - 180 °C and the hot-air fixation is done with temperatures in
the 150 °C - 170 °C range.

3.3 Process settings: Dwell time

The duration of the fixation process is defined with the dwell time
selection knob . Turning the knob clockwise increases the dwell
time and turning this knob counter clock wise results in a dwell time
decrease. The scale gives the dwell time in minutes.
The dwell time can be set continuously in the range from 2 to 30
minutes.

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3.4 Process settings: Fixation medium

Fixation can be done with hot-air for the curing of pigment binder
systems; for all other dyestuff classes, steam is the preferred
medium. The steam generator is switched on with  and off with .

3.5 Process settings: Textile input and output

The Portafix Universal can be used in a continuous mode, for the
fixation of fabrics with lengths above a couple of meters, and in a
discrete mode, for the steaming of pieces of cloth with lengths from
about 10 centimeters to a few meters. The standard Portafix
Universal comes equipped with 2 clamping frames. These are used to
guide the beginning and the end of the textile through the steamer.
The clamping frames can be used in combination with the "clamping
frame" and "end-of-roll" detection sensors.

3.5.1 Continuous mode

The roll-to-roll method is the easiest way to feed large lengths of
textile through the Portafix Universal. In this mode the textile is
rolled onto a cardboard winding core. To create some tension on the
wind-up core the outside diameter of the core should be at least 83
mm.

Input begin
The textile should preferably be fed into the steamer with the
printed side faced upwards.
The core plus textile is clamped between the feed-in
cones on the input side. Position the cardboard core
between the cone fixed to the frame and the second
cone attached to the width adjustment unit. Slightly
lift the front part of the width adjustment unit and
simultaneously move it sideways to accommodate
for the size of the core.
In positioning the width adjustment unit, one should
not apply excessive force to the spring attached to
the cone; the length of the spring, after selecting
the required width, should at least be a few
millimeters.
After the width is adjusted, release the unit so it locks itself.

The unwinding core can be used in both unwinding

directions, that is both for fabric leaving from the
top and for fabric leaving from the bottom side of
the roll.
Use a clamping frame to feed the beginning of the
roll into the steamer. Attach the clamping frame to
the drive belts with the open side of the clamp
frame facing the input cardboard. Start with
attaching hook 1 to the drive belt on both sides.

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Thereafter attach hook 2. Now that the clamping frame is attached

to the drive belt, fasten the cloth to the clamping frame by lifting at
point 3 and inserting cloth from point 4. Release point 3 and the
cloth is fixed. Repeat these steps at several places along the cloth
width.
The transport can now be started.

Input end
After the textile has completely unrolled from the input roll, use a
clamping frame to feed the last couple of meters through the
steamer. Stop the transport and attach the clamping frame to the
drive belts with the clamp open side pointing towards the steamer.
Note that the proper orientation for mounting the roll-end clamping
frame is opposite to the orientation of the frame for the roll-
beginning. After fixing the cloth to the clamping frame, the textile
transport can be resumed.

output begin
After the textile has passed through the steamer it should be rolled
onto a winding core.
Clamp an empty core between the cones on the output side. The
core has to be positioned between the cone fixed to the frame and
the second cone attached to the width adjustment unit. After the
textile front has passed through the steamer and reached the
position of the output core, stop the transport, remove the clamping
frame and attach the textile with adhesive tape to the top side of
the winding core. After attaching the textile to the empty core, the
textile transport can be resumed.

output end
After the clamping frame attached to the end-of-roll has left the
steamer, stop the textile transport, take the cloth of the clamping
frame and remove the core.

alternative input
The textile entering the steamer does not have to be supplied on a
cardboard core. Any input method is allowed, the only requirement
being that the textile is fed into the steamer in an uninterrupted
manner. The textile might for instance be inputted from a cart, as
long as some mild tension on the textile is present.
Since the textile enters the steamer from below, this means the cart
should either be low or one has to use a dedicated input device to
enable smooth and stress-free textile transportation. A feeding frame
is available as an option.

3.5.2 Sample steaming

Sample steaming is performed analogously to continuous mode
steaming. The main difference is the possibility to attach both

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clamping frames at input begin and input end prior to steaming.

Attach 2 clamping frames to the drive belts, with the clamp frames
open sides pointing towards each other. The distance between the
clamping frames should agree with the length of the sample to be
steamed.
After attaching the cloth to the clamping frames, the textile can be
transported through the steamer. To accommodate continuous
sample steaming, one can leave the clamping frames attached to the
drive belt. The drive belts can be equipped with multiple pairs of
clamping frames. No unwinding or winding cores are used in this
configuration.

3.5.3 Sensors
The end-of-roll and clamping frame detection sensors can be used to
avoid situations that might cause damage to the steamer and/or the
textile cloth.

End-of-roll sensor
The end-of-roll sensor is clamped to the beam on the textile input
side that also houses the roll width adjustment unit. To employ the
end-of-roll detection the sensor has to be moved sideways to a
position below the cloth that is moving from the input roll towards
the steamer, thus allowing the sensor to detect the
presence or absence of the cloth.
To activate the end-of-roll detection, the sensor
selection knob  has to be set to the middle
position "both end-of-roll and clamping frame
detection".
Properly placed and activated, the end-of-roll
detection sensor will not interfere with the textile
transport. Only when the sensor detects that there
is no longer any textile above the sensor, it will send
the end-of-roll signal. Upon receiving this signal the
system stops the textile transport.
After taking the appropriate actions (for example
installing a clamping frame) and after turning off the
end-of-roll detection, the textile transport can be started again. To
turn off the "end-of-roll" detection, one has to switch the sensor
selection knob  to either the right "clamping frame detection only"
position or to the left "no sensors" position.

Please note that the end-of-roll detection will not function properly
if the sensor eye is dirty, if something is blocking the sensors field of
view, or if the sensor is not placed correctly in the right position as
described above.

Clamping frame sensor

The clamping frame detection sensor is situated on the textile output

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side, close to the drive pulley just beside the transport belt. The
sensor can be used to detect the passage of a clamping frame.
To activate the clamping frame detection, the
sensor selection knob  has to be set to the middle
"both end-of-roll and clamping frame detection" or
the right position: "clamping frame detection only".
Once activated, the clamping frame detection
sensor does not hinder the textile transport and the
fixation at all. Only when the sensor detects that
something is passing through its detection zone, it
sends the clamping frame detected signal. Upon
receiving the clamping frame detected signal, the
system stops the textile transportation.
After the clamping frame has been removed from
the drive belts and the cloth has been taped to the
winding core, the textile transport can be restarted.
The clamping frame at the end of the roll again
triggers a clamping frame detection stop, after
which both the clamping frame and the full core can be removed
from the steamer.

Please note that the clamping frame detection will not function
properly if the sensor eye is dirty, if something is blocking the
sensor's field of view, or if the sensor is not placed correctly in the
right position as described above.

3.6 Transport
The speed and direction of the textile transport is controlled by the
dwell time selection knob  and the push-buttons transport off ,
transport on , transport reverse  and transport fast .

3.6.1 Dwell time

The speed of the textile transport, and thus the time the textile is
exposed to the selected fixation conditions, is set with the dwell
time selection knob .
Turning the knob clockwise increases the dwell time, while turning
this knob counter clockwise results in a dwell time decrease.
The value (in minutes) for the selected dwell time can be read off
from the dwell time scale.
The dwell time can be set continuously in the range from 2 to 30
minutes.

3.6.2 Forward transport

The textile transport is started by pressing the transport on button .
The button status LED will be illuminated and will remain so until the
transport is turned off by pressing button transport off .

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3.6.3 Reverse transport

Pressing and holding the transport reverse button  reverses the
direction of the textile transport. The reverse transport direction is
maintained until the button is released.
Button  has no effect at all, when the textile transport is turned
off, that is when button  is not illuminated.
Please note that the unwinding core will not function as a winding
core in this situation. If winding of the textile is required, one should
do so by hand.

