80Pro Italiano Español Deutsch Français English Mounter, Laminator and Encapsulator User Manual UM112EN, Rev.1.0 Nov.
User Manual 80Pro
INTRODUCTION English Thank you for purchasing your Seal 80Pro. Maximum effort has been invested in the design of this machine to give you years of reliable service. As you become familiar with your machine you will appreciate the high quality of its output and the excellence in engineering stated in its smartly styled design.
THIS MANUAL This manual is intended for the user of the 80Pro. Read this manual carefully before starting the machine. This manual contains important information for correct installation, operation and maintenance of the machine. It also contains important instructions to prevent accidents, personal injury and/or serious damage prior to or during operation of the machine. Familiarize yourself thoroughly with the functioning and operation of this machine and strictly observe the directions given.
TABLE OF CONTENTS 1.1 1.2 Warranty and Safety instructions Warranty 7 1.1.1 1.1.2 7 7 8 Safety features Safety instructions Warnings 1.3.1 1.3.2 1.3.3 2 Warranty conditions Warranty period Safety 1.2.1 1.2.2 1.3 7 General ESD-warning In this manual On the machine Description 8 9 9 9 9 10 11 2.1 General description 11 2.2 Parts identification 12 2.2.1 2.2.2 12 13 2.3 3 Machine parts Laminating foiles Process principle Specifications 14 15 3.1 Identification 15 3.
5 5.1 5.2 5.3 5.4 5.5 5.6 6 6.1 6.2 Operating 21 Process controls 21 5.1.1 5.1.2 5.1.3 5.1.4 21 23 24 28 Control panel Heater control Additional controls Error indications Operating modes 29 5.2.1 5.2.2 5.2.3 29 29 30 Normal forward mode Reverse mode Slow mode Placing film rolls 31 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 31 31 32 33 33 Auto-grip shafts Use of films with release liner Loading shaft with film rolls Presetting the tension Pressure setting Webbing 34 5.4.1 5.4.2 5.4.3 5.4.4 5.4.
1 WARRANTY AND SAFETY INSTRUCTIONS 1.1 Warranty English The warranty period and conditions stated in this chapter are merely a summary of the general Seal warranty conditions. For the exact details on the warranty period and conditions for your machine, please contact your dealer. 1.1.
1.2 Safety This machine is provided with safety equipment to promote safe machine operation. The manufacturer has done everything possible to prevent any possible danger and to inform you as accurately and comprehensively as possible of any hazards relating to the operation of the machine. You should nevertheless proceed with caution when operating the machine. Read the safety instructions below and familiarize yourself with the warning symbols summarized in the Warnings section. 1.2.
1.2.2 Safety instructions Work safely! The owner of the machine is responsible for safe operation of the machine. He therefore is obliged to familiarize operating personnel with the contents of this manual and make them aware of all possible hazards. Do not change, remove or disable the safety facilities. Warnings English 1.3 1.3.1 General ESD-warning WARNING: DANGER OF ELECTRIC SHOCK BY ELECTROSTATIC DISCHARGE. PROCESSING FILMS THROUGH LAMINATING ROLLERS WILL CAUSE BUILD-UP OF ELECTROSTATIC CHARGES.
1.3.3 On the machine On the machine (See Figure 1) you will find the following warning symbols in black on a yellow background. HOT OBJECTS (1) DANGER OF GETTING BURN WOUNDS. MAKE SURE NOT TO TOUCH THE UPPER MAIN ROLLER WHEN HEATED. This symbol is placed on the inside side panel on both sides of the machine, just above the upper main roller, visible from the front and rear side. Also on the image guide at the input side of the nip and on the output nip safety bar (1).
2 DESCRIPTION This chapter describes the machine and its operating basics. General description The machine described in this manual is a mono-directional machine dedicated for processing pressure sensitive or heat activated materials. While feeding through images and the coating films, the two silicone coated main rollers generate the pressure. The area where the upper and lower main roller meet is called the “nip”.
2.2 Parts identification 2.2.1 Machine parts Figure 2: Main parts identification.
2.2.2 Laminating foiles English Figure 3 shows the cross section of the layers in the decal process. In this process the largest number of layers is possible. Figure 3: Cross section of layers, when making a decal. Decaling in general is a cold process, where the bottom layer has no release liner. The removable foil (6 = release liner) is not removed during the decal process. The carrier (5) is not always present. In that case the removable foil (6) also functions as carrier.
2.3 Process principle In all processes the materials are fed through the nip from the front side to be joined together by pressure and/or temperature. A process that makes maximum use of the machine is shown in Figure 4. Shown is an image roll to roll process with a heat sensitive top and bottom layer. The image that has to be coated on both sides is unwound from a roll in the in-feed table trough (1) and fed between the main rollers (2) via the in-feed table rollers (3).
