SEAL SM110EN User Manual

44Ultra

Laminator

Service Manual

SM110EN, Rev. 2.0

May 2003

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

Front Matter

Service Manual 44Ultra

110SM-2.0

ii

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.

Kanaaldijk O.Z. 3
P.O. Box 29
8100AA Raalte
The Netherlands
Tel: [phone]
Fax: [phone]

Internet:
www.SEALBrands.com

Seal Brands . . . the finishing touch

iii

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 including disconnecting the power
cord.

Only qualified service technicians should remove covers for service purposes

Safety Features

The heating system is provided with an over-temperature device, which will shut off the top roller­heating element once a heating system failure occurs.

The rotation of the rollers will be switched off automatically when the light beam of the self-checking
photoelectric guard is interrupted. For example, if a panel is too thick relative to the roller nip setting,
or if a person’s hands or fingers approach the roller nip.
Once the roller rotation has been stopped and the photoelectric guard has been cleared, a deliberate
start signal has to be given in order to start the roller rotation again.

The machine has two emergency stop buttons that may be pressed in dangerous situations. The
rotation of the rollers will be stopped immediately. After releasing these buttons, a deliberate start
signal has to be given in order to start the roller rotation again.

General Hazards

Danger of getting injured by hot parts

Be careful with parts marked with this symbol, to avoid burns. The heated top roller may
have a surface temperature of 135°C (275°F).
Do not touch the roller. Even after the machine has been switched off, the roller remains
hot for a long time.

Danger of getting injured by rotating parts

Everyone working around the laminator must avoid wearing loose fitting clothing (ties!) or
dangling jewelry, which co u ld catch in the laminator rollers.
Failure to use caution near exposed rollers could result in physical injury.

Location of the

safety labels

iv

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

Front Matter

Table of Contents

1 Machine Characteristics ...................................................................................................................7

1-1 Machine Description..................................................................................................................7

1-2 Identification ..............................................................................................................................7

1-3 Features ....................................................................................................................................8

1-4 Specifications ............................................................................................................................9

2 Transport & Installation...................................................................................................................11

2-1 Transport.................................................................................................................................11

2-2 Workspace Requirements.......................................................................................................11

2-3 Setup & Installation .................................................................................................................11

2-4 Electrical Requirements ..........................................................................................................11

3 Theory of Operation........................................................................................................................13

3-1 Control Knob............................................................................................................................13

3-2 Roller Nip settings ...................................................................................................................13

3-3 Control Panel...........................................................................................................................14

3-4 Motor Control...........................................................................................................................15

3-5 Unwind Brakes ........................................................................................................................16

4 Disassembly/Reassembly Procedures...........................................................................................17

4-1 Plastic Covers..........................................................................................................................17

4-2 Heating Element......................................................................................................................18

4-3 Rear Panel...............................................................................................................................20

4-4 Control System Board & Software...........................................................................................21

4-4-1 Control System Board..........................................................................................................21

4-4-2 Software...............................................................................................................................21

4-5 Solid State Relay.....................................................................................................................22

4-6 Photoelectric Cells...................................................................................................................23

5 Adjustment Procedures ..................................................................................................................25

5-1 Laminating Pressure ...............................................................................................................25

5-1-1 Adjustment using Load Cells and Display Unit...................................................................25

5-1-2 Adjustment using Heat Sensitive Film................................................................................27

5-2 Roller Nip.................................................................................................................................29

5-3 Temperature............................................................................................................................30

5-4 Photoelectric Cells...................................................................................................................31

5-5 Drive Chain..............................................................................................................................32

5-6 Clutch ......................................................................................................................................32

5-7 Image Guide............................................................................................................................33

6 Maintenance...................................................................................................................................35

vi

Front Matter

7 Troubleshooting..............................................................................................................................37

8 Diagrams ........................................................................................................................................43

8-1 Installation Diagram.................................................................................................................43

8-2 Control Panel Diagram............................................................................................................44

8-3 Safety Control System Diagram..............................................................................................45

8-4 Certified Electrical Components List & Sparepart Codes .......................................................46

8-5 Mechanical Spare Parts List, Assembly Drawings & Exploded Views....................................47

8-5-1 Mechanical Spare Parts List................................................................................................47

8-5-2 Assembly Drawings & Exploded Views...............................................................................48

vii

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 a single-phase power supply.

