Fellowes Proteus A3/125 Operating manual

Technical Service Manual
Proteus A3/125
Heavy Duty Laminator
September 2011

Table of Contents
Introduction . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . 1
Control Panel. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . 2
LED Status Display .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. 2
Temperature Adjustment and Function Controls. .. . .. . .. . .. . .. . .. . .. . .. . .. 2
Speed and Motor Controls .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. 3
Safety . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . 3
General Maintenance . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . 4
External Cleaning. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. 4
Internal Cleaning.. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. 4
Inspection .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. 4
Troubleshooting . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . 4
Lamination Problems . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. 5
Electrical Problems .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. 5
Tools .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . 6
Housing Assemblies .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . 6
Remove Housing Cover. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. 7
Remove Rubber Foot . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. 7
Replace Control PCB . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. 8
Mechanical Assemblies .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . 9
Remove Roller Assembly. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. 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
Replace Transformer . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . 21
Remove/Replace Motor . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . 23
Remove/Replace Motor Gear with Wrench Bolt . .. . .. . .. . .. . .. . .. . .. . .. . . 24
Remove/Replace Fan . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . 25
Replace Bridge Diode . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . 26
Remove/Replace Main PCB . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . 26
Replace Bemetal Switch/Sensor and Fixing Mat Set.. . .. . .. . .. . .. . .. . .. . . 27
Wiring Diagram. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . 28

Proteus A3/125 Technical Service Manual Revised 09.15.11 1
Introduction
This Technical Service Manual contains the service and repair
procedures for Fellowes Proteus A3/125 Heavy Duty Laminator. The
manual provides maintenance procedures, a list of required tools,
troubleshooting suggestions, and a wiring diagram.
Use the troubleshooting information to help identify a specic
problem. Then turn to the appropriate section in the manual for
instructions.
Follow the service procedures carefully. Always note the location,
number, color, and position of parts and wires before removing them
so that they can be reassembled correctly. If there are no specic
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 0.008" (2mm). For a pouch, the minumum
thickness is 3 mils (75 microns) per side and maximum thickeness
is 10 mils (250 microns) or 20 mils (500 microns) total thickness for
2 sides.
The Proteus A3 requires a warm-up time of approximately 3 minutes
and a cool down time of 30-60 minutes. The laminator has six
processing speeds up to 37" (95 cm) per minute.

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Control Panel
The control panel is located on the right side of the laminator. The
displays and controls are 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

Proteus A3/125 Technical Service Manual Revised 09.15.11 3
Speed and Motor Controls
DN/UP - Adjusts the roller temperature to
match the thickness of laminating stock
MEAS - Actual temperature of rollers
CARRI - Selects carrier setting (100oC
and motor speed 2) for laminatiing
pouches
PREHT - Select standby setting (80oC
and motor speed 2)
MOUNT - Selects mount board setting
(130oC and motor speed 1), for
laminating hard board more than 1mm
thickness
COLD - Selects no heat lamination
HOT - Selects normal setting (90oC and
motor speed for hot pouch lms)
Safety
When servicing the Proteus A3, observe the following safety
precautions:
Never put a hand, ngers, or foreign objects into the entry
slot.
Keep all loose articles of clothing, ties, jewelry, long hair,
or other loose objects away from the paper entry slot and
mechanism.
Always turn off and unplug the power cord at the wall outlet
before doing any work on the laminator.
Use only Fellowes-approved replacement parts.

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General Maintenance
The Proteus A3 is designed to perform consistently with a minimum
amount of maintenance. This section contains recommendations for
external and internal cleaning and inspection.
External Cleaning
Clean the exterior of the laminator with a soft cloth. Moisten the cloth
with warm water. Do not use ammable synthetic oil, petroleum-
based products, or aerosol lubricants of any kind. Do not use
chemical cleaners, solvents, or aerosol sprays to clean the exterior of
the laminator.
Internal Cleaning
The laminator does not require periodic internal cleaning. However,
when it is being serviced, perform the following maintenance 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 other
problems you notice. Correct any defects and test the laminator
before returning it to the customer.
Troubleshooting
Troubleshooting a laminator begins with checking the machine for
possible faults, such as:
Pouch jams
Lamination quality issues
Electrical problems
Items to be laminated are placed either in a laminating pouch or
between plastic laminating sheets and fed into the pouch entry slot.
The pouch travesl a straight path over the rollers and exits at the rear
of the laminator.

