File - Equipment Services and Calibrations
Contents
1. If heater element is to be reused remove Heater element before roll removal as detailed above Lift Feed Table and Fume Exhaust Duct out of Laminator and set them aside Remove Grounding Brush P N 240 0250 from the respective Pressure Roll near left end of roll inside of Side Plate Disconnect heater wires from slip ring coupling Loosen set screws on Slip Ring Coupling and remove Slip Ring Coupling from Pressure Roll shaft On drive left side disconnect Chain Tension Idler Spring Remove the Drive Chain Remove the Drive Sprocket from the Pressure Roll Remove shoulder screws securing lifter to bearing plate on each side of the Laminator Remove lifter plates Loosen setscrews on bearing block on left side NOTE There are no setscrews on right side to allow Pressure Rolls to expand when heated Remove shoulder screw and idler sprocket on left side bearing plate at pivot and remove bearing plate with bearing block attached Slide Pressure Roll out through left side of Laminator being careful not to bend or disrupt thermocouple assembly riding on roll NOTE If bottom Pressure Roll is also to be removed follow the applicable steps above and proceed as follows 30 n 0 Loosen setscrews on bearing block Remove both lower bearing blocks on each side of Laminator and lift bottom Pressure Roll out through same opening used for the top roll being careful not to disrupt the lower Roll thermo2. NOTE PLEASE SEE APPENDIX FOR COMPLETE USER S MANUAL ON TEMPERATURE CONTROLLER 8 Temperature Control Module XRL 240 Replacement a Turn Circuit Breaker OFF and DISCONNECT POWER CORD b Remove wires from terminal Strip of Controller c Loosen screws securing controller to panel d Reverse above steps to re install new Temperature Control Module NOTE If the controller housing is not faulty it may stay in place and the controller module itself can be changed One screw on the bottom of the controller face is loosened and the module will pull out of the housing 9 Temperature Sensor Replacement a The Temperature Sensor see Figure 10 comes as a unit composed of a flexible stainless steel bracket and a copper heat sink to which is soldered the Type J iron constatan Thermocouple The Thermocouple lead white red is routed back to the connector screws of the Temperature Controller The negative lead is colored red b To replace the Temperature Sensor unscrew the Thermocouple leads from the Temperature Controller disconnect the tie downs holding the lead wire in place and carefully pull the lead wire out of its routing holes 32 FIGURE 10 TEMPERATURE SENSOR SCHEMATIC THERMOCOUPLE SENSOR THERMOCOUPLE JUNCTION ROLLER MOUNTING BAR NOTE The face of thermocouple junction is covered with teflon tape so that resist material will not stick to the copper disc and cause damage to the roller B
3. Position roll of Dry Film Photoresist so it unwinds from bottom toward the laminating roll b Lift Bottom Supply Mandrel from Laminator remove left collet assembly See Figure 7 Collet Assembly drawing c Place Photoresist rolls onto Supply Mandrel replace left collet assembly be sure tension control knob is on the right See Figure 8 Supply Mandrel Assembly d Center the Photoresist roll on the Supply Mandrel e Replace Supply Mandrel on the Laminator f Thread Dry Film Photoresist around lower stripper bar g Using two pieces of masking tape on a corner of the photoresist separate the polyethene cover sheet from the Dry Film h Tape polyethylene cover sheet to Bottom Takeup Roll i Pull an adequate amount of Dry Film Photoresist from Supply Mandrel to fold into a V and push V between separated pressure rollers 16 FIGURE 6 PHOTORESIST THREAD UP DIAGRAM SEPARATOR SHEET TAKEUP ROLL DRY FILM SUPPLY ROLL STRIPPING ROLLER LAMINATING ROLLER SEPARATOR SHEET TAKEUP ROLL LAMINATING ROLLER STRIPPING ROLLER DRY FILM SUPPLY ROLL FIGURE 6 PHOTORESIST THREAD UP DIAGRAM 17 NOTE 3 INCH COLLET ASSEMBLY SHOWN FOR 6 INCH COLLET ASSEMBLY SUBSTITUTE 240 0095 EXPANSION RING FOR 240 0085 AND 240 0246 O RING FOR 240 0245 fu 249 0423 A 53 PS dAs 00A2 3 q ceg amp 459 240 0070 240 0245 OUTSIDE RING 0 RING 240 0085 EXPANSION
4. Red Purple White Purple White Purple Purple PC C WSDOCS WSDATA WIRELIST WIRE240 LST March 8 1996 42 CPS1 1 11 SPS1 3 SPS1 7 K1 5 K1 6 F5 SSR2 4 SSR2 3 F2 SSR1 1 F4 SSR2 1 CL1 10 MC1 L1 MC1 L2 ASPS1 ASPS1 11 TC2 16 TC2 17 F6 F2 F7 F4 240 0293 AIR SWITCH MAGNUM 240 0285 PRESSURE GAUGE WE STERN 313 0208 SWITCH 3 240 0263 KNOB 240 0265 POTENTIOMETER 7245 0501 SPEED INDICATOR H H i CONTROL PANEL UPPER FIGURE 13 A 43 ENR ram mart orn 245 0518 Temperature Controller see appendix TA r CONTROL PANEL LOWER FIGURE 13 B 44 ee SER lass DOE E qus ul BE Ki bo 415 E l 5 IE En 5 0 SA 59 FIGURE 15 46 DOG QE FIGURE IL ITEM NO 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 PART NUMBER Y n PP 245 0008 245 0005 240 0008 240 0065 240 0092 240 0095 240 0072 240 0128 340 0348 240 0104 240 0017 3 240 0011 1 240 0021 245 0006 245 0009 240 0011 2 240 0251 240 0061 240 0153 240 0024 240 0152 240 0342 245 0502 240 0155 245 0012 240 0201 240 0060 PARTS LIST DESCRIPTION SIDE COVER RIGHT
