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CUT-SHEET LAMINATOR 1600-D

1. 26 TACKING BARS NOT AT WORK 27 BREAKDOWN TO TACKING BARS 5 28 BREAKDOWN TO TACKING BARS SENSORS ees 29 LAMINATION ROLLS MOVEMENT FAILURE 30 LAMINATION ROLLS MOVEMENT FAILURE 31 LAMINATION ROLLS NOT COMPLETELY CLOSED 32 LAMINATION ROLLS NOT COMPLETELY OPENED 33 BREAKDOWN TO CLOSED OPENED ROLLS SENSORS 34 BREAKDOWN TO CLOSED OPENED ROLLS SENSORS 35 INDEX CAMME MOVEMENT 36 INDEX CAMME MOVEMENT FAILURE eene 37 INDEX CAMME NOT IN SET 38 INDEX CAMME NOT IN WORK POINT eee 39 REAR EDGE PHOTOCELL DAMAGED eee 40 REAR EDGE PHOTOCELL DAMAGED eem EMERGENCY STOP ACTIVATED eee LOW PRESSURE COMPRESSED AIR SAFETY GUARD OR DOORS OPENED VACUUM PUMP OVERLOADED eene LATERAL CENTERING FAILURE eene SLIDING TROLLEY 1600 D Il 73 orton 1600 D Morton Electronic Materials 41 FILMAROLES NOT LOGKED eee inten cerner 320 42 VACUUM EXCLUSION ON
2. 1011 43 amp BOT CUT HOOKING MOVEMENT FAILURE 2670 44 CUT HOOKING MOVEMENT FAILURE 260 45 BOTTON CUT HOOKING MOVEMENT FAILURE 270 46 amp BOT SHEARS NOT IN 2671 47 SHEARS NOT IN 261 48 BOTTON SHEARS NOT IN SET 271 49 TOP amp BOT TENSION ROLLS NOT IN WORK POINT 670 50 TENSION ROLL NOT IN 60 51 BOTTON TENSION ROLL NOT IN WORK POINT 70 52 TOP amp BOT TENSION ROLLS NOT IN WORK POINT 671 53 TENSION ROLL NOT IN WORK 61 54 BOTTON TENSION ROLL NOT IN WORK POINT 71 55 FRONT EDGE DEVICE MOVEMENT FAILURE 381 56 FRONT EDGE DEVICE MOVEMENT FAILURE 560 57 OUTPUT BOARD TEMPERATURE OUT OF RANGE 51 58 TOP amp BOT END OF FILM OR NO TACKING 3670 59 TOP END OF FILM OR NO TACKING 360 60 BOTTON END OF FILM OR NO 370 61 TOP amp BOT MISSED CUT eese 3671 62 TO
3. During the cutting operation the moving blade is moved symmetrically from both sides due to the right and left hand leverage of the cutting group 1 48 orton 1600 D Morton Electronic Materials It is very important that the cutting speed should not be too slow in order to ensure that the cut takes place on the fly but conversely it should not be too fast or the moving blade might bounce off the counter blade which would give rise to an imperfect cut Counter blade The flow regulators of the double barred pistons make it possible to regulate the speed which should be kept to between 0 6 and 1 sec The manufacturing criteria of the cutting tools are such that they should survive countless operating cy cles before requiring maintenance However when it does become necessary to restore optimum cutting conditions the counter blade will have to be turned so that one by one all four of its cutting corners can be used Cutting corners 2 Cutting corners Counter blade Il 49 orton 1600 D Morton Electronic Materials Once all four cutting corners have been worn out the cutting corners of both the moving blade and the counter blade will have to be restored to 90 Wearing cutting Regenerating corners cutting corners Moving blade The grinding process for these tools is extremely delicate and must be carried out with the greatest preci sion and skill taking care to avo
4. sulted for all necessary information The electrical control cabinet is fitted with three hand grips containing components the main one cannot be moved and has been placed at the back asecondary and movable grip is positioned on the right hand hinge another secondary and movable grip is positioned on the left hand hinge Il 66 orton Morton Electronic Materials INPUTS PLC 0 Set up on push button 1 Emergency line set up off push button 2 Cycle start push button 3 Cycle stop push button 4 Centering board detecting photocell 5 6 7 Upper tension roll work point Lower tension roll in work point 8 Upper both lamination sensor 9 Film rolls free greaped push button 10 Upper vacuum off selector 11 Lower vacuum off selector 12 Film loading set point push button 13 Alarm output temperature regulator 14 Air pressure detector 15 Safety guard switches 16 Introducting board cylinder in work point 17 Introducting board cylinder in set point 18 Barrier in closed position working point 19 Barrier in opened position set point 20 Upper follower cylinder in set ponit 21 Upper follower cylinder in work point 22 Lower follower cylinder in set point 23 Lower follower cylinder in work point 24 Index switches in set point 25 index switches in work point 26 Upper cutting device hooked 27 Lower cutting device hooked 28 Cam in initial cut position 29 Camin tacking position 30 Cam in end cut positi
5. DYNAMIC TENSION ROLLS Il 60 STATIC TENSION FRICTIONS 1 63 LATERAL CUTTING 1 64 ELECTRICAL CONTROL CABINET Il 66 INPUTS PLC 1 67 OUTPUTS PLC Il 68 CONTROL PANEL OF THE ELECTRICAL CABINET Il 69 CONTROL PANEL OF THE MACHINE ITSELF 1 71 CSL 1600D VIDEO DISPLAY KEYBOARD UNIT 1 72 COMPLETE MESSAGES AND IDENTIFICATION CODES 1 73 COMPLETE MESSAGES AND DESCRIPTION CAUSES LIST 11 75 ADVICE FOR LAMINATION Il 90 SETTING UP THE UNIT 11 95 11 1 ZAorton 1600 D Morton Electronic Materials OPERATOR START UP Turn on Main Disconnect Machine does system Check EVERYTHING OK message will display if self check runs OK Pull out Sliding Trolley Start machine by pressing Set Up button on main control panel Machine vacuum pump will start To enable the machine vacuum system repositioning rotating sectors Place film on film spool supply rollers and thread per diagram on side rail of machine Center film by using the centering scale and lock into position Trim leading edge of film against counter blade being careful not to damage tacking strip Close Sliding Trolley machine will start to heat Lamination Rollers Verify proper temperature setting on Temperature Controllers adjust as necessary Verify proper lamination roll pressure adjust as necessary Verify lamination speed front and rear film spacing and tacking time are set correctly Changes can be made by pressing Set Up button on Main Cont
6. EVERYTHING 8 Once the machine has been given its check control apply a short pulse of SET UP ON and immediately afterwards one of SET UP OFF 9 Check whether air is being exhausted or blown through the air outlet nozzle If there is exhaust stop the machinery and disconnect the electricity Then invert two of the three general power supply phases in order to invert the direction of the vacuum pump 10 Apply voltage to the machine once more and if the check control signals OK move out the trolley and proceed with the SET UP ON 11 Put by hand the rotating sectors in the STAR CUTTING POSITION and depress the green switch called FILM LOADING POSITION situated on the mini push buttons panel on the movable unit 12 When this button is activated the index fix the two sectors in this position 11 95 orton 1600 D Morton Electronic Materials 13 14 15 16 17 18 The shafts for the dry film spool be blocked or released by pressing cyclicling the luminous yellow button called FILM ROLLS ON FREE installed on the movable unit Load the two spools rolls of film following the thread up diagram provided on the shoulders of the machine Block the dr y film shafts and centre the spool of dry film using the metric gauges specially provided for this purpose If a lateral cut is also required follow the same thread up diagram Pass the film through the polythen
7. IMPORTANT Never stand near the machine while it is being lifted ATTENTION The machine lifting and handling operations may only be carried out by specialized person nel authorized to use the above mentioned equipment IMPORTANT MORTON declines all responsibility for any damage to persons or property caused by fail ure to comply with the instructions given in this manual and specified by the current Safety Provisions concerning lifting and handling of materials inside and outside fac tories SUITABLE MACHINE LIFTING MEANS 1 orton Morton Electronic Materials DEMOLISHING THE MACHINE Proceed in the following way if the machine must be demolished for any reason owing to age if it can no longer be repaired etc Disconnect the machine by carrying out the operations described in the operations and maintenace sections of this publication in reverse Dismantle all possible parts of the machine casing lamps guards handles chains motors etc dividing them according to their different nature eg pipes rubber components lubricants solvents lacquering products aluminium ferrous material copper glass etc 1600 D Before the machine is scrapped inform the authorities in charge of these matters in writing in compliance with the provisions in force in the individual countries After having received authorization from the above mentioned organizations eliminate
8. as illustrated in the diagrams CYCLE TIMES Pos mm Pos 50 mm Front edge Rear edge The position of Zero edge to which would correspond an equal measurement for board and film has been preset with a code of POS 0 Il 14 orton 1600 D Morton Electronic Materials Similarly a 50 mm edge corresponding to 50 mm of board not covered by film is preset with the code of POS 50 The operator must therefore first set a front edge of 0 mm on the video and then increase this number on the POS 0 presetters if the film is found to be longer than the laminated board Conversely the number must be decreased if the film is found to be shorter than the laminated board Once the position has been corrected for a zero edge a front edge of 50 mm must be set and the number of the presetters POS 50 increased if the edge is found to be less than 50 mm Conversely the number must be decreased if the edge is found to be greater than 50 mm Caution Once these parameters have been changed via the presetters it will be necessary to enter into the page of parameter presetters via SET UP ON and then to leave it once more without making any further modifications via A0 By this means the PLC will be able to read and store the new values set on POS 0 and POS 50 mm Replacement of the control circuit board will not necessitate a
9. orton 1600 D Morton Electronic Materials SETTING UP THE UNIT The Laminator Model 1600 D is delivered with all accessories firmly secured to the main block The vacuum pump which is mounted on shock absorbant rubber pads is attached to the structure during transport by a clamp which should be removed as soon as the machine has been assembled in the yellow room The installation procedure is as follows 1 After having positioned and or levelled the machine at its permanent emplacement remove any fastenings or bindings used in transport and take out the mobile central unit 2 Make the pneumatic connections For this you will need unlubricated compressed air at 6 atm filtered and dehumidified 3 Make the electrical connections For this you will need a three phase system Ground at 25A The voltage required is indicated the specification tag attached to the main switch 4 Connect a 0 150 mm diameter tube between the main exhaust system of the shop floor and the plug of the air outlet of the machine Caution Make sure that there are no sharp bends in this tube or the flow will be reduced 5 Open the general compressed air supply valve situated on the left hand side of the machine 6 After having made sure that all the mechanical parts are in place supply voltage to the machine 7 If any irregularities are found during the systems tests put them right to the point where the machine itself transmits the message
10. 0 and 89 C and from 131 C upwards Alarm The alarm message is Lamination rolls temperature out of range Caution It is important that the temperature transducer should always remain in contact with the rolls but it should also have the possibility to draw back A lack of contact between the thermocouple and the roll would give rise to a dangerous rise in roll tem perature even to the extent of burning the rubber Il 57 orton 1600 D Morton Electronic Materials TEMPERATURE READER FOR THE FINISHED BOARD On the right hand panel of the machine there is an instrument that displays the temperature of the finished board after lamination DYNACHEM IR PYROMETER This parameter is an important coordinate for discovering whether or not the lamination is proceeding within the normally correct limits The infra red ray temperature sensor not in contact is housed in the rear section of the machine Since the IR sensor is influenced by colours the display instrument contains a selector which is posi tioned according to the different colours of dry film green red However these different values must be calibrated in function of the colour of the dry film using the trim mers placed on the back of the instrument itself Generally speaking the temperature recommended for a board laminated with a Dynachem dry film is between 45 C and 55 C If the instrument has been s
11. Mod 1600 D and if so instructed by Morton the Mod 1600 D or any part there of will be shipped freight paid by Morton to Morton for re pair Neither the Mod 1600 D nor any part there of is to be returned to Morton without written authorization from Morton This warranty is effective only under the condition that the Mod 1600 D AU TOMATIC LAMINATOR is installed in accordance with Morton specifica tions The warranty for the 1600 D AUTOMATIC LAMINATOR does not cover the laminating rolls except for original manufacturing defects reported during the warranty period Additionally the warranty is null and void if the Mod 1600 D is abused or operated contrary to the instructions or if alterations or repairs are made by other than authorized Morton representatives or by written permission from Morton Morton s liability for any breach of warranty is limited as set out above to repair or replacement of the defective part and labor charges in certain in stances and in on case shall Morton be responsible for any consequential damages nor shall Morton s liability in any case exceed the amount of the purchase price of the Mod 1600 D AUTOMATIC LAMINATOR This warranty is expressly in lieu of all other warranties express or implied including the warranty of merchantability of fitness for a particular purpose MORTON is a Registered Trademark orton 1600 D Morton Electronic Materials GENERAL INDEX GENERAL DESCRIPTION 1
12. TOP TENSION ROLL NOT IN WORK POINT 60 The machine stopped because during the tension roll extension phase the top sensor FC6 is not activated 51 BOTTOM TENSION ROLL NOT IN WORK POINT 70 The machine stopped because during the tension roll extension phase the bot sensor FC7 is not activated 52 TOP amp BOT TENSION ROLLS NOT IN WORK POINT 671 The machine stopped because during the tension rolls release phase the top and bot sensors FC6 and FC7 are not released 53 TOP TENSION ROLL NOT IN WORK POINT 61 The machine stopped because during the tension roll release phase the top sensor FC6 is not released 54 BOTTON TENSION ROLL NOT IN WORK POINT 71 The machine stopped because during the tension roll release phase the bot sensor FC7 is not released Il 84 orton 1600 D Morton Electronic Materials 55 FRONT EDGE DEVICE MOVEMENT FAILURE 381 The machine has stopped or is unable to start because during the regulation phase of the front edge one of the two overstep microswitches FC100 or FC110 of the movement group is pressed or the thermal protection for the motor placed on the control board is activated 56 FRONT EDGE DEVICE MOVEMENT FAILURE 560 The machine has stopped because during the regulation phase of the front edge the preselected position will not be reached in max 20 sec 57 OUTPUT BOARD TEMPERATURE OUT OF RANGE 51 Alarm connected only if the instrument is equipped with an alarm thresholds During the exit of the lamin
13. can be used In order to rotate tip up or replace the counter blade it is sufficient to proceed as for the Replacement of the tacking bars from point 1 to 3 and from point 7 to 8 These parts should also only be replaced by specially trained personnel using materials which conform both from the point of view of design and characteristics to the originals 11 8 orton 1600 D Morton Electronic Materials REPLACEMENT OF THE MOVING BLADES The moving blades should only be replaced by specially trained personnel using original parts which have been correctly designed and made from the right materials The procedure for replacement of the rolls is as follows 1 Switch off and disconnect the laminator then wait until the heated parts have cooled off 2 Take out the removable part of the machine After loosening all the screws detach the left hand blade guiding flange for the lower blade and the right hand flange for the upper blade 111 9 orton 1600 D Morton Electronic Materials 3 Unblock the blade tensing spring situated at its other extremity and detach the mobile blade completely 4 Insert the new blade and block the spring repositioning all the parts previously removed Lightly lubricate swivel joints and all parts that make mutual contact Take care not to damage the edge of the blade during the entire dismantling and reassembly operation 11 10 orton 1600 D Morton Ele
