usi CSL2700 Owner's Manual page 25

THERMAL FUSE REPLACEMENT -
equipped with DualThermalFuse
1. Unplug the laminator from power supply and allow it to cool to room temperature. Caution: never attempt to service a
machine that is energized!
2. Remove the right side housing by removing four Allen head screws on the side of the machine using a 3mm Allen wrench and
then pulling the cover off gently.
3. Four wires will be noticed exiting the right end of either heat shoe. The two wires exiting from the frontal area of the heat shoe
are heater element leads. The two wires exiting from the rear area of the heat shoe are thermal fuse leads. Note: before
proceeding it may be helpful to take digital photos to document the routing of the thermal fuse wiring, and placement of wiring
harness clamps and wire ties to aid in installation.
a. Replacement of the upper thermal fuse:
a1. When traced, one thermal fuse lead will end at terminal number "4" on the terminal block, unplug this lead.
The second thermal fuse lead will connect to a black lead exiting from the Digital Temperature Control (DTC),
disconnect this lead from the black DTC lead.
a2. Loosen, but do not completely remove the upper thermal fuse retaining screw. This screw is located at the
rear of the upper heat shoe, in approximately 5.5 inches from the right end. Note: this screw may be either an
Allen type requiring a 3mm Allen wrench to remove, or a Phillips type. Keep this screw to refasten the new
thermal fuse.
a3. Unfasten any wiring clamps or wire ties securing the leads for the upper thermal fuse. Gently slide the old
thermal fuse out of the end of the heat shoe. Note: be certain to carefully observe the routing of the thermal
fuse wiring, location of wiring clamps and wire ties as the new thermal fuse wiring must be routed in exactly the
same path and be secured in the same manner.
a4. If the new thermal fuse is not formed to the same shape as the old one, gently form a loop in it to match the
old one. A gentle loop is best; do not sharply crease the part.
a5. Insert the new thermal fuse into the end of the upper heat shoe and hook it on the retaining screw. Tighten
the screw to secure the thermal fuse. Caution: Do not pinch the thermal fuse under the retaining screw; doing
so will cause an electrical short. Be certain the thermal fuse is hooked over the hex screw; gently pull on the
leads and then push back in to feel that the thermal fuse can move and is not pinched. If the thermal fuse was
pinched, it must be removed and inspected for damage; a replacement thermal fuse may be required.
a6. Plug the thermal fuse wires into the appropriate terminals. The thermal fuse must be plugged into the
correct terminals to work properly.
b. Replacement of the lower thermal fuse:
b1. When traced, one thermal fuse lead will end at terminal number "3" on the terminal block, unplug this lead.
The second thermal fuse lead will connect to a black lead exiting from the Digital Temperature Control (DTC),
disconnect this lead from the black DTC lead.
b2. Loosen, but do not completely remove the lower thermal fuse retaining screw. This screw is located at the
bottom of the lower heat shoe, in approximately 5.5 inches from the right end. Note: this screw may be either
an Allen type requiring a 3mm Allen wrench to remove, or a Phillips type. Keep this screw to refasten the new
thermal fuse.
b3. Unfasten any wiring clamps or wire ties securing the leads for the lower thermal fuse. Gently slide the old
thermal fuse out of the end of the heat shoe. Note: be certain to carefully observe the routing of the thermal
fuse wiring, location of wiring clamps and wire ties as the new thermal fuse wiring must be routed in exactly the
same path and be secured in the same manner.
b4. If the new thermal fuse is not formed to the same shape as the old one, gently form a loop in it to match
the old one. A gentle loop is best; do not sharply crease the part.
b5. Insert the new thermal fuse into the end of the lower heat shoe and hook it on the retaining screw. Tighten
the screw to secure the thermal fuse. Caution: Do not pinch the thermal fuse under the retaining screw; doing
so will cause an electrical short. Be certain the thermal fuse is hooked over the hex screw; gently pull on the
leads and then push back in to feel that the thermal fuse can move and is not pinched. If the thermal fuse was
pinched, it must be removed and inspected for damage; a replacement thermal fuse may be required.
b6. Plug the thermal fuse wires into the appropriate terminals. The thermal fuse must be plugged into the
correct terminals to work properly.
4. Be certain to replace any wire ties that were cut or disturbed during the test procedure. Replace and refasten the right side
housing. NOTE: be certain that all tools and service supplies are removed from the laminator before replacing the side
housings.
5. Test run the laminator: allow the machine ample time to heat to the set temperature and stabilize; usually 35-45 minutes.
Ensure that the unit is not exceeding 340˚F when the DTC is set to the maximum temperature setting.
Note: if either of the thermal fuses were deemed as needing replacement, the machine should be checked additionally for an overheat cause.
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CSL Roll Laminators