3 SPECIFICATIONS 3.1 Identification The machine identification label (example in Figure 5) is located at the bottom of the righthand cabinet, on the rear side of the machine. This label indicates the model (version) and the power supply requirements. English CAUTION: The mains supply must match the values indicated on the machine identification label. Figure 5: Machine identification label (example). 3.2 Machine dimensions 3.2.1 Uncrated Width Height Depth (excl.
3.3 Material specifications Maximum width Process up to 50°C (122 °F) Process up to 125°C (257 °F) Maximum roll diameter Material unwind (top and upper unwind) Material unwind (top unwind only) Material unwind (bottom unwind) Release liner wind-up Media in table trough Maximum weight media unwind in table trough Maximum panel thickness Roll core inside diameter 3.4 Metric 2005 mm 1954 mm 200 305 305 180 120 5 38 76.2 American 80 in. 78 in. mm mm mm mm mm kg mm mm 8 1 1 6 4 11 1.5 3 in. ft. ft. in.
4 INSTALLATION WARNING: INSTALLATION MUST BE CARRIED OUT BY SKILLED PERSONNEL. 4.1 English Note: Make sure that the machine, in its final location, has adequate space. You will need room to feed, receive and trim images. Unpacking At delivery, the machine is packed in a plastic bag to avoid moisture penetration. It is transported in a carton box and is fastened onto a wooden pallet. Note: Unpacking the machine requires at least 2 persons. The machine is equipped with castors that allow easy movement.
5. Remove the four securing bolts (1). 6. Turn down the four leveling feet (2) to lift the machine. 7. Remove the wooden blocks (3). Figure 7: Removing transport parts. 8. Turn the support block (6) 90 to make room for the machine to pass by. 9. Turn up the four leveling feet (2) completely to put the machine on its castors (5). 10. Roll the machine off carefully from the pallet using the ramps. WARNING: ROLL THE MACHINE OFF WITH 2 PERSONS. IT IS HEAVY AND CAN NOT BE CONTROLLED ALONE.
4.2 Installation 1. Move the machine (and the accessories) to its final location. English Note: Allow ample working space. See Figure 8. Figure 8: Working space. L = Maximum board length, S = Minimum space 60 cm (24 in.). 2. Turn down the four leveling feet until the castors are off the floor. 3. Remove all transport material. Remove the straps holding the control panel arm Cut the straps around the shaft suspensions and remove the foam pads.
4.3 Transport The machine can be transported on a smooth surface on its castors. CAUTION: Turn the leveling feet up completely to prevent them from bending or breaking if accidentally bumping into an obstacle. On rough surfaces use a pallet truck or forklift. Set the forks as far appart as possible. When moving the machine over long distances, use original pallet and packing material and follow the unpacking procedure in the opposite way.
5 OPERATING This chapter describes the function of the controls and indicators, the operating modes, how to set up and operate the machine and a number of applications. 5.1 Process controls Note: Switch on the heaters approximately 1 hour before use, if a process requires the rollers to be heated. Close the nip and let the machine run at low speed, to avoid uneven hot spots. 5.1.1 Control panel This paragraph describes the controls and indicators on the control panel.
Safety indicator (3), LED; The LED lights up when the beam of the optical safety device at the input side of the nip is not interrupted. Pressure indication (4), 4 LED‟s; The LED‟s indicate the pressure setting of the main rollers. When 2 LED‟s light at the same time, they indicate the tens in between. See specifications for actual pressure range. All four LED‟s flashing indicates a pressure or nip setting error (see section 5.1.4).
5.1.2 Heater control English The two heater controls above the control panel are equal. The upper heater control regulates the temperature of the upper main roller. The lower heater control is for the bottom main roller heater. Figure 10: Heater-control section. The heater control is on as soon as the machine (control) is turned on. The actual temperature of the roller is now displayed (3) on the temperature control display. The heater itself is turned ON and OFF by the 0/I switch (1).
5.1.3 Additional controls Figure 12: Additional controls Emergency stops (1), Stop buttons (1a), push and hold button; When pressed the rotation of the rollers is stopped immediately and the button is locked into this stop position. Turn the button to unlock it. Pressing start, reverse or pressing the footswitch starts the process again. Trip wire (1b), wire attached to a pull and hold switch; When the wire is pulled or stept on the switch will immediately stop the rollers.