14. rolls and repeat all these operations starting from point 2 checking that the distance between the coupling tooth of the moving blades and the counter blades is correct i e 0 7 mm for each unit upper and lower Care should be taken to operate the return cylinders of the cutting groups at the correct pressure Read the description given under point 13 of the chapter Coupling of the cutting groups Il 36 orton 1600 D Morton Electronic Materials CUTTING ON THE FLY REAR EDGE CALIBRATION OF THE SPEED OF THE ROLLS AND THE SENSITIVITY OF THE PHOTOCELL FOR THE REAR EDGE As already illustrated the cutting system employed is a type of shearing i e it consists of a moving blade and a counter blade The entire assembly moves forward at the same speed as the film so that the cuts can be made on the fly without interrupting the lamination process Before the film can be cut the moving blade and the counter blade must be coupled together The fact that the cutting groups are connected to the rotating groups makes this possible see preceding chapter The rear edge is determined by the difference in length between measurements A B and C B Counter blade Photocell Lamination roll D oam B Rolls Since measurement C B is 187 mm it follows that the minimum length of laminable film is 187 mm The command to execute a cut is given by the PLC after the photocell on th
15. rubber tacking bars At 0 the temperature of the tacking bars is the same as room temperature at 100 it is roughly 45 C Its function is subordinated to SET UP ON For further details please turn to the specific chapter EMERGENCY PUSH BUTTON This is a mushroom shaped button which stops the machine instantly cutting off all functions and giving immediate warning via the video monitor Il 70 orton 1600 D Morton Electronic Materials CONTROL PANEL OF THE MACHINE ITSELF LOADING OPERATION FILM LOADING ENABLE SET POINT r VACUUMA FILM ROLLS UPPER LOWER ON FREE OFF ON OFF OO LOADING OPERATION ENABLE This is a luminous pilot light that indicates when the procedure for load ing film onto the machine has been enabled It only lights up when the machine is open FILM LOADING POSITION This is an unlit switch button which enables the procedure for loading the film spool It is dependent upon set up on and also upon the machine being open First rotate by hand the rotating sectors until they reach the Start Cutting position Then push this button in order to fix the index in the mechanical cam If an acoustic alarm is generated with this button that means the rotating sectors are not well positioned FILM ROLLS ON FREE This is a luminous button that operates cyclically The first impulse unblocks the two dry film carrying spools while the second impulse blocks them again This latter condition is si
16. stops the motor in a state of emergency and signals Centering breakdown The same signal is given when one or other of the two overshoot microswitches FC72 FC73 is activated If the centering is to be absolutely precise it is very important that the centering guides should be slowed down decisively once both photocells left and right FC75 and FC76 have been activated Il 8 orton 1600 D Morton Electronic Materials For this reason it is advisable to calibrate the value of the low speed very carefully using potentiometer LT On the other hand with potentiometer RM one can calibrate the off cycle time of the centering guides once the board has been centered With potentiometer CL one can determine the maximum cycle time Once this has expired the centering reopens even if the board has not yet been centered This is useful in that it prevents overloading of the motor in the event of mechanical blockage of the centering unit or any other failure The cycle time allowed should however always be longer than the real time needed to center the board including off cycle time otherwise the centering unit would be unable to complete its run and its off cycle pause correctly prior to reopening With potentiometer RT finally one can set the off cycle time of the centering unit between one command to close generated by the intercepting photocell and the next The operating voltage of the lateral centering is 15V
17. the components as prescribed by the current standards in merit ATTENTION Any irregularity committed by the Customer before during of after dismantling and scrap ping the machine components or in interpret ing and applying the current provisions in force shall be the exclusive responsibility of the Customer himself
18. the fault and after remove by hand the register from this position until the microswitch comes back to off For this operation turn the gear on the micro motor A thermal alarm set at 70 C has also been created for the control circuit of this group In any emergency either one of these two overshoot microswitches or the thermal sensor will stop the motor and give the signal Front edge device movement failed 13 orton 1600 D Morton Electronic Materials Front edge a variation of between 0 and 50 mm is possible at the front edge but only if the board is longer than 250 mm This is because the distance between the input rollers and the lamination lines is approximately 200 mm Since the machine accepts boards of up to 210 mm long the front edge should take the following relation into account Maximum possible front edge length of board 200 mm not more than 50 mm Calibration The ratio between the insertion cylinder stroke and the front edge is 1 66 Therefore 10 mm of front edge on the board correspond to 6 mm of cylinder stroke The insertion group guarantees the highest level of repeatability in time for the front edges of the boards Nevertheless should it become necessary to correct some differences between the preset edge and the real edge the procedure is as follows Inside the PLC which is located in the electrical control panel there is an electronic circuit composed of 4 sets of numerical selectors
19. the shoes during lamination There is vacuum in the upper secondary suction shoe from the start of cutting until the rolls separate once lamination is completed When all three vacuum air hoses have been closed off by their respective gate valves a freely circulating air discharge vent remains open to prevent overloading of the vacuum pump This freely circulating air discharge is noisy by its very nature and has therefore been supplied with a silencer We recommend that this silencer should be cleaned out regularly once a month Similarly we advise cleaning the main filter of the vacuum pump once a month 11 59 orton 1600 D Morton Electronic Materials DYNAMIC TENSION ROLLS The dynamic tensions of the film one set above one set below serve to tighten up any slack that may have developed in the film during the lamination cycle In addition by keeping the film tensioned they serve to prevent the formation of diagonal wrinkles during lamination The tension rolls normally remain in their extended position They retract when the dry film carrying roll ers are disengaged thus allowing the polyethylene take up rollers to move out When the machine is stationary in the Awaiting board position the extended tension rolls hold the film up above the circular sectors When the board for lamination has been centered by the lateral centering unit the tension rolls retract and the rotating sectors move into
20. the tacking position Once tacking has taken place the sectors are rapidly returned to the Awaiting Start of Cutting position the lamination rolls close down onto the board the two tension rolls extend and take up any slack in the dry film thereby stretching it until it is tensioned The tension rolls remain extended during the entire lamination phase until an instant before the com mand to cut arrives At this point they are retracted to relieve tension on the film so that the film will not suffer from an elastic effect as it is cut It is important therefore that the speed of the tension rolls in either direction should not be too much slowed but also that it should take into account the factors shortly to be described It is equally important that they should be positioned in such a way as to smooth out all diagonal wrinkles in the film see the following diagrams Tension rolls Lower here Lower here Il 60 orton 1600 D Morton Electronic Materials The height to which the tension rolls should be adjusted in their extended position is illustrated below Machine shoulder Tension rolls However as can be seen from this diagram the height can be altered on one side only for the elimination of wrinkles The tension rolls are driven by pneumatic cylinders but while the speed of these cylinders can be regu lated their pressure cannot The recommended time for compl
21. thickness of the board to be laminated the temperature of the input board the temperature of the output board the surface preparation As is well known any board that is thicker than another all other parameters being equal will leave the laminator at a lower temperature The opposite is also true When using Morton dry film the correct temperature value for an output board is 45 C 50 C However the temperature of the lamination rolls will have to be regulated in order to obtain this value Range Room temp 130 C The most widely used values are 100 125 thickness of 1 6 mm at 2 8 mt min Input temperature 30 C Caution The temperature of the lamination rolls is not the only decisive parameter in determining the tem perature of the output boards To calculate this value in addition to the thickness and the type of boards the speed the lamination pressure and the temperature of the input boards must also all be taken into account Il 92 1600 D Morton Electronic Materials In any case the rolls must never exceed a temperature of 130 C because this would ruin the rubber Nevertheless it is a good idea to keep both the upper and lower rolls at the same temperature value 6 Static tension on the dry film spools The two spools of dry film slide onto two metal rolls that have been fitted with a brake lining friction disk which serves to curb their unwinding movement This braking action o
22. when calibrating this space switch off the machine and disconnect only one cable from the micromotor M5 which is situated at the top of the front left hand crankcase Switch the machine back on and moving the centering guides slowly by hand center a well squared up rigid board taking care to stop immediately when the stop photocells FC74 and FC77 left and right switch off In these conditions check how much space there is between the centering guide rollers and the board If the space needs to be either increased or decreased move the supports of the stop photocells The total recommended space is approximately 1 mm It is equally important to check the parallelism of the two centering guides which can be done using the same rigid board If necessary their positions can be changed by working through their fastening screws The precise reading distance for the forward movement and reverse movement stop sensors FC71 and 70 is 1 5 mm Their positions can be changed by working through their support units which should be blocked firmly again after the operation Should the overshoot microswitches FC72 and FC73 become activated it will be necessary to remove the cause for example incorrect positioning of the stop sen sors or their failure and then to liberate the centering by hand Il 7 orton Morton Electronic Materials 1600 D The configuration of the electronic circuit which controls the operating cycle of
23. 00 062 02 104 00 062 02 107 00 062 02 108 00 062 01 079 00 062 00 086 00 062 02 640 00 062 02 641 00 PROXIMITY SWITHC D 12mm SIEMENS 3RG 4012 OAB00 PHOTOCELL OMRON E3F DS10 B4 38 ROLLING THERMOCOUPLE ASSY THERMOCOUPLE WIRE INFRARED LAMP 2100W L770 840 PROXIMITY SWITCH D 8mm E2EG X1R5B1 SUPPORT MAGNETIC SENSOR SMC D 79 INDICATOR LAMP TELEMECANIQUE BA9S 30V 2W FUSE 10 3 X 38 mm 16A FUSE 5 X 20 mm 0 8A M FUSE 5 X 20 4A FUSE 5 X 20 2A FUSE 5 X 20 1A MAGNETIC SENSOR BOSCH N 830 100 368 FLAT BELT HABASIT S2 DEVELOPMENT 1015mm 1 20 FLAT BELT HABASIT TYPE P1 DEVELOPMENT 440mm L 20 FLAT BELT HABASIT TYPE 521 25 X 715 SILICON LAM ROLL D 100 DIS 0175 00 007 RUBBER BELT THERMOSOLDERING PEM Q5 D 5 303mm MOVABLE BLADE ASSY FIXED KNIFE DIS 0177 00 008 UPPER SPRING DRW 0177 00 0120 LOWER SPRING DRW 0177 00 0119 BRAKE PAD 0238 00 007 ROLLER D 90 0227 00 003 FILTER CANTRIDGE COD C15124 1 CONVEYOR MOTOR BRUSHES DRIVE SYSTEM TACKING BAR DRUM FLAT BELT HABASIT FOL 20 X 1395 FLAT BELT HABASIT L 20 X 345 FLAT BELT HABASIT L 20 X 545 REGULATING VALVE BOSCH 0821 200 103 RELAY LY3 24 V DC OMRON DISC PAD 0226 00 014 SPRING TYPE CO 2160 2 2 amp a orton 1600 D Morton Electronic Materials MAINTENANCE REPLACEMENT OF THE LAMINATION ROLLS Note When replacement has been made check the
24. 3 LAYOUT 1 4 DIMENSIONS AND CHARACTERISTICS 1 5 OPERATOR START UP 1 2 OPERATING CYCLE 1 3 OPERATION AND CALIBRATION OF THE VARIOUS GROUPS LATERAL CENTERING UNIT 1 6 FRONTAL CENTERING UNIT 1 10 INSERTION GROUP FRONT EDGE 1 12 ROTATING SECTORS VACUUM PUMP TACKING BARS AND COUNTER BLADES 1 16 ELECTRICAL CAMS DIAGRAM 1 18 ROTATING SECTORS TACKING POSITION 1 19 ROTATING SECTORS IN THE ROLLS CLOSED POSITION 1 26 ROTATING SECTORS IN AWAITING START OF CUTTING POSITION 1 27 COUPLING OF THE CUTTING GROUPS START OF CUTTING 1 28 ROTATING SECTORS IN END OF CUTTING POSITION Il 32 CUTTING GROUPS AT THE END OF CUTTING AND THEIR UNCOUPLING 1 33 CUTTING ON THE FLY REAR EDGE CALIBRATION OF THE SPEED OF THE ROLLS AND THE SENSITIVITY OF THE PHOTOCELL FOR THE REAR EDGE Il 37 CALIBRATION OF THE ROLL SPEED 11 38 CALIBRATION OF THE REAR EDGE PHOTOCELL Il 39 ALIGNMENT OF THE TWO SURFACES OF THE REAR EDGE UPPER AND LOWER 1 40 CALCULATION OF THE REAR EDGE CORRECTION OF THE PARAMETERS AND OF THE CYCLE TIMES Il 41 CYCLE TIMES Il 44 EDGES ON BOARD OF MINIMUM LENGTH Il 45 CUTTING GROUPS Il 47 LAMINATION ROLLS PRESSURE HEATING AND THERMAL ALARM SIGNALS Il 51 TEMPERATURE READER FOR THE FINISHED BOARD Il 58 VACUUM CUT OFF VALVES Il 59 DYNAMIC TENSION ROLLS Il 60 STATIC TENSION FRICTIONS 1 63 LATERAL CUTTING Il 64 ELECTRICAL CONTROL CABINET 1 66 INPUTS Il 67 OUTPUTS PLC Il 68 CONTROL PANEL OF THE ELECTRICAL CA
25. BINET Il 69 CONTROL PANEL OF THE MACHINE ITSELF 1 71 CSL 1600D VIDEO DISPLAY AND KEYBOARD UNIT 1 72 orton Morton Electronic Materials COMPLETE MESSAGES AND IDENTIFICATION CODES COMPLETE MESSAGES AND DESCRIPTION OF CAUSES LIST ADVICE FOR LAMINATION SETTING UPTHE UNIT MAINTENANCE REPLACEMENT OF THE LAMINATION ROLLS REPLACEMENT OF THE IR LAMPS REPLACEMENT OF THE TACKING BARS REPLACEMENT OF THE COUNTER BLADES REPLACEMENT OF THE MOVING BLADES TABLE OF PERIODIC MAINTENANCES 1600 D 73 75 90 95 naw ZAorton 1600 D Morton Electronic Materials AUTOMATIC LAMINATOR 1600 D GENERAL DESCRIPTION The Dynachem Laminator model 1600 D is a completely automatic 30 laminator based on a totally new design concept and constructed to guarantee high quality lamination and the absolute reliability of the machine over a long period of time In order to achieve this objective the machine has been designed to incorporate the following innovations A soft contact type lateral centering unit suitable also for inner layers A frontal barrier for alignment of the boards to the lamination rolls Tacking bars that turn eccentrically around the lamination rolls thus preventing any possibility that the board is moved after the tacking and before the lamination starts the main cause of wrinkle formation Dynamic tension rolls for the film in addition to static tension Cutting on the fly by m
