FR-900

FR-900 Vertical
FR-900 Stainless
FRD-1000
DBF-1000
Continuous Band Sealers

WWW.SIMPLESEALERS.COM 1101 HAMILTON ST. ALLENTOWN P.A. Phone: 484-223-0309 Fax: 484-223-0318
 Table Of Contents
1. About Band Sealers
2. About Band Sealers
3. Schematics
4. Schematics
5. Electrical Schematic
6. Specifications
7. Specifications
8. Machine Setup
9. Machine Setup
10. Machine Setup
11. Machine Setup
12. Machine Setup
13. Machine Setup DBF-1000 Self Inflating Band Sealer
14. Machine Setup
15. Machine Setup
16. Machine Operation
17. Sealing Operation
18. Printing Optimization
19. Maintenance
20. Maintenance
21. Troubleshooting
22. Troubleshooting

WWW.SIMPLESEALERS.COM 1101 HAMILTON ST. ALLENTOWN P.A. Phone: 484-223-0309 Fax: 484-223-0318
 About Band Sealers
Continuous band sealers are an ideal solution for sealing and bag making
for a variety of different heat sealable materials. Continuous band
sealers are currently used in many industries including,
pharmaceutical, food, chemical, agricultural for product packaging.
Horizontally oriented machines are typically used for dry materials,
vertically oriented can be used for liquids.

Features of band sealers include high throughput (belts run continuously),

a high level of flexibility in application and material usage, and ease of
use.
FR-900 Being used to seal pregnancy test kits.

Continuous band sealers utilize an upper and lower teflon belt. The belts
pass over an upper and lower heating element. As the pouch/bag
passes from right to left it is heated by the teflon belts, following this
process it passes through a pressure wheel that seals the materials
together. The machines also feature an additional belt set that carries
the sealed pouch as it cools until it is exited at the left side of the
machine. All machines also have a conveyor that lends support to
packages as they pass from right to left through the sealing process.

Operation of FR-900 and FRD-1000 series band sealers is simple and Because the sealing mechanism is continuous there
hassle free. All machines are ready to use out of the box. Simply set Is no limit to the length of a potential seal.
the desired heating temperature, engage belts, adjust belt speed, wait
for machine to reach temperature and seal pouches. All settings are
adjustable using the switches and dials on the control panel.
Reference the control section of this manual for specific information
relating to the machine you have purchased.
 About Band Sealers
FR-900 Basic: Basic Band Sealer. Features an
included embossing wheel.
FR-900 Vertical: Same as basic but with stand
and drive shaft for vertically oriented
operation,
FR-900 Stainless: Same as basic but with
Stainless Steel case and components.
FRD-1000 Model: Larger machine with built in DBF-1000 Inflating Sealer
solid state printer.
DBF-1000 Model : Features stand and
compressor. Used for packaging items such
as food stuffs that require an air puffed
package.

DBF-1000 Compressor
 Schematics

FR-900 Horizontal, Stainless FR-900 Vertical

 Schematics

FRD-1000
 Electrical Schematic

FR-900 Electrical Schematic

 Specifications
Specification FR-900 FR-900 FR-900 DBF-1000 FRD-1000
Vertical Stainless
Power / Voltage 110v or 220v 110v or 220v 110v or 220v 110v or 220v 110v or 220v
50-60 Hz 50-60 Hz 50-60 Hz 50-60 Hz 50-60 Hz

Belt Speed 1-12 meters 1-12 meters 1-12 meters 1-12 meters 1-12 meters
per minute. per minute. per minute. per minute. per minute.
39-468 inches 39-468 inches 39-468 inches 39-468 inches 39-468 inches
per minute. per minute. per minute. per minute. per minute.

