Scott 1800 Instruction Manual
Copy No.:
Instruction Manual
Model No. : Scott 1800.................
Year of Manufacture : 2005.......
Manufactured by :..........
Document Number : S99999--1........
Issue : 1.....................
Date of Issue : July 2005..............
ISSUE NOTE
This is Issue 1; Date of Issue: July 2005
Copyright 2005
Table of Contents
III
Scott 1800
TABLE OF CONTENTS
1 INTRODUCTION & SAFETY 1--1...........................................................
1.1 Introduction 1--3....................................................................
1.1.1 Scott 1800 Machine Specifications & Utility Requirements 1--4..........................
1.2 General Safety Guidelines 1--5.......................................................
1.3 Safety 1--6..........................................................................
1.3.1 Main Power Switch 1--6...........................................................
1.3.2 Main Air Disconnect 1--6..........................................................
1.4 Warnings, Cautions & Notes 1--7.....................................................
1.4.1 Warnings 1--7....................................................................
1.4.2 Cautions 1--7....................................................................
1.4.3 Notes 1--7.......................................................................
1.5 On Machine Warnings 1--8...........................................................
1.5.1 Hazards 1--8....................................................................
1.6 Safety Procedures 1--9..............................................................
1.6.1 Appropriate Dress 1--9............................................................
1.6.2 Keep Area Clean 1--9.............................................................
1.6.3 Grease and Oil 1--9..............................................................
1.6.4 Manual Usage 1--9...............................................................
2 INSTALLATION 2--1......................................................................
2.1 Installation Requirements 2--3........................................................
2.1.1 Pre-Installation Requirements 2--3..................................................
2.1.2 Assembly Instructions 2--4.........................................................
2.1.3 Check Punch & Die 2--5...........................................................
2.1.4 Mount Paper Supports 2--6........................................................
2.1.5 Install Plastic Reel 2-- 6............................................................
2.1.6 Set the Plastic Stop Guide 2--8.....................................................
3 OPERATION 3--1.........................................................................
3.1 GENERAL INFORMATION 3 --3........................................................
3.1.1 Before Operating the Machine 3--3.................................................
3.2 Operator’s Controls 3--4.............................................................
3.2.1 Control Panel Layout 3--4.........................................................
3.2.2 Power On/OFF Selector Switch 3--5................................................
3.2.3 Machine Mode Selector Switch 3--5.................................................
3.2.4 Power On Indicator Lamp 3--5.....................................................
3.2.5 Foot Pedal 3--6..................................................................
3.2.6 Main Air ON/OFF 3--6.............................................................
3.2.7 Plastic Advance/Cut Switch 3--6....................................................
3.2.8 Production Sheet Counter 3--7.....................................................
3.2.9 Machine Heater Controls 3--7......................................................
3.2.10 Machine Timers
3--8..............................................................
Table of Contents
IV
Scott 1800
3.3 Omron Timer Setting Instructions 3--9................................................
3.4 Scott 1800 Frequently Asked Questions 3--10..........................................
3.5 Tab Bank Layout (Method 1) 3--11.....................................................
3.6 Index Tab Set--Up Procedure (Method 2) 3--13..........................................
3.7 Flow Control Valve Setting 3--17.......................................................
3.7.1 Change or Clean Upper Braking 3--17................................................
3.7.2 Setting Flow Control Valves 3--19....................................................
3.7.3 Testing Flow Control Settings 3--21..................................................
4 MAINTENANCE 4--1......................................................................
4.1 Punch and Die Setting Instructions 4--3...............................................
4.1.1 Punch & Die Removal 4--3........................................................
4.1.2 Reinstallation Punch & Die 4--11....................................................
4.1.3 Setting Left Hand Die 4--15.........................................................
4.1.4 Reinstalling the Punch 4--16........................................................
4.2 Care Of Air Cylinder 4--22.............................................................
4.2.1 Lubrication 4--22..................................................................
4.3 Scott 1800 Spare Parts List 4--25......................................................
4.4 C01--1000 Series Filter -- Regulator Combination 4--26...................................
4.4.1 Installation 4--26..................................................................
4.4.2 Adjustment 4--26..................................................................
4.4.3 Maintenance & Cleaning 4--26......................................................
4.4.4 Vendor Contact Information 4--26....................................................
4.5 304-- 1000 & 2000 Series Lubricators 4--28..............................................
