Royal Sovereign RSL-2702S User manual

Roll Laminator Service Manual
MODEL:RSL-2702S/RSL-382S
451-8 24B/9L,Nonhyeon-dong,Namdong-Ku,Incheon city,KOREA
TEL:[phone] FAX:[phone] A/S:080)262-8464
www.royalsovereign.com

3 ~ 3
4 ~ 10
4 ~ 6
6 ~ 7
7 ~ 9
9 ~ 10
11 ~ 11
12 ~ 14
12 ~ 12
13 ~ 13
13 ~ 13
13 ~ 13
13 ~ 13
13 ~ 14
14 ~ 14
15 ~ 16
17 ~ 19
20 ~ 25
26 ~ 29
30 ~ 33
2.5) Poor Lamination Quality ………………………………………………………
…
2.1) Rollers Not Heatin
g
……………………………………………………………
2.2) Rollers Over Heatin
g
…………………………………………………………
…
2.3) Rollers Not Runnin
g
……………………………………………………………
…
2.4) No Main Power …………………………………………………………………
…
Table of Content
1.Safety Precautions ………………………………………………………………………
2.Troubleshooting ……………………………………………………………………………
3.Replacing Parts ………………………………………………………………………………
3.1) Ri
g
ht Cover ………………………………………………………………………
…
3.2) Left Cover ………………………………………………………………………
3.3) Rear Cover ………………………………………………………………………
3.4) Main PCB …………………………………………………………………………
…
3.5) Sub PCB …………………………………………………………………………
…
3.6) Heaters ……………………………………………………………………………
3.7) Cross Cutter ………………………………………………………………………
4.Adjustments ……………………………………………………………………………………
5. Parts List …………………………………………………………………………………………
6.Exploded Drawings ………………………………………………………………………
7.Wire Diagram …………………………………………………………………………………
8.Backup ………………………………………………………………………………………………
…

1. Safety Precautions
Safety Precaution
1
Failure to comply any of the following safety procedures could result in serious injury.
Please read the instructions carefully and keep for future reference.
1. Only a licensed electrician should install wiring and outlet for the laminator.
2. Ensure the unit is plugged into a properly grounded outlet with the correct voltage.
3. Keep hands and clothing(ie.Neckties)away from rollers. The rollers are pinch points that can
trap body parts or clothing and cause serious injury .
4. Keep flammable and wet objects away from the machine .
5. Place machine on a level surface.
6. Avoid excessive sunlight, humidity and extreme temperatures.
7. Ensure the unit is turned off, cooled ,and unplugged from the outlet prior to moving and/or
repairing.
8. Keep out of reach of children.
9. Only Royal Sovereign authorized maintenance and service technicians should make repairs.
10. Do not attempt to laminate items that exceed total recommended material thickness for the
unit.
11. When cleaning the machine, don't use flammable sprays or materials.
12. Do not touch the rollers when they are hot or place foreign objects inside the machine.
13. Do not cover the surface of the machine until the machine has completely cooled.

Note: While repairing:
a. Make sure the power plug is unplugged from the power outlet.
b. Open both side covers and rear cover.
c. Be sure to follow the steps below in order.
2.1 Rollers Not Heating
1. Improper laminating mode.
2. Heating wire is not connected to the main PCB.
3. Blown (burnt) upper and/or lower wire fuse (T/Fuse).
4. Defective Bi-Metal.
5. Defective heater.
6. Defective Main PCB.
1. Improper laminating mode.
a. Ensure that the laminating mode is in the “Hot” mode, not the “Cold” mode.
Press “C/HOT” button on the control panel to change the mode.
2. Heating wire is not connected to the main PCB.
a. Connect the upper and lower heating wires to the main PCB.
2. Troubleshooting
CAUSES:
MEASURE
2