3.6.4 Fast forward transport

Pressing and holding the transport fast button  results in maximum
speed textile transportation in the forward direction.
The fast forward state is maintained until button  is released.
Button  has no effect at all, when the textile transport is turned
off, that is when button  is not illuminated.

3.6.5 Fast reverse transport

Simultaneously pressing and holding the transport reverse button 
and the transport fast button  leads to maximum transport of the
textile in the reverse direction.
The fast reverse state is maintained until either one of the buttons 
or  is released, or both these buttons are released. Releasing one
button switches to the transport state associated with the other
button that remains pressed down. Releasing both buttons  and 
resumes the normal forward transport.
Please note that the unwinding core will not function as a winding
core in this fast reverse state. If winding of the textile is required,
one should do so by hand.
Button  or  have no effect at all, when the textile transport is
turned off, that is when button  is not illuminated.

3.6.6 Cloth Tension

When using the Portafix Universal in roll-to-roll mode, the unwinding
core is held by the unwinding cone. This cone has a friction brake
which can be adjusted with the 7(16,21 .12% at
the outside of the frame. Turning the knob clockwise
will increase the brake function. The maximum
brake function is achieved when the knob is fully
turned in.
The brake should be adjusted to a minimal value to
just prevent the spontaneous unwinding of the cloth
on the core.

The brake on the winding side is similar to the

unwinding side. Here the tension should be just
enough to achieve wind-up of the cloth leaving the
steam chamber. The brake can exhibit some slip-

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stick which has no adverse effects.

Since the diameter of the cores has an influence on the linear braking
tension, large roll diameters may require an intermediate adjustment
of the brake.

3.7 Normal Temperature (NT)

Normal Temperature (NT) fixation refers to the fixation under
saturated steam conditions and process temperatures ranging from
100 ºC to 110 ºC.

To obtain best fixation results the fixation process temperature

should be set approximately 1 degree (1 ºC) above the boiling
temperature of water for the current, local atmospheric pressure.
Since atmospheric pressure variations can influence the boiling point
by more than ±1 °C, a daily correction of fixation temperature in
0.1 °C steps yields best results.

3.7.1 Start-up
The start-up procedure for the Normal Temperature steam fixation
consists of a number of steps. The consecutive steps of the start-up
procedure has to be executed in the order as specified here.
The total time involved with the start-up (cold start) is about 30
minutes.

1. Switch ON
Turn power ON with main power ON/OFF switch  and make
sure the control power ON/OFF key-switch  is also in the ON
position.

2. Select temperature
Select the temperature for the steam fixation process by using
the temperature UP  and temperature DOWN  push-
buttons on the temperature control unit  to increase or
decrease the process temperature setting. The selected
temperature is displayed on the temperature control unit  in
the lower display SV.
The temperatures for the normal steam fixation process are in
the range of 100 °C to 110 °C. Best reproducibility is achieved
by correcting for daily barometric pressure variations.

3. Steam Generator ON
Turn on the steam generator, press steam generator ON
button . The button status LED will be illuminated and will
remain illuminated until the steam generator is turned OFF.

4. Circulation ON
Turn on the circulation ventilator by pressing the circulation
ON button . The button status LED will be illuminated and

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will remain illuminated until the circulation is turned OFF.

5. Heater ON
Turn on the heater by pressing the heater ON button . The
button status LED will be illuminated and will remain
illuminated until the heater is turned OFF.

6. Exhaust fan ON
The exhaust fan is either controlled by the mains power ON/
OFF switch  or by a separately installed ON/OFF switch,
dependent on customer specific situation. Controls for this are
not present on the switchboard.

7. Warming-up
Wait until the temperature in the steam chamber, as
displayed on temperature control unit  on the upper display
PV, has reached the set value as displayed in the lower display
SV within a few degrees.

8. Remove air
Turn off the heater with button  and after that, turn off the
circulation with button . After turning off the heater and the
circulation, wait for about 15 minutes to allow the steam to
push the air out of the steam chamber.

9. Stabilize setpoint
After the air has been removed from the steam chamber, the
circulation  and the heater  can be switched ON again. Allow
5-10 minutes to reach and stabilize to setpoint.

3.7.2 Fixation
Set dwell time
Before starting with the fixation one has to set the duration for the
steam process by using the dwell time selection knob 20. The dwell
time can be set continuously in the range from 2 to 30 minutes.

After completing the start-up procedure and selecting the

appropriate dwell time, the printed cloth can be fed through the
Portafix Universal. The way in which the cloth should enter the
machine and, after it has passed through the steam chamber, has to
be taken out at the output side, is described in section 3.5. The
application of the end-of-roll and clamping-frame detection sensors
is described here as well.

Change dwell time

The duration of the steam process can be set to a different value by
using the dwell time selection knob . The dwell time can be set
continuously in the range from 2 to 30 minutes.

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Please note that changing the dwell time while steaming textile will
affect the material currently in the steam chamber.

Change temperature
The fixation temperature can be set to another value by using the
temperature controls on the temperature control unit . After
setting the process temperature to a new value, one has to wait until
the actual temperature has reached the selected value and has
stabilized for 5 minutes, before one can proceed.
Please note that changing the temperature while steaming textile
will affect the material currently in the steam chamber.

3.7.3 Shutdown
To shutdown the Portafix Universal after finishing a Normal
Temperature steam fixation process, one has to perform the
following steps.

1. Steam generator OFF

Turn off the steam generator with button .

2. Remove moisture
In case the Portafix Universal will not be used for the next
couple of days, it is advisable to remove the excess moisture
from the steam chamber, otherwise proceed to step 3.
• set temperature to 150 °C on the control unit 
• wait until the setvalue is reached
• leave on for 1 hour and proceed with step 3

3. Heater OFF
Turn off the heater with button .

4. Circulation OFF
After turning off the heater, wait about 10 minutes before
switching off the circulation.
Use switchboard button  to turn off the circulation.

5. Switch OFF
Turn power off with main power switch .

6. Turn exhaust fan OFF

Turn off the auxiliary installed exhaust fan if applicable.

3.8 High Temperature (HT)

High Temperature (HT) refers to the fixation in which the steam
chamber is filled with steam and processing temperatures lie in the
range 160 °C to 180 °C.

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3.8.1 Start-up
The start-up procedure for the High Temperature steam fixation
consists of a number of steps. The consecutive steps of the start-up
procedure have to be executed in the order as specified here.

1. Switch on
Turn power on with main power ON/OFF switch  and make
sure the control power ON/OFF key-switch  is also in the ON
position.

2. Remove moisture
In case the Portafix Universal was used for Normal
Temperature steam fixation, and the excess moisture was not
removed during shutdown (see section Normal Temperature
Shutdown for details) it is advisable to remove the excess
moisture from the steam chamber before proceeding with the
High Temperature start-up sequence.

3. Select temperature
Select the temperature for the steam fixation process by using
the temperature UP  and temperature DOWN  push-
buttons on the temperature control unit  to increase or
decrease the process temperature setting. The selected
temperature is displayed on the temperature control unit  in
the lower display SV. The temperatures for high temperature
steam fixation process fall in the range 160 °C to 180 °C.

4. Steam Generator ON
Turn on the steam generator, press steam generator ON
button . The button status LED will be illuminated and will
remain illuminated until the steam generator is turned OFF.

5. Circulation ON
Turn on the circulation ventilator by pressing the circulation
ON button . The button status LED will be illuminated and
will remain illuminated until the circulation is turned OFF.

6. Heater ON
Turn on the heater by pressing the heater ON button . The
button status LED will be illuminated and will remain
illuminated until the heater is turned OFF.

7. Exhaust fan ON
The exhaust fan is either controlled by the mains power ON/
OFF switch  or by a separately installed ON/OFF switch,
dependent on customer specific situation. Controls for this are
not present on the switchboard.

