Sharp SX 1075, SX 1097, SX 1099, SX 1109, SX 1121 Service Maintenance Manual

...

Download

Page 1

arr

Models 1075, 1084, 1097, 1099, 1108, 1109, and 1121

Printed In USA 0924

Parts: (800) 634-6359 ext. 571

www.sharppackaging.com

TTMM

arr

Service & Maintenance Manual

TTM

wiitt

Prrii

ntt

err

parts@sharppackaging.com

Service: (800) 634-6359 ext. 572

service@sharppackaging.com

Page 2

The safety inform ation pr esented is a g uidel ine that

IMPORTANT SAFETY INFORMATION

SX™

WARNING

Operating machine without safety guards in

death.

WARNING

tangled with the machine. Failure to do so

WARNING

GENERAL WARNING. Indicates information important to the proper operation of the

WARNING

important to the proper operation of the

CAUTION

prior to performing any maintenance on the machine.

WARNING

should be followed by all personnel. Anyone operating or maintaining the equipment should read and follow all the information in this manual, without exception.

DEFINITION OF TERMS

Throughout this manual, you will find the following safety notices with this accompanying symbol. This symbol signifies important safety issues regarding the oper ation and maintenanc e of the Sharp SX™.

equipment. Failure to observe may result in damage to the equipment and severe bodily injury or death.

GENERAL CAUTION. Indicates information equipment. Failure to observe may result in

damage to the equipment.

EQUIPMENT SAFETY FEATURES

The Sharp SX™ is equipped with a polycarbona t e shield covering the pressure and heated seal bars.

DO NOT operate the unit with the shield removed.

Operating the unit without the safety guards in place may result in serious bodily injury or death.

SAFETY RULES AND PROCEDURES

The machine requires regular, periodic maintenance to ensure reliable service. No maintenance should be performed unless the safety precautions for maintenance are thoroug hly understood.

• Follow all instructions in this manual for safe operation.

• Follow all company and industry standard safety policies regarding this kind of machinery that ma y exceed thos e liste d in th is manual.

• Keep all safety features, guards, interlocks and sensors in good working order.

• ALWAYS turn off machine power, ensure that all mechanical motion has stopped and allow any heated components to cool down before removing any machine parts.

place may result in serious bodily injury or

Always remove electrical power from the SX

Prior to operating or servicing the SX, remove any loose jewelry, make certain clothing and hair are not loose to interfere with or become

could result in severe bodily injury or death.

Page 3

SAF ETY LABELS

The label shown on th e right

or panel guards electrical

to removing any guards

IMPORTANT SAFETY INFORMATION

SX™

The following label is placed on the Sharp SX™ wherever a removable shield or panel guards the heated sealing area. Always disconnect electrical power from the machine prior to removing any guards and/or panels.

The following label is used where there is the potential of your hands, long hair, jewelry, etc. becoming entangled between two rotating parts. Be sure to secure loose item s before approaching and operating the machine.

The following label on the Sharp SX™ is located where there is the potential of injury due to pinch points or moving parts. Make certain electrical power is disconnec ted befo re rem oving an y guards and/or panels or servicing the machine.

The following label is locat ed in the proximity of a fused circuit. Be certain to replace blown fuses ONLY with fuses with the same electrical rating. Always disconnect electrical power before removing an y guards and/o r panels or s ervic ing the Sharp SX™.

is placed on the Sharp SX™ wherever a removable s hield

components. Always disconnect electrical power from the mac hine pri or

and/or panels.

Page 4

Section 1- Introduction

SX™

General Information ................................................ 1-1

About This Manual .............................................. 1-1

Model Variations ................................................. 1-2

Technical Assistance ......................................... 1-2

Theory of Operation ................................................. 1-3

General ............................................................... 1-3

Faults .................................................................. 1-4

EZ-Bags® and Film Materials ............................. 1-5

Thermal Transfer Ribbon .................................... 1-5

Specifications ........................................................... 1-6

Machine Specifications ....................................... 1-6

Packaging Specifications .................................... 1-6

Machine Dimensions ........................................... 1-6

Section 2 – Maintenance & Adjustments

Maintenance Schedule ............................................ 2-1

Daily Maintenance .......................................... 2-1

Annual Maintenance ........................................... 2-1

Cleaning .................................................................... 2-2

General ............................................................... 2-2

Cleaning the Printhead and Film Feed Rollers.... 2-3

Machine Adjustments .............................................. 2-5

Adjusting the Pinch Roller ................................... 2-5

Checking Belt Tension ........................................ 2-6

Checking Belt Tension ........................................ 2-7

Sharp SX™ with Printer ...................................... 2-8

Section 3 – Component Repair

Electrical Assembly ................................................ 3-1

Pressure Jaw and Film Feed Motor Controller s...3-1

Fuses .................................................................. 3-6

24VDC Power Supply ......................................... 3-8

Line Filter .......................................................... 3-16

Main Power Switch (RED)................................. 3-20

Transformers ..................................................... 3-22

Aromat PLC ...................................................... 3-27

Aromat PLC Battery .......................................... 3-28

Color Touch Screen .......................................... 3-30

Cooling Fan ....................................................... 3-33

Solid State Relay .............................................. 3-35

Grey Relay 24V ................................................ 3-39

Red Relay 24V .................................................. 3-41

Printer GPIO Board ........................................... 3-44

Printer Performance Logic Board ...................... 3-45

Printer Power Supply Board .............................. 3-46

24 VDC Fan Assembly...................................... 3-48

Laminated White Ribbon Cable ........................ 3-49

Datamax LCD Module....................................... 3-51

Printhead Stepper Drive .................................... 3-53

Film Feed Assembly .............................................. 3-56

Photoelectric Sensor ......................................... 3-56

Film Feed Motor Drive Belt ............................... 3-60

Film Feed Roller Drive Belt ............................... 3-61

Platen Roller Drive Belt ..................................... 3-63

Film Feed Roller ............................................... 3-67

Platen Roller ..................................................... 3-69

Film Feed Drive Motor ...................................... 3-72

Cradle Lock Cams ............................................ 3-74

Printhead Cradle Assembly .................................. 3-76

Ribbon Rewind Assembly ................................. 3-76

Ribbon Rewind Motor ....................................... 3-76

Primary Ribbon Drive Belt ................................. 3-79

DC Roller Clutch ............................................... 3-81

Secondary Ribbon Drive Belt ............................ 3-83

Adjustable Slip Clutch ....................................... 3-87

Printhead Position Assembly

Printhead Position Motor ................................... 3-89

Printhead Position Drive Belt ............................ 3-92

Printhead Pressure Cams ................................. 3-94

Printhead Position Sensor ............................... 3-100

Thermal Printhead ........................................... 3-102

Ribbon Supply Assembly

Slip Clutch Spring ............................................ 3-103

Ribbon Motion Sensor ..................................... 3-104

Ribbon Clips .................................................... 3-106

Gas Springs ..................................................... 3-107

Cross Flow Fan ................................................ 3-108

................................... 3-89

........................................ 3-103

Page 5

Cradle Latch Lever .......................................... 3-110

SX™

Cradle Latch .................................................... 3-111

Sealer Assembly .................................................. 3-113

Pressure Bar Drive Motor................................ 3-113

Pressure Bar Gearbox .................................... 3-116

Pressure Bar Belt ............................................ 3-118

Linear Bearings ............................................... 3-120

Stripper Plate Assembly .................................. 3-122

Sealpoint Components .................................... 3-129

Seal Wire Tension Springs.............................. 3-132

Stripper Plate Sensors .................................... 3-135

Jaw Position Sensors ...................................... 3-140

Unwind Assembly ................................................ 3-145

Appendix

Replacement Parts Order Form .......................... A-1

Warranty ............................................................. A-2

Protecting Your Printhead ................................... A-3

Printer Menu Structure ........................................ A-6

Wiring Diagram – Located in the back of this

binder or Click Here

Unwind Spring ................................................. 3-145

Section 4 – Troubleshooting

Troubleshooting Chart ........................................ 4-1

Section 5 – Parts Lists

Electrical Assembly ............................................. 5-1

Film Feed Assembly ........................................... 5-3

Frame Assembly ................................................. 5-4

Printhead Cradle Assembly (Model 1108)........... 5-5

Cradle Assembly (Model 1097) ........................... 5-9

Sealer Assembly ............................................... 5-10

Unwind Assembly ............................................. 5-12

Section 6 – Assembly Drawings

Electrical Assembly ............................................. 6-1

Film Feed Assembly ........................................... 6-5

Frame Assembly ................................................. 6-6

Printhead Cradle Assembly (Model 1108)........... 6-9

Cradle Assembly (Model 1097) ......................... 6-14

Sealer Assembly ............................................... 6-17

Unwind Assembly ............................................. 6-20

Page 6

SX™

SECTION 1 – INTRODUCTION

GENERAL INFORMATION

This manual is designed to be used b y Authorized Service Pers onnel only. Sharp Packaging Systems, Inc. assumes no responsibility for any repairs made on Sharp Packaging units by anyone other than Authorized Service Technicians.

TESTING

ADJUSTMENT

REPLACEMENT

ABOUT THIS MANUAL

This manual has been prepared for your use in servicing the Sharp SX™ Packaging Mac hine and the Sharp SX™ Packaging Machine with Printer. Included in the procedures are helpful facts on service, troubleshooting, specifications and parts information.

All procedures shoul d be performed by a qualified service technician.

It is important that you f amiliarize yourself with the product as much as possible before initiating any maintenance, troubleshooting or repairs.

Make sure you read through the IMPORTANT SAFETY INFORMATION and INTRODUCTION sections of this manual before attempting any service procedures.

As you disassemble your machine to service and replace parts, keep the following points in mind:

• Do not remove or loosen more parts than

needed. Use comm on sense to k eep your work

to a minimum.

• Mark any wires before disconnecting to make

reassembly easier.

• Use Loctite® Blue or eq uivale nt on al l threaded

fasteners without lock washers. Within the Component Repair section of this

manual, each repair pr ocedure is broken do wn into three main categories for each component . These categories are Testing, Adjustment, and Replacement and are identified by the following symbols:

Accompanying this manual, attached to the inside front cover, is a Compact Disc containing an electronic color vers ion of this m anual in Ac robat .pdf format along with other useful digital content. For more information vie w the README.TXT file located on the CD.

Adobe Reader is required to view .pdf files and can be downloaded free of charge from the following website:

http://www.adobe.com/products/acrobat/alternate.html#50

The digital color version of the manual is also interactive, allowing the user to simply click onto a subject within the Table of C ontents to take them to the specified page.

Page 7

SX™

SECTION 1 – INTRODUCTION

GENERAL INFORMATION

Figure 1-1. Serial Tag Location

Serial Tag

Figure 1-2. Model 1075 and 1084 Serial Tag

Model Number

Figure 1-3. Model 1097, 1099, 1108, and 1109

Model Number

MODEL VARIATION

This manual has been developed to assist in servicing and maintaining the Sharp SX™ with Printer model 1108 and the Sharp SX™ model

1109. Although th is manual has been written for this specific model, the procedures and techniques for replacing components and troubleshooting can generally be applied to all models of the SX™. Major differences in machine maintenance or component repair will be noted on a case by case basis. T he parts lists and assembly drawings located in secti ons 5 and 6 of this manual are specifically for these two models. If a replacement part is needed for an older model of machine, please refer to the CD located in the front of this manual. This CD contains the parts lists and assembly drawings for all previous m odels of the Sh ar p SX™ and the Sharp SX™ with Printer.

The replacement parts lists located on the CD have been separated by model number for ease of identifying the parts that are needed. Sim ply locate the section of the manual that coincides with the SX™ model you have and proc eed from there.

TECHINCAL ASSISTANCE

Assistance with the SX™ can be obtained by notifying Sharp Packaging Systems at:

Sharp Packaging Systems

PO Box 124

Sussex, WI 53089, USA

Service: 800-634-6359 (ext. 572)

service@sharppackaging.com

Parts: 800-634-6359 (ext. 571)

parts@sharppackaging.com

Fax: 262-246-3387

To determine which m odel of t he Shar p SX™ you have, refer to Figure 1-1. The serial number is located on a placard or sticker directly below the roll unwind shaft. The highlighted numbers in Figures 1-2 and 1-3 coincide with the model of the machine.

Serial Tag

Page 8

SX™

SECTION 1 – INTRODUCTION

THEORY OF OPERATION

is equipped with a jaw

not designed, nor intended, to be a safety

WARNING

GENERAL

The Sharp SX™ is controlled by a PLC (Programmable Logic Controller). The PLC receives input from the operator touchscreen to control a stepper drive motor and an electric eye sensor on the bag feeder output end.

The Sharp SX™ is equi pped with a sensor on the pressure jaw which c a n d et ec t an obs truc ti on. If an object triggers the sensor , the pressure jaw motor will reverse, and place the bagger into a fault. A message appears on the control panel displaying the jaw fault, allo wing the operator to clear t he seal area and restart the bagging cycle.

Note: the Sharp SX™ is n ot designed to interface with automatic infeed units such as counters, scales, or infeed conveyors.

The Sharp SXTM obstruction detection sensor. This sensor is

sensor.

• The Sharp SX™ uses pre-opened Sharp EZ-

• A constant stream of air opens (inflates) the

• Product is loaded into the bag.

• Once the bag is loaded , t h e op erator cycles the

• The pressure jaw closes and grips the bag.

• An electric eye is used to sense the trailing



. The bags are dispensed through the

Bags

powered drive rollers.

bag, preparing the bag to be loaded.

machine (either by foot control, optional dual

optical palm buttons, f rom the Touchscreen or

the machine can be set on autom atic cycle) to

seal the bag.

The impulse sealer heats up and seals the bag

while the power drive rollers reverse to

separate the bag at the perforation.

edge of the bag. Hang holes , vent holes, etc.

must be prevented from passing over the

electric eye as this will send a false signal to

the PLC. To prevent this, the e lectric eye has been designed to be off center of the bag, however, in som e cases the bags m ay have to be repositioned when larger hang holes, vent holes, etc. are present (see Loading Bag Film).

• When the bag is sealed and seal dwell is complete, the pressure jaw opens.

• The Printhead is lowered and the bag is indexed forward at prin tin g s peed unt il th e l abe l is completed. The Printhead is raised and the balance of the bag length is index ed forward at full index speed (bagger speed). (Note: This

step occurs only if model is equipped with an imprinter)

• As the bags are indexed, the Mat erial Unwind Shaft will spin allowing the bags to be pulled from the roll. The Material Unwind Shaft is comprised of a Roll Tensioner with compression spring, Cor e Chuc k, and a t orsion spring. When the roll of bags is loaded onto the machine, pressure is applied to the Roll Tensioner which in turn applies press ure to the roll side plate c reat ing a kind of slip clutch. The pressure that is ap plied t o t he Rol l Tens ioner is directly proportional to the type and thickness of the material being used. As this pressure increases the amount of tension on the web also increases. The appropriate amount of pressure that should be applied to the Roll Tensioner can be found using trial and error.

• The constant stream of air inflates the bag, preparing the bag to be loaded.

Figure 1-4. Sharp SX™

Page 9

SX™

SECTION 1 – INTRODUCTION

THEORY OF OPERATION

FAULTS

The Sharp SX™ has been designed to alert the operator, via the Touc hscreen, to a situat ion (fault) that requires immediate attention. These faults may indicate a serious condition where, if not corrected, damage to the unit may occur or the fault may simply alert the o perator that th e unit has run out of film. The following is a list of possible faults that may occur duri ng operation. A detailed list of faults, causes an d solutions can be found in the Troubleshooting section of this manual.

• WEB DID NOT BACK UP The machine reverses the drive rollers to separate

the web of bags at the per f or ation. T he b ag ger has a photo eye that it uses to detect the trai ling edge of the bag. When the photo eye does not detect this trailing edge w ithin the allowed time, this fault is triggered.

• JAW FAULT The Obstruction Sensing Jaw has detected an

object in the sealing area during the sealing operation.

• OBSTRUCTION SENSING JAW TIMER FAULT

The Obstruction Sensing Jaw did not close within the preset time, but there was no obstruction sensed.

• THERE ARE NO BAGS COVERING THE EYE

This fault is triggered when the machine cycle is initiated and the photo eye is not activated.

• BATCH IS COMPLETE This message is activated when the bagger has

cycled the specified number of times set by the operator under Batch Target.

Batch Target – A predetermined num ber of cycles that will be completed before the machine will automatically stop.

• WAITING FOR PRINTER SIGNAL* The bagger has sent a print signal to the printer

and is waiting for a return signal.

*Note: This f ault w il l on ly oc cur if the Shar p SX™ is

equipped with an imprinter.