The machine is able to perform the following processes:

• cold/hot mounting

• cold/hot laminating

• mounting & laminating in one pass

• decaling

• encapsulating

Process results can be controlled by:

• the temperature setting

• the speed setting

• the unwind tension of the film(s)

The SEAL 44 Ultra meets the Machinery Directive (89/392/EEC & applicable amendments). The
Notified Body’s TRF report (based on EN60950) is available.
It is ETL and cETL listed per directive UL 1950 3

1-2 Identification

The machine identification label is located on the rear side of the machine.
The machine is available in two different voltages: 110VAC 50/60Hz and 230VAC 50/60Hz, see the
labels below.

MODEL: SEAL 44 ULTRA
POWER SUPPLY: 230VAC 50/60Hz
CURRENT: 9A

SERIAL NO:

MANUFACTURED:

EN 60950
EN 50081-1
EN 50082-1
FCC Part 15 (Class B)

Hunt Graphics Europe BV
Kanaaldijk O.Z. 3, P. O .B . 29
8100AA Raalte, The Netherlands

MODEL: SEAL 44 ULTRA
POWER SUPPLY: 110VAC 50/60Hz
CURRENT: 16A

SERIAL N O:

MANUFACTURED:

EN 60950
EN 50081-1
EN 50082-1
FCC Part 15 (Class B)

Hunt Graphics Europe BV
Kanaaldijk O.Z. 3, P. O .B . 29
8100AA Raalte, The Netherlands

rd

Edition 1995 and CAN/CSA C22.2 No. 950-95.

• EQUIPMENT TO BE CONNECTED TO EARTHED MAINS OUTLET
ONLY.

• TO PREVENT ELECTRIC SHOCK, DO NOT REMOVE COVER.

• NO OPERATOR SERVICEABLE PARTS INSIDE.

• REFER SERVICING TO QUALIFIED SERVICE PERSONNEL.

• CONECTAR EL PRODUCTO A RED DE ALIMENTACION CON TOMA DE TIERRA.

• PARE EVITAR UNA DESCARGA ELECTRICA, NO QUITE LA CUBIERTA.

• NO HAY PIEZAS REPARABLES POR EL USUARIO EN EL INTERIOR.

• REPARACIONES: CONTACTAR CON PERSONAL DE SERVICI O AUTO RIZ ADO .

THIS DEVICE COMPLIES WITH PART 15 OF THE FCC RULES. OPERATION IS
SUBJECT TO THE FOLLOWING TWO CONDITIONS: (1) THIS DEVICE MAY NOT
CAUSE HARMFUL INTERFERENCE, AND (2) THIS DEVICE MUST ACCEPT ANY
INTERFERENCE RECEIVED, INCLUDI NG INT ERF ERENCE THAT MAY CAUSE
UNDESIRED OPERATION.

MADE IN HOLLAND

• EQUIPMENT TO BE CONNECTED TO EARTHED MAINS OUTLET
ONLY.

• TO PREVENT ELECTRIC SHOCK, DO NOT REMOVE COVER.

• NO OPERATOR SERVICEABLE PARTS INSIDE.

• REFER SERVICING TO QUALIFIED SERVICE PERSONNEL.

• CONECTAR EL PRODUCTO A RED DE ALIMENTACION CON TOMA DE TIERRA.

• PARE EVITAR UNA DESCARGA ELECTRICA, NO QUITE LA CUBIERTA.

• NO HAY PIEZAS REPARABLES POR EL USUARIO EN EL INTERIOR.

• REPARACIONES: CONTACTAR CON PERSONAL DE SERV ICI O AUT ORI Z ADO.

THIS DEVICE COMPLIES WITH PART 15 OF THE FCC RULES. OPERATION IS
SUBJECT TO THE FOLLOWING TWO CONDITIONS: (1) THIS DEVICE MAY NOT
CAUSE HARMFUL INTERFERENCE, AND (2) THIS DEVICE MUS T ACCEPT ANY
INTERFERENCE RECEIVED, INCLUDI NG INTE RFE RE NCE THAT M AY CAUSE
UNDESIRED OPERATION.