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8. Warming-up
Wait until the temperature in the steam chamber, as
displayed on temperature control unit  on the upper display
PV, has reached the set value as displayed in the lower display
SV within a few degrees.

9. Remove air
Turn off the heater with button  and after that, turn off the
circulation with button . After turning off the heater and the
circulation, wait for about 15 minutes to allow the steam to
push out the air out of the steam chamber.

10. Stabilize setpoint

After the air has been removed from the steam chamber, the
circulation  and the heater  can be switched on again. After
the setpoint is reached allow 5 minutes to stabilize.

3.8.2 Fixation
Set dwell time
Before starting with the fixation one has to set the duration for the
steam process by using the dwell time selection knob . The dwell
time can be set continuously in the range from 2 to 30 minutes.

After completing the start-up procedure and selecting the

appropriate dwell time, the printed cloth can be fed through the
Portafix Universal. The way in which the cloth should enter the
machine and, after it has passed through the steam chamber, has to
be taken out at the output side, is described in section 3.5. The
application of the end-of-roll and clamping-frame detection sensors
is described here as well.

Change dwell time

The duration of the steam process can be changed with the dwell
time selection knob . The dwell time can be set continuously in the
range from 2 to 30 minutes.
Please note that changing the dwell time while steaming textile will
affect the material currently in the steam chamber.

Change temperature
The fixation temperature can be set to another value by using the
temperature controls on the temperature control unit . After
setting the process temperature to a new value, one has to wait until
the actual temperature has reached the selected value, has
stabilized for 5 minutes, before one can proceed.
Please note that changing the temperature while steaming textile
will affect the material currently in the steam chamber.

© 2005 SETeMa B.V.

 Portafix Universal Manual • Page 18

3.8.3 Shutdown
To shutdown the Portafix Universal after finishing a High
Temperature steam fixation process, one has to perform the
following steps.

1. Steam generator OFF

Turn off the steam generator with button .

2. Heater OFF
Turn off the heater with button .

3. Circulation OFF
After turning off the heater, wait about 10 minutes before
switching off the circulation.
Use switchboard button  to turn off the circulation.

4. Switch OFF
Turn power off with mains power switch .

5. Turn Exhaust fan OFF

Turn off the auxiliary installed exhaust fan if applicable.

3.9 Hot-Air fixation (AF)

Hot-Air fixation (AF) refers to the process in which the chamber is
filled with hot air with temperatures ranging from 150 ºC to 170 ºC.

3.9.1 Start-up
The start-up procedure for the Hot-Air fixation consists of a number
of steps. The consecutive steps of the start-up procedure have to be
executed in the order as specified here.

1. Switch ON
Turn power on with main power ON/OFF switch  and make
sure the control power ON/OFF key-switch  is also in the ON
position.

2. Select temperature
Select the temperature for the steam fixation process by using
the temperature UP  and temperature DOWN  push-
buttons on the temperature control unit  to increase or
decrease the process temperature setting. The selected
temperature is displayed on the temperature control unit  in
the lower display SV.
The temperatures for Hot-Air fixation process fall in the range
150 °C to 170 °C.

3. Circulation ON
Turn on the circulation ventilator by pressing the circulation

© 2005 SETeMa B.V.

 Portafix Universal Manual • Page 19

ON button . The button status LED will be illuminated and

will remain illuminated until the circulation is turned OFF.

4. Heater ON
Turn on the heater by pressing the heater ON button . The
button status LED will be illuminated and will remain
illuminated until the heater is turned OFF.

5. Exhaust fan ON
The exhaust fan is either controlled by the mains power ON/
OFF switch  or by a separately installed ON/OFF switch,
dependent on customer specific situation. Controls for this are
not present on the switchboard.

6. Warming-up
Wait until the temperature in the fixation chamber, as
displayed on temperature control unit  on the upper display
PV, has reached the set value as displayed in the lower display
SV. After the setpoint is reached allow 5 minutes to stabilize.

3.9.2 Fixation
Set dwell time
Before starting with the fixation one has to set the duration for the
baking process by using the dwell time selection knob . The dwell
time can be set continuously in the range from 2 to 30 minutes.

After completing the start-up procedure and selecting the

appropriate dwell time, the printed cloth can be fed through the
Portafix Universal. The way in which the cloth should enter the
machine and, after it has passed through the chamber, has to be
taken out at the output side, is described in section 3.5. The
application of the end-of-roll and clamping-frame detection sensors
is described here as well.

Change dwell time

The duration of the baking process can be changed with the dwell
time selection knob . The dwell time can be set continuously in the
range from 2 to 30 minutes.
Please note that changing the dwell time while baking will affect the
material currently in the chamber.

Change temperature
The fixation temperature can be set to another value by using the
temperature controls on the temperature control unit . After
setting the process temperature to a new value, one has to wait until
the actual temperature has reached the selected value and stabilized
for 5 minutes, before one can proceed.
Please note that changing the temperature while baking textile will

© 2005 SETeMa B.V.

 Portafix Universal Manual • Page 20

affect the material currently in the chamber.

3.9.3 Shutdown
To shutdown the Portafix Universal after finishing a Hot-Air fixation
process, one has to perform the following steps.

1. Heater OFF
Turn off the heater with button .

2. Circulation OFF
After turning off the heater, wait about 10 minutes before
switching off the circulation.
Use switchboard button  to turn off the circulation.

3. Switch OFF
Turn power off with mains power switch .

4. Turn Exhaust fan OFF

Turn off the auxiliary installed exhaust fan if applicable.

3.10 Autostart/stand-by (optional)

The autostart option offers an easy and comfortable way to have the
Portafix Universal ready for production at the selected temperature
and at a specified time of day, without losing time with manually
going through the start-up procedure.
Beside this the stand-by option reduces energy consumption by
approximately 60%.

3.10.1 Autostart (optional)

The autostart has been configured for the automatic start-up for
Normal and High Temperature fixation, as described in previous
sections.

Note: To enable automatic start-up for Hot-Air fixation, the

autostart module has to be reconfigured; contact SETeMa if the
autostart configuration should be changed to Hot-Air fixation start-
up.

Temperature
The autostart prepares the Portafix Universal for a steam fixation
process. The target temperature used in the automatic start-up is
defined by the temperature as shown in the lower display SV of the
temperature control unit. The temperature should be set prior to the
autostart.
For reaching the setpoint for HT steaming, one should observe
approximately 45 minutes after the autostart has finished.

© 2005 SETeMa B.V.

 Portafix Universal Manual • Page 21

Activate
The automatic start-up procedure is activated by turning the
autostart button  clockwise; after releasing the button, it will be
lit thereby indicating the start-up procedure is being executed.

Abort
To abort the autostart in progress, turn the autostart button 
counter-clockwise; after releasing the button, it will no longer be lit.
The machine will maintain in the state it was in before the
cancellation of the autostart. Adjust if necessary.

Stand-by
After completing the automatic start-up procedure, the system is
switched to stand-by status. The stand-by status of the steamer is
shown by the blinking of the stand-by button (button in figure 1).

3.10.2 Countdown timer (optional)

The countdown timer is used to activate the autostart function at a
specific time, ensuring the Portafix Universal to be ready for
production at e.g. the begin of the operator's shift.
The countdown timer is a single shot timer. By e.g. loading the timer
with an 15:00 h value and triggering the countdown, the autostart
function will be triggered after 15:00 h. The autostart function will
require 50 minutes for execution, so the Portafix will be ready in
15:50 h from the start of the countdown timer.

Countdown period
The time period for the countdown is set with the countdown
selection unit . The currently selected countdown time (in
hour:minutes) is shown by the display. Increasing and decreasing the
countdown time period is accomplished by pressing/holding the 83
and '2:1 buttons, respectively.

Start countdown
The countdown timer is started by pushing the countdown button .
The countdown timer will start to blink the h and min LEDs,
indicating that the countdown is active. The remaining countdown
time in hh:mm is displayed by the large display.