5. SIDE PLATE SUPPORT PLATE SHAFT SUPPORT SHAFT TAKE UP COLLET ASSEMBLY 3 EXPANSION RING 6 TUBE SUPPLY ROLL TUBE CORE TAKE UP ROLLER BAR ANTI STATIC THERMOCOUPLE ASSEMBLY PRESSURE ROLLER BAR TIE SQUARE BOTTOM HUB TAKE UP SIDE PLATE LEFT SIDE COVER LEFT BAR TIE SQUARE TOP BRUSH CARBON HOLDER COVER REAR SPROCKET ASSEMBLY JACKSHAFT SUPPORT JACKSHAFT SPROCKET CLUTCH CLUTCH OPTICAL ENCORDER BRACKET CLUTCH EXTENSION SHAFT DRIVE MOTOR MOTOR DRIVE SHROUD MOTOR amp BLOWER 48 t N P gt 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 41 48 49 50 51 52 53 54 240 0215 240 0219 240 0241 240 0014 240 0058 245 0007 240 0205 340 0350 240 0302 240 0222 240 0206 340 0321 240 0056 240 0207 240 0055 550 0514 245 0042 340 0354 240 0344 245 0013 240 0012 240 0114 700 0115 2 240 0255 240 0096 240 0217 240 0036 245 0014 TERMINAL BLOCK 14 POLE TRANSFORMER 240V 120V 50 60 HZ DUCTING 3 INCH ANGLE STIFFENER BASE FLANGE BLOWER OUTLET BASE PLATE BLOWER POWER SUPPLY ANTISTATIC BAR FOOT PAD ASSEMBLY CORD 3 COND 12 GAUGE CURCUIT BREAKER 15 AMP DUCTING FLEXIBLE 6 FRAME FILTER FILTER AIR WIRE MESH PLENUM AIR EXHAUST TERMINAL SLIP RING COUPLING SHAFT CORD POWER ANTISTATIC BAR SWITCH PUSH BUTTON BRACKET ENCORDER ANGLE SIDE PLATE BRACKET AIR INLET CHAIN TENSIONER SPRING EXTENSION
6. duct when service is to be performed The XRL 240 also has a magnetic clutch in the drive system Whenever power is shut off the pressure rollers will become free spinning so nothing can get caught in the rollers If any object were caught in the rollers it could be readily pulled out after the Emergency Off Switch is hit XRL 240 SPECIFICATIONS 1 Dimensions 44 25 Wx 25 D x 37 5 H 112 cm x 63 cm x 95 cm 2 Weight 270 lbs 122 kg Shipping Weight 325 lbs 147 kg 3 Heater Capacity Two 2 1000 watt 240 volt cartridge heaters one for each pressure roller 4 Laminating Temperature Range ambient to 285 degrees F 140 degrees C 5 Maximum Roll Speed Range 0 to 12 fpm 6 Roll Speed Working Range 3 to 5 fpm 7 Maximum PCB Panel Width 25 63 cm 8 Electrical Requirements 240 VAC Single Phase 60 50 HZ 10 amp 15 service DRY FILM PHOTORESIST Dry Film Photoresist is used to transfer design art work onto Printed Circuit Boards through a UV exposure process The Dry Film Photoresist is sandwiched between a layer of polyethylene and a layer of polyethylene terepthalate See Figure 5 The protective polyethylene cover is stripped off as the photoresist is being fed into the rolls The polyethylene terepthalate cover sheet protects the photoresist from contamination and damage during lamination and exposure it is peeled off just before development of the photoresist All operators
7. to remove the heater Pull heater out the right Control side If applicable repeat above steps for removing second Heater 3 Pressure Roll Heater Element Replacement a b c d e g h Clean Heater element throughlv before installing Use Heat Transfer Compound P N 240 0253 1 to coat the Heater element throughly as it is being inserted into the Pressure Roll Shaft Start the Heater into the shaft while coating Heat Transfer Compound on the Heater as it is pushed into the shaft Twist the Heater element slowly as it is being inserted Make sure that a uniform coating of the Heat Transfer Compound is on the Heater to insure proper roll heating Push Heater into Pressure Roll shaft leaving approximately 1 4 showing at the lead end Clean all excess Heat Transfer Compound from the end of Heater element CAUTION The Heat Transfer Compound is electrically conductive so it must be thorougly cleaned off all electrical leads electrical connections and component surfaces Attach and tighten set screws on slip ring coupling Fasten Heater lead wires with supply wires to the slip ring coupling Re install Screw Plug in drive end of Pressure Roll shaft left end of the shaft 29 oo Pressure Roll Removal b c d f g h i j k 1 m Turn Circuit Breaker OFF and DISCONNECT POWER CORD Remove both Side Covers
