Ledco premier 4 series User manual

Page 1
LEDCO PREMIER 4 SERIES LAMINATOR
PROBLEM DIAGNOSTIC CHARTS
Procedure Skill
Problem Possible Cause Re air Procedure Number Level
Laminator will not No power Check power cord 1 *
heat up,heat switch does Check heat switch position 2 *
not illuminate (red) when Check heat control fuse 4 *
engaged Check for wires that are **
disconnected, broken or
shorting out
Heat switch failure Check heat switch 6 **
Heater failure Check heaters 7 **
Heat sensor failure Check heat sensor 8 ***
Heat control board Check specific heat control 12 ***
transformer failure board terminals
Heat control board Check heat control 13 ***
relay coil failure board heat sensor terminals
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Heat control board relay Check heat control board 14 ***
switch failure relay switch terminals
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Heat switch illuminates, Ribbon cable wires to Re-connect plastic wire **
but digital display does display disconnected, harness to the back of
not loose or broken digital display
Re-connect plastic wire 9 ***
harness to heat control
circuit board inside the
machine
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Digital display failure Replace digital display 10 **
___________________________________________________________________
Ribbon cable failure Replace ribbon cable 11 ***
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Heat switch does not Heat sensor wires Check heat sensor wires *
illuminate when disconnected or loose
engaged,digital display
shows three dashes
Heat sensor failure Replace heat sensor 1 **
Ribbon cable failure Replace ribbon cable 11 ***
Heat control board failure Check specific terminals 13,14 ***
at specific terminals on heat control board
Heat control board failure Replace heat control board 16 ***
Skill Level Index: * Basic,End-User ** Intermediate or Dealer *** Advanced or Servicing Dealer/Technician
( - - - )

Page 2
LEDCO PREMIER 4 SERIES LAMINATOR
PROBLEM DIAGNOSTIC CHARTS
Procedure Skill
Problem Possible Cause Re air Procedure Number Level
Laminator heat cannot Heat controls set to "C" Reset heat control for "F"per *
be controlled instructions in owners/
operators manual
Heat sensor failure Check heat sensor wires. **
Check heat sensor. 8 ***
Replace heat sensor/bullet
assembly 1 **
Heat control board failure Check specific heat control 13,14 ***
terminals
Laminating rollers do No power Check power cord. 1 *
not operate Check drive switch position. 17 *
Check drive motor fuse 18 *
Check switch wires. 19 *
Check drive switch 20 **
Check speed dial 21 **
potentiometer
Check drive motor control 2 **
Check drive motor 2 **
Drivetrain failure Check drive chain. 22 *
23 *
Check rubber roll gears 24 *
Replace drive motor control 26 ***
Replace drive motor 27 ***
for celcius instead of "F"
for Farenheit
Check drive sprokets.

Page 3
LEDCO PREMIER 4 SERIES LAMINATOR
PROBLEM DIAGNOSTIC CHARTS
Procedure Skill
Problem Possible Cause Re air Procedure Number Level
Skill Level Index: * Basic,End-User ** Intermediate or Dealer *** Advanced or Servicing Dealer/Technician
Laminating rollers Drivetrain failure Check drive chain. 22 *
operate intermittently, 23 *
sometimes with a Check rubber roll gears 24 *
clunking, skipping or Film "wrap-around" Clear minor "wrap-around" 28 *
grinding noise Clear "wrap-around" of 29 **
front laminating rolls
Clear "wrap-around" of 30 **
rear laminating rolls
Clear "wrap-around" by 31 ***
removing and cleaning or
replacing rolls
Drive motor gear failure Replace drive motor 27 ***
Cooling fans do not Check power cord. 1 *
operate Check fan switch position. 32 *
Check fan switch 33 **
Check cooling fans 34 **
Fan motor failure Replace fan motor(s) 3 ***
The lamination has Item being laminated has Smooth item on feed
wrinkles been folded, rolled, bent table as it is being
or wrinkled. laminated.
Laminating two pieces Only laminate items of the
of unequal thickness same thickness side by side.
side by side.
Thicker material causes This is normal. Trim off
wrinkles on each side. material with wrinkles.
Inadequate supply roll Add tension to take wrinkles
tension. out of film before it gets past
the heat shoes.
Check supply roll dog. 36 *
Check supply roll spring pin. 37 *
Improper rubber roll Check rubber roll dwell line. 38 *
pressure Adjust rubber rolls 39 **
Replace rubber rolls 40 ***
Skill Level Index: * Basic,End-User ** Intermediate or Dealer *** Advanced or Servicing Dealer/Technician
Check drive sprokets.