Abort countdown
To interrupt the ongoing countdown the timer has to be reset. This
requires the switching to reset mode by pressing the 02'( button
(on the timer ) once and subsequently pressing the 83  567
button.
By pressing the 02'( button again one returns to normal mode.

Finished countdown
After the countdown has finished, the autostart function is triggered

© 2005 SETeMa B.V.

 Portafix Universal Manual • Page 22

and the countdown timer has to be reset to perform a new

countdown. Reset the timer by pressing the 02'( button once and
subsequently pressing the 83567 button. Press the 02'( button
again to return to the normal mode.

3.10.3 Stand-by (optional)

The stand-by status of the Portafix Universal is used to reduce the
energy consumption during the time the steamer is not used for
production, but should be ready for production on short notice.

The energy consumption in stand-by is about 60% less compared to

the energy used in the normal, production status.

Activate
The stand-by status is activated by turning the stand-by button 
clockwise. Upon releasing the button, it will begin to blink thus
indicating the stand-by status of the system.

Abort
To switch from stand-by to normal production status, turn the stand-
by button  counter-clockwise; after releasing the button, it will no
longer blink.

© 2005 SETeMa B.V.

 Portafix Universal Manual • Page 23

4 Maintenance
The regular, preventive maintenance is restricted to decalcifying the
steam generator and water nozzle.

4.1 Decalcifying steam generator

The required decalcifying frequency is completely determined by the
hardness of the water and the number of steaming hours per period
of time. For water with a degree of hardness >8 °dH and also in case
of intensive usage it is recommended to decalcify the steam
generator every week. Regular checking the deposits is necessary to
determine the required frequency of decalcifying.

The heating elements are susceptible to

overheating and thermal destruction if the
amount of deposit increases. Regular
decalcifying is necessary.

To avoid any long-term damage due to mineral

deposits on the heating elements, preventive
decalcifying should be performed at least twice a
year. This preventive decalcification should be
performed even when using soft water or a water
softener for the Portafix Universal.

4.1.1 Regular check

The heater elements in the steam generator should
regularly be checked for any mineral deposits. First
turn off the water supply either by closing the water
valve or switching off the power on the switch
board. Drain the compartment by opening the %$//
9$/9(.
The hatch in the heating reservoir can be used to check the heater
element in the steam generator. A flashlight could be necessary.

The steam generator hatch should not be opened

when the steam generator is turned on or within
15 minutes after switching off the steam
generator. Injuries to hands, face and other
body parts might occur if one comes in contact
with steam or boiling water inside the steam
generator or escaping from the hatch.

Open the +$7&+ by turning the lid sideways. Then remove the
© 2005 SETeMa B.V.
 Portafix Universal Manual • Page 24

6&5(: 3/8* to access the generator compartment. To close the

hatch, insert the plug, close the lid.

4.1.2 Decalcifying procedure

Open the hatch as described in the previous section, be aware of the
fact that the steam generator could contain hot
water. Observe the necessary precautions.

Put approximately 100 g of citric acid into the steam

generator compartment.
Close the hatch.
Turn the steam generator on, allow to reach the
boil, then turn off the steam generator and wait for
about 30 minutes to allow the acid to dissolve the
minerals.
Drain the generator by opening the %$//9$/9(.

The water is near boiling temperature. Injuries

to hands, face and other body parts might occur
if one comes in contact with the steam or
boiling water escaping from the ball-valve.

After emptying the steam generator reservoir, close the ball-valve.

Fill the reservoir with fresh water by opening the water tap and
switching on the Portafix by placing main power switch  in the ON
position. The low water alarm will be activated, audible  and LED
, as is normal since the steam generator is drained. This alarm has
to be reset by pressing the steam generator OFF button .

After the generator is filled, turn off the power with switch  and
drain once more to remove the residual acid and deposits.

It is advisable to plan the decalcifying right after the Portafix

Universal has been used, in that case the water in the reservoir is
still hot and does not have to be heated. Since the water in the
steam generator is hot, one should observe the safety precautions.

4.2 Decalcifying the spray water nozzle

The spraying nozzle is located in the ventilator shaft. The nozzle is
susceptible to clogging by hard water deposits. Decalcification should
be performed if the cooling capacity of the Portafix Universal gets
limited thus resulting in an overheating of the steam during
production. An overheating of more than 1 °C should definitely be
© 2005 SETeMa B.V.
 Portafix Universal Manual • Page 25

considered as to much.

4.2.1 Decalcifying procedure

The Portafix should be switched of and allowed to cool for at least an
hour before proceeding with the removal of the nozzle.

The steamer is very hot. Injuries to hands,

face and other body parts might occur if one
comes in contact with the steam or hot
surfaces.

The spray nozzle can be reached by removing the

service plate below the switchboard. Remove the 4
bolts at the corners with a 5 mm Hex Key.
Gently remove the isolation foam at the upper left.
Remove the 4 bolts of the service plate in which the
nozzle is located.
Detach the water supply tube or remove the spray-
ing nozzle from the service plate.

After removing the service plate, soak the nozzle in

an approx. 5% acidic solution, e.g. citric or acetic
acid, for several hours.
Reassemble the nozzle in reversed order thereby
paying attention to a proper sealing of the service
plate by fully inserting the bolts but not overtighten-
ing them.

The spraying nozzle contains a fragile tip

which, if damaged, prohibits the function of
the nozzle. If the tip becomes damaged the
nozzle should be replaced.

© 2005 SETeMa B.V.

 Portafix Universal Manual • Page 26

5 Troubleshooting
5.1 No power
Check the ON position of the main power ON/OFF key-switch , the
control power ON/OFF switch  and whether the power plug is
connected to a wall socket power outlet.

The switchboard cabinet contains high voltages.

Turn off the mains power switch   before
proceeding.

If still no power is present, turn off the service

power switch  and open the cabinet door by turning
the latches  with the service key.
Check the automatic )86(6 in the fuse box. If a
fuse has switched off, turn it on again. Close the
cabinet door and secure the latches . Turn on the
power switch .
If there is still no power, check the power supply to
the wall outlet.
If the power switches of due to a fuse switching off,
check for short circuits in the cabinet.

If the problem is not solved by the above procedure

or if the power repeatedly switches off after
switching on the circulation, heater, steam
generator, or transport, one should bring in a
qualified electrician to have the faulty circuit
checked for short circuits.

5.2 No transport
Check for no power as described in section 6.1.
Check the status of the end-of-roll and clamping frame sensors. Set
the sensor selection knob  to the left position "no sensors" check
the transport. If still no transport is present, switch off the main
power, wait 2 seconds, switch on again, verify the functioning of the
transport.
If the transport function can not be re-enabled one should bring in a
qualified electrician to have the faulty circuit checked.

5.3 No circulation
Check for no power as described in section 6.1.
An interrupted circulation caused by for instance a ventilator

© 2005 SETeMa B.V.

 Portafix Universal Manual • Page 27

malfunction, can lead to overheating of the super-heaters.

Whether or not the circulation ventilator is operating can easily be
heard; the ventilator and the air forced through the circulation shaft
produce an unmistakable and rather audible sound.

5.4 No steam
Check for no power as described in section 6.1.
Check the heaters for short-circuits or burn-out.

The switchboard cabinet contains high voltages.

Turn off the main power switch   before
proceeding.

To check the generator heaters the resistance of the 3 phase heater

should be checked. If the optional autostart/stand-by function is
installed locate SSR2, else locate the control relay Q3. Measure the
resistance between terminal T1 and neutral, repeat for terminal T2
and T3. The resistance should read 14 Ohms ±3 Ohms. If the
resistance is substantially higher, the heater can not generate the
necessary wattage and should be replaced. If the resistance is
substantially lower, the heater or cabling is short circuited and
should be replaced.

