1. Manuals
  2. Brands
  3. Flexco Manuals
  4. Power Tool
  5. Novitool Aero 325
  6. Safety and operation manual

Flexco Novitool Aero 325 Safety And Operation Manual

Splice press
Hide thumbs
Table of Contents

Advertisement

Quick Links

Novitool
Safety and Operation Manual
Aero 325, 625, 925, 1225, 1525, 1835, and 2135
IMPROPER OR UNSAFE use of this tool can result in serious bodily injury! This manual contains important information
about product function and safety. Please read and understand this manual BEFORE operating the tool. Please keep this
manual available for other users and owners before they use the tool. This manual should be stored in a safe place.
Patent number: US 9,090,022 B1 and other Patents Pending
www.flexco.com
Aero
®
®
Initializing Press
Prior to first time operation, you must register your press in order to unlock it
for use. This will also allow Flexco to communicate critical firmware updates.
a. Screen will show press is locked and requires access code.
Go to flexco.com/code to enter your serial number and to obtain your
access code.
b. Use the selector knob and scroll to "Enter Access Code." Depress knob.
c. Scroll down, enter access code, and select "Confirm."
Contact Flexco Customer Service if you have difficulties entering the code.
WARNING
Splice Press

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Novitool Aero 325 and is the answer not in the manual?

Questions and answers

Related Manuals for Flexco Novitool Aero 325

Summary of Contents for Flexco Novitool Aero 325

  • Page 1 Initializing Press Prior to first time operation, you must register your press in order to unlock it for use. This will also allow Flexco to communicate critical firmware updates. a. Screen will show press is locked and requires access code.

  • Page 2: Table Of Contents

    Operation of the Aero® Press ..............10 Press Options ....................24 Recipes ......................25 Technical Assistance ...................28 Aero® Press End Plate Removal and Reassembly ........29 Electrical Diagrams of Power Supply Cables ...........41 Electrical Schematics ..................43 Diagnostics ....................58 Maintenance ....................59 WEE ......................60 CE Declaration .....................61 www.flexco.com —2—...

  • Page 3: Main Components

    Main Components Aero Splice Press ® Top Press Beam Clamp Bars (2) Main Power Cable Connector Display Screen Bottom Press Beam Clamp Bar Studs and Thumbnuts (4) 10. Start Button (Green) Selector Knob End Plates Press Connector Bolts (4) 11. Stop Button (Amber) Silicone Release Cloths (2) Handle Umbilical Power Cable Connector...

  • Page 4: Description

    (outside and inside) to a temperature just below the melting temperature. After the preheat stage, the inside splice temperature can be reached much quicker, minimizing the risk for unwanted flow of material, discoloring or shrinkage. Settings: dwell time splice temperature pre-heat temperature pre-heat dwell time cool down temperature (fans turn off) time www.flexco.com —4—...

  • Page 5: Machine Specifications

    Aero 325, 625, 925, and 1225 ® Aero ® Tool Specifications Specifications Country Aero Aero Aero Aero 1225 ® ® ® ® Effective splice length 325 mm/12.8" 625 mm/24.6" 925 mm/36.4" 1225 mm/48.2" Effective splice width 150 mm/6" 150 mm/6" 150 mm/6"...
  • Page 6 15.1 A 3ph 400V no N 8.6 A 10 A 11.4 A 3ph 460V 9.9 A 11.5 A 13 A 250mm 9.8in 293mm 11.5in 483mm 19.0in Front view and dimensions of Aero presses, sizes 1525, 1835, and 2135. ® www.flexco.com —6—...

  • Page 7: Transport Case

    Transport Case 1. Aero® presses are supplied with a transport case for both storage and easy transport to jobsites. 2. Aero® transport cases have four wheels and handle. 3. Transport cases can be stacked but need to be secured during transport. General Safety Rules –...
  • Page 8 Any machine that cannot be controlled If the electrical supply cord is damaged, it must with a switch is dangerous and must be repaired. be replaced by a special cord available from the manufacturer or it’s service agent. www.flexco.com —8—...

  • Page 9: Press Lifting And Rigging Guidelines

    General Safety Rules – Save These Instructions Check for misalignment or binding of moving CAUTION parts, breakage of parts, and any other condition that may affect machine operation. If damaged, The Aero has been optimized for process speed, have machine serviced before using. portability, and ease of use.

