Royal Sovereign RSL-2702S, Service Manual

Page 1: ...Roll Laminator Service Manual MODEL RSL 2702S RSL 382S 451 8 24B 9L Nonhyeon dong Namdong Ku Incheon city KOREA TEL 032 822 0414 FAX 032 820 7105 A S 080 262 8464 www royalsovereign com ...

Page 2: ...y 2 1 Rollers Not Heating 2 2 Rollers Over Heating 2 3 Rollers Not Running 2 4 No Main Power Table of Content 1 Safety Precautions 2 Troubleshooting 3 Replacing Parts 3 1 Right Cover 3 2 Left Cover 3 3 Rear Cover 3 4 Main PCB 3 5 Sub PCB 3 6 Heaters 3 7 Cross Cutter 4 Adjustments 5 Parts List 6 Exploded Drawings 7 Wire Diagram 8 Backup ...

Page 3: ...4 Keep flammable and wet objects away from the machine 5 Place machine on a level surface 6 Avoid excessive sunlight humidity and extreme temperatures 7 Ensure the unit is turned off cooled and unplugged from the outlet prior to moving and or repairing 8 Keep out of reach of children 9 Only Royal Sovereign authorized maintenance and service technicians should make repairs 10 Do not attempt to lami...

Page 4: ...ot connected to the main PCB 3 Blown burnt upper and or lower wire fuse T Fuse 4 Defective Bi Metal 5 Defective heater 6 Defective Main PCB 1 Improper laminating mode a Ensure that the laminating mode is in the Hot mode not the Cold mode Press C HOT button on the control panel to change the mode 2 Heating wire is not connected to the main PCB a Connect the upper and lower heating wires to the main...

Page 5: ...t hand side 4 Defective Bi Metal a Replace the Bi Metal 5 Defective heater a Using the multi meter test the continuity of the heater If it fails replace the heater b Physically examine the heater assembly for breakage 3 Multi meter Broken WIRE LO T FUSE WIRE UP T FUSE BIMETAL R 145 BIMETAL L 130 ...

Page 6: ... lower and upper heat sensors are reversed on the main PCB a Reverse the heat sensors a Replace the T Fuse wire located on the left hand side 2 Defective T Fuse wire 4 4 Defective main PCB MEASURES 6 Defective Main PCB CAUSES 2 Defective T Fuse wire 3 Defective heater Connector Wire Sensor WIRE LO T FUSE WIRE UP T FUSE ...

Page 7: ...r to the unit 2 Emergency switch is engaged 3 Opened safety cover 4 Opened Front Table Switch 5 Film is jammed on the rollers 6 Disconnected motor wire 7 Blown motor fuse 8 Defective main motor 9 Defective main PCB 1 No power to the unit a Make sure the power plug is connected to the proper source of outlet 220V 15Amp single phase 2 Emergency switch is engaged 5 4 Defective Main PCB CAUSES MEASURE...

Page 8: ...ty cover it engages the safety cover switch 4 Opened Front Table Switch a Properly position the front table to engage the switch 5 Film is jammed on the rollers a Un jam the film using a combination of the pressure lever and reverse button 6 Disconnected motor wire a Check the motor wire connection with PCB 6 Switch is engaged Wire motor ...

Page 9: ... Power 1 No electricity 2 Blown main fuse 3 Disconnected main power wires 4 Defective transformer 1 No Electricity a Double check to insure that you have electricity from your outlet b Check the circuit breaker c Double check that source of power is 220V 15Amp and single phase 2 Blown main fuse a Replace the main fuse located above the main power switch CAUSES MEASURES 7 Motor Fuse ...

Page 10: ...3 Disconnected main power wires a Check that the main power wires are properly connected 4 Transformer is defective a Replace the transformer 8 10 Main Fuse Main Power Wires Transformer ...

Page 11: ...roblem Angled waves on one side of the output Cause Insufficient rear left or right side roller pressure Measure Tighten the rear left or right side roller pressure Problem Straight waves in the output Cause Excessive heat at the nip rollers Measure Lower the roller temperature Problem Wake waves Cause Insufficient heat at the nip rollers Measure Raise the roller temperature Problem Curling Cause ...

Page 12: ...our cover screws using Phillips screw driver Figure 2 b Pull out the male control panel connector from the Sub PCB Figure 3 c Loosen two screws from Sub PCB installed on to new Right Cover Figure 4 d Follow the reverse order to assemble the Right Cover back 3 2 Replacing the Left Cover a Replace the Left Cover by loosening four Left Cover screws 3 Replacing Parts 10 Figure 1 Figure 2 Figure 3 Figu...