Conveyor 10 KG: 22 LBS 10 KG :22 LBS 10 KG :22 LBS 10 KG :22 LBS 10 KG: 22 LBS
Capacity
Sealing Temp 0-300 Celsius 0-300 Celsius 0-300 Celsius 0-300 Celsius 0-300 Celsius
32-572 32-572 32-572 32-572 32-572
Fahrenheit Fahrenheit Fahrenheit Fahrenheit Fahrenheit
Sealing Width 12mm 12mm 12mm 12mm 12mm
0.5 inches 0.5 inches 0.5 inches 0.5 inches 0.5 inches

Sealing 0.01-.2mm 0.01-.2mm 0.01-.2mm 0.01-.2mm 0.01-.2mm

Thickness 10-200 ul 10-200 ul 10-200 ul 10-200 ul 10-200 ul

Sealing Length Unlimited Unlimited Unlimited Unlimited Unlimited

 Specifications Cont.
Specification FR-900 FR-900 FR-900 DBF-1000 FRD-1000
Vertical Stainless
Printing INK or Embossing Embossing Embossing Embossing Ink
Embossing
Characters Max 13 Max 13 Max 13 Max 13 Max 20

Actuated Print Continuous Continuous Continuous Continuous Actuated

Continuous
Print
Compressor NO NO NO YES NO

Cooling Fan Yes Yes Yes Yes Yes

Machine 34inx16inx14in 34inx16inx14in 34inx16inx14in NA 40inx18inx18in

Dimensions

Machine 65lbs (29.5Kg) 65lbs (29.5Kg) 65lbs (29.5Kg) 100lbs 77lbs (34.9Kg)
Weight
Harmonization 8422.30.0000 8422.30.0000 8422.30.0000 8422.30.0000 8422.30.0000
Code
 Machine Setup
FR-900 Vertical Only:
The FR-900 Vertical requires some assembly for use in the vertical orientation. The
machine ships in the horizontal configuration and must be partially disassembled
(conveyor removed) then re-assembled.

1. Remove conveyor assembly. First remove the (Schematic FR-900 horizontal #17.)
Conveyor station in out knob. Then slide the conveyor off the base of the sealers
bottom frame.
2. Assemble the Vertical Stand. This is composed of two legs and two cross beams.
Attach the cross beams (facing downward) with the included metal screws.
3. Mount the sealer onto the vertical stand. See schematic FR-900 Vertical, so that
the sealers exposed bottom frame slots into the vertical stand. Use the Conveyor
station in out knob's to secure the machine to the frame.
4. Remove the existing drive shaft for the conveyor (labeled horizontal short axis)
and replace with the long drive shaft (labeled horizontal long axis) and the
(umbrella gear set).
5. Put the long drive shaft into the hole in the drive gear on the machine. Tighten
screws.
 Machine Setup
FR-900, Basic, Vertical, Stainless, FRD-1000:
1. The machine is equipped with a three prong grounded plug. Inspect to make sure
that it is free from damage and in good order. Plug into a grounded outlet.
2. Set a low temperature setting for initial running period, run the machine for 10
minutes or more to ensure that the heating element is in good working order. The
machine can sometimes become damp in storage or shipment and running on a
low temperature setting will serve to dry any residual moisture.
3. Adjust the height and forward back position of the conveyor module to an
appropriate setting for the dimensions of the bag/pouches to be sealed.
4. Attach and adjust the sealing material guide (#13 on the FR-900 schematic) to
adjust sealing width.
5. Adjust the belt and sealing wheel tensions to a desirable level if necessary. Note:
The machine should be setup and ready for operation when it arrives.
6. Check moving parts and lubricate if necessary.

All 900 Series Machines Embossing Print Wheel:

All 900 Series Machines and DBF-1000 are shipped with an embossing wheel. To
emboss characters on materials that are being sealed the standard waffle wheel
(#6 on the FR-900 Schematic) must be replaced with the embossing wheel.
 Machine Setup
FRD-1000 only
The FRD-1000 is equipped with a solid ink
printing wheel. The temperature of the ink
heating element and the delay need to be
adjusted prior to use. Additionally check that
the raised characters on the print wheel
make good contact with the solid ink roller to
ensure the best quality printing. If the
characters are not making good contact
adjust the spacing between the rollers.
 Machine Setup
FR-900 Vertical

1. Open Box and Check Contents For Damage 2. Remove Sealer and Parts

3. Remove knobs (both sides) to 4. Slide conveyor (with drive

remove conveyor. shaft attached) off of sealer
frame.
 Machine Setup

5. Assemble the upright stand, 6. Use provided screws to

by attaching cross beams to L secure beams.
shaped legs.