Page 10

SX™

SECTION 1 – INTRODUCTION

THEORY OF OPERATION

SHARP EZ-BAGS AND FILM MATERIALS

The Sharp SX™ is design ed to use a wide variety of bag sizes and materials. Sharp EZ-Bags recommended for opt imum operating performance, efficiency and safety. System performance specifications are based on utilizing consistent, high quality, pre-ope ned bags . Any bag used mus t meet Sharp Packaging Systems’ manufacturing tolerances. The following list shows some of the Sharp EZ-Bags



films available through Sharp

Packaging Systems, Inc.

• Low Density Polyethylene (LDPE)

• Linear Low Density Polyethylene (LLDPE)

• High Molecular Weight, High Density

Polyethylene (HMWHDPE)

• Laminated Oriented Polypropylene

(Laminate/OPP)

• Polypropylene

• Metallic Films (including conductive films)

• Co-Extruded Films (combination films)

• Other Laminates (any other laminates

laminated with polyethylene)

• Anti-static and Triboelectric films

• VCI corrosion inhibiting films

• Opaque films

Contact Sharp Customer Service (800-634-6359) or www.customerserviceteam@sharppackaging.com to order Sharp EZ-Bags regarding film and bag specifications.



and for information



are

THERMAL TRANSFER RIBBON*

The Sharp SX™ uses thermal transfer ribbon to print variable information onto the bags as they pass through the mac hine. The follo wing is a list of ribbon that is available through Sharp Packaging Systems, Inc. For ordering inf ormation refer to the Replacement Parts Order F orm i n the Append ix on page A-1.

• Standard Direct Wax Ribbon

• Premium Wax Resin Ribbon

*Note: Used only if the Sharp SX™ is equipped with an imprinter.

SUPPLIES Thermal Transfer Ribbons

Sharp thermal transfer ribbons are selected specifically for use with our printer. Use of ribbons other than those suppli ed by Sharp, m ay result in a poor quality printing , especiall y bar-codes and th eir ability to be succes sfully scanned. This may also void the print head warranty.

Recommended Sharp ribbons are:

• Black ink, scratch and smudge resistant

• 2000’ (609 meters), 3.5 to 4.5 microns thick

• 1” core, no notch required

• Ink side in

• Back coated ribbons only

Special purpose thermal transfer ribbons, sizes other than those listed above, such as colored ribbons, or low temperature release ribbons are available.

Page 11

SX™

SECTION 1 – INTRODUCTION

SPECIFICATIONS

Minimum

Maximum

Bag Width

Bag Length

Film Gauge

2” (5.08 cm)

4” (10.16 cm)

9” (22.86 cm)

32” (81 cm)

.004” (4 mil) 100 microns

.001” (1 mil) 25 microns

Width

Height

Depth

Weight

Power

Rate

Operating

Humidity

** Size of package along with weight and size of product will cause rate to vary.

35.25" [89.54 cm]

26.75" [67.94 cm]

26.00" [66.04 cm]

PACKAGING SPECIFICATIONS

MACHINE SPECIFICATIONS

26.75”

(67.9 cm)

19”

(48.3 cm)

35.25”

(89.5 cm)

DIMENSIONS

200 lbs.

(91 kg)

Req.

115 VAC 50/60 Hz 15 Amps

35**

bags per

minute

Temp

0°-40°C

32°-140°F

Range

10%-90%RH

Non-

Condensing

Page 12

SX™

SECTION 2 – MAINTENANCE AND ADJUSTMENTS

MAINTENANCE SCHEDULE



on the machine.

WARNING

Always remove electrical power from the

prior to performing any maintenance

DAILY MAINTENANCE

• Inspect the electric eye. Clean with a c otton

swab if dirty. Do not use any solvents or cleaning solutions on the s ensing portions of the electric eye.

• Clean any excess material from the drive

roller and platen roller on the film feed assembly. Plastic com pounds tend to buildup on the rollers. Clean regular ly with a soft, lint-free cloth using a rubber platen roller conditioner/cleaner or isopropyl alcohol.

• Inspect Teflon tape on the seal wire and

replace if damaged or worn.

• Inspect the anvil rubber on the pressure bar

assembly and replace if damaged or worn.

• Inspect all electrical li nes for any sign of wear

or damage. Replace any lines that appear worn or unsafe.

• If the Sharp SX is equipped with a printer,

the printhead needs to be cleaned with a soft, lint-fr ee cloth a nd is oprop yl alcoho l. T his will be explained further on page 2-3 in the section entitled “Cleaning the Printhead and Film Feed Rollers.”

ANNUAL MAINTENANCE

• Check all electrical connections.

• Check entire machine for loose bolts or nuts.

• Inspect all drive belts for excessive wear and

slack.

• Grease the four pressure bar linear guide bearings using lithium grease (JIS Type 2).*

• Apply a light film of grease to the pressure bar rack and pinion gearing using lithium grease (JIS Type 2).*

* Note: The recommended lubrication interval for

the linear guide bearings based on total travel is approximately 500,000 cycles. Sharp Packaging Systems suggests greasing the bearings at this frequency or once a year, whichever comes first. Both the linear guide be arin gs and th e pr ess ur e bar gear rack and pinion gear can be lubricated with the same frequency.

MONTHLY MAINTENANCE

• Clean the foam element located on the cooling fan on the rear of the machine with water, wring out, and reinstall.

Page 13

of the machine with any liquid while components can cause shorts,

WARNING

the machine prior to performing any

WARNING

Do not attempt to clean the machine

injury or death.

WARNING

SX™

SECTION 2 – MAINTENANCE AND ADJUSTMENTS

CLEANING

GENERAL

This machine requires regular, periodic cleaning to ensure reliable service. Shift and daily cleaning can be performed by the operator with a minimum of training.

Regular cleaning is important for the proper operation and performance of the machine. During operation there wil l be a normal buildup of dirt, dust, and lubricants on various parts of the machine. If using the Sharp SX™ with Printer, ink rubbed off of printed film can also build up.

The machine and areas directly adjacent to it should be kept clean of debris as these can create safety hazar ds for the operator and the machine.

Disconnect electrical power cords from maintenance on machine.

Do not spray the electrical components power is applied. Liquids on electrical damaging the components and causing

personal injury or death.

Avoid hot surfaces. Do not service the machine until the heated surfaces have cooled after disconnecting power.

while it is running. Cleaning the machine while it is running can damage the machine and cause severe personal

No cleaning should be performed unless these safety precautions are thoroughly understood and are adhered to without exception.

Clean machine surfaces during each pause in production – NEVER while the machine is running. Remove contaminants a nd debr is, and use a c lean, soft lint-free cloth to wipe down the machine.

• Inspect the machine to determine if there has been an accumulation of dust or other contamination. Clean if necessary.

• ALWAYS SHUT OFF AND UNPLUG machine power cord before cleaning or removing any guards.

• NEVER defeat an y saf et y d evic e or i nterlock on the machine.

• DO NOT use steel wool on machine surfaces. Particles of steel wool m ay break off and cause rusting or contaminate lubricated surfaces.

• DO NOT allow wrenches, fittings or other metallic objects to lie on machine surfaces during production.

• DO NOT use chlorine, am monia, alkalis, acids, or cleaning solutions that will damage m etallic machine surfaces, cause corrosion or contaminate containers.

Page 14



on the machine.

WARNING

Do not pour isopropyl alcohol or any cleaning solution directly onto the

the machine.

CAUTION

Cradle Cradle Latch

Figure 2-1. Opening the Printhead Cradle

Figure 2-2. Cleaning the Printhead

Thermal

SX™

SECTION 2 – MAINTENANCE AND ADJUSTMENTS

CLEANING

CLEANING THE PRINTHEAD & FILM FEED ROLLERS

*Note: This section is specifically for t he Model



with Printer . If your model does not have

SX a printer, only follow st eps 5 and 6 for clean ing the film feed drive roller.

Always remove electrical power from the

1. With power removed from the machine,

2. Gently slide the ribbon to the side to

3. Moiste n a soft, lint-free cloth with is opropyl

4. Slide the ribbon into its original position.

prior to performing any maintenance

release the cradle latch to grant access to the printhead and the rubber rollers on the film feed assembly. Also, open the printhead cradle cover (Figure 2-1).

expose the printhead.

alcohol and gentl y wipe the surf ace of the printhead to clean dust and residue from the surface, as shown in Figure 2-2.

printhead or rollers. Liquids may short electrical components, causing damage to

Make approximately ten tur ns on t he ribbo n rewind hub to take up slack and wrinkles, ensuring it is completel y flat over the rib bon rollers and printhead.

Cover

Printhead

Page 15

SX™

SECTION 2 – MAINTENANCE AND ADJUSTMENTS

CLEANING

Figure 2-3. Cleaning the Film Feed Drive Roller

Film Feed

Platen Roller

CLEANING THE PRINTHEAD & FILM FEED ROLLERS (cont.)

5. Rem oisten the lint-free cloth with isopropyl alcohol and rub back and forth along film feed drive roller as shown in Figure 2-3. Clean roller until residue is removed. Be careful not to damage rubber coating on roller, as this will affect machine performance.

6. Manually rotate film feed drive roller, and repeat procedure in step 5. Continue wiping and rotating until the entire surface of the drive roller is clean.

7. Repe at steps 5 and 6 on the platen roller, again being careful to not damage the rubber surface.

Drive Roller

8. When both rollers are clean, thread bag film through the machine, and close the printhead cradle cover. Turn the cradle latch to the locked position.

Page 16

SX™

SECTION 2 – MAINTENANCE AND ADJUSTMENTS

MACHINE ADJUSTMENTS

SX™

SECTION 2 – MAINTENANCE AND ADJUSTMENTS

MACHINE ADJUSTMENTS

Figure 2-4. Pinch Roller Adjustment Screws

Pinch Roller Adjustment Set Screws

Figure 2-5. Jam Nut and Set Screw

Set Screw and Jam Nut Flush for Initial Adjustment

ADJUSTING THE PINCH ROLLER

The pinch roller adjustment is used to control excess “traveling” of the film to either side of the pinch roller. This traveling is due to uneven pressure distributed by the pinch roller onto the drive roller. This pressure is created by slidespring mechanisms on each end of the pinch ro ller. Under normal usage, the pinch roller should not come out of adjustment. Before changing the factory settings on the pinch roller, be sure to check the unwind for proper web tension and alignment. If changing the roll setting does not prevent traveling, follow these steps to adjust the pinch roller tension.

1. O pen the printhead cradle cover to expose the printhead components and pinch roller.

2. Confirm the preset adjustment of the pinch roller. The top of the set s crew should be flush with the top of the hex jam nut. If either side is not flush, turn the j am nut counter-clockwise to unlock the set scr ew. Adjust the set screw to the proper height, an d retighten the jam nut to lock into place. Clos e cradle cover, and cycle machine to check for traveling issues.

3. If the pinch roller adjustment springs are set correctly and the film still travels, release the jam nut and turn the set screw opposite the side the media is pulling towards down in 1/4 turn increments. Loc k the jam nut, and check for traveling. Continue this process until the bag film feeds out ev enly and does n ot walk to either side.

Page 17

SX™

SECTION 2 – MAINTENANCE AND ADJUSTMENTS

MACHINE ADJUSTMENTS



on the machine.

WARNING

Figure 2-7. Pressure Bar and Film Feed Belts

Pressure Jaw Drive Belt

Film Feed Motor

Drive Belt

Figure 2-6. Frame Cover Screws

CHECKING BELT TENSION

Sharp SX

The Sharp SX has three belts, one whic h drives the pressure jaw and two that drive the film feed drive roller. To ensure proper operation of the machine, these belts ne ed t o be c hecked for proper tension to avoid slip.

Always remove electrical power from the

1. With machine power disconnected, remove

2. Locate the pressure jaw drive belt (Figure 2-

prior to performing any maintenance

the left side frame guard. Remove the two screws on the rear face plate, the t wo screws on the front face plate, and the two s crews on the middle unwind plate (Figure 2-6).

7). Depress the center of the belt to determine if the tension is appropriate. The belt should deflect approximately 1/8” when depressed with one finger at the center of the longest belt span.*

3. If the belt deflects more than 1/8 loosen the four motor mounting screws and apply downward pressure to the pressure bar drive motor. When m otor is in desired position for proper belt tension, tighten four screws and verify the belt deflects the recommended amount. Repeat until belt is correctly tensioned.

4. Locate the film feed motor drive belt (Figur e 2-

7). Repeat the process in step two to check for correct tension. This belt should deflect approximately 3/32” at proper tension. If too tight or too loose, repea t step thr ee o n the f ilm feed drive motor.

*Note: Belt tension shou ld be just e nough to ensure

a positive interference between belt and sprocket teeth without allowing th em to jum p. If too t ight , t he load may cause undue stress on the shafts and shorten belt life. If too loose, the belt will not engage the sprocket pr operly and the drive w ill slip under normal loads. For a mor e de tai led method of determining proper belt tension, contact Sharp Packaging Systems customer service or consult the belt manufacturer.

Page 18

SX™

SECTION 2 – MAINTENANCE AND ADJUSTMENTS

MACHINE ADJUSTMENTS

Film Feed Roller Drive Belt

Figure 2-8 Pulley Guard Screws

Note: Cradle Removed for Clarity

Sharp SX (con’t)

5. Rele ase the cradle latch and open the c radle. Remove the pulley cover to expose the drive roller belt.

6. Chec k the film feed drive roller belt for tension (Figure 2-9). This belt should deflect approximately 1/16” using one finger to push on the center of the belt span. If adjustment is needed, loosen the idler screw and slide to increase tension. Retighten screw and check tension.

7. Reinstall frame guard and pulley guard that were removed earlier. Clos e cradle and lock into position.

Page 19

SX™

SECTION 2 – MAINTENANCE AND ADJUSTMENTS

MACHINE ADJUSTMENTS



on the machine.

WARNING

Figure 2-12. Ribbon Rewind Motor Belt and

Ribbon Rewind Motor Belt

Printhead Lift Drive Belt

Figure 2-10 Platen Roller Drive Belt

Note: Cradle Removed for Clarity

Platen Roller

Drive Belt

Outside Cradle Screws

Figure 2-11. Removing the Outside Cr ad le Cov er

Sharp SX with Printer

The Sharp SX with Printer utilizes seven drive belts during operation: one to drive the pressure jaw, two to drive film feed roller s, one for the plat en roller, one for the printhead lift cams, and two to drive the printer ribbon rewind hub.

Always remove electrical power from the

prior to performing any maintenance

1. Foll ow steps 1 through 6 o n pages 2-6 and 2-7 to check for proper tensio n of the pressure bar drive belt and the two film feed drive belts.

2. Check the platen roller drive belt for tension (Figure 2-10). This belt should deflect approximately 1/16” using one finger to push on the center of the belt span.

3. If belt tension is incorrect, loosen the idler screw and slide idler t o add or rem ove tension. Tighten screw and check belt. Repeat as necessary.

4. Repl ac e t he pu lley guard by reinstall ing th e t wo mounting screws.

5. Rem ove the four screws that hold the outside cradle cover (Figure 2-11). Slide the cover off to expose the ribbon r ewind hub drive and the printhead lift drive.

6. Chec k the tension on the ribbon rewind motor drive belt (Figure 2-12) using the same procedure for the film feed drive belt. This belt should deflect about 1/16”.

Printhead Lift Drive Belt

7. If belt does not have proper tension, loosen four motor mounting screws and apply pressure to motor towards the rear of the machine. Retighten motor screws and check for tension. Repeat as necessary.

Page 20

SX™

SECTION 3 – COMPONENT REPAIR

MACHINE ADJUSTMENTS

Ribbon Rewind Slip Clutch Belt

Figure 2-13. Ribbon Rewind Slip Clutch Belt

Sharp SX with Printer (con’t)

8. Check the tension on the printhead lift drive belt (Figure 2-12). This belt should deflect 1/16”. If incorrect, fol low method in step seven to achieve proper tension.

9. Repl ace outsid e cradle c over, and reinstal l four screws removed in step 5.

10. Close the printhead cradle and turn the latch counter-clockwise to lock into position.

11. Open the top cradle cover by lifting on the recessed plastic handle.

12. Locate the slip clutch belt between the left printhead plate and the outer plate on the hinged side of the cradle (Figure 2-13). At proper tension, this belt should deflect about 1/16”.

13. To add or remove tension to this belt, loosen the two screws on the idler plate and slide it forward or backward to ad d or remove tension. Tighten the screws, and rec heck belt. Repeat as necessary.

14. Once all belt tensio ns have been check ed and properly set, replace the side frame guard.

Page 21

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

TESTING

Figure 3-3. Fuse Probe Locations

Figure 3-1. Load Plate Screws

Figure 3-2. TM4500 Drive locations

Pressure

Jaw

Film

Feed



on the machine.

WARNING

PRESSURE JAW AND FILM FEED MOTOR CONTROLLERS

The Sharp SX technology to precisely control the movement of various mechanical systems. This section will describe how to service the two TM4500 stepper drive units. These units control the Pressure Jaw and Film Feed motors.