Page 13: ...om 6 white plastic holders Figure 7 c Replace the board with new PCB and connect all the wires 3 5 Replacing the Sub PCB a Refer to Replacing Right Cover 3 6 Replacing the Heaters Note Cotton or surgical gloves are recommended while handling the heater assembly a Disassemble Right and Left Covers Refer to Replacing Right Cover and Replacing Left Cover b Take out the heater brackets on each side by...

Page 14: ...od in gently b Use an air blower to blow out the broken pieces of heating rod Please ensure that no one is standing on the other side 3 7 Replacing the Cross Cutter a Disassemble the nut from the Frame Cutter b Unfasten the spring from the cutter c Change the Cutter d Assemble the Cutter by reversing the above steps 12 Figure 11 ...

Page 15: ...djust the roller pressure 5 spots as shown on Figure B C Front roller should be 5 6 and back rollers should be 6 8 2 Checking for over all tension 3 Pressure mark checking Heat Line stop the machine for 30 seconds to 4 Adjustments CAUSES MEASURES C W Tighten C C W Lossen C W Increase pressure C C W Decrease pressure 1 Using Push Pull Scale measure create a heat line Then check to see if you have t...

Page 16: ...14 4 Laminating Test Laminate samples with different thickness of substrates 5 Check above steps 2 through 4 with 3mil 5mil films Figure C ...

Page 17: ...2 021LR4001A LIMIT SWITCH COVER 23 023LR3005A BUTTON FUNC 24 023LR4002A KNOB BOLT GUIDE 25 023LR4004A KNOB TENSION 26 023LR4007A KNOB LEVEL 27 026LR4006A FOOT 28 032LR3002A SHEET FUNC 29 111LR4004A BOLT CORE 30 111LR4006A BOLT GUIDE 31 111LR4018A SCREW H 32 112004001D NUT 33 120LR3004G SHAFT FILM L 34 120LR3023A SHAFT CAM 35 120LR4008A SHAFT TABLE 36 120LR4014A SHAFT TAKE UP 37 12200X005A BEARING ...

Page 18: ...R4001A HOLDER SHAFT FILM 76 140LR4021A HOLDER SHAFT T 77 141LP4018A BRACKET T FUSE 78 141LR3017A PLATE PRESSURE L 79 141LR3018A PLATE PRESSURE R 80 141LR4005A PLATE SHAFT FILM 81 141LR4020A BRACKET HEATER LO R 82 141LR4035A PLATE DU BUSH 83 141LR4040A PLATE SLIP 84 141LR4041A BRACKET FAN 85 141LR4043A FRONT TABLE SAFETY LEVER 86 141LR4054A BRACKET LIMIT SWITCH 87 141LR4059A BRACKET SENSOR 88 141LR...

Page 19: ... 381LR4030D WIRE UP HEATER1 EU 117 381LR4043A WIRE SAFETY S W 118 381LR4044A WIRE MAIN 119 381LR4052A WIRE MOTOR 120 381LR4054A WIRE LO HEATER2 EU 121 381LR4055A WIRE UP HEATER2 EU 122 381LR4084A WIRE T FUSE UP 123 381LR4091A WIRE LO HEATER1 EU 124 381LR4092A WIRE T FUSE LO 125 443LR4001A L WRENCH 126 ASMLR1339A ASM AUTO GRIP FILM CORE 2 126 1 ASMLR1339B ASM AUTO GRIP FILM CORE3 127 KPS03012D2 KEY...

Page 20: ...2 021LR4001A LIMIT SWITCH COVER 23 023LR3005A BUTTON FUNC 24 023LR4002A KNOB BOLT GUIDE 25 023LR4004A KNOB TENSION 26 023LR4010A KNOB LEVEL 27 026LR4006A FOOT 28 032LR3002A SHEET FUNC 29 111LR4004A BOLT CORE 30 111LR4006A BOLT GUIDE 31 111LR4018A SCREW H 32 112004001D NUT 33 120LR3004E SHAFT FILM L 34 120LR3031B SHAFT CAM 35 120LR4008A SHAFT TABLE 36 120LR4014C SHAFT TAKE UP 37 12200X005A BEARING ...

Page 21: ...ACKET T FUSE 78 141LR3017A PLATE PRESSURE L 79 141LR3018A PLATE PRESSURE R 80 141LR4005A PLATE SHAFT FILM 81 141LR4020A BRACKET HEATER LO R 82 141LR4035A PLATE DU BUSH 83 141LR4040A PLATE SLIP 85 141LR4043A FRONT TABLE SAFETY LEVER 86 141LR4054A BRACKET LIMIT SWITCH 87 141LR4059A BRACKET SENSOR 88 141LR4060A PLATE PRESSURE LAMI 89 141LR4061A PLATE PRESSURE PULL 90 141LR4081A BRACKET HEATER LO L 91...

