ProSeal 25 and 44 Laminator Service Manual Provided By http://www.MyBinding.com http://www.MyBindingBlog.
Technical Service Manual 1
Front Matter TM TM ProSeal 25 / ProSeal 44 Technical Service Manual REV 2.0 Revision History Amendments will be listed on this page, including their descriptions and dates. REV Date 1.0 Nov 1999 2.0 Feb 2000 Description Original version (pre-release). Released version; the manual covers US as well as EU machines. Page numbering starts with each section. Changed pages: all.
Front Matter Safety Statements TM The ProSeal laminators have been designed with operator safety as a primary objective; however, operators must be familiar with the controls, as well as the operation before using the unit. The electrical and drive-system components are isolated from contact with the operator by enclosing them within plastic end covers that are bolted on.
Front Matter Note: When performing procedures that require the side covers to be opened, ensure that the power cable is disconnected from the mains. Several parts, like the mains switch (1) and the overtemperature switch (2), could cause electrical shock if the power is not disconnected! 1 2 fig. 2 fig.
Table of Contents Section 1. 1-1. 1-2. Section 2. 2-1. 2-2. Section 3. 3-1. 3-2. Section 4. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. Section 5. 5-1. 5-2. 5-3. Section 6. 6-1. 6-2. 6-3. Section 7. 7-1. Section 8. 8-1. 8-2. 8-3. Machine Characteristics Machine Description........................................................................................1-1 Machine Specifications ....................................................................................1-1 Installation Preinstallation.............
Machine Characteristics Section 1. 1-1. Machine Characteristics Machine Description TM TM The ProSeal 25 and ProSeal 44 laminators are electro-mechanical devices containing two silicone rollers, a heating element for the top roller, an electronic PIZ controller for a fixed temperature, and a synchronous drive AC motor to maintain a constant process speed. The ProSeal laminators have been designed to be used with ProSeal Pouch Boards and ProSeal Flexible Pouches.
Installation Section 2. 2-1. Installation Preinstallation The following requirements are applicable: 2-1-1. Electrical Requirements This unit should only be connected to a power supply outlet of the voltage, amperage, and frequency marked on the rear panel. The laminator has a grounded plug (three prongs). To reduce the risk of electrical shock, this plug is intended to fit only a grounded outlet of the proper amperage, and in only one way.
Installation Wirecolours: General (EU) Blue Yellow/Green Brown 2-1-2. • • • • • USA White Yellow/Green Black Name Neutral Ground Phase (Live) Workspace Requirements This unit should be situated away from heat sources such as heat registers or stoves. The laminator’s location or position should not interfere with its proper ventilation. There should be enough space around the laminator to feed-in, exit, and trim mounted and/or laminated images.
Theory of Operation Section 3. 3-1. Theory of Operation Control Knob The Control Knob (see figure 4) is located on the right hand side of the laminator and is operated from the front of the machine. The Control Knob has four (4) purposes: 1. 2. 3. 4. Turn the power on. Turn the heat on. Turn the rollers on. Adjust the height of the rollers. The Control Knob can be operated by pushing it in approximately 1/4” (6mm) to the left.
Theory of Operation 3-2. Control Panel The Control Panel (see figure 6) is located on the front right of the machine and has three LED indicators. A diagram of the Control Panel is shown in figure 7. 1. The top LED when lit indicates the machine is plugged in and the power is on. 2. The middle LED indicates if the heat is on. Heat is required for ProSeal Pouch Boards and ProSeal Flexible Pouches. If lit, the laminator is in Hot Operation Mode and will heat up to its factory setting.
Disassembly / Reassembly Procedures Section 4. 4-1. Disassembly / Reassembly Procedures Opening / Closing the Aluminum Top Cover Necessary tools: medium flat head screwdriver. Approximate time: 1 minute. To open the cover, do the following steps: 1. Insert the screwdriver in one of the holes, situated on the top of the cover. Make sure, that the head fits in the screw, mounted directly underneath this hole. See figure 8. 2.
Disassembly / Reassembly Procedures 4-2. Feed-in Table Necessary tools: medium flat head screwdriver. Approximate time: 1 minute. To remove the feed-in table, do the following steps: Insert the screwdriver in one of the holes, situated on the feed-in table. See figure 9. 1. Rotate the screwdriver approximately ¼ turn; the direction is not important, as the screw is a so-called ‘quarter-turn snap-in screw’. 2. Repeat this at the other side of the top cover. 3.