Check the steam generator fault indicator . If a fault is present the
audible signal  should also be noticeable. The fault can be caused
by the level switch in the steam generator or the thermal safety
cutout of the steam generator heaters. One or both fault sensors
kick-in when a low water level is present. Check the supply of fresh
water to the Portafix.

5.5 No heating
Check for no power as described in section 6.1.
Check the heaters for short-circuits or burn-out.

The switchboard cabinet contains high voltages.

Turn off the service power switch   before
proceeding.

To check whether or not the heater is working properly, the

resistance of the 3 phase heater should be checked. Locate the solid-
state relay SSR1 and measure the resistance between terminal T1 and
neutral, repeat for terminal T2 and T3. The resistance should read 26
Ohms ±5 Ohms. If the resistance is substantially higher, the heater

© 2005 SETeMa B.V.

 Portafix Universal Manual • Page 28

can not generate the necessary wattage and should be replaced. If

the resistance is substantially lower, the heaters or cabling is short
circuited and should be replaced.

5.6 No smooth transport

The smooth transport of cloth through the steam chamber can be
obstructed. A visual inspection may be necessary. The steam cham-
ber has to be opened to inspect the interior.

The steamer can be very hot. Injuries to hands,

face and other body parts might occur if one
comes in contact with the steam or hot
surfaces. Observe a cooling period.

5.6.1 Opening the steam chamber

The steam chamber can be accessed via the service hatch. The hatch
is located on the steamer exit side, that is the same side the
transport drive can be found.

Outer panels
The top 3 of the outer panels have to be removed to gain access to
the steamer inside.
Start with removing the 2 top panels. Take out the bolts, and gently
take off the panels by lifting them from the middle
separation (see illustration). Take care that the
panels are secured against falling since both panels
are released simultaneous. This is best done by two
persons.
The backside of the outer panels are covered with
insulation material, to avoid any damage to the
insulation, the panels should be handled with care.

The insulation layers on the outer panels do not all

have the same shape and size. This implies that the
panels have to be placed back at the same position
they were taken off.

Remove the third outer panel.

Service panel hatch

The service panel separates the steam from the surrounding air and
this is sealed airtight.

© 2005 SETeMa B.V.

 Portafix Universal Manual • Page 29

To avoid any damage to the steam chamber

sealing, one should use caution and the correct
tools for loosening and fastening the bolts.

Untighten the bolts of the service panel. Remove all but the upper
middle bolt. Remove this last bolt, thereby securing the service panel
against falling, and take off the panel. Again, this is best done with
two persons.

5.6.2 Closing the steam chamber

Service panel
Mount the service panel by inserting the upper left and upper right
bolts. Insert the remaining bolts. After all bolts are inserted, tighten
the bolts in a linear pattern. Do not apply excessive tightening force,
just enough to reach the end stop.

Outer panels
Attach the outside panels. Make sure that the 3 panels are mounted
in the same order as they came off the steamer. Start with the
lowest panel. Then mount the top two panels, these
should be mounted together in reversed motion.

© 2005 SETeMa B.V.

 Portafix Universal Manual • Page 30

6 Warranty
SETeMa BV warrants on the terms and conditions herein, that we will
repair, replace or adjust any part manufactured by SETeMa BV and
found by us (in the exercise of our reasonable discretion) to be
defective in factory material or workmanship.

This warranty is limited to six month from the date of delivery for
any Portafix Universal that is used for commercial or any other
income producing purpose.

This warranty extends only to the original retail purchaser of the

equipment. This warranty may not be assigned or transferred without
the prior express written consent of SETeMa BV.

The warranty period commences upon the date of delivery.

The Portafix Universal equipment, including any defective part, must

be returned to SETeMa BV within the warranty period.

The warranty shall extend to the expense of repair or replacement

(as determined by us) of the defective part, including labor.

The warranty shall not extend to the expense of delivering the

defective parts to SETeMa for warranty work nor the expense of
returning it back to the owner after repair or replacement.

Our responsibility in respect to claims is limited to making the

required repairs or replacements, and no claim of breach of warranty
shall be cause for cancellation or rescission of the contract of sale of
any Portafix Universal.

Proof of purchase may be required to substantiate any warranty

claim.

All warranty work must be performed by an authorized service dealer

or directly by SETeMa.
This warranty extends only to Portafix Universal machines operated
under normal conditions and properly serviced and maintained.

The warranty expressly does not cover:

(i) any damage or deterioration due to normal use, wear and tear,
or exposure;
(ii) normal maintenance services, such as decalcifying and
lubrication; adjustment;
(iii) replacement of service items, such as ??, or other items subject
to normal service replacement;
(iv) damage or defects arising out of or relating to misuse, neglect,
alteration, negligence or accident;

© 2005 SETeMa B.V.

 Portafix Universal Manual • Page 31

(v) repair or replacement arising from operation of or use of the

Portafix Universal equipment which is not in accordance with
operating instructions as specified in the operator's manual or
other operational instructions provided by SETeMa BV;
(vi) repair or replacement arising as a result of any operation from
Portafix Universal equipment that has been altered or modified
so as to, in the determination of SETeMa Company, adversely
affect the operation, performance or durability of the
equipment or that has altered, modified or affected the Portafix
Universal equipment so as to change the intended use of the
product;
(vii) repair or replacement necessitated by use of parts, accessories
or supplies, including lubricants, incompatible with the Portafix
Universal equipment or other than as recommended in the
operator's manual or other operational instructions provided by
SETeMa BV;
(viii) repairs or replacements resulting from parts or accessories
which have adversely affected the operation, performance or
durability of the Portafix Universal equipment; or
(ix) damage or defects due to or arising out of repair of Portafix
Universal equipment by person or persons other than SETeMa BV
or an authorized SETeMa service dealer or the installation of
parts other than genuine SETeMa BV recommended parts.

As a condition to this warranty, customer shall have read the

operator's manual and shall have completed and returned to SETeMa
BV, within the prescribed time, the SETeMa BV warranty registration.

The sole liability of SETeMa BV with respect to this warranty shall be

repair and replacement as set forth herein. Neither SETeMa BV or any
of SETeMa’s dealers shall have any liability for any other cost, loss or
damage, including but not limited to, any incidental or consequential
loss or damage. In particular, we shall have no liability or
responsibility for:
(i) expenses relating lubricants;
(ii) loss, cost or expense relating to transportation or delivery of
Portafix Universal equipment from the location of owner or
location where used by owner to or from SETeMa BV or any
authorized SETeMa service dealer;
(iii) travel time, overtime, after hours time or other extraordinary
repair charges or charge relating to repairs or replacements
outside of normal business hours at the place of business of the
authorized SETeMa service dealer;
(iv) rental of like or similar replacement equipment during the
period of any warranty, repair or replacement work;
(v) any telephone or telegram charges or travel charges;
(vi) loss or damage to person or property other than that covered by
the terms of this warranty;

© 2005 SETeMa B.V.

 Portafix Universal Manual • Page 32

(vii) any claims for lost revenue, lost profit or additional cost as a
result of a claim of breach of warranty; or
(viii) attorney's fees.

There are no representations or warranties which have been

authorized and provided to the buyer of the Portafix Universal
equipment, other than as set forth in this warranty. Any and all
statements or representations made by any seller of this equipment,
including those set forth in any sales literature or made orally by any
sales representative, are superseded by the terms of this warranty.
Any affirmation of fact or promise made by SETeMa or any of their
representatives to the buyer which relates to the goods that are the
subject of this warranty shall not be regarded as part of the basis of
the bargain and shall not be deemed to create any express warranty
that such goods shall conform to the affirmation or promise.

THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS,

OR WARRANTIES, EXPRESS OR IMPLIED (INCLUDING BUT NOT LIMITED
TO ANY REGARDING THE MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE), NOT SPECIFIED HEREIN, RESPECTING THE
EQUIPMENT WHICH IS THE SUBJECT OF THIS WARRANTY.

