This document is a user manual for the Star Universal (Gosport) Ltd heat sealing machine, specifically models 106-106C. It provides comprehensive information on the machine's operation, maintenance, and technical specifications.
Function Description
The Star Universal heat sealing machine is designed for packing a wide variety of products by creating strong, flat heat seals on bags or other materials. These machines are built in-house to high standards, undergo rigorous testing, and comply with all relevant regulations. The core function involves applying heat and pressure to seal materials, with options for vacuum sealing in certain models. The machine is equipped with controls for adjusting weld and cool times, and compensation settings to ensure consistent seal quality.
Important Technical Specifications
The manual provides detailed technical specifications for various seal lengths, including 500mm, 600mm, 750mm, and 900mm models.
General Specifications:
- Seal Width: Standard 6mm, with options for 2.5mm, 9.5mm, 12.5mm, and 20mm.
- Jaw Opening (Solenoid): Approximately 30mm.
- Max Material Thickness: Approximately 1000µm (4000g).
- Sealing Cycle Time: Typically 4-10 seconds.
- Vacuum Cycle Time: Typically 2-20 seconds, dependent on pack size and vacuum level required.
- Power Supply: 230V 50/60Hz Single Phase, with a 115V Optional variant.
- Average Power Consumption / Cycle: 0.02kWh.
- Average Power: Vacuum 160W, Weld 1730W, Cool 250W, Standby 25W.
Dimensions and Weight (Solenoid Machine):
| Feature |
500mm Model |
600mm Model |
750mm Model |
900mm Model |
| Jaw Length |
565mm |
665mm |
815mm |
965mm |
| Machine Body Length |
500mm |
500mm |
500mm |
500mm |
| Depth |
415mm |
415mm |
415mm |
415mm |
| Overall Height |
430mm |
430mm |
430mm |
430mm |
| Weight |
46kg |
48kg |
50kg |
53kg |
All weights and dimensions are approximate and based on the standard machine. Star Universal reserves the right to change specifications without prior notice.
Usage Features
The machine features a user-friendly control panel with indicators for weld control, power on, keypad locked, alarm, and cool control.
Setting Weld and Cool Times/Temperatures:
- Weld Time/Temperature: Adjusted using the weld control ▲ or ▼ keys. The amber weld indicator flashes, and the screen displays the current setting. A starting point of 0.7/80 is suggested.
- Cool Time/Temperature: Adjusted using the cool control ▲ or ▼ keys. The blue cool indicator flashes. Cool time should generally be approximately three times the weld time, but can be adjusted based on material requirements.
Compensation Settings:
- Heating Compensation: Reduces weld time after each operation to compensate for residual heat build-up. A value of 0 disables it, while higher values reduce weld time more significantly. Adjusted by pressing both weld control ▲ and ▼ keys for 2 seconds until "hc" appears.
- Cooling Compensation: Increases weld time when the machine is idle to compensate for cooling down. A value of 0 disables it, while higher values increase weld time more rapidly. Adjusted by pressing both cool control ▲ and ▼ keys for 2 seconds until "cc" appears.
Key Lock:
- A control lockout feature prevents unauthorized alteration of settings. To engage or disengage, press the cool ▲ or ▼ key, then press and hold both weld ▲ and ▼ keys for 2 seconds. The green keypad locked light indicates the status.
Jaws Timeout:
- This setting defines the time allowed for the jaws to close, open, or for the automatic knife to complete its travel before alarms engage. Adjusted by pressing the cool ▲ key and weld ▼ key for 2 seconds.
Machine Operation:
- After setting vacuum level, weld, and cool times, the machine is ready.
- Operation involves placing the bag between the jaws, closing the clamp jaw until sufficient vacuum is applied, pressing the foot switch (or push button), and allowing the top jaw to descend for the weld and cool cycle.
- Important Safety Note: Release the clamp jaw once the sealing jaws have closed to prevent damage to the clamp jaw rubber from the returning probe. Keep hands clear of the sealing jaws during operation.
Vacuum Level Setting (for vacuum models):
- Cover the vacuum probe with a bag.
- Close the clamp jaws to start the pump; the vacuum gauge should show a reading.
- Adjust the vacuum regulator to achieve the desired maximum level and lock it in position.
