P. Energy L150A Manual

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USER AND MAINTENANCE HANDBOOK
LAMINATOR L150A
SERIAL NUMBER:

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GENERAL INDEX
1. GENERAL INFORMATION
1.1. GENERAL INSTRUCTION
1.2. MACHINE SERIAL NUMBER
1.3. GENERAL DESCRIPTION OF MACHINE COMPONENTS
1.4. GENERAL DESCRIPTION OF LAMIANTION PROCESS
1.5. INTENDED USE OF THE MACHINE
1. . WARRANTY
2. SAFETY
2.1. INTRODUCTION
2.2. GENERALI GENERAL SAFETY RULES
2.3. MACHINE CONNECTIONS
2.4. GROUNDING SYSTEM
2.5. MACHINE SAFETY DEVICES
2. . IDENTIFICATION OF RESIDUAL RISK
3. INSTALLATION
3.1. INTRODUCTION
3.2. FONDATIONS
3.3. EQUIPMENT FOR LIFTING & TRANSPORTING
3.4. ELECTRICAL CONNECTION
3.5. PNEUMATIC CONNECTION
3. . HYDRAULIC CONNECTION
3.7. DESCRIPTION OF WORKING CYCLE AND ALLARMS MACHINE
3.7.1. DESCRIPTION OF PUSHBUTTONS OPERATOR PANNEL
3.7.2. DESCRIPTION OF TOUCH SCREEN PAGES
3.7.3. MACHINE START-UP
3.8. TROUBLESHOOTING
4. LAMINATION INSTRUCTION
5. MAINTENANCE
5.1. ORDINARY MAINTENANCE
5.1.2 REPLACEMENT MEMBRANE
5.2. EXTRAORDINARY MAINTENANCE
5.2.1. REPLACEMENT ELECTRICAL RESISTORS
5.2.2. REPLACEMENT THERMOCOUPLES
5.2.3. REPLACEMENT O-RING
6. MACHINE DISPOSAL
7. RECCOMENDED SPARE PARTS
8. MECHANICAL COMPONENT LIST
9. SUPPORTING DOCUMENTS
A. CE CERTIFICATE OF CONFORMITY
B. ELECTRICAL SCHEME
C. PNEUMATIC SCHEME
D. VACUUM PUMP MANUAL
E. INTERNAL TESTING REPORT

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1. GENERAL INFORMATION
1.1. GENERAL INSTRUCTION
• Questo This manual describes the correct way to use the laminator L150A for photovoltaic panels with maximum dimension
1500x1000mm, made and sold from this company:
P.ENERGY SRL
Via dell’artigianato, 12 – 35014 Fontaniva (PD) – ITALY
Phone: [phone]
Fax: [phone]
Web Site: www.penergy.it
e-mail: [email protected]
• THIS MANUAL IS PART OF THIS MACHINE AND CONTAIN ALL NECESSARY INFORMATION CONCERNING USE AND
MAINTENANCE.
• IF YOU DON’T PAY ATTENTION TO INSTRUCTION AND RACCOMANDATION OF THIS MANUAL THE GUARANTEE IS NOT
ACTIVE
• IT’S PERMITTED TO USE THE MACHINE ONLY TO WELL-TRAINED OPERATORS.
• THE OPERATOR HAS TO READ CAREFULLY THIS MANUAL BEFORE TO INSTALLATION AND START-UP.
• The Manufacturer reserves to suspend the production of some machine model, to modify characteristic and drawings
without obligation advice.

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1.2. SERIAL NUMBER
In order to identify the laminator it’s necessary to recognize the following specification data plate fixed on
side machine.
Data on CE identification plate
Example:

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1.3. GENERAL DESCRIPTION OF MACHINE COMPONENTS
The laminator is a machine controlled from an operator that laminate together all material introduced inside. Through a program is it possible to control the
parameters like temperature level, the vacuum and the working time.
The laminator is mainly composed of two parts: An aluminum plate is heated through a series of electric resistances or cooled through an hydraulic circuit
according to set up parameters and by an hermetic shifting cover.
The electrical cabinet is fixed in front of machine and inside the frame is positioned the pneumatic circuit, protected by sheet guard, included the vacuum pump
and hydraulic circuit.
On the back side there are the electrical, pneumatic, hydraulic feeding.
The area inside the cover is protected by two light barriers fixed on the corner of the aluminium plate .
The laminator is controlled by LCD keyboard supported through a mobile arm.
View of Laminator component
12
13
lamination chamber
1 2 3 4 5 7 8 9 10 11
left side sheet guard
15
1
18
19
Pos Description
1
Adjustable fe
et
2
left front side sheet guard
3
electrical cabinet
4
Lamiantor frame
5
Base machine
laminator cover
7
cover vacuum gauge
8
plate vacuum gauge
9
Light barrier mirror on the
right front side
10
Mobile arm of operator panel
on left front side
Pos Description
11
electrical pannel
12
Light barrier sender on right
front side
13
Light barrier mirror on the left
back side
15
Membrane frame
1
Membrane
18
heating plate
19
plate frame

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20
40
21
22
23
Back view without cover
24
25
2
27
28
29
30
31
32
33
34
Pos
Description
20
Column cover
21
inlet pneumatic feeding
22
hydraulic circuit outlet
23
inlet hydraulic circuit
24
upper bearing for ball bearing
screw
25
Siren
2
Blu lamp
2
7
Red Lamp
28
Green lamp
29
sectional guide
30
Slide
31
upper point limit switch
32
Cable carrier chain system
33
ball bearing nut
34
ball bearing screw
35
lower bearing connection of
ball bearing screw
3
cover el. motor
37
reduction gear of cov
er
electrical motor
38
pneumatic pression regulator
39
vacuum pump
40
Hook
35
3
37
38
39
LENGHT=19
00mm
WITH=2100mm
HIGHT=2200mm
WEIGHT=2000Kg

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1.4. GENERAL DESCRIPTION OF LAMINATION PROCESS
DESCRIPTION OF WORKING CYCLES:
1. PRESTART SETPOINT REACHED
The starting parameter are reached in automatic mode according to setting recipe and the end phase is diplayed by signal lamp
2. SANDWICH INTRODUCTION
Operator introduce in manual mode the sandwich
3. LAMINATION CYCLE
The automatic lamination cycle start when the operator push the two hand pushbutton and the cover move to the close position before the
beginning of lamination process.
Following inside the hermetic chamber between cover and plate the vacuum is reached in order to remove the air residue between the
sandwitch, after a membrane lower and exert uniform pressure over the panel.
Simultaneously a constant temperature is maintained for a programmed time in order to join the component
Next step is cooling the plate by an hydraulic circuit and to reset the pressure value inside the laminator chamber.
All parameter are edited by the operator panel
4. LAMINATED SANDWICH EXRACTION
At the end of recipe the cover move in automatic mode to the upper point and the laminated panel is removed.
PRESTART
SETPOINTS
REACHED
SANDWICH
INTRODUCTION
LAMINATION CYCLE
:
1. VACUUM
2. HEATING AND PRESSURE
3. COOLING
LAMINATED SANDWICH
EXTRACTION

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NOTE: In order to adjust the temperature inside the laminator chamber the heating plate is divided in areas with 3 heating resistor and 1
thermocouple probe per area.
The heating plate is even cooling by a dedicated circuit.
Follow the plate layout:
CIRCUIT ON HEATING PLATE
Coolin circuit in
Coolin circu
it out
Resistor
T
hermocouples

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1.5. INTENDED USE OF THE MACHINE
The
P.ENERGY L15
0A
laminator is designed only to be used to with maximum dimension panel
15
00
x1000mm
.
The maximum thickness is 40mm.
The P.ENERGY L150A laminator work with Standard/FAST/Ultra fast cure EVA
P. Energy suggest to work with the follow raw materials:
glass: LIPIK GLASS ULTRALIGHT
lamianted: TEDLAR CTE COVEME
cells: GINTECH 4’’,5’’, ’’
eva: STANDARD/FAST/ULTRAFAST CURE ETIMEX
the laminator in your possession has been designed such a way that’s operated by a single operator who shares the cycle of work and visions
successful.
The technical specifications such as: worked hours, Quantity of Production, and type of finished products are specified at the time of the bid.
1.6. ARRANTY
The warranty refers to the contractual terms agreed with the customer, in any case:
THE WARRANTY STOP IF:
• Manual instructions are not respected
• There will be modifications without authorization
• Programmed maintenance is not followed
• The machine will be used from a different purpose from that designed
• The machine will be done from not licensed people

