Sharp SX 1075 User manual

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Service & Maintenance Manual
Models 1075, 1084, 1097, 1099, 1108, 1109, and 1121
Printed In USA 0924
PN: 960714-02B Copyright © 2007
Parts: [phone] ext. 571
[e-mail]
Service: [phone] ext. 572
[e-mail]
www.sharppackaging.com

The safety information presented is a guideline that
should be followed by all personnel. Anyone
operating or maintaining the equipment should read
and follow all the information in this manual, without
exception.
DEFINITION OF TERMS
Throughout this manual, you will find the
following safety notices with this accompanying
symbol. This symbol signifies important safety
issues regarding the operation and maintenance of
the Sharp SX™.
EQUIPMENT SAFETY FEATURES
The Sharp SX™ is equipped with a polycarbonate
shield covering the pressure and heated seal bars.
DO NOT operate the unit with the shield removed.
SAFETY RULES AND PROCEDURES
The machine requires regular, periodic
maintenance to ensure reliable service. No
maintenance should be performed unless the
safety precautions for maintenance are thoroughly
understood.
•Follow all instructions in this manual for safe
operation.
•Follow all company and industry standard
safety policies regarding this kind of
machinery that may exceed those listed in this
manual.
•Keep all safety features, guards, interlocks
and sensors in good working order.
•ALWAYS turn off machine power, ensure that
all mechanical motion has stopped and allow
any heated components to cool down before
removing any machine parts.
IMPORTANT SAFETY INFORMATION
SX™
Service and Maintenance Manual 960714-02B © 2007 I2407
Operating the unit without the safety guards in
place may result in serious bodily injury or
death.
WARNING
Operating machine without safety guards in
place may result in serious bodily injury or
death.
WARNING
Prior to operating or servicing the SX

, remove
any loose jewelry, make certain clothing and
hair are not loose to interfere with or become
tangled with the machine. Failure to do so
could result in severe bodily injury or death.
WARNING
GENERAL WARNING. Indicates information
important to the proper operation of the
equipment. Failure to observe may result in
damage to the equipment and severe bodily
injury or death.
WARNING
GENERAL CAUTION. Indicates information
important to the proper operation of the
equipment. Failure to observe may result in
damage to the equipment.
CAUTION
Always remove electrical power from the SX

prior to performing any maintenance on the
machine.
WARNING

SAFETY LABELS
The following label is placed on the Sharp SX™
wherever a removable shield or panel guards the
heated sealing area. Always disconnect electrical
power from the machine prior to removing any
guards and/or panels.
The following label is used where there is the
potential of your hands, long hair, jewelry, etc.
becoming entangled between two rotating parts.
Be sure to secure loose items before approaching
and operating the machine.
The following label on the Sharp SX™ is located
where there is the potential of injury due to pinch
points or moving parts. Make certain electrical
power is disconnected before removing any guards
and/or panels or servicing the machine.
The following label is located in the proximity of a
fused circuit. Be certain to replace blown fuses
ONLY with fuses with the same electrical rating.
Always disconnect electrical power before
removing any guards and/or panels or servicing the
Sharp SX™.
The label shown on the right
is placed on the Sharp SX™
wherever a removable shield
or panel guards electrical
components.
Always disconnect electrical
power from the machine prior
to removing any guards
and/or panels.
IMPORTANT SAFETY INFORMATION
SX™
Service and Maintenance Manual 960714-02B © 2007 I2407