4.5.1 Installation 4--28..................................................................
4.5.2 Oil Adjustments 4--28..............................................................
4.5.3 Tamper Proof 4--28................................................................
4.5.4 Maintenance 4--28................................................................
4.5.5 Part Information 4--29..............................................................
4.5.6 Vendor Contact Information 4--29....................................................
5 PARTS 5-1..............................................................................
5.1 Drag Roller Assembly 5-4................................................................
5.2 Idle and Drive Feed Assembly 5-6.........................................................
5.3 Plastic Feed Air Cylinder Assembly 5-8....................................................
5.4 Punch Assembly 5-10....................................................................
5.5 Heater Press Air Cylinder Assembly 5-12....................................................
5.6 Frame Press Mounting Assembly 5-14......................................................
5.7 Die Assembly 5-16.......................................................................
5.8 Paper Guide Assembly 5-18...............................................................
5.9 Plastic Reel Holder Assembly 5-20.........................................................
5.10 Column Mounting Assembly 5-22..........................................................
5.1 1 Body Mounting Assembly 5-24............................................................
5.12 Air Valve Assembly 5-26.................................................................
5.13 Cover and Plate Assembly 5-28...........................................................
5.14 Leg Extension Assembly 5-30............................................................
5.15 Machine Mounting Rail Assembly 5-32.....................................................
5.16 Bottom Support Rail Assembly 5-34.......................................................
Table of Contents
V
Scott 1800
5.17 Guard Assembly 5-36...................................................................
5.18 Controls Mounting Assembly 5-38.........................................................
6 SCHEMATICS 6-1........................................................................
1 Introduction & Safety
1--1
Scott 1800 Issue 1
1 INTRODUCTION & SAFETY
Scott 1800 Issue 1
1 Introduction & Safety
1--2
Scott 1800 Issue 1
1 Introduction & Safety
1--3
Scott 1800 Issue 1
1.1 Introduction
The Scott 1800 Plastic Index Tab Machine is a semi--automatic, manually fed machine for laminating plastic
to index tabs. The plastic is coated with a heat--seal adhesive which is activated when run through the
machine under heat and pressure. The standard width of the plastic is 1--5/8 inches wide.
The Scott 1800 machine can operate at the rate of up to 4,500 sheets per hour.
Fig. 1-1. Machine Front View
Fig. 1-2. Machine Rear View
1 Introduction & Safety
1--4
Scott 1800 Issue 1
1.1.1 Scott 1800 Machine Specifications & Utility Requirements
Model Scott 1800t
Speed
Up to 4,500 sheets per hour.
Sheet Size
MIN: 5 1/2” (140MM) LENGTH
MAX: 15” (381MM) WIDE
Plastic Size
MIN: 1” (25.4mm)
MAX: 5.5” (139.7MM)
Paper
32lb. Bond to 25pt.
Electrical Requirements
5AMP 120VAC 50 or 60hz.
Decibel Rating
70dB
Dimensions
Length: 51”
Width: 35”
Height: 38”
Shipping Weight
330lb (150kg)
Warranty
One year against defects in parts
1 Introduction & Safety
1--5
Scott 1800 Issue 1
1.2 General Safety Guidelines
Providing a safe working environment for operating your machine is the responsibility of the user. The
suggested precautions, material safety data and other suggestions that follow do not have preference over
the user’s own plant practices, regulations or safety committee recommendations.
Personal injury and equipment damage can be avoided by the continued adherence to the safety features
provided with this machine and in keeping with the necessary governmental requirements. The guarding
and interlocking safety switches have been installed on the machine for the operator’s safety. These items
should be maintained in good working order by the user.
It is assumed that the user’s safety department has established a safety program that is in keeping with a
complete analysis of industrial hazards. Before installing and operating or performing maintenance and
clean--up procedures on the machine, it is suggested that the safety program be reviewed to ensure that it
covers the possible hazards that might occur with the operation of this machine.
Due consideration must be given to those hazards which arise from the presence of electrical power, high
temperature, and cleaning materials used in the operational areas of the machine. Proper installation and
care of protective devices and over--pressure protective equipment should be considered an essential part of
any safety program.
Special lock--out features are to prevent the possibility of applying power to the equipment at any time when
maintenance work is in progress.