8. CHAIN TENSIONER SPROCKET SPROCKET PLATE BEARING X PLATE AIR CLAMP 49 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 3 74 75 76 77 78 79 80 81 82 83 240 0106 240 0282 240 0062 240 0027 240 0156 245 0022 245 0023 240 0257 1 240 0284 240 0299 313 0211 245 0021 240 0257 2 240 0266 240 0262 245 0518 245 0011 245 0519 240 0218 240 0212 245 0015 245 0503 245 0501 240 0263 240 0265 313 0208 313 0215 240 0293 240 0283 BLOCK AIR CLAMP AIR CYLINDER ANGLE COVER RETAINING DUCT EXHAUST BRACKET SWITCH FRONT PLATE SUPPORT BEARING PLATE SPACER SPROCKET CHAIN CUT LONG REGULATOR VALVE SOLENOID AIR VALVE SOLENOID AIR DUCT EXHAUST OUTLET CHAIN CUT SHORT FUSE HOLDER FUSE 6 AMP CONTROLLER TEMPERATURE BRACKET CONTROL TEMPERATURE SOLID STATE RELAY BEARING SWITCH MOMENTARY REVERSE BRACKET SWITCH MICROSWITCH DIGITAL SPEED INDICATOR KNOB MOTOR CONTROL POTENTIOMETER MOTOR CONTROLLER SWITCH LENS SWITCH AMBER SWITCH ROCKER AIR ON PRESSURE GAUGE 0 100 50 B e HH H H t 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 245 0010 712 0211 240 0161 245 0504 240 0111 240 0098 240 0112 240 0214 240 0216 245 0024 240 0057 240 0202 240 0272 240 0343 200 0508 240 0220 550 0514 245 0520 PANEL CONTROL FUSE 3 AMP BRACKET SWITCH REAR FUSE HOLDER BRACKET SWITCH ACTUATO
9. E SURE that the teflon tape is kept clean Replace tape with new teflon tape if it becomes worn or damaged FIGURE 10 TEMPERATURE SENSOR SCHEMATIC 33 B 10 11 e Unscrew the two screws holding the stainless steel bracket to the square laminator cross bar Remove the Temperature Sensor assembly from the Laminator Reverse above steps to replace the Temperature Sensor with a new unit Transport Speed System Servicing a The Transport Speed System uses a illuminated digital display with a bi directional rotary optical encoder mounted on the rotating motor shaft of the laminator The device is calibrated in Feet Per Minute FPM The programmable settings are made at the factory and should not require any adjustment Magnetic Clutch Servicing a b c d A type SL 30 shaft mounted magnetic clutch provides 125 lb in torque static in the roller drive system The clutch draws 091 amps at 90 VDC The air gap in the clutch is set by the manufacturer The clutch is installed for safety purposes so the pressure rollers will turn freely if power is turned OFF If slipping of the rollers should occur verify first that the entire chain drive system is functioning properly and there is no binding of any of the chain sprockets Next verify that the roll bearing blocks are functioning properly and have not slipped askew If all parts of the drive system are function
10. EDURE To shut down the XRL 240 Laminator NOTE 1 2 3 Push HEAT Switch OFF Push DRIVE Switch OFF Push POWER Switch OFF When shutting down for overnight or other extended periods of non use also Switch CIRCUIT BREAKER OFF and external AIR supply OFF 23 SECTION IV MAINTENANCE 24 A IV MAINTENANCE CLEANING THE XRL 240 1 PRESSURE ROLLS the single most important part of the XRL 240 Laminator to keep clean Lamination results can be adversely affected by dirty Pressure Rolls Use the following procedures a Turn the DRIVE Switch OFF the POWER Switch OFF and the CIRCUIT Breakers OFF For added safety disconnect the power cord b Remove the Feed Table and the Fume Exhaust Duct c Clean the rolls with mild soap and water or mild solvent use a damp sponge or lintless cloth d Rotate the Pressure Rolls by turning them by hand to a new roll area to be cleaned and continue cleaning the new section of roller CAUTION DO NOT clean the Pressure Rolls while power is connected to the laminator DO NOT clean the Pressure Rolls while they are hot DO NOT use a razor blade or knife to scrape the Pressure Rolls The XRL 240 Laminator should be kept clean at all times so that no dust or chips accumulate on the working surfaces Such debris can adversely affect lamination results Use the following procedures daily before starting the Laminator a With a damp sponge w
11. EMPERATURE CONTROLLER TEMPERATURE ADJUSTMENT The temperature setting for each pressure roller can be adjusted on the top and bottom controller by pressing the up or down arrows on the face of the controller The display on the bottom LED will change to a higher or lower set point temperature as required to a maximum of 300 F 149 C AIR PRESSURE SYSTEM Air cylinders mounted on each side of the frame apply pressure to the top roller bearing plates An air regulator has been factory set to approximately 50 PSIG and should not require re adjustment A setting of 50 PSIG as indicated on the pressure gauge will provide approximately 86 pounds of force at the nip of the pressure rolls CAUTION Do not exceed 50 PSIG improper adhesion of Photoresist occurs consult factory The air Solenoid valve is energized through the AIR rocker switch located at the top of the control panel Push it up ON to close the pressure rollers and provice air assist see para 14 Push DRIVE Switch ON Set SPEED Control knob to mid range approximately 6 Feet Per Minute Rolls should turn freely Transport Speed Indicator digital readout should read 6 FPM 12 11 Run SPEED Control through entire speed range Rolls should 12 13 14 15 respond smoothly Transport Speed Indicator should read speed setting of each point Push momentary REVERSE DRIVE Switch Pressure Rolls should reverse direction smoothly Note The Reverse Drive