Foot switch (3), snap switch; Press and hold the switch to start the rotation of the rolls. Insert the forefoot completely to disable the safety lock that prevents accidental starting. When the switch is released, the rotation of the rolls will stop. Nip setting wheel (4), geared wheel; Turn the wheel clockwise to narrow (close) the nip and increase the pressure or When both rollers touch the materials, the pressure is set.
Pull roller locking knob (8); Snap-lock (right-hand side, seen from the rear of the machine) to lock the top pull roller into position. Pull roller handle (9); Handle to lever the top pull roller into position. Main power switch (10); Rotary switch to switch the mains supply to the machine ON or OFF. The switch can be locked in the OFF position with a padlock. Pull roller cover-plate lock (11); Retaining block and locking screw with knob.
Figure 15: In-feed table controls The in-feed table can swing up around pivot point (P) till it is upside down. In the upper position it is stopped by the shaft supports and in the lower position by the table stops (M). The in-feed table has a number of features to help feeding images correctly. Some of these features can only be used in some of the processes. Unwind trough (A) To unwind a medium from a roll.
5.1.4 Error indications When an error is detected, one or more LED‟s are flashing and any rotation will stop. Power indicator flashing; Machine is in stand-by mode. The power is on and the optical safety device is active. Press the control ON/OFF button to activate the machine. Forward indication flashing; Motor overload. Press the stop button and check the material flow and the tension setting of the unwind shafts. Reverse indicator flashing; Motor overload.
5.2 Operating modes The machine is working either in normal mode or in slow mode. In the normal mode the rollers can rotate in forward or in reverse direction. A special mode is the jog mode. This mode is used when the machine is left on for some time whithout being used. Normal forward mode can be activated from standstill by the start button or by the footswitch (when slow mode indication is not active). The rotation speed of the rollers in normal mode is set via the speed control knob.
5.2.3 Slow mode Slow mode is selected and de-selected by pressing the slow mode button for 1 second. Selection is indicated by the slow mode indication LED. When selecting slow mode from normal forward mode, the speed (normal speed) will not change until the footswitch is pressed. Selecting slow mode speed in reverse direction is not posible. Normal speed Normal speed in slow mode is still determined by the speed control setting.
5.3 Placing film rolls All shafts are the same. Their function is determined by their position in the machine. The shafts fit into the machine in both ways. On the control panel side of the machine the shaft and the suspension snap together by a gripper slot and gripper. At the left-hand side of the machine the shaft has a thrust piece in the suspension. This thrust piece pushes the shaft into locking position when the shaft is turned.
5.3.3 Loading shaft with film rolls The film roll is put on the shaft depending on the type of film and the use in the upper or lower section of the machine. From European and Asian producers of film with release liner in general the film is rolled up with the liner (and adhesive) to the outside, whereas the American films have the liner and adhesive on the inside. Film without release liner has its adhesive layer to the inside of the roll.
5.3.4 Presetting the tension Note: The unwind/wind-up shafts have a split tension setting: Turn clockwise for unwind tension and counter-clockwise to release the unwind tension. Turning further counterclockwise will set wind-up tension (see also section 5.1.3). When the film is webbed, it is recommended to set a low tension to each shaft by turning the knob clockwise until you feel some resistance. On the unwind shaft this will prevent film to unwind without tension.
5.4 Webbing For most processes the machine must be webbed before images on thin film or on panels can be processed. The machine can be webbed for single sided or double sided processing. Single sided is generally used for processing boards. Note: In single sided processes adhesive residues will stay behind on the bottom roller where the film is wider than the images. To prevent this, a release liner of the same width as the top film can be used in the bottom section.
3. Pull the film forward until approximately 10 cm (4 in.) is on the in-feed table. If the film has a release liner: Peel off the release liner, Pull the release liner up and stick it to the scrap core on the wind-up shaft. 4. Stick the leader panel to the film. 5. Feed the panel into the nip using slow mode. 6. Butt up the next panel or, English When thin images must be processed: 7. stop when the panel is at the end of the table. 8. Bring the image guide in the upper position. 9.
5.4.2 Upper and lower section A leader panel is provided to help webbing the machine. Figure 20: Upper and lower section webbed. The film in the upper section is webbed first 1. Stow away the image guide. 2. Feed the film underneath the splitter bar (between splitter bar and upper roller). Pressure sensitive film without a release liner from the top unwind shaft must be fed over the splitter bar. 3. Pull the film forward until it almost reaches the in-feed table and apply it to the upper roller.
Note: Use a leader panel of the same material, thickness and width as the panels to process. When encapsulating it is recommended to use the provided release board as a leader. Processing boards: 11. Set the pressure for optimum result when the leader board passes through. 12. Butt up the next boards. 13. End up again with the leader board. Processing thin images: 11. When the leader board is through the nip, set the nip to zero and the pressure to 80%. 12. Flip up the image guide and the table rollers. 13.