  • Page 10: Operation Of The Aero® Press

    1ph 230V, 10A 09018 1ph 230V, 13A 09009 1ph 230V, 16A 09010 1ph 230V, 30A 09021 1ph 230V, 16A 09022 1ph 230V, 32A 09024 1ph 230V, 20A 09365 1ph 230V, 30A (F= full power operation, R= reduced power operation) www.flexco.com —10—...
  • Page 11 Operation of the Aero Press ® Aero Power Compatibility for 325, 625, 925, 1225, 1525, 1835, and 2135 ® Item Code Power Country 1225 1525 1835 2135 Plug End 09011 3ph 230V, 20A 09020 3ph 230V, 30A 09081 3ph 230V, 18-20A 09366 3ph 230V, 16A 09012...
  • Page 12 You may decide to use different release material, for a different appearance of the splice (matte or glossy). If belt has a profile on top or bottom, you may use profiled silicone pads in order to get same profile on the splice. www.flexco.com —12—...
  • Page 13 Operation of the Aero Press ® c. Carefully position prepared belt ends on silicone pad, centering in the splice zone. NOTE: The splice zone is in the center 150 mm (6") width of the platen. The prepared splice and/or ply separation must be within the heated zone, as material outside the heated zone will not melt.
  • Page 14 After splicing remove the top beam in reverse order. Make sure the top beam will not drop off the roller slider at the end of the stroke. www.flexco.com —14—...
  • Page 15 Operation of the Aero Press ® c. With top beam properly centered above bottom beam, rotate all four press connector bolts up and hand tighten them, ensuring all bolts are seated properly in their spherical recess on top beam. DANGER: Do not operate any press size with a missing or broken bolt, as this can cause serious physical harm and/or damage to press.
  • Page 16 Operation of the Aero Press ® Initializing Press: Prior to first time use you must register your press. This will allow Flexco to communicate critical firmware and features in the future. a. Screen will show press is locked and requires access code.
  • Page 17 Operation of the Aero Press ® Display: Home Screen a. The Home screen shows a number of different set values and selections. Scroll through list by rotating selector knob and select by depressing knob. Home Screen Choices i. Pressure ii. Switch preheat OFF/ON iii.
  • Page 18 3. Bottom temperature iii. Splicing heat up 1. Pressure 2. Top temperature 3. Bottom temperature iv. Splicing dwell time 1. Time 2. Top temperature 3. Bottom temperature v. Cool down 1. Fans start 2. Top temperature 3. Bottom temperature www.flexco.com —18—...
  • Page 19 Operation of the Aero Press ® vi. Release Pressure 1. Pressure 2. Cycle time WARNING: Keep fingers clear of deflected beams during splicing cycle. STOP: If press needs to be stopped mid-cycle, depress amber stop button. Stop Button When splice is complete, an audible noise will occur and display will indicate it is complete.
  • Page 20 150 mm then the splice process must be completed in the traditional way (across the width of the press).. Contact Customer Service at www.flexco.com to order silicone belt template pads and end belt clamp system retrofit (09592). Splice Preparation for End-to-End: a.
  • Page 21 Operation of the Aero Press ® c. While holding prepared splice in place, latch end belt clamps at press ends and tighten thumbscrews to hold belting in place. 45 mm d. Place silicon cloth over top of prepared belt the length of the press. Note: silicone spray is not needed.
  • Page 22 Place top press beam on top of prepared belt and hand tighten all four press connector bolts. 45 mm g. Proceed with Aero press operation instructions starting with section A5 page 15. Contact Flexco at www.flexco.com for additional belt template options. www.flexco.com —22—...
  • Page 23 Operation of the Aero Press ® Inspect splice a. Inspect top of splice, both in a flat and bent state. Fingers should be fully closed along entire finger, especially at the finger tips. (If not: Consider if temperature is too low.) b.

  • Page 24: Press Options

    Export Data Log k) Administration Menu l) Back to HOME To access these options, scroll to the appropriate text and depress the button. To return to the main menu, scroll to the bottom text and select ‘Back to HOME’ . www.flexco.com —24—...

