SEAL 80Pro User Manual
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SEAL 80Pro User Manual

Mounter, laminator and encapsulator
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80Pro
Mounter, Laminator and Encapsulator
User Manual
UM112EN, Rev.1.0
Nov.2003

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Summary of Contents for SEAL 80Pro

  • Page 1 80Pro Mounter, Laminator and Encapsulator User Manual UM112EN, Rev.1.0 Nov.2003...
  • Page 2 User Manual 80Pro...
  • Page 3 This manual gives a general description of various processes. For more details on film choice and application solutions refer to the Seal films and adhesives product catalog. On this machine the process results can be controlled by: •...
  • Page 4 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.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Warranty and Safety instructions Warranty 1.1.1 Warranty conditions 1.1.2 Warranty period Safety 1.2.1 Safety features 1.2.2 Safety instructions Warnings 1.3.1 General ESD-warning 1.3.2 In this manual 1.3.3 On the machine Description General description Parts identification 2.2.1 Machine parts 2.2.2 Laminating foiles Process principle...
  • Page 6 Mounting images or decals 5.5.2 Pre-coating panels 5.5.3 Single-sided lamination 5.5.4 Over-lamination 5.5.5 Double-sided lamination 5.5.6 Encapsulation 5.5.7 Decaling Settings Maintenance Cleaning 6.1.1 Cleaning the silicone covered rollers Preventive maintenance 6.2.1 Auto-grip shafts Trouble shooting Technical assistance Glossary User Manual 80Pro...

  • Page 7: Warranty And Safety Instructions

    1 WARRANTY AND SAFETY INSTRUCTIONS Warranty 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.

  • Page 8: Safety

    In slow mode the machine is started with the footswitch and will then run at slow speed so that the operator has both hands free to position and feed new film or image correctly into the machine. User Manual 80Pro...

  • Page 9: Safety Instructions

    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.

  • Page 10: On The Machine

    This symbol is placed on those places where electrostatic charges can be build-up. The output side of the machine and the output material are most likely building up charges. Therefore ESD-symbols are placed on the output nip and pull roller safety bars (3) Figure 1: Warning symbol locations. User Manual 80Pro...

  • Page 11: Description

    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.

  • Page 12: Parts Identification

    25 Top pull roller 11 Swivelling arm 26 Slitter bar ruler 12 Heater control 27 Slitter 13 Unwind tension control 28 Pull roller lever 14 Nip-setting indication 29 Pull roller detent 15 Unwind/wind-up tension control 30 Finger protection bracket User Manual 80Pro...

  • Page 13: Laminating Foiles

    2.2.2 Laminating foiles 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.

  • Page 14: Process Principle

    The slitters (11) can be used to cut off the edges when processing roll to roll. Figure 4: Creating Pop-up art, including image supply from roll. User Manual 80Pro...

  • Page 15: Specifications

    3 SPECIFICATIONS Identification The machine identification label (example in Figure 5) is located at the bottom of the right- hand cabinet, on the rear side of the machine. This label indicates the model (version) and the power supply requirements. CAUTION: The mains supply must match the values indicated on the machine identification label.

  • Page 16: Material Specifications

    Unwind/wind-up 3 (auto-grip) Optional features Slitters Nip (gap) setting 0–40 0 – 1 Pressure 1–2.5 N/mm 5.71–14.28 lbf/in. Process speed Maximum m/min ft/min Slow mode 0.6 m/min ft/min Maximum roller temperature °C °F Noise level <70 dB(A) User Manual 80Pro...

  • Page 17: Installation

    4 INSTALLATION WARNING: INSTALLATION MUST BE CARRIED OUT BY SKILLED PERSONNEL. 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.
  • Page 18 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. Note: Save all packing material for later moving over long distances or discard of according to local regulations. User Manual 80Pro...

  • Page 19: Installation

    Installation 1. Move the machine (and the accessories) to its final location. 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.

  • Page 20: Transport

    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. User Manual 80Pro...

  • Page 21: Operating

    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. Process controls This section gives an overview of the functions of the controls on the control panel (Figure 9), the heater control (Figure 10) and elsewhere on the machine (Figure 12).
  • Page 22 Sets the speed anywhere in a range between 0 and 10 (See specifications for actual speed range). Start (12), pushbutton; Press to start the rotation of the rolls in the forward direction. Forward indicator (13), LED; The LED lights when the forward mode is selected. User Manual 80Pro...

