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

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

Printed In USA 0924

Parts: (800) 634-6359 ext. 571

www.sharppackaging.com

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Service & Maintenance Manual

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parts@sharppackaging.com

Service: (800) 634-6359 ext. 572

service@sharppackaging.com

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.

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.

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

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

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.

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

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™

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.

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.

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

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.

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.



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

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.

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.

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.

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.

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.

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.

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

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.

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.

Figure 3-11 Green Connector Block

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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.

Figure 3-13. TM4500 Wiring Configuration

Figure 3-12. TM4500 Configuration

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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.

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.

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

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

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).

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.

+ 180 hidden pages

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

Specifications and Main Features

Frequently Asked Questions

User 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