12. R EXIT TABLE ASSEMBLY ARM SWITCH MOUNTING SWITCH LEVER TERMINAL BLOCK 4 POLE SPACER IDLER SPROCKET PANEL POWER ENTRY CONTROLLER MOTOR FUSE CONTROLLER POWER SUPPLY CLUTCH SOCKET RELAY MOUNTING RELAY POWER DPDT CONNECTOR 90 DEGREE SLIP RING 51 B SECTION VI SPARE PARTS 52 ITEM 240 0017 3 240 0104 1 240 0253 1 245 0204 245 0522 245 0518 1 245 0520 712 0211 313 0208 245 0519 OPTIONAL 240 0202 RECOMMENDED SPARE PARTS LIST FOR MODEL XRL 240 HOT ROLL LAMINATOR DESCRIPTION QTY HOT ROLL 2 IR THERMOCOUPLE ASSEMBLY 2 HEAT TRANSFER COMPOUND 1 HEATER 1 FUSE 6 AMP 4 TEMPERATURE CONTROLLER 1 SLIP RING 1 FUSE 2 AMP 4 SWITCH CONTROL PANEL 1 RELAY 1 DRIVE MOTOR CONTROLLER 1 UNIT PRICE 1 175 00 348 00 28 00 250 00 5 00 475 00 110 00 5 00 41 00 88 00 TOTAL EXT PRICE 2 350 00 696 00 28 00 250 00 20 00 475 00 110 00 20 00 41 00 88 00 4 078 00 389 00
13. RING DOWEL PIN 1 240 0071 INSIDE RING COLLET 240 0068 FIGURE 7 COLLET ASSEMBLY SUPPLY ROLL 18 SHAFT SUPPLY ROLL 240 0073 SHAFT COLLAR 240 0078 SETSCREW q S CLUTCH DISC NZ 240 0075 I OILITE TUBE SUPPLY ROLL 240 0227 240 0072 N S N TAN 240 0074 VA CLUTCH PLATE V DOG POINT SETSCREW NSS SGN Ney 240 0256 NI IN NIS COMPRESSION SPRING PLAIN WASHER 240 0077 KNOB MANDREL SUPPLY ROLL FIGURE 8 19 3 k Place Bottom Take up Roll into deep slots so it rests onthe Dry Filmroll Take up cover sheet slack on Take up Roll Loading Upper Supply Mandrel a b c e g h i j k 1 m Position roll of Dry Film Photoresist so it unwinds from rear toward laminating roll See Figure 6 Lift Top Supply Mandrel from Laminator remove left collet assembly Place Photoresist roll onto Supply Mandrel replace left collet assembly Be sure tension control knob is on the right Center the Photoresist roll on Supply Mandrel Verify that both Top and Bottom Photoresist rolls are aligned laterally with each other You may place one roll on top of other roll prior tof 5 above to obtain near compatable alignment Replace Supply Mandrel in the Laminator Thread Dry Film Photoresist around upper stripper bar Using two pieces of ma
14. Switch is functional only when the DRIVE switch in ON On the right rear of the machine approximately level with the exit tray is the Air Actuation Panel Sensor Switch This switch is adjusted by means of a thumb screw and wing nut and moves up and down ina slot The switch changes the set point of a microswitch which controls the ON OFF of the air assist cylinders paragraph 9 above For thicker boards the position of the switch is raised up and secured by the wing nut This will turn the air pressure off until a panel is inserted in the rollers When the upper roller is lifted by the board the switch will energize and pressure will be applied This provision is installed so that the thicker panels will start easier into the rollers Open the pressure rollers by pushing the AIR switch to the down position OFF This completes the check out The Laminator is ready for laminating DRY FILM PHOTORESIST 13 SECTION III OPERATION 14 III OPERATION SAFETY 42 Operators should read Section INSTALLATION first then proceed to this Section THROW CIRCUIT BREAKER OFF and DISCONNECT POWER CABLE before servicing the XRL 240 The XRL 240 can be stopped instantly from four separate positions 1 Main Control Panel front right side 2 Emergency Off Switch rear right side 3 Emer gency Off Switch front left side and 4 Main Circuit Breaker rear left side The XRL 240 has a magnetic drive clutch Whe
15. XRL 240 LAMINATOR OPERATING MANUAL USE OF OPERATING MANUAL This manual has been prepared as a quide in the use of the Western Magnum XRL 240 LAMINATOR and DRY FILM PHOTORESIST The advice contained in this manual is furnished free and is based upon tests and information believed to be reliable The customer should decide for his own purposes whether such advice is valid and suitable for each application Western Magnum does not guarantee results and assumes no obligation or liability for this technical advice All advice is given and is to be accepted at the customer s risk LIMITED WARRANTY Western Magnum Corporation warrants all of its equipment to be free from defects in manufacture for a period of 90 days from date of delivery for initial installation This warranty applies to any defects of material or workmanship which appear under normal and proper use unless caused by the fault or negligence of the customer its agents employees licensees or invitees Western Magnum s sole obligation under this warranty shall be to correct at its expense any defects of material or workmanship either by repair or replacement at its option This warranty does not include and the user will be charged for parts and labor service including transportation to replace expendable items e g bulbs rollers gaskets Western Magnum shall not be liable for other damages whether direct indirect and or consequential This wa