Section 1- Introduction
General Information ................................................1-1
About This Manual..............................................1-1
Model Variations.................................................1-2
Technical Assistance .........................................1-2
Theory of Operation.................................................1-3
General...............................................................1-3
Faults..................................................................1-4
EZ-Bags® and Film Materials.............................1-5
Thermal Transfer Ribbon....................................1-5
Specifications...........................................................1-6
Machine Specifications.......................................1-6
Packaging Specifications....................................1-6
Machine Dimensions...........................................1-6
Section 2 – Maintenance & Adjustments
Maintenance Schedule ............................................2-1
Daily Maintenance.......................................... 2-1
Annual Maintenance...........................................2-1
Cleaning....................................................................2-2
General...............................................................2-2
Cleaning the Printhead and Film Feed Rollers....2-3
Machine Adjustments..............................................2-5
Adjusting the Pinch Roller...................................2-5
Checking Belt Tension........................................2-6
Checking Belt Tension........................................2-7
Sharp SX™ with Printer......................................2-8
Section 3 – Component Repair
Electrical Assembly................................................3-1
Pressure Jaw and Film Feed Motor Controllers...3-1
Fuses..................................................................3-6
24VDC Power Supply.........................................3-8
Line Filter..........................................................3-16
Main Power Switch (RED).................................3-20
Transformers.....................................................3-22
Aromat PLC ......................................................3-27
Aromat PLC Battery..........................................3-28
Color Touch Screen..........................................3-30
Cooling Fan.......................................................3-33
Solid State Relay.............................................. 3-35
Grey Relay 24V ................................................ 3-39
Red Relay 24V.................................................. 3-41
Printer GPIO Board........................................... 3-44
Printer Performance Logic Board...................... 3-45
Printer Power Supply Board.............................. 3-46
24 VDC Fan Assembly...................................... 3-48
Laminated White Ribbon Cable........................ 3-49
Datamax LCD Module....................................... 3-51
Printhead Stepper Drive.................................... 3-53
Film Feed Assembly.............................................. 3-56
Photoelectric Sensor......................................... 3-56
Film Feed Motor Drive Belt............................... 3-60
Film Feed Roller Drive Belt............................... 3-61
Platen Roller Drive Belt..................................... 3-63
Film Feed Roller ............................................... 3-67
Platen Roller..................................................... 3-69
Film Feed Drive Motor ...................................... 3-72
Cradle Lock Cams............................................ 3-74
Printhead Cradle Assembly .................................. 3-76
Ribbon Rewind Assembly................................. 3-76
Ribbon Rewind Motor ....................................... 3-76
Primary Ribbon Drive Belt................................. 3-79
DC Roller Clutch............................................... 3-81
Secondary Ribbon Drive Belt............................ 3-83
Adjustable Slip Clutch....................................... 3-87
Printhead Position Assembly ................................... 3-89
Printhead Position Motor................................... 3-89
Printhead Position Drive Belt............................ 3-92
Printhead Pressure Cams................................. 3-94
Printhead Position Sensor ...............................3-100
Thermal Printhead...........................................3-102
Ribbon Supply Assembly........................................3-103
Slip Clutch Spring ............................................3-103
Ribbon Motion Sensor .....................................3-104
Ribbon Clips ....................................................3-106
Gas Springs.....................................................3-107
Cross Flow Fan................................................3-108
TABLE OF CONTENTS
SX™
Service and Maintenance Manual 960714-02B © 2007 I2407

Cradle Latch Lever.......................................... 3-110
Cradle Latch.................................................... 3-111
Sealer Assembly .................................................. 3-113
Pressure Bar Drive Motor................................ 3-113
Pressure Bar Gearbox.................................... 3-116
Pressure Bar Belt............................................ 3-118
Linear Bearings............................................... 3-120
Stripper Plate Assembly.................................. 3-122
Sealpoint Components.................................... 3-129
Seal Wire Tension Springs.............................. 3-132
Stripper Plate Sensors.................................... 3-135
Jaw Position Sensors...................................... 3-140
Unwind Assembly................................................ 3-145
Unwind Spring................................................. 3-145
Section 4 – Troubleshooting
Troubleshooting Chart ........................................4-1
Section 5 – Parts Lists
Electrical Assembly.............................................5-1
Film Feed Assembly ...........................................5-3
Frame Assembly.................................................5-4
Printhead Cradle Assembly (Model 1108)...........5-5
Cradle Assembly (Model 1097)...........................5-9
Sealer Assembly............................................... 5-10
Unwind Assembly .............................................5-12
Section 6 – Assembly Drawings
Electrical Assembly.............................................6-1
Film Feed Assembly ...........................................6-5
Frame Assembly.................................................6-6
Printhead Cradle Assembly (Model 1108)...........6-9
Cradle Assembly (Model 1097).........................6-14
Sealer Assembly............................................... 6-17
Unwind Assembly .............................................6-20
Appendix
Replacement Parts Order Form..........................A-1
Warranty.............................................................A-2
Protecting Your Printhead...................................A-3
Printer Menu Structure........................................A-6
Wiring Diagram – Located in the back of this
binder or Click Here
TABLE OF CONTENTS
SX™
Service and Maintenance Manual 960714-02B © 2007 I2407