Always remove electrical power from the

prior to performing any maintenance

1. Remove the four screws holding the Load Plate, set screws and Load Plate aside (Figure 3-1).

2. Locate the two identical stepper drives inside the Sharp SX drive is on the left and the Film F eed drive is on the right (Figure 3-2).

3. Loc ate the fuse on th e defective u nit (Figure 3-

3).

4. Set your Digital Volt/Ohm Meter (DVOM) to test for continuity.

5. With the red probe, make contact with the metal on one side of the fuse and with the black probe make c ontact with the ot her side of the fuse (Figure 3-3).

6. If your DVOM indicates that there is no continuity, replace the fuse.

Note: A blown fuse can be an indication of a larger problem. If you continue to blow fuses, test the stepper motors and power connections.

bagger uses stepper drive

Bagger. The Pressure Jaw

Page 22

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

Figure 3-5. TM4500 Wiring Configuration

Figure 3-4. Status LED Location

Red LED

MACHINE WHILE POWER IS APPLIED. UNEXPECTED MACHINE STARTUP CAN CAUSE SERIOUS INJURY.

WARNING

AND ARMS CLEAR OF MOVING PARTS.

WARNING

USE PROPER TROUBLESHOOTING TECHNIQUES TO AVOID ELECTRICAL SHOCK.

WARNING

PRESSURE JAW AND FILM FEED MOTOR CONTROLLERS (con’t)

7. If the fuse is OK, check the wiring of TB1 and TB2. Reconnect any loose wires. (Figure 3-5).

8. Connect power cords to the Sharp SX and turn the bagger on.

USE EXTREM E CAUTION WHILE SERVICING A

DO NOT ATTEMPT TO SERVICE THE MACHINE DURING NORMAL OPERATION. KEEP HANDS

WHEN TESTING ELECTRICAL COMPONENTS WHILE POWER IS APPLIED TO T HE MACHINE,

9. Loc ate Red LED on the de fective drive (Figure 3-4).

Bagger

10. If the LED is blinking, use the following information to diagnose the problem.

• Is the LED blinking once?

This error code indicates t hat there is an open

or sporadic connection in one of the motor wires. Check the wiring and ensure that the connector screws are tight.

• Is the LED blinking twice?

This error code indica tes th at ther e is a s hort in

one of the motor lines . This can either occur in the windings of the motor or be caused by loose wiring.

1. Disconnect the motor from the drive at the

white 2x3 pin plug.

2. Check the motor and wiring for shorts.

Page 23

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

Figure 3-8. TM4500 Configuration

B C ADJUSTMENT

Figure 3-6. Load Plate Screws

Figure 3-7. TM4500 Drive locations

Pressure

Jaw

Film

Feed

PRESSURE JAW AND FILM FEED MOTOR CONTROLLERS (con’t)

11. Refer to section on testing transformers to test incoming voltage.

The TM4500 Stepper Drives are controlled by the Aromat PLC and should be left at the factory default settings. T he following steps will guide you through resetting the drives to factory defaults.

1. Remove the four screws from the Load Plate and set aside (Figure 3-6).

2. There are two identical TM4500 drives, the Pressure Jaw motor controller is on t he lef t and the Film Feed motor controller is on the right (Figure 3-7).

3. Set Jumpers JP1, JP2 and JP3 so that the jumpers covers pins 1 and 2 (Figure 3-8 A)

4. Adjust Kick Current POT (potentiometer) so that arrow points to 100 (Figure 3-8 B).

5. Set jumper JP4 so that the jumper covers pins 2 and 3 (Figure 3-8 C).

6. Reattach Load Plate to front of machine with screws and locking washers.

Page 24

Figure 3-11 Green Connector Block

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

REPLACEMENT

Figure 3-10. TM4500 Drive locations

Pressure

Jaw

Film

Feed

Figure 3-9. Load Plate Screws



on the machine.

WARNING

PRESSURE JAW AND FILM FEED MOTOR CONTROLLERS (con’t)

Always remove electrical power from the

1. Remove the four screws holding the Load

2. Loc ate the TM45 00 Steppe r Drive tha t requires

3. Unscrew all connections from the green

4. Slide drive out of grey DIN rail holder. The

5. Remove new drive from static bag.

prior to performing any maintenance

Plate, set screws and Load Plate aside (Figure 3-9).

replacement. The Pressure Jaw motor controller is on the lef t and the Fi lm Feed motor controller is on the right (Figure 3-10).

connection blocks TB1 and TB2 (Figure 3-11).

drive is held in the DIN rail holder by friction and requires considerable force to remove. Brace the machine with one hand while firm ly pulling the drive toward you with the other hand.

Page 25

Figure 3-13. TM4500 Wiring Configuration

Figure 3-12. TM4500 Configuration

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

PRESSURE JAW AND FILM FEED MOTOR CONTROLLERS (con’t)

6. Set jumpers JP1, JP2 and JP3 so that the jumper covers pins 1 and 2 (Figure 3-12 A).

7. Set the POT so that the arrow points to 100 (Figure 3-12 B).

8. Set jumper JP4 so that the jumper c overs pins 2 and 3 (Figure 3-12 C).

9. O rientate drive so T B2 is on your left and slide new drive into DIN rail holder. This will take considerable force. Brace the machine with one hand wile firml y pushing the new drive into the DIN rail holder.

10. Reconnect all wires as they were con nected to the previous drive (Figure 3-13).

11. Reattach Load Plate t o front of machine using screws and locking washers.

Page 26

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

TESTING

Figure 3-14. Frame Cover Screws

Figure 3-16. Pivot Fuse Holder

Figure 3-17. Fuse Access Door

Figure 3-15. Fuse Locations

System Fuse

Stepper Fuse



on the machine.

WARNING

FUSES

The Sharp SX protect the machinery from overloads. Fuses are NOT intended to prot ect against electrocution and are not considered a safety device.

Always remove electrical power from the

prior to performing any maintenance

1. Remove Frame Cover Screws. There are six screws to remove (Figure 3-14).

2. Remove Frame Cover and set aside.

3. Locate the two Fuses. (Figure 3-15)

Bagger uses a series of fuses to

4. Pivot fuse holder to gain access to the Fuse Access Door on the defective fuse.

5. Open Fuse Access Door and remove fuse (Figure 3-17)

6. With a DVOM set to test for continuit y, touch the

black probe to one side of the fuse and the red probe to the other side of the fuse. If the DVOM does not indicate continuity, replace fuse.

Page 27

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

ADJUSTMENT

REPLACEMENT

Figure 3-18. Frame Cover Screws

Figure 3-19. Pivot Fuse Holder

Figure 3-20. Fuse Access Door



on the machine.

WARNING

FUSES (con’t)

There are no adjustments necessary on fuses.

A blown fuse can be an indic ation of a larger issue with the electronics in t he Sharp SX NOT REPLACE A BLOWN FUSE WITH A LARGER AMPERAGE FUSE. If you continue to blow fuses, troubleshoot other components to discover problem.

Always remove electrical power from the

prior to performing any maintenance

1. Remove Frame Cover Screws; there are six screws to remove (Figure 3-18).

2. Loc ate the defective fus e. The 10 Amp system fuse is on the left and the 5 amp stepper driv e fuse is on the right.

3. Pivot fuse holder to gain access to the Fuse Access Door (Figure 3-19).

4. Open Fuse Access Door and remove fuse (Figure 3-20).

5. Replace with a 5x20mm fuse of the same amperage.

6. Close ac cess door and pivot fuse holder back into its home position.

7. Repl ace Frame Cover with sc rews and locking washers.

Bagger. DO

Page 28

TESTING

Figure 3-22. Motor Cover Front Screws

Figure 3-21. Motor Cover Rear Screws

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

24 VDC POWER SUPPLY

The Sharp SX power supply for all sensors, relays and control components. This section will explain how to troubleshoot and if necessary, replace the power supply.

The symptoms of a non-functioning Power Supply are easy to spot. The “Bag Open Cage Fan” and “Cabinet Cooling Fan” are not powered by the 24 VDC power supply. If when powering up a machine, the fans can be heard running, but the rest of the system is unresponsive, The Power Supply is most likely defective. If a machine is completely unresponsive, refer to the section on checking and replacing fuses.

1. Plug machine in but do not turn on.

2. Remove any bags in the machine web path and remove bag roll.

3. Rem ove the two rear screws a nd the two front screws from the Motor Cov er (Figure 3-21 and Figure 3-22).

4. Remove Motor Cover and set aside.

5. Loc ate the 24 VDC Po wer Sup ply.

Note: The Power Supply location changes

depending on your version of the Sharp SX Bagger. The wiring however is exactly the same.

bagger uses a single 24 VDC

Page 29

Figure 3-23. 24 VDC Power Suppl y

Figure 3-24. Power Supply Status LED

Status

LED

Figure 3-25. Probing 120 VAC on Power Supply

MACHINE WHILE POWER IS APPLIED. CAUSE SERIOUS INJURY.

WARNING

AND ARMS CLEAR OF MOVING PARTS.

WARNING

USE PROPER TROUBLESHOOTING TECHNIQUES TO AVOID ELECTRICAL SHOCK.

WARNING

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

24 VDC POWER SUPPLY (con’t)

6. Visua lly check wir ing on Power S upply. (Figure 3-23)

Note: The “V-“connection on the Power Supp ly

is connected to “Earth Ground ” by a short wire. Also, lines labeled with “Printer” are only present on baggers with a printer.

7. If there is a noticeable problem with the wiring of the Power Supp ly, refer to the re placement section for directions to rewire power supply.

8. T urn ON device using the power switch in the back of the machine.

9. Check that the Green Status LED is illuminated. (Figure 3-24) If it is, you may proceed to step 13.

10. Set your DVOM to a range capable of testing 120 Volts AC.

USE EXTREM E CAUTION WHILE SERVICING A UNEXPECTED MACHINE STARTUP CAN

DO NOT ATTEMPT TO SERVICE THE MACHINE DURING NORMAL OPERATION. KEEP HANDS

WHEN TESTING ELECTRICAL COMPONENTS WHILE POWER IS APPLIED TO T HE MACHINE,

11. Probe the L and N contacts on the Power Supply with a DVOM; it should display approximately 120 VAC (Figure 3-25).

Page 30

Figure 3-26. Probing “V-“ and “V+”

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

24 VDC POWER SUPPLY (con’t)

12. If 0 VAC is displayed, there is no power reaching the Power S upply. Check the 10 amp system fuse and ensure there are no loose wires.

13. Set your DVOM to a range capable of measuring 24 VDC. Prob e bet ween th e “ V-“and “V+” contacts on the Power Supply (Figur e 3-

26).

14. If 0 Volts DC is displayed, then the Power Supply is defective. Ref er to the Replacement section.

Page 31

ADJUSTMENT

Figure 3-29. Voltage Selector Switch

Figure 3-27. Motor Cover Rear Screws

Figure 3-28. Motor Cover Front Screws

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

24 VDC POWER SUPPLY (con’t)

The Sharp SX user adjustable setti ngs. These settings are set at the factory and do not require regular adjustment. The following steps will guide you through setting the Power Supply to the factory defaults.

1. Rem ove the two rear screws a nd the two front screws from the Motor Cov er (Figure 3-27 and Figure 3-28).

Bagger’s Power Supply has two

2. Loc ate the 24 VDC Po wer Sup ply.

Note: The power supply location changes depending on your version of the Sharp SX

Bagger. The wiring however is exactly the

same

3. Loc ate the red Switch on t he side of the Power Supply. (Figure 3-29).

4. Set the Voltage Selector Switch to 115V.

Note: If your region uses 230 VAC as the standard voltage, a step-down transformer is required. This will lower the voltage entering the machine to 115 VAC. Set the Voltage Selector Switch to 115V regardless of your region.

Page 32

Figure 3-30. Adjusting Power Supply Voltage

Figure 3-31. Testing 24 VDC on Power Supply

E WHILE POWER IS APPLIED. UNEXPECTED MACHINE STARTUP CAN CAUSE SERIOUS INJURY.

WARNING

AND ARMS CLEAR OF MOVING PARTS.

WARNING

USE PROPER TROUBLESHOOTING TECHNIQUES TO AVOID ELECTRICAL SHOCK.

WARNING

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

24 VDC POWER SUPPLY (con’t)

5. Plug the Sharp SX machine on.

USE EXTREM E CAUTION WHILE SERVICING A MACHIN

DO NOT ATTEMPT TO SERVICE THE MACHINE DURING NORMAL OPERATION. KEEP HANDS

WHEN TESTING ELECTRICAL COMPONENTS WHILE POWER IS APPLI ED TO THE M ACHINE,

6. Set your DVOM to a range capable of measuring 24 VDC.

7. W ith one hand, position a small screwdriver on the voltage adjustment POT (Figure 3-30).

8. Place the black probe on the “V-“contact and the red probe on the “V+” contact (Figure 3-31).

9. Adjust the POT until your DVOM reads 24.0 VDC +/- .5.

Note: Depending on your v ersion of the Sharp

Bagger, the Power Supply POT may be

difficult to reach. If this is the case, measure the voltage, then set the probes aside and adjust the voltage with a small screwdriver. Repeat until DVOM indicates 24.0 VDC.

10. Replace Motor Cover us ing s crews and loc king washers.

Bagger in and turn the

Page 33

REPLACEMENT

Figure 3-32. Motor Cover Rear Screws

Figure 3-33. Motor Cover Front Screws

Figure 3-34. Power Supply screw locations

Figure 3-35. Voltage Selector Switch



on the machine.

WARNING

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

24 VDC POWER SUPPLY (con’t)

1. T urn off the Shar p SX all power cords.

Always remove electrical power from the

prior to performing any maintenance

2. Rem ove the two rear screws a nd the two front screws from the Motor Cov er (Figure 3-32 and Figure 3-33).

Bagger and disconnec t

3. Disconnect all wires from the Power Supply.

4. Remove the three screws holding the Power Supply to the frame. (Figure 3-34).

5. Remove the defective Power Supply and set aside.

6. W ith new power supp ly, check that the Voltage Selector Switch is set to 115 VAC (Figure 3-

35).

Page 34

Figure 3-36. 24 VDC Power Suppl y

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

24 VDC POWER SUPPLY (con’t)

7. Reconnect all wires to the Power Supply (Figure 3-36).

8. Place new Power Supply in the Sharp SX Bagger in the sam e location and or ientation as the old power supply.

9. Us e screws from old Power Suppl y and secure new Power Supply to the frame.

10. Reconnect power cord to the Sharp SX Bagger and turn machine on.

11. Set your DVOM to a range capable of measuring 24 VDC.

Page 35

Figure 3-38. Testing 24 VDC on Power Supply

Figure 3-37. Adjusting Power Supply Voltage

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

24 VDC POWER SUPPLY (con’t)

12. With one hand, position a sm all screwdriver on the voltage adjustment POT (Figure 3-37).

13. Place the black probe on the “V-“contact and the red probe on the “V+” contact (Figure 3-38).

14. Adjust the POT until your DVOM reads 24.0 VDC.

Note: Depending on your v ersion of the Sharp

Bagger, the Power Supply POT may be

difficult to reach. If this is the case, measure the voltage, then set the probes aside and adjust the voltage with a small screwdriver. Repeat until DVOM indicates 24.0 VDC.

15. Replace Motor Cover.

Page 36

TESTING

Figure 3-39. Frame Cover Screws

Figure 3-42. Remove three spade connectors

Figure 3-XX Mandrel Support screws

Figure 3-41. Mandrel Support Plate Bottom

Screws

Plate

screws

Mandrel

screws

Figure 3-40. Mandrel Support Screws

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

LINE FILTER

This procedure requires working with exposed high voltages. Only qualifie d personnel familiar with electrical safety should perform this procedure.

1. Remove all power to the machine.

2. Remove the six screws holding the Frame Cover. Set screws and Frame Cover aside (Figure 3-39).

3. Remove any bags on a roll from machine.

4. Rem ove the seven scr ews holding th e Mandrel Support Plate, set screws and plate aside (Figure 3-40 & Figure 3-41).

Note: There are seven screws holding the Mandrel Support Plate. Use care when removing bottom scr ews and never work on an unstable platform.

5. Detach the three spade connectors from the Line Filter (Figure 3-42).

Support

Page 37

GRN-Earth

BLK-L

BLU-N

Figure 3-43. Wire colors and locations

Figure 3-44. Mandrel Support Plate alignment

Recessed

Circle

MACHINE WHILE POWER IS APPLIED.

STARTUP CAN

CAUSE SERIOUS INJURY.

WARNING

AND ARMS CLEAR OF MOVING PARTS.

WARNING

TECHNIQUES TO AVOID ELECTRICAL SHOCK.

WARNING



on the machine.

WARNING

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

LINE FILTER (con’t)

6. Reconnect the power cord to the machine.

Note: There will be exposed 120 VAC. Use extreme caution when working with expos e d wires .