16. are directed or should be instructed by Supervisors to discard both protective cover sheets after removal DO NOT use these films for any other purpose as they are covered with trace amounts of photo sensitive materials POLYETHYLENE SEPARATOR SHEET ORY FILM PHOTORESIST POLYETHYLENE TEREPHTHALATE COVER SHEET FIGURES DRY FILM COMPOSITION SECTION 11 INSTALLATION 10 II INSTALLATION OPERATING SITE 1 Optimum Clearances A work table of approximately 30 x 48 by 27 high is recommended for mounting the XRL 240 A three foot clearance on all sides is desirable Lighting Since Dry Film Photoresist is photosensitive the resist film must be used in work areas with only yellow light illumination gold fluorescent bulbs Do not allow white light or daylight to enter the work area when Photoresist is being used INSTALLATION PROCEDURE 1 The XRL 240 Laminator is shipped completely assembled The Laminator has been thoroughly tested at the factory prior to shipping Note Immediately upon arrival open crate in delivery drivers presence and inspect the Laminator for damage and if damaged file a claim with the carrier Remove all shipping tiedowns Place Laminator on work table Adjust height of each foot to share the weight of the Laminator equally Verify Laminator is level Connect the Laminator to a 240 VAC 50 60 HZ single phase electric supply line having 15 or 20 AMP circuit pro
17. couple assembly Pressure Roll Installation a b c d e g Main a b 9 Reverse the steps 4 above to re install the Pressure Rolls In addition do the following The Pressure Rolls should be centered with respect to the side frames i e the roll end is equal distance from each side frame and the roll ends are aligned one to the other Tighten Set Screws on ONLY the left side Bearing Block to avoid lateral shifting Replace the Pressure Roll drive sprocket Align the sprocket with that of the opposite Pressure Roll sprocket Position the Temperature Thermocouple Replace the Grounding Brush Replace the Drive Chain Replace the Chain Tensioner Spring Motor Replacement Turn Circuit Breaker OFF and DISCONNECT POWER CORD Remove left Side Cover Remove Rear Cover Remove Short Drive Chain Remove Motor Drive Sprocket Encoder and Safety clutch Remove electrical leads to Motor Remove motor mounting bolts Remove Main Motor 31 i To replace Main Motor reverse the above steps j Make sure Motor Drive Sprocket aligns with other drive sprockets and Chain Tensioner Sprocket 7s Temperature Controllers Adjustment The temperature can be adjusted by depressing either the up or down arrows on the face of each controller The bottom LED display will indicate the set point temperature as it is changed
18. d DISCONNECT POWER CORD Remove both Side Covers Disconnect the heater wires from the shaft an slip ring coupling See Figure 9 Heater and Slip Ring Installation drawing Loosen set screws on slip ring coupling slide slip ring coupling and connectors from Roll Shaft Remove heater element by pulling on heater end DO NOT pull on heater wires The Heater is covered with a coating of Heat Transfer Compound and should slide out easily If heater does not come out easily proceed to step f On left side remove Screw Plug from drive end of pressure Roll Shaft Insert a metal rod 3 16 diameter in the center of the shaft to push the heater element out 28 VW tre x E NC T EEE ee RRS DN CAPO AL AR L COMPLETELY COAT TEM 7 HEATER wiry 240 02 1 NOTES ENGINEERS STANDARD FORM vez 2 7 b M 10 32 x E SE TSCBEW HEX SOCKET 9 32 x 216 serew HEX SLET HEAD CA D 9 210 028 210 0283 7 e 5 245 0008 SIDE COVER RG UT 4 245 0005 SIDE RATE RICHT 240 0017 3 ROLCER PRESSURE HEATED 245 0520 sese RING 245 0042 SHAFT WESTERN MAGNUM CORPORATION EAE d d IVSTALLATION HEATER F SLIP RNG FIGURE 9 UBA h CAUTION Excessive tapping might mushroom the end of the heater inside of the shaft making it extremely difficult