MADE IN HOLLAND

7

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 standby
7 Nip knob To adjust the gap between the rollers
8 Process control sheet Shows how to preset the machine
9 Lower unwind shaft The shaft is suitable for rolls having a 3-inch core

10 Foot switch To engage slow mode
11 Safety device Prevent the supply rolls from falling out
12 Floor anchor Renders the machine immovable once installed

The ID-label is located on the rear side of the machine.

11

2

1

9

11

12

10

3 4

5

8

7

2

6

7

5

12

8

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 mm 44 in
Maximum material width (processes up to 125°C) 1067 mm 42 in
Maximum material diameter (top unwind) 160 mm 6.3 in
Maximum material diameter (bottom unwind) 200 mm 8 in
Maximum material diameter (release liner windup) 125 mm 5 in
Maximum panel thickness 10 mm 3/8 in
Core size 76.2 mm 3 in

Machine specifications

Nip settings 0 (nip closed)
2 mm 1/16 in
3 mm 1/8 in
5 mm 3/16 in
6 mm 1/4 in
8 mm 5/16 in
10 mm 3/8 in

Linear pressure 0.97 N/mm 5.54 lbf/in
Roller torque (bottom roller driven) 29 Nm 257 lbfin
Maximum process speed 1.5 m/min 4.92 ft/min
Maximum roller temperature 135 °C 275 °F
Temperature settings off (ambient temperature)

50 °C 125 °F
90 °C 195 °F
120 °C 250 °F

Noise level < 70 dB(A)

9

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.

• There should be enough space around the laminator to feed-in, exit, and trim mounted and/or

laminated images.

• The background dust level must not exceed that found in a typical office/computer room
environment.

• The work area should be level, flat, and well lit.

2-3 Setup & Installation

Refer to the Unpacking/Set Up Instruction Sheet which is packed inside the crate, on top of the inner
box.

2-4 Electrical Requirements

This unit should only be connected to a power supply outlet having the voltage and amperage as
shown on the Identification Label (see Identification, 1-2). The 110VAC version of the SEAL 44 Ultra is
provided with a powercable having a NEMA 20Amp plug; the 230VAC version is provided with two
powercables: one having a BS 1363 plug, the other has a Schuko plug.

The electrical specifications of the machines are shown in 1-3, Electrical specifications.

The Seal 44 Ultra machines must be installed next to the power outlet; extension
cords are not to be used. The plug and the outlet must be easily accessible by the
operator.

11

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).

Continue to rotate the knob until the desired nip
setting corresponds with the indicator window at
the base of the knob. Inside the window, the
possible rotation directions are shown. Select the
value that corresponds to the thickness of the material you will be using with the machine.
Releasing the knob so that it moves back to the right and clicks into place will set the rollers for use.

Select the next lower value in case there is no match for the thickness of the used
substrate.

Internal functionality

See figure 2.
Inside the machine, a rod is mounted
between the left- and right-hand framesheets.
The knob is mounted on the rod; it allows
axial movement, but no radial movement.
The knob is provided with a pin (1), that falls
in the indents (2) of a bracket (3). The same
rod is provided with an eccentric (4) on either
side of the machine. These eccentrics push
or pull the arms (5), where the top roller is
mounted in, upward or downward.

3-2 Roller Nip settings

Whenever you mount onto a board, etc., it is important to adjust the rollers to create a gap nearly
equal to the thickness of the board being used. This is done so that anything passing between the
rollers will receive the right amount of pressure and prevent damage to the rubber surface of the roller
(and possibly the board).

fig. 1

5

4

fig. 2

1

2

3

13

Theory of Operation

y

p

g

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

Drive

mechanism

mbol

s

the rollers

speed

control

area

temperature
control area

LED (green)

Lit when machine

runs forward

Safety eye

symbol

LED (green)

Lit when safety

eyes are NOT

LED (green)

machine runs

LED’s (green)

temperature

interru

Lit when

reverse

Three

settin

ted

s

Pushbutton

Stops any roller

movement

Pushbutton

Runs the rollers in

reverse direction

(as long as the

button is pressed)

Speed

adjustment

knob

Pushbutton
To cycle through the
temperature presets

Press 2 seconds to

switch the heater on or

off

power

control

area

fig. 3

LED (green)

Lit when machine

is switched on

To switch the power on or off

Pushbutton

(standby-function)

14