Fellowes Proteus A3/125 Technical & Service Manual Download | Manualshive

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Technical Service Manual

Proteus A3/125

Heavy Duty Laminator

September 2011

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Summary of Contents for Proteus A3/125

Page 1: ...Technical Service Manual Proteus A3 125 Heavy Duty Laminator September 2011 ...

Page 2: ...y 9 Remove Replace Hot Rollers Red 10 Remove Replace Hot Roller Blue 12 Remove Replace Cold Roller Gray 13 Remove Side Panel and Roller Press Side Panel Cover 14 Remove Roller Electric Brush 15 Replace Metal Gears 15 Replace PVC Gear 16 Replace Roller Bushing 17 Electrical Assemblies 18 Replace Fuse 19 Remove Replace Cord Socket 19 Remove Replace Power Switch 20 Remove Replace Noise Filter 21 Repl...

Page 3: ...tion of parts and wires before removing them so that they can be reassembled correctly If there are no specific instructions for reassembling an item simply reverse the disassembly procedure The Proteus A3 accepts the most common paper sizes used in the global workplace European A4 and A5 Japanese A4 and U S letter size It accepts paper up to 12 6 32cm wide and maximum documents thickness up to 0 ...

Page 4: ...described below LED and Status Display Indicates roller temperature pre set and actual Indicates the running speed of the rollers Indicates roller temperature is ready to laminate Temperature Adjustment and Function Controls Selects motor speed to suit the pouch thickness 1 mounting boards 2 250 microns and carriers 3 200 175 and 150 microns 5 125 100 and 80 microns ...

Page 5: ... motor speed 1 for laminating hard board more than 1mm thickness COLD Selects no heat lamination HOT Selects normal setting 90 o C and motor speed for hot pouch films Safety When servicing the Proteus A3 observe the following safety precautions Never put a hand fingers or foreign objects into the entry slot Keep all loose articles of clothing ties jewelry long hair or other loose objects away from...

Page 6: ...tenance tasks Remove any paper or plastic pieces that may have accumulated Use a small brush or vacuum to remove dust from the non lubricated surfaces such as the motor rollers heating elements housing and wiring If necessary use mineral spirits to clean the rollers Inspection When servicing the laminator visually inspect it for defects such as loose screws loose terminals and connectors and any o...

Page 7: ...ments of 5 degrees Cloudy one side of lamination the roller pressure may need to be increased Wavy entire lamination the temperature may be too high Increase the speed and or reduce the temperature in increments of 5 degrees Pass a cleaning sheet through or turn up the speed to reduce the temperature Increase the thickness of the pouch Wavy one side of lamination the roller pressure may need to be...

Page 8: ...g Assemblies The laminator housing consists of the top housing cover and a bottom metal plate The housing cover holds the operator control panel power switch and cord socket The bottom plate holds all the mechanical and electrical assemblies and has four rubber feet attached to prevent the laminator from moving This section has procedures to Remove Housing Cover Remove Rubber Foot Replace Control ...

Page 9: ...ing cover on its side 3 Disconnect the cable from the Control Panel PCB Remove Rubber Foot 1 Turn the laminator over and place it face down on a soft surface to avoid damaging the cover housing 2 Remove the screw in the center of the rubber foot 3 Replace foot and secure it with the screw DO THIS FIRST Unplug the Laminator TOOLS Phillips screwdriver TOOLS Phillips screwdriver ...

Page 10: ...the mounting tabs one on each side on the Control PCB Fixing Panel 3 Pull out on mounting tabs to separate the Control PCB Keypad and Fixing Panel 4 Push the new Control PCB in to the housing cover The tabs lock into position when properly in place Control PCB Fixing Panel Keypad Control PCB DO THIS FIRST Remove Housing Cover TOOLS Phillips screwdriver ...

Page 11: ...ss Side Panel Covers Remove Roller Electric Brush Remove Replace Metal Gears Remove Replace PVC Gears Replace Roller Bushing Remove Roller Assembly 1 Remove the 4 acorn nuts from the Metal Bottom Plate on the reverse side of the laminator 2 Remove the 4 screws that hold the Roller Assembly to the Bottom Plate 3 Carefully lift and rotate the Roller Assembly and place it on its end opposite the moto...