7. Repeat until assembly is completed 8. Completed assembly.

 Machine Setup

9. Completed assembly of 10. Re-orient assembly so legs 11. Attach slide adjustment
upright frame is ready for are facing up and slide onto knobs and secure.
attachment. sealer frame.

12. Attach rubber feet to 13. Stand sealer on its feet. 14. Slide conveyor onto assembly
frame.
 Machine Setup

15. Re-attach slide knobs 16. Remove horizontal drive shaft. 17. Conveyor drive should look
like this

19. Feed vertical drive shaft

18. Remove back panel of sealer. up through drive shaft 20. Groove in drive shaft must align with
channel. Groove in drive cog.
 Machine Setup

21. Orient elbow gears to attach to conveyor. 22. Secure the drive shaft to conveyor
 Machine Operation
Operation:
Adjust the printing position based on the width
of the package. Test the factory preset first.
(FRD-1000 Only)
Switch on the master power switch.
Adjust the appropriate conveyor speed.
Adjust the sealing heating temperature control.
Adjust the print wheel heating control. (FRD-
1000 Only)
Run until the machine reaches temperature.
(Usually indicated by a light on the temperature
control that switches from Red to Green).
FR-900 Control Diagram
Operate cooling device (Fan) if required for
material that you are sealing.
Shutdown:
1. Switch off Heaters and Reduce Thermostat
settings to zero. ( The FRD-1000 model has the
separate ink heating element control)
2. Run Machine until belts are cool. This will
significantly prolong belt and machine life.
3. Shutdown main power.

FR-900 Control Picture

 Sealing Optimization
1. Sealing performance can be adjusted using, sealing temperature, sealing speed,
and the cooling fan. Although the temperature setting is of primary importance with
harder to seal materials adjusting the other settings may allow for a quality seal.
2. Sealing speed and temperature are related. The higher the speed the less
exposure the material will receive, therefore a higher temperature will be required.
3. Experiment with your material to determine the specific settings that you require.
4. Polythene: The cooling device (Fan) is designed for use when sealing single-layer
film like normal polythene. When sealing polythene, switch on the fan, then raise
the temperature slowly until the material seals. This is important as trying a
temperature that is too high initially will cause the material to melt and stick to the
belts. This will impede proper sealing on later passes and greatly diminish the life
of the belts.
5. Compound Materials: If you are sealing a compound film, the sealing conditions
are more flexible and the cooling fan will not be required.
6. Make sure that the pattern-pressing wheel tension is correct. This is important to
ensuring a good quality seal. If it is too tight it may damage your material, too
loose and the material may not seal correctly.
 Printing Optimization
FRD-1000 Model Only.