26. CUT SHEET LAMINATOR 1 600 D ae t t5 So ie OPERATING AND SERVICE MANUAL Morton Morton Electronic Materials orton Morton Electronic Materials NOTICE PRIOR TO INSTALLING OPERATING OR PERFORMING MAINTENANCE ON THE 1600 D AUTOMATIC LAMINATOR THIS INSTRUCTION MANUAL SHOULD BE READ CAREFULLY TO THE BEST OF OUR KNOWLEDGE THE INFORMATION CONTAINED HEREIN IS CORRECT HOWEVER MORTON DOES NOT GUARANTEE THE COMPLETENESS OR ACCURACY OF THE INFORMATION USER IS RESPONSIBLE FOR THE SAFE INSTALLATION AND OPERATION OF THE 1600 D AUTOMATIC LAMINATOR 1600 D ZAorton 1600 D Morton Electronic Materials WARRANTY The Mod 1600 D AUTOMATIC LAMINATOR is warranted by Morton Corpo ration against defects in material and workmanship for a period of 90 days from date of receipt by the customer during which time Morton will be re sponsible for the replacement or repair at its option of any defective parts and for any labor charges connected with repair of the Mod 1600 D AUTO MATIC LAMINATOR Morton for an additional 90 days period warrants that it will replace or re pair at its option any part proves to be defective however the customer will be responsible for all labor charges during this additional 90 days period Morton should be notified in writing of any defect in material or workman ship of the
27. E REAR EDGE CORRECTION OF THE PARAMETERS AND OF THE CYCLE TIMES Between the instant when the rear edge photocell looks the end of the board and the point at which the rotating sectors are synchronised with the speed of the moving film in order to execute a cut the PLC provides a delay interval which is calculated by taking into account the lamination speed the rear edge required and any delays in response by the mechanical parts in function of the lamination speed The formula for determining this value is as follows 50 Edge x X 5 Speed x Y 2 Speed x 1000 where T Resultant delay time sec 50 Maximum rear edge mm Edge Programmed rear edge X Multiplication factor 60 5 Maximum lamination speed that can be set mt min Speed Programmed lamination speed read on Dynamo Y Multiplication factor for the delay due to mechanical responses 195 The delay interval will be 0 when lamination speed is 5 mt min with a rear edge of 50 mm It will be somewhat longer however when laminating at a very low speed and with a rear edge of 0 mm The two multiplication factors X and Y may assume slightly different values from one machine to an other or even vary with time on the same machine due to even very slight differences in roll diameters their operating temperatures and the response time of the electromagnetic clutches the moving me chanical or pneumatic parts Inside the PLC located within t
28. E lectronic M aterials DIMENSIONS AND CHARACTERISTICS Input roller Length 600 mm 23 6 Fold down 300 mm 11 87 Width 900 mm 35 4 Height 860 1050 mm 34 41 Output roller Length 250 mm 10 Width 900 mm 35 4 Height 860 1050 mm 34 41 Boards for lamination Length Min 200 mm 7 97 Max 787 mm 31 Width Min 120 mm 4 7 Max 787 mm 31 Thickness Min 0 05 mm core with thin layer option 0 002 Max 5 mm 0 196 Lamination rolls Diameter 100 mm 3 9 Hardness 60 Shore Length 814 mm 32 Front and rear edge Both adjustable between 0 and 50 mm 0 1 9 to be compatible with the length of the board See detailed specifications later on Dimensions of the film for lamination 1600 D Exhaust e Air consumption approximately 300 m hr for exhaust purposes Conveyor speed 0 5 mt min Speed lamination rolls 0 5 mt min Temperature of lamination rolls Room Temperature 130 C Pressure of lamination rolls 320 kg max at 6 bar Tacking time 0 1 9 9 sec Temperature of tacking bars Room temperature 45 C Noise level 75 dB continuous ponderated equivalent value A Length Min 187 mm 7 4 Max 762 mm 30 Width Min 120 mm 4 7 Max 762 mm 30 Thicknesses All that are available Electrical power supply Standard 380V 415V 480V 3Phase 50 60 Hz Ground Other voltages av
29. OARD PUSHING DEVICE SENS 1171 The machine has stopped because during the return phase of the board pushing device the set point proximity switch FC17 is already activated Il 78 orton 1600 D Morton Electronic Materials 23 TACKING BARS MOVEMENT FAILURE 331 The machine has stopped because during the closing phase of the tacking bars the opening proximity switch FC33 is not released 24 TACKING BARS MOVEMENT FAILURE 351 The machine has stopped because during the opening phase of the tacking bars the closing proximity switch FC35 is not released 25 TACKING BARS NOT AT SET POINT 330 The machine has stopped or is unable to start because during the opening phase of the tacking bars the opening proximity switch FC33 is not activated 26 TACKING BARS NOT AT WORK POINT 350 The machine has stopped because during the closing phase of the tacking bars the closing proximity switch FC35 is not activated 27 BREAKDOWN TO TACKING BARS SENSORS 1331 The machine has stopped because during the opening phase of the tacking bars the opening proximity switch FC33 is already activated 28 BREAKDOWN TO TACKING BARS SENSORS 1351 The machine has stopped because during the closing phase of the tacking bars the closing proximity switch FC35 is already activated Il 79 orton 1600 D Morton Electronic Materials 29 LAMINATION ROLLS MOVEMENT FAILURE 2331 The machine has stopped because during the closing phase of the lamination rolls
30. OV 15V a c which is then transformed into d c by the control circuits S C C The alarm signal and fault diagnosis of the centering unit is Centering breakdown Should it be necessary to replace the control circuit all the potentiometers will have to be recalibrated copying their positions from the previously used circuit board Il 9 orton 1600 D Morton Electronic Materials FRONTAL CENTERING UNIT Insertion roll Front barrier Operating cycle The alignment of the board with the lamination line is very important when one has to laminate with a front edge of 0 mm In this case the film must not be detached in any way from the board during the tacking operation Alignment is achieved by allowing the board pushed forward by the input rollers to come to rest against the frontal barrier where it automatically becomes aligned In order to insert the board into the machine this barrier is lowered by its own pneumatic cylinder 1 10 orton 1600 D Morton Electronic Materials The barrier will be raised once more when the board has passed completely through the input unit Calibration If the board is not in perfect alignment with the rolls this can be corrected by working on the fastening screws of the frontal barrier Minute successive adjustments will have to be made to carry out this operation using a laminated board and measuring the result
31. P MISSEB GUT iere ain 361 63 BOITON MISSED QUT irte ettet 371 64 TOP amp BOT CUTTING DEVICE NOT IN SET POINT 2022 65 CUTTING DEVICE NOT IN SET POINT 200 66 BOTTON CUTTING DEVICE NOT IN SET POINT 220 67 TOP amp BOT CUTTING DEVICE NOT IN WORK POINT 2123 68 CUTTING DEVICE NOT IN WORK 210 69 BOTTON CUTTING DEVICE NOT IN WORK POINT 230 70 INITIAL CUT POSITION NOT REACHED 281 71 TACKING POSITION NOT 291 72 CUT POSITION NOT 301 73 SLOWING DOWN POSITION NOT REACHED 311 74 ROLLS CLOSING POSITION NOT 391 75 INITIAL CUT POSITION SENSOR 280 76 POSITION SENSOR DAMAGED 290 77 CUT POSITION SENSOR DAMAGED 300 78 SLOWING DOWN POSITION SENSOR DAMAGED 310 79 ROLLS CLOSING POSITION SENSOR DAMAGED 390 80 LAMIN ROLLS TEMPERATURE OUT OF 131 Il 74 orton 1600 D Mo
32. agnetic clutches FZ5 6 7 which are commutated by the PLC at the appropriate moments 12 orton 1600 D Morton Electronic Materials If the board is pushed to the exact edge of the tacking bars it will have a front edge of 0 mm On the other hand if it is pushed 50 mm beyond this edge it will itself have an edge of 50 mm Front edge In order to limit the stroke of the insertion cylinder and thus also the distance covered by the front edge of the board a mobile mechanical regulator has been attached to the cylinder shaft This regulator Register is powered by a d c micromotor M6 controlled by an electronic circuit known as a Positioner AZ3 which receives information on the exact position of the regulator from a conductive plastic transducer P6 When the PLC transmits a command to move the regulator to a certain position the Positioner compares the present position with the one to be found and then commands the motor to turn in one direction or the other until the transducer transmits the information that the new position has been reached In order to prevent the group from overshooting the limit of its mechanical stroke because of some irregu larity two overshoot microswitches have been installed FC100 and FC110 As in the case of the centering these switches can stop the motor M6 immediately In case the two overshoot microswitches FC100 FC110 have been activated it needs to find the cause of
33. ailable on request and by specific prior agreement Power consumption 8 KVA Building line main switch 25A motor starting type Air supply Dry compressed air at 6 Atm Consumption 45 Nl min 7 98 orton 1600 D Morton Electronic Materials INDEX OPERATING CYCLE 1 3 OPERATION AND CALIBRATION OF THE VARIOUS GROUPS LATERAL CENTERING UNIT 1 6 FRONTAL CENTERING UNIT 1 10 INSERTION GROUP FRONT EDGE 1 12 ROTATING SECTORS VACUUM PUMP TACKING BARS COUNTER BLADES 1 16 ELECTRICAL CAMS DIAGRAM Il 18 ROTATING SECTORS IN TACKING POSITION Il 19 ROTATING SECTORS IN THE ROLLS CLOSED POSITION 1 26 ROTATING SECTORS AWAITING START OF CUTTING POSITION 1 27 COUPLING OF THE CUTTING GROUPS START OF CUTTING 1 28 ROTATING SECTORS IN END OF CUTTING POSITION Il 32 CUTTING GROUPS AT THE END OF CUTTING AND THEIR UNCOUPLING 1 33 CUTTING ON THE FLY REAR EDGE CALIBRATION OF THE SPEED OF THE ROLLS AND THE SENSITIVITY OF THE PHOTOCELL FOR THE REAR EDGE 1 37 CALIBRATION OF THE ROLL SPEED 1 38 CALIBRATION OF THE REAR EDGE PHOTOCELL 1 39 ALIGNMENT OF THE TWO SURFACES OF THE REAR EDGE UPPER AND LOWER 1 40 CALCULATION OF THE REAR EDGE CORRECTION OF THE PARAMETERS AND OF THE CYCLE TIMES 1 41 CYCLE TIMES 1 44 EDGES BOARD OF MINIMUM LENGTH 1 45 CUTTING GROUPS 1 47 LAMINATION ROLLS PRESSURE HEATING AND THERMAL ALARM SIGNALS 1 51 TEMPERATURE READER FOR THE FINISHED BOARD 1 58 VACUUM CUT OFF VALVES Il 59
34. ard Caution As already explained in the chapter Front Edge it is not possible to set any front edge value greater than Board length 200 mm Read carefully the explanations given in the relative chapter Il 46 orton 1600 D Morton Electronic Materials CUTTING GROUPS The film cutting system is as already mentioned of the shearing type It consists of a moving blade and a fixed counter blade Both these implements are made from a steel with a very high hardness value Counter blade Before coupling can be achieved between the moving blade and the counter blade the first must be placed in an oblique position with respect to the second to enable the coupling tooth to engage in the appropriate cavity situated between the main and secondary vacuum shoes Il 47 orton 1600 D Morton Electronic Materials The moving blade is driven by two pneumatic cylinders connected in series The first which has a short stroke positions this blade obliquely while the second with a double bar and a long stroke moves the blade from both sides in order to cut the film Counter blade The return cylinder of the group and the spring placed at the end opposite the coupling tooth ensure that the two blades remain in contact Inside the group there is a stop inductive sensor FC26 27 which perceives the positions in which coupling or uncoupling have taken place
35. ard is perceived by the fibre optic sensor but that it also goes out immediately if the board is moved back 5 mm from its inspection point Fibre optic sensor ON Board GL Hysteresis Normally this situation is achieved by increasing the sensitivity value of the photocell up towards its maxi mum switching on the light without any boards and coming back to the minimum up to the light switches off again Il 39 orton 1600 D Morton Electronic Materials ALIGNMENT OF THE TWO SURFACES OF THE REAR EDGE UPPER AND LOWER As already described the distance between the point of Awaiting start of cutting and the lamination point is in theory 187 mm Nevertheless possible changes in the dimensions of the secondary vacuum shoes and the allowances within the assembly might give rise to differences in the length of film between part of the machine and another or between the upper and lower units of the same machine Before proceeding with the calibration of the rear edge the upper and lower edges must therefore be evened up Since the actual differences will always be less than 1 mm to make them precisely equal in measurement it will be sufficient to shim the secondary vacuum shoe corresponding to the shorter edge in such a way as to obtain a larger strip of film on that side LOWER UPPER Il 40 orton 1600 D Morton Electronic Materials CALCULATION OF TH
36. ated board a reading flash is activated if the readout is out of the preselected range the message will appear followed by a series of beeps without stopping the machine 1 85 orton 1600 D Morton Electronic Materials 58 amp BOT END OF FILM TACKING 3670 The machine has stopped because the film in the front side is not attached to the board because the rolls of dry film are finished or because too much dry film has been feeded by mistake The check is managed by upper and lower sensors FC36 FC37 59 TOP END OF FILM OR NO TACKING 360 The machine has stopped because the film in the front side is not attached to the board because the top roll of dry film is finished or because too much dry film has been feeded by mistake The check is managed by upper sensor FC36 60 BOTTOM END OF FILM OR NO TACKING 370 The machine has stopped because the film in the front side is not attached to the board because the bottom roll of dry film is finished or because too much dry film has been feeded by mistake The check is managed by lower sensor FC37 61 TOP amp BOT MISSED CUT 3671 The machine has stopped because the film has not been partially or completey cut The check is managed by upper and lower sensors FC36 and FC37 62 TOP MISSED CUT 361 The machine has stopped because the film has not been partially or completey cut The check is managed by upper sensor FC36 63 BOTTOM MISSED CUT 371 The ma
37. cal code and the causes which provoked the machine stop Il 72 orton Morton Electronic Materials COMPLETE MESSAGES AND IDENTIFICATION CODES 7 ONE BOARD IS STOPPED INTO LAMINATOR 8 ONE BOARD IS STOPPED INTO LAMINATOR 9 ONE BOARD IS STOPPED INTO LAMINATOR 0 1 ONE BOARD IS STOPPED INTO LAMINATOR 11 BOARDS STOPPING BARRIER 12 BOARDS STOPPING BARRIER 13 BARRIER UP MOVEMENT NOT COMPLETED 14 BARRIER DOWN MOVEMENT NOT 15 BREAKDOWN TO FRONT BARRIER SENSORS 16 BREAKDOWN TO FRONT BARRIER SENSORS 17 BOARD PUSHING MOVEMENT FAILURE 18 BOARD PUSHING DEVICE MOVEMENT FAILURE 19 BOARD PUSHING DEVICE NOT AT SET POINT 20 BOARD PUSHING DEVICE NOT AT WORK POINT 21 BREAKDOWN TO BOARD PUSHING DEVICE SENS 22 BREAKDOWN TO BOARD PUSHING DEVICE SENS 23 TACKING BARS MOVEMENT FAILURE eee 24 TACKING BARS MOVEMENT FAILURE eee 25 TACKING BARS NOT
38. chine has stopped because the film has not been partially or completey cut The check is managed by lower sensor FC37 1 86 orton 1600 D Morton Electronic Materials 64 TOP amp BOT CUTTING DEVICES NOT IN SET POINT 2022 The machine has stopped or is unable to start because during the return phase of the cutting group devices the upper and lower set point proximity switches FC20 and FC22 are not activated Set point position and retracted cylinders 65 TOP CUTTING DEVICE NOT IN SET POINT 200 The machine has stopped or is unable to start because during the return phase of the cutting group device the upper set point proximity switch FC20 is not activated Set point position and retracted cylinder 66 BOTTOM CUTTING DEVICE NOT IN SET POINT 220 The machine has stopped or is unable to start because during the return phase of the cutting group device the lower set point proximity switch FC22 is not activated Set point position and retracted cylinder 67 TOP amp BOT CUTTING DEVICES NOT IN WORK POINT 2123 The machine has stopped because during the unhooking phase of the cutting group devices the upper and lower work point proximity switches FC21 and FC23 are not activated Work point position and extended cylinders 68 TOP CUTTING DEVICE NOT IN WORK POINT 210 The machine has stopped because during the unhooking phase of the cutting group device the upper work point proximity switch FC21 is not activated Work point posi