5.4.3 Roll to roll When webbing for an image roll to roll process, the lower front unwind/wind-up shaft is used as a supply (unwind) shaft for the images. Single sided lamination; When laminating single sided the unwind/windup shaft in the rear of the lower section can be used to wind-up the completed product (Figure 22, A). Note: To prevent adhesive residues from staying behind on the bottom roller use a release liner in the bottom section and follow the double sided lamination process.
5.4.4 Pull rollers English The pull rollers are generally used in the encapsulation process (hot processing double sided lamination) to get a better encapsulation result. Before webbing set the top pull roller in the upper position and lock it on both sides. Webbing is the same as described before, except the films are now, with a leader board, pushed through the main roller nip and the pull roller nip. Figure 23: Roll to roll with pull rollers engaged. 5.4.
5.5 Processes 5.5.1 Mounting images or decals In this process the machine is not webbed with film. When mounting images onto a (pre-coated) board (B), the adhesive is on the mounting side of the board, When mounting decals (A), the adhesive is on the back of the image. The mounting process is equal for both. 1. Stow away the image guide and table roller. 2. Remove the shafts from the upper section. 3. Preset the nip and the pressure (see section 5.3.5). 4. Put the board on the in-feed table.
7. Apply the image to the board (3). 8. Insert the edge with the image adhered to into the nip. 9. Lay the loose end of the image smoothly over the upper roller (4). Note: Use the footswitch to start the machine in slow mode, keeping your hands free to guide the image. WARNING: English KEEP YOUR FINGERS CLEAR OF THE NIP. THE OPTICAL SAFETY DEVICE IS NOT FUNCTIONING IN SLOW MODE. 10.
At the end, use a leader board again to finish. This prevents the adhesive from touching the bottom roller. 6. Butt up the leader board and feed it in until the previous panel is out of the nip. After removing the release liner from the pressure sensitive mounting film, the board has an adhesive coating ready to mount an image. For mounting images see section 5.5.1. To unload the machine; CAUTION: Do not cut film close to or on the rollers.
5.5.6 Encapsulation Encapsulation is the term for sealing an image with heat sensitive laminates on both sides. Switch ON both heaters. Set the temperatures (see the specifications of the materials used) and allow ample time to reach the set temperature. Set the upper pull roller in the upper position before webbing and lock it in position. The procedure is the same as the double-sided lamination above (section 5.5.5). 5.5.
6 MAINTENANCE 6.1 Cleaning The machine has to be cleaned regularly. Dirt and dust will have a negative influence on the result of the lamination processes. CAUTION: Do not use abrasive materials for cleaning the machine. This can damage the painted surfaces or the silicone covering of the rollers. Use a damp cloth for cleaning. CAUTION: Make sure water does not run into any of the cabinets. This can damage the electrical circuits when power is applied.
6.2 Preventive maintenance Our machines are designed in such way that they need little (preventive) maintenance in addition to the cleaning. The following checks have to be performed regularly: Auto-grip shafts with blocking cords. 6.2.1 Auto-grip shafts English Check the auto-grip mechanism on each shaft. The distance (d) between the rubber cords and the edges of the recess should be 8 ± 2.5 mm minimum (the cord must not touch the skew).
Pressure too low. Figure 28: Wrinkles due to low pressure. Increase the roller pressure a little (5-10%). Unwind tension too low. Figure 29: Wrinkles due to low unwind tension. Increase the unwind tension until the wrinkles (6) in the film on the roller disappear. The lines (7) in the process result will disappear as well. Pull tension too low. Figure 30: Wrinkles due to low pull tension 46 This is a machine adjustment error. Contact your dealer and ask for technical assistance.
Too much heat in the final result. Figure 31: Wrinkles due to too much heat. English The result is still too hot after the pull rollers. The bottom pull roller also gets hot. Reduce the heater settings. Check the function of the cooling device. Roller alignment fault. Figure 32: Wrinkles due to faulty roller alignment. The wrinkles occur on one side only (left or right). This is a machine adjustment error. Contact your dealer and ask for technical assistance. Material rolls are jumping.
7 GLOSSARY Carrier board or sled A board with a non-stick surface that is used when laminating one side of an image only. Decal An image with an adhesive backside (Am.: Sticker). Decaling Providing an image with laminate on the image side and adhesive on the backside. Encapsulating Sandwiching an image between two heat sensitive films. Laminate A thin film of clear material to be permanently affixed onto an image. Laminating Providing an image with a thin film of clear material.
