H&H AI-002 User manual

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AI-002 Hot Air Sealing Machine
Operation Manual
is powered by
H&H Asia Group Limited

AI-002 operation manual
Issue 1 21.09.09 display version 13 . main controller version 69 . servo version 61 P. 1 of 59
Table of Content
> Precautions Regarding to Safety..........................................................................................3
> Name Plate...................................................................................................................................5
> Introduction.................................................................................................................................6
> Specifications.............................................................................................................................7
> Features .......................................................................................................................................8
> Identification of Components.................................................................................................9
>> Front View .........................................................................................................................9
>> Cutter Assembly............................................................................................................10
>> Heater Positioning Assembly (front)........................................................................10
>> Heater Positioning Assembly (rear) .........................................................................11
>> Touch Screen Control Panel & Pressure Adjustment Panel .............................12
> Principle of Seam Sealing.....................................................................................................13
> Preparation for Installation ...................................................................................................14
> Control Method.........................................................................................................................15
>> Touch Screen Control Panel ......................................................................................15
>> Foot Switch.....................................................................................................................15
>> Control Menu Navigation ............................................................................................16
>> Pressure Adjustment....................................................................................................19
> Start Up and Shut Down Procedures .................................................................................20
>> Start up Procedures......................................................................................................20
>> Shut down Procedures................................................................................................23
> Basic Operation .......................................................................................................................24
>> Procedures of Seam Sealing......................................................................................25
>> Tape Cutting....................................................................................................................25
>> Tape Loading..................................................................................................................26
>> Nozzle...............................................................................................................................27
> Advance Operation .................................................................................................................28
>> Personality 1...................................................................................................................29

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>> Advance Mode................................................................................................................30
>> Differential Speed..........................................................................................................31
>> Electronic Nozzle Position Adjustment...................................................................32
>> Memory ............................................................................................................................34
>> Individual Program for Start/ Middle/ End of Tape ...............................................35
>> Digital Tensioner............................................................................................................36
>> Alarm.................................................................................................................................37
> Maintenance..............................................................................................................................38
>> Preventative....................................................................................................................38
>> Procedures for Replacing Parts................................................................................39
> Trouble Shooting.....................................................................................................................41
Appendix A . Nozzle Air Flow Cross Reference Table.......................................................42
Appendix B . Penumatic Scheme...........................................................................................43
Appendix C . Wiring Scheme...................................................................................................44
Appendix D . Tape Start, Tape Middle, Tape End Parameters.........................................45
> Tape Start Program .........................................................................................................45
> Tape Middle Program......................................................................................................51
> Tape End Program...........................................................................................................56

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> Precautions Regarding to Safety
Please observe these safety tips for a safe, efficient, and injury free operation of your equipment. By
strictly following all instructions contained in this manual you will certainly obtain an excellent
performance from the use of this equipment for many years.

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> Precautions Regarding to Safety (cont.)

AI-002 operation manual
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> Name Plate

AI-002 operation manual
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> Introduction
Thank you for choosing AI-002 hot air sealing machine by H&H.
The hot air sealing machine described in this manual is one of the most sophisticated machines in the
market today. Built on pure digital platform and designed for the professional users, AI-002
incorporated many new features that makes seam sealing much easier than before. Operators are
recommended to have basic knowledge and skill in seam sealing operation before using this machine.
In order to fully understand how to use this machine properly, and avoid damage to both the machine
and operating personnel, please read this manual carefully and keep it safe for future reference.

AI-002 operation manual
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> Specifications
Model : AI-002
Voltage : AC 220 V
Frequency : 50/60 Hz
Power Consumption : 3600 W
Compressed Air : 0.4- 0.6 Mpa
Air Consumption : 100 L/min max
Sealing Speed : 1-28, 36–60 ft/min
Nozzle Temperature : 50 C –800 C
Nozzle Unit : 22.0 mm standard, other optional
Upper Roller Width : 25.4 mm
Lower Roller Width : 31.0 mm
Overall Dimensions : 1200 mm (L) x 660 mm (W) x 1800 mm (H)
Overall Weight : 130 kg
Note : due to continuous improvement, specifications are subjected to change without prior
notification

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> Features
Real time variable speed sealing for non-stop long seam, ideal for narrow tape running on curve
as well as improving waterproof on crossed seam.
Differential speed for top and bottom rollers, ideal for reducing stretch fabric puckering.
Electronic nozzle positioning adjustment by control panel entries, ensuring 100% repeatability.
“Remember” function to store multi-nozzle position to be recall at a later time.
Digital tape length counter, ideal for costing calculation.
Multi-function foot pedal for easy one-footed control operation.
Multi-lingual support for touch screen display interface.
Heat press emulator function to simulate the function of heat press machine

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> Identification of Components
>> Front View
1
3
4
5
6 7
8
2
9
10
1. tape spool
2. tape dispenser
3. heater
4. upper roller
5. lower roller
6. left foot pedal
7. right foot pedal
8. water filter assembly
9. power switch
10. emergency stop switch

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> Identification of Components (cont.)
>> Cutter Assembly
21 3
4
>> Heater Positioning Assembly (front)
5
6
1. presser roller
2. blow forward
3. tape cutter
4. tape feed blowing
5. heater holder
6. heater shroud

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> Identification of Components (cont.)
>> Heater Positioning Assembly (rear)
1
3
2
1. hot air deflector
2. temperature sensor
3. air nozzle