39. ctronic Materials BEFORE PROCEEDING ANY FURTHER MAINTENANCE OPERATION SWITCH OFF THE MACHINE AND WAIT FOR ALL PARTS IN TEMPERATURE TO BE COMPLETELY COLD Periodic maintenances recommended every 1600 D Shift Day Week Month Six months Year Cleaning of lamination rolls with alcohol Cleaning of boards introduction rolls e and input rollers with alcohol Cleaning of blades counterblades with alcohol Cleaning of upper and lower vacuum shoes with alcohol Cleaning of tacking bars with alcohol Cleaning of upper and lower black feed rolls with alcohol Cleaning of lateral polyethylene separeted rolls and tension rolls with alcohol Replacement of small lateral cut blades General cleaning safety guards etc Cleaning of board detecting mirrors e with alcohol Cleaning the antistatic bars e with alcohol and brush Cleaning of the brake pads with brush Cleaning of the vacuum pump filter Check and remove any condensate e cleaning of the compressed air filter Check up on the belts tension and their condition brake pads Check up motor brushes dynamo etc e Check up on clutch gaps all at 0 2 mm e Check up on cut blades efficiency e Replacement of vacuum pump filter e 111 11 1600 D Morton Electronic Materials PACKING AND SHIPPING The machine is normally shipped
40. d activate the electrovalve EV25 by hand or via the PLC keyboard to insert the index into the slot of the mechanical cam 4 Move the two cutting groups by hand upper and lower into the space between the main and secondary vacuum shoes 5 Block them firmly in this position and give the command to couple the cutting groups by activat ing the electrovalve EV20 upper and lower 6 Release the two cutting groups so that they come slowly to a complete halt Il 29 orton 1600 D Morton Electronic Materials 2 mm without plate 0 7 mm witha 4 8 plate 7 Using a thickness gauge check that the distance between the coupling tooth of the moving blade and the fixed blade is as indicated in the Table 2 mm 8 If adjustments are necessary work on the right and left rear stops of each cutting group and if this is not sufficient work on the adjustment screws of the cylinder bars Cylinder Rear stop for the cutting groups Adjustment of the bar Caution Should it be necessary to work on the adjustment screws of the cylinder bars it will subse quently also be necessary to check the end of cutting position see chapter Cutting Groups and End of Cutting and their sequels Il 30 orton 1600 D Morton Electronic Materials 9 Bring the cutting groups back towards the center of the vacuum shoes units by hand and uncouple them by deactivating EV20 then return the
41. disconnect the laminator and wait for the heated parts to cool down 2 Take out the removable part of the machine and detach the secondary suction shoe 111 5 orton 1600 D Morton Electronic Materials 3 Detach the counter blade and place it somewhere where it will not be damaged 4 Disconnect the cables of the tacking bar from the rotating MERCOTAC connector which is located on the left hand side of the machine Connect to the existing cables a free cable which can be used to pull back the cables of the new tacking bar 11 6 orton 1600 D Morton Electronic Materials 5 Unscrew and then detach the tacking bar from the main vacuum shoe 6 Insert the new bar passing the cables through the special holes placed on the left hand side of the machine and connect them to the Take care that the pads are mounted facing in the right direction the thicker end of the screws towards the out side 7 Tighten up all the screws that block the bars then position and block the counter blades 8 Reposition and block the secondary vacuum shoes remembering correcting shims for the rear edge if necessary 9 Repeat the operations described from point 3 onwards for the other tacking bar also 11 7 orton 1600 D Morton Electronic Materials REPLACEMENT OF THE COUNTER BLADES If the counter blades are rotated on their own axes or tipped up all four cutting edges of the utensil
42. e PLC receives this latest signal it switches off the electromagnetic clutch FZ1 of the rotating groups and inserts the Indexes into the slots of the mechanical cams Screw coupling Start of cutting position Tacking a 5 PA CY The start of cutting position and its repeatability are governed by the design of the mechanical cam LL Slowing down cam It is however inadvisable to use the screws coupling to change this position be cause as a result the previously established positions for tacking and end of cut ting would also have to be changed If it should prove necessary to put forward or to delay the insertion of the Index into the mechanical cam the electrical awaiting start of cutting cam will also have to be put forward or delayed with respect to its own sensor FC28 Remember also to refasten the cam firmly with its appropriate screws once this adjust ment has been made Il 27 orton 1600 D Morton Electronic Materials COUPLING OF THE CUTTING GROUPS START OF CUTTING While the rotating sectors are stationary in the position of Awaiting start of cutting the upper and lower cutting groups are coupled to them by means of the moving blades Counter blade The fact that the rotating sectors are coupled to the cutting groups means that they are now being drawn by the cutting groups and the two groups will now move in synchronisat
43. e inserted 1600 D IMPORTANT Never stand near the machine while it is being lifted IMPORTANT MORTON declines all responsibility for any damage to persons or property caused by fail ure to comply with the instructions given in this manual and specified by the current Safety Provisions concerning lifting and handling of materials inside and outside fac tories DO NOT LIFT HERE SUITABLE LIFTING MEANS 11 0 INDICATIONS ON THE CRATE orton Morton Electronic Materials LIFTING THE MACHINE After having placed the crate in the position where the machine is to be installed unpack the con tents with extreme care IMPORTANT Should the Customer note any defects defor mation or damage caused by transport on the crate and or machine he should immediately inform the haulage contractor of the matter both by phone if the contractor is no longer present and by Registered Letter with return receipt attached MORTON should also be notified in merit The machine must only be lifted by transpallet or lift truck after having checked that the chosen lift ing means is suited to the weight of the machine itself see the indications on the technical charac teristics page of this manual Check that the lift forks correctly hold the bottom of the machine before it is lifted and that the ma chine weight is adequately balanced 1600 D
44. e rear edge FC47 no longer perceives the board To guard against a hole on the board being mistaken for the end of the board this particular photocell is custom made in fibre optics and is able to overlook holes of even 10 mm diameter while at the same time offering a precision of 0 1 mm Fibre optic sensor of rear edge photocell Il 37 orton 1600 D Morton Electronic Materials The rear edge photocell is very precisely positioned on the input roller Its distance from the lamination line is approximately 246 mm Nevertheless when calibrating the rear edge it can be moved either forwards or backwards from its theo retical position by means of regulating system in Fibre optic sensor of Lamination rear edge photocell rolls 246 mm he Before commencing calibration of the rear edge it is important to carry out the following operations Calibration of the conveying speed and lamination speed while the machine is performing a lamination Calibration of the hysterisis sensitivity of the fibre optic photocell Equalise the upper rear edge with the lower CALIBRATION OF THE ROLL SPEED In order to calibrate the conveying and lamination speed the speed of 5 mt min should be programmed into the control panel and the true speed measured with a tachometer attached not to the rolls but to a very long board which will actually undergo lamination betw
45. e separation rolls following the thread up diagram To make it easier to insert the film through the vacuum shoes vacuum can be suppressed in the main shoes via the yellow selector switch Vacuum Upper Lower ON OFF situated on the movable unit Pull the film through by hand and unwind a length of about a metre checking that the thread up route has been followed correctly Then lay it over the main vacuum shoe Pull the film in tension and using the counterblade for support cut the film along its cutting edge with a sharp knife Take care not to cut the rubber pads 19 Repeat the operation described under point 18 for both the upper and the lower films Insert the movable unit into the machine and block it with the locking handle provided Caution If the movable unit is moved out there will be an immediate emergency stoppage of the ma chine with the message MOBILE UNIT UNLOCKED It is possible to by pass this safety device via a key switch placed on the front right crankcase in order to run the machine while it is open This should only be done by qualified maintenance personnel and on their own entire responsibility 20 21 Il 96 When the movable unit has been firmly mounted inside the machine block the locking handle provided A microswitch will record its precise position and the machine will make the Set point Set all the lamination parameters Roll temperature Tacking bars temperature Tack
46. e towards the front of the machine Fig B Front side Rear side Front side Rear side Bring the groups together again and read the new measurement Repeat this operation until the desired value has been obtained Asa result of this manoeuvre the lower groups will also have to be calibrated until they are perfectly aligned Block the two screws coupling The position of the tacking bars with respect to the tangent line of the rolls is a determinant factor in preventing the formation of air bubbles in the first millime tres of lamination Il 21 orton 1600 D Morton Electronic Materials As has already been demonstrated the operating cycle of the laminator envisages that the rolls will close down on the board at the exact point at which tacking was carried out Due to the width of the counter blade the film is cut 3 mm beyond the tacking bars Tacking bars Im Fim Counter blade When the film is tacked onto the board therefore the first 3 mm of film cannot be stuck down This strip of film must nevertheless be stuck down by the lamination rolls If the lamination rolls close down onto the board in front of the tacking area the air underneath the 3 mm of non stuck film will be unable to escape and trapped between the tacking and the lamination roll will create large bubbles Lamination roll Il 22 or
47. e value stored in the memory is 0 T3 z Lower supplementary enrichment time As above This is equal to T2 plus the value preset for T3 T4 Enrichment time at the Set Point This is between the start of cutting and end of cutting posi tions an operation that is carried out only after having loaded the film and closed up the machine CAUTION The values preset on the selectors T1 T4 are read directly by the PLC and are therefore not recorded on the parameter variation sheets They are all expressed in hundredths of a second The time taken before unloading of a laminated board from the rolls is stored in the memory and is calcu lated automatically by the PLC in function of the lamination speed Nevertheless it can be shortened by setting indicators no 905 909 using the PCA2 P10 heads 909 9096 908 8096 907 7095 90626096 and 905 50 N B Every time this is done all the other indicators even those not directly involved will also have to be reset i e for 50 we shall have 905 ON 1 and 906 909 OFF 0 Il 44 orton 1600 D Morton Electronic Materials EDGES ON BOARD OF MINIMUM LENGTH As already described in the chapter on Front edges the shortest board that can be laminated measures 210 mm Since the distance between the lamination point and the rear edge photocell is approximately 246 mm when a board with a length of less than 246 mm is laminated the value set for the rear edge should take i
48. each time The cylinder which moves the barrier has two stop sensors FC18 for forward movement and FC19 for reverse If neither of these are activated within a time limit of 10 seconds they give the following alarm signals Barrier up movement not completed Barrier down movement not completed Il 11 orton 1600 D Morton Electronic Materials INSERTION GROUP FRONT EDGE Insertion roll 3 3 dips Res ANUAS Bu G Front barrier 2 Insertion cylinder Operating cycle The task of the board insertion group is to insert the board between the tacking bars Normally the lower roller turns at the same speed as the input roller Once the board has been aligned against the frontal barrier the lower roller stops while the upper one is lowered onto the board firmly enough to grip it The frontal barrier is tilted away by its driving cylinder and the insertion cylinder is fully extended This causes the lower roll to turn thus pushing the board forward The distance covered by the board depends upon the number of revolutions and fractions of revolutions made by the lower roll It can also depend on the stroke of the insertion cylinder or on its rack The motion of the lower roll is therefore generated either by the input roller or by the rack system of the insertion group The switch between these two movement forces is achieved by means of two electrom
49. eans of SHEARS which do not move the film sideways This ensures a clean and reliable cut throughout innumerable operating cycles Direct hot lamination by two rolls 100 mm diameter heated from external highly efficient short wave infra red lamps very fast temperature recovery time Controlled by electronic microprocessor with mother tongue interface through keyboard and display including a dyagnostic alarms and operator s guide ZAorton 1600 D Morton Electronic Materials LAYOUT The 1600 D laminator consists of the following component parts Astatic front unit containing the input roller the systems governing the centering and insertion of the board between the lamination rolls the vacuum pump for the exhaust shoes and an exhaust fan with pipes for the discharge of fumes arising from the lamination process A static rear unit containing the output roller on which are mounted an IR sensor which reads the temperature of the laminated board a photocell to signal a stationary board and the grounding bars A removable central unit on which are mounted the lamination rolls the vacuum shoes the tacking bars the cutting groups rollers to feed in the rolls of dry film the film tensions rolls the lateral cutting groups the IR lamps to heat the lamination rolls and the protective cap Acontrol panel mounted on wheels containing all the electrical commands the monitor and the keyboard orton Morton
50. een the lamination rolls Lamination rolls Tachometer 22 7 r gt d n i S Ge 9 If the speed thus measured should be found to differ from the programmed speed adjustment will have to be made through the trimmer of the driver ref AZ1 installed in the control panel until the precise pro grammed speed has been obtained After that it would be necessary to regulate the trimmer of the speed divider module DVDM since to read the 8 96 V at 5 mt min between the E57 input and the 46 PLC wire This value is the one of the tachometric dynamo and represents the precise point of correspondance between speed and power read by the PLC 1 38 orton 1600 D Morton Electronic Materials CALIBRATION OF THE REAR EDGE PHOTOCELL In order to calibrate the sensitivity hysterisis of the fibre optic photocell Ref FC47 the removable front crankcase will have to be removed and with the rolls stationary a board inserted until it makes contact with the insertion rolls A red signal lamp will light up on the rear edge photocell which is mounted on the base of the mirror photocell When the board is removed this light will switch off The calibration of the sensitivity and the hysterisis of the photocell is carried out through the adjustment screws situated to the side of the red signal lamp and this should be done in such a way that the red lamp lights up as soon as the front edge of the bo
51. en correctly designed and made from the right materials The procedure for replacement of the lamps is as follows 1 Switch off and disconnect the laminator then wait until the heated parts have cooled down 2 Take out the removable part of the machine and detach the two fixed upper and lower circular sections not the rotating ones by removing only the lateral screws 4 on the right and 4 on the left 3 Disconnect the two lamps from the electric terminals positioned on the right hand side of the machine 11 3 orton 1600 D Morton Electronic Materials 4 Slacken the lamp holding clamp and take it out 5 Insert the new lamp connect it to the electricity and insert it into its holder Do not block the lamp on both sides since this would hinder the natural expansion of the glass due to ther mal dilatation The radiating element should be di rected towards the centre of the roll 6 Once the assembly has been completed wipe the lamp over with a cloth soaked in alcohol 7 Repeat this operation for the other lamp 111 4 orton 1600 D Morton Electronic Materials REPLACEMENT OF THE TACKING BARS The tacking bars should only be replaced by specially trained personnel using original parts which have been correctly designed have the correct electrical characteristics and are made from the right materials The procedure for replacement of the tacking bars is as follows 1 Switch off and
