GL INSTRUMENTS & Operating Instructions Safe Seal Cut & Seal Welder for Filter Sacks GL1200T Cut & Seal (GL1200 Seal only) For industrial use only Important Safety & Operating Instructions Please read carefully and keep for future reference Based on the original design by Graham Lee Supplied by Capricorn Controls Limited Unit 1 9c, Thorpe Close Banbury, OX16 4SW, England T : +44 (0) 1 295 272 360 (4 lines) F : +44 (0) 1 295 264 766 E : sales@capricorn-controls.com W: www.capricorn-controls.com Publication GL1200 Issue: 001 Dated: January 6th 2014
Technical Safety Information for the User This description contains the necessary information for the correct application of the product described below. It is intended for use by technically qualified personal only. Safety Instructions The following instructions are provided for the personal safety of operators and also for the protection of the described product and connected equipment.! Warning! Hazardous Voltage 230VAC if Control Box cover removed Failure to observe can Kill, cause serious injury or damage Isolate from mains before installation or dismantling work, fuse changes or replacement of spare parts. Observe the prescribed accident prevention and safety rules for the specific application. Before putting into operation check if the rated voltage for the unit conforms to the local supply voltage. The Control Box must be earthed at all times. On completion of the seal, the bars will be hot. The operator should take care to avoid bodily contact with the heated surfaces and to store the top bar safely, during this time. When choosing a working position it should be kept in mind that the standard machine is not sealed against the ingress of water or dust. Specified Use The units described herein are heat sealers for use in industrial applications. They are designed for use with polythene sheet or tubing and other similar materials. Contents Page User Safety information 2 Certificate of Conformity 3 1.0 Introduction 4 2.0 Seal Control Module 4 3.0 Operation 5 4.0 Safety 6 5.0 Maintenance 6 6.0 Trouble Shooting 7 7.0 Specification 8 Capricorn Controls Limited Page 2 of 8 GL1200 Issue: 001
Declaration of Conformity We, Capricorn Controls Limited, registered at the address shown at the top of this page, as the manufacturer of the products listed, confirm that these products: GL Heat Sealers (without Cut facility) GL Heat Sealers (with Cut facility) Part Numbers: GL1200-115; GL1200-230 Part Numbers: GL1200T-115; GL1200T-230 are in conformity (where applicable) with the following standards: BS EN 61000-6-4:2007 Electromagnetic compatibility (EMC). Generic Emissions standards for Industrial environments. BS EN 61000-6-2:2005 Electromagnetic compatibility (EMC). Generic Immunity standards for Industrial environments. and therefore conform (where applicable) with the protection requirements of: The Electromagnetic Compatibility (EMC) Directive 2004/108/EC and implemented into UK Law by Statutory Instruments UKSI 2006/3418 as The Electromagnetic Compatibility Regulations 2006. The Low Voltage Directive 2006/95/EC and implemented into UK Law by Statutory Instruments UKSI 1994/3260 as The Electrical Equipment (Safety) Regulations. CE marks are normally applied but in such a position as not to be easily visible when the Capricorn Controls product is mounted into the customer s equipment. Capricorn Controls Quality control in vendor assessment and manufacturing procedures ensures the ongoing compliance of these products. These statements do not infer that the customer s product in which Capricorn Controls supplied products are installed, by the right of Capricorn Controls compliance statements, comply with the directives. CERTIFICATION We hereby certify that the products detailed above unless otherwise stated have been inspected in accordance with the requirements of the purchase order and conform to the specifications and drawings relevant thereto. Issued: Authorised: F Oliver F.W. Oliver Managing Director Ref: CCM_DC_GL1200 Iss.1 Capricorn Controls Limited Page 3 of 8 GL1200 Issue: 001