Page 4
LEDCO PREMIER 4 SERIES LAMINATOR
PROBLEM DIAGNOSTIC CHARTS
Procedure Skill
Problem Possible Cause Re air Procedure Number Level
The film does not Thicker documents Run at a higher temperature
adhere to the document absorb the heat. not to exceed 340 degrees
Thin (1. mil) films lose Run at higher temperature
heat from heat shoe to increase speed slightly
the roller nip.
Thicker films do not Reduce speed
absorb enough heat.
.
Film between heat shoe Run a few inches of film
and nip cool while idle. before inserting sheets to
be laminated.
Inkjet print still wet. Let inkjet prints dry at least
2 hours.
Incompatible Inkjet Test samples before
print media and inks. laminating many pieces.
Film shrinks as it Excessive supply roll Reduce supply roll tension.
passed over heat shoe. tension
Excessive heat. Reduce heat.
Laminated item has Excess adhesive is Run a few inches of film
"oily" spot near the created when machine before inserting sheets to
leading edge. left hot and idle for a be laminated.
few minutes.
Milky, hazy line appears Rollers not evenly heated. When warming up the
after initial warm-up machine, keep the rollers
moving slowly.
The machine squeals Dirty heat shoes. Clean heat shoes.
when laminating
Excessive heat. Reduce heat.
Excessive supply roll Reduce supply roll tension.
tension.
Coating on film Try different type or
different brand of film.

Page
LEDCO PREMIER 4 SERIES LAMINATOR
PROBLEM DIAGNOSTIC CHARTS
Procedure Skill
Problem Possible Cause Re air Procedure Number Level
Skill Level Index: * Basic,End-User ** Intermediate or Dealer *** Advanced or Servicing Dealer/Technician
Laminated item has Adhesive build-up or Clean the rollers.
pitted, irregular surface. dirt on rollers.
Cuts or other damage Replace rubber rolls. 40 ***
to the rubber rollers
General haziness or Not enough heat. Increase the temperature.
cloudiness in film
after lamination
Bubbles in the center Excessive laminating Adjust rubber rolls 39 **
of the web and/or film roll pressure
not sticking to center Worn rollers Check rubber roll dwell line. 38 *
Replace rubber rolls. 40 ***
Adjust rubber rolls 39 **
Skill Level Index: * Basic,End-User ** Intermediate or Dealer *** Advanced or Servicing Dealer/Technician

Page 6
LEDCO PREMIER 4 SERIES LAMINATOR
PROBLEM DIAGNOSTIC CHARTS
Procedure Skill
Problem Possible Cause Re air Procedure Number Level

PREMIER 4 SERIES LAMINATOR
REPAIR PROCEDURES
Page 6
1. Check ower cord.
a. Power cord must be securely inserted into the wall outlet (110v AC).
b. Power cord must be securely inserted into the receptical on the back of the laminator.
2. Check heat switch osition.
Heat switch must be in the up or "I" position as denoted by the label markings nest to switch.
3. Remove right or left lastic housing.
a. Disconnect the ower cord.
b. Remove the 11 screws from the plastic housing using a phillips head screw driver.
c. Remove the cam shaft handle using a 1/8" allen wrench (right side only)
d. Remove speed control knob using a small straight blade screwdriver (right side only)
e. Remove the plastic housing.
4. Check heat control fuse.
The heat switch will illuminate red when engaged, indicating power is getting to the system.
If the switch does not light up, check the heat control fuse as follows:
a. Remove the right plastic housing as described in 3 above.
b. Examine the 1. amp heat system fuse located to the right of the wiring terminal block
c. If the fuse appears discolored and the element inside
is broken, replace it with a new 1. amp fuse.
5. Check for heating wires that are disconnected, broken or shorting out.
a. Remove the right plastic housing as described in 3 above.
b. Examine all wires and connectors for the heat system.Use the wiring diagram included for reference
(1.) Power cord to terminal block
#14 Black wire from power cord to terminal block.
#14 White wire from power cord to terminal block.
(2.) Heat Switch
Check all wires and connections from back of heat switch to the terminal
block,fan switch and 1. amp fuse.
(3.) Heat Control Board Wires
Check the 4 wires and connections coming from the heat control board
(thru the side panel from inside the machine) to the terminal block and 1. amp fuse.
(4.) Heaters
Check 2 biege colored wires and connections from Bottom Heater Cartridge to terminal block,
and the 2 biege colored wires and connections from Top Heat Cartridge to the quick
disconnects, where they change to black and white wires,to the terminal block
( .) Digital Display
Check ribbon cable wires and plastic harness connector at the back of digital display
(6.) Heat Sensor Wires
Check 2 thin,black Heat Sensor wires and connectors coming from the top heat shoe to
the quick disconnects where they change to blue and yellow wires respectively.
c. If a wire is disconnected, re-connect exactly as shown in the wiring schematic.
6. Check heat switch.
a. Remove the right plastic housing as described in 3 above.
b. Engage the switch.
c. Check continuity of the switch with a multimeter.
(1.) Disconnect the two inner most terminals of the heat switch (# and # 6))
(2.) Place one probe on the # terminal and one probe on the # 6 terminal of the heat switch
d. If there is no continuity, replace the switch (Part #PRS311) and rewire
exactly as shown in the schematic.