52. etion of the movement is approximately 1 sec The tension applied by the tension rolls to the film before lamination causes the dry film spool to unwind This movement may vary according to its diameter its static tension or the speed of the tension rolls Excessive unwinding of the film could create problems if the boards undergoing lamination are short less than 300 mm Il 61 orton 1600 D Morton Electronic Materials In fact the amount of slack created in the film if the dry film spool unwinds too far can never be either completely tensioned or used up by the board because of its reduced length Consequently after the passage of several boards the tension rolls will no longer be able to stretch the film sufficiently because the film will have developed a slack greater than the travel of the tension rolls themselves Film slack It is therefore important to control the unwinding of the spools during the tension phase and to regulate their degree of friction so that the film always remains at the correct tension If these measures are not sufficient the speed of movement of the tension rolls must also be reduced Il 62 orton 1600 D Morton Electronic Materials STATIC TENSION FRICTIONS The static film tensions one above and one below provide a braking action on the unwinding of the dry film spools This braking action applied to the shafts of the spool carrying rollers is obtained by mean
53. f the boards stopping barrier the opening proximity switch FC19 is not activated 15 BREAKDOWN TO FRONT BARRIER SENSORS 1181 The machine has stopped because during the closing phase of the front barrier the closing proximity switch FC18 is already activated 16 BREAKDOWN TO FRONT BARRIER SENSORS 1191 The machine has stopped because during the opening phase of the front barrier the opening proximity switch FC19 is already activated Il 77 orton 1600 D Morton Electronic Materials 17 BOARD PUSHING MOVEMENT FAILURE 161 The machine has stopped because during the return phase of the board pushing device the work point proximity switch FC16 is not released 18 BOARD PUSHING DEVICE MOVEMENT FAILURE 171 The machine has stopped because during the insert phase of the board pushing device the set point proximity switch FC17 is not released 19 BOARD PUSHING DEVICE NOT AT SET POINT 170 The machine has stopped or is unable to start because during the return phase of the board pushing device the set point proximity switch FC17 is not activated 20 BOARD PUSHING DEVICE AT WORK POINT 160 The machine has stopped because during the insert phase of the board pushing device the work point proximity switch FC16 is not activated 21 BREAKDOWN TO BOARD PUSHING DEVICE SENS 1161 The machine has stopped because during the insert phase of the board pushing device the work point proximity switch FC16 is already activated 22 BREAKDOWN TO B
54. f the central unit the intercepting photocell for the centering unit FC69 the photocell for detecting boards in frontal barrier FC45 and the photocell for detecting output boards FC46 must be free otherwise the message will stay without allowing the machine to continue further operations 9 ONE BOARD IS STOPPED INTO LAMINATOR 461 At the end of every cycle at the reopening of the lamination rolls the photocell FC46 checks the output of the previous board eventually stopped on the same photocell The machine stops at the end of cycle 10 ONE BOARD IS STOPPED INTO LAMINATOR 460 At every cycle the exact transport sequence of the board is checked if this doesn t happen as established the machine will stop in emergency Il 76 orton 1600 D Morton Electronic Materials 11 BOARDS STOPPING BARRIER FAILURE 181 The machine has stopped because during the opening phase of the boards stopping barrier the closing proximity switch FC18 is not released 12 BOARDS STOPPING BARRIER FAILURE 191 The machine has stopped because during the closing phase of the boards stopping barrier the opening proximity switch 19 is not released 13 BARRIER UP MOVEMENT NOT COMPLETED 180 The machine has stopped because during the closing phase of the boards stopping barrier the closing proximity switch 18 is not activated 14 BARRIER DOWN MOVEMENT NOT COMPLETED 190 The machine has stopped or is unable to start because during the opening phase o
55. f the dry film rolls serves to keep the film stretched and taut and therefore plays an important part in the final lamination result However due to the design of the machine it is better to exert this braking force directly on the dry film rolls because their action can then be adapted to either standard or oversize spools Lever arm EN T T 1 Applicated force Lever arm Counter force Applicated force It is therefore advisable to calibrate the pressures of these friction devices in function of the types of dry film spool Range 0 6 bar Recommended value 2 5 bar Caution For boards shorter than 300 mm it is always advisable to keep the friction pressure at maximum and to take care that the speed of the film dynamic tension rolls is not excessive Il 93 1600 D Morton Electronic Materials 7T Distance between input boards This should be adjusted in function of length of the board tacking time lamination speed We recommend keeping this distance to a minimum in order to avoid loss of productivity of the machine The operating cycle itself gives rise to shortenings and lengthenings of the preset distance between input boards This does not cause any problem however so the machine will not require any adjustment We therefore recommend that in practice each user should calculate this distance according to its own specific requirements Il 94
56. follows 1 Prepare the machine for lamination with film and key in the normal values of temperature and pressure 2 Seta speed of 5 mt min and a rear edge of 50 mm 3 Laminate a board with a length of not less than 300 mm and measure the rear edge obtained Il 42 orton 1600 D Morton Electronic Materials 4 Should the measured edge be found to be greater than 50 mm bring the fibre optic sensor of the rear edge photocell 47 closer to the lamination rolls by the same amount as that by which the edge exceeds 50 mm 5 Conversely if the edge measures less than 50 mm increase the distance between the sensor and the rolls by the same amount as the edge falls short of 50 mm 6 Verify the edge once more laminating the board until the exact position of the fibre optic sen sor is found 7 Maintaining a speed of 5 mt min now set the rear edge to be 0 and laminate the board while measuring the actual edge obtained 8 If the film is shorter than the board the value of X must be increased if on the other hand the film is longer than the board the value of X must be lowered 9 Repeat this operation until the optimum value of X has been found 10 Now set the rear edge to be 50 mm and the lamination speed to 1 mt min 11 Laminate the board and measure the real edge obtained 12 If it is less than 50 mm the value of Y will have to be lowered if it is greater than 50 mm the value of Y wil
57. ging to the end of cutting electric has identified this slot the PLC disengages the electromagnetic clutch FZ1 thus depriving the rotating sectors of their locomotive force and activates electrovalve EV25 which then inserts the Indexes into the slots of the mechanical cams Screw coupling ie 2 7 Start of Cutting position nd of cutting position End of cutting cam Both the end of cutting position and its repeatability and the start of cutting position are all governed by the design of the mechanical cams It is therefore inadvisable to use the screws coupling to vary them in any way oth erwise the positions of tacking and Awaiting start of cutting will also have to be changed Should it become necesssary to put forward or to delay the insertion of the Indexes in the mechanical cams the end of cutting electrical cam will also have to be brought forward or delayed with respect to its own sensor FC30 Remember to refasten it firmly using the appropriate screws once the adjustment has been made Il 32 sorton 1600 D Morton Electronic Materials CUTTING GROUPS AT THE END OF CUTTING AND THEIR UNCOUPLING At the end of the cutting operation when the rotating groups are stationary in their end of cutting position with the Indexes inserted the blades and counter blades are tightly closed along their entire length In order to return t
58. gnalled by a light set into the button itself VACUUM UPPER OFF ON LOWER OFF This is a luminous selector switch with three positions which inhibits vacuum in the main exhaust shoes in order to facilitate film loading In order to operate automatically this selector switch should be in its central position ON Il 71 orton 1600 D Morton Electronic Materials CSL 1600D VIDEO DISPLAY AND KEYBOARD UNIT HOO Se tells amp Log Ju 1 LCD Display 4 lines 40 characters 2 Function keys F1 F22 F1 front edge adjustment F2 rear edge adjustment lamination speed adjustment F4 tacking time adjustment F5 panel counter to see total counting and reset partial counting 3 Numerical keys for data input parameters 4 HELP key for additonal parameters during the adjustment 5 INFO key for information to the operator during the adjustment During every phase of the machine the display will supply you all information required for the outstanding operations the possible choises the settlements and modifications of lamination parameters as well as all emergency messages with the respective numerical code Every information is written in the language of the country for which the laminator is destined so the relative numerical code identical in all languages leaves no room for doubt as to the meaning You can find here below the messages the numeri
59. he cutting groups to their stationary position start of cutting position the PLC will detach the moving blades from the counter blades by extending the return cylinders after which it will reset the moving blades from oblique to parallel thus uncoupling them from the rotating groups Finally it will command the re entry of the two return cylinders It is important that when the return cylinders of the cutting groups are fully ex tended there is space enough between the moving blades and the counter blades to prevent these implements from rubbing against each other This space will vary according to the thickness of the boards passing between the lamination rolls Il 33 orton 1600 D Morton Electronic Materials Ideal measurements should be 2 mm upper and lower with no board between closed lamination rolls between closed lamination rolls 0 7 mm above and below with three 1 6 mm boards 4 8 mm 2 mm without plate 0 7 mm with 4 8 plate If it becomes necessary to verify this measurement proceed as follows 1 Switch off the machine take out the removable central access hatch and position the rotating groups in the position opposite to that for tacking 2 By hand or by using the PLC keyboard activate the electrovalve EV19 to close the lamination rolls without inserting any board between them 3 Move the rotating groups into the END OF CUTTING position by hand and
60. he electrical control panel there is an electronic circuit composed of 4 sets of numerical presetters as shown in the two diagrams The values of X and Y have been broken down into two parts one is fixed stored in the program memory and the other is edgevariable must be added to the fixed quantity and must be preset via the presetters mentioned above The fixed value of X is 55 0 and to this can be added a quantity that may vary between 0 0 and 9 9 Il 41 orton 1600 D Morton Electronic Materials y 150 x 55 CYCLE TIMES Pos 0 mm mm Pos 50 mm Front edge Rear edge For example when the presetter is set to 1 3 X 55 0 1 3 56 3 The fixed value of Y is 150 to which can be added a quantity that may vary between 00 99 For example when the presetter is set to 52 Y 150 52 202 Caution Once these parameters have been changed via the presetters the operator must enter the page for presetting lamination parameters on the display via SET UP ON and then leave it again without carry ing out any further modification By this means the PCL will be able to read and store in memory the new values of X and Y During the final commissioning inspections of the laminator these parameters are identified and stored in the memory of the PLC However should it prove necessary to recalibrate them the procedure is as
61. id absolutely any heating of the steel of which they are made Caution Do not rub any abrasive objects such as files glass paper etc over the cutting corners of these implements The blades will cut quite efficiently if cleaned only with a rag dipped in alcohol Due to the effects of gravity the return springs of the upper and lower blades have different calibrations 11 50 orton 1600 D Morton Electronic Materials LAMINATION ROLLS PRESSURE HEATING AND THERMAL ALARM SIGNALS The 1600 D laminator laminates dry film onto boards by means of a pair of hot rollers of original design known as lamination rolls These rolls have a total diameter of 100 mm including a 5 mm thick layer of rubber They 800 mm long coloured black and have a rubber hardness of 60 shore The material of its core provides a more equal distribution of pressure over the board Both the upper and lower rolls as also in the case of the rotating sectors move symmetrically with respect to the lamination plane The movement is obtained by two pneumatic cylinders synchronised through a mechanical cam shaft and a system of levers Il 51 orton 1600 D Morton Electronic Materials Screws conpling for parallelism adjustment The parallelism of the rolls with respect to the theoretical lamination line can be regulated by means of the upper and lower screws coupling
62. in wooden crates specially sized to suit the equipment in question The wooden crates are basically of two types as illustrated in the figure below The first type A has a square base while the other is more rectangular in shape TYPES OF PACKING CRATE 1 orton Morton Electronic Materials LIFTING THE CRATE The crate must be handled with extreme care in order to prevent damage to the machine inside It can be lifted by using a A Transpallet B Lift truck NOTE In both cases always check that the utilized lift ing means and accessories ropes chains lift ing forks etc are sized according to the over all weight of the crate as stamped on the same The machine weight is also indicated on the rela tive page of this instruction manual where all the technical characteristics are listed ATTENTION The crate lifting and handing operations may only be carried out by specialized personnel authorized to use the above mentioned equip ment Check the data plates and or indications on the crate before it is lifted There are indications on the sides X and Y marking the places where the lifting forks should b
63. ing time Length of the front edge Length of the back edge Lamination speed Lamination pressure Static tension of the film orton 1600 D Morton Electronic Materials 22 Press the luminous yellow switch CYCLE START mounted on the control cabinet and if all the parameters necessary for lamination are correct roll temperature pads temperature etc insert a discarded board between the rolls to check on the mechanical quality of the lamination edges absence of wrinkles bubbles etc 23 Finally proceed to the automatic loading of the boards leaving between each board a distance which will depend upon the board length the lamination speed and the tacking time selected Caution every time the machine stops for an emergency the film must be repositioned as described from point 18 onwards before lamination is started up again Il 97 orton 1600 D Morton Electronic Materials AUTOMATIC CUT SHEET LAMINATOR MOD 1600 D Kit of recommended spare parts PART NUMBER DESCRIPTION Q TY 062 00 004 00 062 00 005 00 062 02 830 00 062 02 829 00 062 02 818 00 062 00 017 00 062 01 067 00 062 00 021 01 062 00 070 00 062 00 099 00 062 00 080 00 062 00 085 00 062 00 073 00 062 01 008 02 062 02 052 00 062 02 053 00 062 02 106 00 062 02 200 00 062 02 390 00 062 02 571 00 062 02 579 00 062 02 864 00 062 02 863 00 062 02 616 00 062 02 656 00 062 02 717 02 062 02 418 11 062 02 522 00 062 02 619
