44Ultra Laminator Service Manual SM110EN, Rev. 2.
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 1.0 1.1 2.0 Date Jan 2001 Mar 2001 May 2003 Description Original version (pre-release). Changes in Sparepart list and Chapter 8 (Diagrams) Seal branding Service Manual 44Ultra 110SM-2.
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. SEAL GRAPHICS EUROPE B.V.
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.
Front Matter Note: When performing procedures that require the side covers to be opened, ensure that the power cable is disconnected from the mains.
Front Matter Table of Contents 1 2 3 4 Machine Characteristics ................................................................................................................... 7 1-1 Machine Description .................................................................................................................. 7 1-2 Identification .............................................................................................................................. 7 1-3 Features ...................
Front Matter 7 Troubleshooting .............................................................................................................................. 37 8 Diagrams ........................................................................................................................................ 43 8-1 Installation Diagram................................................................................................................. 43 8-2 Control Panel Diagram ...........................
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.
Machine Characteristics 1-3 Features 1 2 3 4 5 6 7 8 9 10 11 12 Identification of parts Idler (removable) to support the wind-up core for the release-liner Stop the rotation of the rollers immediately To help feed-in images.
Machine Characteristics 1-4 Specifications Dimensions & weights depth width height weight Uncrated 56 cm (22 in) 148 cm (58.3 in) 111 cm (43.7 in) 101 kg (222 lbs) Crated 63 cm (24.8 in) 160 cm (63 in) 72 cm (28.4 in) 135 kg (297 lbs) Electrical specifications Part no. 60958 Part no.
Machine Characteristics 10
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.
Transport & Installation 12
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 counterclockwise, viewed from the right hand side of the unit).
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.
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 pressed.
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 counterclockwise 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.
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 shown in figere 5. 3.
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.
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. The heating element can now be taken out of the roller. 2 1 When a heating element has to be installed into the roller, the quartz tube has to be cleaned first. fig.
Disassembly / Reassembly Procedures 4-3 Rear Panel Necessary tools: Phillips crosshead screwdriver (medium), open-ended spanner 8mm, and knife. Approximate time: 10 minutes. Perform the following steps: 1. Remove the seven self-tapping screws from the rear panel. Take care not to loose the serrated washers and the 3 plastic straps. 2. See figure 13: carefully pull the rear panel backward a bit; next swing the rear panel a quarter turn away from the machine. 3.
Disassembly / Reassembly Procedures 4-4 Control System Board & Software 4-4-1 Control System Board To change the Control System Board, it is necessary to disassemble Rear Panel, as described in section 4-3. 1. Remove all connectors. 2. Remove the five M3 socket screws. 3. Remove the print. Assemble in reverse order. Never change the settings of the three potmeters, marked 1, 2 and 3 in figure 15. 4-4-2 Software The Control System of the Seal 44 Ultra is software driven.
Disassembly / Reassembly Procedures 4-5 Solid State Relay Necessary tools: medium flat-head screwdriver, Allen key 3 mm. Approximate time: 20 minutes. Note: To remove the Solid State Relay, it is necessary to perform the Rear Panel disassembly procedure (see Section 4-3) first. Perform the following steps: 1. 2. 3. 4. 5. Loosen all four screws that clamp the wires. They are marked 1 through 4. See figure 16. Bend the wires a bit away from the Solid State Relay.
Disassembly / Reassembly Procedures 4-6 Photoelectric Cells Note: to perform the following adjustments, it is necessary to remove both plastic side covers first. See section 4.1: Disassembly / Reassembly plastic side covers. Necessary tools: small flat head screwdriver, Allen key 3mm Necessary materials: two tie-wraps (2.5 – 3 mm wide), per Photoelectric Cell. Approximate time: 10 minutes. Note: perform the Photoelectric Cells Adjustment procedure once the Photoelectric Cell(s) have been replaced.
Disassembly / Reassembly Procedures 4. Remove the two M4 bolts (see the white arrows in figure 20, the left hand Photoelectric Cell is shown here). 5. The Photoelectric Cell can now be removed. Reassembly 6. When reassembling the Photoelectric Cell, make sure that the bracket is positioned in such a way, that the M4 bolt is in the middle of the vertical slot as in figure 20 (three white lines). The same procedure counts for the other Photoelectric Cell. fig. 20 7.
