REMP Plate Sealer LHS-056 Manual

User Manual

Version 1.2 Oberdiessbach, 20.05.2005

LHS (Landscape Heat Sealer with Stacker)


User Manual

2005 © by REMP AG, CH-3672 Oberdiessbach www.remp.com Tel: +41 31 770 70 70 Fax: +41 31 770 72 66Version: 1.2 Filename: LHS with Stacker_BA_050520_English.doc Page II of IV

Document Control

Filename: LHS with Stacker_BA_050520_English.doc

Version: 1.2

Date of Issue: 20.05.2005 Status: Approved

Classification: Customer Doc.-Owner: dasp

Distribution: Project Team

Document Updates

Version Date Description Page(s) Author(s)

1.2 20.05.05 Document layout all dasp


User Manual

2005 © by REMP AG, CH-3672 Oberdiessbach www.remp.com Tel: +41 31 770 70 70 Fax: +41 31 770 72 66Version: 1.2 Filename: LHS with Stacker_BA_050520_English.doc Page III of IV

Overview

1 General Information ..........................................................................................................................1 2 System Description...........................................................................................................................2 3 Safety Regulations............................................................................................................................5 4 Assembly and Function..................................................................................................................10 5 Operating Information.....................................................................................................................12 6 Maintenance and Support ..............................................................................................................35


User Manual

2005 © by REMP AG, CH-3672 Oberdiessbach www.remp.com Tel: +41 31 770 70 70 Fax: +41 31 770 72 66Version: 1.2 Filename: LHS with Stacker_BA_050520_English.doc Page IV of IV

Table of Contents

1 General Information ..........................................................................................................................1 1.1 System information.................................................................................................................1 1.2 Purpose of this User Manual ..................................................................................................1

2 System Description...........................................................................................................................2 2.1 Intended Use ..........................................................................................................................2 2.2 Short Function Overview ........................................................................................................2 2.3 Technical Data and Performance Characteristics..................................................................3

2.3.1 General Data ........................................................................................................3 2.3.2 Measurements and Weights.................................................................................3 2.3.3 Installation and Storage Requirements ................................................................4 2.3.4 Technical Maintenance Data................................................................................4

2.4 Options and Accessories........................................................................................................4 2.4.1 Options .................................................................................................................4 2.4.2 Consumables, Accessoires ..................................................................................4

3 Safety Regulations............................................................................................................................5 3.1 Introduction – General Safety Information .............................................................................5 3.2 Installation Site and Ventilation ..............................................................................................6 3.3 Power Supply and Electric Mains...........................................................................................7 3.4 Compressed Air Connection ..................................................................................................8 3.5 Heating of the Sealer..............................................................................................................9 3.6 Dangers Of Inappropriate Use ...............................................................................................9 3.7 Safety and Monitoring Devices...............................................................................................9 3.8 Specific Product Dangers.......................................................................................................9

4 Assembly and Function..................................................................................................................10 4.1 Detailed Function Description ..............................................................................................10 4.2 Mechanical Assembly...........................................................................................................11

5 Operating Information.....................................................................................................................12 5.1 Operation and Display Information.......................................................................................12 5.2 Menu Description..................................................................................................................13

5.2.1 EQUIPMENT INFORMATION............................................................................13 5.2.2 MAIN Menu.........................................................................................................13 5.2.3 Menu: CYCLE.....................................................................................................14 5.2.4 Menu: MANUAL OPERATIONS (Individual Moves) ..........................................14 5.2.5 Menu: PARAMETER ..........................................................................................15 5.2.6 Menu: SUPPORT ...............................................................................................16

5.3 User Messages.....................................................................................................................17 5.3.1 Messages in Menu CYCLE ................................................................................17 5.3.2 User Messages in Menu: MANUAL OPERATION .............................................19 5.3.3 User Messages in Menu: PARAMETERS..........................................................21 5.3.4 User Messages in Menu: SUPPORT .................................................................22

5.4 Errors....................................................................................................................................22


User Manual

2005 © by REMP AG, CH-3672 Oberdiessbach www.remp.com Tel: +41 31 770 70 70 Fax: +41 31 770 72 66Version: 1.2 Filename: LHS with Stacker_BA_050520_English.doc Page V of IV

5.5 Heat Control Settings ...........................................................................................................26 5.5.1 Switching the Controller On / Off........................................................................26 5.5.2 Adjusting the Set-Value......................................................................................26 5.5.3 Auto Tuning (After Changing the Voltage) .........................................................27 5.5.4 Basic Factory Settings........................................................................................28

5.6 Modifications to Fit Different Microplates .............................................................................29 5.6.1 Specific Plate Adapters ......................................................................................29 5.6.2 Perform Modification Operations Only When Sealer is At Room Temperature. 30 5.6.3 Precision Adjustment Of The Cutting Blade In Manual Operations ...................31 5.6.4 Adjustment Of The Lifter ....................................................................................32

5.7 Installing Foil Roll .................................................................................................................33 5.7.1 Side Feed Sealer................................................................................................33

6 Maintenance and Support ..............................................................................................................35 6.1 Introduction...........................................................................................................................35 6.2 Maintenance Work ...............................................................................................................35