64. ion so as to follow the film during the cutting phase This coupling is possible because the moving blade is set obliquely by the first of the two pistons which make up the blade movement The coupling process is governed by EV20 both for the upper and lower cutting The position at which coupling or uncoupling takes place is recorded by two sensors 26 for the upper cut and FC27 for the lower If these two sensors are not activated or deactivated within a time limit of 10 secs the PLC stops the machine as for an emergency and gives the signals Top and bot cut hooking movement failed Il 28 orton 1600 D Morton Electronic Materials Once the coupling has taken place the moving blade and the counter blade should be kept apart until the sectors start to move There should therefore be a gap between the blades of 2mm upper and lower with no board between closed rolls 0 7 mm upper and lower with 3 boards of 1 6 mm total 4 8 mm placed between closed rolls Should it be necessary to verify or calibrate this measurement the recommended procedure is as follows 1 Switch off the machine take out the movable central section and place the rotating groups in a position opposite to that of tacking 2 Byhandor using the PLC keyboard give EV19 the command to close the lamination rolls but do not insert any board between them 3 Turn the rotating groups manually to the position Awaiting start of cutting an
65. l closing cam In order to calibrate this position exactly it is necessary to turn the sectors by hand and to stop them in the position opposite to that of the tacking operation Next draw the rolls together using the PLC keyboard or the manual command to EV19 and move the sectors backwards until they are at the minimum possible distance from each other and to the back of the machine Check whether or not sensor FC39 is able to identify the slot of its own cam in these conditions If it proves necessary to correct the positioning unscrew the locking screws and turn the cam in the direction required Retighten the screws once the job is finished Il 26 orton 1600 D Morton Electronic Materials ROTATING SECTORS IN AWAITING START OF CUTTING POSITION When the rolls start their closing movement the groups are at about 90 to the tacking position but are already turning at a speed of 13 3 mt min in order to reach the position of Awaiting start of cutting To allow the groups to come to a gradual stop the PLC receives a timing command from an electric cam connected to the sensor FC31 known as the slowing down cam This cam is positioned so as to be 15 ahead of the Awaiting start of cutting position From this point onwards the speed of the two sectors is reduced to only 3 mt min until the electric cam connected to the sensor FC28 is activated This cam is known as the Start of cutting cam As soon as th
66. l have to be raised 13 Repeat this operation until the optimum value of Y has been found Note Remember to fix the new X and Y values in the PLC memory following the instruction as per previ ous page Caution The value of the rear edge due to the specific design of this machine may be subject to some slight shift from the set value depending upon the thickness of the board undergoing lamination There fore discrepancies may be found between the set values and the real ones We would suggest modifying the set values in function of such discrepancies in order to obtain the precise value required In spite of this the laminator offers excellent repeatability in time which is without doubt the most important characteristic of a lamination process Il 43 _ 1600 D Morton Electronic Materials CYCLE TIMES During the lamination cycle the PLC directs several timing intervals involved in the opening and closing of the electromagnetic gears of the enrichment rolls upper and lower and the time taken for the laminated boards to emerge T1 Main enrichment time This is the time taken to activate the electromagnetic clutch upper and lower during the rotation of the sectors away from the position of end of cutting and to the tacking position The value stored in the memory is 0 5 sec T2 Upper supplementary enrichment time This comes between the end of cutting time and the opening of the rolls Th
67. lange provided for rewinding the cut strips of film In order to obtain a neat cut both blades should always be well sharpened Never allow the blades to touch the metal rolls This would not only ruin the rolls but would also compro mise the entire operation Il 65 _ 1600 D Morton Electronic Materials ELECTRICAL CONTROL CABINET The automatic laminator model 1600 D is controlled by a SAIA PLC series PCA1 46 which interacts with the operator via a numerical keyboard and a display that writes in his own mother tongue This PLC has been incorporated in the control cabinet together with all other electrical components and switches The control cabinet is mounted on wheels and can therefore be easily moved around It is connected to the machine by multi wire cables and connectors It can be positioned either to the left or to the right of the machine but in order to facilitate removal of the central part of the machine it is advisable whenever possible to stand it to the left The electrical power supply to the machine also supplies the control panel and is therefore three phase plus ground without a neutral 50 60 Hz The universal power transformer of the control panel makes it possible to use network voltages of 380V 415V 480V Should it ever be necessary to connect the machine to voltages other than those for which it has been designed our technical assistance office should first be con
68. left and right hand inserted on the control levers of the roll bearing supports and the exhaust unit supports The distance between the rolls when separated should be 90 mm ET LE 90mm 90mm Should this distance require adjustment the appropriate screw coupling should be used Il 52 orton 1600 D Morton Electronic Materials First of all however it is better to make sure that the closure line of the rolls coincides with that of the plane of the input and output rollers Next it is advisable to regulate first the height of the lower roll and then the space between the two rolls when separated The opening and closing movement of the lateral little shoulders and therefore of the rolls should be as rapid as possible However while there are no disadvantages attached to rapid opening a too rapid clo sure could lead to damage to the rubber if the roll were to close down onto the sharp edge of a board The opening and closing speeds must be optimised by simultaneous and equal adjustment of the left and right hand flow regulators of the actuator cylinders and their pneumatic brakes Brakes Air flow regulators The recommended closure time is from 0 8 to 1 0 sec The rolls are heated by means of 2100W 220V short wave infra red lamps activated by solid state relays Ref RL1 RL2 Il 53 orton 1600 D Morton Electronic Materials The strong heating power
69. ll Intercepting photocell Slowing down photocell s PLC d c Motor 2 x gt When the board for lamination conveyed by the input roller passes between the mirrors the intercepting photocell FC69 signals its presence to the control panel S C C The motor M5 sets the two centering guides in motion so that they will if necessary move the board towards the center of the machine When both slowing down photocells FC75 76 have been activated by the board the motor decelerates immediately drawing the centering guides slowly towards the board until the two stop photocells are also activated FC74 FC77 The motor M5 will stop for the interval selected on the controls S C C Then inverting the direction of rotation it will reopen the centering guides and come to a final halt when the stop sensor FC70 for reverse movement is activated Should either the forward stop sensor FC71 or the reverse stop sensor FC70 be out of action for any reason the safety microswitches FC72 FC73 will take over immediately cut off the power supply to the motor and signal the irregularity through the video monitor Il 6 orton 1600 D Morton Electronic Materials Adjustment and calibration of the lateral centering unit For the centering unit to function correctly there should not be too much clearance between the centering guides and the board when the unit is closed The following steps must be followed
70. m to their stationary position 10 Remove the Index and separate the rolls 11 Insert three 1 6 mm thick boards between the rolls and repeat all these operations starting from point 2 checking that the distance between the coupling tooth of the moving blade and the counter blade is correct 0 7 mm for both the upper and lower units 12 order to ensure a stable coupling between the moving blades and their respective counter blades as the rotating sectors turn during the cutting phase the upper cylinder for the return of cutting groups is moved in the opposite direction thus offering resistance to the rotatory mo tion of the sector itself Due to the effect of gravity the lower group does not need help from the cylinder Its own weight is also sufficient It is in any case better that this opposing force should not be excessive because it could slow down or even stop the rotation of the rotating sectors The pression of the upper return cylinder is 6 atm Its regulator is situated on the left side of the back of the machine Il 31 orton 1600 D Morton Electronic Materials ROTATING SECTORS IN END OF CUTTING POSITION The film is cut by shears between the start of cutting and the end of cutting positions As they move forwards the rotating groups also draw with them the two cutting groups which extend the cylinder bars attached to them Start of cutting position Once the sensor FC30 belon
71. n this case the machine will immediately stop in emergency 79 ROLLS CLOSING POSITION SENSOR DAMAGED 390 During the operation and before starting for its own positioning phase the actual activated state of the sensor rolls closing position FC39 is checked if this sensor is already in OFF condition you could detect a failure of the sensor or of the position In this case the machine will immediately stop in emergency 80 LAMIN ROLL TEMPERATURE OUT OF RANGE 131 During the awaiting time for the new board the programmed alarms values on the thermoregulators are checked if the temperature is over the settled range the machine stays in a waiting condition until the temperature returns within the desired range 1 89 ZAorton 1600 D Morton Electronic Materials ADVICE FOR LAMINATION As is well known dry film lamination of printed circuit boards involves slap down of the mask directly onto the board at a given pressure and temperature Because of its particular construction and its operating cycle the Automatic laminator 1600 D does not require critical adjustments to the regulation of its parameters in order to achieve high quality lamination We give below a list of recommended values for the various lamination parameters 1 Temperature of the input board This can even be at room temperature However if the lamination should be performed more rapidly the board may be preheated but not above 35 C Range 20 35 Cau
72. nto account the size of the front edge the length of the board and the real rear edge required Knowing that the minimum length of film that can be laminated is 187 mm the board must have a mini mum length of 287 mm in order to obtain front and rear edges of 50 mm Film Lamination roll Fibre optic photocell Rolls For boards with a length of between 287 mm and 210 mm the value of the rear edge will be modified as follows If we designate B the maximum rear edge possible for a board with a length of less than 287 mm we have Length of board 187 mm front edge B If gt greater than or equal to 50 the rear edge will correspond to the value actually programmed into the control panel If on the other hand B lt less than 50 B will in fact correspond to the programmed value of 50 mm For example Board length 227 mm Front edge 10 mm What figure should be preset in order to have a rear edge of 10 mm Il 45 orton 1600 D Morton Electronic Materials If we apply the above relation we have 227 mm 187 mm 10 mm 30 mm B When B 50 it is found that the maximum real edge corresponding to the programmed value of 50 mm is in fact 30 mm hence Preset edge Real edge 50 30 40 20 30 10 20 0 10 10 film extending beyond board than board which means that in order to obtain a rear edge of 10 mm a value of 30 mm must be entered on the keybo
73. ny readjustment of the measurements or of the electrical calibrations Il 15 orton 1600 D Morton Electronic Materials ROTATING SECTORS VACUUM PUMP TACKING BARS AND COUNTER BLADES KO A Operation The upper and lower rotating units grip the film and convey it from the start cutting position to the tacking position A vacuum pump installed to the front of the machine ensures that the film adheres to the rotating units Between this pump and the exhaust units there are three valves which can cut off the vacuum They are commanded by the PLC according to the requirements of the operating cycle The vacuum in the vacuum shoes is cut off during the lamination phase and re stored when the groups start to turn again in order to follow the film and carry out the cutting operation The vacuum shoes remain under vacuum from the starting of cutting until the next tacking has taken place The secondary vacuum shoes are positioned beneath the main set The film adheres to the upper unit by exhausting after it has been cut to prevent it from falling back onto the board The lower set does not need to be under vacuum because the film adheres to it by gravity alone Il 16 orton 1600 D Morton Electronic Materials Both the tacking bars and the counter blades are fixed to the main vacuum shoes and therefore turn together with them as one unit A rotating mercury connector Mercotac
74. of these elements together with the dark colour of the rolls leads to an extremely rapid response of the system to the command to increase the temperature of the rolls The average time required to pass from room temperature to 110 C is approximately 7 minutes The IR lamps are housed in the semi cylindrical aluminium cover which also acts as a protective hood for the rolls The lamps are mounted in such a way that they can slide lengthwise along one side This displace ment is caused by expansion due to the very high temperatures The IR lamps have a lifetime of several thousands of hours operating at full power and continuously In view of the fact that they will only work intermittently their working life can therefore be considered to be even longer Il 54 orton 1600 D Morton Electronic Materials The temperature of the rolls is measured by a rotary type thermocouple sensor Thermocouple wire v GR E RE ARI SE E PE t SHO os RRR IZZ ZZ 272 A 4 The temperature transducer is made such a as to avoid any friction between the probe and the roll because its copper roller turns on the lamination roll The heat inertia of the transducer is very low so any fall in roll temperature is signalled immediately to the thermoregulator Il 55 orton 1600 D Morton Electronic Materials The low heat inertias of the sens
75. on 31 in slowing down position 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 56 57 58 59 60 61 1600 D Upper lower film rolls greaped Lamination rolls and tacking bars opened Laminator rolls closed Tacking bars closed Upper end of film and missed cut control Lower end of film and missed cut control Front edge overtravel control Cam comand for lamination rolls closing Sliding trolley locked Vacuum pump overload Lateral centering failure Missed cut amp end of film for both side On Off select Remote syncronisme signal Board in front barrier position Output board from lamination area Rear edge board detecting photocell Voltage feed back of front edge register Voltage feed back of dynamo thaco Numerical presetters board 48 49 50 51 52 53 54 55 Enrichment time at the set point Lower enrichment time Upper enrichment time Main enrichment time Front edge adjustment 50 mm Front edge adjustment O mm Rear edge adjustment X value Rear edge adjustment Y value Il 67 orton 1600 D Morton Electronic Materials OUTPUTS PLC Set up on lamp buffer relay for set up Cycle on start lamp Upper both lamination selector lamp oO 8 EV film dynamic tension rolls 9 Enable for control panel into machine 10 11 Relay for speed range selection 12 Flashing lamp alarm 13 Acoustic buzzer alarm 16 EVfor gripping board rools 17 EVforfront bar
