GETINGE ProSeal Classic/Plus/ Premium SERVICE MANUAL

Transcription

1 GETINGE ProSeal Classic/Plus/ Premium SERVICE MANUAL EN P/N: V.9 Service manual Getinge ProSeal V.9 V.9

2 History Name Version Date Comment Coen van de Laar Manual adjusted after first review by GvR Coen van de Laar Manual adjusted after second review by GvR Contents General notes Prerequisites Danger of injury Risk of electric shock Risk of burning Risk of Entrapment Tools Preventive maintenance plan Opening the unit Removing the base frame from the housing Replacing the PTFE material The belt guides The heating elements Transport belts Printer (only ProSeal Premium) Upper pressing wheel Lower pressing wheel Trouble shooting Error codes Print head (ProSeal Premium) Repair Repair printer (ProSeal Premium) Control board Assembling Heating elements Transport belts Belt guides Upper pressure roller Mounting the base frame in the bottom housing Validation Validation Kit Classic Logging in Pressure Speed Temperature Plus and Premium Logging in

3 5.3.2 Pressure Speed Temperature Spare parts

4 General notes This manual provides the user with the appropriate instructions for safe and proper maintenance and repair of the sealing unit. Each person involved in maintenance or repair of the sealing unit must be familiar with these instructions or the safety regulations respectively. In order to avoid operating errors and to ensure trouble-free operation of the sealing unit these instructions must always be accessible for the personnel. By receiving this document you do not automatically participate in an updating service. Copyright This maintenance instruction manual must only be handed over to third parties with the written consent of GETINGE. All documents are protected by copyright law. Disclosure as well as reproduction of documents, even in form of excerpts, utilization and announcement of its content is prohibited, if not explicitly admitted. Violations are liable to prosecution and oblige to compensation. We reserve the right for the exercise of industrial property rights. Warranty and liability We assume liability for possible faults or omissions within the framework of the specified warranty obligations, under exclusion of further claims. In the course of further development we reserve the right for technical modifications to the sealing unit, which is subject of these maintenance instructions. We will not assume liability for any damage or malfunction caused by operating errors, negligence of these maintenance instructions or inappropriate repairs. We would like to point out that only genuine spare parts and accessories from GETINGE which have been approved by us should be used. The installation or use of spare parts or accessories which have not been approved, will lead to the exclusion of any liability of GETINGE for damage resulting from this. Technicians preferably should be trained by Getinge Academy. Drawings and graphical presentations are not to scale. For maintenance work it is necessary to open the housing. During maintenance and repair work the unit must be disconnected from the power supply! 4

5 . Prerequisites Getinge has ESD protection integrated into the production and testing of electronic equipment, and also requires ESD protection to be used after delivery for the warranty to apply. It is important to reduce the likelihood of ESD to avoid damage to sensitive electronic components. As a basic precaution, it is recommended to wear ESD wrist strap, sole grounders or conductive shoes when preforming maintenance on the unit. Keep electronic components in the anti-static bag until you are ready to install them in order to prevent charge from building up. Requirements when performing maintenance to avoid ESD: Use ESD pads connected to the earth in accordance with the manufacturer s instructions to hold disassembled or new electronic boards during assembly work. Do not touch electronic boards with tools that may be charged, like screwdrivers with a plastic or wooden handle. Use grounded tools, if necessary. Always use an ESD wrist strap connected to the earth in accordance with the manufacturer s instructions when working in the electronic enclosure or when handling boards. Do not keep any foreign objects, such as drawings or plastic pockets, inside the electronic box. Test the ESD protective equipment on a regular basis. To start with the maintenance/repair inspection the following steps should always be followed first: Check whether the mains plug of the unit has been pulled out. Attention! To avoid damage caused by electrostatic charging..2 Danger of injury During troubleshooting, calibrating or validation of the unit it may be necessary to turn on the unit with an open housing. You should do this with extreme care.2. Risk of electric shock Operating a running unit with open housing can result in an electric shock. The areas marked in Pic use mains voltage. 5