Proteus A3/125 Technical Service Manual Revised 09.15.11 5
If a laminator is pushed beyond its rated capacity, the quality of the
lamination may not be acceptable, even if the material is able to
move through the machine. If a jam occurs, the rollers or transport
mechanism may be defective. Press the Reverse button on the
operator panel to attempt to clear the jam.
WARNING!
Do not pull the pouch in an effort to clear a jam. This may
damage the machine.
Lamination Problems
Identify the type of lamination problem that is occurring. For each
instance, try the recommended solution.
Cloudy (entire lamination) - the temperature may be too low
or the speed may be too high. Reduce the speed and try
again. If the problem persists, increase the temperature in
increments 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 reduced.
Spotted - the rollers may be dirty. Pass the cleaning sheet
through the rollers. If needed, the rollers may be wiped with
mineral spirits.
Open on edges - the pouch may be too wide. Make sure
the contents are at least 1/8" (3 mm) from the unsealed
edges of the pouch.
Note: When servicing, always test the lamination quality
before returning the machine to the customer.
Electrical Problems
The most common electrical problems result from loose wires or a
defective switch or PCB (PC Board). If the switch or PCB is defective,
the laminator may not run at all.

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Tools
Screwdrivers Phillips screwdrivers
Flathead screwdrivers
Pliers Long nose pliers
E-clip pliers
Wrenches/Sockets Allen wrenches
Socket wrenches
Nut drivers
Gauges Roller pressure gauge
Housing 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 PCB
PC Board and
Keypad
Housing
Cover
Bottom Metal
Plate

Proteus A3/125 Technical Service Manual Revised 09.15.11 7
Remove Housing Cover
1Remove the 4 screws that hold the housing cover to the
base.
2Carefully lift and turn the housing cover on its side.
3Disconnect the cable from the Control Panel PCB.
Remove Rubber Foot
1Turn the laminator over and place it face-down on a soft
surface to avoid damaging the cover housing
2Remove 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

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Replace Control PCB
1Place the Housing Cover face down on soft surface.
2Push in and down on the mounting tabs (one on each
side) on the Control PCB Fixing Panel.
3Pull out on mounting tabs to separate the Control PCB,
Keypad, and Fixing Panel.
4Push 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

Proteus A3/125 Technical Service Manual Revised 09.15.11 9
Mechanical Assemblies
This section has procedures to:
Remove Roller Assembly
Remove/Replace Hot Rollers (Red)
Remove/Replace Hot Rollers (Blue)
Remove/Replace Hot Rollers (Gray)
Remove Side Panels and Roller Press Side Panel
Covers
Remove Roller Electric Brush
Remove/Replace Metal Gears
Remove/Replace PVC Gears
Replace Roller Bushing
Remove Roller Assembly
1Remove the 4 acorn nuts from the Metal Bottom Plate
on the reverse side of the laminator.
2Remove the 4 screws that hold the Roller Assembly to
the Bottom Plate.
3Carefully lift and rotate the Roller Assembly and place it
on its end opposite the motor.
DO THIS FIRST
Remove Housing Covers
TOOLS
Phillips screwdriver

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4Remove the 2 screws that hold the power wires to the
assembly.
Note: Wires are connected only to blue and red rollers. No
wire is connected to the gray roller
Remove/Replace Hot Rollers (Red)
Caution: The Hot Rollers (Red) must be in the middle position.
1Remove the 2 screws each from the right and left Roller
Press Side Panel Covers.
2Carefully 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 pliers

Proteus A3/125 Technical Service Manual Revised 09.15.11 11
4 Remove the E-clip on the ends of each Roller.
Note: The upper red Roller has 2 bushings, 1 metal gear,
and 1 PVC Gear. The lower red Roller has 2 bushings and
1 PVC gear.
5Replace lower red Roller.
Note: Make sure the PVC gear is on the left end (away
from the motor) and that the at side of the Roller bushings
is facing up.
6Replace the upper red Roller.
Note: Make sure the PVC gear is on the left end (away
from the motor) and that the at side of the Roller bushings
is facing up.
7Replace the Side Panel Covers and secure with
2 screws each.