76. or and of the IR lamps mean that the temperature of the rolls varies very little from the set value This ensures that the temperature values of the laminated boards remain more constant in time Caution Due to the position at which it is mounted the transducer reads the temperature of the roll after it has yielded some heat to the board so it is inevitable that the display of the thermoregulator shows a temperature slightly below the set value The maximum temperature permissible for the rolls is 140 C Since the heating element is outside the rolls it is of the greatest importance that the rolls should continue to rotate whenever the lamps are on to prevent the rub ber burning A toothed disk and a sensor are attached to the righthand side of each roll Ref CRR1 Ref CRR2 to indicate that the rolls are rotating If a roll should stop rotating for any reason this rotation sensor will cut off the heating to that particular roll The thermoregulators controlling the roll heaters are commanded by a microprocessor housed inside them The thermoregulators can be programmed for different operations and offer the possibility to set an alarm value 11 56 orton 1600 D Morton Electronic Materials The alarm is expressed in C and represents the value below or above which the machine will not accept boards for lamination For example Set value 110 C alarm 20 C The alarm will be activated between
77. placed on the lefthand side of the exhaust units is used to provide electrical power to the tacking bars The heating element for the tacking bars has been placed inside their rubber It has a value of roughly 17 Q and an electric power of 300 W The heating elements are powered by a voltage of 50V and are equipped with a device SRT which regulates their duty cycle or the ratio between time ON and time OFF The analog regulation has a range of between 0 and 100 At 0 the temperature of the tacking bars remains at room temperature and at 100 it is approximately 45 C It should be borne in mind that the temperature of the tacking bars is influenced by that of the lamination rolls which means that variations from the declared values may be found Similarly it should be remembered that the temperature of the tacking bars is not a decisive factor for the success of the lamination process This is due to the fact that after tacking the board does not move on until lamination starts with the intervention of the rolls The counter blades of the cutting system which operates on a shearing technique are bolted to the tack ing bars and therefore move together with the entire rotating assembly when a cut has to be made Both rotating groups are powered by the main motor through an electromagnetic clutch FZ1 situated on the left side of the machine Adjustment and calibration of the positions of the ratating sectors The rotating sec
78. pool film Lateral cutting rolls Reading point A millimetric ruler permits the knives to be accurately positioned at both sides of the machine The edges of film to be cut for example 10 mm are subtracted from the measurements carried out on the dry film spools using the built in millimetric rulers The position of the knives is read at the point outside the supports Range 5 200 mm for each side The cut strips of film are taken up and wound onto two metal rollers each of which is driven by its own gear motor which does not suffer damage if the rotation of its shaft is suddenly blocked Il 64 orton 1600 D Morton Electronic Materials This occurs when all the loose strips have been salvaged and the dry film spool stops unwinding These two motors rotate in opposite directions so care must be taken not to mix them up if they ever have to be dismantled In those cases where lateral cutting is unnecessary these motors can be shut down via a special switch mounted on the panel to the right of the machine This switch bears the sign Lateral cutting ON OFF In order to make dismantling of the polyethylene take up rollers easier we recommend that the shafts of the winding gear motors for the strips of laterally cut film should always be removed first following the diagram below Guiding flanges Guiding flanges AJ It is advisable to use the guiding f
79. r commands to the machine It stays alight until the Set up is turned off by the SET UP OFF button or itis overruled by one of the emergency buttons or it goes out automatically if the machine goes into a state of alarm It activates the heating of the tacking bars activates the vacuum pump the exhaust fan the cap ventilation and the motors for lateral cutting Caution Before giving the SET UP command be sure that there is no film between the rolls SET UP OFF This is an unlit button which deactivates the SET UP ON switch and its functions 11 69 ZAorton 1600 D Morton Electronic Materials CYCLE START This is a luminous button used to start up the lamination cycle It is dependent on the SET UP ON and sets the input roller and lamination rolls in motion enables the operation of the centering mechanism and the board insertion group The Start Cycle is switched off via the Cycle Stop button or whenever the machine stops for an emergency This command works only when the machine has been closed and the film has been loaded CYCLE STOP This is an unlit button which deactivates all the functions activated by the Cycle Start LAMINATION UPPER BOTH This is a luminous selector switch permitting lamination either on both sur faces of the board or only on the upper surface The selection must be made when the machine is stationary TACKING BAR HEATING This is a potentiometer which regulates the percentage heating of the
80. ric cam does not influence the positions of the mechanical cams This position can be adjusted by regulating the screw coupling of the Indexes which are situated on the left hand side of the machine Screw coupling End of cutting position Start of cutting position Mechanical cam It is important that this operation should be performed with a considerable amount of skill The procedure is as follows Switch off the machine and bring the rotating sectors into the tacking position by hand Block the groups in this position by inserting the Index and activate the relative electrovalve EV25 either manually or through the programming keyboard PCA2 P10 05 Insert a board between the groups and bring them together as though for a tacking operation by activating the relative solenoid valve EV19 Go to the rear of the machine and check that the distance between the counter blade and the rear edge of the shoulders of the machine is 347 mm 348 mm REN mu Counter blades Se tie Il 20 orton 1600 D Morton Electronic Materials Should it be necessary to adjust this measurement separate the two groups by deactivating the electrovalve EV 19 When the upper and lower screws coupling are turned upwards the tacking bars move to wards the back of the machine Fig A Conversely when the screws coupling are turned down wards the tacking bars mov
81. rier 18 EV for introduction board cylinder 19 EV for lamination roll amp tacking bars closed opened cylinder 20 EV for hooking cutting device 21 EV for follower cutting device 24 for grip free dry film rolls 25 EV for index insert upper and lower 26 E V for vacuum in upper main shoe 27 EV for vacuum in lower main shoe 28 EV for upper cut 29 EV for lower cut 32 Enable for driver of front edge 34 Relay for clutch FZ7 introduction board roll 35 EV for vacuum in secondary upper shoe 36 Enable for centering control board 37 Enable for main motor 40 Syncronisme signal with loading machine 41 Relay for clutch FZ5 input conveyor 42 Relay for clutch FZ2 lamination rolls amp output conveyor 43 Relay for clutch FZ1 revolving sectors 44 Relay for clutch FZ3 upper film feed roll 45 Relay for clutch FZ4 lower film feed roll 62 Main motor speed adjustment 63 Front edge value adjustment 1 68 ZAorton 1600 D Morton Electronic Materials CONTROL PANEL OF THE ELECTRICAL CABINET CE AUTOMATIC LAMINATOR 1600 IV S SET UP CYCLE MAIN POWER ON ON OFF START STOP LAMINATION UPPER BOTH TACKING BAR HEATING MAIN POWER ON This is a pilot light indicating that there is voltage present in the electrical cabinet It lights up when the general switch at the rear of the panel is turned off SET UP ON This is a luminous button used to enable all the othe
82. right positioning of the thermocouples The lamination rolls should only be replaced by specially trained personnel using original parts which have been correctly designed and made from the right materials The procedure for replacement of the rolls is as fol lows 1 Switch off and disconnect the laminator then wait until the rolls have returned to room temperature 2 Take out the removable part of the machine and detach the small unit that supports the incoming board 111 1 orton Morton Electronic Materials 2 1600 D 3 Block the shaft of the lamination roll with a 30 mm key and proceed to unscrew the three screws of the right hand flange Repeat the operation for the left hand flange 4 Hold the roll carefully so that it does not fall remove the right hand flange and push the roll to the left 5 Still holding the roll firmly remove the left hand flange also 6 Detach the roll taking great care not to let it fall onto the IR lamp located inside the aluminium group 7 Insert the new roll applying anti gripping silicone paste on both extremities in order to facilitate subsequent dismantling Check that the thermocouple is in the correct position 8 Repeat the operations from point 3 onwards for the other roll orton 1600 D Morton Electronic Materials REPLACEMENT OF THE IR LAMPS The IR lamps should be replaced by specially trained personnel using original parts which have be
83. rol Panel Start automatic lamination cycle by pressing Cycle Start button on Main Control Panel Machine will not start to process panels until lamination rolls are at the selected temperature set point Whenever an automatic cycle is started the first panel to be processed should be a scrap panel This will ensure that all production panels will have the correct film spacing Also film tension and align ment will be correct NOTE Machine Maintenance is extremely important Lamination Rolls should be cleaned at the start of Il 2 every shift and during every change of the film rolls Conveyor rolls should be wiped clean and the Tacking Strips should be cleaned and inspected for damage at the start of every shift orton 1600 D Morton Electronic Materials OPERATING CYCLE The board for lamination arrives at the input roller where it is centered onto the center line of the machine by the soft contact centering unit The board is then gripped between two rolls and inserted between the exhaust units which also include the tacking bars and the counter blades of the cutting shears Lamination roll Front edge Il 3 Morton 1600 D Morton Electronic Materials Here the film is tacked onto both edges of the board according to pre programmed time and temperature They then turn away to allow the lamination rolls to close down onto the board at
84. rton Electronic Materials COMPLETE MESSAGES AND DESCRIPTION OF CAUSES LIST 1 EMERGENCY STOP ACTIVATED 1111 The machine has been stopped in emergency by one of the emergency push buttons or by the set up off push button 2 LOW PRESSURE COMPRESSED AIR 140 The machine has stopped or is unable to start due to a low compressed air pressure 3 SAFETY GUARD OR DOORS OPENED 150 The machine has stopped or is unable to start because one of the lateral doors or the left small one are open 4 VACUUM PUMP OVERLOADED 410 The machine has stopped or is unable to start because the motor of the vacuum pump has gone into overload and its thermal relay has been activated 5 LATERAL CENTERING FAILURE 421 The machine has stopped or is unable to start because during the closing or opening phase one of the 3 overstep proximity switches FC72 FC73 FC73A is pressed or the thermal protection for the motor placed on the board is activated 6 SLIDING TROLLEY NOT LOCKED 400 The machine has stopped or is unable to start because the removal central unit is open or has not been firmly coupled to the fixed unit Il 75 orton 1600 D Morton Electronic Materials 7 ONE BOARD IS STOPPED INTO LAMINATOR 451 The machine has stopped because during the ascent phase of the frontal barrier the photocell FC45 is checked if interfered it stops in emergency 8 ONE BOARD IS STOPPED INTO LAMINATOR 4461 During the set point phase and during the opening o
85. s without allowing the machine to continue further operations 11 82 orton 1600 D Morton Electronic Materials 43 TOP amp BOT CUT HOOKING MOVEMENT FAILURE 2670 The machine has stopped because during the cutting groups hooking phase the top and bot proximity switches FC26 and FC27 are not activated 44 TOP CUT HOOKING MOVEMENT FAILURE 260 The machine has stopped because during the cutting group hooking phase the top proximity switch 26 is not activated 45 BOTTOM CUT HOOKING MOVEMENT FAILURE 270 The machine has stopped because during the cutting group hooking phase the bot proximity switch FC27 is not activated 46 TOP amp BOT SHEARS NOT IN SET POINT 2671 The machine has stopped or is unable to start because during the cutting groups unhooking phase the top and bot proximity switches FC26 27 are not released 47 TOP SHEARS NOT IN SET POINT 261 The machine has stopped or is unable to start because during the cutting group unhooking phase the top proximity switch FC26 is not released 48 BOTTOM SHEARS NOT IN SET POINT 271 The machine has stopped or is unable to start because during the cutting group unhooking phase the bot proximity switch FC27 is not released Il 83 orton 1600 D Morton Electronic Materials 49 TOP amp BOT TENSION ROLLS NOT IN WORK POINT 670 The machine stopped because during the tension rolls extension phase the top and bot sensors FC6 and FC7 are not activated 50
86. s have separated Attach it firmly to the supporting rollers with sticky tape Laythe other half of the film down onto the board and bring the rotating groups into the tacking position orton 1600 D Morton Electronic Materials Activate the electrovalve EV25 insert the Index draw the sectors rolls together again for a few seconds in order to perform a tacking operation Tacking bar nae Sica A 9 o Separate the groups remove the board and check whether the two imprints that of the rolls and that of the tacking agree with the following sketch Board Tacking foot print Film Roll foot print Il 25 orton 1600 D Morton Electronic Materials ROTATING SECTORS IN THE ROLLS CLOSED POSITION Once the tacking has been carried out and the vacuum cut off the rotating groups lift off the board and after the electromagnetic clutch FZ1 has been engaged begin to turn at a speed of 13 3 mt min which allows the rolls to close down onto the board as rapidly as possible As soon as the groups reach a position of approximately 90 with respect to the tacking position the PLC commands closure of the rolls by activating the electrovalve EV19 The electric cam which tells the PLC when the groups are in the 90 position is the same one that is connected to sensor FC39 situated on the left hand side of the machine and it is known as the rol
87. s of a friction block pressed against a disc fixed to the ends of the shafts The force applied to the friction block is created by air pressure in a pneumatic cylinder Pression regulator Shaft for spool film Dry film spool Ferodo Pneumatic cylinder The amount of pressure to be applied to this pneumatic cylinder will depend upon the diameter of the dry film spool As is well known the spools can be either standard size or oversize In the latter case the lever arm of the force needed to pull the film is greater as is also the flywheel formed by the spool itself In these cases therefore it is advisable to increase pressure to its maximum to obtain a braking action equal to that obtained with spools of standard diameter As already mentioned in the chapter Dynamic tension good lamination results also depend upon the efficiency of this spool friction device particularly when working with shorter boards We therefore recom mend careful reading of what has been described in this chapter and point no 6 in the chapter entitled Advice on lamination Il 63 orton 1600 D Morton Electronic Materials LATERAL CUTTING The 1600 D laminator is normally constructed with lateral film cutting This device one for the upper and one for the lower film reduces the width of the lamination film depend ing upon individual job requirements Film feed roll enrichment Shaft for s