6 Touching these areas can cause lethal injury! Pic.2.2 Risk of burning During operation, the heat elements can reach temperatures to 200 C. Touching these parts or parts around them can result in severe burning..2.3 Risk of Entrapment In standby mode, the sealer transport belt can start to move to avoid radiant heat on the transport belt..2.4 Tools Tools needed to service and repair the unit are: Allen key, 4, 5 and 8 2 Circlip pliers ESD protection Knife Non aggressive solvent and degreasing agent Pinch pliers 3M VHB cleaner 2 Preventive maintenance plan In order to avoid damage or a failure of the unit as a result of insufficient maintenance we recommend servicing the unit at least once every year or after 00,000 seals. During maintenance the above-mentioned precautions should be followed. The sealing result should be checked after each maintenance. Daily or after 400 seals Visual seal seam check Check printed text on seal bag Yearly or after 00,000 seals whichever occurs first Preventive maintenance 6

7 2. Opening the unit Open the housing; remove the side covers (Pic 2) Pic 2 Remove the screws on both sides of the top cover(pic 3) Pic 3 Lift the top cover somewhat on the front and pull it forward so you can remove it (Pic 4 + Pic 5) Pic 4 Pic 5 7

8 2.2 Removing the base frame from the housing Disconnect the wiring from the base frame and the control board (Pic 6). Use special care with the flat cable coming of the display. This cable is easily damaged. Control board Base frame Pic 6 Turn the unit on the front side, be careful with the touchscreen! Remove screws () to separate the base frame from the housing (Pic 7). After removing the screws, turn the sealer back. Pic 7 8

9 2.3 Replacing the PTFE material The belt guides and the heating rails are lined with a non-stick strip (PTFE tape). It is non-stick so your pouches will not stick on the heating rails. It is also on the belt guides which expands the life of the transportation belts. For preventive maintenance the PTFE material on the heating rails and belt guides must be replaced The belt guides The base frame has been removed from the housing. Unscrew the belt guides (Pic 8) Pic 8 Press the upper belt guide down. The top of the upper belt guide can now move forward and the whole upper belt guide can be removed.(pic 9) Pic 9 When the upper belt guide is loose, the lower belt guide can be pulled out. 9

10 Remove the press plate and the guide plate of the upper belt guide assembly (Pic 0) Pic 0 Remove the worn PTFE strips on the guide plate and press plates. Clean off the bonding agent residues with a solvent and degrease the bonding surface with a non-aggressive degreasing agent. Stick the new PTFE tape on the guide plate and press plate; do not touch the cleaned bonding surface and press the tape over the complete area thoroughly. Reinstall the belt guide assembly. Make sure that the press plate moves freely. See paragraph for the mounting instruction of the belt guide assembly to the base frame; for preventive maintenance, see paragraph The heating elements Disconnect the ground wire of the upper and lower heating element with a plier. Attention! Do not pull the cables; this could damage the heating elements! Use a plier on the connector. Remove the upper pressure roller (Pic ) by releasing the pressure with screw (). After releasing the pressure remove the screws (2) to dismount the suspension of the upper pressure roller. 2 Pic 0

11 Unscrew the two screws on top of the heating elements to release the upper heating element with isolation from the frame (Pic 2). Pic 2 When the upper element is removed it is easy to remove the lower element and insulation (Pic 3). Pic 3 Remove the insulation foam from the heating rails (Pic 4). Pic 4 Remove the worn PTFE strip. Clean off the bonding agent residues with a solvent and degrease the bonding surface with a non-aggressive degreasing agent. Stick the new PTFE strip on the element. Cut the PTFE strip to fold the

