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SEAL 44Ultra Laminator manual

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Table of contents for the manual

  • Page 1

    44 Ultra Laminator Service Manual SM110EN, Rev. 2.0 May 2003[...]

  • Page 2

    Front Matter ii SEAL 44 Ultra Technical Ser vice Manual REV 1.1 Revision History Amendm ents wil l be listed on th is pa ge, incl uding their descripti ons and dates. REV Date Description 1.0 Jan 2001 Origin al vers ion (pre- releas e). 1.1 Mar 2001 Changes i n Spare part list a nd Chapt er 8 (Diagr am s) 2.0 May 2003 Seal branding Service Manual 4[...]

  • Page 3

    Front Matter iii ©2003,2000 SEAL® Graphics Europe BV All tech nica l and t echnolog ic al inform ation include d in t his m anual as well as an y drawin gs and technica l spec ific ations we have m ade a vailable rem ain our pr opert y. The y shall n ot be us ed (other than for op eration of this produc t), cop ied, repro duced , trans m itted to[...]

  • Page 4

    Front Matter iv Safety Stat ements The SE AL 44 U ltra lam inator has been designe d with operat or saf ety as a prim ar y objec tive; ho wever, operator s m ust be f amiliar with the c ontro ls, as well as the oper atio n befo re using the unit. The elec trica l and dr ive-s ystem c omponents are iso lated fr om contact with th e op erator b y enc[...]

  • Page 5

    Front Matter v Note: When performing pr ocedures that require the side covers to be opened, ensure that th e pow er cable is di sconn ected from the mai ns. Sev eral part s, like t he fast -on connecto r strips of the ov ertempe rature sw itch ( white ar row s in picture sho w n below ), could cau se elect rical sho ck if t he pow er is no t discon[...]

  • Page 6

    Front Matter vi Table of Contents 1 Machine Character istics ...................................................................................................... ............. 7 1-1 Machine Desc ription ........................................................................................................ .......... 7 1-2 Identif ication .......[...]

  • Page 7

    Front Matter vii 7 Troubles hootin g .............................................................................................................. ................ 37 8 Diagram s ..................................................................................................................... ................... 43 8-1 Installat ion Diagram ...[...]

  • Page 8

    Machine Ch aracteristic s 7 1 Machine Characteristics 1-1 Machine Description The SE AL 44 U ltra lam inat or is an electr o-m echanical device b asical l y containin g two si licon ized laminati ng roll ers, t wo silic oni zed pull r oller s and a t op and bottom film unwind. O nly the top ro ller is heated. T here ar e three te m perature ranges [...]

  • Page 9

    Machine Ch aracteristic s 8 1-3 Features Identification of parts 1 W ind-up idler Idler (rem ovab le) to s uppor t the win d-up cor e f or the re lease- liner 2 Emer gency stop buttons Stop the r otatio n of the r oller s imm ediatel y 3 Image guid e To help f eed-in im ages. It is removab le when m ount ing 4 Upper un wind sh aft The s haft is s u[...]

  • Page 10

    Machine Ch aracteristic s 9 1-4 Specificat ions Dimensions & weights Uncrated Crated depth 56 cm (22 in) 63 cm (24.8 in) width 148 c m ( 58.3 in) 160 cm (63 in) height 111 cm (43.7 in) 72 c m (28.4 in) weight 101 k g (222 lbs ) 135 kg ( 297 lbs) Electrica l specif ication s Part no. 6 0958 230VAC 50/ 60Hz 9A Part no. 6 0959 110VAC 50/ 60Hz 1 6A[...]

  • Page 11

    Machine Ch aracteristic s 10[...]

  • Page 12

    Transport & Install atio n 11 2 Transport & Installati on 2-1 Transport Only use a pall et jack or f orklift to lift and transport the machine. The m achine is tr anspor ted on a wooden pall et, which is an integra l part of the pa ckaging. T he machine is wrapped in plas tic film to avo id m oisture p enetr ation. 2-2 Workspace Requirement[...]

  • Page 13

    Transport & Install atio n 12[...]

  • Page 14

    Theory of Op eration 13 3 Theor y of Operation 3-1 Control Knob The Control Knob (s ee f igure 1) is locate d on the right han d side of the lam inator and is opera ted from the front of the m achine. The Control Knob ca n be o perated b y pushi ng it in approxim atel y 6mm (1/4”) to the left. Onc e the knob has disenga ged f rom the sto p, it m [...]