3. Blown (burnt) upper and/or lower wire fuse (T/Fuse).
a. Replace the T/Fuse wire located on the left-hand side.
4. Defective Bi-Metal.
a. Replace the Bi-Metal
5. Defective heater.
a. Using the multi-meter, test the continuity of the heater. If it fails, replace the heater.
b. Physically examine the heater assembly for breakage.
3
Multi-mete
r
Broken
WIRE-LO-T/ FUSE
WIRE-UP-T/FUSE
BIMETAL-R(145℃)
BIMETAL-L(130℃)

a. Replace the PCB Main.
2.2) Rollers Over Heating
1. Lower and upper heat sensors are reversed on the PCB Main.
1. Wires for lower and upper heat sensors are reversed on the main PCB.
a. Reverse the heat sensors.
a. Replace the T/Fuse wire located on the left-hand side.
2. Defective T/Fuse wire.
4
4. Defective main PCB.
MEASURES
6. Defective Main PCB.
CAUSES
2. Defective T/Fuse wire.
3. Defective heater.
Connector-Wire Sensor
WIRE-LO-T/ FUSE
WIRE-UP-T/FUSE

3. Defective heater.
a. Test continuity of the heater. If it fails, replace the heater.
b. Glass tube that surrounds heating coil is broken – replace the heating element.
a. Replace the PCB Main.
2.3) Rollers Not Running
1. No power to the unit.
2. Emergency switch is engaged.
3. Opened safety cover.
4.Opened Front Table Switch.
5. Film is jammed on the rollers.
6. Disconnected motor wire.
7. Blown motor fuse.
8. Defective main motor.
9. Defective main PCB.
1. No power to the unit.
a. Make sure the power plug is connected to the proper source of outlet
(220V, 15Amp, & single phase).
2. Emergency switch is engaged.
5
4. Defective Main PCB.
CAUSES
MEASURES
Switch is engaged

3. Opened safety cover.
a. Close the safety cover and double check to insure that the safety cover switch
is engaged.
Note: By closing the safety cover, it engages the safety cover switch.
4. Opened Front Table Switch.
a. Properly position the front table to engage the switch.
5. Film is jammed on the rollers.
a. Un-jam the film using a combination of the pressure lever and reverse button.
6. Disconnected motor wire.
a. Check the motor wire connection with PCB.
6
Switch is engaged
Wire-motor

7. Blown motor fuse.
a. Replace the motor fuse located above the main power switch.
8. Defective main motor.
a. Replace the main motor.
9. Defective main PCB.
a. Replace the main PCB.
2.4) No Main Power
1. No electricity.
2. Blown main fuse.
3. Disconnected main power wires.
4. Defective transformer.
1. No Electricity.
a. Double check to insure that you have electricity from your outlet.
b. Check the circuit breaker.
c. Double check that source of power is 220V, 15Amp, and single phase.
2. Blown main fuse.
a. Replace the main fuse located above the main power switch.
CAUSES
MEASURES
7
Motor Fuse

3. Disconnected main power wires.
a. Check that the main power wires are properly connected.
4. Transformer is defective
a. Replace the transformer.
8
10
Main Fuse
Main Power Wires
Transformer

Problem: Straight wave lines across the output.
Cause: Excessive front roller pressure.
Measure: Loosen the front roller pressure.
Problem: Concave waves in the lamination.
Cause: Excessive rear (pulling) roller pressure.
Measure: Loosen the rear back roller pressure.
Problem: Angled waves on both sides of the output.
Cause: Insufficient rear roller pressure.
Measure: Tighten the rear roller pressure.
Problem: Angled waves on one side of the output.
Cause: Insufficient rear left (or right) side roller pressure.
Measure: Tighten the rear left (or right) side roller pressure.
Problem: Straight waves in the output.
Cause: Excessive heat at the nip rollers.
Measure: Lower the roller temperature.
Problem: Wake waves.
Cause: Insufficient heat at the nip rollers.
Measure: Raise the roller temperature.
Problem: Curling.
Cause: 1.The film tension is very tight;2.The decurling bar is not in the
working location.
Measure: 1.Loose the tension;2.Adjust the decurling bar to working
location.
9
2.5 Poor Lamination Quality

Note: While replacing parts:
a. Make sure the power plug is unplugged from the power outlet.
b. Open both side covers and rear cover.
3.1 Replacing the Right Cover.
a. Take out the pressure lever (Figure 1) and four cover screws using Phillips screw driver (Figure 2).
b. Pull out the male control panel connector from the Sub-PCB（ Figure 3）.
c. Loosen two screws from Sub-PCB , installed on to new Right Cover (Figure 4).
d. Follow the reverse order to assemble the Right Cover back
.
3.2 Replacing the Left Cover
a. Replace the Left Cover by loosening four Left Cover screws.
3. Replacing Parts
10
Figure 1 Figure 2
Figure 3
Figure 4