User Manual

2005 © by REMP AG, CH-3672 Oberdiessbach www.remp.com Tel: +41 31 770 70 70 Fax: +41 31 770 72 66Version: 1.2 Filename: LHS with Stacker_BA_050520_English.doc Page 1 of 3

1 General Information

1.1 System information

System identification: LHS with Stacker (Landscape Heat Sealer)

Manufacturer: REMP AG, Weststrasse 12, CH-3672 Oberdiessbach Tel.: +41 (0)31 770 70 70 Fax.: +41 (0)31 770 72 66 Internet: www.remp.com Email: [email protected]

Customer service: REMP AG, Service & Support Weststrasse 12, CH-3672 Oberdiessbach Tel.: +41 (0)31 770 73 73 Fax.: +41 (0)31 770 73 74 Internet: www.remp.com Email: [email protected]

1.2 Purpose of this User Manual

The purpose of this User Manual is to ensure risk-free initiation, serviceable operation and proper maintenance of the system described. This documentation is subject to alteration. REMP AG provides no warranty for this material nor does it grant silent warranty for commercial quality and suitability for a specific purpose.

© Copyright 2004 REMP AG

All rights reserved. No part of this documentation may be reproduced, photocopied, stored on an electronic data carrier or transmitted by electronic media without the prior written permission of Remp AG.


User Manual


2 System Description

2.1 Intended Use

The main purpose of this system is to heat seal PP-microplates for the long term storage of reagents with a pierceable REMP foil, or for multiple heat sealing of microplates with the removable REMP foil for short term storage.

The sealer is designed to be installed in a robot system. A portal robot takes care of the loading and unloading.

It is however also possible to work manually.

The sealer is designed to process stacks of microplates.

Picture 2-1: REMP MTP384 Picture 2-2: REMP MTP384 sealed

2.2 Short Function Overview

One cycle includes the following functions:

• Dropping into position of plate from the stack

• Plate input

• Heat sealing the plate with foil from the roll

• Exit of sealed plate

• Transfer to completed stack

A detailed function description can be found in chapter 4.1.


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2.3 Technical Data and Performance Characteristics

2.3.1 General Data

The sealing can be varied by adjusting the sealing time and/or the heating temperature.

Normal sealing time: 3 sec (changes can be made on the operator‘s terminal)

Normal sealing temperature: 160°C - 175°C (the heat regulator can be adjusted)

Cycle time for one plate: approx. 18 sec

Stacker capacity: 50 pcs. 384 MTP

35 pcs. 384 DWP

50 pcs. 96 MTP

17 pcs. 96 DWP

2.3.2 Measurements and Weights

Setup: Width Length Height

Roll sideways: 600mm 500mm 1000mm

Weight: 76 kg (167 lbs, without foil roll)

Microplate size: Analog SBS standard for microplates


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2.3.3 Installation and Storage Requirements

Storage and Transport

Permissible ambient temperature -10° to + 60°C

Permissible relative humidity < 70% at 30°C

Operation

Permissible ambient temperature +10° to + 40°C

Permissible relative humidity < 70% at 30°C

2.3.4 Technical Maintenance Data

System of protection: IP 31

Power supply: 230V or 110V

Frequency: 50/60 Hz

Power consumption: 1'500 VA at 230 V or 330 VA at 110 V (because of heating)

2.4 Options and Accessories

Only equipment described in this document is to be used. The manufacturer does not take responsibility for any defects or malfunctions resulting from the use of other material.

2.4.1 Options

This equipment can be used with varying microplates (MTP’s and DWP’s) through the use of accessories (see 5.6).

2.4.2 Consumables, Accessoires

Modifications to fit other microplates requires specific tools, which are available and can be ordered from the customer service department.

The modifications are described in detail in chapter 5.6 ‘Modifications to Fit Different Microplates’.


User Manual


3 Safety Regulations

3.1 Introduction – General Safety Information

The system is only to be used for the purposes described in the User Manual under 2.1 ‘Intended Use’ and should only be operated by trained or specially instructed personnel who are familiar with the User Manual.

The manufacturer does not take responsibility for any use of the system or its individual parts and components other than as described. The same applies for maintenance and repair work not executed by authorized maintenance personnel. Noncompliance with these instructions results in the voiding of all warranties. This also applies to parts not directly effected by unauthorized repair work.

The system operates with electrical current and compressed air. It is hazardous to manipulate the system or to use it for anything other than as specifically described in this manual.

Danger signs warn of the following dangers:

Caution high voltage! Disconnect from power source before opening!

Danger! Observe User Manual: Extreme heat in vicinity of the seal press.

Danger! Observe User Manual: Danger due to different press functions.

If there are any questions regarding the system or the User Manual please contact the manufacturer. To contact REMP see chapter 1.1 (General Information).

The following safety regulations must be observed!!!!


User Manual


3.2 Installation Site and Ventilation

It is prohibited to operate the system in potentially explosive environment.

If fluid enters the system it has to be switched off immediately.