19. d possibly wrinkle Too little tension can also allow the Photoresist to wrinkle when laminated to the PC Board To correct for Photoresist wrinkling caused by too much tension turn the Tension Control Knob counterclockwise until the web no longer stretches To correct for too little tension turn the knob clockwise NOTE Too much tension can result in poor adhesion of the Photoresist at the edge of the Board Proper tension is the MINIMUM tension which will avoid wrinkling of the photoresist on the laminated surface of the PC Board Verify the edges of the two sheets of Dry Film Photoresist remain aligned Adjust the guide on Feed Table for PC Board width Recheck Photoresist Thread Up Diagram to verify the Dry Film has been threaded properly 21 C LAMINATING OPERATION 1 Double sided lamination a b c d e g h i j POWER Switch ON HEAT Switch ON allow 15 20 minutes for Pressure Rolls to heat up and the temperature to stabilize the Laminator is ready when both temperature controller load lights have been cycling ON and OFF Verify that Photoresist edges are aligned evenly Set the adjustable Feed Table Guides to the PC Board width AIR Switch ON DRIVE Switch ON select proper Speed setting NOTE Thicker PC Boards require more heat for proper lamination than do thinner boards For thicker boards slow down roll speed by turning SPEED control knob counterc
20. e Gray White Gray White Gray White Purple Green White Purple White Yellow Yellow Red White Red Black Black Yellow White Yellow White Yellow Yellow Red 40 T1 TB2 2 TB1 3 T1 TB2 1 TB1 1 TB2 6 1 2 3 M2 MC1 P1 MC1 P2 MC1 P3 54 53 1 12 1 1 12 3 B TB2 2 TB1 4 K1 2 TB2 1 S3 1 A TB2 5 P1 3 S3 3 5 5 52 2 1 HTR 1 F3 HTR 2 F2 2 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 WIRE LIST con t Purple Black White Purple White Red White Blue White Blue Red White Red White Red Red Red Red Orange Orange White Red White Brown Orange Gray Brown White White Red Red Black 41 F7 SSR1 4 F6 SSR1 3 SSR1 2 SSR2 2 TC1 11 TC1 9 TC2 11 TC2 9 CB1B 1 S7 C CB1A 1 S6 NO S5A NC S5A NO M2 S3 S8 A 53 58 2 2 TC2 10 TC1 16 TC1 10 TC1 17 HTR 1 HTR 2 TS1 TS1 TS2 TS2 S7 NO TB1 1 S6 NO TB1 4 S5B NC S5B NC TB2 6 S8 A 9 C TSI 1 SOL1 TB2 4 F3 1 CL1 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 WIRE LIST con t COLOR Black Black White Black Black Black White Black Black
21. ing properly then the clutch might be slipping In this case replace the clutch with P N 240 0342 If the magnetic clutch fails to operate the full wave rectifier that provides power to the clutch may have failed This part is mounted on the right side plate under the side cover P N 240 0343 Replace as necessary XRL 240 Electrical Diagram Wiring Figure 11 Schematic electrical Figure 12 Wire List 34 or n sow 292112393 IILVWAHI ds HON EE M OLLDIHHOD os 115 ed s 199 e 95 53 2H 09 05 Hal A Ove mM 245 WIRE LIST Model XRL 240 Hot Roll Laminator No COLOR FROM TO 1 Black P1 X CB1B 2 2 White 1 1 2 3 Green P1 G1 Ground 4 Green TB2 13 G1 Ground 5 Green TB2 14 GB2 6 Green TB2 14 GB1 7 Green TB2 13 M1 8 Black TB2 12 M1 9 Red TB2 11 M1 10 White TB2 10 M1 11 Brown TB2 9 M1 12 Orange TB2 12 M1 13 Orange White TB2 11 S5A NC 14 Brown White TB2 10 MC1 F1 15 Brown TB2 9 MC1 F2 16 Gray TB2 8 10 17 Gray TB2 8 1 18 Black TB2 3 F5 19 T1 TB2 3 20 Black T1 TB2 4 21 Black White TB2 5 K1 4 22 Black White K1 4 MC1 L2 23 Black White K1 4 S2 B 39 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 WIRE LIST con t COLOR Black White Red Red Red Red Red Red Gray White Gray Whit
22. ipe the Feed Table and Exit Table working surfaces and rollers the Stripper Bars Take up Rolls Supply Mandrels side plates front and back Access Covers 25 b If necessary a cloth dampened with Trichlorethane or Methylene Chloride may be used on everything except plastic parts to remove particles of resist on working surfaces NOTE Use Neoprene gloves when handling solvents or cleaning resist condensate AVOID getting resist condensate or solvents on bare skin If it should get on the skin inadvertently wash immediately with soap and water AVOID breathing solvent or resist fumes Insure adequate ventilation DO NOT use any solvent on HOT surfaces clean the parts only when they have cooled down 3 Inspect the Photoresist condensate filter monthy and clean as necessary 26 SECTION V SERVICE 27 A V SERVICE CAUTION Always turn CURCUIT BREAKER to OFF and DISCONNECT POWER PLUG from receptacle before working on the XRL 240 LAMINATOR SERVICING THE XRL 240 l Side Covers Removal a b c Turn CIRCUIT BREAKER to OFF and DISCONNECT POWER CORD Remove the right SIDE COVER Control Side by unscrewing attaching screws and then pull cover off be careful of wire bundles Remove the left SIDE COVER by unscrewing attaching screws and pulling cover off Pressure Roll Heater Element Removal a b c d e f Turn CIRCUIT BREAKER to OFF an