3.3 Replacing Rear Cover
a. Take off the left and right covers.
b. Take out the four screws from frames,two screws of each side(Figure 5,Figure 6)
3.4 Replacing the Main PCB
a. Remove the rear cover and label all the wires before unplugging from the Main PCB.
b. Detach the Main PCB from 6 white plastic holders ( Figure 7).
c. Replace the board with new PCB and connect all the wires.
3.5 Replacing the Sub-PCB
a. Refer to “Replacing Right Cover”.
3.6 Replacing the Heaters
Note: Cotton or surgical gloves are recommended while handling the heater assembly.
a. Disassemble Right and Left Covers (Refer to “Replacing Right Cover” and “Replacing Left Cover”).
b. Take out the heater brackets on each side by loosening screws (Figure 8, 9, & 10).
11
Figure 5 Figure
Fi
g
u
r
Figure8 Figure Figure10

c. Take out the broken heater. Figure 11
Note:
a. When inserting the heater into the roller, rotate the heater slightly and push the rod in gently.
b. Use an air blower to blow out the broken pieces of heating rod.
(Please ensure that no one is standing on the other side.)
3.7 Replacing the Cross Cutter
a. Disassemble the nut from the Frame-Cutter.
b. Unfasten the spring from the cutter.
c. Change the Cutter.
d. Assemble the Cutter by reversing the above steps.
12
Figure 11

4.1 Adjusting Take-up Shaft Speed
1.Main rollers and take-up shaft speed is not synchronized.
Adjust take-up shaft speed,by loosenning or tightenning the knob
According to label-take up.
4
.2 Adjusting front and rear rollers
when the machine is running, check tha
t
the top and the bottom films are fed in
without any wrinkles.
Pressure
• Use Screwdriver
to adjust the roller pressure:
5 spots as shown on Figure B &C:
Front roller should be 5~6 and back
rollers should be 6~8.
2.Checking for over all tension –
3.Pressure mark checking (Heat Line) –
stop the machine for 30 seconds to
4. Adjustments
CAUSES:
MEASURES:
C.W – Tighten.
C.C.W – Lossen.
C.W – Increase pressure.
C.C.W – Decrease pressure.
1.Using Push-Pull Scale, measure
create a heat line. Then check to see if
you have two even parallel lines from
one end to other. Note: A narrow parallel
lines indicate that it has less pressure
at that point.
13
Figure B
Figure A
C.W
C.C.W

14
4.Laminating Test – Laminate samples
with different thickness of substrates.
5.Check above steps 2 through 4 with
3mil & 5mil films.
Figure C

RSL-2702S Part lis
t
No. Part No. Part Nam
e
Remar
k
1 013LR2012F FRAME-SENSOR
2 013LR2087A FRAME-L
3 013LR2088A FRAME-R
4 013LR3002K FRAME-CUTTER
5 013LR3009A FRAME-REAR
6 013LR3021A PLATE-MIDDLE
7 013LR3075A BASE-FRONT
8 013LR3076A BASE-REAR
9 013LR4004A FRAME-COVER SAFETY
10 014LR3001A TABLE-FRONT
11 015LR2001B IDLE BAR LOW
12 015LR3011A IDLE-BAR
13 015LR3012A SHAFT-DECURLING
14 021CR3001A KNOB-CUTTER,C
15 021LR0001A COVER-L
16 021LR2008A COVER-TAKE UP,L
17 021LR2013A COVER-TAKE UP,R
18 ASMLR1602A ASM-SENSOR
19 ASMLR1608A ASM-SENSOR
20 021LR3018A COVER-R
21 021LR3024B COVER-SAFETY
22 021LR4001A LIMIT SWITCH COVER
23 023LR3005A BUTTON-FUNC
24 023LR4002A KNOB-BOLT GUIDE
25 023LR4004A KNOB-TENSION
26 023LR4007A KNOB-LEVEL
27 026LR4006A FOOT
28 032LR3002A SHEET-FUNC
29 111LR4004A BOLT-CORE
30 111LR4006A BOLT-GUIDE
31 111LR4018A SCREW-H
32 112004001D NUT
33 120LR3004G SHAFT-FILM,L
34 120LR3023A SHAFT-CAM
35 120LR4008A SHAFT-TABLE
36 120LR4014A SHAFT-TAKE UP
37 12200X005A BEARING-TRUST NEEDLE
38 12200X009A DU BUSH
39 12200X022A BEARING-RADIAL TRUST
40 12200X027A DU BUSH
41 12200X028A DU BUSH
42 12200X029A DU BUSH
43 12200X030A DU BUSH
44 12200X032A DU BUSH
45 12200X034A DU BUSH
46 12200X040A DU BUSH
47 122LR4024A BUSH-ROLLER LAMI,UP
48 122LR4026A BUSH-ROLLER PULL,UP
49 122LR4042A BUSH-ROLLER LAMI,LO-LEFT
50 122LR4047A BUSH-ROLLER PULL,LO
5. Part list
RSL-2702S
15

