Audion Elektro D 552 AVT User manual

Continuous Sealer
D 552 AVT
D 552 AVT ENG Rev.01
User manual
www.audion.com

2

'translation of the original instructions'
All rights reserved.
No part of this publication may be reproduced and/or published by means of print, photocopy,
or in any other way, without prior written permission from Audion Elektro BV.
Audion Elektro BV reserves the right to modify the machine and/or change the operating manual
without prior notice.
Audion Elektro BV is not liable for any damage caused by specifications deviating from the
standard version.
Although this operating manual was compiled with the utmost care, Audion Elektro BV does not
accept any liability for any mistakes it may contain and/or the consequences of any incorrect
interpretation of its contents.
Audion Elektro BV is not liable for any damage or problems resulting from the use of parts other
than original parts. If this operating manual does not provide instructions for certain repairs,
settings or maintenance, please contact your dealer or Audion Elektro BV.

Please read this operating
manual carefully before using
the sealer or carrying out
maintenance on it.
The sealer is part of the Audion
product range. We also provide:
- Impulse sealers.
- Heat sealers.
- Continuous sealers.
- Vacuum sealers.
- Vacuum chambers.
- Crimping machines.
- Validatable sealers.
- Form, fill and seal machines.
Since its inception in 1947,
Audion has gained a lot of
experience and expertise with a
wide variety of sealing and
packaging machines. Our
solutions for packaging
problems are unique. Our many
years of experience together
with our modern production,
assembly and testing methods
ensure that our packaging
machines meet the highest
quality standards. We can also
customise the machines
according to your specific
requirements.
Audion is the right supplier for
a packaging machine that is
geared to your requirements.
Continuous Sealer
D 552 AVT

Contents
4
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Machine type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Warranty conditions and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Symbols used in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2.1 Operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2.2 Maintenance personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3.2 What to do in case of fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3.3 Use for special applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 Safety provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5 Safety symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 Unpacking the sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 Placing the sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 Connecting the sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Adjusting the sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4.1 Adjusting the height of the sealing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4.2 Adjusting the horizontal position of the conveyor belt . . . . . . . . . . . . . . . . . . . 15
3.4.3 Adjusting the height of the conveyor belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 Description of the sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 Overview of the sealer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1 Preparing the sealer for production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1.1 Switching on the sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1.2 Setting the sealing temperature and speed. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1.3 Switching on the heating, the cooling and the blower . . . . . . . . . . . . . . . . . . . 21
5.1.4 Starting the sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.3 Stopping the sealer (STANDBY mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.4 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Continuous Sealer
D 552 AVT
Contents 5
5.4.1 Restarting after an emergency stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.5 Switching off the sealer completely. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.1.1 Daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.1.2 Weekly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.1.3 Annual maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.2 Switching off the sealer and opening the protective cover . . . . . . . . . . . . . . . . . . 29
7.3 Replacing the PTFE belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.4 Replacing the V belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.5 Adjusting the V belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.6 Replacing the heating elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.7 Adjusting the pressing force of the heating blocks. . . . . . . . . . . . . . . . . . . . . . . . 35
7.8 Adjusting the pressing force of the press rollers . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.9 Adjusting the pressing force of the cooling plates . . . . . . . . . . . . . . . . . . . . . . . . 36
7.10 Adjusting the pressing force of the after-press rollers. . . . . . . . . . . . . . . . . . . . . . 36
7.11 Adjusting the tension of the conveyor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8 Disposing of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.1 Directive 2002/96/EC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.2 Correct disposal for reuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Annex 1 Technical information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
A1.1 Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
A1.2 Technical information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Annex 2 Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Annex 3 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
A3.1 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
A3.2 Exploded views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Annex 4 Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
A4.1 Maintenance log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Annex 5 CE declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Introduction
6
1 Introduction
1.1 Manufacturer
The Continuous Sealer was manufactured by:
1.2 Machine type plate
The sealer has an EC mark. This means that the sealer meets the fundamental
health and safety requirements of the European Communities.
Audion Elektro BV
Hogeweyselaan 235
1382 JL Weesp
The Netherlands
Telephone: [phone]
Fax: [phone]
Email: [email protected]
Web: www.audion.com
Figure 1-1: Machine type plate of the Continuous Sealer