This warranty applies to all SETeMa Portafix Universal equipment sold

in member states of the European Union and all other European
countries and United States and intended to be used for commercial
purposes.

© 2005 SETeMa B.V.

 Portafix Universal Appendix A: Technical Specifications • Page 33

A: Technical Specifications

Type PU3 PU6 PU9

Fabric length inside steam chamber 3 6 9 [m]

Production capacity 2 min fixation process 90 180 270 [m/h]
10 min fixation process 18 36 54 [m/h]
30 min fixation process 6 12 18 [m/h]
3
Forced circulation 475 1000 1430 [m /h]

Steaming temperature 100 - 180 [°C]

Air fixation temperature 50 - 180 [°C]
3
Volume steam chamber 1.5 [m ]
Fabric maximum width 1.85 / 2.5 [m]
minimum length 0.2 [m]
Fabric roll maximum weight 25 [kg]
maximum diameter 0.55 [m]
Dwell time 2 - 30 [min]

Steam generator 11 [kW]

Steam/air heating 6 [kW]
Slit heating 0.32 [kW]
Steam cooling 0.8 [kW]

Connections power voltage N + 3 x 230/400 [VAC]

power current 25/32 [A]
water 15 [l/h]
3
steam/air exhaust ± 450 [m /h]
condensate ± 1.5 [l/h]

Shipping dimensions upper lower

(crate) height ±2 ± 1.8 [m]
width ± 3(3.7) ± 3(3.7) [m]
depth ± 0.65 ± 0.65 [m]
weight 300 ± 250 [kg]

© 2004 SETeMa B.V.

 Portafix Universal Appendix B: Installation and Commissioning • Page 34

B: Installation and Commissioning

Correct assembly is essential in ensuring safe and reliable

operation of the Portafix Universal.

Installation tools
The following tools are needed for the installation of the
Portafix Universal:

1. Allen Hex key set for hex-head bolts; preferably with Ball
Ends; Metric sizes 4, 5, 6 and 8
2. Set of open ended spanners Metric sizes 10, 13 and 17
3. Hex key (bit) Metric size 6 for electric screwdriver
4. Fork-lift truck

Parts as shipped
The Portafix Universal ships in 2 parts: Upper Part and Lower
Part. These parts are transported in separate crates; the
Lower Part crate also contains the Switch Box.
The approximate dimensions of the Upper Part crate are: 2 m
tall by 3 m wide by 0.65 m deep, and it weighs ± 300 kg.
The Lower Part comes packed in a crate with approximate
dimensions: 1.8 m tall by 3 m wide and 0.65 m deep. The
Lower Part weight is ± 200 kg.

Unpacking the parts

The installation begins with removing the part from the
shipping crates. Before unpacking the steamer parts, inspect
the shipping crates for signs of damage. Notify the carrier and
your agent immediately if any damage is noted.

Unpacking the Upper Part

Place the crate upright on a flat, level surface.
Remove all panel boards and the plastic wrapping. Remove the
wood screws that fix the upper part to the crate bottom.
Later on, the Upper Part can be lifted, with the aid of a fork-
lift truck, from the crate bottom.

Unpacking the Lower Part

Place the crate upright on a flat, level surface.
Remove panels apart from the few that keep the vertically

© 2004 SETeMa B.V.

 Portafix Universal Appendix B: Installation and Commissioning • Page 35

orientated Lower Part from falling over.

Also remove the plastic wrapping.
Take/unscrew the items (Switch Box, etc.) from the crate,
that is; see the packing list for a complete list of items
shipped in the Lower Part crate.

Check contents
After unpacking the parts, check the delivery for
completeness by comparing the contents of the crates with
the packing list. Check the contents for visible damage.
If you notice any shipping damage or inconsistencies between
the contents of the crates and the packing list, you should
notify SETeMa immediately.
Do not proceed with the installation if one or more of the
required items is missing or damaged.

Level Lower Part and put onto wheels

Mount the two top wheels, if necessary use some tape to fix
the wheels, and apply the brakes. Remove the cross brakes
that hold the Lower Part upright, and gently turn over the
lower part and lower it onto the floor. Finally, lift the Lower
Part side still without wheels and insert the remaining wheels.

Upper en Lower Part unpacked (rollers removed already)

Assembly of Upper and Lower Part

Before starting with the assembly place the Lower Part on
level surface, and make sure the brakes are applied.
© 2004 SETeMa B.V.
 Portafix Universal Appendix B: Installation and Commissioning • Page 36

Apply brakes before assembly

Remove rollers Lower Part

Placing the Upper Part on top of the Lower Part requires the
Lower Part rollers to be taken out.

Lower Part rollers

Before taking the rollers out, one has to release one of the
belt tension gas springs. Because it is easier to access one
should release the gas spring mounted on the side panel
opposite to the drive motor.

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 Portafix Universal Appendix B: Installation and Commissioning • Page 37

Remove clip to release gas spring head

To release the gas spring, one first has to take off the little
clip spring that locks the gas spring head.

Gas spring released (rollers taken out already)

The "take rollers out" operation then proceeds with removing

the bearing units holding the roller end-bars. Loosen the
bearing bolts and take out the bearing units. The bearings
units at both ends of the roller have to be removed. While
removing the second one, the opposite end of the roller is
supported by the cut-away in the side panel. After removing
both bearings, take out the roller.
Remember which side panel holes were used for the bearing
bolts; later on, when the rollers are being put in again, the
same holes should again be used for mounting the bearings.
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 Portafix Universal Appendix B: Installation and Commissioning • Page 38

Next, place Upper Part on top of Lower Part. Gently lifting the
Upper Part from the pallet with the aid of a fork-lift truck,
and place in on the Lower Part.

Place Upper Part onto Lower Part

The Upper Part weighs ± 250 kg, one thus has to use a fork-lift
truck to place the Upper Part.

Use fork truck to place Upper part

The Upper Part should be positioned on the Lower Part such

that the 4 bolt holes in Upper and Lower Parts are aligned.

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 Portafix Universal Appendix B: Installation and Commissioning • Page 39

Use bolt holes to position; insert bolts

After correctly aligned placing of the Upper part, insert the 4

bolts (M10) from the top and the nuts from the bottom, and
tighten to fix Upper and Lower parts.

Put the rollers back into the Lower Part. First place the roller
without the bearing on the cut-away near the bearing holes in
the side panel. Then put the bearing on the end-bar of the
roller, raise the roller plus bearing block such that the bolt
holes in the bearing block are aligned with the side panel
mounting holes, and insert the bolts.
Make sure that the correct side panel holes are used for the
bearing bolts, that is the same ones that were used before the
rollers were taken off.

Use correct side panel holes for bearing bolts

Next, fix the other bearing onto the opposite end of the roller,
carefully slide roller and bearing into the correct position, and
insert and tighten the bolts.

The bolt holes are slightly wider than the bolt diameter. The
ensuing freedom in positioning the bearing blocks should be
used to mount the rollers such that the paths of drive belts
are in the center of the steam chamber entrance and exit
slits. The exact drive belt path will of course be visible only
after installing the belts. It thus might be necessary to fine-

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 Portafix Universal Appendix B: Installation and Commissioning • Page 40

tune the roller positions after the drive belts have been
installed.

After the bearing bolts have been fastened the roller should
be shifted horizontally to bring the roller precisely in the
middle of the two side panels. After that, install the bearing
lock ring by sliding it onto the roller end shaft and rotating the
bearing ring to allow it to snap onto the eccentric bearing top.
Turn lock ring until it is fixed to the bearing and then fasten
the small screw of the lock ring.

Connections Upper & Lower parts

Steam generator
The flexible steam hose of the Upper Part has to be connected
to the steam generator exit tube of the Lower Part. The hose
is fixed to the tube using a hose clamp.

Put hose clamp around flexible hose.