1.0 Introduction The heat sealers described here are purpose designed for safe disposal of used filters in a wide range of applications and industries. They are semi-automatic in operation and no special operator skills are required. However, some adjustment is required to obtain the best results from the equipment, which is described later in this document. Heat sealing of polythene tubing and similar materials is achieved by simultaneous application of heat and pressure and these machines operate on the impulse principal, which means that the seal bar is not continuously heated. On initiation of the sealing cycle, by momentarily pressing the green push-button, the electronic timer circuit passes a high current through the heating element for a brief period, typically of a few seconds in duration. The Red LED (adjacent to the push-button) indicates that the Heat + Cool cycle is in operation. As soon as this LED extinguishes, the weld is complete, the toggle clamps can be released to remove the top bar and the welded material removed. 2.0 Seal Control Module The SCM200 Seal Control Module, fitted in the Control Box, provides a simple system for setting the machine to seal any particular material and to accurately repeat those settings when subsequently required - by simply recording the numbers on the four thumb-wheel switches. Seal Time setting = 00 > 99 representing 0 > 10 seconds (example 3 4 setting = approx. 3.4 seconds) Trim setting = 0 > 9.. Where 9 represents minimum compensation (factory set at 9 ). See below Cool Time setting = 0 > 9 representing 0 > 20 seconds (example 4 setting = approx. 8 seconds) Note: The above timings are only approximate but what is important is there repeatability. Note: Always record the four numbers for future use (i.e. 3 4 9 4 in this example) Trim Setting This adjusts a simulated rate of cooling of the heated bar after the Seal Time has elapsed in order to automatically foreshorten the second and subsequent Seal Times to compensate for heat remaining in the tool. Assuming there will be some considerable time between Seals, this is factory set at 9 for effectively no compensation (no heat retained). If adjustment is required, we recommend reducing one number at a time and doing two or three test seals at the required interval. Capricorn Controls Limited Page 4 of 8 GL1200 Issue: 001
3.0 Operation The machine consists of a Control Box and separate Sealing Head CONTROL BOX Power Transformer to provide high current at low voltage to the heating circuit Protection Fuse accessed from the rear of the unit, to protect the Transformer primary winding. SCM200 Seal Control Module to set repeatable Seal, Trim and Cool times Power relay to switch the high current supply to the Heater Bar 7-pin power socket to connect control circuits and high current supply, to the Sealing Head. Please order for 115V or 230V operation As standard, 230V units include an integral 1.4 metre mains lead with moulded UK 13A Plug. As standard, 115V units include an integral 1.4 metre mains lead with un-fused 32A IP44 Industrial Plug. SEALING HEAD Base assembly with Heating Bar, Green Push-Button, Red Seal Cycle LED, 2.6 metre cable with 7-pin plug Top Bar with handles and silicon rubber Pressure Pad. 3.1 Preparation of Machine Plug the Sealing Head 7-Pin connector into the mating half on the Control Box and remove the Top Bar and place this in a clean and safe place. Do not plug into the mains supply at this time. Note: It is important that the machine is NOT stored with the Top Bar clamped, as this will damage the Silicon Rubber pressure pad. 3.2 Preparation of Filter Bag for Sealing Isolate from the Mains Supply Lay the Filter Bag across the Bottom (Sealing) Bar ensuring that the bag lies flat and is free from creases and folds Replace the Top Bar, and secure using both Toggle Clamps. The Bag is now ready for Sealing. 3.3 Sealing Operation Connect the Control Box to a mains supply and the RED Power LED should light in the display window Press the Green Push-Button on the Sealing Head and the adjacent Red Led should light, indicating that the Sealing Cycle is in progress (additional LEDs in the window on the Control Box will also indicate the separate Seal and Cool times within the Seal Cycle. When the RED LED on the Seal Head extinguishes, the Seal cycle has finished. Switch off the mains supple, release the toggle clamps, remove the Top Bar and Filter Sack It is strongly recommended that prior to doing a safe change, the operator does a sample seal to ensure that the seal is satisfactory for that material. Remember to record the Thumbwheel switch positions for future use. Capricorn Controls Limited Page 5 of 8 GL1200 Issue: 001