The system is only to be installed and operated on a site which complies with the following conditions:

• No direct sunlight

• Temperature + 10°C to + 40°C

• Relative humidity ≤ 70 % at + 30°C

• No vibrations

• Level, stable and dry installation surface

The ventilation openings on the back of the equipment must remain open. Reducing ventilation to the equipment will impair its ability to function.


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3.3 Power Supply and Electric Mains The system is only to be operated with the power supply and frequency specified on the identification plate mounted on the side of the system. Operating the system with any other power supply and frequency can result in damage to the equipment.

The mains plug has to be plugged into an outlet which is equipped with protective grounding. It is prohibited to make the protection ineffective by connecting an extension cable which is not equipped with protective grounding. If the power supply is adjusted with a regulating transformer, it is only allowed to use one transformer which does not interrupt the protective grounding.

Any interruption of the protective conduct within or outside the System or cutting off the protective conduct connection will cause danger to the system users (Life Danger!) and therefore is strictly prohibited.

The mains cable is not allowed to have any cuts or abrasion marks and it has to be connected correctly. Non compliance could result in fire or electrical shock.

The mains cable is not allowed to be excessively pulled or bent.

When unplugging the mains cable, it should be unplugged by pulling the plug, not on the cord!

Never touch the mains plug with wet hands. This could result in electrical shock.

When the system is connected to the main, system internal connectors can conduct dangerous voltage. Opening covers or removing parts could expose hot wires and connections. (Life Danger!). Therefore the system should be unplugged before it is opened for adjustments, maintenance or service work.

When an adjustment, repair or maintenance work of the current carrying system is necessary, it must be done by skilled personnel only.

Special attention should be given that only system fuses for the recommended nominal current and specifications are used as replacements. The shorting of the fuse carrier as well as the use of make-shift fuses is prohibited.

As soon as it is noticed that the safety precautions are not effective anymore, the system has to be switched off and protected against unintentional operation. The manufacture’s service personnel has to be contacted for repair work.

In case of doubt, the voltage can be checked on the inside of the power supply box.


User Manual


Picture 3-1: 230V / 50Hz

Picture 3-2: 110V / 60 Hz

The heating elements are the same for 230V as for 110V. This means that with 110V the system needs more time to warm up. Important: The heat regulators are adjusted according to the set voltage on the work side. If the system is switched to another voltage, no guarantee is given for the correct regulation functions. See 5.5 'Heat Control Settings'.

3.4 Compressed Air Connection

6 bar filtered compressed air Hose diameter 6 x 1

The average air consumption is approx. 6 norm liters / min.

When the equipment is installed in a system without a maintenance system, a filter and pressure reducer device have to be added.

Picture 3-3: Compressed Air Connection

As long as the system is connected to the compressed air, a system internal valve is switched manually. Movements with forces of up to 2 tons are released. Opening covers or removing parts therefore can be dangerous. The system therefore has to be disconnected from the compressed air before opening it for any adjustments, repairs or maintenance work.

If repairs, maintenance or adjustments under pressure are necessary they must be done by skilled personnel only.


User Manual


3.5 Heating of the Sealer

The sealer has an approx. temperature of 172°C when operational.

Important: Tooling changes are not to be made until it is insured that the sealer has cooled down. The cooling period takes considerable time due to the insulation.

3.6 Dangers Of Inappropriate Use

Important: Only microplates which were tested and recommended by REMP are to be used in the LHS. Noncompliance may result in damage to the equipment.

No tools, objects or liquids are allowed in vents or any of the system’s openings. This could result in electrical shock, malfunctions or even fire. In such a case the mains plug has to be unplugged immediately and the service partner or manufacturer has to be contacted.

It is prohibited to spray the system with cleaning detergent, disinfecting sprays or similar products. Sprays can contain gases which can ignite.

3.7 Safety and Monitoring Devices

If the Sealer is integrated into a robot system, access to the sealer is not possible during automatic operation. During manual operation, potentially dangerous machine movements set off a warning, and are not released until they have been reconfirmed. With the reconfirmation the user takes over the responsibility.

The plate feeding is equipped with a slip clutch with time monitoring of the forward movement. A faulty run is detected and shown as a plain text error message.

3.8 Specific Product Dangers

As long as the microplates are not sealed the substances stored therein are freely accessible. The property of the substance therefore has to be taken into account when handling the microplates. The manufacturer is not liable for any accidents or injuries.


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4 Assembly and Function

4.1 Detailed Function Description The function is described best with the following step by step illustration.

1. One microplate is taken from the stacker and is transported to the sealing station.

2. The microplate arrives simultaneously with the foil in the sealing station.

3. The microplate is lifted up by mechanical means

from below as the sealing plate descends from above.

4. The hot sealing plate melts the foil onto the

microplate and the knife then cuts the foil.

5. The microplate is then lowered and placed on the transport chain and leaves the sealing station.

6. The sealed microplate is then transported to the finished stack which it enters from below.


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4.2 Mechanical Assembly

The system is built rather robust and heavy because of the high level of pressing and cutting power which is needed. The system is fabricated mostly of aluminum which appears in a colorless anodized surface treatment, or of stainless steal. The covers are of stainless steel.