PREMIER 4 SERIES LAMINATOR
REPAIR PROCEDURES
Page 7
7. Check heaters.
a. Remove the right plastic housing as described in 3 above.
b. Check continuity of the top heater with a multimeter by placing a probe on each wire lead of the top heater.
(disconnect them from the black and white wires first)
c. Check continuity of the bottom heater with a multimeter by placing a probe on
each of the wire leads of the bottom heater (disconnect from terminal block)
d. If there is no continuity, replace the heater (Part #PRH147) and rewire exactly as shown in the schematic.
8. Check heat sensor.
a. Remove the right plastic housing as described in 3 above.
b. Disconnect the two thin,black heat sensor wires (that come out of the top heat shoe) from where they
connect with the blue and yellow wires
c. Check the resistance of the heat sensor using a multimeter. The sensor should have an approximate
resistance of 1.089 at room temperature.
d. If the sensor has no resistance (or reads open line or circuit) replace the sensor (Part # PRC212S)
and rewire exactly as shown in the schematic.
9. Access heat control board,motor control board,drive motor,fan motors
and all interior wiring.
a. Remove both plastic housings as described in 3 above.
b. Place machine upside down on work bench
(1.) Remove the five self tapping screws that secure the bottom motor cover to the front motor cover,
using a phillips head screwdriver.
(2.) Remove the two flat head and two round head phillips screws that secure the bottom motor cover
to the right and left hand side panels.
(3.) Carefully pull back the bottom motor cover enough to gain access to the components and wiring
and fuse holder to completely remove the bottom motor cover.Make careful note of these
connections as to re-connect them correctly later.
c. If a wire is disconnected,re-connect exactly as shown in the wiring schematic.
10. Re lace digital dis lay.
a. Remove the right plastic housing as described in 3 above.
b. Gently disconnect the plastic wire harness and ribbon cable from its receptacle on the back of the
display by depressing the small tab on the harness.
c. Unscrew three plastic acorn nuts from back of display board to remove.
d. Install new display board in exact reverse sequence.
11. Re lace ribbon cable
a. Disconnect plastic wire harness and ribbon cable from the digital display as described
in 10 above.
b. Access heat control board as described in 9 above.
c. Remove and replace the ribbon cable from the heat control board in the same manner as
described in 10-b.
d. Re-assemble in exact reverse sequence.
within.NOTE:You may find it necessary to disconnect the leads to the power cord receptacle