Slide the Upper Part flexible steam hose over the end of the
Lower Part steam tube. Make sure that the hose covers at
least 2 cm of the steam generator outlet tube.

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 Portafix Universal Appendix B: Installation and Commissioning • Page 41

Move hose down around steam generator tube

Move the hose clamp to the place where the hose encloses the
tube and tighten the clamp screw.

Position hose clamp and tighten

Fresh water
The spray nozzle in the Upper Part, used for the cooling steam
in the recirculation shaft, has to be connected to the fresh
water inlet valve in the Lower Part.

Guide the yellow fresh water hose connected to Upper Part

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 Portafix Universal Appendix B: Installation and Commissioning • Page 42

through the opening at the bottom of the Upper Part.

Fresh water hose

Guide the hose to the fresh water inlet valve. To ensure that
the hose does not interfere with the drive belts and/or the gas
spring construction, keep the hose close to the side panel.

Hose-valve configuration

Push the end of the Upper Part hose into the rear valve exit.

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 Portafix Universal Appendix B: Installation and Commissioning • Page 43

Hose-valve connection in progress

Make sure that the hose is firmly inserted into the valve exit.
The Upper Part hose connected to the fresh water inlet valve
should look as follows:

Hose connected to valve

Mounting the drive belts

The proper installation of the drive belts requires also correct
placing of the belt on the pulleys inside the steam chamber.
The steamer inside is accessed via the service panel. But
before the service panel can be taken off, one first has to
remove the outer panels covering the service panel.

Open the steam chamber

The service panel is located on the steamer output side, that
is the side on which the transport engine is placed.

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 Portafix Universal Appendix B: Installation and Commissioning • Page 44

The back of the outer panels is covered with insulation

material. The panels themselves are interchangeable,
but the dimensions of the insulation attached to the panels
are not equivalent. Outer panels should thus not be swapped,
and mounted at the same position when the steamer is closed
again.

Take out the bolts on the two topmost outer panels. Make sure
the panels can not fall out once the bolts have been taken
out.

Secure the panels

Then, take out the topmost panels simultaneously. This is

preferably a two-man job, one panel per person.

Take out topmost panels together

Then, take out the last of the outer panels that covers the
service panel.

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 Portafix Universal Appendix B: Installation and Commissioning • Page 45

Remove third (from the top) panel.

After the topmost three outer panel have been removed the
complete service panel can be reached.

Service panel revealed

Loosen and remove all but the upper middle bolt. Remove
this last bolt, thereby securing the service panel against
falling, and take off the panel.

Loosen service panel bolts

Remove the service panel.

Placing the transport belts

The transport belts are already mounted to the Upper Part

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 Portafix Universal Appendix B: Installation and Commissioning • Page 46

rollers. The transport belts sections that have to be placed

around the Lower Part rollers can be found in the Upper Part
inside, coiled up and bound together with cable ties.

First, cut the cable ties holding together the neatly folded
transport belt.

Cut cable ties

Push the belt excess through the textile entrance and exit
opening at the bottom of the steam chamber.

The Lower Part support beams are now outside the loop
formed by the transport belt, but the beam has to be inside
this loop. The drive belts thus have to be moved over the
support beams. The beam can be detached from the side
panel to let the belt pass, by loosening two bolts: One on the
side-panel outside and another that is located on the inside.
Both drive belts have to pass their respective support beam
heads.

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 Portafix Universal Appendix B: Installation and Commissioning • Page 47

Loosen outside bolt

Unfastening the inside bolt requires an open wrench to hold

the nut fixed to the bolt.

Loosen inside bolt and nut

Next slip the transport belt over the support beam. Make sure
that the drive belt is not rotated with respect to the part
attached to the Upper Part. See the following photos for the
various steps in the belt-support beam crossing.

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 Portafix Universal Appendix B: Installation and Commissioning • Page 48

Drive belt correctly orientated and flattened

Slide drive belt over beam head

Move belt sideways

After guiding the drive belt over the support beam head, move
the support beam up again and fasten it with the inside bolt
and nut and the side-panel outside bolt.
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 Portafix Universal Appendix B: Installation and Commissioning • Page 49

Move back support beam

Fasten bolt/nut and tighten

Textile input sensor

The drive belts have to be moved around the support beam on
both sides of the steamer. The support beam configurations as
such are symmetrical. But on the drive side one also
temporarily has to remove the textile input sensor and cable.
The input sensor is attached to the support beam by a couple
of cable ties; cut the cable ties and take of sensor plus cable
to allow the belt to be moved around the support beam. After
the belt has been passed around the support beam, sensor and
cable have to be placed back as before.

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 Portafix Universal Appendix B: Installation and Commissioning • Page 50

Temporarily remove input sensor and cable

Next, place the belt over the input and output pulleys. But
before stretching the drive belt make sure that the belt is
correctly placed around all pulleys inside the steam chamber.
The drive belt alignment inside the steamer should agree with
the following two pictures:

Belt and top pulleys

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 Portafix Universal Appendix B: Installation and Commissioning • Page 51

Belt and bottom pulleys

Pull the belt with two hands, as shown in the picture below.
The belt has to be pulled with considerable force, but any
crumpling or folding should be avoided. One person should
bring the belt to required length whilst a second person should
place the belt correctly on the pulley. Of the 2 rows of holes
in the drive belt, the outside ones (nearest to the side panel)
should be aligned with the pulley pins.

Pull drive belt and place on pulley

After placing the drive belt on the pulley the drive belt has to
be tensioned by the pulley unit. Use one hand to pull the gas
spring unit up, and put the belt with the other hand under the
gas spring loaded pulley.

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 Portafix Universal Appendix B: Installation and Commissioning • Page 52

Pull tension pulley up and place belt

The final configuration, after correctly installing the transport

belt looks as follows:

Drive belt mounted and tensioner in place

Closing the steamer

Having installed the drive belt, the steamer can be closed
again. The steamer closing follows the steps of the steamer
opening but in the reversed order.

Note: It might be advisable to postpone the closing of the

steamer until after finishing the post-installation tests.

First, mount the service panel, an activity that involves two

persons: One to hold the panel in place and a second to
inserts the bolts.
To avoid any damage to the panel sealing, the surface panel
bolts should not be fastened too tight. Preferably one should

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 Portafix Universal Appendix B: Installation and Commissioning • Page 53

use a torque wrench or an electric screwdriver with torque

limiter to tighten these service panel bolts.

Do not fasten too tight!

Then, mount the three outer panels that were taken off to get
to the service panel. Make sure that the outer panels are
placed back at the same positions they were removed from.
The mounting position is not relevant to the outer panel as
such, but it is important for the insulation material attached
to the back-side of the outer panels. Make sure that the
insulation material is correctly clamped to the back of the
panel before placing back the panel.

First, place the lowest one of the panels taken off.

Place the lowest panel first

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 Portafix Universal Appendix B: Installation and Commissioning • Page 54

The two topmost outer panels have to be mounted

simultaneously. With two persons it should be easy to bring
the panels to the following outwards-slanting state:

Panels at small angle two panels

And then after carefully aligning the bottom of the top panel
with the top of the bottom panel, push the two panels inwards
together:

Push panels inwards together

Finally, to conclude the steamer closing procedure, insert the

panel bolts and tighten them.

Move to destination
To continue the installation move the assembled steamer to its
permanent position, that is a location equipped with the
required fresh water and power connections. The steamer
should be placed on level surface and before proceeding with
the installation the brakes should be applied.
© 2004 SETeMa B.V.
 Portafix Universal Appendix B: Installation and Commissioning • Page 55

Connections

Fresh water
Connect the Portafix Universal to the fresh water supply by
using the bayonet joint located near the drive motor.

Connect fresh water inlet

Waste water
The steamer waste water is accumulated in the Lower Part
bottom bin. The waste water bin should be drained regularly,
at least once each 8 hours of steam generator operation. It is
however better to use the waste water outlet bayonet at the
bottom to connect the steamer permanently to the waste
water system, in which passive draining (gravitation driven)
usually suffices.