  • Page 23: Heater Control

    5.1.2 Heater control 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.

  • Page 24: Additional Controls

    The control panel is mounted on an extendable arm. By pulling the grips the arm can be extended (B) approximately 27cm. The panel assembly can rotate (C) within a limited radius of 90°. Figure 13: Control panel arm User Manual 80Pro...
  • Page 25 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;...
  • Page 26 Pressing (H) and (G) on slitter (A) allows to move slitter (A) without moving slitter (B). The vertical position of the slitter-knife (up is disengaged, down is engaged) is altered by pushing down or pulling up the knife holder at (A) and (B). User Manual 80Pro...
  • Page 27 In-feed table (13) 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.

  • Page 28: Error Indications

    All four pressure indication LED’s are flashing; Pressure too high or nip setting too narrow. The LED’s start flashing at 10% overload. When the pressure exceeds a 20% overload an audible signal is generated. Increase the nip to lower the pressure. User Manual 80Pro...

  • Page 29: Operating Modes

    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.

  • Page 30: Slow Mode

    To change from slow mode speed to normal speed without stopping, press and hold the start button, release the footswitch and then release the start button. Note: Changing to normal speed will not deactivate slow mode. Pressing the footswitch again will slow down rotation to slow mode speed again. User Manual 80Pro...

  • Page 31: Placing Film Rolls

    Placing film rolls 5.3.1 Auto-grip shafts 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.

  • Page 32: Loading Shaft With Film Rolls

    When both upper and lower section are used, align both films by pulling the top film down at the rear side on to the bottom film. 8. Make sure the films (and scrap cores) are set up and aligned properly. User Manual 80Pro...

  • Page 33: Presetting The Tension

    5.3.4 Presetting the tension To enable the film to unwind without wrinkles a momentum (brake or tension) can be set to the roll. On the right-hand side of the machine you will find tension control knobs, corresponding with each shaft. Turn the tension control knob clockwise to set the tension or counter-clockwise to release the tension.

  • Page 34: Webbing

    2. Unwind the film from the upper or top unwind roll. • Feed a pressure sensitive film without release liner from the top unwind roll over the splitter bar (A), • Feed all other films underneath the splitter bar (B). User Manual 80Pro...
  • Page 35 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.

  • Page 36: Upper And Lower Section

    Peel off the release liner, • Pull it up and stick it onto the cylinder on the wind-up shaft. Now web the lower section Figure 21: Webbing lower section. 4. Lift the in-feed table and put it in the upper position. User Manual 80Pro...
  • Page 37 5. Unwind the film from the lower unwind roll at the rear side of the machine and pull it up till it reaches the upper material roll. 6. Allign the lower roll with the upper one. 7. Now web the lower material roll. •...

  • Page 38: Roll To Roll

    To unload the machine; When the image and through the nip (roll is empty), cut the films at approximately the same length (at the splitter bars). Open the nip and pull out the result at the rear side. User Manual 80Pro...

  • Page 39: Pull Rollers

    5.4.4 Pull rollers 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. •...

  • Page 40: Processes

    6. Turn back approx. 25 mm (1 in.) release liner (2) at the machine side and crease this evenly from the inside out. Note: The final quality depends on the way in which the leading edge of the image is applied to the board. User Manual 80Pro...

  • Page 41: Pre-Coating Panels

    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.

  • Page 42: Single-Sided Lamination

    5. Cut the film with the blade cutter when the images are clear of the rollers. To unload the machine; 6. Cut both films along the splitter bar using an enclosed blade cutter. 7. Open up the nip and remove the film between the rollers by pulling it out from the rear. User Manual 80Pro...

  • Page 43: Encapsulation

    5.5.6 Encapsulation Encapsulation is the term for sealing an image with heat sensitive laminates on both sides. Note: The heated rollers need time to reach their set temperature (e.g. from room temperature to maximum takes approximately 1 hour). It is recommended to let the machine run at low speed, to avoid uneven hot spots.

  • Page 44: Maintenance

    MAKE SURE THE ROLLERS ARE COLD WHEN USING ALCOHOL FOR CLEANING. ISOPROPYL ALCOHOL IS VERY EASY FLAMMABLE. Difficult stains can be removed with the aid of isopropyl alcohol (IPA) and a clean lint-free cloth. Do not pour isopropyl alcohol directly on the machine. User Manual 80Pro...

  • Page 45: Preventive Maintenance

    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 Check the auto-grip mechanism on each shaft. •...
  • Page 46 The lines (7) in the process result will disappear as well. Pull tension too low. Figure 30: Wrinkles due to low pull tension • This is a machine adjustment error. Contact your dealer and ask for technical assistance. User Manual 80Pro...

  • Page 47: Technical Assistance

    Too much heat in the final result. Figure 31: Wrinkles due to too much heat. 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.

  • Page 48: Glossary

    One part of the main element in the machine that performs the actual process (see main rollers). Scrap core An empty cardboard cylinder left over when all material on a roll is used. Webbing Loading the machine with film, so that the machine is ready for processing. User Manual 80Pro...

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