  • Page 15

    Theory of Op eration 14 3-3 Control Panel The Control Pane l is loc ate d on the f ront r ight of the m ac hine an d has s even LED indicator s. A diagram of the Contro l Panel is s hown in f igure 3 . speed control area temperature control area power control area Drive mechanism s y mbol Safety eye symbol LED (green) Lit when machine runs reverse [...]

  • Page 16

    Theory of Op eration 15 3-4 Motor C ontrol The s peed of the r ollers is contin uous ly adjusta ble bet ween 0 a nd 1.5 m /m in. (0 and 4. 9 ft/m in.) Pressing the  k e y runs th e rollers in f orward dir ectio n, press ing the  k ey rever ses the d irection of the roller s (as long as this b utton is pressed) . The s top ke y stops the ro ll[...]

  • Page 17

    Theory of Op eration 16 3-5 Un w ind Brakes Tighten t he un wind brak e so tha t it ap plies s uff icient tension to lam inate. T urning t he k nurled co llar in a clock wise dir ection increa ses the u nwind t ensio n app lied to the lam inate. T urnin g the c ollar cou nter- clock wise decre ases the tens ion. T he best sett ing f or the brak e t[...]

  • Page 18

    Disassembly / Reassembly Procedu re s 17 4 Disassembly /Reassembl y Procedures 4-1 Plasti c Covers Necessar y tools: hexalobu lar s crewdr iver T X25, Al len k ey 4mm . Approx imate tim e: 5 m inutes To rem ove the s ide cov ers, perf orm the follo wing steps : 1. Remove the two se lf- tapping s crews, us ing the T X25 driver, as s hown in figure 4[...]

  • Page 19

    Disassembly / Reassembly Procedu re s 18 5. The em ergenc y stop cont actbloc k can be rem oved us ing a little sc rewdri ver whic h can i nserted below the c lamping sprin g and t he contac t block . See the arrow on figure 8. 6. The proc edure f or the lef t-h and side c over is sim ilar, though it’s o bvious that t here’s no patchcab le on t[...]

  • Page 20

    Disassembly / Reassembly Procedu re s 19 3. See figur e 11. D isconnec t the white connector 1 , locate d on the right-hand side of the m achine f rom the heater wire. Remove the heater brack et by rem oving the two b olts 2. T ak e care not to l oose the serrate d w ashers. The heati ng elem ent can n ow be tak en out of the roller. W hen a heatin[...]

  • Page 21

    Disassembly / Reassembly Procedu re s 20 4-3 Rear Panel Necessa ry tools: Phil lips c rosshead s cre wdriver (m edium ), open-ende d spanner 8m m, and k nife. Approx imate tim e: 10 m inutes. Perform the f ollowin g steps : 1. Remove the s ev en self -tapping s crews f rom the rear p anel. T ak e care not to loose the serr ated washers an d the 3 p[...]

  • Page 22

    Disassembly / Reassembly Procedu re s 21 4-4 Control System Board & Sof tware 4-4-1 Con trol Syst em Board To c hange the C ontrol S ystem Board, it is nec essar y to disas sem ble Rear Panel, as desc ribed i n section 4-3. 1. Remove al l con nectors. 2. Remove the f ive M3 sock et sc rews. 3. Remove the print. Assem ble in re vers e order. Nev[...]

  • Page 23

    Disassembly / Reassembly Procedu re s 22 4-5 Solid State R elay Necessar y tools: m edium f lat-head screwdr iver, Allen ke y 3 mm. Approx imate tim e: 20 m inutes. Note: To remo ve the So lid State Relay, it is necess ary to p erform the R ear Pan el disass embly procedur e (see S ection 4- 3) fi rst. Perform the f ollowin g steps : 1. Loosen al l[...]

  • Page 24

    Disassembly / Reassembly Procedu re s 23 4-6 Photoelectric Cells Note: to per form the follo wing a djustm ents , it is neces sar y to remove both p lastic side co vers f irst. See secti on 4.1 : Disasse mbly / Rea ssembly plast ic side cov ers. Necess ary tools: s m all flat head sc rewdriver , Allen k ey 3m m Necessar y mater ials: two t ie-wra p[...]