Continuous Sealer
D 552 AVT
Introduction 7
1.3 Warranty conditions and liability
Subject to the restrictions stated below, we provide a 12-month warranty
regarding the products delivered by us. This warranty is limited to manufacturing
defects and therefore does not cover any malfunctions caused by any form of
wear, or any part of the delivered product that is subject to wear.
•The warranty we provide for parts or accessories purchased from third parties
is limited to the warranty the third-party provides to us.
•If the other party, and/or any third parties engaged by them, makes unskilled
use of the product delivered, the warranty becomes void.
•The warranty is also void if the other party and/or any third parties engaged by
them carries out work and/or modifications on the delivered product.
•Any parts we replace in order to meet our warranty obligations become our
property.
•Should the other party not meet obligations resulting from the agreement
entered into between the parties in whole or in part or in a timely manner, we
are not obliged to provide warranty for as long as that situation continues.
We exclude all liability to the extent that the liability is not regulated by law. Our
liability will never exceed the total amount of the order in question.
Subject to the generally applicable legal rules of public order and good faith, we
are not obliged to pay compensation to the other party or any third party for
damages of any nature whatsoever, incurred directly or indirectly, including trading
loss, damage to movable or immovable property or persons.
In any case, we are not liable for any damage resulting from or caused by using
the delivered product or its unsuitability for the purpose for which the other party
purchased it.

Safety
8
2 Safety
2.1 Symbols used in this manual
The following symbols are used in this user manual:
A tip on how a task can be carried out more efficiently.
Instructions for carrying out a task in the correct manner.
Danger of injury to the user or damage to the sealer if the
instructions are not observed.

Continuous Sealer
D 552 AVT
Safety 9
2.2 User
The sealer should only be operated by authorised personnel.
Improper use of the sealer may lead to serious personal injury and
considerable material damage.
Keep bystanders at a distance. Do NOT allow unauthorised
personnel to operate the sealer.
2.2.1 Operating personnel
The company using the machine has organized a training to inform its operating
personnel of the potential risks of unskilled behaviour while carrying out their
tasks.
Installation, maintenance and repair require specialised knowledge,
which is why these tasks should only be performed by
maintenance personnel.
Observe the safety instructions in this user manual. Failure to
observe the safety instructions may cause unacceptable risks.
The operating personnel must be familiar with all chapters of this user manual with
the exception of ’Installation’ and ’Maintenance’. Always observe the following
safety instructions before using the sealer or carrying out any maintenance work.
2.2.2 Maintenance personnel
This personnel's professional training, knowledge and experience, and knowledge
of the manufacturer's terms enable them to carry out the assigned work and
immediately recognize any risks that may arise.
Observe the safety instructions in this user manual. Failure to
observe the safety instructions may cause unacceptable risks.
Maintenance personnel must be familiar with all chapters of this user manual.
Always observe the following safety instructions before using the sealer or
carrying out any maintenance work on it.

Safety
10
2.3 Safety instructions
The sealer meets the fundamental health and safety requirements of the European
Community. This means that the sealer can be operated and maintained safely if
all safety instructions are carefully observed. However, improper or careless use
can create dangerous situations.
Observe the safety instructions in this user manual. Always
remain alert to dangerous situations and avoid any improper or
careless use.
2.3.1 General safety instructions
Observe the following general safety instructions:
•Tie back long hair.
•Do not wear loose clothing or jewellery.
•Always wear the personal protective equipment (PPE) prescribed by the
company, such as safety shoes, gloves, and goggles.
Use the PPE required on the shop floor, such as safety shoes,
gloves and goggles and/or hearing protection, in particular when
carrying out maintenance work.
•Check the operation of the sealer every day.
•Keep your hands away from dangerous parts of the sealer.
•Always leave protective covers in place during production.
•Never bypass or deactivate any safety provisions.
•The sealer should never be operated or maintained by people who are under
the influence of alcohol, medication and/or drugs.
•Only use sealable material that is suitable for the sealer.
•The user is obliged to observe the normally applicable hygienic measures
•If you are in doubt about the correct functioning of the machine, switch it off
and consult the maintenance personnel.
•Both the user and the sealer must be supervised while the sealer is in use.