Page 22: ... HEATER2 EU 122 381LR4084A WIRE T FUSE UP 123 381LR4091A WIRE LO HEATER1 EU 124 381LR4092B WIRE T FUSE LO 125 443LR4001A L WRENCH 126 ASMLR1339A ASM AUTO GRIP FILM CORE 2 126 1 ASMLR1339B ASM AUTO GRIP FILM CORE3 127 KPS03012D2 KEY PLAIN 128 KPS05010D2 KEY PLAIN 129 RC001200C8 SNAP RING 130 RE001000C8 E RING 131 RIV05018E8 RIVET 132 SKE04010D2 SET SCREW 132 1 SKE05006D2 SET SCREW 132 2 SKE05010D2 ...

Page 23: ...Frame L Frame R Frame Roller and Other View Wire Front Table Film Shaft and Control PCB 6 Explode View 21 Explode View ...

Page 24: ...001A HOLDER SHAFT FILM 76 140LR4021A HOLDER SHAFT T 77 141LP4018A BRACKET T FUSE 78 141LR3017A PLATE PRESSURE L 79 141LR3018A PLATE PRESSURE R 80 141LR4005A PLATE SHAFT FILM 81 141LR4020A BRACKET HEATER LO R 82 141LR4035A PLATE DU BUSH 83 141LR4040A PLATE SLIP 84 141LR4041A BRACKET FAN 85 141LR4043A FRONT TABLE SAFETY LEVER 86 141LR4054A BRACKET LIMIT SWITCH 87 141LR4059A BRACKET SENSOR 88 141LR40...

Page 25: ...M 72 138LR4015A SPRING PRESSURE 77 141LP4018A BRACKET T FUSE 78 141LR3017A PLATE PRESSURE L 82 141LR4035A PLATE DU BUSH 86 141LR4054A BRACKET LIMIT SWITCH 88 141LR4060A PLATE PRESSURE LAMI 89 141LR4061A PLATE PRESSURE PULL 90 141LR4081A BRACKET HEATER LO L 91 141LR4087A BRACKET HEATER UP 92 143LR3001A SUPPORTER SHAFT 97 147LR4013A STOPPER HEATER UP 108 363LP3001A BI METAL LO 111 36400X014B MICRO S...

Page 26: ...R4003A BUSH PULLEY 68 136LR4001C CHAIN 69 136LR4001G CHAIN 2 TAKE UP 71 138LR4012A SPRING TENSION 72 138LR4015A SPRING PRESSURE 73 138LR4018A SPRING LEVER 79 141LR3018A PLATE PRESSURE R 81 141LR4020A BRACKET HEATER LO R 83 141LR4040A PLATE SLIP 88 141LR4060A PLATE PRESSURE LAMI 89 141LR4061A PLATE PRESSURE PULL 91 141LR4087A BRACKET HEATER UP 93 144LR4001B CLAMPER LEVER 96 147LR4010A PAD TAKE UP 9...

Page 27: ... LAMI LO LEFT 50 122LR4047A BUSH ROLLER PULL LO 51 122LR4050A BUSH ROLLER LAMI LO RIGHT ASS Y 53 124LR4006A 1 CORE 62 133LR2021A ROLLER LAMI LO 63 133LR2021B ROLLER LAMI UP 64 133LR2022A ROLLER PULL LO 65 133LR2022B ROLLER PULL UP 70 138LR4001A SPRING CUTTER CROSS 74 140LR3001A HOLDER CUTTER C 75 140LR4001A HOLDER SHAFT FILM 76 140LR4021A HOLDER SHAFT T 80 141LR4005A PLATE SHAFT FILM 84 141LR4041A...

Page 28: ...ER S W 115 381LR4020B WIRE FUSE EU 116 381LR4030D WIRE UP HEATER1 EU 117 381LR4043A WIRE SAFETY S W 118 381LR4044A WIRE MAIN 119 381LR4052A WIRE MOTOR 120 381LR4054A WIRE LO HEATER2 EU 121 381LR4055A WIRE UP HEATER2 EU 122 381LR4084A WIRE T FUSE UP 123 381LR4091A WIRE LO HEATER1 EU 125 443LR4001A L WRENCH 126 ASMLR1339A ASM AUTO GRIP FILM CORE 2 126 1 ASMLR1339B ASM AUTO GRIP FILM CORE3 131 RIV050...