23. lockwise to about 3 FPM This permits longer contact with the heated roller transfers more heat to the board and results in better Photoresist adhesion Feed PC Board into Laminator guiding the board against the guide on the Feed Table NOTE DO NOT force PCBs into the roller nip The dual driven rolls will pull the PCB into and through the rolls thicker panels excepted As the front edge of the laminated PC Board exits from the Pressure Rolls across the Exit Table cut the excess Photoresist Film across the leading edge Trim the Photoresist flush leaving no overhang or tails As the trailing edge of the laminated PC Board exits from the Pressure Rolls cut the Photoresist film across the trailing edge OPERATORS SHOULD BE INSTRUCTED TO TAKE GREAT CARE IN TRIMMING PCB s AS THEY EXIT THE PRESSURE ROLLS AVOID DAMAGE TO THE RUBBER COVERED ROLLS OPERATORS SHOULD ALLOW THE COPPER BOARDS TO MOVE WELL CLEAR OF THE PRESSURE ROLLS BEFORE TRIMMING THE PHOTORESIST 22 D Single sided lamination a b To prevent Photoresist from transferring to the Pressure Rolls a back up paper is required on the side opposite the Photoresist roll For this type operation mount a roll of paper wider than the resist on the opposite Supply Mandrel and allow the paper to advance with the Photoresist A hard finish dust free paper or polyester type film is adviseable Proceed as in paragraph III C 1 SHUT DOWN PROC
24. never the power is shut off as specified just above the pressure rolls are free spinning enabling anything caught in the rolls to be pulled out CAUTION The rollers are very hot and will take considerable time to cool down The Pressure Roll REVERSE DRIVE Switch located on right side plate can be operated from either the front or back of the machine to reverse the rolls NOTE POWER and DRIVE SWITCHES must be ON to operate the REVERSE DRIVE function ALWAYS DISCARD the polyethylene protective covering and the polyethylene terephthalate cover sheet after removal from photoresist rolls DO NOT wear loose clothing or jewelry while operating or servicing the laminator KEEP AWAY from hot laminating rolls Rolls operate at about 235 F and can burn the skin of a careless operator WASH THOROUGHLY with soap and water after handling Photoresist materials 15 THREAD UP PROCEDURE l ASSURE THAT POWER IS DISCONNECTED Refer to the PHOTORESIST THREAD UP DIAGRAM Figure 6 for the proper procedure to thread up the Laminator Remove adjustable Feed Table and Fume Duct Place nearby Place both empty Take Up Rolls in their respective utility groves Be sure top and bottom Photoresist Supply Mandrels are oriented correctly i e the Tension Control Knobs on each mandrel are on the right hand side NOTE When loaded with Photoresist the Supply Mandrels are NOT interchangeable Loading Bottom Supply Mandrel a
25. ram Collet Assembly Supply Roll Mandrel Supply Roll Heater and Slip Ring Assembly Temperature Sensor Schematic Wiring Diagram Electrical Schematic Control Panel Illustrated Parts Diagram Right Side Illustrated Parts Diagram Left Side Illustrated Parts Diagram Rear SECTION I INTRODUCTION 4 1 j 2 4 4 FIGURE 4 I INTRODUCTION TO THE XRL 240 LAMINATOR vv GENERAL 1 The XRL 240 LAMINATOR is designed for use with any DRY FILM PHOTORESIST The Laminator is a new design incorporating significant improvements in dry film laminator technology See Figure 1 for a photograph of the Laminator 2 The XRL 240 uses heat and pressure to laminate DRY FILM PHOTORESIST to flexible or rigid materials up to 25 inches wide and 0 250 inches thick Maximum Photoresist film width 24 inches Materials typically laminated with DRY FILM PHOTORESIST include copper clad laminate used in the manufacture of printed circuit boards and sheets or rolls of metal for chemical milling Photoresist can be laminated to one or both sides of the working material in a single pass through the laminator 4 Figures 2 3 and 4 show major features of the XRL 240 LAMINATOR 5 The XRL 240 has two large diameter internally heated Pressure Rolls with roll temperature controlled by two solid state digital reading potentiometric input thermocouple temperature controllers Thi
26. rranty is in lieu of any other warranties express or implied including any implied warranty of merchantability or fitness for a particular purpose and of any other obligation or liability PN II III XRL 240 LAMINATOR OPERATING MANUAL TABLE OF CONTENTS Use of Operating Manual Warranty INTRODUCTION TO THE XRL 240 LAMINATOR A General B Operating Safety C XRL 240 Specifications D DRY FILM PHOTORESIST INSTALLATION A Operating Site B Installation Procedure OPERATION A Safety B Thread Up Procedure Laminating Operation D Shut Down Procedure IV VI MAINTENANCE A Cleaning the XRL 240 B Lubricating the XRL 240 SERVICE A Servicing the XRL 240 l Side Covers Removal 2 Pressure Roll Heater Elements Removal 3 Pressure Roll Heater Elements Replacement 4 Pressure Roll Removal 5 Pressure Roll Installation 6 Main Motor Replacement 7 Temperature Controllers Adjustment 8 Temperature Control Module Replacement 9 Temperature Sensor Replacement 10 Transport Speed System Servicing ll Magnetic Clutch Servicing B XRL 240 Electrical Diagram wiring Schematic Electrical Wire List C Parts List SPARE PARTS A Ordering Parts FIGURE 10 11 12 13 14 15 16 ILLUSTRATIONS DESCRIPTION XRL 240 Front View XRL 240 Right control Side XRL 240 Left Side XRL 240 Rear View Dry Film Composition Photoresist Thread Up Diag