Page 12: ... gray roller Remove Replace Hot Rollers Red Caution The Hot Rollers Red must be in the middle position 1 Remove the 2 screws each from the right and left Roller Press Side Panel Covers 2 Carefully remove Side Panel Covers Note The Covers are spring loaded 3 Lift the upper red Hot Roller up and out then lift the lower red Roller DO THIS FIRST Remove Housing Covers TOOLS Phillips screwdriver E clip ...

Page 13: ...as 2 bushings and 1 PVC gear 5 Replace lower red Roller Note Make sure the PVC gear is on the left end away from the motor and that the flat side of the Roller bushings is facing up 6 Replace the upper red Roller Note Make sure the PVC gear is on the left end away from the motor and that the flat side of the Roller bushings is facing up 7 Replace the Side Panel Covers and secure with 2 screws each...

Page 14: ...ully remove Side Panel Covers Note The Covers are spring loaded 3 Remove the upper red Hot Roller up and out 4 Lift the upper blue Hot Roller up and out and then lift the lower blue Roller 5 Remove the E clip on the ends of each blue Roller Note The upper blue Roller has 2 bushings and 1 PVC gear The lower blue Roller has 2 bushings 1 metal gear and 1 PVC gear 6 Replace lower blue Roller Note Make...

Page 15: ...n push the Rollers out of alignment Remove Replace Cold Roller Gray Caution The Cold Rollers Gray must be in the rear position If the gray Cold Rollers are in the wrong position the system will burn and be damaged 1 Remove the 2 screws each from the right and left Roller Press Side Panel Covers 2 Carefully remove Side Panel Covers Note The Covers are spring loaded 3 Remove the upper red Hot Roller...

Page 16: ... red Roller 9 Replace the Side Panel Covers and secure with 2 screws each Note Make sure the Rollers are level The Panel Covers are spring loaded and can push the Rollers out of alignment Remove Side Panels and Roller Press Side Panels Covers 1 Remove the 2 screws each from the right and left Roller Press Side Panel Covers 2 Carefully remove Side Panel Covers Note The Covers are spring loaded 3 Re...

Page 17: ...ew that holds the brush bracket to the side panel 2 Lift the bracket straight up 3 Remove the screw washer and nut that holds the brush to the bracket Remove Replace Metal Gears Caution The Hot Rollers must be in the middle position 1 Remove the 2 screws each from the right and left Roller Press Side Panel Covers 2 Carefully remove Side Panel Covers Note The Covers are spring loaded DO THIS FIRST ...

Page 18: ...e Hot Rollers must be in the middle position 1 Remove the 2 screws each from the right and left Roller Press Side Panel Covers 2 Carefully remove Side Panel Covers Note The Covers are spring loaded 3 Remove the roller with the damaged PVC gear 4 Remove the E clip on the end of each Roller 5 Replace damaged PVC Gear DO THIS FIRST Remove Housing Cover TOOLS Flathead screwdriver Phillips screwdriver ...

Page 19: ...15 11 17 Replace Roller Bushing 1 Remove the Roller with damaged bushing 2 Remove the E clip and gear from the end of the roller 3 Replace damaged bushing DO THIS FIRST Remove Metal Gears Remove PVC Gears TOOLS Flathead screwdriver Phillips screwdriver ...

Page 20: ...ents and connect to the main PC board located at the rear of the laminator In addition the motor drives the mechanical components that ensure the efficient movement of material through the rollers Most of the wires are insulated to protect them by the heat required for lamination Make sure all replacement wiring is also insulated See the wiring diagram for additional information This section has p...

Page 21: ...connect 2 power wires from the Power Switch 2 Disconnect 2 power wires from the Cord Socket 3 Disconnect the grounding wire from Noise Filter center connector 4 Remove the screw from the grounding wire 5 Press down on 4 locking tabs on the Cord Socket and push the Socket out DO THIS FIRST Unplug the Laminator TOOLS Flathead screwdriver DO THIS FIRST Remove Housing Cover TOOLS Long nose pliers Phil...