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> Identification of Components (cont.)
>> Touch Screen Control Panel & Pressure Adjustment Panel
1
3
4
25
6
7
8
1. touch screen control panel
2. digital nozzle pressure display
3. nozzle air pressure regulator
4. nip roller pressure regulator
5. digital nip roller pressure display
6. data lock
7. USB socket
8. heater power outlet

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> Principle of Seam Sealing
When seam tape is heated up, the adhesive on the tape is activated. This activated tape is applied on
the water proof coating or lamination of the fabric seam under pressure. When cooled, a strong bond
is formed between the tape and the seam. This bond is so strong that it will prevent pressurized water
from penetrating the sewn seam. As a result, a water proof seam is produced.
A hot air machine, like AI-002, produces hot air with precisely controlled temperature to directly heat
up the adhesive of seam tape. The heated tape and the fabric are feeding into two oppositely rotating
rollers under pressure called nip rollers. The linear speed of the nip rollers is called sealing speed.
During sealing, hot air is being blown out from the nozzle. The hot air that actually reaches the surface
of the tape is a mixture of hot air from the nozzle and surrounding air, hence the actual temperature
that appeared on the tape is somewhat lower than the nozzle temperature. The farther the distance
between the nozzle and the tape, the higher the percentage of surrounding air becomes. On the other
hand, a higher hot air flow rate will reduce the percentage of surrounding air causing the hot air
temperature appeared on the tape to be higher. So both the nozzle position and hot air flow rate are
very important factors.
So, the major factors that can affect the seam sealing are as follows:
Hot air temperature
Sealing speed
Nozzle air pressure
Air flow rate
Nozzle position
When a consistent product is required, the combination of the above factors have to be set precisely
as their effects towards a proper sealing are all interconnecting.

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> Preparation for Installation
Installation must be carried out by authorized personnel. Follow the steps below:
1. Position the machine on a flat surface and allow at least 50cm clearance on both sides as well as
the back side, this is essential for the hot air deflector to work properly and also to allow enough
room for carrying out necessary service and maintenance
2. Adjust the foot stand so that the machine is level and stable.
3. Cut loose all packing cable ties and materials in order to free up all machine movements.
4. Connect the power plug to a suitable outlet with at least 15A capacity.
5. Locate the air hose supplied with the machine. Connect one end to the inlet of the water filter at
the back side of the machine; connect the other end to a compressed air supply such as air
compressor or central air supply. Make sure the compressed air supply has at least 0.6 Mpa (6 bar)
of pressure and a flow rate of no less than 100L/min.
6. Install the tape dispenser assembly at the top of the machine and align the tape spool at right
angle to the width of the machine. (see diagram below)
Install tape
7. Install a roll of seam tape with the adhesive side facing the operator (refer to the section on tape
loading).
8. The machine is now ready for operation.

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> Control Method
>> Touch Screen Control Panel
Almost all settings and timing control of the machines can be input from the touch screen control
panel. Use you finger tip to touch the parameter to be modified. Switch to different pages to modify
other parameters (refer to section on control menu navigation). The screen has a protective cover
to prevent the surface from damage and scratch, however, avoid using excessive force when
touching the panel. You can also change the contrast of the display so as to obtain the best picture
when viewing at a different angle.
>> Foot Switch
There are 2 foot pedals for the machine. The design of these pedals is such that they can be
operated either individually or in combination to achieve a number of preset tasks by the
operator‟s feet only. As a result, the operator‟s hands are free to manipulate the processing fabric.
Left foot pedal
The left pedal is a multi function pedal. You can use it to raise the upper roller and start sealing .
To raise the upper roller - heel back the left foot pedal.
To start sealing - press forward.
Right foot pedal
The right pedal is a simple switch. It performs different function according to the timing.
During idle –jog function that makes the rollers rotate forward without the nozzle coming in.
During idle –cut function that cuts the tape if left pedal is in heel back position.
During sealing –cut function that cuts the tape

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> Control Method (cont.)
>> Control Menu Navigation
The AI-002 has many parameters that can be adjusted according to the operational situations.
These parameters are arranged in different menu pages on the touch screen control panel
according to their functionality. The structure of the menu page arrangement is represented in the
following diagram.
AI-002 Menu Structure
H&H
contact
information
software
information
language
main
tape start
tape middle
tape end
nozzle adjust
memory
write & read
personality 1
personality 2
statistics
heat press
tensioner
alarm
Operation Menu Group
Support Menu Group
tools

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> Control Method (cont.)
>> Control Menu Navigation (cont.)
The followings are typical menu pages, all of them have names at the top left corner for easy
identification. Right arrow buttons are for navigating in the operation menu group. Down arrow
buttons are for navigating in the support menu group. Please note that page „main‟ is the hub of
the menu network so only this page has navigation buttons for both operation and support menu
groups.
1
4
2
1
3
2
5

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1
4
6
5
1. page name
2. next page in the operation menu group
3. previous page in the operation menu group
4. next page in the support menu group
5. hot key to return to page “main”
6. previous page in the support menu group

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> Control Method (cont.)
>> Pressure Adjustment
To adjust corresponding pressure, pull out the adjusting knob by one notch, turn the knob
clockwise or anti-clockwise to increase or decrease the neede d pressure accordingly. When
finished, lock the air regulator pressure by pushing the adjusting knob toward the regulator.
Nip roller pressure regulator
Nozzle pressure regulator