1. Print Quality will be effected by/ determined by the

degree of melt of the ink wheel, distance between
ink wheel and printing wheel and distance between
the silica wheel and the print wheel.
2. To ensure that the ink wheel is melting correctly, it
must be heated for 10-15 minutes at 230-250
degrees u (446-482 degrees Fahrenheit).
3. Over time and ink wheel usage, decrease the gap
between the ink wheel and the printing wheel. For
a new wheel the gap must be larger than for a
used wheel.
4. Make sure that there is adequate pressure on the
silica wheel by the print wheel. The applied
pressure is dictated by the thickness of the
material being sealed. Try the factory default
setting before adjusting.
5. Too much or two little ink in the printing is
indicative of an incorrect temperature adjustment.
Too low and insufficient ink will transfer, the letters
will look grainy. Too much heat and there will be
ink outside of the print area on the letters.
6. Make sure the silica wheel is cleaned should the
ink wheel revolve when there is no material
present to take the printing.
 Maintenance
Changing The Sealing Belts: FRD-1000
1. Remove the protective cover over the
belts
2. Lift the position setting spacer (#7
(1,2,3,4)) and separate the two heating
and cooling blocks.
3. Loosen the tension adjustment screws
(#1) and push inwards the passive wheel
stands A and B (#2).
4. Remove sealing belts.
5. Load new sealing belts.
6. Adjust tension adjustment screws (#1) so
that the belts will not slide during
operation. Do not over tighten as this will
reduce belt life.
7. Replace spacers (#7 (1,2,3,4)).
8. Run the machine with no heat.
9. Adjust position with the screws.
 Maintenance
Cleaning:
Keep machine clean. Wipe down with a damp cloth or use alcohol based cleaning
solvents. Remove any buildup of plastic material or shavings.
Oil and Grease:
Oil machine with 50g 20# Oil Monthly.
Belts:
Replace belts when they break or appear to need replacement.
Calibration:
Periodically check to make sure that belts are properly tensioned and that screws, nuts
and bolts are properly tightened. Replacing or correcting wheels or gears before they
break completely will prolong the overall life of the machine and ensure the best
performance from your heat sealer.
 Troubleshooting
Problem Possible Cause Correction

Machine Will Not Start 1. Power Not Reaching Machine 1. Check three prong plug is inserted correctly in outlet
2. Circuit broken in the speed regulation and in machine. Check to make sure the main fuse
plate is not blow (usually located near in-plug on
machine).
2. Change the speed regulation plate.
Electrical Leakage 1. Moisture buildup in heating elements. 1. Pre-heat machine to dry heating elements.
2. Electro-Thermal Lead is contacting the 2. Make sure that there are no improper contacts being
machine case. made to the machine case. Check to make sure
3. No grounding Device there is no missing insulation on wiring.
3. Make sure plug and outlet are properly grounded.
Speed Regulation 1. Speed regulation plate or 1. Replace plate or potentiometer
Malfunction potentiometer are out of order.

Machine is Not Heating 1. Electro thermal tube is broken 1. Replace thermal tube
2. The lead terminal of the electro- 2. Fix the lead and tighten the fixing screw.
thermal tube has come off. 3. Replace the meter
3. The temp control meter is broken 4. Replace the electro-thermal coupling.
4. The electro-thermal coupling is broken

Sealing Belt Loose 1. The belts are not adjusted correctly 1. Adjust belt tensioners on the front side of the
machine. Remove rear panel and adjust wheel
positions by loosening retaining bolts, shifting and
retightening.
Sealing Pattern is 1. The pressure adjustment knob is too 1. Tighten knob
Undefined loose. 2. Clean rubber wheel surface
2. The rubber wheel surface is uneven. 3. Clean pattern wheel surface
3. Something is stuck to the pattern 4. Increase sealing temperature
wheel surface.
4. The seal temperature is too low.
 Troubleshooting
Problem Possible Cause Correction

Sealing Belts Break Easily 1. The space between the upper and lower heating 1. Adjust the heating element spacing
elements is too large thus causing the temperature to to allow for some belt travel when
become too high. material is running through the
2. Something is stuck between the upper and lower machine
heaters and coolers 2. Clean debris from machine
3. Film residue melted in the sealing process is stuck to 3. Clean belts
belts. 4. Switch off heat and allow machine
4. Machine is not cooled properly at shutdown to run until cool before shutting
5. Sealing Belts are over tensioned down completely
5. Reduce tension on sealing belts
using tension adjustment screws.
Sealing Belts Slipping 1. Upper and lower belts are too loose. 1. Adjust B1 and B2 screws.
2. Too much pressure on the sealing belts from the 2. Reduce the pressure on the belts by
upper heating and cooling elements. adjusting the heating and cooling
element positions.
Conveyor Belt Slipping 1. The elasticity screws on the conveyor are improperly 1. Adjust screws until conveyor
adjusted. functions correctly.