RSL-2702S
51 122LR4050A BUSH-ROLLER LAMI,LO-RIGHT ASS'Y
52 124LR4005A CAM
53 124LR4006A 1"CORE
54 125LR4001A HANDLE-TENSION
55 125LR4003B LEVER-PRESSURE
56 125LR4004A SHAFT-TENSION 2
57 125LR4008A SUPPORT-SPRING
58 131LR4017A SPROCKET-LAMI
59 131LR4022B SPROCKET-DOUBLE
60 131LR4023A SPROCKET-TAKE UP
61 131LR4034A SPROCKET-MOTOR
62 133LR2021A ROLLER-LAMI,LO
63 133LR2021B ROLLER-LAMI,UP
64 133LR2022A ROLLER-PULL,LO
65 133LR2022B ROLLER-PULL,UP
66 134LR4001A PULLEY-CHAIN
67 134LR4003A BUSH-PULLEY
68 136LR4001C CHAIN
69 136LR4001G CHAIN-2(TAKE UP)
70 138LR4001A SPRING-CUTTER CROSS
71 138LR4012A SPRING-TENSION
72 138LR4015A SPRING-PRESSURE
73 138LR4018A SPRING-LEVER
74 140LR3001A HOLDER-CUTTER,C
75 140LR4001A HOLDER-SHAFT FILM
76 140LR4021A HOLDER-SHAFT,T
77 141LP4018A BRACKET-T/FUSE
78 141LR3017A PLATE-PRESSURE,L
79 141LR3018A PLATE-PRESSURE,R
80 141LR4005A PLATE-SHAFT FILM
81 141LR4020A BRACKET-HEATER,LO-R
82 141LR4035A PLATE-DU BUSH
83 141LR4040A PLATE-SLIP
84 141LR4041A BRACKET-FAN
85 141LR4043A FRONT TABLE SAFETY LEVER
86 141LR4054A BRACKET-LIMIT SWITCH
87 141LR4059A BRACKET-SENSOR
88 141LR4060A PLATE-PRESSURE,LAMI
89 141LR4061A PLATE-PRESSURE,PULL
90 141LR4081A BRACKET-HEATER,LO-L
91 141LR4087A BRACKET-HEATER,UP
92 143LR3001A SUPPORTER-SHAFT
93 144LR4001B CLAMPER-LEVER
94 145LR3002A GUIDE-DOCUMENT
95 147LR4002A PAD-TENSION
96 147LR4010A PAD-TAKE UP
97 147LR4013A STOPPER-HEATER,UP
98 210004002A MOTOR-MAIN
99 211003004A FAN
99-1 211003004B FAN
100 213LR4001A CUTTER-CROSS
101 223LR2007B HEATER ASS'Y
101-1 223LR2007C HEATER ASS'Y
101-2 223LR2007D HEATER ASS'Y
101-3 223LR2007F HEATER ASS'Y
16