The microplate transporter and foil feeder are powered by direct current electrical motors. The high level of pressing and cutting power is generated pneumatically using a toggle method. The gates controlling access to the stackers are electromagnetically controlled. The foil tension rollers are spring loaded.


User Manual


5 Operating Information

5.1 Operation and Display Information

All operation functions are controlled via the small operation panel and its five keys. The operation panel is equipped with a 4 line display.

Cycle = F1

Manual Operations = F2

Parameter = F3

Support = F4

Picture 5-1: Main menu as shown on display

The ON / OFF switch and the heat temperature are both controlled directly on the heat regulator.

The top number, in red, displays the actual temperature.

The number underneath, in green, displays the set-temperature.

OUT: When the OUT signal lights up it is an indication that the temperature regulator has turned the heating on.

A1: As soon as the A1 signal lights up, the heating system is at operating temperature and a sealing cycle can begin.

OUT/OFF: The on / off switch. This button must be pushed continuously for 5 seconds to turn the Sealer on or off. When the Sealer is turned off, then OFF will be displayed where the number in red normally is displayed. When turned on, the actual temperature will then be displayed in red, and it will quickly rise to match the set-temperature. As the temperature nears the set-temperature the heating will switch very rapidly off and back on again to avoid overshooting the set-temperature.

For more information, refer to 5.5 Heat Control Settings.


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5.2 Menu Description

The Sealer is designed to be operated either in Manual-Mode, or by either of two remote modes. While in Manual-Mode the Sealer can be operated by using the keyboard on the Sealer itself. The first remote control method would be operation through a PC (personal computer), via the RS 232 Interface. The second remote control method is through an Impulse carried out through a Hardware Interface. The RS 232 Interface is a standard Sbus (Serial Bus), which communicates between the PLC (Programmable logic controller) in the Sealer and a PC. This has the advantage of being able to include the Sealer in a complex Module. The PC can then give the instruction to complete a sealing cycle, and all warnings and alarm systems can be controlled and overseen and accounted for from the PC.

When using the Hardware Interface method, an Input signal can begin a sealing cycle. Their are four possible operating modes: Sealer ready, sealing cycle in progress, microplate sealed, and Alarm (system problem). These operating modes are communicated by two Outputs. The acknowledgement of alarm and the reference are carried out directly on the keyboard.

For more complete information please see the sections on Display and Keyboard.

By means of the F5 key one can leave a lower menu, leave a Function altogether, or acknowledge a Function.

5.2.1 EQUIPMENT INFORMATION

REMP LH Sealer Type: 36720411 Code: 100 Vers: 20001101

← Equipment description ← Model number ← Software Code designation ← Software Version

5.2.2 MAIN Menu

CYCLE =F1 MANUAL OPER. =F2 PARAMETERS =F3 SUPPORT =F4

← Functions: Start, Seal cycle, Reference ← Individual manual operations ← Equipment parameters ← Special functions – System information


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5.2.3 Menu: CYCLE

CYCLE: Seal =F1 Reference =F2 Remote mode =F3 OPTIONS =F4

← Start seal cycle using keyboard or via Hardware interface ← Start reference run. Positioning of the plate feed ← Release of the remote control mode. RS232 interface ← Sub menu options and other Sealer possibilities

OPTIONS:

START BATCH =F1 HANDLING =F3 Up =F5

← Sealer w/ Stacker: plates in Stacker will be automatically sealed ←Automatic plate collection: Hardware interface

START BATCH:

START BATCH: Front Stacker=F1 Back Stacker =F2 Up =F5

← The plates in the front Stacker will be sealed. ← The plates in the back Stacker will be stacked in the front Stacker.

HANDLING:

Plate pickup via handling device =F1 Up =F5

←

5.2.4 Menu: MANUAL OPERATIONS (Individual Moves)

MANUAL OPERATIONS: PLATE TRANSP.=F1 Foil feed =F2 PRESS =F3 STACKER =F4

←Sub menu: plate movement forwards or backwards ← Foil movement of one plate length ← Sub menu: Press ← Sub menu: Stacker

PLATE TRANSPORT:

PLATE TRANSPORT: forwards =F1 backwards =F2 Up =F5

← Plate movement forwards of one plate length ← Plate movement backwards of one plate length

PRESS:


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PRESS: Position Not defined! close =F1 open =F2

← Display shows current position of press ← To close press ← To open press

STACKER: 1. Possibility

LIFT: up Down wiou. Pl=F2 Down with plate Front=F3/Back=F4

← Display shows current position of the lifter. ← Moves the lifter down without a plate. ← Moves the lifter dowm with a plate from the front, or the back stacker.

STACKER: 2. Possibility

LIFT: down upwards =F2 Up =F5

←Display show current posiotion of the lifter. ←Moves the lifter up.

5.2.5 Menu: PARAMETER

PARAMETER: PLATE TRANSP.=F1 SEAL TIME =F2 SAFETY BARR. =F3 STACKER =F4

← Sub menu: plate transport direction ← Sub menu: sealing time ← Safety guard present or not ← Sub menu: Sealer with Stacker

PLATE TRANSPORT:

PLATE TRANSPORT: Forw/forw Forw/backw =F2 Up =F5

← Display: current status of transporter Change to the other status of transport. (forw/forw = Transports continually ← forwards / forw/backw Transports plate forwards, then backwards to original place).