  • Page 25

    Disassembly / Reassembly Procedu re s 24 4. Remove the two M4 bolts (see the white ar ro ws in figure 20, the le ft hand Photoel ectric Cell is sho wn here). 5. The Phot oelectr ic Cell c an now be rem oved. Reassembl y 6. W hen reassem bling th e Photoe lectr ic Cel l, mak e sure that the brack et is positioned in suc h a wa y, that the M4 bolt is[...]

  • Page 26

    Adjustment Pr ocedur es 25 5 Adjustment Procedures 5-1 Laminating Pressur e Note: To perform the following adjustments, it is necessary to remove both plastic side covers first. See Sect ion 4-1: Di sasse mbly / R eassembl y Plasti c Side Co vers. There ar e two wa ys to adj ust the lam inating press ure: 1. Adjustm ent us ing lo ad cells and displ[...]

  • Page 27

    Adjustment Pr ocedur es 26 4. Position the load c ells at eit her side of the ro llers , betw een the j ournals , as s hown in figure 24. 5. Push and r otate the nip a djustm ent k nob until the pin, mounted in the k nob, f alls into t he last n otch (relative to top) from the ind ent brack et (see f igure 25, white ar row). The pres sure wil l be [...]

  • Page 28

    Adjustment Pr ocedur es 27 5-1-2 Adjustment using He at Sensitive Film This pr ocedure ref ers to th e press ure adj ustm ent to be do ne at th e custom er’s site. Note: as th is procedu re is p erformed u sing heat sensit ive film ( JetGuard 5 mil o r Thermashield 5 mil), the top roller temper ature sho uld be set to 120 ° C (2 50 º F). 1. Rem[...]

  • Page 29

    Adjustment Pr ocedur es 28 • If the roll pr essure i s too high , then th e footp rint looks lik e: This is the case if the e nds of the f ootprint (m eas ured 1’’ f rom either side) are at least 1m m (0.04’’) wider tha n the m iddle. Change t he press ure as de scr ibed belo w. • If the roll pr essure i s too low , then the foo tprint [...]

  • Page 30

    Adjustment Pr ocedur es 29 5-2 Roller Nip Note: to per form the follo wing a djustm ents, it is neces sar y to remove both p lastic side co vers f irst. See section 4 -1: Di sassembly / Rea ssembly Pl asti c Side C overs. Necessar y tools: Allen Key 4m m, a s et of m etric thick ness gauges . Approx imate tim e: 5 m inutes Note: the top roller must[...]

  • Page 31

    Adjustment Pr ocedur es 30 5-3 Temperature Necessar y tools: I nfr ared tem peratur e meter, sm all f lat-head sc rewdriver . Approx imate tim e: 30 - 45 m inutes. 1. Set the ro ller n ip to 10m m (3/8’’). 2. Set the t op roll er tem peratur e to the 120°C setti ng on t he contro l panel; the ro ller is being h eated up. 3. After approx . 5 m [...]

  • Page 32

    Adjustment Pr ocedur es 31 5-4 Photoelectric Cells Note: to per form the follo wing a djustm ents , it is neces sar y to remove both p lastic side co vers f irst. See secti on 4-1: Disassembly /Reasse mbly Pl astic Sid e Covers. Necessar y tools: s m all flat- head sc rewdriv er. The Phot oelectr ic Cells are m ounted on the arm assem blies of the [...]

  • Page 33

    Adjustment Pr ocedur es 32 5-5 Driv e Chain Necessar y tools: Allen ke y 4mm, m edium flat-head sc rewdri ver. Approx imate tim e: 8 m inutes. Note: to per form the follo wing a djustm ents, it is neces sar y to remove t he right- hand s ide co ver fir st. See section 4 -1: Di sassembly / Rea ssembly Pl asti c Side C overs. The chain g uide ensures[...]

  • Page 34

    Adjustment Pr ocedur es 33 5-7 Image Guide To perf orm the follo wing ad justm ent, it is necessar y to r em ove both plas tic sid e cover s fir st. See Section 4- 1: D isassem bl y/Reassem bly Plasic Side C overs. Necessar y tools: allen k ey 3m m, gauge 2mm . The dis tance bet ween the upper edge of the Im age Guid e and th e roll s urf ace mus t[...]

  • Page 35

    Adjustment Pr ocedur es 34[...]