27. s combination of temperature and pressure provides optimum dry film lamination conditions The heated Pressure Rolls are in intimate contact with the Photoresist for heat transfer to the Photoresist and the Printed Circuit Board An air pressure system provides high unit pressure to the rollers to insure satisfactory Dry Film lamination The transport speed system includes a digital readout of transport speed in feet per minute OPERATING SAFETY The XRL 240 has been conceived with OPERATOR SAFETY as a key design goal The machine can be stopped instantly from four separate positions 1 Main Control Panel front right side of machine 2 Emergency Off Switch front left side of machine 3 Emergency Off Switch rear right side of machine and 4 Main Circuit Breaker rear left side of machine 2 In addition the Pressure Roll REVERSE DRIVE Switch right side plate can be operated from either the front or back of the machine to reverse the direction of the laminating rollers the power and drive switch must be ON An additional OPERATOR SAFETY FEATURE is provided by the Placement of the fume exhaust duct and shield located directly in front of the pressure rolls The fume duct and shield are positioned so operators can not get their hands or unwanted objects near the rollers If the fume duct is removed POWER TO THE MACHINE DRIVE WILL SHUT OFF As an extra precaution the power plug should be disconnected before removing the
28. sking tape on a corner of the photoresist separate the polyethylene cover sheet from the Dry Film Tape polyethylene cover sheet to Top Takeup Roll Turn roll to take up slack in cover sheet Pull an adequate amount of Dry Film Photoresist from both Supply Mandrels to fold into a V With Pressure Rolls open push Dry Film through the roll gap Place Top Take up Roll into deep slots so it rests on the Dry Filmroll Take up cover sheet slack on Take up Roll Verify the alignment of the Top and Bottom Dry Film Photoresist with each other if necessary move one of the Dry Film rolls laterally on its respective Supply Mandrel to make the Dry Film edge alignment exact 20 ll 12 13 14 15 16 Pull several inches of Dry Film through Pressure Rolls to prevent Dry Film wrap around Replace Fume Exhaust Duct and Feed Roller Table CONNECT POWER TO LAMINATOR With Speed Control at Zero turn DRIVE Switch ON Turn Air Switch ON closing pressure rolls Run several feet of Dry Film through the Laminator at low speed until major wrinkles are gone opening and closing Pressure Rolls while the DRIVE is ON helps dissipate wrinkles Dry Film Photoresist web tension is controlled by the Tension Control knobs on the right end of each Supply Mandrell Proper tension is mandatory to eliminate wrinkles in the Photoresist Too great a pressure from the Tension Control Knob will cause the Photoresist to stretch an
29. tection Use the twist lock receptable supplied with the machine This matches the line plug of the Laminator Note If the plant receptacle does not match the Laminator plug replace the plant receptacle with that provided Check that the Pressure Roll thermocouples make good contact with the roll surfaces Verify that the Pressure Rolls are securely installed and do not shift from side to side If necessary to tighten rolls see Service Section V A 5 for details 11 5 6 7 8 Remove Feed Roller Table and Fume Exhaust Duct for access to pressure rolls Wash pressure rolis with a damp sponge rinsed in soap and water After cleaning rolls re assemble Fume Duct and Feed Table Connect plant air supply 60 100 lbs to the 1 4 knurled nut compression fitting supplied on the unit located in the circuit breaker panel in rear Place Laminator Circuit Breaker to ON Push POWER Switch ON The amber light in the POWER Switch should glow If it does not glow check to see that both emergency off switches are pulled outward TEMPERATURE CONTROLLERS Push HEAT Switch ON The two LED displays will light up on each of the two controllers The bottom LED will display the set point temperature and the top will be the actual temperature for each pressure roller Temperatures will be displayed in fahrenheit unless other wise requested for centigrade NOTE PLEASE SEE APPENDIX FOR COMPLETE USER S MANUAL ON 9 10 T
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