SEAL TIME:

SEAL TIME **** +100=F1 -100=F2 Up =F5

← Display: actual sealing time ← To change sealing time: +/- 100ms

SAFETY GUARD:

SAFETY BARRIER: present not present =F2 Up =F5

← Display: current status ← To change to the other status.

STACKER:

DURATION FOR CLICKS =F1 BATCH END =F2 STACKER TEST =F3

← Time required to collect a plate from the Stacker ← The sealed plate is ready to be stacked: either in the front or rear Stacker ← Selection: Stacker test with seal active or inactive

DURATION FOR CLICKS:

DURATION FOR CLICKS **** +100=F1 -100=F2

← Display: Actual collection time ← To change time: +/- 100ms

BATCH END:


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BATCH END: back fron =F2 Up =F5

← Display: current status ← To change to the other status.

STACKER TEST:

STACKER TEST: Sealing: active deactivate =F2 Up =F5

← Display: current status ← To change to the other status. All plates will be sealed ← Plates will not be sealed

5.2.6 Menu: SUPPORT

SUPPORT:

LANGUAGE =F1

Num.of Cycles=F2

See Errors =F3

Up =F5

← Sub menu: Change language

← Displays the total number of sealing cycles

← Displays the acknowledged and existing errors / warnings

LANGUGE:

LANGUAGE:

English

German =F2

Up =F5

← Display current status

← Change to the other language.

Number of cycles: (1. Part)

SEAL CYCLES:

Total ****

Since service

Up=F5 ****

← Total number of seal cycles performed on this system

← Total number of seal performed since last service (after a service this will be set back to zero)

Number of cycles: (2. Part)

Need service

in ****

cycles!

Up =F5


User Manual


5.3 User Messages

In this chapter a description of all possible User Messages is presented. The User messages are grouped into 4 main Menus.

They are: Cycles, Manual operations, Parameters and Support.

In this section all menu options will be printed in bold. For example: Seal cycle, Plate forwards, Foil feed, etc.

5.3.1 Messages in Menu CYCLE

Message

Description

Caution: Keep hands away from the press ! Ok=F1-F4 / Up=F5

Safety warning

Searching for

reference

position!

Reference run in process

Wait !

Cycle running

Alarm present:

See alarms in

Menu: Support.

Ok =F5

Function not possible. Errors still existing. Reference is only been carried out if no alarm is present with the exception: Error reference necessary. Seal cycle is only carried out if there is no existing error. Start Operation will only be carried out when there is no existing error.

Attention:

Press is closed!

Ok =F5

Reference is only carried out when press is opened

Work temperature not reached!

Ok =F5

Seal cycle is only carried out if the temperature regulator is switched on and the set-temperature is reached. The same goes for Start Operation.


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Attention:

No plate at

entry position!

Ok =F5

Seal cycle can only be executed when a plate is in the entry position. The status ‘plate sealed’ is set at the hardware interface as soon as a plate is positioned at the entry position. Transport: forwards – backwards

Attention:

Plate at exit

Position!

Ok =F5

Seal cycle will only be executed when exit position is free

Reference run is only carried out if there is no plate in the sealer

Attention: No plate at exit position! Ok =F5

The status “plate sealed” is set at the hardware interface as soon as a plate is positioned at the entry position. Transport: forward – forward

Attention: Plate at entry Position Ok =F5

Reference run will be executed only when there is no plate in the sealer.

Attention: Plate At press posit. Need transport! Ok =F5

Seal cycle is only executed if no plate is in the press. The reference run is only executed if there is no plate in the sealer. In order to erase this flag go to menu “Manual Operation”, plate forward or plate backwards, to carry out the transport.

LH SEAL: Remote-mode! End =F5

The system is being remote controlled, RS232 Interface

Displays all errors (5 s)! Ok =F5

After acknowledgment of the remote control mode the program will show all existing Errors.

Attention: Handling will pick the plate! Ok =F5

Security as warning at the hardware interface. This status “Plate Sealed” is only applied if the plate has reached the end of the automatic seal cycle.

Warning: Maintenance necessary! Ok =F5

The sealer must be serviced every 10,000 seal cycles. This message only appears when the meter reading has been reached. After this, it will only reappear when the machine is started up.

Seal excecuting batch! End =F5

Start operation: The Sealer carries out one operation after the other. One operation consists of the microplates which are in the front Stacker and ready to be sealed.

END OF BATCH. Please remove Plates. Ok =F5

The sealed plates are in the Stacker. The Stacker may now be removed.

Table 5-1: User Messages in Menu Cycle


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5.3.2 User Messages in Menu: MANUAL OPERATION

Message

Description

Caution: Keep

Hands away from

the press!

Ok=F1-F4 / Up=F5

Safety warning Acknowledge by pressing any key

Wait !

Command in process

Alarm present:

See alarms in

menu: Support

Ok =F5

Function not possible, errors still existing

Attention:

Press is closed!