Adjustment Procedures 5 Adjustment Procedures 5-1 Laminating Pressure Note: To perform the following adjustments, it is necessary to remove both plastic side covers first. See Section 4-1: Disassembly / Reassembly Plastic Side Covers. There are two ways to adjust the laminating pressure: 1. Adjustment using load cells and display unit. 2. Adjustment using Heat Sensitive Film (JetGuard 5mil or Thermashield 5mil).
Adjustment Procedures 4. Position the load cells at either side of the rollers, between the journals, as shown in figure 24. fig. 24 fig. 25 5. Push and rotate the nip adjustment knob until the pin, mounted in the knob, falls into the last notch (relative to top) from the indent bracket (see figure 25, white arrow). The pressure will be applied to the pressure sensors, and the pressure can be read on the PDU. 6.
Adjustment Procedures 5-1-2 Adjustment using Heat Sensitive Film This procedure refers to the pressure adjustment to be done at the customer’s site. Note: as this procedure is performed using heat sensitive film (JetGuard 5 mil or Thermashield 5 mil), the top roller temperature should be set to 120°C (250ºF). 1. Remove any film from the machine. 2. Remove the Image Guide. 3. Cut several sheets of film from the supplyroll. The offcut size should be 43’’ by 8’’ (so it’s easy if 43’’ film is used). 4.
Adjustment Procedures • If the roll pressure is too high, then the footprint looks like: This is the case if the ends of the footprint (measured 1’’ from either side) are at least 1mm (0.04’’) wider than the middle. Change the pressure as described below. • If the roll pressure is too low, then the footprint looks like: This is the case if the ends of the footprint (measured 1’’ from either side) are at least 1mm (0.04’’) smaller than the middle. Change the pressure as described below.
Adjustment Procedures 5-2 Roller Nip Note: to perform the following adjustments, it is necessary to remove both plastic side covers first. See section 4-1: Disassembly / Reassembly Plastic Side Covers. Necessary tools: Allen Key 4mm, a set of metric thickness gauges. Approximate time: 5 minutes Note: the top roller must be at room temperature, before this procedure is being performed. 1. Set the roller opening to its minimum position by pushing and turning the nip setting knob fully counter-clockwise.
Adjustment Procedures 5-3 Temperature Necessary tools: Infrared temperature meter, small flat-head screwdriver. Approximate time: 30 - 45 minutes. 1. Set the roller nip to 10mm (3/8’’). 2. Set the top roller temperature to the 120°C setting on the control panel; the roller is being heated up. 3. After approx. 5 minutes, turn the top roller roughly a quarter of a turn, and repeat this every 2 minutes, until the green LED, next to the 120°C setting, is steady. 4.
Adjustment Procedures 5-4 Photoelectric Cells Note: to perform the following adjustments, it is necessary to remove both plastic side covers first. See section 4-1: Disassembly/Reassembly Plastic Side Covers. Necessary tools: small flat-head screwdriver. The Photoelectric Cells are mounted on the arm assemblies of the upper roller. Viewed from the frontside of the machine, the transmitter is mounted at the left-hand side and the reciever is mounted at the right-hand side of the machine. 1.
Adjustment Procedures 5-5 Drive Chain Necessary tools: Allen key 4mm, medium flat-head screwdriver. Approximate time: 8 minutes. Note: to perform the following adjustments, it is necessary to remove the right-hand side cover first. See section 4-1: Disassembly / Reassembly Plastic Side Covers. The chain guide ensures that the chain has sufficient grip on the clutch assembly. 4 See figure 36.
Adjustment Procedures 5-7 Image Guide To perform the following adjustment, it is necessary to remove both plastic side covers first. See Section 4-1: Disassembly/Reassembly Plasic Side Covers. Necessary tools: allen key 3mm, gauge 2mm. The distance between the upper edge of the Image Guide and the roll surface must be 2±0.5mm (0.0787±0.0196 inch), see figure 37. 1. To adjust the Image Guide, it is necessary to position it in front of the top roller, onto the two support brackets (see arrow #1). 2.