USE EXTREM E CAUTION WHILE SERVICING A UNEXPECTED MACHINE

DO NOT ATTEMPT TO SERVICE THE MACHINE DURING NORMAL OPERATION. KEEP HANDS

WHEN TESTING ELECTRICAL COMPONENTS WHILE POWER IS APPLIED TO T HE MACHINE, USE PROPER TROUBLESHOOTING

7. With a DVOM configured to m easure 120 V AC, contact the red probe to the L pin and th e Blac k probe to the N pin. If 120 VAC is not indicated, the Line Filter is defective or no power is reaching the machine.

8. Unplug machine from any power sources.

Always remove electrical power from the

9. Rec onnect spade connectors to th e Line Filter

10. Replace the seven screws for the Mandrel

prior to performing any maintenance

(Figure 3-43).

Support Plate but do not tighten down.

11. Hand tighten the four top s crews, ens uring that the end of the Material Roll Mandrel is sitting inside the recessed circle of the Mandrel Support Plate (Figure 3-44).

12. Tighten all screws with an Allen Wrenc h.

Page 38

ADJUSTMENT

REPLACEMENT

Figure 3-45. Frame Cover Screws

Figure 3-48. Remove three spade connectors

Mandrel

screws

Figure 3-46. Mandrel Support screws

Figure 3-47. Mandrel Support Plate Bottom

Screws

Plate

screws



on the machine.

WARNING

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

LINE FILTER (con’t)

There are no adjustments necessary on the Line Filter.

Always remove electrical power from the

1. Remove the six screws holding the Frame

2. Rem ove the seven scr ews holding th e Mandrel

3. Remove the three spade connectors from the

prior to performing any maintenance

Cover, set screws and Frame Cover aside (Figure 3-45).

Support Plate, set screws and plate aside (Figure 3-46 & 3-47).

Note: There are seven screws holding the Mandrel Support Plate. Use care when removing bottom scr ews and never work on an unstable platform.

Line Filter (Figure 3-48).

Support

Page 39

Module Screws

Figure 3-49. Line Filter Screws

GRN-Earth

BLK-L

BLU-N

Figure 3-50. Wire colors and locations

Figure 3-51. Mandrel Support Plate alignment

Recessed

Circle

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

LINE FILTER (con’t)

4. Rem ove the two screws h olding the Line Filter to the Rear Face Plate (Figure 3-49).

5. Remove Line Filter.

6. Orientate new module so the two spade connectors are towards the top.

7. Refasten new module to frame with screws from defective module.

8. Reattach the three connector wires, Earth (Green) on the left, Neutral (Blue) on the top right, and Live (Black ) on the bottom (Figure 3-

50).

9. Replace the seven screws for the Mandrel Support Plate but do not tighten down.

10. Hand-tighten the four top s crews, ensur ing that the end of the Material Roll Mandrel is sitting inside the recessed circle of the Mandrel Support Plate (Figure 3-50).

11. Tighten all screws with an Allen wrench.

12. Replace Frame Cover with screws and lock washers.

Page 40

TESTING

ADJUSTMENT

Figure 3-52. Frame Cover Screws

Figure 3-53. Main Red Switch location

Main

Switch

5A Fuse

10A Fuse

Figure 3-54. Fuse Locations



on the machine.

WARNING

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

MAIN POWER SWITCH (RED)

Always remove electrical power from the

1. Remove the six screws holding the Frame

2. T urn the switch to the OFF posit ion (Figure 3-

3. Configure your DVOM to test for continuity,

4. Turn the switch to the ON position.

5. Configure your DVOM to test for continuity,

6. If the Main Power Switch is not found to be

There are no adjustments necessary on the Main Power Switch.

prior to performing any maintenance

Cover, set screws and Frame Cover aside (Figure 3-52).

53).

contact one probe to th e 5 A F use a nd the other probe to the 10A Fuse (F igure 3-54) It should NOT read continuity.

contact one probe to th e 5 A F use and the other probe to the 10A Fuse ( Figure 3-54). It should read continuity. If it does not, ensure there are no loose wires. If the wiring is not defective, replace the Main Power Switch.

defective, troubleshoot the Line Filter and fuses if you haven’t already done so.

power

Page 41

REPLACEMENT

Figure 3-55. Frame Cover Screws

Figure 3-56. Plastic divider locat ion

Plastic divider

Figure 3-57. Back of Main Power Switch

Retaining

Clips



on the machine.

WARNING

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

MAIN POWER SWITCH (RED) (con’t)

Always remove electrical power from the

1. Remove the six screws holding the Frame

2. Rem ove the seven scr ews holding th e Mandrel

3. Remove the three spade connectors from the

4. The switch is held in place by four retaining

5. O rientate switch so t he plastic divi der is on the

6. Reconnect the three spade connectors. The

prior to performing any maintenance

Cover. Set screws and Frame Cover aside (Figure 3-55).

Support Plate, set screws and plate aside.

back of the Main Power Switch (Figure 3-56).

clips, squeeze clips on eith er side of the switch while firmly pushing switch out of Rear Face Plate (Figure 3-57).

left side as you are look ing at the back of the switch as you snap it into the Rear F ace Plate. Snap replacement switch into Rear Face Plate.

Light Blue wire is attached to the contact furthest from you; the two Black wires are attached to the remaining contacts.

Page 42

TESTING

Figure 3-59. Motor Cover Rear Screws

Figure 3-58. Motor Cover Front Screws

Figure 3-60. Load Plate Screws



on the machine.

WARNING

Figure 3-61. Transformer locations for the SX

Stepper Drive

Seal Wire

Solid State Relay

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

TRANSFORMERS

The Sharp SX transformers. One is used for the Seal Wire and the other is used for the two TM4500 stepper drives. They are each 0.365 KVA transformers with a 120(P):28(S) voltage rat io. Only replace with equal or greater KVA rating and same voltage ratio.

Always remove electrical power from the

prior to performing any maintenance

1. Rem ove the two rear screws a nd the two front screws holding the Motor Cover. (Figure 3-58 and Figure 3-59)

Bagger uses two “Step-Down”

2. Remove Motor Cover and set aside.

3. Remove the four screws holding the Load Plate, set screws and Load Plate aside (Figure 3-60.)

4. Locate the transformer you wish to troubleshoot and proceed to that section (Figure 3-61).

Note: Transformer locations will change depending on your version of the SX. The Stepper Drive transformer’s wires terminate in a terminal block. T he Seal Wire transformer is connected to the Solid State Relay and Seal Wire.

1108 and 1109

Page 43

Figure 3-63. Left side Seal Bar connection

Figure 3-64. Probing right side of Seal Wire

Figure 3-62. Testing pin 2 of Solid State Relay

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

TRANSFORMERS (con’t)

Seal Wire Transformer

1. Rem ove clear plastic covering over Solid State Relay.

2. Set your DVOM to test for continu ity. With the Black probe, contact the B lue terminal block in the electrical area, with the Red prob e, contact pin 2 of the Solid State Relay. (Figure 3-62) Your DVOM should indicate continuity. If it does not, check the transformer wiring. If the wiring is correct, the transformer is defective and will require replacement.

3. Rem ove the Left scr ew holding the Red wire to the Seal Wire. Pull wire away from contact (Figure 3-63).

4. W ith a DVOM set to t est for continuit y, contact one probe to the loose Red wire you just disconnected, and contact the other probe to the right screw holding the other Red wire to the Seal Wire (Figure 3-64).

5. T he DVOM will indica te co ntinuit y, if it does not the Seal Wire Transformer is defective and must be replaced.

6. If the transformer is not defective, troublesho ot the Solid State Relay and the Seal Wire.

Page 44

ADJUSTMENT

Figure 3-66 Testing two front terminal blocks

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

Figure 3-65 Print Head Stepper Drive

Stepper

Terminal

MACHINE WHILE POWER IS APPLIED. UNEXPECTED MACHINE STARTUP CAN CAUSE SERIOUS INJURY.

WARNING

AND ARMS CLEAR OF MOVING PARTS.

WARNING

USE PROPER TROUBLESHOOTING TECHNIQUES TO AVOID ELECTRICAL SHOCK.

WARNING

TRANSFORMERS (con’t)

Stepper Drive Transformer

1. Locate the two terminal blocks with the Red wires connected to the transformer (Figure 3-

65).

Note: Location and orientation will vary depending on model.

2. W ith a DVOM set to test for continuity, probe the two front terminal blocks and the two rear terminal blocks . Both s hould in dic at e c ont inu ity. (Figure 3-66).

3. Rec onnec t machine to po w er and turn m ac hine on.

USE EXTREM E CAUTION WHILE SERVICING A

DO NOT ATTEMPT TO SERVICE THE MACHINE DURING NORMAL OPERATION. KEEP HANDS

WHEN TESTING ELECTRICAL COMPONENTS WHILE POWER IS APPLIED TO T HE MACHINE,

4. Set your DVOM measure 120 VAC. Probe the two terminal blocks connected to the Black wires from the transform er. The DVOM should indicate 120 VAC. If it does not, troubleshoot the wiring from the main DIN Rail (located under the frame guard behind the display, where terminals, PLC, and fuse blocks are snapped onto).

There are no adjustments necessary on transformers.

Transformer

Note: Electrical assembly isolated for clarity

Page 45

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

REPLACEMENT

Figure 3-67. Motor Cover Rear Screws

Figure 3-68. Motor Cover Front Screws

Figure 3-69. Transformer locations on an 1108 or

Stepper Drive

Seal Wire

Figure 3-70. Frame Cover Screws



on the machine.

WARNING

TRANSFORMERS (con’t)

Always remove electrical power from the

1. Remove the two rear and two front screws

prior to performing any maintenance

holding the Motor Cover on. Set screws and Motor Cover aside (Figures 3-67 & 3-68)...

2. Locate transformer that requires replacement (Figure 3-70).

1109

3. If you are replacing the Seal W ire Transformer Remove the six screws holding the Frame Cover, set screws and Frame Cover aside (Figure 3-70).

Page 46

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

Figure 3-71. Load Plate Screws

Figure 3-72 Transformer Bolt Locations

TRANSFORMERS (con’t)

4. If you are replacing the Stepper Drive Transformer, remove the four screws holding the Load Plate, set screws and Load Plate aside (Figure 3-71).

5. Foll ow each of the four wir es coming out of the Transformer and note the ir locations and color. You may want to write this information down.

Note: The wiring diagram i n this ma nual can b e

used to determine transformer connections; however it is easier to write this information down.

6. Disconnect the ends of each wire and feed them back through any Wire Troughs or Wire Ties. You will prob ably have to cut a few W ire Ties to do this.

7. Remove the four screws holding the Transformer to the Base Plate (Figure 3-72).

8. Note the orientation of the Red and Black wires. Remove transformer.

9. With the replacement Transformer, orientate Red and Black wires so that the y are facing t he same direction as the old Transformer.

10. Fasten Transform er to Base Plate wit h the four screws from the old Transformer.

11. Reconnect the two Red and two B lack wires to their previous locations.

Note: If replacing the Seal Wire Transformer,

you will have to terminate t he Red wires with a Ring Terminal of similar size.

12. Replace Frame Cover and Motor Cover using screws and locking washers.

Page 47

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

REPLACEMENT

ADJUSTMENT

TESTING

Figure 3-73. Frame Cover Screws

Figure 3-75 Removing PLC

Figure 3-74 PLC Connections

X-1

X-2

Y-1

Y-2

PLC

Power

Display



on the machine.

WARNING

AROMAT PLC

The Sharp SX

FPΣ PLC. This is an NPN (sinking outputs) device

with 16 inputs and 16 outputs.

Check that there is power reaching the PLC by checking for green lights o n top of the PLC. If there are no lights, check the PLC Power connector, or troubleshoot the 24VDC Po wer Suppl y. If there is a red blinking light on the PLC, the PLC has faulted, contact Sharp Packaging.

There are no adjustments necessary on the Aromat PLC

Always remove electrical power from the

prior to performing any maintenance

1. Remove the six screws holding the Frame Cover. Set screws and Frame Cover aside (Figure 3-73).

2. Rem ove all connections fr om the Aromat PLC. There are six connec tions: Power, Displa y and four ribbon cables. Note where the ribbon cables are connected to the PLC (Figure 3-74).

3. Us ing a small flat screwdriv er, pu ll the b lue DIN rail release tab toward you and pivot the PLC up and back (Figure 3-75).

4. Remove old Aromat PLC and set aside.

5. Place new Aromat PLC onto DIN rail with the circular plug closest to you.

6. Reconnect all wires (Figure 3-74).

Bagger is controlled by an Aromat

Page 48

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

REPLACEMENT

ADJUSTMENT

TESTING

Figure 3-76. Frame Cover Screws

Figure 3-78. Removing PLC

Figure 3-77. PLC Connections



on the machine.

WARNING

AROMAT PLC BATTERY

The Aromat PLC battery is a 1.5 VDC “Button” battery. It is used by the PLC to retain user settings. The average lifetime of the PLC batter y is two years. It is suggested that you replace the battery annually.

Note: Not all m achines ar e equipp ed wit h a P LC Battery. If no battery is present in your PLC, you do not have to install one.

There are no testing procedures to be performed on the Aromat PLC battery.

There are no adjustments necessary on the Aromat PLC battery.

Always remove electrical power from the

1. Remove the six Frame Cover screws (Figure 3-

2. Remove Frame Cover and set aside.

3. Disconnect the touch screen communications

4. Using a small flat screwdriver, pull the blue DIN

5. Remove the PLC from the DIN Rail.

prior to performing any maintenance

76).

cable and the power wiring connector (Figure 3-

77).

rail release tab toward you and pivot the PLC up and back (Figure 3-78).

Page 49

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

Figure 3-80. PLC Battery Connector

Battery

Plug

Figure 3-79. PLC Battery Location

Battery

Cover

Figure 3-81. PLC Connections

PLC

Power

Display

AROMAT PLC BATTERY (con’t)

6. Rem ove the batt er y cover by lif ting the edge of the cover and remove the cover (Figure 3-79).

7. Remove replacement battery from any packaging.

Note: To avoid losing any data, connect the ne w battery to the PLC within 30 seconds of disconnecting the old one.

8. Dis connect old PLC battery wiring plug (Fig ure 3-

80).

9. Install the new battery and connect the wiring plug.

Note: the plug is keyed an d can only be installed

in the correct orientation.

10. Snap the battery cover back into place.

11. Install the PLC onto the din rail.

12. Reconnect the touch screen communications cable and the power wiring (Figure 3-81).

13. Replace Frame Cover; there are six screws with locking washers to replace.

Page 50

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

TESTING

Figure 3-83. Measuring 24 VDC on Display

Figure 3-82. Frame Cover Screws

MACHINE WHILE POWER IS APPLIED. UNEXPECTED MACHINE STARTUP CAN CAUSE SERIOUS INJURY.

WARNING

AND ARMS CLEAR OF MOVING PARTS.

WARNING

USE PROPER TROUBLESHOOTING TECHNIQUES TO AVOID ELECTRICAL SHOCK.

WARNING

COLOR TOUCH SCREEN

The Sharp SX touch sensitive user interface. The screen interfaces with the Arom at PLC to provide the user with setup functions and status information.

1. If the displa y does not tur n on with the m achine or it turns on but no thing is displa yed, proceed to the “Power Problem” section on the next page. If “ERRF” is displayed in the corner, proceed to the “Communication Problem” section on the nex t page. If “Screen No . Error” is displayed proceed to the “Program Problem” on the next page.

USE EXTREM E CAUTION WHILE SERVICING A

DO NOT ATTEMPT TO SERVICE THE MACHINE DURING NORMAL OPERATION. KEEP HANDS

WHEN TESTING ELECTRICAL COMPONENTS WHILE POWER IS APPLIED TO T HE MACHINE,

bagger includes a three color,

1. Remove the six screws holding the Frame Cover, set screws and Frame Cover aside (Figure 3-82).

2. W ith a Digital Vo lt/Ohm Meter (DVOM) set to a range capable of measuring 24VDC, contact the red probe to the 92 connection and the black probe to the 91 connection (Figure 3-83).

3. If 24 VDC is not displayed, troubleshoot the wiring between the power terminal blocks and the display. If 24VDC is displayed, the displa y is defective and will require replacement.

Page 51

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

BRO - ORNG - GRN

Figure 3-84. Display Connections

ADJUSTMENT

REPLACEMENT

Figure 3-85. Frame Cover Screws



on the machine.

WARNING

COLOR TOUCH SCREEN (con’t)

Communications Problem

1. Inspect Data Cable connection with PLC. Ensure that the cable is pus hed all the wa y into the socket on the PLC

2. Check that the wiring in the Display Plug is correct and securel y screwed down (Figure 3-

84).

3. Check that the PLC has power by looking for any illuminated lights o n top of the PLC. If the PLC is not receiving po wer, ref er to the Arom at PLC Section.