  • Page 36

    Troubleshooti ng 35 6 Maintenance Cleaning of the M achine The equi pment m us t be disconnec ted fr om the m ains bef ore clea ning. The lam inator m a y be cl eaned by the oper ator with a lint- free c loth, lig htly dam pened with a m ild soa p and water s olution . Spra y-on c leaners are not t o be us ed. No par t of the m achine is to be imm [...]

  • Page 37

    Troubleshooti ng 36[...]

  • Page 38

    Troubleshooti ng 37 7 Troubleshooti ng Note: The ‘Caus es’, as desc ribed bel ow, are p laced in a log ical or der of occ urrence; pl ease follo w this seq uenc e in ord er to sol ve the problem . Problem: The po wer LED does not c om e on, when the s tandb y pushbu tton is pr essed . Causes: The po wer cable has not b een plu gged i n the m ai[...]

  • Page 39

    Troubleshooti ng 38 Problem: The po wer LED does com e on, but it is flashin g at a l ow rate. T his is an err or-con dition. Cause: The s upply volt age is t oo lo w. Problem s like thes e occur us ually if extensi on cords a re used; in partic ular exten sion cords , that have a (t oo) lo w rating. W hen the heater of the m achin e is s witched o[...]

  • Page 40

    Troubleshooti ng 39 Problem: The For ward LED o n the c ontrol pa nel is f lashing; the m achine has stop ped. Cause: The drive m otor has bee n overl oaded. Solution: Press the s tart butt on. The LED wil l ceas e flashi ng and wil l be lit continuous ly. Problem: The Revers e LED on the c ontrol panel is flash ing; the m achine has stop ped. Caus[...]

  • Page 41

    Troubleshooti ng 40 Problem: The m otor is not ru nning when t he For ward or R evers e buttons ar e pres sed, the Forwar d or Rev erse LED’s do not com e on eith er; howev er the L ED for the Photoe lectric Cells on the control panel is lit. Cause: One or b oth Em ergenc y Stop b uttons ha ve bee n enga ged. Solution: Check if the E-s top butt o[...]

  • Page 42

    Troubleshooti ng 41 Problem: The tem peratur e-ready LE D keeps on flashi ng at a sl ow rate ( after 20 m inutes) , once th e heat ing has been acti vated. Causes: The heati ng elem ent is defectiv e, or one of its connec tors had not bee n ins talled. Solution: Check the volta ge between point 1 and 2 on the Solid State Re la y. If the voltage is [...]

  • Page 43

    Troubleshooti ng 42 Problem : The qual it y of the lam inatio n is poor : wrink les and/ or cr eases sho w up in t he outp ut. Cause: The lam inatin g pressur e settin g is wrong. Solution: Perform the Lam inat ing Pre ssur e Adjustm ent Pr ocedur e describ ed in Section 5- 1. Miscellan eous Cont rol S ystem Boa rd Error Messag es Error: LED no. L6[...]

  • Page 44

    Diagram s 43 8 Diagrams 8-1 Installation Diagram[...]

  • Page 45

    Diagram s 44 8-2 Control Panel Diagra m[...]

  • Page 46

    Diagram s 45 8-3 Safety Control Sy stem Diagram[...]

  • Page 47

    Diagram s 46 8-4 Certified Electrical Components List & Sp arepart Codes DWG Ref. NAME MA NUFA CT URER TYPE TECHNICAL DETA IL S UL LI STI NG S PAREPA RT NO: SSR1 sol id s t ate r el ay Omron G3NA-220B 240Vac / 20A E64562 S P 961- 0001 E1 he ate r 44 U ltra 110V/ 1850W Quar tz T ubi ng I nc. 147-124 120Vac / 1850W ** SP 147- 124 E1 h e a te r 4 [...]

  • Page 48

    Diagram s 47 8-5 Mechanical Sp are Parts List , A ssembl y Dra wings & Exploded V iews 8-5-1 Mech anical Spare Part s List Item Sparepart c ode Dwg a dded Ass y bottom roller Pr oS ea l 44 SP 144-004 Y Ass y nipknob Pr oSea l 44 SP 144-0 21 Y Ass y rh arm pull rol ler SP 144-1 90 Y Ass y lh arm pull ro ller SP 144-1 91 Y Clutch pull ro ll er SP[...]

  • Page 49

    Diagram s 48 8-5-2 Assemb ly D rawing s & Explod ed View s Thes e assem bly drawin gs ar e availa ble on r equest.[...]