RSL-2702S
102 23200X002A SUPPORT-PCB
103 23300X001A BUSHING-CORD
104 32500X0005 FUSE-MAIN
104-1 32500X0008 FUSE-MAIN
105 34000S011A POWER TRANSFORMER
106 350LR3022A PCB-SUB ASS'Y
107 350LR3036C PCB-MAIN ASS'Y
108 363LP3001A BI-METAL LO
109 363LR4001F BI-METAL UP
110 36400X002B SWITCH-MAIN
111 36400X014B MICRO S/W
112 36600X001A FUSE-HOLDER
113 380CR4003A POWER CORD
113-1 380CR4004A POWER CORD
113-2 380LR4001A POWER CORD
113-3 380LR4001B POWER CORD
113-4 380LR4003A POWER CORD
113-5 380LR4007A POWER CORD
114 381LR4013C WIRE-POWER S/W
115 381LR4020B WIRE-FUSE,EU
116 381LR4030D WIRE-UP HEATER1,EU
117 381LR4043A WIRE-SAFETY S/W
118 381LR4044A WIRE-MAIN
119 381LR4052A WIRE-MOTOR
120 381LR4054A WIRE-LO HEATER2,EU
121 381LR4055A WIRE-UP HEATER2,EU
122 381LR4084A WIRE-T/FUSE(UP)
123 381LR4091A WIRE-LO HEATER1,EU
124 381LR4092A WIRE-T/FUSE(LO)
125 443LR4001A L-WRENCH
126 ASMLR1339A ASM-AUTO GRIP FILM CORE 2"
126-1 ASMLR1339B ASM-AUTO GRIP FILM CORE3"
127 KPS03012D2 KEY-PLAIN
128 KPS05010D2 KEY-PLAIN
129 RE001000C8 E-RING
130 RC001200C8 SNAP-RING
131 RIV05018E8 RIVET
132 SKE04010D2 SET SCREW
132-1 SKE05006D2 SET SCREW
132-2 SKE05010D2 SET SCREW
132-3 SKE05015D2 SET SCREW
133 013LR4010A FRAME-GUIDE，R
134 013LR4011A FRAME-GUIDE，L
135 141LR4127A BRACKET-DECURLING BAR,R
136 141LR4128A BRACKET-DECURLING BAR,L
137 111LR4022A KNOB-GUIDE
17

RSL-382S Part lis
t
No. Part No. Part Nam
e
Remar
k
1 013LR2012G FRAME-SENSOR
2 013LR2087A FRAME-L
3 013LR2088A FRAME-R
4 013LR3002H FRAME-CUTTER
5 013LR3035A FRAME-REAR
6 013LR3036A PLATE-MIDDLE
7 013LR3069A BASE-FRONT
8 013LR3070A BASE-REAR
9 013LR4004A FRAME-COVER SAFETY
10 014LR3001B TABLE-FRONT
11 015LR2010A IDLE BAR LOW
12 015LR3011B IDLE-BAR
13 015LR3012B SHAFT-DECURLING
14 021CR3001A KNOB-CUTTER,C
15 021LR0001A COVER-L
16 021LR2008A COVER-TAKE UP,L
17 021LR2013A COVER-TAKE UP,R
18 ASMLR1604A ASM-SENSOR
19 ASMLR1608A ASM-SENSOR
20 021LR3018A COVER-R
21 021LR3024A COVER-SAFETY
22 021LR4001A LIMIT SWITCH COVER
23 023LR3005A BUTTON-FUNC
24 023LR4002A KNOB-BOLT GUIDE
25 023LR4004A KNOB-TENSION
26 023LR4010A KNOB-LEVEL
27 026LR4006A FOOT
28 032LR3002A SHEET-FUNC
29 111LR4004A BOLT-CORE
30 111LR4006A BOLT-GUIDE
31 111LR4018A SCREW-H
32 112004001D NUT
33 120LR3004E SHAFT-FILM,L
34 120LR3031B SHAFT-CAM
35 120LR4008A SHAFT-TABLE
36 120LR4014C SHAFT-TAKE UP
37 12200X005A BEARING-TRUST NEEDLE
38 12200X009A DU BUSH
39 12200X022A BEARING-RADIAL TRUST
40 12200X027A DU BUSH
41 12200X028A DU BUSH
42 12200X029A DU BUSH
43 12200X030A DU BUSH
44 12200X032A DU BUSH
45 12200X034A DU BUSH
46 12200X040A DU BUSH
47 122LR4024A BUSH-ROLLER LAMI,UP
48 122LR4026A BUSH-ROLLER PULL,UP
49 122LR4042A BUSH-ROLLER LAMI,LO-LEFT
50 122LR4047A BUSH-ROLLER PULL,LO
5. Part list
RSL-382S
18