In general, personnel should be guided by all basic rules of safety associated with the equipment and the
process. It should be further understood that information contained in this manual does not relieve operating
and maintenance personnel of the responsibility of exercising normal good judgment in operating and care of
the machine and its attendant equipment.
1 Introduction & Safety
1--6
Scott 1800 Issue 1
1.3 Safety
Fig. 1-3. Turn Machine Off Before Making
Adjustments
1.3.1 Main Power Switch
If machine is to be shut down for adjustments or
repairs, turn the power supply to the machine off.
Fig. 1-4. Shut Off Main Air Before Working on
Machine
1.3.2 Main Air Disconnect
Shut off main air before making any machine
adjustments.
1 Introduction & Safety
1--7
Scott 1800 Issue 1
1.4 Warnings, Cautions & Notes
In order to emphasize certain areas in the interest of personal safety and a properly operated and maintained
machine, you will encounter the words WARNING, CAUTION, and NOTE throughout this manual.
WARNING!
Fig. 1-5. Warnings Indicate Personal Danger
1.4.1 Warnings
AN OPERATING PROCEDURE,
PRACTICE, ETC. WHICH IF NOT
CORRECTLY FOLLOWED, COULD
RESULT IN PERSONAL INJURY OR
LOSS OF LIFE.
WARNING!
CAUTION!
Fig. 1-6. Cautions Indicate Potential Damage to
Equipment
1.4.2 Cautions
AN OPERATING PROCEDURE,
PRACTICE, ETC. WHICH, IF NOT
STRICTLY OBSERVED, COULD RESULT
IN DAMAGE TO OR DESTRUCTION OF
EQUIPMENT.
CAUTION!
Note !
Fig. 1-7. Notes Indicate Essential Information
1.4.3 Notes
An Operating Procedure, Condition,
etc. Which is Essential To Highlight.
Note !
1 Introduction & Safety
1--8
Scott 1800 Issue 1
1.5 On Machine Warnings
Fig. 1-8. Hot Surface Hazard
1.5.1 Hazards
Observe Hazard signs.
Fig. 1-9. Voltage Warnings
There are two hazardous voltage warnings. One is
on the main electrical cabinet above the operator’s
controls and the other is on the top cover.
1 Introduction & Safety
1--9
Scott 1800 Issue 1
1.6 Safety Procedures
Fig. 1-10. Wear Proper Clothing
1.6.1 Appropriate Dress
Personnel working in the machine operation area
must remove jewelry and neckties. Personnel
must wear clothing appropriate for the work area.
Fig. 1-11. Keep Work Area Clean and Neat
1.6.2 Keep Area Clean
Loose materials, tools and equipment, not
essential to the operation of the machine, must be
removed from the machine work area.
Fig. 1-12. Clean Up Oil and Grease Spills
1.6.3 Grease and Oil
Clean up all oil and grease spills around the
machine work area.
Fig. 1 -13. Read Manuals First
1.6.4 Manual Usage
Read and understand the instructions in the
manual before operating, adjusting or servicing
machine.
2 Installation
2--1
Scott 1800 Issue 1
2 INSTALLATION
Scott 1800 Issue 1
2 Installation
2--2
Scott 1800 Issue 1
2 Installation
2--3
Scott 1800 Issue 1
2.1 Installation Requirements
All procedures in this section provide advance planning and site preparation data for installation of the Scott
1800. Environmental requirements, unpacking instructions, electrical and physical specifications are
included. This information should be used as a reference during the development of site preparation plans
before you install your machine.
If any questions arise while performing any of the following procedures, contact:
Note ! A forklift is required to lift the machine off the shipping skid and place it on the floor.
2.1.1 Pre-Installation Requirements
The environmental requirements of the Scott 1800 must be considered well in advance of the actual
installation. Providing a well suited operating environment will help ensure a trouble free installation process.
Consideration should be given to the following items:
● Power, location and rating of power connections.
● Floor strength
● Level floor
● Adequate space must be provided around all four sides of the machine to permit normal operation and
maintenance procedures. The figure shows the minimum space required.
3’ (914mm)
3’ (914mm)
3’ (914mm)
3’ (914mm)
Fig. 2-1. Scott 1800 Space Requirements
● Space should be allocated near the paper tray for a small table that can be used for small jobs, samples,
etc.
● Provide plenty of space In front of the machine so large jobs can be easily moved in and out with skids or
carts.