Ok =F5

Plate forward can only be started if press is open

Attention:

Plate at exit

Position!

Ok =F5

Plate forward can only be started if the exit position is free.

Option Sealer with Stacker: The Lifter cannot be lowered when a plate is present in the exit position.

Attention:

Plate at entry

Position!

Ok =F5

Plate backwards can only be started if the entry position is free. Option Sealer with Stacker: The Lifter cannot be lowered when a plate is present in the entry position.

Attention: Plate

at press posit.

Need transport

Ok =F5

The forward transport can only be started if the message is acknowledged and a forward transport has been executed. In order to erase this flag go to menu “Manual Operation”, plate forward or plate backwards in order to execute the transport.

Don’t forget the

foil between

press and plate!

Ok=F1-F4 / Up=F5

Please make sure that the foil is placed under the press. In case that there is no foil under the press go to menu “Manual Operation”, foil feed, to execute this function until the foil is place under the press. Attention: Keep hands off press, danger of bruising!


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Attention:

The lift is up!

Ok =F5

Option Sealer with Stacker: The lifter should not be given a command to go into the "up“ position when it is already in the "up“ position.

Attention:

The lift is

down!

Ok =F5

Option Sealer with Stacker: The lifter should not be given a command to go into the "down“ position when it is already in the "down“ position.

Please move the

lift first up!

Ok =F5

Option Sealer with Stacker: The function, "Take plate from front (or back) Stacker is only possible when the Lifter is in the "up“ position.

Table 5-2: User Messages in Menu Operations


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5.3.3 User Messages in Menu: PARAMETERS

Message

Description

Plate transport:

Forward/forward

Ok =F5

Sealer is now set that the plates are transported to the exit position after being sealed

Plate transport

Forward/backward

Ok =F5

Sealer is now set so that the plate will return to its entry position after being sealed

Searching for

Reference

Position

A reference run will automatically occur after a change in the Plate Transport command

Safety barrier

Present in

Sealer!

Ok =F5

Message is confirmation

No safety

Barrier present

In sealer

Ok =F5

Message is confirmation

End of batch:

At the back.

Ok =F5

Option Sealer with Stacker: Message as confirmation

The sealed plates will be stacked in the back Stacker.

End of batch:

At the front.

Ok =F5

Option Sealer with Stacker: Message as confirmation

The sealed plates will be stacked in the front Stacker.

Table 5-3: User Messages in Menu Parameter


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5.3.4 User Messages in Menu: SUPPORT

Message

Description

Language:

German

Ok =F5

Language is changed to German

Language:

English

Ok =F5

Language is changed to English

Display all

Errors (5 s)!

Ok =F5

All Errors present will be shown in 5 second intervals

No Errors

Present!

Ok =F5

Table 5-4: User Messages in Menu Support

5.4 Errors

• New errors will appear directly on the display and have to be acknowledged.

• Errors will abort seal cycles and menu functions!

• In this case, plates must be removed manually from the sealer.

• New seal cycles may be started when all errors and warnings have been eliminated.

• The option “Error Messages” in the menu “Support” shows all pending errors. This includes Errors which have been acknowledged but still exist.

• The error numbers are always shown together with the error on the display.

• Additional information pertaining to the individual elements such as relays, sensors, etc., which are installed within the sealer can be found in the sealer’s electrical schematics.

In the following table the different error descriptions can be found.


User Manual


Error

No.: Description

02 Reference run necessary: This error occurs after startup or after error numbers: 03, 18, 19, 20, 21, 37, 38, 44, 45 or 46. this error will persist until the reference in the menu “Cycle” has been completed.

03 Referencing has taken too long. Error as warning. After acknowledgement the warning will disappear.

04 XOB00 Info for REMP.














18 K1006 Switch - Transport is turned off

19 K1006 Switch – Transport is sticking

20 K1005 Switch - Direction of rotation transport is turned off

21 K1005 Switch - Direction of rotation transport is sticking

22 K1105 Switch – Foil feed not turned on

23 K1105 Switch – Foil feed is sticking

24 S1201 Press is not open

25 S1202 Press is not closed

26 S1201 and S1202 Both sensors covered

27 S1203 Magnet is not open

28 S1204 Magnet is not closed

29 S1203 and S1204 Both sensors covered


User Manual


Error No.

Description

30 A1302 Work temperature not reached. The temperature control1 has to be switched on and the set operation temperature has to be reached. This error only comes up in the remote mode. However, a check can also be performed in the Seal cycle, using the keyboard.

31 F1301 Safety switch has been triggered

32 X1101 Foil fuse has been blown – please replace

33 S1112 Foil is too loose or there isn’t any more foil in the Sealer

34 S1113 Foil is too tight. The check is done before a seal cycle.

35 S1111 Foil is not in position. Use the Menu: Manual Operations to feed the foil.

36 B1013 Plate at entry position. Alarm serves as warning. After being acknowledged it disappears.

37 There is a plate at the press. Perform a "plate forward movement" (without a plate), using the Menu: Manual Operations.

38 B1014 Plate at exit position.

Alarm serves as warning. After being acknowledged it disappears.