Disassembly / Reassembly Procedures 2. Remove the self-tapping screw, situated at the rear side of the machine, using the TX25 driver, as shown in figure 11. fig. 12 fig. 11 3. Remove, using the Allen key 4mm, the two M5 socket screws, situated at the bottom of the cover. It’s best practice to slide the machine to the edge of the table or counter where it’s placed. See figure 12. 4. Carefully remove the right hand cover from the frame of the machine.
Disassembly / Reassembly Procedures 4-4. Heating Element Necessary tools: Allen key 3mm. Approximate time: 10 minutes. Note: To disassemble / reassemble the heating element, it is necessary to perform the ‘Plastic Side Covers’ Procedure, described in Section 4-3. Make sure that the power cord is disconnected from the mains! The heating element (see figure 14), is a quartz tube, having a spiral wound filament mounted inside. The quartz tube is fragile; take care when handling the element.
Disassembly / Reassembly Procedures 4. Loosen the screw, which attaches the heater wire to the Solid State Relay. See figure 17. fig. 17 5. fig. 18 Remove the heater bracket on the right hand side of the machine (see figure 18), and slide the heater wire out of the slot, that’s in the heater bracket. Now, the heating element can be taken out of the roller. Note: When a heating element has to be installed into the roller, the quartz tube has to be cleaned first.
Disassembly / Reassembly Procedures 4-5. Software The Control System of the ProSeal Laminator is software driven. The software resides in a small embedded controller, mounted on the Control PCB. Necessary tools: small flat-head screwdriver. Approximate time: 3 minutes. Note: To change / upgrade the software, it is necessary to perform the ‘Plastic Side Covers’ Procedure, described in Section 4-3. Make sure that the power cord is disconnected from the mains! 1.
Disassembly / Reassembly Procedures 4-6. Rear Panel Necessary tools: Phillips crosshead screwdriver (medium), open-ended spanner 8mm, knife. Necessary materials: two tie-wraps (2.5 – 3 mm wide). Approximate time: 10 minutes. Note: To remove the rear panel, it is necessary to perform the ‘Plastic Side Covers’ Procedure (see Section 4-3) first. Perform the following steps: 1. See figure 21. Cut the two tie-wraps (arrows) at the left-hand side of the machine.
Disassembly / Reassembly Procedures 9. Apply the two new tie-wraps exactly on the original positions (into the holes), put the blue connector back onto the overtemperature switch, and mount the ground wire back to it’s position. Put the serrated washers back the way they came off: one on either side of the two wire-eyelets. 4-7. Solid State Relay Necessary tools: medium flat-head screwdriver, Allen key 3 mm. Approximate time: 5 minutes.
Adjustment Procedures Section 5. 5-1. Adjustment Procedures Laminating Pressure Adjustment Note: • To perform the following adjustments, it is necessary to remove both plastic side covers first. See Section 4-3: Disassembly / Reassembly Plastic Side Covers. • Note: the top roller must be at room temperature, before this procedure is being performed. • Next, the heating element, including both heater brackets, has to be removed. See the ‘Heating Element’ Procedure described in Section 4-4.
Adjustment Procedures Next, the nip adjustment strips have to be loosened on either side of the machine. See figure 28 and 29; the detailed adjustment strip is shown figure 30. Note that the strip must not touch the top roller bearing housing during the pressure adjustment procedure. adjustment strip fig. 28 fig.
Adjustment Procedures To insert a sensor support into the right-hand journal of the bottom roller, the belt tensioner assembly has to be removed first (already removed in figure 32). Use the small screwdriver to remove the retaining clip from the tensioner arm pivot axis. See figure 32. After disassembly of the belt and tensioner, the supports can be inserted (1) as previously described. 1 2 fig.
Adjustment Procedures 5-2. Nip Adjustment Note: to perform the following adjustments, it is necessary to remove both plastic side covers first. See Section 4-3: Disassembly / Reassembly Plastic Side Covers. Necessary tools: Allen key 4mm. In addition, a metal adjustment sheet, having a specific thickness, is necessary. For the ProSeal 25, the thickness of this sheet must be 0.5 mm; size: 700x250 mm. For the ProSeal 44, the thickness of this sheet must be 1.25 mm; size: 1150x250 mm.