12 strip around the heating cables. Do not touch the cleaned bonding surface and press the strip thoroughly over the complete area. Cut a notch into the PTFE strip () (Pic 5). Pic 5 See paragraph 4.3. for the mounting instruction of the heating elements to the base frame. 2.4 Transport belts During use, the transport belts in the ProSeal will start to get worn out. It is therefore important to replace the transport belt during preventive maintenance. Remove the belt guides (paragraph 2.3.). It is not necessary to remove the heating elements. Remove the clamp with a circlip plier holding the smooth wheel in place (Pic 6). Do this with the upper and lower wheel. Pic 6 Remove the upper and lower smooth wheel (Pic 7) and replace the transport belt. Make sure that the arrows on the belt are pointing in the movement direction of the belt. Pic 7 2

13 Tension the belt by hand and fasten the belt pulley. (Pic 8)Make sure that the belt is not sag down. Pic Printer (only ProSeal Premium) We recommend to exchange the printer ribbon each time during maintenance. Remove screw () and remove lid (2). (Pic 9). 2 Pic 9 Unscrew the fastening screws a couple mm to release the printer module. (Pic 20) Pic 20 Remove the printer ribbon from the printer module. Pull at the printer ribbon at the bottom side of the printer module to remove it.(pic 2) Pic 2 3

14 Turn the printer module upside down and clean the area around the printer needles(pic 22). Pic 22 Switch the unit on. Produce some seal samples with printing. Check if the text on the seal samples is printed well. If the text is illegible, turn the pin on the printer ribbon housing (2) (Pic 23). Produce some seal samples again with printed parameters or text. Check if the text on the seal samples is printed well. If the text is illegible, check if the distance between the printer head and the printer wheel is still mm (depending on sealing material). Use a feeler gauge with mm thickness. If the distance is not mm, loosen the screw; see Pic 23 (). 2 Pic 23 Lay a feeler gauge with a 0,3-0,4 mm thickness above the printer head. Place the nylon printing wheel so that it is lying on top of the feeler gauge. Fasten the screw and remove the feeler gauge. Check the printing result. 2.6 Upper pressing wheel. Check at every maintenance inspection if the surface of the upper pressing wheel is worn out or damaged. If the upper pressing wheel is worn out or damaged, it should be replaced. 4

15 The upper pressure wheel can be removed and exchanged. See paragraph for the mounting instruction of the upper pressure roller. 2.7 Lower pressing wheel For the lower pressing wheel one should follow the same procedure as for the upper pressing wheel. Check if the surface of the lower pressing wheel is worn out or damaged. If the lower pressing wheel is worn out or damaged, replace the complete part. Remove the spur gear () from the shaft (Pic 24) by removing the clamping pin Ø3x2mm (2). 2 Pic 24 The lower pressing wheel can be pulled out of the base frame and exchanged with the new one. Reassemble the unit in the opposite order; after assembly check if the mechanism is running properly. 3 Trouble shooting 3. Error codes Error codes higher than 2 are critical errors. Sealing is not possible anymore, only after turning off and on the sealer, the error is reset. Always try first to turn the sealer off and on to fix the problem. Also check if newer software version is available. Nr. Error text Description Possible problem / solution Bag too small for printer text Selected printer text doesn't fit on the inserted pouch Insert larger pouch or adjust printed text length (chapter 7.9) or decrease dot spacing (printer menu) PCB on the inlet of the pouch mounted incorrectly Check sensors active parameter by inserting pouch Cable start sensors disconnected / broken Start sensor PCB defect 5

16 2 3 4 Could not print due to pouch depth Temperature too low Temperature too high 5 Pressure too low 6 Pressure too high 7 Speed too low Not able to print due to pouch insertion depth Temperature below set point - alarm limit Temperature above set point + alarm limit Pressure below set point - alarm limit Pressure above set point + alarm limit Speed below set point - alarm limit Pouch not entered deep enough into the sealer. The pouch doesn t run over the printer head PCB on the inlet of the pouch mounted incorrectly Check sensors active parameter by inserting pouch Cable start sensors disconnected / broken Start sensor PCB defect Pouch detected before temperature was reached Alarm limit temperature too low Cable temperature sensor disconnected / broken Temperature sensor on heating element defect Pouch detected before temperature was reached Alarm limit temperature too low Cable temperature sensor disconnected / broken Temperature sensor on heating element defect Set point pressure not correct Alarm limit pressure too low Pressure not correct (adjust the screw on the pressure sensor according to paragraph 4.3.3) Pressure wheel not clean Pressure sensor defect Pouch too thick Set point pressure not correct Alarm limit pressure too low Pressure not correct (adjust the screw on the pressure sensor according to paragraph 4.3.3) Pressure wheel not clean Pressure sensor defect Pouch too heavy or thick Alarm limit speed too low Belt too loose or too tight PCB on the inlet of the pouch mounted incorrectly Encoder sticker on the belt pulley damaged Cable start sensors disconnected / broken Start sensor PCB defect 6