Continuous Sealer
D 552 AVT
Safety 11
•Do not switch the sealer back on until the malfunction has been repaired.
•Should any liquid or foreign object enter the machine, switch off the sealer
and immediately remove the plug from the wallsocket and have the sealer
checked by maintenance personnel before using it again.
•Should an unusual event occur, such as the development of smoke, remove
the plug from the socket immediately and have the sealer checked by
maintenance personnel before using it again.
•Remove the plug from the socket before carrying out any maintenance work.
•Never open the sealer's housing while it is connected to the mains power.
•Do not use any water, abrasive cleaning agents, chemical solvents or other
liquids when cleaning the sealer.
2.3.2 What to do in case of fire
NEVER use water to extinguish a fire. This may result in life-
threatening situations because the sealer may be live.
Should the sealer catch fire, never use water to extinguish the fire. Because the
machine is live, this may result in life-threatening situations. During use, you are
obliged to have a fire extinguisher within reach of the machine. The following
types of fire extinguishers are suitable to extinguish fires occurring to this
machine:
•Powder extinguisher.
•Foam extinguisher.
2.3.3 Use for special applications
If the machine is used in a specialised environment, the company
using the machine is responsible for making sure any specific
instructions that apply are observed.
•If the machine is used in a medically sterile environment or cleanroom, the
company using the machine is responsible for making sure any specific
instructions that apply there are observed.
•If the machine is used for the packaging of medical instruments, the company
using the machine is responsible for making sure any specific instructions that
apply are observed.
•If the machine is used for the packaging of food, the company using the
machine is responsible for making sure any specific instructions that apply are
observed.

Safety
12
2.4 Safety provisions
The sealer has the following safety provisions:
1. Safety covers.
-Electrical and mechanical parts in the housing are protected.
2. Metal parts are earthed.
-No dangerous voltage can develop between (external) metal parts and the
earth.
3. Fuse in 230 V circuit.
-If the voltage gets too high, the fuse will blow, cutting off the power sup-
ply.
4. Emergency stop button
-In case of a hazard, this will immediately and completely switch off the
sealer.
2.5 Safety symbols
The following safety symbols are applied to the Continuous Sealer:
•’Hot surfaces’.
On the front of the Continuous Sealer on the
cover. It may get hot because of the heating
elements.

Continuous Sealer
D 552 AVT
Installation 13
3 Installation
3.1 Unpacking the sealer
Check the following when unpacking the sealer:
1. Are all parts and accessories present?
-Sealer
-User manual
The sealer is packaged in environmentally friendly material that
can be disposed of as ordinary household waste.
Keep the crate and the packaging material so the sealer can be
safely transported, should such be necessary.
3.2 Placing the sealer
1. Place the sealer in the desired location.
2. Lock the castors by depressing the
brakes.

Installation
14
3.3 Connecting the sealer
1. Check whether the main switch is in the
’0’ position.
2. Put the plug in the socket.

Continuous Sealer
D 552 AVT
Installation 15
3.4 Adjusting the sealer
You can make the following adjustments:
•Height of sealing unit in relation to the conveyor belt; to adjust the length of
the bags.
•Horizontal distance between conveyor belt and sealing unit; to adjust the
position of the bags on the conveyor belt.
•Height of conveyor belt in relation to the floor; to adjust the working height.
3.4.1 Adjusting the height of the sealing unit
The height of the sealing unit in relation to the conveyor belt is adjusted as
follows:
3.4.2 Adjusting the horizontal position of the conveyor belt
The horizontal distance of the conveyor belt in relation to the sealing unit is
adjusted as follows:
1. Set the height of the sealing unit by
rotating the crank.
The top of the bag to be sealed
should be able to move freely along
the top of the infeed guide.
1. Loosen the four locking bolts a number
of turns.
2. Adjust the position of the conveyor belt
in relation to the sealing unit by shifting
the conveyor belt.
The position of the conveyor belt is
to be adjusted in such a way that
the bag to be sealed is in the centre
of the conveyor belt as far as
possible.
3. Tighten the locking bolts again.