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DO THIS FIRST
Remove Housing Cover
TOOLS
Phillips screwdriver
E-clip pliers
Remove/Replace Hot Roller (Blue)
Caution: The Hot Roller (Blue) must be in the front position.
1Remove the 2 screws each from the right and left Roller
Press Side Panel Covers.
2Carefully remove Side Panel Covers.
Note: The Covers are spring loaded.
3Remove the upper red Hot Roller up and out.
4Lift the upper blue Hot Roller up and out, and then lift
the lower blue Roller.
5Remove 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.
6Replace lower blue Roller.
Note: Make sure the PVC gear is on the left end (away
from the motor) and that the at side of the Roller bushings
is facing up.

Proteus A3/125 Technical Service Manual Revised 09.15.11 13
DO THIS FIRST
Remove Housing Cover
TOOLS
Phillips screwdriver
E-clip pliers
7Replace the upper blue Roller.
Note: Make sure the PVC gear is on the left end (away
from the motor) and that the at side of the Roller bushings
is facing up.
8Replace the upper red Roller.
9Replace 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/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.
1Remove the 2 screws each from the right and left Roller
Press Side Panel Covers.
2Carefully remove Side Panel Covers.
Note: The Covers are spring loaded.
3Remove the upper red Hot Roller up and out.
4Lift the upper gray Cold Roller up and out, and then lift
the lower gray Roller.
5Remove the E-clip on the ends of each gray Roller.
Note: The upper gray Roller has 2 bushings and 1 PVC
gear. The lower gray Roller has 2 bushings, 1 metal gear,
and 1 PVC gear.

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6Replace lower gray Roller.
Note: Make sure the PVC gear is on the left end (away
from the motor) and that the at side of the Roller bushings
is facing up.
7Replace the upper gray Roller.
Note: Make sure the PVC gear is on the left end (away
from the motor) and that the at side of the Roller bushings
is facing up.
8Replace the upper red Roller.
9Replace 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
1Remove the 2 screws each from the right and left Roller
Press Side Panel Covers.
2Carefully remove Side Panel Covers.
Note: The Covers are spring loaded.
3Remove the Hot and Cold Rollers.
4Lift the upper gray Cold Roller up and out, and then lift
the lower gray Roller
DO THIS FIRST
Remove Housing Cover
TOOLS
Flathead screwdriver
Phillips screwdriver

Proteus A3/125 Technical Service Manual Revised 09.15.11 15
5Remove the 4 acorn nuts from the Metal Bottom Plate.
Remove the 4 screws each from the Side Panels.
6Remove the 2 screws that hold the power wires to the
assembly.
Note: Wires are connected only to blue and red rollers. No
wire is connected to the gray roller.
Remove Roller Electric Brush
1Remove the screw that holds the brush bracket to the
side panel.
2Lift the bracket straight up.
3Remove 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.
1Remove the 2 screws each from the right and left Roller
Press Side Panel Covers.
2Carefully remove Side Panel Covers.
Note: The Covers are spring loaded.
DO THIS FIRST
Remove Hot and Cold Rollers
TOOLS
Flathead screwdriver
Phillips screwdriver
DO THIS FIRST
Remove Hot and Cold Rollers
TOOLS
Flathead screwdriver
Phillips screwdriver

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3 Remove the roller with the damaged metal gear.
4 Remove the E-clip on the end of each Roller.
5Replace damaged Metal Gear.
Replace PVC Gears
Caution: The Hot Rollers must be in the middle position.
1Remove the 2 screws each from the right and left Roller
Press Side Panel Covers.
2Carefully 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.
5Replace damaged PVC Gear.
DO THIS FIRST
Remove Housing Cover
TOOLS
Flathead screwdriver
Phillips screwdriver
E-clip pliers

Proteus A3/125 Technical Service Manual Revised 09.15.11 17
Replace Roller Bushing
1Remove the Roller with damaged bushing.
2Remove 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

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18
Electrical Assemblies
This section provides information on repairing and replacing
the electrical components of the laminator. Since temperature
control during hot lamination is very important, it is critical that the
heating elements, sensors, and thermoswitches operate properly.
Several heat sensors and switches monitor the temperature when
the laminator is running. The sensors are located near the front
rollers which contain the heating elements 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 efcient 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 procedures to:
Replace Fuse
Remove/Replace Cord Socket
Remove/Replace Power Switch
Replace Noise Filter
Replace Transformer
Remove/Replace Motor
Remove/Replace Motor Gear with Wrench Bold
Replace Fan
Replace Bridge Diode
Replace Main PCB
Replace Control PCB
Replace Bimetal Switch/Sensor and Fixing Mat Set