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2. SAFETY
2.1. INTRODUCTION
It is forbidden to use the machine for reasons other than that describe above, and/or by person who are not suitably trained.
2.2. GENERAL SAFETY RULES:
1. Always keep clean and tidy the work area
2. Do not leave tools or spanners on the machine, or near to it. After any maintenance work or the replacement of accessories, check carefully, before
switching on the machine.
3. Always be sure that you are in a safe position with respect to the machine in a secure, well-balanced position.
4. Never leave the machine unsupervised
5. All the operations of normal or special maintenance carried out on the machine, as well as cleaning ad running the machine must only be undertaken
by trained personnel
. Any normal or special maintenance work must only take place with the machine stopped and electrical supply cut off, the pneumatic and hydraulic
plant must only be carried when the pressure has been released from the equipment
7. Before each work shift, ensure that the safety system operate correctly
8. The working place have to be protected from atmospheric conditions
2.3. MACHINE CONNECTIONS:
It is responsibility of the client to set up the electrical and pneumatic supply system of a suitable size to withstand small power surges of the laminator, see data
sheet present on the SUPPORTING DOCUMENTS
The electrical and pneumatic supply system to be connected to the plant must only be carried out by qualified personnel, and carried out according to general
regulations for electrical plant installation
2.4. GROUNDING SYSTEM
It is responsibility of the client must be connected to an efficient grounding system
2.5. MACHINE SAFETY SYSTEM
• MECHANICAL
a) Protective panel in painted sheet metal, protecting the electrical and pneumatic plant
b) Protective panel in painted sheet metal, protecting the danger area
c) The cover movement is controlled by a sensor maximum openness and a sensor minimal.
d) The access door to the electrical panel is fitted with a main switch for the main machine electrical power supply. This is of the type that can be
padlocked and is fitted with mechanical lock, which does not allow the electrical cabinet to be opened unless the switch is at the “0” position.
e) The speed of descent and ascent of the cover is sufficiently slow so that the operator has the time to evaluate the potential risk.
f) The laminator is designed to be used by a single operator to operate the movement of the cover must use the special command with two hands.
• ELECTRICAL
a) All perimeter of laminator is protected by an infrared barrier that blocking the cover movement in case of introductions.
b) The electrical circuit is protected by thermal-magnetic circuit breaker and fuse
• TOWER SIGNAL LAMP:
- Red lamp: danger
-Green lamp: fixed lamp =automatic cycle; Blinking lamp = pre-start conditions reached.
-Blue lamp: cooling circuit activated
• SIREN, it signals with an acoustic signal, the alarm presence ( fixed sound), and the cover movement ( Intermittent sound)
2.6. IDENTIFYING THE ZONES OF RESIDUAL RISK NEAR THE MACHINE
the area along the entire perimeter of the laminator to a width of 1 meter can be a source of hazard for the operator if the rules of behavior are not respected
and if the operator fails adequately monitor the working area

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3. INSTALLATION
3.1. INTRODUCTION
The laminator is delivered to the customer as agreed upon contract.
Before proceeding to the positioning of the machine, check the general status and the correspondence as described on the transport
document
IMPORTANT: FOR EVERY PROBLEM RISCONTRATO CONTACT IMMEDIATELY THE MANUFACTURER
3.2. FOUNDATIONS
The laminator must stand an a solid, well leveled floor.
The client must check load bearing capacity (especially if on raised floors), and that the fixing used for the foundation fixing bolts of good
quality.
3.3. EQUIPMENT FOR LIFTING AND TRASPORTING
It is the responsibility of the client to obtain all the equipment necessary for lifting and moving the laminator.
We recommend that the movement are make by a lift trucks, following this instructions.
a) Use a right lift truck has a load capacity suitable for the weight of the machine to be moved
b) The forks lift truck ‘s extensioned clamp must have the same length of the machine
c) Place the forklift truck ‘s extensioned clamp between the base and the Adjustable feet
d) Move the machine to the place of installation, taking care to fix the Mobile arm of operator panel
e) If the machine must work in line with other production plant, it is important to make sure it is positioned correctly in line with the
line
f) Check the level of the machine on the various sides
NOTE: The operations of lifting and moving the laminator must be carried only by allocated personnel who have been suitably trained in the
operations of lifting and moving the machine.