4. Display is defective.

Program Problem

A Screen No. Error occurs when the PLC requests a screen number that is not programmed into the display. T his typical ly occurs when the PLC B atter y loses its charge. In th is case, the PLC will require reprogramming.

There are no adjustm ents necessary on the Color Touch Screen.

Note: The replacement C ol or T ouc h Scr ee n wi ll require reprogramming if not obtained from Sharp Packaging.

Always remove electrical power from the

1. Remove the six screws holding the Frame

prior to performing any maintenance

Cover, set screws and Frame Cover aside (Figure 3-85).

Page 52

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

Com Cable

Figure 3-86. Display Connections

Screws

Figure 3-87. Touch Screen Housing Scr ews

Screws

Figure 3-88. Display Screws

Figure 3-89. Reattach Retaining Clips

Clip

COLOR TOUCH SCREEN (con’t)

2. Unpl ug com m unications ca ble fr om display and unscrew the power connections (Figure 3-86).

3. Remove the four screws holding the Touch Screen Housing (Figure 3-87).

4. Pul l Touch Screen Ho using off Fr ont Plate and place on a table, Touch Screen side down.

Note: Do not place display on any harsh surfaces as this will scratch the screen.

5. Loos en th e scr ews on the f our cl ips hold ing t he Touch Screen. Remove clips from Touch Screen (Figure 3-88).

6. Remove the Touch Screen from the housing.

7. Ins ert new Touch Scree n into housing; position Touch Screen so that the connections will be on top when reinserted into Front Plate.

8. Reattach retaining clips to Touch Screen (Figure 3-89).

9. Tighten the screws on the four retaining clips.

10. Reattach Touch Screen Ho using to Front Plate with the four screws.

11. Reconnect Power and Communications Cable.

12. Replace Frame Cover.

Page 53

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

TESTING

ADJUSTMENT

REPLACEMENT

Figure 3-90. Motor Cover Rear Screws

Figure 3-91. Motor Cover Front Screws

Figure 3-92. Outside Cover - Right Screws



on the machine.

WARNING

COOLING FAN

Check that all con nec ti ons to t h e f an are c o nnec t ed and secure.

There are no adjustments necessary on the Cooling Fan.

Always remove electrical power from the

1. Remove the two rear scre ws and the two front

2. Remove Motor Cover and set aside.

3. Rem ove the Outside Cover – Right (Figure 3-

prior to performing any maintenance

screws from the Motor Cov er (Figure 3-90 and Figure 3-91).

92).

Page 54

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

Figure 3-94. Cooling Fan screws

Figure 3-95. Airflow direction indicator

Figure 3-93. Remove Cooling Fan plug

COOLING FAN (con’t)

4. Unplug power connection from Cooling Fan (Figure 3-93).

5. Remove the four screws holding the Cooling Fan to the Outside Plate (Figure 3-94).

6. Remove the old Cooling Fan.

7. With replacement fan, orientate so that the airflow direction indicator points towards the outside of the fram e and s o that t he Cooler Fan plug is at the top facing you (Figure 3-95).

8. Line up the screw holes in the Outside Plate with those on the Cooler Fan.

9. With the screws from the old Cooler Fan, reattach the new Cooler Fan to the Outside Plate.

10. Reattach Cooler Fan plug.

11. Replace Motor Cover and Outside Cover.

Page 55

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

TESTING

Figure 3-98. Solid State Rela y with cover

Figure 3-96. Load Plate Screws

Figure 3-97. Frame Cover Screws

UNEXPECTED MACHINE STARTUP CAN CAUSE SERIOUS INJURY.

WARNING

AND ARMS CLEAR OF MOVING PARTS.

WARNING

USE PROPER TROUBLESHOOTING TECHNIQUES TO AVOID ELECTRICAL SHOCK.

WARNING

SOLID STATE RELAY

The Sharp SX provide power to the heating element.

There are two sets of connections to chec k on the Solid State Relay. One is the incoming control signal from the PLC, pins 3 and 4. The other connection is the incoming power, pins 1 and 2.

Control Signal

1. Remove the four screws holding the Load Plate, set Load Plate aside (Figure 3-96).

2. Remove the six screws holding the Frame Cover, set Frame Cover aside (Figure 3-97).

Bagger uses a Solid State Relay to

USE EXTREM E CAUTION WHILE SERVICING A MACHINE WHILE POWER IS APPLIED.

DO NOT ATTEMPT TO SERVICE THE MACHINE DURING NORMAL OPERATION. KEEP HANDS

WHEN TESTING ELECTRICAL COMPONENTS WHILE POWER IS APPLIED TO T HE MACHINE,

3. Locate Solid State Relay and remove clear plastic cover (Figure 3-98).

4. Power up machine and cycle. If the LED momentarily lights, proce ed to Incoming Power section.

Page 56

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

Figure 3-99. Pin 3 on Solid State Relay

Figure 3-100. Solid State Relay Control

UNEXPECTED MACHINE STARTUP CAN CAUSE SERIOUS INJURY OR DEATH.

WARNING

AND ARMS CLEAR OF MOVING PARTS.

WARNING

USE PROPER TROUBLESHOOTING TECHNIQUES TO AVOID ELECTRICAL SHOCK.

WARNING

SOLID STATE RELAY (con’t)

5. Set your DVOM to a range capable of measuring continuity. Contact the black probe to the red colored terminal block in the electrical area and the re d pr obe to the num ber 3 contact on the Soli d State Rela y as shown in (Figure 3-99).The DVOM should indicate continuity.

6. With your DVOM set to test for continuity, contact the black probe to pin 14 on the Y Breakout Module in the ele ctrical area, and the red probe to pin 4 of the Solid State Relay as shown in (Figure 3-100). The DVOM should indicate continuity, if it does proceed to the Incoming Power section.

7. If the tests in steps 5 and 6 show in continu ity, there is a loose con nection between the Solid State Relay and a term inal block. Troublesho ot the number 3 and 4 connections looking for shorts, disconnects or frayed wires.

Incoming Power

1. Reconnect all power to the machine and turn on.

Note: This procedure involves testing high voltages. Only qual ified personnel familiar wi th testing electronics should perform this procedure.

USE EXTREM E CAUTION WHILE SERVICING A MACHINE WHILE POWER IS APPLIED.

DO NOT ATTEMPT TO SERVICE THE MACHINE DURING NORMAL OPERATION. KEEP HANDS

WHEN TESTING ELECTRICAL COMPONENTS WHILE POWER IS APPLIED TO THE MACHINE,

Page 57

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

Figure 3-101. Testing 120VAC on Solid State Relay

SOLID STATE RELAY (con’t)

2. Set your DVOM to a range capable of measuring 120 VAC. With one probe, contact pin number 1, with the other probe, contact pin number 2 (Figure 3-101). 120 VAC should be shown. If 0 VAC is s hown, refer to the section on testing the Seal Wire Transformer.

3. If nothing is found wrong with the Seal Wire Transformer, the relay is defective and will require replacement.

Page 58

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

Black

Black 2 91

Dark Blue

ADJUSTMENT

REPLACEMENT

Figure 3-102. Load Plate Screws

Figure 3-103. Solid State Relay with cover

Table 3-1. Solid State Relay connections



on the machine.

WARNING

SOLID STATE RELAY (con’t)

There are no adjustments necessary on the Solid State Relay.

Always remove electrical power from the

1. Remove the four screws holding the Load

2. Loc ate Solid State Relay; remove clear plastic

3. Remove the four wire screws.

4. Rem ove the two screws ho lding t he So lid State

5. Remove defective relay.

6. Orientate replacement Solid State Relay so

7. Screw Solid State Relay down onto Base Plate.

8. Reconnect the four wires and tighten holding

9. Snap clear plastic cover over Solid State

10. Reattach Load Plate using screws and locking

prior to performing any maintenance

Plate, set Load Plate aside (Figure 3-102).

cover (Figure 3-103).

Relay to the Base Plate and set aside.

that connections 3 and 4 are towar ds the front of the machine.

screws (Table 3-1).

Relay.

washers.

Wire Label Wire Color Terminal Number

Page 59

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

TESTING

Figure 3-104. Frame Cover Screws

MACHINE WHILE POWER IS APPLIED. UNEXPECTED MACHINE STARTUP CAN CAUSE SERIOUS INJURY.

WARNING

AND ARMS CLEAR OF MOVING PARTS.

WARNING

USE PROPER TROUBLESHOOTING TECHNIQUES TO AVOID ELECTRICAL SHOCK.

WARNING

Figure 3-106. Using a jumper on A2-

Figure 3-105. Grey Relay location

A2-

A1+

GREY RELAY 24V

The Grey Wago relay is only pres ent in Shar p SX Baggers that are equippe d with a printer. It is us ed to trigger the start print signal to the imprinter.

1. Remove the six screws holding the Frame Cover, set screws and Frame Cover aside (Figure 3-104).

2. Plug machine in and turn on.

USE EXTREM E CAUTION WHILE SERVICING A

DO NOT ATTEMPT TO SERVICE THE MACHINE DURING NORMAL OPERATION. KEEP HANDS

WHEN TESTING ELECTRICAL COMPONENTS WHILE POWER IS APPLIED TO T HE MACHINE,

3. Locate Relay, 24V SPDT (Single Pole Double Throw) (Figure 3-105).

4. With a DVOM (Digital Volt/Ohm Meter) set to test for continuit y, probe pins 11 and 14 of the Grey Relay. There should be no continuity.

5. Ins ert a piece of jum per wire into t he 92 (Blac k) Terminal block. Contact the other end to A2(Figure 3-106). If red LED does not illuminate check the wiring of A1+

6. With the jumper wire installed and a DVOM (Digital Volt/Ohm Meter) set to test for

continuity, probe pins 11 and 14 of the Grey Relay. There should be continuity.

Page 60

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

Dark Blue

ADJUSTMENT

REPLACEMENT

Figure 3-107. Frame Cover Screws

Figure 3-108. Relay location

Figure 3-109. Removing Relay



on the machine.

WARNING

GREY RELAY 24V (con’t)

There are no adjustments necessary on the grey Relay.

Always remove electrical power from the

1. Remove the six screws holding the Frame

2. Locate Grey Relay (Figure 3-108).

3. Using a small screwdriver, remove all wires

4. Rem ove Relay from DIN rail b y taking a small

5. Remove Relay from DIN Rail.

6. Sna p repl ac ement Relay onto DIN rail, red L ED

7. Reconnect all wires (Table 3-2).

prior to performing any maintenance

Cover, set screws and Frame Cover aside (Figure 3-107).

from Relay.

screwdriver and pulling tab out while pivoting Relay back (Figure 3-109).

should be towards the outside.

Wire Label Wire Color Terminal Number

Table 3-2. Relay wire locations (Note: Lines in 11

and 14 are interchangeable).

Page 61

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

Figure 3-110. Frame Cover Screws

TESTING

Figure 3-111. Grey Relay location

4 3 1



on the machine.

WARNING

RED RELAY 24V

The red 24V Relay is only present in Sharp SX Baggers that are equipped with a printer. This relay receives an end of pr i nt sign al f r om the print er and communicates that to the PLC.

Always remove electrical power from the

prior to performing any maintenance

1. Remove the six screws holding the Frame Cover. Set screws and Frame Cover aside (Figure 3-110).

2. Rem ove fuse drawer from top of Relay (Figure 3-111).

3. W ith a DVOM set to t est for continuit y, contact one probe to each side of the fuse. If the DVOM does not indicate continuity, replace fuse.

Note: A blown fuse can be an indication of a larger issue. If you continue to blow fuses inspect the wiring for shorts or frays.

4. Push the fuse back into position.

Note: Occasionally this fuse will not make a good contact with the fuse holder. Reseating the fuse may resolve the issue.

5. With a DVOM (Digital Volt/Ohm Meter) set to test continuity, probe bet ween pins 1 and 2 of the relay. The DVOM should not indicate continuity.

Page 62

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

MACHINE WHILE POWER IS APPLIED. UNEXPECTED MACHINE STARTUP CAN CAUSE SERIOUS INJURY.

WARNING

AND AR MS CLEAR OF MOVING PARTS.

WARNING

USE PROPER TROUBLESHOOTING TECHNIQUES TO AVOID ELECTRICAL SHOCK.

WARNING

GPIO

Port

Figure 3-112. GPIO Location

RED RELAY 24V (con’t)

6. Plug machine in and turn on.

USE EXTREM E CAUTION WHILE SERVICING A

DO NOT ATTEMPT TO SERVICE THE MACHINE DURING NORMAL OPERATION. KEEP HANDS

WHEN TESTING ELECTRICAL COMPONENTS WHILE POWER IS APPLIED TO T HE MACHINE,

7. Cycle the machine with the printer enabled. Observe the LED on top of the Relay. If the LED does not momentarily illuminate, check the wiring on pins 3 and 4. If wiring is OK, inspect GPIO connector for damage (Figure 3-

112).

8. Cycle machine with printer enabled again. Observed input LED X7 on the PLC. If LED does not momentarily illuminate, check wiring of pin 2.

9. If all wiring is functional, relay is defective.

Page 63

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

Terminal

Number

Dark Blue

Red 3 -

White & Blue

ADJUSTMENT

REPLACEMENT

Figure 3-113. Frame Cover Screws

Figure 3-114. Remove Red Relay

RED RELAY 24V (con’t)

There are no adjustments necessary on the Red Relay.

1. Remove the six screws holding the Frame Cover, Set screws and Frame Cover aside (Figure 3-113).

2. With a small screwdriver, remove all connections from Red Relay.

3. Using the same screwdriver, pull the DIN release tab out and pivot R ela y up and towards you (Figure 3-114).

4. Remove Relay.

5. Sna p replacement Relay onto DIN rai l with the Red LED closest to you.

6. Reconnect all wires (Table 3-3).

Wire Label Wire Color

Table 3-3. Red Relay connections

Page 64

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

WARNING

This procedure deals with handling parts susceptible to damage from electrostatic

TESTING

ADJUSTMENT

REPLACEMENT

Card

GPIO

Board

Figure 3-115. GPIO and Card Carriage Locations.

Figure 3-116. Card Track



on the machine.

WARNING

PRINTER GPIO BOARD

The Printer GPIO Board is only present in Sharp

Baggers that are equipped with a printer. It is

SX used for comm unications b etween t he PLC an d the Datamax Printer. A defective GPIO board will typically result in the printer running continuously without the bagger running. A non-functioning printer is usually c aused by faulty rela ys. Refer to the Grey and Red Rela y sections to troublesh oot a non responsive printer.

There are no testing procedures for the Printer GPIO Board.

There are no adjustments necessary on the GPIO Board.

Always remove electrical power from the

1. Unplug the GPIO cable from the GPIO Board

prior to performing any maintenance

(Figure 3-115).

Carriage

2. Remove the two screws holding the GPIO Board to the Card Carriage.

discharge (ESD). Use static control precautions while servicing this equipment.

3. Pul l the board straight out t owards you and set aside.

4. Line up new board with the card track inside the Card Carriage (Figure 3-116).

Note: Frame Cover Removed for Clarity

5. Slide new board all the way into Carriage. Resistance will increase i n the last inch as the board slides into the connector.

6. Screw new GPIO Board to Card Carriage.

7. Reattach GPIO cable.

Page 65

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS

WARNING

This procedure deals with handling parts susceptible to damage from electrostatic

Card

Logic

Board

Figure 3-117. Printer Performance Logic Board

and Card Carriage Locations.

TESTING

ADJUSTMENT

REPLACEMENT

Figure 3-118. Card Track



on the machine.

WARNING

PRINTER PERFORMANCE LOGIC BOARD

The Printer Performance Logic Board is only present in Sharp SX with a printer. The s ymptoms of a defective board will be a nonfunctionin g Pri nter LCD Display and an unresponsive printer.

There is no testing procedure for the Printer Performance Logic Board.

There are no adjustm ents necessar y on the Printer Performance Logic Board.

Always remove electrical power from the

prior to performing any maintenance

1. Snip the cable tie holding the GPIO cable to the Printer Perform ance Logic Board (Fi gure 3-

117).

Carriage

Baggers that are equipped

2. Remove the two screws holding the board to the Card Carriage

discharge (ESD). Use static control precautions while servicing this equipment.

3. Pull the board out of the Card Carriage.

4. Remove new board from static bag.

5. Line up new board with the card track inside the Card Carriage (Figure 3-118).

6. Slide new board all the way into Carriage. Resistance will increase i n the last inch as the board slides into the connector.

7. Screw new board to Card Carriage.

8. Reconnect any cables that may have been connected to Printer Performance Logic Board.

Note: Frame Cover Removed for Clarity

Page 66

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS (1099 & 1108 )

TESTING

ADJUSTMENT

REPLACEMENT

Figure 3-119. Frame Cover Screws

Mandrel

Figure 3-120. Mandrel Support Screws

Figure 3-121. Mandrel Support Plate Bottom

Screws

Plate

screws



on the machine.