  • Page 25: Recipes

    Recipes Visit www.flexco.com for detailed instructions and Recipe Management Tool updates. Aero® Recipes The Aero is capable of storing recipes for future use. Recipes are stored in ‘Groups’ , which allow you to organize your splice recipes. • Group 0 Recipes: Up to 99 recipes can be manually input into the press using the selector knob.
  • Page 26 “Export Data Log”, “Import Recipes”, “Export Recipes”, and “Back”. Scroll to “Import Recipes” and depress selector knob. Select “Cancel or Confirm. ” If “Cancel” is selected, it will return to Options menu. If “Confirm” is selected, the display states “Processing”. www.flexco.com —26—...
  • Page 27 Recipes c. Once complete display reads “Import complete”. Select “Return” or “Undo”. “Return” brings you back to “Options0 where you can scroll down to “Back to Home”. At end of updating recipes the USB flash drive may be removed. “Undo” allows you to remove the USB flash drive without making recipe updates.

  • Page 28: Technical Assistance

    Technical Assistance Contact Flexco’s Customer Service if technical assistance or repair is needed: www.flexco.com www.flexco.com —28—...

  • Page 29: Aero® Press End Plate Removal And Reassembly

    Aero Press End Plate Removal and Reassembly ® Tools to Service Press • 2 mm hex key • 6 mm hex key • 7 mm crescent wrench • Aero® splice press instruction manual End Plate Removal to Access Electrical Tray Both top and bottom press beams contain an electrical tray with all electrical and pneumatic components.
  • Page 30 NOTE: pull on connectors not wires themselves: a. Heater connector (gray): 2 white wires and 1 red wire b. Thermal fuse connector (gray): white wire c. Thermocouple connector (yellow): 2 mm hex key may be used to assist in removal www.flexco.com —30—...
  • Page 31 End Plate Removal and Reassembly 4. Disconnect the 2 pneumatic connections. Hold down blue ring of connector and pull hose out. 5. Using 6 mm hex key, unscrew 3 screws located on front end plate. Ensure wires are free to move and not tangled. Then gently pull top end plate to slide electrical tray out of beam.
  • Page 32 2. Disconnect ground wires from end plate. Remove end plate. 3. Disconnect by pulling three connectors straight out inside top beam of press. NOTE: pull on connectors not wires themselves: a. Heater connector (gray): 2 white wires and 1 red wire www.flexco.com —32—...
  • Page 33 End Plate Removal and Reassembly b. Thermal fuse connector (gray): white wire c. Thermocouple connector (yellow): 2 mm hex key may be used to assist in removal 4. Using 6 mm hex key unscrew 4 screws located on front end plate. Ensure wires are free to move and not tangled.
  • Page 34 B. Main controller with display and G. Thermal fuse relay control knob H. Power control PCB C. Press release valve Solid state relay D. USB connector S/P relay E. Cooling fans Aero® 625 Top Beam Electrical Tray Aero® 1525 Top Beam Electrical Tray www.flexco.com —34—...
  • Page 35 End Plate Removal and Reassembly Bottom Beam Electrical Tray Contents: A. Power connection F. Power controller PCB B. Umbilical cable connection G. Solid state relay C. Cooling fans H. S/P relay D. 24VDC power supply Buzzer E. Thermal fuse relay Fuses Aero®...
  • Page 36 2. Using 6 mm hex key, screw 3 screws located on front of end plate starting with the two lower screws and finalizing with the top screw. 3. At rear of press re-connect the 2 pneumatic connections. Press hose into quick connect fitting. www.flexco.com —36—...
  • Page 37 End Plate Removal and Reassembly 4. Reconnect three connectors inside top beam of press: a. Heater connector (gray): 2 white wires and 1 red wire b. Thermal fuse connector (gray): white wire c. Thermocouple connector (yellow): brown wire. Match prongs to same size slot (typically + and - up).
  • Page 38 If there is resistance a wire may be pinched and must be adjusted. 6. Using 6 mm hex key, screw the rear top end plate starting with the two lower screws and finalizing with the top screw. www.flexco.com —38—...
  • Page 39 End Plate Removal and Reassembly Ü Bottom Beam End Plate Reassembly: 1. Gently slide electrical tray into beam ensuring wires are free to move and not tangled and that there is no binding. The tray should slide in with no resistance and the end plate should fit flush to the extrusion. If there is resistance, check to make sure wires are not catching.
  • Page 40 If there is resistance a wire may be pinched and must be adjusted. 5. Using 6 mm hex key, screw 4 screws located on rear bottom end plate. www.flexco.com —40—...