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3.1. ELECTRICAL CONNECTIONS
All electrical connections must be provided by trained personnel.
Electrical specification: The right values are showed on the CE laminator plate
Rated Power: The value is showed on the CE laminator plate
Feeder cable: The electrical connection with machine have to be done with a suitable cable (minimum cross section 4x mm
2
with a maximum
length of 20 mt)
Connecting place: - Connect the machine main switch to the power supply network through the cable gland behind the electric cabinet (see
the electric scheme).
In order to connect the machine it’s necessary to remove the side casing and the column cover.
3.2. PNEUMATIC CONNECTIONS
All pneumatic connections must be provided by trained personnel.
Min and Max working Pressure: The working pressure is reported on the pneumatic scheme (Pmax=8bar; Pworking bar)
Air consuming: 0l/min
Pipe type: Pneumatic connection must be done based on norm with a suitable pipe section
Connecting place: the connection is made through the rear side input by a prepared hole on the column cover, (see position n. 21 of laminator
components view)
3.3. HYDRAULIC CONNECTIONS
The Hydraulic connections must be provided by trained personnel.
Water consuming: 10 l/min ( only if cooling is used )
Note: the water temperature influence the cooling cycle, check that the temperature input is suitable to the working cycle
Pipe type: Hydraulic connection must be done based on norm with a suitable pipe section.
Connecting place: the connection is made through the rear side input by prepared connection, (see position n.r 22 and 23 of the view of
laminator components view)

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3.7. LAMINATOR START UP
BEFORE TURN ON THE LAMIANTOR IT’S NECCESARY TO KNO THE CONTROL PANEL :
IN THE FOLLO ORDER IT ILL BE DESCRIBED:
1- PUSH OPERATOR PANEL BUTTONS
2- TOUCH SCREEN PAGES
3- LAMINATOR START UP
3.7.1.- Description of push operator panel buttons:
LAMIANTOR IS CONTROLED BY A OPERATOR PANEL FASTEN TO A ADJASTUBLE ARM
Auxiliary
push button
This push button turn on the
auxiliary circuit after a emergency
stop or during the laminator turn
on
Touch screen panel
Emergency
push button; This push
button stop immediately the
machine and cut off power
Silent siren
Two hand p
ush b
utton
control of
laminator closing cover, It’s
necessary to push simultaneously
the two hand push buttons to
move the cover otherwise with
only one pushed the cover stop

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3.7.2-Touch screen Panel:
Touch screen allows to setup, monitor and edit the values of controller parameters, to monitor and manage alarms, manage recipes and
command directly the output.
- The display is used as input device for interacting with the display's field, removing the keyboard and the mouse.
-The numeric input data are edited according to following procedure:
1.Touch the input data field (after a keyboard touch will appear)
2.Edit the value by the keyboard touch
3.Confirm the value with the Enter button
4.The keyboard will disappears and the input value is stored in the PLC memory
HOMEPAGE TOUCHSCREEN
It’s automatic loaded at start up
In the bottom of screen there are the
“START”, “P.Energy details” and “About Machinery” pushbuttons that allow access to general information concerning
manufacturer and machine type.All pages have in common the same top menu bar that allow access to the laminator control pages
CYCLE
PUSHBUT
TON: This page contains all working parameters, as actual recipe step, plate temperature, upper and lower vacuum chamber valu
e. In
this page the operator starts the working cycle in automatic mode by the start cycle pushbutton. The cycle page contains a PLATE TEMPERATURE
submenu where it’s possible to monitor the actual plate temperature detected through the temperature probes in order to verify the temperature
uniformity and the possible breaking of resistance.
PARAMETER PUSHBUTTON: This page contains th
e machine parameters essential in working mode. Every parameters modification/adjustment should
be performed by very skilled technician.
MANUAL MODE PUSHBUTTON:
In this page it’s possible to command in manual mode all the laminator functionality and ver
ify the working status
. The
manual commands are free without restrictions and not associated with the working mode. It’s possible to test the follow laminator functionality:
1 Testing of vacuum circuit by the VACUUM COMAND submenu
2 Testing of heat resistance by setting temperature on HEAT. COMAND submenu
3 Opening/closing the cover in manual mode, enable/disable the cooling system, drain of water cooling circuit by the GENERAL COMAND submenu.
ALLARMS: This page contains details regarding the possible al
arms and the reset command
It shows the machine operating status: prestart, manual o automatic mode
Recipe: It contains all parameter concerning the working recipe used when the automatic cycle start
Stato:
???