Page 22: ...e the Power Switch 1 Press down on 2 locking tabs on the Power Switch and push the Switch out 2 Push the new Switch into the panel The tabs lock into position when properly in place 3 Push the Cord Socket with Switch into the panel The tabs lock into position when properly in place 4 Reconnect power and grounding wires DO THIS FIRST Remove Housing Cover TOOLS Long nose pliers Philips screwdriver ...

Page 23: ...e the new Noise Filter and secure it with the 2 screws 5 Reconnect input grounding and output wires Replace Transformer 1 Disconnect the 2 wires from the Noise Filter 2 Disconnect the 2 wires from Main PCB rear next to the Roller Assembly 3 Unscrew and open the wire holders on right and left side of Main PCB DO THIS FIRST Remove Housing Cover TOOLS Long nose pliers Phillips screwdrivers DO THIS FI...

Page 24: ...nectors from Transformer to Main PCB 6 Remove the 4 screws that hold the Transformer to the Metal Bottom Plate 7 Place new Transformer and secure it with the 4 screws 8 Attach the wires to Main PCB and secure them with the wire holders 9 Replace the Bimetal Switch Sensor Fixing Mat and secure it with the 2 screws 10 Connect the power and grounding wires to the Noise Filter 11 Replace Roller Assemb...

Page 25: ...ide Note The 2 screws have a washer head Be sure to use these screws on this Mat 3 Remove 2 screws Motor Fixing Mat motor right side Note The 2 screws each have a lock washer and a flat washer Be sure to use these screw on this Mat 4 Place new Motor and secure it with the 4 screws 5 Reattach connector to Main PCB DO THIS FIRST Remove Housing Cover TOOLS Long nose pliers Phillips screwdriver ...

Page 26: ...lt 1 Remove the Allen head screw from the Motor Double Gear 2 Loosen the Wrench Bolt and remove the Motor Gear Allen Head Screw Motor Double Gear Wrench Bolt Motor Fixing Mat Motor Gear Fixing Mat Motor Double Gear Motor Gear DO THIS FIRST Remove Roller Assembly TOOLS Phillips screwdriver Allen wrench ...

Page 27: ...Plate 2 Remove the Fan wires from below it 3 Remove 2 screws that hold the Fan to the Metal Bottom Plate 4 Place new Fan and secure it with 2 screws 5 Re attach connector to Main PCB 6 Replace the Bimetal Switch Sensor Fixing Mat and secure it with the 2 screws 7 Replace Roller Assembly DO THIS FIRST Remove Housing Cover TOOLS Phillips screwdriver Mat Screws Fan Wires ...

Page 28: ...e the 5 white connectors from the right side of the Main PCB 3 Remove the cable from the Control Panel PCB 4 Loosen the 2 screws on terminal block and remove wires from the Bimetal Switch Sensor Fixing Mat 5 Remove the 4 screws that hold the Main PCB to the Metal Bottom Plate 6 Place new Main PCB and secure it with the 4 screws 7 Reconnect the wires from the sensor and the connectors to the right ...

Page 29: ...below the Mat 4 Loosen the 2 screws on Mat terminal block and remove the wires from sensor 5 Place new Mat and secure down with the 2 screws 6 Attach wires from Bimetal Switch Sensor to the terminal block on Main PCB and tighten the screws 7 Replace the wire connectors to the Main PCB 8 Close and secure with a screw the wire holder on the left side of the Main PCB 9 Replace Roller Assembly DO THIS...

Page 30: ...Proteus A3 125 Technical Service Manual 28 Wiring Diagram Fan Motor To Control PCB Black Black Black Black Blue Black Blue Black Black Green Black Brown Brown Black Gray Gray Red Red Black White Black Black Black Black ...

Page 31: ...1789 Norwood Avenue Itasca IL 60143 998 telephone 630 893 1600 fax 630 893 7527 1 800 955 3344 ...

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