- Probe Blocking: If the vacuum probe is blocked by the bag, reposition the product closer to the probe or gently tension the bag away from the probe.
Maintenance Features
Regular maintenance is crucial for the machine's longevity and performance.
Daily Maintenance:
- Visually check barrier tape: Replace if there are burn marks, rips, or damage.
- Jaws move freely: Manually shut jaws before turning on the machine to ensure free movement.
Monthly Maintenance:
- Sealing jaws: Change tapes, element, and rubber if necessary. Check end blocks for damage.
- Clamp bars: Change tape and sponge if necessary.
- Clean filters: If applicable.
- Cutter rail: Check condition for excessive wear and change if necessary.
6-Month Maintenance:
- Repeat monthly maintenance. A 6-month maintenance kit can be ordered from Star Universal.
- Internal inspection: Visually check the power relay (replace if discoloured). Lubricate solenoids using graphite powder.
Yearly Maintenance:
- Contact Star Universal for an onsite visit or to send the machine for service.
Replacing Consumable Items (detailed instructions provided):
- Barrier Tape: Prevents plastic sticking to the element ribbon. Peel off old tape, clean adhesive, and apply new tape loosely, ensuring it's not in contact with the element ribbon when jaws are open.
- Element Ribbon: Remove barrier tape. Use loading pins to compress springs. Loosen Allen key bolt, remove old ribbon. Cut new ribbon slightly longer than the jaw, fold ends, and fit into expansion blocks, tightening Allen bolts. Replace barrier tape.
- Brass Shim: Remove barrier tape and element ribbon. Unscrew Allen bolt, replace shim, and reassemble.
- Silicone Rubber/Sponge (Heated Jaw): Remove barrier tape and element ribbon. Peel off old rubber, clean adhesive, apply a narrow bead of silicone adhesive, press new rubber into the channel, and replace ribbon and tape.
- Clamp Bar Rubber: Remove old barrier tape and rubber, clean the aluminium, apply silicone adhesive, and stick new rubber. Replace barrier tapes. Fasten jaws together for about 2 hours to allow adhesive to set.
- Compression Spring and Ball Bearing: Remove barrier tape and element ribbon. Carefully remove loading pin (spring is under tension). Replace spring and ball bearing. Refit element ribbon and tape.
Thermocouple Replacement:
- Cut a shallow V shape into the silicone rubber.
- Place the thermocouple through the hole in the jaw, ensuring the tip/disc sits on top of the rubber in the center of the silicone.
- Secure with thermocouple adhesive strip.
- Place backing tape over the rubber and replace the element ribbon.
Safety Instructions:
- Read the manual in full before operation.
- Follow all warnings and instructions on the machine.
- The machine is supplied with a 3-wire power cable and a 13 amp fused plug (UK). A secondary fuse is on the circuit board. An RCD is recommended for increased safety.
- Not rated for direct water contact unless stated otherwise.
- Switch off power and remove the plug before any service work.
- Regular servicing with genuine Star parts is required.
- Switch off when not in use.
- Install on a flat, level surface.
- Handle with care when moving due to its weight.
- Not for use in flammable or explosive environments.
- Avoid touching sealing jaws due to residual heat.
- Keep hands clear of sealing jaws during operation.
- Use in a ventilated environment as sealing certain plastics may create fumes.
- Meets health and safety requirements of The Supply of Machinery (Safety) Regulations 1992 No. 3073 and The Machinery Directive 2006/42/EC.
Environmental Responsibility:
- As the machine contains electrical and electronic components, it must be disposed of correctly and not in general landfill.
- Star Universal offers a collection service for machines they built at the end of their useful life for recycling. Contact them for prices, stating the machine model and serial number. Producer Registration No. WEE/MM7018AA.
Warranty Policy:
- 1-year warranty from the date of delivery on all Star Heat Sealing machines for defects due to faulty manufacture.
- Warranty conditions: fault reported to Service Department, not caused by misuse/neglect/faulty adjustments, not due to normal wear and tear, serviced/repaired only by authorized personnel, and machine returned to Star Universal.
- Expendable items (jaw barrier tape, heating elements) are not covered but are available for purchase.
- Travel time for onsite visits may be charged.
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