  • Page 41: Electrical Diagrams Of Power Supply Cables

    Technical Assistance Electrical Diagrams of the Power Supply Cables - Single Phase 1 PHASE 110V BLACK BLUE BLUE GREEN/YELLOW PE GREEN/YELLOW BROWN BROWN BLACK 1 PHASE 230V BROWN BROWN GREEN/YELLOW GREEN/YELLOW BLUE BLUE —41—...
  • Page 42 Technical Assistance Electrical Diagrams of the Power Supply Cables - 3 Phase BLACK 3 PHASE 230V BROWN BROWN GREEN/YELLOW GREEN/YELLOW GRAY GRAY BLACK BLACK BLACK 3 PHASE 460V BROWN BROWN GREEN/YELLOW GREEN/YELLOW GRAY GRAY BLACK BLACK www.flexco.com —42—...

  • Page 43: Electrical Schematics

    Schematics Schematics Main Controller 325, 25, 925, 1225, 1525, 1835, 2135 RD 0,50mm² 06-3C WH 0,50mm² 06-3C FLEXCO Main Controller USB Cable 3x 0.25mm² 06-8C 06-7C 06-7C 3x 0.25mm² 07-1C 07-1C 07-1C —43—...
  • Page 44 Schematics Schematics Lower Press 325 www.flexco.com —44—...
  • Page 45 Schematics Schematics Lower Press 325 —45—...
  • Page 46 3x 0,25mm² Heater SSR - Fan M2 VT 0,5mm² S/P relay + Omron relay K2 S/P relay - WH 0,5mm² Power Controller Fan M1 TB 4 WH 0,5mm² Buzzer YE 0,5mm² BK 0,25mm² RD 0,25mm² BK 0,25mm² RD 0,25mm² www.flexco.com —46—...
  • Page 47 Schematics Schematics Upper Press 625 GNYE 2.5 mm² 05-1A F4 20Amp 2.5mm² OG 2.5mm² OG 2.5mm² 05-1A F3 20Amp GY 2.5mm² 2.5mm² GY 2.5mm² 05-1A F2 20Amp 2.5mm² BK 2.5mm² F1 20Amp 2.5mm² BN 2.5mm² F5 4.0Amp 1.5mm² BK 1.5mm² TB 1 OG 0.50mm²...
  • Page 48 VT 0,5mm² Fan M2 S/P relay + Omron relay K2 S/P relay - BK 0.25mm BK 0.25mm WH 0,5mm² RD 0.25mm RD 0.25mm Power Controller Fan M1 TB 4 WH 0,5mm² Buzzer YE 0,5mm² WH 0,75mm² GY 0,75mm² www.flexco.com —48—...
  • Page 49 Schematics Schematics Upper Press 925 GNYE 2.5mm² +24Vdc RD 0.75mm² +24Vdc 07/A1 0 Vdc 0 Vdc WH 0.75mm² 07/A1 OG 0.50mm² 07-1A Power controller Heater WH 0.50mm² 07-1A VT 2.5mm² BU 2.5mm² 3x 0.25mm² Ground pin 4 A1+ A2- Extrusion PCB Top Headplate Ground pin 3 backside...
  • Page 50 VT 0,5mm² Fan M2 S/P relay + Omron relay K2 S/P relay - BK 0.25mm BK 0.25mm WH 0,5mm² RD 0.25mm RD 0.25mm Power Controller Fan M1 TB 4 WH 0,5mm² Buzzer YE 0,5mm² WH 0,75mm² GY 0,75mm² www.flexco.com —50—...
  • Page 51 Schematics Schematics Upper Press 1225 GNYE 2.5mm² +24Vdc RD 0.75mm² +24Vdc 07-1A 0 Vdc WH 0.75mm² 0 Vdc 07-1A OG 0.50mm² 07-5D Power controller Heater WH 0.50mm² 07-5D VT 2.5mm² BU 2.5mm² Ground pin 4 A1+ A2- Extrusion PCB Top Headplate Ground pin 3 backside Grill plate...
  • Page 52 Power controller heat SSR1 WH 0,5mm Heater SSR - VT 0,5mm S/P relay + Omron relay K2 S/P relay - WH 0,5mm BK 0.25mm RD 0.25mm Power Controller TB 4 WH 0,5mm Buzzer YE 0,5mm WH 0.75mm GY 0.75mm www.flexco.com —52—...
  • Page 53 Power controller heater SSR 2 WH 0.5mm Heater SSR - VT 0.5mm S/P relay + Omron relay S/P relay - WH 0.5mm BK 0.25mm BK 0.25mm RD 0.25mm Compressor Flexco RD 0.25mm WH 0.50mm YE 0,50mm F6 - 4A WH 0.75mm GY 0.75mm —53—...
  • Page 54 WH 0,5mm Heater SSR - BK 0.25mm VT 0,5mm BK 0.25mm S/P relay + RD 0.25mm Omron relay K2 RD 0.25mm S/P relay - WH 0,5mm Power Controller TB 4 WH 0,5mm Buzzer YE 0,5mm WH 0.75mm GY 0.75mm www.flexco.com —54—...
  • Page 55 Power controller heater SSR 2 WH 0.5mm Heater SSR - VT 0.5mm S/P relay + Omron relay S/P relay - WH 0.5mm BK 0.25mm BK 0.25mm RD 0.25mm Compressor Flexco RD 0.25mm WH 0.50mm YE 0,50mm F6 - 4A WH 0.75mm GY 0.75mm —55—...
  • Page 56 VT 0,5mm S/P relay + Omron relay K2 S/P relay - BK 0.25mm WH 0,5mm BK 0.25mm RD 0.25mm RD 0.25mm Power Controller TB 4 WH 0,5mm Buzzer YE 0,5mm BK 0.25mm WH 0.75mm RD 0.25mm GY 0.75mm www.flexco.com —56—...
  • Page 57 Power controller heater SSR 2 WH 0.5mm Heater SSR - VT 0.5mm S/P relay + Omron relay S/P relay - WH 0.5mm BK 0.25mm BK 0.25mm RD 0.25mm Flexco RD 0.25mm WH 0.50mm YE 0,50mm F6 - 4A WH 0.75mm GY 0.75mm —57—...