Exhaust
To remove the exhaust steam/air, the exhaust ventilator
should be installed properly. The ventilator should be
connected to the steamer exhaust outlet using heat resistant
(temperatures up to 110°C) tubes or flexible hoses.
The exhaust ventilator requires either a separate power
supply or it is switch on from the control cabinet, dependent
on configuration.

Placing the switch board

Remove the protective film from the parts where the switch
board will be installed.
Place the switch board onto the Upper Part such that the
holes in the switch board mounting lips align with nut holes in
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 Portafix Universal Appendix B: Installation and Commissioning • Page 56

the Upper Part. Then insert the 4 bolts (M8) and tighten them.

Switch board top-side bolts

Switch board bottom-side bolts

Insert the plugs of the power cables of Lower and Upper Parts
into the appropriate sockets on the switch board. Working
from left-to-right, first insert the plug connecting Upper Part
and switch board.

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 Portafix Universal Appendix B: Installation and Commissioning • Page 57

Attach Upper Part cable

The insert the thermocouple plug into the wall socket on the
switch board. Make sure to use the right orientation for the
thermocouple plug (two different sized pins).

Insert thermo couple plug

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 Portafix Universal Appendix B: Installation and Commissioning • Page 58

Thermo couple plug inserted

And the last cable to deal with is the one connecting the
Lower Part to the switch board. Insert the biggest plug into
the right-most socket.

Insert Lower Part cable

Install service panel

To conclude the installation of the switch board, mount the
service panel.

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 Portafix Universal Appendix B: Installation and Commissioning • Page 59

Mount service panel

Miscellaneous installation

Width adjustment unit

There are two width adjustment unit, one support beam on
the steamer input side and the other for the steamer outside.
The width adjustment units are to be mounted on the Lower
Part support beam. Fold the unit open, put the long part on
the support beam.

Fold open and rest on beam

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 Portafix Universal Appendix B: Installation and Commissioning • Page 60

Then lower the part folded up and clamp it onto the support
beam

Clamp around beam

After mounting the width adjust unit onto the support beam,
its cone has to align with the opposing, fixed cone. If these
two cones, holding the two sides of the textile carrying
cardboard winding cores, are not adequately aligned the
textile transport will perform poorly.
Whether or not the cone alignment is correct, can be
established by moving the unit sideways to the fixed cone. If
the alignment in incorrect, the unit can be adjusted by
loosening the two countersunk bolts at the bottom side,
adjusting and finally tightening at the correct position.

Move the width adjustment unit to the far side by gently

lifting and sliding it.
Slide a cardboard tube on the fixed cone and then move the
width adjustment unit into the cardboard tube.

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 Portafix Universal Appendix B: Installation and Commissioning • Page 61

Move width setting unit towards cardboard core

Release the width unit cone

Make sure to not compress the full width of the spring behind
the cone.
The cardboard tube should now be held by the width
adjustment unit.

Testing the system

Before putting the steamer into production, one should
perform a number of tests to ensure that all parts have been
installed properly and that the steamer parts are functioning
correctly.

When the steamer is switched on for the first time, there will
not any water in the steam generator.
The visible and audible low water level warnings that will be
due to the empty steam generator, can be ignored during the
testing of the power supply phasing and the transport system.
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 Portafix Universal Appendix B: Installation and Commissioning • Page 62

Do not take the Portafix Universal into production if one or

more of the post-installation tests fail, but rather contact
SETeMa to find out about the severity of the problem and to
correct way to deal with the problem.

Power supply phasing

Connect the power plug to the wall outlet.
Establish whether or not the phasing of the three phase power
supply agrees with the phasing of the Portafix Universal.
Incorrect phasing will cause the 3 phase motors to rotate in
the wrong direction.
To check the phasing, start the circulation. The motor of the
circulation fan should rotate counter clockwise, as seen from
the switch board.
If the fan motor moves in the clockwise direction, the phase
angle should be reversed by interchanging any two of the
incoming three phase power lines. In case the phasing has to
be changed, the required modification should be applied not
to the switch board inside, but rather to the connection plug
of the fixed socket-outlet.

Transport
Before closing the steam chamber test the drive belt
transportation system. Switch the power on and start the
forward transport. Observe the way the belts move over the
pulleys. The belt should smoothly roll over the pulleys, and
the pulley pins have to be aligned with the holes in the
transport belt.

Also check the path of the belt in the steam chamber entrance
and exit slits. The easiest way to assess the entrance and exit
paths of the drive belts is to observe the way the belts move
through the slits while the steam chamber is open. The belt
should pass through the middle of the slit. In case the belt
path does not lie in the middle of the slit position, the
associated Lower Part roller should be adjusted.

Winding friction ranges

Check the range of the friction brake system on both the
textile input and output sides of the steamer. The friction can
be tuned by using the screw knob to adjust the length of the
tension spring.
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 Portafix Universal Appendix B: Installation and Commissioning • Page 63

Turn to adjust winding friction force

The amount of friction required is determined by the

application. Never use more than just enough friction to
establish winding of the cloth.

On the feeding side, the brake should be adjusted to a

minimal value to just prevent the spontaneous unwinding of
the cloth on the core.

Change spring to tailor (un)winding friction

Clamping frame
Still with the steam chamber open, attach a clamp frame onto
the drive belts and let it pass through the steam chamber. The
clamp frame should smoothly turn over the pulleys and should
not come in contact with the edges of entrance and exit slits.

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 Portafix Universal Appendix B: Installation and Commissioning • Page 64

Heating and steam generator

After closing the steam chamber, test the steam generator and
heating systems. These tests, in particular the steam
generator test, require the steam generator to be filled. The
low water level warning should hence not be ignored during
these tests. The following tests should be performed.
• Connect the water hose to a tap and open it.
• Wait a few minutes until the steam generator is filled.
The valve will close but the alarm will still be active. By
pushing the "steam generator off" button, the alarm will
be canceled. If the water is at the correct level the alarm
will remain canceled.
• Switch on the exhaust fan if this is required.
• Enter a process temperature of 102 °C. Turn on the
circulation fan and the heater; wait until the steamer
temperature reaches the target temperature.
• Turn off the heaters and the fan.
• Turn on the steam generator. After approximately 10
minutes steam should start to emerge from exhaust fan.
• Allow 20 minutes of steam generation to press out the air
in the steam chamber.
• Turn on the fan and the heaters and wait until the
temperature reaches the setpoint temperature. The
temperature should be stable after 10 minutes and it
should remain stable within ± 0.2 °C at Normal
Temperature setting.
• Adjust the setpoint to 175 °C and allow 45 minutes of
heating.
• Then allow 10 minutes to stabilize the temperature. The
temperature should remain within ± 0.5 °C at High
Temperature setting.

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Portafix Universal Appendix B: Installation and Commissioning • Page 65

© 2004 SETeMa B.V.

 Portafix Universal Appendix C: Installation and Commissioning • Page 66

C: Boilingpoint versus Pressure

For best results in Normal Temperature steam fixation, a

fixation temperature of +1 °C above boiling point is optimal.
Since the boilingpoint of water is dependent on pressure, a
daily correction for local variations is advisable. If the
absolute pressure is know, the corresponding boilingpoint of
water can be found with the help of the following graph.

p, T diagram H2O (880-1050 hPa)

101.0
100.8
100.6
100.4
100.2
100.0
T (°C) —›

99.8
99.6
99.4
99.2
99.0
98.8
98.6
98.4
98.2
98.0
97.8
97.6
97.4
97.2
97.0
96.8
96.6
96.4
96.2
96.0
880 890 900 910 920 930 940 950 960 970 980 990 1000 1010 1020 1030 1040 1050

p (hPa) —›

© 2004 SETeMa B.V.