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CYCLE PAGE
The cycle page is divided in two submenu:
COMMANDS AND TEMPERATURE PLATE
NEXT STEP:This pushbutton force to next recipe step
“CO
MMAND
”
PAGE
:
STEP N°:Info field where is showed the current recipe step
START CYCLE:Automatic start cycle pushbutton
Working parameter concerning th
e current recipe step.
Parameters are divided into two columns:
1- Real: it corresponds to measuring real value
2- Set: it correspond to the setpoint value expected to have reached
within a set window time. The operator can modify this value but
this modify work only in the actual recipe step and only for the
current lamination cycle. It’s not possible to save the new value in
the recipe.
Description of parameters that appears:
Time: time duration of recipe step
Vup: Upper chamber vacuum value
Vdw: Lower chamber vacuum value
Reset Safety:
reset the safety Beams, when the button is yellow
This monitoring page shows for each resistance the temperature graph
and the temperature plate settled in the recipe
“HEATING COMMANDS” PAGE

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PARAMETERS PAGE
Every parameters modification/adjustment should be performed by very skilled technician. It’s advisable to keep a backup copy of the manufacturer value.
The parameters page consists of 4 submenu:
PARAMETERS, VACUUM PARAMETER, TEMEPERATURE PARAMETERS, GENERAL
HOURS N°: N° working hours
CYCLE N°: N° lamination cycles done
ALLARM RAW: Alarms view
Linearization parameters regarding the upper/lower vacuum gauge by the follow
function: VacuumUP/DW = m * (Sensor Value) + q
Where "m" and "q" are set parameters
Time in seconds after which laminator stops the
cover opening. Changing this value you can modify the height of the cover when it’s
open.
Overrun Time in ms after closing cover point from limit switch. This extra time is
useful when the cover close without hermetic sealing and it’s necessary to manually
force down the cover.
Parameters regarding the vacuum pipeline
This page contains the main temperature parameters regarding the automatic cycle,
the maximum temperature limit of tolerance to pass to next recipe step and the
intervention threshold of cooling circuit
By pushing the button "Use cooling system" is enabled or not the hydraulic cooling
system.
This page includes the general parameters of setting panel (Language, brightness of
the panel, date and time)

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“MANUAL COMMANDS” PAGE
The manual commands page consists of 4 submenu:
VACUUM COMANDS, HEATING COMANDS, GENERAL COMAND.
pressure value of upper chamber
Pressure value of lower chamber
Vacuum pump: Activate (ON) / deactivate (OFF)
Upper vacuum valve: Activate (ON) / deactivate (OFF) the suction valve of upper
chamber with precise and/or coarse adjustment
Upper vacuum valve: Activate (ON) / deactivate (OFF) the outflow valve of upper
chamber with precise and/or coarse adjustment
Lower vacuum valve: Activate (ON) / deactivate (OFF) the suction valve of lower
Lower vacuum valve: Activate (ON) / deactivate (OFF) the outflow valve of lower
chamber with precise and/or coarse adjustment
Set point temperature concerning a heating zone
Actual temperature concerning a heating zone of plate
Activation of a determined zone with the beginning value “<” should get to set point
value
It allows the opening movement of cover
Water pump activation (option)
Activate (ON) / deactivate (OFF) the cooling valve (hydraulic circuit), zone1 /zone2
Activation of hydraulic exhaust
Activate (ON) / deactivate (OFF) the IN/OUT valves of hydraulic circuit