WARNING

PRINTER POWER SUPPLY BOARD

There are no testing procedures for the Printer Power Supply Board.

There are no adjustm ents necessar y on the Printer Power Supply Board.

Always remove electrical power from the

1. Remove the six screws holding the Frame

2. Remove any bags on a roll from the machine.

3. Remove the seven screws from the Mandrel

prior to performing any maintenance

Cover, set screws and Frame Cover aside (Figure 3-119).

Support Plate (Figure 3-120 & 3-121).

Support screws

Page 67

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS (1099 & 1108 )

Figure 3-123. Printer Power Supply Screws

Figure 3-124. Printer Power Supply Board

Connections

Figure 3-122. Printer Power Supply Board Screws

PRINTER POWER SUPPLY BOARD (con’t)

4. Remove the two screws holding the Power Supply Board to the Base Plate and the one additional screw sec ur ing it to t he upright frame plate (Figure 3-122).

5. Remove the two screws holding the Power Supply Board to the Rear F ace Plate ( Figur e 3-

123).

6. Disconnect the five cables from the board (Figure 3-124). There also will be a short ground wire by the rear plate that will need to be removed from the base plate.

7. Remove defective Power Supply Board from machine.

8. Remove new Power Supply Board from packaging.

9. Place new board in machine, position so that the power switch and plug receptacle are aligned with their cutouts in the Rear Face Plate.

10. Screw the Power Supply onto the case using the five screws from the old Power Supply.

11. Reconnect the five cables to the board; the plugs will only fit in their respective connectors.

12. Replace Frame Cover.

Page 68

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS (1099 & 1108 )

TESTING

ADJUSTMENT

REPLACEMENT

Figure 3-125. Frame Cover Screws

Figure 3-126. Fan Cover

Figure 3-127. Remove Fan Guard



on the machine.

WARNING

24 VDC FAN ASSEMBLY

The 24 VDC Fan Assembly is only present in Sharp

Baggers that are equipped with a printer.

There are no testing procedures for the 24 VDC Fan Assembly. If the fan is not receiving power, the printer will not turn on, as they both use the same power source.

There are no adjustments necessary on the 24 VDC Fan Assembly

Always remove electrical power from the

1. Rem ove six screws holding Frame Guard, set

2. Snap off Air Filter Holder (Figure 3-126).

3. Remove Filter (clean if necessary).

4. Remove four screws holding 24 VDC Fan to

5. Unplug and remove fan.

6. Using the screws from the old fan, screw the

7. Snap Air Filter Holder and Air Filter onto Fan

8. Reconnect power cord to Power Supply Board.

9. Replace Frame Cover.

prior to performing any maintenance

screws and Frame Guard aside (Figure 3-125).

Rear Face Plate. When removing last screw, hold fan so it doesn’t fall (Figure 3-127).

replacement fan to the Rear Face Plate.

Guard.

Page 69

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS (1099 & 1108 )

TESTING

ADJUSTMENT

REPLACEMENT

Figure 3-128. Frame Cover Screws

Figure 3-130. White Ribbon Cable Lock

Figure 3-129. Loose ribbon cable example



on the machine.

WARNING

LAMINATED WHITE RIBBON C ABLE

The Ribbon Cable is only present in Sharp SX Baggers that are equipped with a printer. The Ribbon Cable is the data connection between the Datamax Logic Board and the LCD Module. If this cable becomes dam aged or dislodged, t he printer’s LCD Display will malfunction. Use the following procedures to remedy the problem.

1. Remove the six screws holding the Frame Cover, set screws and Frame Cover aside (Figure 3-128).

2. Ins pect both sid es of the Ri bbon Cable a nd the Cable itself; look for exposed metal contacts, cuts or sharp bends (Figure 3-129). Also ensure both ends of the cable are completely seating in the cable receptacles.

3. If the Cable does not appear damaged, troubleshoot the Printer LCD Module and the Printer Performance Logic Board.

There are no adjustm ents necessary on the White Ribbon Cable.

Always remove electrical power from the

prior to performing any maintenance

1. Remove the six screws holding the Frame Cover, set screws and Frame Cover aside.

2. Snip any cable ties holding the Cable.

3. Unlock both sides of the cable from their connectors by pulling the sides of the connectors out (Figure 3-130).

Page 70

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS (1099 & 1108 )

Figure 3-131. White Ribbon Cable Position 1

Pin 1

Figure 3-132. White Ribbon Cable Position 2

Pin 1

LAMINATED WHITE RIBBON C ABLE (con’t)

4. Remove Cable.

5. Insert one side of the replacement cable in Position 1 with exposed metal contacts facing up and lock down (Figure 3-131).

6. Foll ow the LEFT edge of the cable (Pin 1) and insert cable into Position 2 with that edge on TOP.

7. Lock down the other end of cable.

8. Secure cable into position with cable ties.

9. Replace Frame Cover.

Page 71

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS (1099 & 1108)

TESTING

ADJUSTMENT

REPLACEMENT

Figure 3-134. White Ribbon Cable Lock

Figure 3-133. Frame Cover Screws

Figure 3-135. Remove LCD Module Cover Screws



on the machine.

WARNING

DATAMAX LCD MODULE

The Datamax LCD Module is only present in Sharp

Baggers that are equipped with a printer.

There are no testing procedures for the Datamax LCD Module.

There are no adjustments necessary on the Datamax LCD Module.

Always remove electrical power from the

1. Remove the six screws holding the Frame

2. Remove the White Ribbon Cable from the back

3. Remove the two screws holding the Printer

prior to performing any maintenance

Cover, set screws and Frame Cover aside (Figure 3-133).

of the Display (Figure 3-134).

Front Panel (Figure 3-135). Remove panel and set aside.

Page 72

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS (1099 & 1108)

Figure 3-137. Remove Face Plate

Figure 3-138. Remove Display Screws

Figure 3-136. Release tabs

Release

Tabs

DATAMAX LCD MODULE (con’t)

4. Release the two lower Face Plate tabs (Figure 3-136).

5. Remove Face Plate (Figure 3-137).

6. Unscrew the two screws holding the LCD Module to the Front Plate (Figure 3-138).

7. Remove LCD Module from Front Plate.

8. Replace LCD Module with new Module.

9. Screw LCD Module to Front Plate with screws from old Module; be sure to include the two spacers.

10. Snap Font Bezel onto LCD Module.

11. Reattach Printer Front Panel to Machine Front Panel.

12. Reattach White Ribbon Cable to back of LCD Module (Refer to Laminated White Ribbon Cable section on page 3-49 for assistance).

13. Replace Frame Cover using screws and locking washers.

Page 73

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS (1099 & 1108 )

WARNING

This procedure deals with handling parts

le to damage from electrostatic

Figure 3-139. Motor Cover Rear Screws

TESTING

ADJUSTMENT

REPLACEMENT

Figure 3-140. Motor Cover Screws

Disconnect electrical power cords from the machine. Unexpected machine startup can

WARNING

Figure 3-139. Print Head Stepper Drive

Status LED

Screw Terminals

PRINT HEAD STEPPER DRIVE

If your Sharp SX printer, there will b e an additional Stepper Dr ive to control the Print Head. This drive controls the motor that drops the print head onto the platen roller.

1. Check that the Stepper Drive is receiving power by looking for the RED Status LED (Figure 3-139).

2. Visually inspect all electrical components looking for burn marks or deformed casings.

3. Make sure all wires are securely tightened in their screw terminals.

There are no adjustments necessary on the Print Head Stepper Drive.

SX™ prior to performing any maintenance on cause serious injury or death.

susceptib discharge (ESD). Use static control precautions while servicing this equipment.

1. Rem ove the two rear screws a nd the two front screws from the Motor Cover (Figure 3-140).

2. Remove the Motor Cover and set aside.

Bagger is equipped with a

Page 74

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS (1099 & 1108 )

Figure 3-142. Print Head Stepper Drive

Figure 3-143. Print Head Stepper Drive

Speed

POT

DIP

ON-OFF

POTs

Jumper

Figure 3-141. Print Head Stepper Drive (Electrical assembly isolated for clarity)

Print Head

Stepper Drive

PRINT HEAD STEPPER DRIVE (con’t)

3. Loc ate the Print Head Step per Drive (Figure 3-

141).

Note: Depending on your v ersion of the Sharp

Bagger, the orientation of the stepper

drive will vary; the wiring however is ex ac tly t he same.

4. Remove all connections from the Stepper Drive

5. Remove the screws holding the stepper drive to the Base Plate and remove drive.

6. Position replacement Stepper Drive in the same orientation as the old drive.

7. Screw new Stepper Drive to Base Plate.

8. Reconnect all wires; there are nine lines (Figure 3-143).

9. If you ordered a replacement Stepper Drive from Sharp Pack aging, it will be pre c o nf igured, proceed to step 17.

10. Set the POTs to their m aximum value (Figure 3-143).

11. Set the configuration DIP Switches (Figure 3-

143).

12. The Speed POT controls the speed of the Print Head and requires fine tuning. Using a small screwdriver, turn the brass adjusting knob counterclockwise as far as it will go.

13. Turn the Speed POT five full rotations clockwise. This will get the speed close to its correct value.

14. Set Jumper to “SLEW” (Figure 3-142).

Switches

Page 75

SX™

SECTION 3 – COMPONENT REPAIR

ELECTRICAL COMPONENTS (1099 & 1108 )

MACHINE WHILE POWER IS APPLIED. UNEXPECTED MACHINE STARTUP CAN CAUSE SERIOUS INJURY.

WARNING

AND ARMS CLEAR OF MOVING PARTS.

WARNING

USE PROPER TROUBLESHOOTING TECHNIQUES TO AVOID ELECTRICAL SHOCK.

WARNING

PRINT HEAD STEPPER DRIVE (con’t)

15. Further adjustment of the Speed POT requires that the machine be operating . Load bags into machine and setup to print.

USE EXTREM E CAUTION WHILE SERVICING A

DO NOT ATTEMPT TO SERVICE THE MACHINE DURING NORMAL OPERATION. KEEP HANDS

WHEN TESTING ELECTRICAL COMPONENTS WHILE POWER IS APPLIED TO T HE MACHINE,

16. Adjust the Speed POT , counterclockwise if the Print Head comes down too f as t and the pr int is distorted, and clockwise if the Print Head comes down too slow and the m achine faults. Repeat this step until the machine is printing satisfactorily

17. Replace Motor Cover with screws and locking washers

Page 76

SX™

SECTION 3 – COMPONENT REPAIR

FILM FEED ASSEMBLY

TESTING

UNEXPECTED MACHINE STARTUP CAN CAUSE SERIOUS INJURY.

WARNING

DO NOT ATTEMPT TO SERVICE THE KEEP HANDS AND ARMS CLEAR OF

MOVING PARTS.

WARNING

WHILE TESTING ELECTRICAL THE MACHINE, USE PROPER

TROUBLESHOOTING TECHNIQUES TO AVOID ELECTRICAL SHOCK.

WARNING

Figure 3-144. Frame Cover Screws

Figure 3-145. The PLC

PLC ‘X2’ Input

PHOTOELECTRIC SENSOR

Some of the procedures in this section require that the electrical power to the machine remain ON.

USE EXTREME CAUTION WHILE SERVICING A MACHINE WHILE POWER IS APPLIED.

MACHINE DURING NORMAL OPERATION.

COMPONENTS WITH POWER APPLIED TO

The photoelectric s ensor is locat ed beh ind th e fr ont finger plate below the film feed drive roller. This sensor detects the edge of the bag when the film feed drive roller is reversed, thus stopping the reverse motion of the film . There are three steps involved in testing the photoelectric sensor.

- Ensure machine power is on.

1. Check the photo sensing eye to ensure the sensing beam is illuminated. The sensing beam is the red light visible from the front of the machine. If the red sensor beam is not on, either the sensor is fault y or there is no power to the electric eye. Remove the frame guard (see Figure 3-144) and follow the wires from the sensor to the terminal block/breakout module and ensure the wires are making a positive connection with the terminals. If the connections are good, th e sensor is faulty and needs replacement.

2. With the cradle cover open, locate the two indicator lights on the left-hand side of the sensor. The lower light should be illuminated green. Pass your hand in front of the eye (within 1 inch of the front finger plate) while watching the indicator lights. The upper light should illuminate orange when the sensor is activated. If it does not, the sensor is faulty and needs replacement.

3. Remove the frame guard by removing the six screws shown in (figure 3-144). Locate the PLC. Watch the indicator light on the PLC labeled “X2” and watch to see if it turns on when the sensor is acti vated. If it does n ot, the sensor wires are faulty and the sensor needs replacement.

Page 77

SX™

SECTION 3 – COMPONENT REPAIR

FILM FEED ASSEMBLY

Figure 3-146. Calibrating the Photoelectric Sensor

Calibration Object

PHOTOELECTRIC SENSOR (con’t)

Adjustment of the photoelectric sensor involves calibrating the sensor’s range to approximately 2” from the front of the f inger plate. T his range has been determined to be effective for hand loading applications to prevent accidental triggering of the sensor with one’s hand or the product itself. Setting the sensor includes the following steps.

- Ensure machine power is on.

1. Place a solid object 2” from the front finger plate of the machine, being careful to keep it parallel to the plate. The object should be located such that the sensor beam hits the object. (See Figure 3-146).

2. On the rear of the sensor, there is a digital display which will show a number . Record the number, as it will be needed in the following step.

3. Remove the object used in step 1 from the front of the machine. Using the “up” and “down” arrows on either side of the display, adjust the preset value until it matches the number recorded in step two abo ve. This will set the sensing range to approximately 2”.

Page 78

SX™

SECTION 3 – COMPONENT REPAIR

FILM FEED ASSEMBLY

Wire Color

Terminal

Brown

91 (Red Terminals)

Blue

92 (Black Terminals)

Pink

92 (Black Terminals)

Black

X18 (Breakout Module)

Figure 3-148. Front Finger Plate

Front Finger



on the machine.

WARNING

Table 3-4. Photoelectric Se nsor Wiring

Figure 3-147. Guard Identification

Load

Plate

Outside

Covers

Motor Cover

PHOTOELECTRIC SENSOR (con’t)

Use the following steps to repl ace the photoelectr ic sensor.

Always remove electrical power from the

prior to performing any maintenance

1. Remove the frame guard, the load plate, and the motor cover (Figure 3-147).

Frame

3. Rem ove the ph otoelectric sensor from the f ront finger plate. This is done by removing two screws from the bottom of the sensor.

4. Follow the photoelectric sensor wires back through the machine and remove any cable ties attached to the sensor wire as necessary.

Plate Screws

2. Remove the two screws that hold the front finger plate onto the machine (Figure 3-148). Be careful not to p ull this plate away from the machine too brisk ly, as the sensor is affixed to it.

5. Once the cable has been followed to the electrical area, rem ove the wire duc t cover and gently remove the sensor wire.

6. Disconnect the wires from the terminals. Wiring is as follows:

Page 79

SX™

SECTION 3 – COMPONENT REPAIR

FILM FEED ASSEMBLY

Breakout Module

Colored Terminal Blocks

Figure 3-149. Electrical Components

TESTING

Screw

Figure 3-150. Photoelectric Sensor Positioning

Front Plate

Screw

E POWER IS APPLIED. UNEXPECTED MACHINE STARTUP CAN CAUSE SERIOUS INJURY.

WARNING

WHILE TESTING ELECTRICAL THE MACHINE, USE PROPER

TROUBLESHOOTING TECHNIQUES TO AVOID ELECTRICAL SHOCK.

WARNING

PHOTOELECTRIC SENSOR (con’t)

Note: On older models of the SX, the photoelectric sensor may be wired to the machine using an RJ11 ‘modular connector’ (the same plugs used on telephone jacks). Simply remove this plug to disconnect the sensor from the machine on these models. The replacement sensor will be from the current model, which will need to be hard wired using the following steps.

7. Gently remove the sensor from the machine. Pull the wire out of the machine, being extremely careful to not p ull any other wir es in the machine that may become free.

8. Thread the new sensor wire through the machine following the same routing the old wire followed. Be su re to keep the w ire aw ay

from any moving parts inside of the machine.

9. Rewire the sensor to the terminal blocks and breakout module following the wiring list in Table 3-4 of the previous page.

Completely Forward

Completely Rearward

11. Mount the front finger plate to the machine. Ensure the fingers are c entered in the grooves on the film feed drive roller.

12. Power now needs to be app lied to the m achine to calibrate and test the sensor.

10. Mount new sensor to the s ens or brack et on the front finger plate. To ac hieve proper a lignment of the sensor, position the sensor as shown in (figure 3-150). The left screw should be completely to the front of the slot, while the right screw should be completely to the rear of the slot. This will position the sens or correctly to “see” the bag film.