2 Installation
2--4
Scott 1800 Issue 1
2.1.2 Assembly Instructions
Fig. 2 -2. Machine on Shipping Skid
The machine is shipped assembled.
Step: 1. Remove the machine from shipping skid.
Note ! Now you are ready to bring power to the machine.
DO NOT APPLY AIR PRESSURE TO THE MACHINE AT THIS TIME!!
Step: 2. Plug in the electric cord.
Step: 3. Turn the on/off switch on. The Heat light should come on and both heat controller lights will come
on if the temperature is set high enough.
Step: 4. Set both controllers to 225_F.
After the machine has reached running temperature, the lights on the heat controllers will go on
and off.
2 Installation
2--5
Scott 1800 Issue 1
Fig. 2-3. Check Punch and Die
2.1.3 Check Punch & Die
Check the Punch and Die set of the machine. They
may or may not need to be reset, but they do need
to be checked before you start to operate the
machine for the first time, or after any time the
machine has been moved from one location to
another.
Step: 1. Follow the instructions in the
Maintenance section in this manual on
punch and die setting.
Fig. 2-4. Connect Air to Machine
Step: 2. After the dies have been checked and
properly reset if necessary, you may now
connect the air to the machine. Make
sure the pressure regulator is set to 80
P.S.I.
2 Installation
2--6
Scott 1800 Issue 1
Fig. 2-5. Mount Paper Supports
2.1.4 Mount Paper Supports
Step: 1. Mount the paper supports, the paper side
guide and the plastic stop to the front of
the machine on the black bar locate
directly in front of the punch and die area.
Fig. 2-6. Place Plastic on Reel Holder
2.1.5 Install Plastic Reel
Step: 1. Place a reel of plastic on the plastic reel
holder on the left side of the machine.
Fold the plastic so the coating is on the
inside.
Note ! The coated side is always on the
outside of the reel.
Step: 2. Thread the machine.
Make sure the plastic goes around the
tension arm coming from the table.
Once you get the plastic started through
the tunnel, you can feed with the manual
toggle switch marked “Plastic
Advance/Plastic Cut”.
Fig. 2-7. Turn Knob for Tighter or Looser Fold
Step: 3. To adjust a tighter or looser fold, turn the
knurled pin located between the plastic
feed rollers and the drag roller.
Note ! Recommended Tension is three
Plastic Thicknesses.
2 Installation
2--7
Scott 1800 Issue 1
A
B
Fig. 2-8. Turn Knob to Adjust Tape Tension
Step: 4. To adjust the tape tension, rotate the
black knob (A) on top of the roller with
the two rubber “0” rings.
This is the drag roller.
Adjust for slight amount of drag.
Note ! This should not need frequent
adjustment.
Step: 5. To adjust the tension between the two
feed rollers by loosening or tightening
tension arm (B) attached to upper feed
roller.
Fig. 2-9. Plastic Size Adjustment (LH Shown)
Step: 6. To adjust the size of plastic, unlock the
pinch lock on the left end of the machine
and set the scale to the desired size.
Note ! Be sure to lock the assembly.
Step: 7. Every time you set the left gauge, you
must set the gauge on the right side of
the machine to the same setting.
This centers the press on the tab you are
making.
If this is not done, you will get bad
bonding since the press will be hitting off
center.
2 Installation
2--8
Scott 1800 Issue 1
Fig. 2-10. Manually Feed and Cut Plastic
2.1.6 Set the Plastic Stop Guide
To set the Plastic Stop Guide, do the following:
Step: 1. Run tape through the machine past the
punch and die set then, cut off the plastic
with the manual switch.
Fig. 2-11. Feed Piece of Plastic
Step: 2. Feed out a piece of plastic with the
manual feed switch but DO NOT CUT the
plastic.
A
Fig. 2 -12. Bring Stop Guide to End of Plastic
and Add 1/16”, Tighten Guide
Step: 3. Bring the stop guide (A) up to the end of
the plastic and then back it away about
1/32 to 1/16th of an inch. The purpose of
the plastic stop is to help keep the plastic
registered to the same spot on the paper.
Step: 4. Tighten the guide in place.
3 Operation
3--1
Scott 1800 Issue 1
3 OPERATION
Scott 1800 Issue 1
3 Operation
3--2
Scott 1800 Issue 1
3 Operation
3--3
Scott 1800 Issue 1
3.1 GENERAL INFORMATION
3.1.1 Before Operating the Machine
AVOID SERIOUS INJURY OR EQUIPMENT
DAMAGE. RESTRICT OPERATION OF THIS
MACHINE TO TRAINED, QUALIFIED
PERSONNEL ONLY.