17 8 Speed too high 9 Reverse error 0 No seal command received NetCOM event 2 NetCOM error 3 USB overcurrent 4 5 Printer over temperature Print buffer underrun 6 Printer overcurrent 7 Printer needle stuck Speed above set point + alarm limit Reverse button pressed during sealing Trying to seal when the unit is in NetCOM command mode but no seal command received from the NetCOM NetCOM sent an error event that must be acknowledged by the user NetCOM communication error Overcurrent event detected on (unit) USB port Printer head over temperature event detected Pouch too heavy or thick Alarm limit speed too low Belt too loose or too tight PCB on the inlet of the pouch mounted incorrectly Encoder sticker on the belt pulley damaged Cable start sensors disconnected / broken Start sensor PCB defect Reverse button pressed during sealing (only used in log and reported to the NetCOM) Send seal command from NetCOM and seal again. Use the sealer in auto mode instead of command mode Check manual NetCOM Software error Update firmware Ribbon motor or needle drive circuit detected an overcurrent event Print current measured while no printer needle was activated Cable(s) between control PCB and NetCOM disconnected / broken Wrong software version in NetCOM No activated license for sealer in NetCOM NetCOM defect Short circuit in attached USB device Too much printer activity Cable printer disconnected / broken Printer head defect Too much printer activity Printer head defect Ribbon motor defect Printer head defect 7

18 8 Temperature difference error 9 Heating error TempK8Calib error TempK2Calib error PressFullCalib error PressNullCalib error Pressure sensor error Pressure sensor 2 error 26 SPI flash error Mains detection error Temperature overheat error Large temperature difference between lower and upper heater element Heating elements are on but the temperature doesn't rise (fast enough). Temperature selftest of the control PCB failed. Temperature selftest of the control PCB failed. Pressure self-test of the control PCB failed. Pressure self-test of the control PCB failed. No communication with pressure sensor No communication with pressure sensor 2 Error while communicating with flash memory Error while measuring mains frequency and voltage Temperature of one or two temperature sensors above 20 C Cable heating element (power) disconnected / broken One of the 2 heating elements defect (check resistance, should be almost equal) Cable temperature sensor disconnected / broken Temperature sensor on heating element defect Cable heating element (power) disconnected / broken Thermostat upper heating element activated Thermostat lower heating element activated Heating element(s) defect (check resistance) Cable temperature sensor disconnected / broken Temperature sensor on heating element defect To reset thermostat: Wait until heating elements are cooled down and press button on thermostat to reset, use low force. If thermostat was activated a click can be felt when pressing the reset button Cable pressure sensor disconnected / broken Pressure sensor defect Cable pressure sensor disconnected / broken Pressure sensor defect Firmware update Mains voltage or frequency out of range for sealer specification Cable temperature sensor disconnected / broken Temperature sensor on heating element defect 8

19 29 Software error 30 Hardware error General software error General hardware error Firmware update Firmware update 3.2 Print head (ProSeal Premium) Attention! A defective print head can destroy the electronic system in the sealer. Therefore, first check whether the print head is defective. Measure the resistance of the individual contacts (Pic 25). If the resistance is not correct, the print head must be replaced. Measure the resistance between the ground and the other contacts. If the resistance on one of the contacts is lower than stated, the printhead is defective. Attention! A defective print head can destroy the electronic system in the sealer. Pic 25 9