SX™
Service and Maintenance Manual 1-1 960714-02B © 2007 I2407
SECTION 1 – INTRODUCTION
GENERAL INFORMATION
ABOUT THIS MANUAL
This manual has been prepared for your use in
servicing the Sharp SX™Packaging Machine and
the Sharp SX™ Packaging Machine with Printer.
Included in the procedures are helpful facts on
service, troubleshooting, specifications and parts
information.
All procedures should be performed by a qualified
service technician.
It is important that you familiarize yourself with the
product as much as possible before initiating any
maintenance, troubleshooting or repairs.
Make sure you read through the IMPORTANT
SAFETY INFORMATION and INTRODUCTION
sections of this manual before attempting any
service procedures.
As you disassemble your machine to service and
replace parts, keep the following points in mind:
•Do not remove or loosen more parts than
needed. Use common sense to keep your work
to a minimum.
•Mark any wires before disconnecting to make
reassembly easier.
•Use Loctite® Blue or equivalent on all threaded
fasteners without lock washers.
Within the Component Repair section of this
manual, each repair procedure is broken down into
three main categories for each component. These
categories are Testing, Adjustment, and
Replacement and are identified by the following
symbols:
Accompanying this manual, attached to the inside
front cover, is a Compact Disc containing an
electronic color version of this manual in Acrobat .pdf
format along with other useful digital content. For
more information view the README.TXT file located
on the CD.
Adobe Reader is required to view .pdf files and can
be downloaded free of charge from the following
website:
http://www.adobe.com/products/acrobat/alternate.html#50
The digital color version of the manual is also
interactive, allowing the user to simply click onto a
subject within the Table of Contents to take them to
the specified page.
This manual is designed to be used by Authorized Service Personnel only. Sharp
Packaging Systems, Inc. assumes no responsibility for any repairs made on Sharp
Packaging units by anyone other than Authorized Service Technicians.
TESTING
ADJUSTMENT
REPLACEMENT

SX™
Service and Maintenance Manual 1-2 960714-02B © 2007 I2407
SECTION 1 – INTRODUCTION
GENERAL INFORMATION
MODEL VARIATION
This manual has been developed to assist in
servicing and maintaining the Sharp SX™with
Printer model 1108 and the Sharp SX™model
1109. Although this manual has been written for
this specific model, the procedures and
techniques for replacing components and
troubleshooting can generally be applied to all
models of the SX™. Major differences in
machine maintenance or component repair will
be noted on a case by case basis. The parts lists
and assembly drawings located in sections 5 and
6 of this manual are specifically for these two
models. If a replacement part is needed for an
older model of machine, please refer to the CD
located in the front of this manual. This CD
contains the parts lists and assembly drawings
for all previous models of the Sharp SX™and the
Sharp SX™with Printer.
The replacement parts lists located on the CD
have been separated by model number for ease
of identifying the parts that are needed. Simply
locate the section of the manual that coincides
with the SX™ model you have and proceed from
there.
To determine which model of the Sharp SX™you
have, refer to Figure 1-1. The serial number is
located on a placard or sticker directly below the
roll unwind shaft. The highlighted numbers in
Figures 1-2 and 1-3 coincide with the model of
the machine.
TECHINCAL ASSISTANCE
Assistance with the SX™ can be obtained by
notifying Sharp Packaging Systems at:
Sharp Packaging Systems
PO Box 124
Sussex, WI 53089, USA
Service: 800-634-6359 (ext. 572)
[email protected]
Parts: 800-634-6359 (ext. 571)
[email protected]
Fax: [phone]
Figure 1-1. Serial Tag Location
Serial Tag
Figure 1-2. Model 1075 and 1084 Serial Tag
Model Number
Figure 1-3. Model 1097, 1099, 1108, and 1109
Serial Tag
Model Number