USE EXTREME CAUTION WHILE SERVICING A MACHINE WHIL

COMPONENTS WITH POWER APPLIED TO

13. Follow the procedures in the Testing section (page 3-56) to ensure the new sensor has power and is comm unicating with the PLC. If the sensor passes all thre e tests, calibrate the sensor using the steps in the Adjustment section (page 3-57).

Page 80

SX™

SECTION 3 – COMPONENT REPAIR

FILM FEED ASSEMBLY



on the machine.

WARNING

REPLACEMENT

Figure 3-152. File Feed Drive Motor Mounti ng

ADJUSTMENT

TESTING

Figure 3-151. Guard Identification

Load

Plate

Outside

Guard

PHOTOELECTRIC SENSOR (con’t)

14. Follow the cable through the m achine and wire tie it to the cable bundle.

15. Reinstall all guards removed in step 1, and close the cradle cover.

FILM FEED MOTOR DRIVE BELT

Always remove electrical power from the

prior to performing any maintenance

1. Ensure the film feed motor drive belt has the proper tension. Refer to Machine Adjustments: Checking Belt Tension section to determine the correct tension.

2. Perf orm a visual inspection of the belt. If it is showing signs of wear, such as cracking or fraying, it needs to be replaced.

Refer to the Machine Adjustments: Checking Belt Tension section.

Frame

2. Loos en the four motor mounting scre ws. The head of the screws can be accessed through the opening exposed by removing the load plate (Figure 3-152).

Perform the follo wing steps to re place the f ilm feed drive motor belt.

1. Rem ove the outside fram e guard and the front load plate (Figure 3-151).

3. Once loosened, slide the motor up to create slack in the belt. Remove the belt from the motor pulley and release the motor. The belt can then be removed from the machine and replaced.

Page 81

SX™

SECTION 3 – COMPONENT REPAIR

FILM FEED ASSEMBLY

ADJUSTMENT

REPLACEMENT

TESTING



on the machine.

WARNING

Film Feed

Take-Up Shaft

Platen Roller

Figure 3-154. Film Feed Belt Take-Up Shaft

Figure 3-153. Guard Identification

Pulley Guard

Outside

Guard

FILM FEED MOTOR DRIVE BELT (con’t)

4. Lif t the motor up to allow room for the ne w belt to be installed. Once the belt is over the pu lley, apply downward pressure on the motor to tension the belt, following the tensioning guidelines outlined in Section 2, Maintenance and Adjustments.

5. Repl ace the load plate and the frame cover to complete belt replacement.

FILM FEED ROLLER DRIVE BELT

Always remove electrical power from the

prior to performing any maintenance

1. Ensure the film feed roller drive belt has the proper tension. Refer to Machine Adjustments: Checking Belt Tension section to determine the correct tension.

2. Perf orm a visual inspection of the belt. If it is showing signs of wear, such as cracking or fraying, it needs to be replaced.

3. Ref er to the M achine Adjustments: Checking Belt Tension section to d etermine the correct tension.

1. Remove the outside frame guard and the pulley guard (Figure 3-153).

2. Loos en the belt tak e-up shaft to c reate slack in

3. Loosen the four screws that mount the film

Frame

the belt (Figure 3-154). (Note: if the model SX is equipped with a printer, the platen roller belt take-up shaft must also be loosened to give the platen roller drive belt slack.

Take-Up Shaft

(Optional)

feed drive motor and remove the belt. (See section entitled Film Feed Motor Drive Belt for a more detailed description of how to remove this belt.)

Page 82

SX™

SECTION 3 – COMPONENT REPAIR

FILM FEED ASSEMBLY

Figure 3-156. Removing the Transfer Shaft

Transfer Shaft

Nylon Washer

Figure 3-155 Pulley Identification

Transfer

(Film Feed)

Transfer Shaft Pulley (Platen Roller)

FILM FEED ROLLER DRIVE BELT (con’t)

4. Loos en the two set s crews on the p ulley on the transfer shaft (Figure 3-155). This will allow the pulley to slide on the transfer shaft. Also loosen the clamping collar located next to the middle frame plate. (Note: if the m odel SX is equipped with a printer, the platen roller drive pulley set screws will also need to b e loosened to allow the transfer shaf t to slide. This pulley is the substitute for th e clamping collar. Refer to Figure 3-155 for details.)

If no printer, clamp collar is here.

5. Remove the transfer shaft by pulling outward

Shaft Pulley

on the driven motor pulle y. W hile rem oving the transfer shaft, be careful not to misplace the two nylon washers on the transfer shaft: one between the film feed drive pulley and the lef t bearing plate and one betw een t h e coll ar c lamp and middle frame plate. These washer s act as spacers for proper belt alig nment. (Note: if the model SX is equipped with a printer, the collar clamp will be substituted with the platen roller drive pulley on the transfer shaft. It will also have a nylon washer loc ated between the pulley and the middle frame plate.)

6. Repl ace the belt, putting it on the roller pul ley first. Place the tra nsfer shaft pulley inside the belt, and reinstall the transfer shaft. Do not forget to reinstall the nylon washer. (Note: if the model SX is equipped with a printer, als o align the transfer shaft with the platen roller drive pulley and the second nylon washer.)

7. Pres s the transf er shaf t pu lley tig ht to t he n ylon washer. Perform a quick visual inspection to ensure the pulleys are aligned.

8. Once pulleys are aligned, tighten the set screws to locate the pulley(s) on the transfer shaft. The shaft has 2 flat areas 90° apart f or the set screws to seat on. Be sure the set

screws are tightened onto the flat areas of the transfer shaft (Figure 3-157). Also tighten

the clamping collar once it i s moved tight t o the nylon washer by the m iddle frame plate. This will capture the transfer shaft to prevent movement during operation.

Page 83

SX™

SECTION 3 – COMPONENT REPAIR

FILM FEED ASSEMBLY

Figure 3-157. Transfer Shaft

Shaft

TESTING

ADJUSTMENT

Figure 3-158. Guard Identification

Pulley Guard

Outside

Cover

REPLACEMENT



on the machine.

WARNING

FILM FEED ROLLER DRIVE BELT (con’t)

Flats

9. Sl ide the film feed belt take-up shaft to the belt to put tension on the belt. This belt should deflect approximat ely 1/16” at the cent er of belt span for proper tension. (Note: Repeat this procedure on the platen rol l er belt take-up shaft if the SX is equipped with a printer.)

10. Reinstall the drive motor belt and adjust the belt to proper tensio n. This belt sho uld deflect about 3/32” when tightened correctly.

on pages 2-6 to 2-9 to determine the correct tension.

2. Perf orm a visual inspection of the belt. If it is showing signs of wear, such as cracking or fraying, it needs to be replaced.

Refer to the Machine Adjustments: Checking Belt Tension section on pa ges 2-6 to 2-9.

1. Remove the outside frame guard and the pulley guard (Figure 3-158).

11. Replace the pulley guard a nd t he o utsid e f r am e guard removed in step 1, and close the cradle cover.

PLATEN ROLLER DRIVE BELT (optional)



This section only applies to the Sharp SX Printer.

with

Always remove electrical power from the

prior to performing any maintenance

1. Ensure the platen roller drive belt has the proper tension. Refer to Machine Adjustments: Checking Belt Tension section

2. Loos en the film f eed belt take-up s haft and the

Frame

platen roller belt take-up shaft to create slack in these two belts (Figure 3-159).

Page 84

SX™

SECTION 3 – COMPONENT REPAIR

FILM FEED ASSEMBLY

PLATEN ROLLER DRIVE BELT (con’t)

Figure 3-160. Drive Pulleys

Figure 3-161. Removing the Transfer Shaft

Note: Viewed from Rear; Cradle Removed for Clarity

Nylon Washers

Left Bearing Plate

Middle Frame Plate

Figure 3-159. Belt Take-Up Shafts

Film Feed

Shaft

Platen Roller

Shaft

Take-Up

5. Remove the transfer shaft by pulling outward on the driven motor pulle y. W hile rem oving the transfer shaft, be careful not to misplace the nylon was her bet ween the film feed drive pulle y and the left bearing plat e and the n ylon wash er between the middle fram e plate and the platen roller drive pulley. These washers act as spacers for proper belt alignment (Figure 3-

161).

Note: Viewed from Rear; Cradle Removed for Clarity

3. Loosen the four screws that mount the film feed drive motor and remove the belt. (See section entitled Film Feed Motor Drive Belt for a more detailed description of how to remove this belt.)

4. Loosen the set screws on the three pulleys identified in Figure 3-160.

6. Remove the front finger plate from the machine. Do not pull the plate away from the

machine too quickly, as the photoelectric eye is attached to the plate and wired to the machine. Gently place the plate under the

rollers, ensuring the sensor wire is not excessively pulled (Figure 3-162).

Note: Viewed from Rear; Cradle Removed for Clarity

Page 85

SX™

SECTION 3 – COMPONENT REPAIR

FILM FEED ASSEMBLY

Figure 3-162. Front Finger Plate

Front Finger

Figure 3-164. Reinstalling the Transfer Shaft

Note: Viewed from Rear; Cradle Removed for Clarity

Nylon Washers

Left Bearing Plate

Middle Frame Plate

Right Bearing Plate

Figure 3-163. Right Bearing Plate and Screws

PLATEN ROLLER DRIVE BELT (con’t)

Plate Screws

9. Ins tall the new be lt by sliding it thr ough the ga p created in step 8. Once the new belt is in place, the platen roller can be reinserted into the bearing in the m iddle fram e plate. B e sure

to reinstall the nylon washer between the bearing and the pulley.

10. Reinstall the right bearing plate. Align the platen roller and the film feed roller with the two bearings on the plate. Once in position, replace the five screws removed in step 7 to secure the plate.

11. Mount the front finger plate to the machine. Before tightening the screws, perform a quick visual inspection to ensure the fingers are not rubbing on the film feed roller.

7. Remove the right bearing plate by removing three screws from the base and two screws from the face plate (Figure 3-163). Slide the plate to the right to release the rollers from the bearing plate. (Note: the film feed roller will be free to dip on the right side.)

8. Gently pull the platen roller out of the middle frame plate to create a small gap. This gap needs to be just large enough to slide the belt through. Between the plat e and th e pul ley there will be a nylon washer . Do not misplace this

washer, as it is needed for proper belt alignment.

12. Insert the transfer shaft through the bearing in the middle frame plate. Slide one nylon washer onto the shaft. Place the platen roller pulley and film feed pulley inside their respective belts, and caref ull y push the transf er shaft through the pul leys. Slide the remaining nylon washer onto the shaf t, and put the shaft into the left bearing plate (Figure 3-164).

Page 86

SX™

SECTION 3 – COMPONENT REPAIR

FILM FEED ASSEMBLY

Figure 3-165. Transfer Shaft

Shaft

Figure 3-166. Belt Take-Up Shafts

Film Feed

Shaft

Platen Roller

Shaft

PLATEN ROLLER DRIVE BELT (con’t)

13. Press the transfer shaft pulley for the platen roller tight to the nylon washer. Perform a quick visual inspection to ensure the pulleys are aligned.

14. Once pulleys are aligned, tighten the set screws to locate the pulley(s) on the transfer shaft. The shaft has 2 flat areas 90° apart f or the set screws to seat on. Be sure the set

screws are tightened onto the flat areas of the transfer shaft (Figure 3-165).

15. Slide the transfer shaf t pulley for the film feed roller tight to the n ylon washer between it and the left bearing plate. Visually check pulley alignment.

16. Tighten the set screws on the film feed roller drive pulley. Again, be sure the set screws

are tightened onto the flat areas of the transfer shaft.

Flats

18. Slide the film feed belt take-up shaft to the belt to put tension on the belt. This belt should deflect approximat ely 1/16” at the cent er of belt span for proper tension. Repeat on the platen roller take-up shaft. As shown in (Figure 3-

166.)

19. Replace the pulley guard a nd the o uts id e f r am e

Take-Up

Note: Viewed from Rear; Cradle Removed for Clarity

guard removed in step 1, and close the cradle cover.

Take-Up

17. Reinstall the film feed motor drive belt. (See section entitled Film Feed Motor Drive Belt for a more detailed description of how to reinstall this belt.)

Page 87

SX™

SECTION 3 – COMPONENT REPAIR

FILM FEED ASSEMBLY

TESTING

ADJUSTMENT

REPLACEMENT



on the machine.

WARNING

Film Feed

Take-Up Shaft

Platen Roller

Figure 3-168. Film Feed Belt Take-Up Shaft

Figure 3-169. Film Feed Pulley Set Screws

Set

Screws

Set

Screws

Figure 3-167. Guard Identification

Pulley Guard

Outside Cover-

Right

FILM FEED ROLLER

Always remove electrical power from the

prior to performing any maintenance

1. Testing of the film feed roller consists of a visual inspection to determine the wear level of the rubber surface. This s urfac e s hould be f ree of pitting, grooves, or other defects to ensure the best machine performance. If the roller shows severe wear, it needs to be replaced.

No adjustments are necessary on the film feed roller.

1. Remove the pulley guard and the outside cover-right (Figure 3-167).

2. Loos en the belt tak e-up shaft to c reate slack in the belt (Figure 3-168).

Take-Up Shaft

(Optional)

3. Loos en the four set screws on the two pulle ys shown in Figure 3-169. Slide the p ulle ys to the left until the top pulley on the film feed drive roller is completely removed.

Page 88

SX™

SECTION 3 – COMPONENT REPAIR

FILM FEED ASSEMBLY

FILM FEED ROLLER (con’t)

Figure 3-170. Front Finger Plate

Front Finger Right Bearing Plate

Figure 3-171. Right Bearing Plate and Screws

Film Feed

Roller

Figure 3-172. Removing the Film Feed Roller

FILM FEED ROLLER (con’t)

4. Remove the front finger plate from the machine. Do not pull the plate away from the

machine too quickly, as the photoelectric eye is attached to the plate and wired to the machine. Gently place the plate under the

rollers, ensuring the sensor wire is not excessively pulled (Figure 3-170).

5. Remove the right bearing plate by removing three screws from the base and two screws from the face plate (Figure 3-171). Slide the plate to the right to release the rollers from the bearing plate. (Note: the film feed roller will be free to dip on the right side if your model is equipped with an imprinter.)

Plate Screws

6. Rem ove the film feed roll er (shown i n Figure 3-

172) by sliding it to the right, f reeing it from the left bearing plate.

7. Install the new film feed roller by sliding the longer end with the t wo machined f lats into the left bearing plate.

8. Reinstall the right bearing plate. Align the film feed roller with the bear ing and slide plate into roller. (Note: if the model SX is equipped with a printer, the platen roller s haft also needs to be aligned with the right bearing plate rear bearing before mounting the plate to the machine.) Replace the f ive screws rem oved in step 5 (Refer to Figure 3-171).

9. Mount the front finger plate to the machine. Before tightening the screws, perform a quick visual insp ection to ensure the fingers ar e not rubbing on the film feed roller.

Page 89

SX™

SECTION 3 – COMPONENT REPAIR

FILM FEED ASSEMBLY

Figure 3-173. Transfer Shaft

Shaft

TESTING

ADJUSTMENT

REPLACEMENT



on the machine.

WARNING

Pulley Guard

Outside Cover-

Right

Figure 3-174. Guard Identification

FILM FEED ROLLER (con’t)

10. Reinstall the film feed roller pulley, remembering to firs t place the pulley inside of the belt. Slide the tr ansfer shaft pulley and the roller pulley in unison to ensure the be lt stays on the pulleys. Move the pulleys until the pulley on the transf er shaft is tight to t he nylon washer.

11. Align the transfer shaft pulley set screws with the two flats on the transfer shaft and tighten set screws.

12. Using a straightedge, align the film feed roller pulley with the transf er shaft pulley. Once the pulleys are in-line, rotate the film feed roller until the two machined flats ar e aligne d with t he set screws and tighten them.

Flats

13. Slide the film feed belt take-up shaft to the belt to put tension on the belt. This belt should deflect approximat ely 1/16” at the cent er of belt span for proper tension.

14. Reinstall the guards removed in step 1, and close the cradle cover.

PLATEN ROLLER

This section only applies to the Sharp SX with Printer.

Always remove electrical power from the

prior to performing any maintenance

1. Testing of the film feed roller consists of a visual inspection to d etermine the wear level of the rubber surface. This s urfac e s hould be f ree of pitting, grooves, or other defects to ensure the best machine performance. If the roller shows severe wear, it needs to be replaced.

No adjustments are necessary on the platen roller.