PREMIER 4 SERIES LAMINATOR
REPAIR PROCEDURES
Page 8
12. Check the heat control board transformer.
a. Remove the right plastic housing as described in 3 above.
b. Access heat control board as described in 9 above.
c. Disconnect all wire leads from their respective terminals on the heat control board,make note of
their locations.
d. Check for proper resistance readings with a multi meter by placing the probes on terminals:
All readings at room temp.,if any of these terminal checks show an open (infinite) or closed
(no resistance) the heat control board has failed and should be replaced.
13. Check the heat control board relay coil.
a. Remove the right plastic housing as described in 3 above.
b. Access heat control board as described in 9 above.
c. Disconnect wire leads from terminals T10 and T11.
d. Check the resistance of the relay coil with a multimeter by placing probes on
If the reading shows an open or closed circuit,the board has failed and should be replaced.
14. Check heat control board relay switch.
a. Remove the right plastic housing as described in 3 above.
b. Access heat control board as described in 9 above.
c. Disconnect wire leads from terminals T6 and T7.
d. Check the resistance of the power switch with a multimeter by placing a probe on terminals T6 and T7.
e. With no power, there should be an open reading.
f. If you get a closed circuit reading with no power, the board has failed and should be replaced.
15. Re lace heat sensor / bullet assembly.
a. Remove both plastic housings as described in 3 above.
b. Disconnect top heater wires and heat sensor wires from their respective terminals.
c. Remove top heat shoe/threading guide/idler assembly.
(1.) Loosen 2 small thumbscrews that secure the heat shoes to the side panels near the feed tray.
(2.) Loosen and remove the two cap head screws and sleeves that secure the heat shoe through the
side panels near the center of the side panels.Use a 9/64 allen wrench.
(3.) Cut the small white wire tie that secures the heater and heat sensor wires to the side panel
(they are covered with black heat shrink tubing).
Carefully lift out the top heat shoe/threading guide/idler assembly to gain access to heat sensor/
bullet assembly.
(1.) Remove four flat head screws (and phenolic spacers) that secure the heat shoe to right and
left heat shoe brackets.
(2.) Use a /64 allen wrench to loosen the set screw that secures the heat sensor and bullet to the
inside of the heat shoe.This set screw is located in the center of the back of the heat shoe,
in line with the round head phillips screws that hold the rubber roll heater in place.
(3.) Extract the faulty heat sensor /bullet from the inside of the shoe and replace with new (part #'s
PRC212S and 428 -061.4).
Reassemble in exact reverse sequence and rewire exactly as shown in the schemetic.
_____________________________________________________________________
T4(common) and T1(208V) should read read approximately .910 k ohms.
T4 and T2(240V) should read approximately .76 k ohms.
T4 and T3 should read approximately .410 k ohms.
terminals T10 and T11.The resistance should read 32.9 k ohms.

PREMIER 4 SERIES LAMINATOR
REPAIR PROCEDURES
Page 9
16. Re lace heat control board.
a. Remove both plastic housings as described in 3 above.
b. Access heat control board as described in 9 above.
c. Disconnect all wire leads from their respective terminals on the heat control board,make note of
their locations.
d. Remove the heat control board from its 4 plastic stand-offs by gently depressing the very small
retaining tabs on the stand-off legs.
e. Replace with new heat control board (part # PRH130).
Reassemble in exact reverse sequence and rewire exactly as shown in the schemetic.
17. Check drive switch osition.
Engage the Forward/Reverse Jog switch to the upper "I", forward position. The drive motor should be on.
18. Check drive motor fuse
a. Gently pop out the spring loaded fuse holder and fuse from the rear of the machine next to the
power cord receptacle,using a small straight blade screwdriver.
b. Visually examine the 3/4 amp fuse (part # PRF141).
c. If the fuse appears discolored and the element inside is broken, replace it with a new 3/4 amp fuse.
Always replace fuses with exactly the same rated fuse.
19. Check switch wires.
a. Remove the right plastic housing as described in 3 above.
b. Examine all wires and connectors for the drive system.
(1.) Power cord to terminal block
#14 Black wire from power cord to terminal block.
#14 White wire from power cord to terminal block.
(2.) Forward/Reverse Jog switch
Check all six wire leads and connectors as they come out of the back of the switch to their
respective quick disconnects,and on to the side panel.
(3.) Speed Dial potentiometer
Check the grey and brown wires from the back of the potentiometer to their respective
quick disconnects,and on to the side panel.
If a wire is disconnected,re-connect exactly as shown in the wiring schematic.
20. Check the forward/reverse jog switch.
a. Remove the right plastic housing as described in 3 above.
b. Check continuity of the forward/reverse jog switch with a multimeter
(1.) Move the switch to the forward position.
(2.) Identfy the row of three terminals closest to you (marked 3,2,and 1 on the switch).
(3.) Place one probe on the middle (common) terminal, 2.
(4.) Place probe on the lower terminal, 3.
c. Check continuity of the reverse jog switch with a multimeter
(1.) Hold the switch to the reverse jog position.
(2.) Place one probe on the middle (common) terminal, 2.
(3.) Place one probe on the upper terminal, 1.
d. If there is no continuity on either switch element, replace the switch (Part #PRS312) and rewire
exactly as shown in the schematic.