SX™
Service and Maintenance Manual 1-3 960714-02B © 2007 I2407
SECTION 1 – INTRODUCTION
THEORY OF OPERATION
GENERAL
The Sharp SX™ is controlled by a PLC
(Programmable Logic Controller). The PLC
receives input from the operator touchscreen to
control a stepper drive motor and an electric eye
sensor on the bag feeder output end.
The Sharp SX™ is equipped with a sensor on the
pressure jaw which can detect an obstruction. If an
object triggers the sensor, the pressure jaw motor
will reverse, and place the bagger into a fault. A
message appears on the control panel displaying
the jaw fault, allowing the operator to clear the seal
area and restart the bagging cycle.
Note: the Sharp SX™ is not designed to interface
with automatic infeed units such as counters,
scales, or infeed conveyors.
•The Sharp SX™ uses pre-opened Sharp EZ-
Bags. The bags are dispensed through the
powered drive rollers.
•A constant stream of air opens (inflates) the
bag, preparing the bag to be loaded.
•Product is loaded into the bag.
•Once the bag is loaded, the operator cycles the
machine (either by foot control, optional dual
optical palm buttons, from the Touchscreen or
the machine can be set on automatic cycle) to
seal the bag.
•The pressure jaw closes and grips the bag.
The impulse sealer heats up and seals the bag
while the power drive rollers reverse to
separate the bag at the perforation.
•An electric eye is used to sense the trailing
edge of the bag. Hang holes, vent holes, etc.
must be prevented from passing over the
electric eye as this will send a false signal to
the PLC. To prevent this, the electric eye has
been designed to be off center of the bag,
however, in some cases the bags may have to
be repositioned when larger hang holes, vent
holes, etc. are present (see Loading Bag Film).
•When the bag is sealed and seal dwell is
complete, the pressure jaw opens.
•The Printhead is lowered and the bag is
indexed forward at printing speed until the label
is completed. The Printhead is raised and the
balance of the bag length is indexed forward at
full index speed (bagger speed). (Note: This
step occurs only if model is equipped with an
imprinter)
•As the bags are indexed, the Material Unwind
Shaft will spin allowing the bags to be pulled
from the roll. The Material Unwind Shaft is
comprised of a Roll Tensioner with
compression spring, Core Chuck, and a torsion
spring. When the roll of bags is loaded onto
the machine, pressure is applied to the Roll
Tensioner which in turn applies pressure to the
roll side plate creating a kind of slip clutch. The
pressure that is applied to the Roll Tensioner is
directly proportional to the type and thickness
of the material being used. As this pressure
increases the amount of tension on the web
also increases. The appropriate amount of
pressure that should be applied to the Roll
Tensioner can be found using trial and error.
•The constant stream of air inflates the bag,
preparing the bag to be loaded.
The Sharp SXTM
is equipped with a jaw
obstruction detection sensor. This sensor is
not designed, nor intended, to be a safety
sensor.
WARNING
Figure 1-4. Sharp SX™