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“ALLARMS” PAGE
This alarm icon appears on touch screen when a alarm occur. By pushing the
button on the upper menu bar is possible to see details and cause of actual
alarm and reset the state.
The alarms page contains the follow information:
Chronological List of alarms
The pushbutton “alarm display” show a description of specific alarm selected
by the alarm list.
This pushbutton allow the alarm acknowledge from operator.
FOLLOWING THE COMPLETE LIST OF THE POSSIBILE SYSTEM ALARMS
ALLARM
POSSIBLE CAUSES
HOW TO FIX
ALARM EMERGENCY STOP
the emergency button has been pre
ssed
Restore the emergency button and press auxiliary
start to give back voltage
ALARM POWER SUPPLY 24 VDC
The current consumption is too high or it’s happened
a short circuit.
Verify is some short circuit is occurred and the current
consumption; after restart the thermal protection
ALARM WATER PUMP
The power consumption of the motor is too high or
the contactor doesn’t respond
Verify the real efficiency of the motor and that the
control relay is not broken. Restart the thermal
protection.
ALARM VACUUM
PUMP
The consumption of the motor is too high or the
contactor doesn’t respond
Verify the real efficiency of the motor and that the
control relay is not broken. Reset the thermal
protection
ALLARM SAFETY BEAM
Someone or something has interrupt the safety
light
curtain during the cover closing
Restore the safety beam and reset the alarms
ALARM MAXIMUM TEMPERATURE (HEATING
STOP)
The plate temperature exceed the “heating stop”
threshold
Check the thermocouple efficiency and if the
temperature setpoint in current recipe are too high.

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RECIPE PAGE
The recipe page includes all parameters concerning the management of
machine.
Each lamination cycle is divided into 19 steps + 1 step for prestart values.
The data is sorted progressively in 3 consecutive pages.
In the recipe pages it is possible to modify the time, temperature and
vacuum vales regarding the lamination cycle. The recipe will move
forward to the following step only if all the set conditions in the relative
fields will be reached.
In the last step the “T.Temp. field must be 9999.
Following the description of the adjustable parameters:
1. dur(s): working time of recipe step
2. Temp(°C): heating plate temperature
3. Vup(mB):Upper chamber vacuum value
4. Vdw(mB):Lower chamber vacuum value
It’s advisable to keep a backup copy of set values if you want to do
different types of working cycles.

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3.7.2
–
START UP LAMINATOR
INITIAL REQUIREMENTS (Valid for
all tests)
The operator who works with this machine have to know all instructions of this man
ual.
All electrical, pneumatic and hydraulic connections have been done as previously described.
The laminator main switch on electric cabinet should be on "0" position.
SAFETY REQUIREMENTS (Valid for
all tests)
The operator has to be in front of opera
tor panel which must be placed outside the opening radius of cover.
A second operator has to support the first one in order to avoid dangerous behaviour.
1. It’s necessary to remove the closing plate on the left side
2. Giving power supply to the electrical cabinet by turning on the main switch in “1” position
3. Check the operator panel start up and verify the home page appears on the touch
4. Turn to release the red "Emergency" pushbutton.
5. Push the blue button "Auxiliary insertion".
. If some alarms appear on operator panel, select the "ALARMS" page where it’s possible RESET all alarms
7. Choose the "MANUAL COMMANDS” PAGE AND PUSH FOR FEW SECONDS THE VACUUM PUMP BUTTON.
The second operator will be positioned on the left side of the laminator to control the pump rotation direction correspond to direction indicated by a sticker
applied to the pump.
8. If the pump rotation direction is not the same it is necessary to take off immediately the vacuum pump command on touch screen, and cut off the voltage.
After that, it’s necessary to reverse two phase of laminator power cable and test again the rotation of direction.
If the pump rotation direction is right the laminator is ready to work
We recommend testing one to one all the manual commands in
order to verify that all features are ok before to start an automatic cycle.