Installation
16
3.4.3 Adjusting the height of the conveyor belt
The height of the conveyor belt is adjusted as follows:
1. Loosen the 2 mounting nuts at the back
of the conveyor-belt brackets.
2. Take the conveyor belt from the
frame.
Always make sure two people lift
the conveyor belt from the frame
together.
3. Position the conveyor belt on the
frame at the desired height.
The height of the conveyor belt is
to match the infeed and outfeed
belts.
Always make sure two people
position the conveyor belt on the
frame together.
4. Tighten the mounting nuts again.

Continuous Sealer
D 552 AVT
Description of the sealer 17
4 Description of the sealer
4.1 Function
The Continuous Sealer is a band sealer for the packaging of a wide variety of
products in larger quantities. The products are packaged in ready-to-use bags and
subsequently sealed. The sealer is suitable for the sealing of ready-to-use bags
made of polyethylene (PE), polypropylene (PP), thin PVC, and various laminates
with a thickness of between 20μm and 150μm.
Do not use the Continuous Sealer for any other applications.
The sealer is not suitable for the following applications:
•Use in a clean room environment.
•Use in a medical, sterile environment.
•Use in an explosive environment.
•Use of toxic, asphyxiant or irritating gases.
•Use of the machine in a dusty environment.
4.2 Overview of the sealer
Figure 4-1: Overview of the sealer
1
5
24
3

Description of the sealer
18
1. Housing
2. Control panel
3. Conveyor belt
4. Setting of distance and height of the conveyor belt in relation to the sealing
unit
5. Frame with castors.
The sealer comprises a frame with castors onto which a conveyor belt and housing
are mounted. The housing comprises the electrical and drive components; the
operating panel is mounted on top of the housing. During maintenance work, the
housing can be tilted to make the interior easily accessible.
The conveyor belt will transport the bags to be sealed along the heating blocks,
the press rollers, the cooling plates, and the after-press rollers that are positioned
inside the housing.
The height of the conveyor belt is adjustable to make it seamlessly match the
infeed and outfeed belts. Also, the vertical distance between the conveyor belt
and the housing is adjustable so that bags of different heights can be sealed, and
the horizontal position of the conveyor belt in relation to the sealing unit is
adjustable so that the bags are in the centre of the conveyor belt as far as possible.
4.3 Control panel
Figure 4-2: Control panel
1
3
2
59
4
6 7 8

Continuous Sealer
D 552 AVT
Description of the sealer 19
Coolrun mode
The coolrun mode prevents burning of the PTFE belts. After the machine has been
stopped, the heater is switched off; however, the blower and the motor will
continue to run. When the sealing temperature has dropped to below 80°C, the
sealer is switched to stand-by mode and the blower and the motor will also be
switched off.
1. Display Indicates the actual sealing temperature, speed or a
malfunction notification. While adjusting the values,
the set value will be shown.
2. Prog Press to change the settings menu of the sealer. An
led next to the button will indicate which setting can
be adjusted:
Temp, the sealing temperature.
Speed, the sealing speed.
Sync., synchronising the sealing speed and the speed
of the conveyor belt.
3. Up/down Press to increase or reduce a setting.
4. Emergency
stop button
In case of a hazard, this will immediately and com-
pletely switch off the sealer.
5. Start/stop Press to start or stop the sealer. An led above the but-
ton indicates whether the sealer is switched on or off.
When the actual sealing temperature upon switching
off is over 80°C, the sealer will first switch to Coolrun
mode.
6. Heat Press to switch the heating on or off. An led above the
button indicates whether the function is switched on
or off.
7. Fan Press to switch the blower on or off. An led above the
button indicates whether the function is switched on
or off.
8. Motor Press to switch the motor on or off. An led above the
button indicates whether the function is switched on
or off.
9. Main switch Press to switch the sealer on or off.