SX™
Service and Maintenance Manual 1-4 960714-02B © 2007 I2407
SECTION 1 – INTRODUCTION
THEORY OF OPERATION
FAULTS
The Sharp SX™ has been designed to alert the
operator, via the Touchscreen, to a situation (fault)
that requires immediate attention. These faults
may indicate a serious condition where, if not
corrected, damage to the unit may occur or the
fault may simply alert the operator that the unit has
run out of film. The following is a list of possible
faults that may occur during operation. A detailed
list of faults, causes and solutions can be found in
the Troubleshooting section of this manual.
•WEB DID NOT BACK UP
The machine reverses the drive rollers to separate
the web of bags at the perforation. The bagger has
a photo eye that it uses to detect the trailing edge
of the bag. When the photo eye does not detect
this trailing edge within the allowed time, this fault
is triggered.
•JAW FAULT
The Obstruction Sensing Jaw has detected an
object in the sealing area during the sealing
operation.
•OBSTRUCTION SENSING JAW TIMER
FAULT
The Obstruction Sensing Jaw did not close within
the preset time, but there was no obstruction
sensed.
•THERE ARE NO BAGS COVERING THE EYE
This fault is triggered when the machine cycle is
initiated and the photo eye is not activated.
•BATCH IS COMPLETE
This message is activated when the bagger has
cycled the specified number of times set by the
operator under Batch Target.
Batch Target – A predetermined number of cycles
that will be completed before the machine will
automatically stop.
•WAITING FOR PRINTER SIGNAL*
The bagger has sent a print signal to the printer
and is waiting for a return signal.
*Note: This fault will only occur if the Sharp SX™ is
equipped with an imprinter.

SX™
Service and Maintenance Manual 1-5 960714-02B © 2007 I2407
SECTION 1 – INTRODUCTION
THEORY OF OPERATION
SHARP EZ-BAGS

AND FILM MATERIALS
The Sharp SX™ is designed to use a wide variety
of bag sizes and materials. Sharp EZ-Bagsare
recommended for optimum operating performance,
efficiency and safety. System performance
specifications are based on utilizing consistent,
high quality, pre-opened bags. Any bag used must
meet Sharp Packaging Systems’ manufacturing
tolerances. The following list shows some of the
Sharp EZ-Bagsfilms available through Sharp
Packaging Systems, Inc.
•Low Density Polyethylene (LDPE)
•Linear Low Density Polyethylene (LLDPE)
•High Molecular Weight, High Density
Polyethylene (HMWHDPE)
•Laminated Oriented Polypropylene
(Laminate/OPP)
•Polypropylene
•Metallic Films (including conductive films)
•Co-Extruded Films (combination films)
•Other Laminates (any other laminates
laminated with polyethylene)
•Anti-static and Triboelectric films
•VCI corrosion inhibiting films
•Opaque films
Contact Sharp Customer Service (800-634-6359) or
[e-mail]
to order Sharp EZ-Bagsand for information
regarding film and bag specifications.
THERMAL TRANSFER RIBBON*
The Sharp SX™ uses thermal transfer ribbon to
print variable information onto the bags as they
pass through the machine. The following is a list of
ribbon that is available through Sharp Packaging
Systems, Inc. For ordering information refer to the
Replacement Parts Order Form in the Appendix on
page A-1.
•Standard Direct Wax Ribbon
•Premium Wax Resin Ribbon
*Note: Used only if the Sharp SX™ is equipped
with an imprinter.
SUPPLIES
Thermal Transfer Ribbons
Sharp thermal transfer ribbons are selected
specifically for use with our printer. Use of ribbons
other than those supplied by Sharp, may result in a
poor quality printing, especially bar-codes and their
ability to be successfully scanned. This may also
void the print head warranty.
Recommended Sharp ribbons are:
•Black ink, scratch and smudge resistant
•2000’ (609 meters), 3.5 to 4.5 microns thick
•1” core, no notch required
•Ink side in
•Back coated ribbons only
Special purpose thermal transfer ribbons, sizes
other than those listed above, such as colored
ribbons, or low temperature release ribbons are
available.