88. t reached the slot its own cam 1 88 orton 1600 D Morton Electronic Materials 75 INITIAL CUT POSITION SENSOR DAMAGED 280 During the operation and before starting for its own positioning phase the actual activated state of the sensor initial cut position 28 is checked if this sensor is already in OFF condition you could detect failure of the sensor or of the position In this case the machine will immediately stop in emergency 76 TACKING POSITION SENSOR DAMAGED 290 During the operation and before starting for its own positioning phase the actual activated state of the sensor tacking position 29 is checked if this sensor is already in OFF condition you could detect failure of the sensor or of the position In this case the machine will immediately stop in emergency 77 END CUT POSITION SENSOR DAMAGED 300 During the operation and before starting for its own positioning phase the actual activated state of the sensor end cut position FC30 is checked if this sensor is already in OFF condition you could detect a failure of the sensor or of the position In this case the machine will immediately stop in emergency 78 SLOWING DOWN POSITION SENSOR DAMAGED 310 During the operation and before starting for its own positioning phase the actual activated state of the sensor slowing down position FC31 is checked if this sensor is already in OFF condition you could detect a failure of the sensor or of the position I
89. the centering is shown on the following page 15V 1 Power supply input OV 2 Output OV 42 Output 24 5 Output 415 167 Motor Motor 73 72 Security SW _ 9A dg 10 Output alarm signal 0020 12 74 Left Stop photocell i1 Tx A9 7 Rx 77 Right Stop photocell 0007 Tx Input for set up Input Fc 78 Mirror photocell Input Fe 75 left slowing down photocell Input Fe 76 right slowing down photocell Input Fe 71 totally closed proximity Input Fc 70 totally open proximity switch HC 90 598 LL RELE 24VDC Rx Changing of the return speed AMPLIFIERS FOR OMRON AMPLIFIERS e 2 2 lt auto man 5 6701 2929999 ES Fo fe Speed adjustment for manual command Slowing down speed adjustment set to min Manual commands Delay time for mirror photocell set to max Total cycle time to centre the board set to max Time of stop before to come back set to max Fe 78 mirror photocell Ready to work set up 75 Left slowing down photocell Fe 76 Right slowing down photocell Fe 71 totally closed proximity sw Fe 70 totally open proximity sw In order to protect the transistors that power the motor from overheating a 70 C thermal switch has been placed on their heat dissipator This switch
90. the index cam the set point proximity switch FC24 is not activated 38 INDEX CAM NOT IN WORK POINT 250 The machine has stopped because during the insertion phase of the index cam the work point proximity switch FC25 is not activated Il 81 orton 1600 D Morton Electronic Materials 39 REAR EDGE PHOTOCELL DAMAGED 470 At every cycle when the photocell on the boards stopping barrier is activated the state in ON of the rear edge photocell FC47 is checked otherwise the machine stops in emergency Verify the exact adjustment of the sensitivity in case by acting on the trimmer of the photocell 40 REAR EDGE PHOTOCELL DAMAGED 471 At every cycle when the photocell on the boards stopping barrier is not activated the state in OFF of the rear edge photocell FC47 is checked otherwise the machine stops in emergency Verify the exact adjustment of the sensitivity in case by acting on the trimmer of the photocell 41 FILM ROLLS NOT LOCKED 320 During the film loading and the repositioning of the rotating sectors the upper and lower proximity switches FC32A and FC32B for film rolls not locked are checked An OFF condition detects if the dry film rolls are not locked without allowing the machine to continue further operations 42 VACUUM EXCLUSION ON SELECTOR 1011 During the film loading and repositioning of the rotating sectors the vacuum exclusion selectors S10 and S11 are checked An ON condition detects a wrong positioning of selector
91. the opening proximity switch FC33 is not released 30 LAMINATION ROLLS MOVEMENT FAILURE 341 The machine has stopped because during the opening phase of the lamination rolls the closing proximity switch FC 34 is not released 31 LAMINATION ROLLS NOT COMPLETELY CLOSED 340 The machine has stopped because during the opening phase of the lamination rolls the opening proximity switch FC34 is not activated 32 LAMINATION ROLLS NOT COMPLETELY OPENED 2330 The machine has stopped or is unable to start because during the opening phase of the lamination rolls the proximity switch FC33 is not activated 33 BREAKDOWN TO CLOSED OPENED ROLLS SENSORS 3331 The machine has stopped because during the opening phase of the lamination rolls the opening proximity switch FC33 is already activated 34 BREAKDOWN TO CLOSED OPENED ROLLS SENSORS 1341 The machine has stopped because during the closing phase of the lamination rolls the closing proximity switch FC34 is already activated 1 80 orton 1600 D Morton Electronic Materials 35 INDEX CAM MOVEMENT FAILURE 241 The machine has stopped because during the insertion phase of the index cam the external proximity switch FC24 is not released 36 INDEX CAM MOVEMENT FAILURE 251 The machine has stopped because during the outlet of the index cam the proximity switch FC25 is not released 37 INDEX CAM NOT IN SET POINT 240 The machine has stopped or is unable to start because during the outlet of
92. the precise tacking point 1 1 1 d M rra Y 52 2 11 4 orton 1600 D Morton Electronic Materials The tension rolls put the dry film in tension and the lamination rolls move to laminate the film on the board When the electronic controls send the signal to cut the exhaust units and the counter blades move forward once again together with the film Simultaneously the blades of the shears close down over the counter blades and cut the film stretched between them Start of cutting position End of cutting position Board Once the board has been completely laminated the rolls separate and if there is another board ready in position for lamination the exhaust units return to the tacking position Meanwhile the laminated board has arrived at the output roller where static electricity is drawn off and its temperature is read by an IR sensor Il 5 orton 1600 D Morton Electronic Materials OPERATION AND CALIBRATION OF THE VARIOUS GROUPS LATERAL CENTERING UNIT Operating cycle The lateral centering unit is powered by a low inertia d c micro motor and a toothed belt The motor is controlled by an electronic circuit board Ref S C C and by two pairs of photocells mounted on the lateral shoulders plus another photocell known as the intercepting photocell Intercepting 4 photocell Slowing down Mirrors photoce
93. tion The possibility of laminating at higher speed does not only depend upon the temperature of the incoming board but on many other factors such as the surface preparation or the type of dry film in use at the time 2 Temperature of the rubber of the tacking pads This can be regulated between room temperature and 45 C max We recommend establishing a temperature value in function of level of adhesion of the film level of the surface preparation time set for tacking temperature of the input board Range room temp 45 C Note Certain types of dry film need completely cold pads With these even slightly raised temperatures create bubbles in the tacking area 3 Tacking time This value can be set from the control cabin and should take into consideration the level of adhesion of the film the level of surface preparation the temperature of the tacking pads the temperature of the input board Range 0 1 9 9 secs Recommended range 1 5 2 5 secs 11 90 ZAorton 1600 D Morton Electronic Materials 4 Lamination pressure The lamination pressure should be set in function of the type of board to be laminated the type of dry film the pressure of the compressed air supplying the pressure roll the diameter of the lamination rolls the rubber s hardness of the lamination rolls the width of the board to be laminated the temperature of the input board the temperature of the lamina
94. tion and extended cylinder 69 BOTTOM CUTTING DEVICE NOT IN WORK POINT 230 The machine has stopped because during the unhooking phase of the cutting group device the lower work point proximity switch FC23 is not activated Work point position and extended cylinder Il 87 orton 1600 D Morton Electronic Materials 70 INITIAL CUT POSITION NOT REACHED 281 The machine has stopped because during its own positioning phase and within a maximum time referred to the speed the sensor initial cut position FC28 has not reached the slot on its own cam 71 TACKING POSITION NOT REACHED 291 The machine has stopped because during its own positioning phase and within a maximum time referred to the speed the sensor tacking position FC29 has not reached the slot on its own cam 72 END CUT POSITION NOT REACHED 301 The machine has stopped because during its own positioning phase and within a maximum time referred to the speed the sensor end cut position FC30 has not reached the slot on its own cam 73 SLOWING DOWN POSITION NOT REACHED 311 The machine has stopped because during its own positioning phase and within a maximum time referred to the speed the sensor slowing down position FC31 has not reached the slot on its own cam 74 ROLLS CLOSING POSITION NOT REACHED 391 The machine has stopped because during its own positioning phase and within a maximum time referred to the speed the sensor rolls closing position FC39 has no
95. tion rolls The 1600 D laminator with a pressure of 6 atm develops a force of 320 kg This force is distributed over the entire length of the rolls 800 mm and over the entire width of the footprint of the rolls 9 mm Foot Print Lamination rolls This means that the specific mean pressure exerted over each square centimetre of dry film in lamination the pressure reading on the manometer being equal will vary in function of the width of the board Example a board 200 mm wide 320 kg Roll force 200 mm Width of board x 10 mm Foot print Surface area 16 kg cm Example a board 400 mm wide 320 kg 400 mm x 10 mm 4 kg cm Whereas insufficient lamination pressure can result in a loss of adhesion between the dry film and the board too much pressure might lead to the formation of some wrinkles around moderate size holes These wrinkles will be due to too much film penetrating into the holes themselves Il 91 1600 D Morton Electronic Materials Film Films LI Hole Board Too much pressure Insufficient pressure Range 0 6 Atm Recommended range 4 6 Atm 5 Temperature of the lamination rolls This temperature can be preset via two thermoregulators mounted on the right shoulder of the machine This temperature setting of the rolls should take into consideration the lamination speed the type of dry film the type of board to be laminated the
96. ton 1600 D Morton Electronic Materials If the other hand the roll comes down precisely on the tacked line while the rubber is being compressed these 3 mm of film will be laminated onto the board in such a way that the air will be able to escape towards the front Since the contact surface of the compressed roll is approximately 9 mm and the tacked area only 3 mm when the roll presses down it will completely cover both the strip of film already stuck by the tacking and the 3 mm that have not yet adhered The precise position of the pads with respect to the rolls can be checked by the following procedure Switch off the machine take out the central unit and turn the rotating sectors by hand to bring them into the position exactly opposite to that of tacking Take arigid board and lay a piece of dry film over it attaching it by hand to only one side of the board Il 23 orton 1600 D Morton Electronic Materials Il 24 Make a vertical cut along this film with a sharp blade but do not detach it from the board Board Dry film Insert the board between the lamination rolls keeping one of the two strips of film folded back from the board Use either manual commands or the PLC keyboard to activate the EV19 in order to close the lamination rolls against the board reopen them after a few seconds Take care not to move the board from its position once the roll
97. tors together with the tacking bars and the counter blades have three different stationary positions selected by the PLC in function of the cycle Il 17 orton Morton Electronic Materials ELECTRICAL CAMS DIAGRAM FC 39 FC 31 FC 30 FC 29 FC 28 Il 18 1600 D Cam command for lamination rolls closing Cam for position of slowing down rotating sectors Cam for the end of cutting position Cam for the tacking position Cam for the start of cutting position orton 1600 D Morton Electronic Materials ROTATING SECTORS IN TACKING POSITION This is given by one of the three positions of the mechanical cams and by the INDEX which is inserted into them The phase on the other hand is read by an electric cam and by its sensor 29 When the sensor FC29 identifies the slot on its own electric cam the PLC disengages the clutch for the units and inserts the INDEX into the tacking slot of the mechanical cam The position and its repetitivity is thus guaranteed by the INDEX Should it be necessary to put forward or to delay the command to activate the INDEX it will have to be done by changing the position of the electric cam in relation to the sensor FC29 with the cam firmly refastened using the appropriate screws once the task has been completed Sensors and cams for the machine cycle Il 19 orton 1600 D Morton Electronic Materials The position of the elect
98. upplied with an alarm system one could even set minimum and maximum alarms for these temperatures Such alarms would be entered on the instrument and could be included or excluded by means of a switch In order to increase the temperature of the outgoing board one can either increase the temperature of the rolls lower the speed or preheat the board before lamination 1 58 orton 1600 D Morton Electronic Materials VACUUM CUT OFF VALVES Between the vacuum pump and the exhaust shoes of the rotating sectors there is a vacuum distributor with three secondary air hoses each of which contains a gate valve moved by a mini pneumatic cylinder and electrovalves EV26 EV27 and EV35 The three secondary air hoses create vacuum for the main upper exhaust shoe the secondary upper exhaust shoe and the lower main exhaust shoe respectively Vacuum Vacuum Vacuum The lower secondary exhaust shoe does not need to be under vacuum because the cut film remains attached to it by force of gravity Vacuum in the upper secondary exhaust shoe acts to hold the extreme edge of the cut film away from the board until it has been laminated Depending upon the point reached in the cycle the valves by opening and closing control communica tion between the exhaust shoes and the vacuum pump Vacuum is present in the main exhaust shoes from the start of cutting phase through to the tacking There is no vacuum in any of
99. using either manual commands or the PLC keyboard activate the electrovalve EV25 in order to insert the Indexes into the slots of the mechanical cams Il 34 orton Morton Electronic Materials 1600 D 4 Move the two cutting groups by hand upper and lower into the space between the main and secondary vacuum shoes 5 Using either manual commands or the PLC keyboard activate electrovalve EV21 in order to extend the return cylinders of the cutting groups 6 Give the command to couple the cutting groups by activating electrovalve EV20 upper and lower 7T Using a thickness gauge check that the distance between the coupling tooth of the moving blade and the counter blade is as indicated in the Table 2 mm 8 Should it prove necessary to adjust this distance use the adjustment screws on the cylinder bars Caution If the adjustment screws of the cylinder bars are used the coupling start of cutting position should then also be checked see the chapter on Coupling of the cutting groups Cylinder Rear stop for the cutting groups Adjustment of the bar Il 35 orton 1600 D Morton Electronic Materials 9 Detach the cutting groups from the rotating groups by deactivating electrovalve EV20 Bring them back to their stationary position by deactivating EV21 10 Remove the Indexes and separate the rolls 11 Insert three 1 6 mm thick boards between the lamination

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