Page 29: ...N 72 138LR4015A SPRING PRESSURE 73 138LR4018A SPRING LEVER 74 140LR3001A HOLDER CUTTER C 75 140LR4001A HOLDER SHAFT FILM 76 140LR4021A HOLDER SHAFT T 77 141LP4018A BRACKET T FUSE 78 141LR3017A PLATE PRESSURE L 79 141LR3018A PLATE PRESSURE R 80 141LR4005A PLATE SHAFT FILM 81 141LR4020A BRACKET HEATER LO R 82 141LR4035A PLATE DU BUSH 83 141LR4040A PLATE SLIP 85 141LR4043A FRONT TABLE SAFETY LEVER 86...

Page 30: ... 72 138LR4015A SPRING PRESSURE 77 141LP4018A BRACKET T FUSE 78 141LR3017A PLATE PRESSURE L 82 141LR4035A PLATE DU BUSH 86 141LR4054A BRACKET LIMIT SWITCH 88 141LR4060A PLATE PRESSURE LAMI 89 141LR4061A PLATE PRESSURE PULL 90 141LR4081A BRACKET HEATER LO L 91 141LR4087A BRACKET HEATER UP 92 143LR3001A SUPPORTER SHAFT 97 147LR4013A STOPPER HEATER UP 108 363LP4013A BI METAL UP 111 36400X014B MICRO S ...

Page 31: ...CHAIN 67 134LR4003A BUSH PULLEY 68 136LR4001C CHAIN 69 136LR4001G CHAIN 2 TAKE UP 71 138LR4012A SPRING TENSION 72 138LR4015A SPRING PRESSURE 73 138LR4018A SPRING LEVER 79 141LR3018A PLATE PRESSURE R 81 141LR4020A BRACKET HEATER LO R 83 141LR4040A PLATE SLIP 88 141LR4060A PLATE PRESSURE LAMI 89 141LR4061A PLATE PRESSURE PULL 91 141LR4087A BRACKET HEATER UP 93 144LR4001B CLAMPER LEVER 96 147LR4010A ...

Page 32: ...034A DU BUSH 46 12200X040A DU BUSH 48 122LR4026A BUSH ROLLER PULL UP 49 122LR4042A BUSH ROLLER LAMI LO LEFT 50 122LR4047A BUSH ROLLER PULL LO 51 122LR4050A BUSH ROLLER LAMI LO RIGHT ASS Y 53 124LR4006A 1 CORE 62 133LR3001A ROLLER LAMI 64 133LR3002A ROLLER PULL 70 138LR4001A SPRING CUTTER CROSS 74 140LR3001A HOLDER CUTTER C 75 140LR4001A HOLDER SHAFT FILM 76 140LR4021A HOLDER SHAFT T 80 141LR4005A ...

Page 33: ... FUSE EU 116 381LR4030D WIRE UP HEATER1 EU 118 381LR4044B WIRE MAIN 119 381LR4052A WIRE MOTOR 120 381LR4054A WIRE LO HEATER2 EU 121 381LR4055A WIRE UP HEATER2 EU 122 381LR4084A WIRE T FUSE UP 123 381LR4091A WIRE LO HEATER1 EU 125 443LR4001A L WRENCH 126 ASMLR1339A ASM AUTO GRIP FILM CORE 2 126 1 ASMLR1339B ASM AUTO GRIP FILM CORE3 131 RIV05018E8 RIVET 132 SKE04010D2 SET SCREW 132 1 SKE05006D2 SET ...

Page 34: ...7 RSL 2702S RSL 382S Wire Diagram 32 ...

Page 35: ...1 Wire Main 6 Wire Up Heater 2 Wire Sensor Up 7 Wire Fan 2EA 3 Wire Sensor Low 8 Wire Power Transformer In 4 Wire Power 9 Motor wires 5 Wire Low Heater 10 Wires Power Transformer Output 33 Connect part ...

Page 36: ... SUB PCB and Frame R Heater Layout 34 SUB PCB Wire Bimetal Wire Up Heater Wire Lo Heater Bimetal 145 Wire Up Sensor Power Cord Fuse Main Power cord Wire power Wire Fuse Motor ...

Page 37: ...35 MICRO SWITCH and Frame L Heater Layout Wire F Fuse 133 Bimetal 130 Wire F Fuse 133 Safety Cover Micro S W Front Table Micro S W Wire Bimetal Wire Motor Wire Safety S W ...