20 4 Repair 4. Repair printer (ProSeal Premium) The print head needs to be handled very carefully. For correct printing, the print head needs to be replaced by following the next steps. Attention! To avoid damage caused by electrostatic charging. Before starting always remove the base frame from the housing (paragraph 2.2). Remove the printer ribbon housing () (Pic 26). Pic 26 Remove the defective print head and replace it with a new one. Place the blue lever () (Pic 27) on its middle position. A space of mm has to be applied between the print head and the nylon printing wheel (see paragraph 2.5). Loosen the screw (2) (Pic 6). Lay a feeler gauge from mm above the print head. Place the nylon printing wheel so that it is lying on top of the feeler gauge. Fasten the screw and remove the feeler gauge. Place the printer ribbon housing back. 20

21 Put the blue lever () back on its lowest position (Pic 27). 2 Pic 27 Check whether the flat cable or the control board is defective. Before removing the flat cable, the upper part of the connecter must be lifted (Pic 28). Lift upper part connector Pic Control board Attention! Ground yourself to avoid damage caused by electrostatic charging. Disconnect all connectors from the control board (Pic 29) (). Remove the 2 connectors between the control board and the power supply, and unscrew the power supply. Disassemble the defective control board by loosening the socket head screws. Dispose of the defective control board in an environment-friendly manner or send it back to the manufacturer. Install a new control board. Re-assemble the complete unit in the opposite order. (Don t forget to reconnect the protective ground.) 2

22 Pic 29 Check all functions. After replacing the control board, the speed, temperature and pressure should be revalidated. For the ProSeal Classic the speed and temperature should be validated. For instructions how to validate see section Assembling Clean the parts and the lower housing of the unit with compressed air and surface cleaner Heating elements Turn the heat element upside down and place it in the isolation (Pic 30). Pic 30 Place the heat element and isolation on the suspension of the base frame (Pic 3). 22

23 Pic 3 Align the upper heating element in line with the lower heating element, and press the spring between the upper heating element and the clamp.(pic 32) Pic 32 Fasten the right side, of the upper heating element, until the heating elements are just separated from each other(pic 33) Pic 33 Do the same with the left side, but the elements must barely touch each other.(pic 34) Pic 34 23

24 Connect the wiring of the upper and lower element. Do not forget to connect the ground cable. Make sure that the correct cable is connected to the corresponding control board slot Transport belts Place the belt around the toothed wheel. (Pic 35), make sure that the arrows on the belt are pointing in the movement direction of the belt. Upper belt wheel Pic 35 Place the smooth wheel in the belt (Pic 37). Make sure the wheel with sticker goes to the upper belt (Pic 36). Lower belt wheel Pic 36 Pic 37 24

25 Fix the smooth wheel with the original clamp and the circlip pliers. Make sure the clamp is properly fixated. (Pic 38) Clamp wrong Clamp good Pic Belt guides Mount the upper belt guide to the base frame, slide the guide over the inside of the belt and press it down until the belt can move over the belt guide. Check that the flat belt wheel and the toothed wheel run smoothly (Pic 39). Belt guide Pic 39 After fastening the upper belt guide, mount the lower belt guide in the same way. 25

26 4.3.4 Upper pressure roller First mount the suspension and the pressure roller on the base frame (Pic 40). Pic 40 Place the spring between the suspension and the load cell and fasten it with the M4 screw (Pic 4). Pic Mounting the base frame in the bottom housing Place the base frame upside down; be careful with the touchscreen! Place the bottom housing over the base frame and secure it with 4 screws (Pic 42). Pic 42 26

27 After assembling the sealer, calibrate the replaced parts if possible. It is advised to validate the pressure, speed and temperature to ensure the ProSealer is still within specs. 5 Validation During preventive maintenance, the ProSeal needs to be validated to ensure the sealer is still within specifications. 5. Validation Kit The ProSeal can be validated using the validation kit. This kit contains: Tachometer Temperature meter Temperature probe Heat conductive paste Pressure meter ProSeal Pressure tool Adapter Pressure meter Cable ProSeal Pressure tool Pressure meter ProSeal Pressure tool Adapter Pressure meter Temperature probe Cable ProSeal Pressure tool Pic 43 Temperature meter Tachometer 27