39 B1013 No plate at entry position. Alarm serves as warning. After being acknowledged it disappears.

40 B1014 No plate at exit position.


41 X1001 Plate fuse blown. Please replace.

42 Time for foil feed too long. Alarm serves as warning. After being acknowledged it disappears.

43 Time for transport too long. Alarm serves as warning. After being acknowledged it disappears.

44 Seal time is too long. This check is not performed in the Menu:Manual Operations. Alarm serves as warning. After being acknowledged it disappears.

45 Cycle time is too long.



User Manual


Error

No.:

Description

46 Sealer service necessary. Please contact REMP.

A service is necessary after every 10,000 seal cycles.

This Error message will be displayed when when 10,000 seal cycles has been reached since the last service and thereafter each time the Sealer is turned on, until the service is performed. After acknowledgment normal operation can be continued. This Error is given as a warning in the Remote Mode.

47 K3006 Stacker switch not turned on

48 K3006 Stacker switch is sticking

49 K3005 Stacker: direction of rotation switch not turned on

50 K3005 Stacker: direction of rotation switch is sticking

51 K3052 Front gates: switch not turned on

52 K3052 Front gates: switch is sticking

53 K3056 Back gates: switch not turned on

54 K3056 Back gates: switch is sticking

55 S3106 Front gates: Gates are not open

56 S3105 Front gates: Gates are not closed

57 S3105 + S3106 Front gates: Both sensors are covered

58 S3107 Back gates: Gates are not closed

59 S3108 Back gates: Gates are not open

60 S3107+S3108 Back gates: Both sensors are covered

61 X3001 Stacker fuse blown. Please replace.

62 S3103 + S3104 Lifter not being recognized. Both sensors are covered.

Perform a Lifter advance (without plate) in the Menu: Manual Operations.

Possibility: A sensor is defective or not properly adjusted.

63 S3103 + S3104 Lifter: Both sensors are covered.

Possibility: A sensor is defective or not properly adjusted.

64 Stacker transport time is too long.

65 Stacker not plugged in.

66 Front gates are open too long

67 Back gates are open too long

68 B3101 Entry: plate is improperly placed

69 B3102 Exit:: plate is improperly placed

Table 5-5: Error Descriptions


User Manual


5.5 Heat Control Settings

5.5.1 Switching the Controller On / Off

Normal operation Switch off control Switch on control

During normal operation the control can be switched on and off by means of the OUT/OFF button. This button has to be pressed for approx. 5 seconds to activate.

5.5.2 Adjusting the Set-Value

Normal operation Adjusting set-value Acknowledging set-values

1) Press the MODE button 2) The set-value can be adjusted with the UP (▲) and DOWN (▼)buttons. 3) Confirm the settings with the MODE button. The new set-value now appears in the bottom

display.


User Manual


5.5.3 Auto Tuning (After Changing the Voltage)

The Temperature Regulator monitors the temperatures defined by the User and is responsible for keeping the sealing temperature constant.

The Temperature Regulator is set to the proper voltage by Remp personnel upon delivery.

In the event the voltage is changed (only to be executed by specially trained personnel) an Auto Tuning must then be performed. The control readjusts its own parameters, when the steps below are followed:

• Press and hold the ▲ button, then simultaneously press and hold the MODE button for three seconds.

• Press the ▲ button again.

• Press the MODE button again, to start the Auto Tuning

During the Auto Tuning the red light “AT“ will be blinking.

The process requires about five minutes. When it finishes, the Temperature Regulator will automatically change to normal operations.


User Manual


5.5.4 Basic Factory Settings

The values described in this chapter are not to be altered. This chapter serves to document what parameters the controls are set on.

Set-Points Set at Meaning, Description

Warning type A1 üLd An automatic cycle is not possible as long as the temperature is not within the tolerated range of the set value. If the LED lights up in display A1 it means that the actual temperature is within tolerance.

Temperature tolerance 3 The temperature tolerance range, with relation to the set value.

Maximum set-value 185 The user can adjust the set temperature no higher than this value. Higher temperatures are not allowed.

Sensor type k C Thermal sensor type K °C


User Manual


5.6 Modifications to Fit Different Microplates

5.6.1 Specific Plate Adapters

Prerequisite for a smooth operation are the specific plate adapters.

Picture 5-2: Specific Plate Adapters

The proper adapters for each plate are listed below.

Brief Plate Description Adapter number Gauge for setting Transport Level

Plate Manufacturer

co 96MTP-U 3-18-05938 4-18-06350 Costar

gr 96MTP-U 3-18-05938 4-18-06350 Greiner

gr 96MTP-V 3-18-05932 4-18-06350 Greiner

re 384MTP 3-18-05932 4-18-06348 REMP

co 384MTP 3-18-05932 4-18-06350 Costar

gr 384MTP 3-18-05932 4-18-06350 Greiner

gr 96DWP-U 3-18-06068 4-18-06559 Greiner

gr 384 DWP 3-18-06099 4-18-06560 Greiner

Table 5-6: Adapter Overview

Adapters and setting gauges for other microplates available on request.