4.0 Safety The machine contains parts that are electrically Live, even when the SCM200 Controller is in standby. The electrical supply MUST be disconnected prior to removal of the control box cover. A competent Electrician must carry out any repair or test work, or alternatively the machine should be returned to the supplier. The machine is fitted with a mains supply fuse, accessible at the rear of the Control Box, to protect the transformer primary winding. The machine is also fitted with a mains lead and moulded 13A Mains plug on the 230VAC version and with an unfused 32A IP44 Industrial Plug on the 110VAC version. The machine must be earthed at all times. The machine incorporates several features to help ensure operator safety - a) The source of the heating current, is isolated from the mains supply and is at a safe low voltage. b) For the machine to operate, the Sealing Head must be plugged into the Control Box c) The top bar must be fitted and secured by the toggle clamps. d) Press the green push-button for approx. 1 sec and the adjacent Red LED will light to indicate that the Seal Cycle is in operation e) Red LED extinguishes to indicate Seal Cycle complete and Top Bar and material can be removed WARNING: - Immediately after the seal cycle has completed, the bars will be hot. The operator should avoid finger contact with heated surfaces and in particular when removing the top bar and sealed material. Ensure that the top bar is placed safely such that it cannot be damaged and cannot damage anything else. WARNING: - When choosing a working position, it should be noted that the machine as a whole is not sealed against the ingress of water or dust. However, a dust proof door assembly is fitted to the Seal Controller to protect the Thumb-Wheel switches. 5.0 Maintenance 5.1 Mechanical The design and construction of the machine makes regular mechanical lubrication and maintenance unnecessary. Keep the Teflon fabric cover over the heating element clean and free of contamination Keep the silicon rubber Pressure Pad free from contamination, and NEVER store the sealer clamped 5.2 Cover Tape and Heating Element The seal bars, both heated and unheated, will require attention at intervals, dependant on factors such as workload, material thickness and temperature. Bars in good condition will produce seals of constant width throughout the entire length and will exhibit a clear impression of the texture of the Teflon cover tape. If the seal quality is unsatisfactory, then check the bar condition as follows, ensuring that only manufacturer s approved materials are used. Examine the Silicon Rubber and replace if required Examine the Teflon cover tape for cracks, surface defects or burn marks. Please contact the supplier or Manufacture for guidance as the Teflon cover tape cannot be replaced without dismantling the Sealing Head. Capricorn Controls Limited Page 6 of 8 GL1200 Issue: 001
6.0 Trouble Shooting SYMPTOM CHECK Machine inoperative, no LEDs Lit Mains Supply, Plug Fuse and Control Box fuse Supply LED Lit, machine inoperative 7-Pin Plug secure Polythene or similar material correctly positioned Top Bar correctly fitted and Toggle Clamps closed Press Green Push-Button for 1 second Still no response or Heat & Cool LEDs flash momentarily Micro-switch and SCM200 Controller Thumb-wheel settings No improvement SCM200 Controller Note: Contact the Supplier or Manufacturer for Technical Support before attempting a repair 6.1 Repairs & Servicing Spare parts do not include Teflon Tape or Heater Strips as we offer service exchange on the major items GL-CB1 Control Box GL-SCM200 Seal Control Module GL1200-Top Bar GL1200-SH1 GL1200T-SH1 6.2 Warranty Contact the supplier for Warranty claims, spares and Service Exchange parts In addition to our standard Terms & Conditions of Supply; the conditional Warranty on this product excludes Teflon, Elements and Silicon Rubber. Capricorn Controls Limited Page 7 of 8 GL1200 Issue: 001
7.0 Specification Rated Voltage (230V version) Rated Voltage (115V version) Operating Frequency Supply Burden Mains Plug Fuse Rear Fuse (Motor Rated) On Load Output Open Circuit Output nominal 230-240V nominal 110-120V nominal 50 / 60Hz 600VA Transformer 13A (230V) 10A (230V); 20A (115V) 44A at 35VAC intermittent operation at 1 : 3 duty cycle 45VAC Absolute Maximum Seal Length 1270 mm Overall Dimensions (mm) Control Box Sealing Head Net Weights Control Box Sealing Head 380d x 230w x 260 h (incl. feet and handle) 1555 length x 140 h (Toggle clamp levers, Down) 1525 length x 200 h (Toggle clamp levers, Up) 76 wide but allow 120 with cable exit 9.6 Kg 7.3 Kg Dimensions and weights are approximate. 7.1 Ordering Information GL1200T-115 Seal & Cut Filter Sack Heat Sealer GL1200T-230 Seal & Cut Filter Sack Heat Sealer GL1200-115 As GL1200T but Seal Only, no Cut GL1200-230 As GL1200T but Seal Only, no Cut Manufactured in England and Distributed world-wide by... Capricorn Controls Limited Unit 1 9c, Thorpe Close Banbury, OX16 4SW, England Tel: +44 (0) 1295272360 (4 lines) Fax: +44 (0) 1295264766 Email: sales@capricorn-controls.com Web: www.capricorn-controls.com Capricorn Controls Limited Page 8 of 8 GL1200 Issue: 001