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44Ultra
Laminator
Service Manual
SM110EN, Rev. 2.0
May 2003
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Front Matter SEAL 44 Ultra Technical Service Manual REV 1.1 Revision History Amendments will be listed on this page, including their descriptions and dates. REV Date Description 1.0 Jan 2001 Original version (pre-release). 1.1 Mar 2001 Changes in Sparepart list and Chapter 8 (Diagrams) 2.0 May 2003 Seal branding Service Manual 44Ultra 110SM-2.0 ii
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Front Matter ©2003,2000 SEAL® Graphics Europe BV All technical and technological information included in this manual as well as any drawings and technical specifications we have made available remain our property. They shall not be used (other than for operation of this product), copied, reproduced, transmitted to or disclosed to third parties without our prior written consent. The Information contained herein is general and does not constitute any warranties or guarantees.
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Front Matter Safety Statements The SEAL 44 Ultra laminator has been designed with operator safety as a primary objective; however, operators must be familiar with the controls, as well as the operation before using the unit. The electrical and drive-system components are isolated from contact with the operator by enclosing them within plastic end covers that are bolted on. Only qualified service technicians should remove these protective covers after power to the machine is removed
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Front Matter Note: When performing procedures that require the side covers to be opened, ensure that the power cable is disconnected from the mains. Several parts, like the fast-on connector strips of the overtemperature switch (white arrows in picture shown below), could cause electrical shock if the power is not disconnected! v
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Front Matter Table of Contents 1 Machine Characteristics...................................................................................................................7 1-1 Machine Description..................................................................................................................7 1-2 Identification..............................................................................................................................7 1-3 Features.............
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Front Matter 7 Troubleshooting..............................................................................................................................37 8 Diagrams........................................................................................................................................43 8-1 Installation Diagram.................................................................................................................43 8-2 Control Panel Diagram ..................
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Machine Characteristics 1 Machine Characteristics 1-1 Machine Description The SEAL 44 Ultra laminator is an electro-mechanical device basically containing two siliconized laminating rollers, two siliconized pull rollers and a top and bottom film unwind. Only the top roller is heated. There are three temperature ranges; the speed can be set to any value between zero and maximum speed. There is a set of nip values to accommodate for the various panel thicknesses. The machine runs on
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Machine Characteristics 1-3 Features Identification of parts 1 Wind-up idler Idler (removable) to support the wind-up core for the release-liner 2 Emergency stop buttons Stop the rotation of the rollers immediately 3 Image guide To help feed-in images. It is removable when mounting 4 Upper unwind shaft The shaft is suitable for rolls having a 3-inch core 5 Unwind brake A simple means of setting the unwind tension 6 Control panel Controls rotation of the rolls, temperature and stand
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Machine Characteristics 1-4 Specifications Dimensions & weights Uncrated Crated depth 56 cm (22 in) 63 cm (24.8 in) width 148 cm (58.3 in) 160 cm (63 in) height 111 cm (43.7 in) 72 cm (28.4 in) weight 101 kg (222 lbs) 135 kg (297 lbs) Electrical specifications Part no. 60958 230VAC 50/60Hz 9A Part no. 60959 110VAC 50/60Hz 16A Metric Imperial Material specifications Maximum material width (processes up to 50°C) 1118
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Machine Characteristics 10
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Transport & Installation 2 Transport & Installation 2-1 Transport Only use a pallet jack or forklift to lift and transport the machine. The machine is transported on a wooden pallet, which is an integral part of the packaging. The machine is wrapped in plastic film to avoid moisture penetration. 2-2 Workspace Requirements • This unit should be situated away from heat sources such as heat registers or stoves. • There should be enough space around the laminator to feed-
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Transport & Installation 12
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Theory of Operation 3 Theory of Operation 3-1 Control Knob The Control Knob (see figure 1) is located on the right hand side of the laminator and is operated from the front of the machine. The Control Knob can be operated by pushing it in approximately 6mm (1/4”) to the left. Once the knob has disengaged from the stop, it may be rotated forward or backward (clockwise or counter- clockwise, viewed from the right hand side of the unit). Continue to rotate the knob until the d
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Theory of Operation 3-3 Control Panel The Control Panel is located on the front right of the machine and has seven LED indicators. A diagram of the Control Panel is shown in figure 3. Pushbutton Starts the forward process direction of the rollers Drive mechanism symbol LED (green) Pushbutton Lit when machine Stops any roller runs forward movement Safety eye symbol speed control Pushbutton area Runs the rollers in LED (green) reverse direction Lit when
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Theory of Operation 3-4 Motor Control The speed of the rollers is continuously adjustable between 0 and 1.5 m/min. (0 and 4.9 ft/min.) Pressing the key runs the rollers in forward direction, pressing the key reverses the direction of the rollers (as long as this button is pressed). The stop key stops the roller movement. Slow-mode The machine has a so-called slow-mode, which can be activated by pressing the foot switch. To maintain slow-mode, keep the foot switch presse
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Theory of Operation 3-5 Unwind Brakes Tighten the unwind brake so that it applies sufficient tension to laminate. Turning the knurled collar in a clockwise direction increases the unwind tension applied to the laminate. Turning the collar counter- clockwise decreases the tension. The best setting for the brake tension is determined by the materials you are using and is learned through experience. Note: In general, no or light unwind tensions will be required. 16
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Disassembly / Reassembly Procedures 4 Disassembly/Reassembly Procedures 4-1 Plastic Covers Necessary tools: hexalobular screwdriver TX25, Allen key 4mm. Approximate time: 5 minutes To remove the side covers, perform the following steps: 1. Remove the two self-tapping screws, using the TX25 driver, as shown in figure 4. The right hand cover is shown here. fig. 4 fig. 5 2. Remove the self-tapping screw, situated at the rear side of the machine, using the TX25 driver, as
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Disassembly / Reassembly Procedures 5. The emergency stop contactblock can be removed using a little screwdriver which can inserted below the clamping spring and the contact block. See the arrow on figure 8. 6. The procedure for the left-hand side cover is similar, though it’s obvious that there’s no patchcable on this side. The assembly of the covers is in reverse order. Make sure that all connectors are fitted when mounting the covers. fig. 8 4-2 Heating Element
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Disassembly / Reassembly Procedures 3. See figure 11. Disconnect the white connector 1, located on the right-hand side of the machine from the heater wire. Remove the heater bracket by removing the two bolts 2. Take care not to loose the serrated washers. 2 1 The heating element can now be taken out of the roller. When a heating element has to be installed into the roller, the fig. 11 quartz tube has to be cleaned first. Proceed as follows: Insert the heating element