1. Remove the pulley guard and the outside cover-right (Figure 3-174).

Page 90

SX™

SECTION 3 – COMPONENT REPAIR

FILM FEED ASSEMBLY

Figure 3-175. Belt Take-Up Shafts

Film Feed

Shaft

Platen Roller

Shaft

Figure 3-176. Belt Take-Up Shafts

Platen Roller

Driven Pulle y

Platen Roller

Drive Pulley

Figure 3-177. Front Finger Plate

Front Finger Right Bearing Plate

Figure 3-178. Right Bearing Plate and Screws

PLATEN ROLLER (con’t)

2. Loos en the film f eed belt take-up s haft and the platen roller belt take-up shaft to create slack in these two belts (Figure 3-175).

Take-Up

Note: Viewed from Rear; Cradle Removed for Clarity

3. Loos en the four set screws on the two pulle ys shown in Figure 3-176 until they are free to slide.

Take-Up

4. Remove the front finger plate from the machine. Do not pull the plate away from the

machine too quickly, as the photoelectric eye is attached to the plate and wired to the machine. Gently place the plate under the

rollers, ensuring the sensor wire is not excessively pulled (Figure 3-177).

Plate Screws

5. Remove the right bearing plate by removing three screws from the base and two screws from the face plate (Figure 3-178). Slide the plate to the right to release the rollers from the bearing plate. Note: the platen roller will be free to dip on the right side if your model is equipped with an imprinter.

Note: Viewed from Rear; Cradle Removed for Clarity

Page 91

Platen Roller

Roller Pulley

Figure 3-179. Removing the Platen Roller

SX™

SECTION 3 – COMPONENT REPAIR

FILM FEED ASSEMBLY

Nylon Washer

Middle Frame Plate

Figure 3-180. Reinstalling the Platen Roller

Roller Pulley

PLATEN ROLLER (con’t)

6. Sl ide the platen roller (shown in Figur e 3-179) out of the machine to the right, freeing it from the left bearing plate. W hile pulling the roller, place one hand on the roller pulley, as this pulley will be free t o fall once the platen roller shaft is removed. Between t he pulley and the middle frame plate is a nylon washer. Be

careful not to misplace th is washer, as it is needed for proper belt alignment.

8. Continue sliding the platen roller into the machine until the shaft is tight to the rear bearing on the left bearing plate. The end of the shaft will need to be aligned with a s econd bearing in the middle frame plate.

9. Reinstall the right bearing plate. Align the film feed roller and the platen roller with their respective bearings, and slide the plate over until both shafts are completely inserted. Replace the five screws removed in step 5.

10. Slide the platen roller pulle ys in tandem tight to the middle frame plate. Once in position, tighten the four set screws on the pulleys.

7. Install the new platen roller. First, slide the long end of the shaft into the left bear ing plate. Once the shaft is about halfway in, slide the two platen roller pulleys in tandem over until the roller pulley is fully engaged on the roller shaft. Also, place t he n ylon washer removed in step 6 onto the shaft af ter the pulle y (Figure 3-

180).

11. Mount the front finger plate to the machine. Before tightening the screws, perform a quick visual inspection to ensure the fingers are not rubbing on the film feed roller.

12. Slide the film feed belt take-up shaft to the belt to put tension on the belt. This belt should deflect approximat ely 1/16” at the cent er of belt span for proper tension.

13. Reinstall the guards removed in step 1, and close the cradle cover.

Page 92

SX™

SECTION 3 – COMPONENT REPAIR

FILM FEED ASSEMBLY

TESTING



on the machine.

WARNING

Figure 3-181. Load Plate Screws

Figure 3-182. Film Feed Drive Location

Film Feed

Stepper Drive

Figure 3-183. TM4500 Configuration

6 5 4 3 2 1

Motor Cable

Terminals

FILM FEED DRIVE MOTOR

Always remove electrical power from the

prior to performing any maintenance

1. The wire for the film feed motor has a quick disconnect plug ab out 5 inc hes from the m otor. Ensure the plug is c ompletely inserted into the receptacle.

2. Using a Digital Volt/Ohm Meter (DVOM), first check continuity on the motor at the film feed stepper drive. Use the following step to do this.

a. Remove the four screws shown in Figure

3-181 to remove front load plate.

b. Locate the film feed stepper drive (Figure

3-182)

c. On the righ t-rear c orner of the dr ive ar e the

motor cable terminals. Check continuity between terminals 1 and 2, 1 and 3, and 2 and 3. Also check continuity between terminals 4 and 5, 4 and 6, and 5 and 6 (refer to Figure 3-183 for terminal identification). If all six tests for continuit y pass, the motor is not faulty and other troubleshooting techniques need to be followed. (Refer to Pres su r e Jaw and Film Feed Motor Controllers on Page 3-1 for information on how to check the stepper drive).

Page 93

SX™

SECTION 3 – COMPONENT REPAIR

FILM FEED ASSEMBLY

ADJUSTMENT

REPLACEMENT

Figure 3-185. Guard Identification

Load

Plate

Outside

Guard

Figure 3-186. File Feed Drive Motor Mounti ng

4 5 6

Figure 3-184. Motor Plug

FILM FEED DRIVE MOTOR (con’t)

3. If there is no contin uity at the stepp er drive, the quick disconnect cable may be faulty. Follow these steps to check the motor at the plug.

a. Unplug the quick disconnect located near

the motor.

b. Us ing a DVOM, check the c ontinuit y on th e

motor end of the plug. First, check between pins 1 and 3, 1 and 6, and 3 and

6. Then check for continuity between 2 and 4, 2 and 5, and 4 and 5 (see figure 3184 for pin locations). If all six checks pass, the motor is not fau lty, and there is a problem with the motor c able. Check the cable and connections to make sure the wires are not broken or pin ched, an d check pins to ensure they are still connected.

1. Rem ove the outside frame guard and the load plate. (See Figure 3-185.)

Frame

The film feed drive motor is adjustment free.

2. Unplug the quick disconnect on the motor cable, and remove the four motor mounting screws. The head of the screws can be accessed through the opening exposed by removing the load plate (Figure 3-186).

Page 94

SX™

SECTION 3 – COMPONENT REPAIR

FILM FEED ASSEMBLY

TESTING

Figure 3-187. Cradle Latch

Cam Follower

Cradle Latch Lever



on the machine.

WARNING

FILM FEED DRIVE MOTOR (con’t)

3. Lift the motor upwards to remove the pulley from the belt. Caref ully slide the motor out of the machine through the opening exposed by the load plate.

4. Remove the pulley from the old motor and reinstall on the new motor. Note location and

orientation of pulley on motor shaft, and duplicate when installing on new motor. Be

sure to tighten the pulley set screws on the machined flat areas of the motor shaft.

5. Ins tall the motor into the machine. The m otor should be oriented such that the plu g and wire pigtail are to the back of the machine. Do not tighten the screws at this tim e, as the film feed belt needs to be tensioned.

6. Plu g the motor cable into the quick disconnect harness.

7. Apply downward pressure on the motor to tension the belt. At proper tension, the belt should deflect about 3/32” at the c enter of belt span using one finger to pus h the belt. When proper tension is achieved, tighten the four motor mounting screws.

8. Reinstall guards removed in step 1.

CRADLE LOCK CAMS

Note: Earlier models of the Sharp SX are equipped with latch pins in the place of cam followers. If the latch pins need re placing , the latc h mechanism needs to be upgraded to the cam followers. This procedure is best completed at Sharp Packaging Systems’ facility by our service personnel because substantial machine disassembly is required.

Always remove electrical power from the

prior to performing any maintenance

1. T urn the cam follower (sho wn in Figure 3-187) by hand, ensuring it spins smoothly with no spots that stick. Also check that it is free of lateral movement.

Page 95

SX™

SECTION 3 – COMPONENT REPAIR

FILM FEED ASSEMBLY

ADJUSTMENT

Figure 3-188. Cradle Latch

Figure 3-189. Cradle Locking Cams

Jam Nut

Cam Follower

REPLACEMENT

CRADLE LOCK CAMS (con’t)

2. Inspect the cradle latch (shown in Figure 3-

188) and the cradle latch lever to ensure the surfaces that the cams ride on show minimal wear.

The cradle lock cams on the Sharp SX are adjustment free.

1. With the cradle open, loos e n the j am nut on the interior of the bearing plate (Figure 3-189) while holding the shaft of the cam with a 1/8” hex wrench.

2. Remove the cam follower from the plate, and place new cam into bearing plate hole.

3. Reinstall hex jam nut, using Loctite

® 242.

Page 96

SX™

SECTION 3 – COMPONENT REPAIR

PRINTHEAD CRADLE ASSEMBLY

TESTING

UNEXPECTED MACHINE STARTUP CAN CAUSE SERIOUS INJURY.

WARNING

DO NOT ATTEMPT TO SERVICE THE MACHINE DURING NORMAL OPERATION. KEEP HANDS AND ARMS CLEAR OF MOVING PARTS.

WARNING

WHILE TESTING ELECTRICAL THE MACHINE, USE PROPER

S TO

AVOID ELECTRICAL SHOCK.

WARNING

Outside Cradle

Figure 3-190. Removing the Outside Cradle Cover

READY STOP ERROR

PAUSE CANCELFEED

REV ENTFWD

ESCESC TEST

Figure 3-191. Printer Control Panel

Feed Button

RIBBON REWIND ASSEMBLY

RIBBON REWIND MOTOR

Some of the procedures in this section require that the electrical power to the machine remain ON.

USE EXTREME CAUTION WHILE SERVICING A MACHINE WHILE POWER IS APPLIED.

COMPONENTS WITH POWER APPLIED TO TROUBLESHOOTING TECHNIQUE

1. Remove the outside cradle cover.

Screws

2. Press the “Feed” button on the printer control panel, and watch the ribbon rewind motor. If the motor spins and th e rewind hub does not, the ribbon motor is work ing proper ly and further troubleshooting of th e ribbon rewind assembly is required.

Page 97

SX™

SECTION 3 – COMPONENT REPAIR

PRINTHEAD CRADLE ASSEMBLY

Figure 3-192. Ribbon Rewind Motor Pin ID

Figure 3-193. Guard Identification

Outside

Guard

Ribbon Rewind

(Labeled ‘J6’)

Figure 3-194. Ribbon Rewind Cable Connector

ADJUSTMENT

RIBBON REWIND MOTOR (con’t)

3. If the motor is not turning, unplug the motor cable and check for continuity. Using a Digital Volt/Ohm Meter (DVOM) set to test for continuity, probe between pins 1 & 2, 1 & 3, and 2 & 3. Repeat continuity check between pins 4 & 5, 4 & 6, and 5 & 6. If the motor passes all continuity checks, the motor is functioning properly.

4. Remove the outer frame guard.

2 3 4 5

Frame

5. Locate the printer power supply board in the lower rear corner of the e lec trical are a. U nplug the motor cable plugged into “J6”. Using the DVOM, check continuit y between pins 1 and 2, 1 and 3, and 2 and 3 on the cable. Also check continuity between pins 4 a nd 5, 4 an d 6, a nd 5 and 6. Since the pins m ay be sm aller than the probes on the DVOM, wire leads may need to be inserted into the plug for testing. If the motor has continuity and the cable does not, the cable needs rep lacement. If both the m ot or and cable are continuous, troubleshoot the printer power supply board (page 3-46). If no component replacem ent or further testing is to be done, reinstall the outside cradle cover and outside frame guard.

The ribbon rewind motor is adjustment free.

Motor Connector

Page 98

SX™

SECTION 3 – COMPONENT REPAIR

PRINTHEAD CRADLE ASSEMBLY



on the machine.

WARNING

REPLACEMENT

Outside Cradle Screws

Figure 3-195. Removing the Outside Cradle Cover

Figure 3-196. Ribbon Motor Mounting Screws

RIBBON REWIND MOTOR (con’t)

Always remove electrical power from the

1. Remove the outside cradle cover.

2. Unplug the cable from the motor.

3. Open the cradle cover, and remove the four

prior to performing any maintenance

motor mounting screws from the cradle plate. This will free the motor f rom the machine. Be careful of the drive belt when taking the motor out of its position.

4. Rem ove the pulley and four standof fs from the old motor, and install on the new motor.

5. Place the new motor into the machine, being sure to orientate the cable receptacle to the inside of the machine. Also be sur e the belt is over the pulley.

6. Reinstall the screws into the motor standoffs through the slots in the cradle side plate. Before tightening into position, be sure to set the belt tension to a satisfactory level. The center of belt span should displac e about 1/1 6

of an inch when pressed with one finger perpendicular to the belt travel (Refer to “Checking Belt Tension” in Section 2 Machine Adjustments for a more detailed explanation).

7. Replace all guards removed in the previous steps.

Page 99

SX™

SECTION 3 – COMPONENT REPAIR

PRINTHEAD CRADLE ASSEMBLY

TESTING



on the machine.

WARNING

ADJUSTMENT

REPLACEMENT

Outside Cradle Screws

Figure 3-197. Removing the Outside Cradle Cover

Figure 3-198. Ribbon Motor Mounting Screws

PRIMARY RIBBON DRIVE BELT

This belt runs between the ribbon rewind drive motor and the ribbon transfer shaft.

Always remove electrical power from the

1. Ensure the primary ribbon drive belt has the

prior to performing any maintenance

proper tension. Refer to Machine Adjustments: Checking Belt Tension section

to determine the correct tension.

2. Perform a visual inspectio n of the belt. If it is showing signs of wear, such as cracking or fraying, it needs to be replaced.

Refer to the Machine Adjustments: Checking Belt Tension section for a more detailed explanation.

1. Remove the outside cradle cover.

2. Unplug the ribbon drive motor cable, and remove the drive motor.

Page 100

SX™

SECTION 3 – COMPONENT REPAIR

PRINTHEAD CRADLE ASSEMBLY

Figure 3-199. Transfer Shaft Pulley

Set Screws

Figure 3-200. Removing the Belt

Nylon

Washer

Remove Belt through This Gap

PRIMARY RIBBON DRIVE BELT (con’t)

3. Loosen the set screws on the transfer shaft pulley. This will allow the pul ley to slide freely, and also allow the transfer s haft to move side to side in the bearings.

4. Slide the shaft into the bearing towards the center of the machine until the belt can be removed from the outer end of the shaft. When sliding the shaft, there will be a nylon washer that will be free to be removed from between the clamp collar and the outer cradle plate bearing. Do not m isplace this washer, as it is needed for proper machine operation.

5. Insert the new belt onto the shaft through the gap created in step 4.

6. Slide the transfer shaft into the outer cradle plate until the clamp collar and nylon washer are tight against the bearing. Also, slide the pulley tight to the inner cradle plate. Once in position, tighten the pulley set screws on the flat areas of the transfer shaft.

7. Reinstall the ribbon rewind drive motor. Be sure to properly tension the new belt. The center of belt span should displac e about 1/1 6 of an inch when pressed with one finger perpendicular to the bel t travel (Refer Machine Adjustments: Checking Belt Tension section for a more detailed explanation).

8. Reinstall the outer cradle cover.

Sharp SX 1075, SX 1097, SX 1099, SX 1109, SX 1121 Service Maintenance Manual

Parts: (800) 634-6359 ext. 571

Service & Maintenance Manual

Service: (800) 634-6359 ext. 572

IMPORTANT SAFETY INFORMATION

IMPORTANT SAFETY INFORMATION

Section 1- Introduction

TABLE OF CONTENTS

Section 2 – Maintenance & Adjustments

TABLE OF CONTENTS

SECTION 1 – INTRODUCTION

ABOUT THIS MANUAL

As you disassemble your machine to service and replace parts, keep the following points in mind:

SECTION 1 – INTRODUCTION

MODEL VARIATION

SECTION 1 – INTRODUCTION

SECTION 1 – INTRODUCTION

SECTION 1 – INTRODUCTION

SECTION 1 – INTRODUCTION

SECTION 2 – MAINTENANCE AND ADJUSTMENTS

SECTION 2 – MAINTENANCE AND ADJUSTMENTS

SECTION 2 – MAINTENANCE AND ADJUSTMENTS

SECTION 2 – MAINTENANCE AND ADJUSTMENTS

SECTION 2 – MAINTENANCE AND ADJUSTMENTS

SECTION 2 – MAINTENANCE AND ADJUSTMENTS

SECTION 2 – MAINTENANCE AND ADJUSTMENTS

SECTION 2 – MAINTENANCE AND ADJUSTMENTS

SECTION 2 – MAINTENANCE AND ADJUSTMENTS

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

PRESSURE JAW AND FILM FEED MOTOR CONTROLLERS

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

FUSES

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

24 VDC POWER SUPPLY

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

LINE FILTER

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

MAIN POWER SWITCH (RED)

SECTION 3 – COMPONENT REPAIR

MAIN POWER SWITCH (RED) (con’t)

SECTION 3 – COMPONENT REPAIR

TRANSFORMERS

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

AROMAT PLC

SECTION 3 – COMPONENT REPAIR

AROMAT PLC BATTERY

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

COLOR TOUCH SCREEN

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

COOLING FAN

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

SOLID STATE RELAY

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR

SECTION 3 – COMPONENT REPAIR