User Manual


5.6.2 Perform Modification Operations Only When Sealer is At Room Temperature.

The following pictures show how these adapters should be installed.

Picture 5-3: One rotation results in appx 0.2 mm adjustment

Picture 5-4: Setting of Transport level

The plate height adapter can be exchanged directly on the Sealer.

Picture 5-5: Mounting plate height adapter

Picture 5-6: Mounting plate height adapter


User Manual


5.6.3 Precision Adjustment Of The Cutting Blade In Manual Operations

Picture 5-7: Transportation of plate into sealing station

• Insert plate in transport chain

• Forward plate to sealing station

• Close press

• Open press

• Transport plate out of sealing station

• Check cutting depth – correct by turning knob, if necessary

• One rotation of the knob to the right will raise the plate appx. 0.2 mm

Picture 5-8: Plate before the cold piercing

Picture 5-9: Plate after the cold piercing

Ideal depth of blade cut in plate should be 0.1 mm

Cutting depth


User Manual


5.6.4 Adjustment Of The Lifter

If the Sealer is modified to seal a different size microplate the Lifter must be adjusted accordingly. Loosen the screws of the bracket and slide the bracket to the appropriate marker for the new microplate size. This should match the number which is shown on the Transport level adapter. Tighten the screws. The level of the Lifter forks should be appx. 2 mm under the level of the transport chain. In Manual Operation move the Lifter down.

Adjustment bracket for positioning Lifter


User Manual


5.7 Installing Foil Roll

5.7.1 Side Feed Sealer

Picture 5-10: Mount foil roll

Picture 5-11: Mount cover plate

Picture 5-12: Lay foil over the tension rollers

Picture 5-13: Pull foil through slot in the side wall, then over the diagonal guide bar


User Manual


Picture 5-14: Place foil end at transport in feed

Picture 5-15: Push key F3 as many times as necessary to feed the foil far enough until the upper sealing plate is covered

If the foil slips to one side or the other, please follow the following procedure:

Picture 5-16: Shows foil centered over guide bar

• Pull foil over guide bar and center it

• While constantly adjusting the angle of the guide bar, feed approx. 1 meter of foil, using Manual Operations.

• When the foil runs centered on the guide bar, tighten the screws to the guide bar.

• Start seal testing with at least 20 new microplates.

• The foil must stay centered at all times.

Guide bar


User Manual


6 Maintenance and Support

6.1 Introduction

Maintenance and support work is only to be carried out by specially trained personnel.

For all service work the system has to be disconnected from power by switching the system off and unplugging the cable from the socket. The compressed air supply has to be disconnected as well. Please make sure that the heat plate is cooled down.

Do not allow any liquids to get inside the equipment!

6.2 Maintenance Work

According to the environmental conditions (dust, etc.) the system has to be checked weekly or monthly for its cleanliness. The transport chains have to be greased once a month.

If it is discovered that there is dirt or plastic residue on the heat plate, the heat plate has to be completely cooled down. Because of its special coating, even plastic residue can be removed from the hot plate by means of a scraper-like device which is not sharp-edged. The heat plate can be cleaned with a slightly damp cloth.


User Manual


List of Tables

Table 5-1: User Messages in Menu Cycle ..................................................................................................18 Table 5-2: User Messages in Menu Operations..........................................................................................20 Table 5-3: User Messages in Menu Parameter...........................................................................................21 Table 5-4: User Messages in Menu Support...............................................................................................22 Table 5-5: Error Descriptions.......................................................................................................................25


User Manual


List of Illustrations

Picture 2-1: REMP MTP384 ..........................................................................................................................2 Picture 2-2: REMP MTP384 sealed ..............................................................................................................2 Picture 3-1: 230V / 50Hz ...............................................................................................................................8 Picture 3-2: 110V / 60 Hz ..............................................................................................................................8 Picture 3-3: Compressed Air Connection ......................................................................................................8 Picture 5-1: Main menu as shown on display..............................................................................................12 Picture 5-2: Specific Plate Adapters............................................................................................................29 Picture 5-3: One rotation results in appx 0.2 mm adjustment .....................................................................30 Picture 5-4: Setting of Transport level .........................................................................................................30 Picture 5-5: Mounting plate height adapter .................................................................................................30 Picture 5-6: Mounting plate height adapter .................................................................................................30 Picture 5-7: Transportation of plate into sealing station ..............................................................................31 Picture 5-8: Plate before the cold piercing ..................................................................................................31 Picture 5-9: Plate after the cold piercing .....................................................................................................31 Picture 5-10: Mount foil roll..........................................................................................................................33 Picture 5-11: Mount cover plate ..................................................................................................................33 Picture 5-12: Lay foil over the tension rollers ..............................................................................................33 Picture 5-13: Pull foil through slot in the side wall, then over the diagonal guide bar .................................33 Picture 5-14: Place foil end at transport in feed ..........................................................................................34 Picture 5-15: Push key F3 as many times as necessary to feed the foil far enough until the upper sealing plate is covered ...........................................................................................................................................34 Picture 5-16: Shows foil centered over guide bar .......................................................................................34

Documents

REMP Plate Sealer LHS-056 Manual