Adjustment Procedures 34
Troubleshooting 6 Maintenance Cleaning of the Machine The equipment must be disconnected from the mains before cleaning. The laminator may be cleaned by the operator with a lint-free cloth, lightly dampened with a mild soap and water solution. Spray-on cleaners are not to be used. No part of the machine is to be immersed in water or other liquids. Do not use an abrasive cleaner, which can damage the painted surfaces.
Troubleshooting 36
Troubleshooting 7 Troubleshooting Note: The ‘Causes’, as described below, are placed in a logical order of occurrence; please follow this sequence in order to solve the problem. Problem: The power LED does not come on, when the standby pushbutton is pressed. Causes: The power cable has not been plugged in the mains wall outlet. Solution: Plug the power cable into the mains outlet. The (external) mains circuit breaker is tripped. Solution: Reset the mains circuit breaker.
Troubleshooting Problem: The power LED does come on, but it is flashing at a low rate. This is an error-condition. Cause: The supply voltage is too low. Problems like these occur usually if extension cords are used; in particular extension cords, that have a (too) low rating. When the heater of the machine is switched on, the voltage usually drops. Solution: Do not use extension cords. Check if the power supply of the office/building, where the 44 Ultra is used, supplies enough voltage to power the machine.
Troubleshooting Problem: The Forward LED on the control panel is flashing; the machine has stopped. Cause: The drive motor has been overloaded. Solution: Press the start button. The LED will cease flashing and will be lit continuously. Problem: The Reverse LED on the control panel is flashing; the machine has stopped. Cause: The drive motor has been overloaded. Solution: Press the reverse button. The LED will cease flashing and will be lit continuously (as long as the button is pressed).
Troubleshooting Problem: The motor is not running when the Forward or Reverse buttons are pressed, the Forward or Reverse LED’s do not come on either; however the LED for the Photoelectric Cells on the control panel is lit. Cause: One or both Emergency Stop buttons have been engaged. Solution: Check if the E-stop buttons are clear: rotate the red knob clockwise until it pops out.
Troubleshooting Problem: The temperature-ready LED keeps on flashing at a slow rate (after 20 minutes), once the heating has been activated. Causes: The heating element is defective, or one of its connectors had not been installed. Solution: Check the voltage between point 1 and 2 on the Solid State Relay. If the voltage is close to 0V, while the red LED on the Relay is lit, check the wiring to the heating element, and perform the Heating Element assembly/reassembly procedure, see Section 4-4.
Troubleshooting Problem: The quality of the lamination is poor: wrinkles and/or creases show up in the output. Cause: The laminating pressure setting is wrong. Solution: Perform the Laminating Pressure Adjustment Procedure described in Section 5-1. Miscellaneous Control System Board Error Messages Error: LED no. L6 is NOT lit. Cause: The +5V voltage is not present. Solution: Check the fuses F1, F2 and F3. If OK, check if there are no loose connections in the cable harness.
Diagrams 8 Diagrams 8-1 Installation Diagram 43
Diagrams 8-2 Control Panel Diagram 44
Diagrams 8-3 Safety Control System Diagram 45
Diagrams 8-4 Certified Electrical Components List & Sparepart Codes DWG Ref. SSR1 NAME MANUFACTURER TYPE TECHNICAL DETAILS UL LISTING SPAREPART NO: solid state relay heater 44 Ultra 110V/1850W heater 44 Ultra 230V/1850W Omron G3NA-220B 240Vac / 20A E64562 SP 961-0001 Quartz Tubing Inc. 147-124 120Vac /1850W ** SP 147-124 Quartz Tubing Inc.
Diagrams 8-5 Mechanical Spare Parts List, Assembly Drawings & Exploded Views 8-5-1 Mechanical Spare Parts List Item Sparepart code Dwg added Assy bottom roller ProSeal 44 Assy nipknob ProSeal 44 Assy rh arm pull roller Assy lh arm pull roller Clutch pull roller Assy bottom pull roll Seal 44 Ultra Sprocket wheel Z=29 Assy mounting plate control system 230V Assy mounting plate control system 110V Assy lh cover Seal 44 Ultra Assy unwind brake Assy autogrip shaft Assy lh cone Assy stand Seal 44 Ultra Assy i
Diagrams 8-5-2 Assembly Drawings & Exploded Views These assembly drawings are available on request.