28 5.2 Classic 5.2. Logging in A service technician can use the service functions of the unit after logging in the service login. The service password is Without this password, the configuration settings can be viewed but cannot be changed. Turn knob left Pressure Press button to select Configuration. It is not possible to validate the pressure of the ProSeal Classic Speed Password blinking. Turn knob to enter passcode. To select press button. (all 4 digits need to be confirmed) Turn knob right. Turn knob right. Press button. Speed will blink. Turn knob left or right to adjust speed. Confirm speed by pressing the button. Hold a pouch under the sensor and validate the speed with the tachometer Temperature Turn knob right. Press button. Put heat conducting paste on the upper heat element. Temperature will blink. Validate the temperature with the temperature meter and probe. Turn knob left or right to adjust temperature. Confirm temperature by pressing the button. 5.3 Plus and Premium The ProSeal Plus and ProSeal Premium can be validated using the validation menu. In order to reach the validation menu, you must login as service. 28

29 5.3. Logging in A service technician can use the service functions of the unit after logging in the service login. The service password is Without this password, the configuration settings can be viewed but cannot be changed. Press Menu Press Service login Enter password 8729 Press OK to log in Press Configuration Press Service to enter service menu After logging in, the validation menu can be reached to navigate to the service menu. In this menu press validaton to reach the validation menu (Pic 44) Pressure Pic 44 Pic 45 In the pressure menu (Pic 45) the pressure set point and the measured pressure can be seen. Both values should be equal(±n). If there is a difference you can change the measured pressure by adjusting screw () (Pic 46). 29

30 Pic 46 For validation of the pressure you need the ProSeal pressure tool. Mount the tool on the pressure load cell (Pic 47). Pic 47 Adjust screw () so that the value of the measured pressure on the display of the unit is 0. The value of the display of the ProSeal calibration tool should be equal to the pressure set point (±0N) (Pic 48). If the pressure exceed the tolerance of 0N, a new load cell and load cell print needs to be installed.. Pic 48 Remove the ProSeal calibration tool, and check if the measured pressure of the unit is equal to the pressure set point. If not, adjust it with screw () (Pic 48). You have validated the pressure of the unit Speed Pic 49 Go back to the validation menu and press Speed. In the speed settings (Pic 49) the speed settings can be changed. By pressing on the + or from Motor manual you can turn on or shut off the motor manually. 30

31 Press the + button to turn on the motor forward. On the right in the display you can read the speed of the running motor; the value should be the same (± 0 mm/sec). For validation adjust the speed to 20 mm/s (min. speed); check with a tachometer if the speed of the belt is equal, check also at 70 mm/s (max. speed). The factory setting for speed is 60mm/s Temperature Be aware of the tolerance of the temperature device you use. Pic 50 Go back to the validation menu and press Temp. In this Temperature menu (Pic 50) you see the temperature set point and the measured temperature of the unit. There will always be a difference between these values which is caused by the temperature control. Place heat conduction paste on top of the heat element (Pic 5). Pic 5 Change the set temperature to 00 C Place the temperature probe on top of the heat conducting paste. Compare the temperature of the upper heat element with the temperature meter. Be sure that the measured temperature is the same as the temperature of the upper heat element (± 5 C). Change the set temperature to 200 C Compare the temperature of the upper heat element with the temperature meter. Be sure that the measured temperature is the same as the temperature of the upper heat element (± 5 C). 6 Spare parts Spare parts can be ordered by means of the enclosed drawings. Always state the type designation and the serial number of the unit when ordering spare parts. Copy the respective drawing and mark the required spare part. 3

32 The following spare parts are delivered as pre-assembled assemblies: Part number Description Classic Plus Premium PM kit x PM kit x x 32