EACH OPERATOR SHOULD KNOW THE
LOCATION AND FUNCTION OF ALL
MACHINE STOPPING CONTROLS.
REVIEW MANUAL FOR EMERGENCY
STOP BUTTON LOCATION.
Do not attempt to operate the machine before reading and understanding the manual. Pay close attention to
all WARNINGS, CAUTIONS and NOTES. Failure to do so may cause serious injury and extensive machine
damage.
Read through the inspection and pre--start procedures before starting the machine. Make these checks part
of your routine to insure efficiency and quality during the production run.
3 Operation
3--4
Scott 1800 Issue 1
3.2 Operator’s Controls
3.2.1 Control Panel Layout
Fig. 3-1. Control Panel
Fig. 3-2. Operator’s Switches
3 Operation
3--5
Scott 1800 Issue 1
Fig. 3-3. Power On/OFF Selector Switch
3.2.2 Power On/OFF Selector Switch
OFF -- Turns Power off to the machine.
ON -- Brings Power to the machine.
Fig. 3-4. Machine Mode Selector Switch
3.2.3 Machine Mode Selector Switch
This selector switch determines the operational
mode of the machine.
AUTO -- When the selector switch is in the Auto
mode, the tab laminating function will operate
when a sheet is inserted into the platen area. By
inserting a sheet into the platen area, contact is
made with a switch which will laminate one tab.
OFF -- Tab laminating cannot be activated in this
mode. This is the standby mode.
MANUAL -- When the switch is in this position, the
switch in platen area is bypassed allowing the tab
laminating operation to be performed using the foot
pedal.
Fig. 3-5. Power On Indicator Lamp
3.2.4 Power On Indicator Lamp
Lamp is illuminated when power (power switch in
ON position) is on.
3 Operation
3--6
Scott 1800 Issue 1
Fig. 3-6. Operator’s Foot Pedal
3.2.5 Foot Pedal
The foot pedal is used by the operator to activate
the tab laminating function.
NOTE! Machine Mode switch must be in the
Manual position to operate by foot
pedal.
Fig. 3-7. Main Air
3.2.6 Main Air ON/OFF
Slide the quick disconnect up to allow air to the
machine or down to shut it off.
Fig. 3-8. Plastic Advance & Cut Selector Switch
3.2.7 Plastic Advance/Cut Switch
This switch allows plastic to be advanced and cut
manually.
Plastic Advance -- Manually feeds plastic into the
punch and die area.
Plastic Cut -- Activates the punch to cut the
plastic.
3 Operation
3--7
Scott 1800 Issue 1
Fig. 3-9. Production Sheet Counter
3.2.8 Production Sheet Counter
Can be reset at any time to keep track of sheets
run.
PROCESS VALUE
SCROLL KEY
RETURN KEY
SET
VAL UE
CON:
Control
Output
ALM:
Alarm
Output
Fig. 3-10. Heater Temperature Control
3.2.9 Machine Heater Controls
Controls the upper and lower platen temperatures
by cycling power to the heaters. The setpoint
temperature is adjusted by using the buttons below
the indicator display.
The controller maintains process parameters when
power is off.
Touch Keys Description Function
Scroll Key Advances the index display to the desired position.
Indexes advanced continuously and cyclically by
pressing this keypad.
Up Key Increases the parameter (Set Point or Other)
Down Key Decreases the parameter (Set Point or Other)
Return Key Resets the controller to its normal status. Also stops
auto--tuning, output percentage monitoring and
manual mode operation.
Press for 6 seconds
Long Scroll Allows more parameters to be inspected or
changed.
Press for 6 seconds
Long Return 1. Executes auto--tuning function.
2. Calibrates control when in calibration level.
Press and
Output Percentage
Monitoring
Allows the set point display to indicate the control
output value in percent.
Press and
for 6 seconds
Manual Mode Execution Allows the controller to enter the manual mode.
This can be used if the sensor fails.
3 Operation
3--8
Scott 1800 Issue 1
Fig. 3-11. Plastic Feed and Punch Timers
3.2.10 Machine Timers
Controls the operation of the air valves which
control the operation of the Press and Plastic feed
cylinders as well as the Punch.
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