  • Page 58: Diagnostics

    If the press is used in this state and the problem becomes more serious, the press will then display a Warning Message. Depending on the issue, a potential action may be to arrange for press repair by contacting your local Flexco Customer Service. Warning example:...

  • Page 59: Maintenance

    CABLE-UMBILICAL-AERO-G3 Top beam umbilical power cable 09343 FUSE-ASSY-THERMAL-AERO-G3 Thermofuse 09351 FUSE-ASSY-CERAM-FL-0326020.MSP Main power fuse 325-1225 09374 CARTRIDGE-FUSE-F-20A-RS-3375256 Main power fuse 1525-2135 08700 AERO-FUSE-CERAMIC-4A Power supply fuse/Large compressor fuse 1525-2135 Contact Flexco’s Customer Service if other parts are required: www.flexco.com. —59—...

  • Page 60: Wee

    WEEE Flexco takes WEEE compliance very seriously. This equipment is intended to be repairable in foreseeable circumstances. Should product disposal be required, contact Flexco Europe at 011-49-7428-9406-0 or Flexco UK at 011-44-1274-600-942. www.flexco.com —60—...

  • Page 61: Ce Declaration

    Aero Safety and Operation Manual ® —61—...
  • Page 64 Flexco Europe GmbH • Maybachstrasse 9 • 72348 Rosenfeld • Germany Tel: +49-7428-9406-0 • Fax: +49-7428-9406-260 • E-mail: europe@flexco.com Visit www.flexco.com for other Flexco locations and products. ©2020 Flexible Steel Lacing Company. 06/03/20. For reorder: X5003...

This manual is also suitable for:

Novitool aero 625Novitool aero 925Novitool aero 1225Novitool aero 1525Novitool aero 1835Novitool aero 2135

Table of Contents