Adjustment Procedures 5. Push and rotate the nip setting knob fully counter-clockwise , until the pin, mounted in the knob, reaches its lowest position in the indent bracket. See figure 38. The top roller is now applying pressure on the adjustment sheet. lowest position fig. 38 6. Push the adjustment strip against the top roller bearing housing. Whilst holding the strip in this position, fasten the M5 bolt(s) firmly using the Allen key 4mm. See figure 39. 7.
Adjustment Procedures 5-3. Temperature Adjustment Note: • To perform the following adjustments, it is necessary to remove the right-hand plastic side cover first; see Section 4-3: Disassembly / Reassembly Plastic Side Covers. • To measure the temperature of the top roller, it is necessary to have the interlocking bolts of the top cover in the unlocked position; see Section 4-1: Opening / Closing the Aluminium Top Cover. Necessary tools: Infrared Temperature meter, small flat head screwdriver.
Maintenance Section 6. 6-1. Maintenance Cleaning of the Machine The laminator may be cleaned by the operator with a lint-free cloth, lightly dampened with a mild soap and water solution. Spray-on cleaners are not to be used. No part of the machine is to be immersed in water or other liquids. 6-2. Regular Cleaning of the Rollers by the Operator The laminating rollers of the machine should be periodically cleaned of adhesive build up that might occur during normal operation.
Maintenance It’s best practice to clean the top roller first; adhesive from the top roller is likely to fall on the bottom roller. See figure 42: cleaning the top roller, and figure 43: cleaning the bottom roller. fig. 43 fig.
Troubleshooting Section 7. 7-1. Troubleshooting Troubleshooting Problem: The power LED does not come on, when the nip setting knob has been set to one of the nip settings (board thicknesses). Causes: The power cable has not been plugged in the mains wall outlet. Solution: Plug the power cable into the mains outlet. The processor, containing the software, is not installed. Solution: Install the software (see Software Installation, Section 4-5).
Troubleshooting The Solid State Relay is defective (it has a permanent ‘open’ state; in this case, the red LED on the Solid State Relay is constantly on). Solution: Replace the Solid State Relay, see Section 4-1. The overtemperature switch is defective (it has a permanent ‘open’ state; in this case, the line voltage can be measured between it’s connectors). Solution: Replace the overtemperature switch. See Section 8-3-2, Assembly Drawings & Exploded Views, drawing no. 144-185 / 144-187, art. code 961-6003.
Diagrams Section 8. Diagrams 8-1. Electrical Schematics 8-1-1.
Diagrams 8-1-2.
Diagrams 8-1-3.
Diagrams 8-1-4.
Diagrams 8-1-5.
Diagrams 8-1-6.
Diagrams 8-1-7.
Diagrams 8-2. Certified Electrical Components Lists & Sparepart Codes 8-2-1. 110VAC/60Hz Machines See also Section 8-1-1 through 8-1-4. DWG Name REF Manufacturer SSR1 Solid State Relay Omron Type Technical Details UL Listing no. Sparepart no. G3NA-220B 240Vac / 20A E64562 SP 961-0001 E1 heating element Proseal 25 Quartz Tubing Inc. 144-158 120 Vac /1500W N.A. SP 144-158 E1 heating element Proseal 44 Quartz Tubing Inc. 144-157 120Vac /1850W N.A.
Diagrams 8-2-2. 230VAC/50Hz Machines See also Section 8-1-4 through 8-1-7. DWG Name REF Manufacturer SSR1 Solid State Relay Omron Type Technical Details UL Listing no. Sparepart no. G3NA-220B 240Vac / 20A E64562 SP 961-0001 E1 heating element Proseal 25 Quartz Tubing Inc. 144-160 230 Vac /1500W N.A. SP 144-160 E1 heating element Proseal 44 Quartz Tubing Inc. 144-159 230Vac /1850W N.A.
Diagrams 8-10 November 1999
Diagrams 8-3. Mechanical Spare Parts List, Assembly Drawings & Exploded Views 8-3-1.
Diagrams 8-12 November 1999
Diagrams 8-3-2. Assembly Drawings & Exploded Views The next pages contain assembly drawings and exploded views.
