Italiano Español Deutsch Français High Production Laminator, Encapsulator, and Mounter English 65ProMD User Manual 7003338, May 2013
English All rights reserved All information included in this manual as well as information included in supplements or addendum to this manual is subject to copyright law. This information shall not be used, copied, reproduced, transmitted or disclosed to third parties without our prior written consent.
INTRODUCTION English Thank you for purchasing your SEAL 65 Pro MD. Many months of design and engineering have been invested in the creation of this laminator in order to give you years of reliable service. As you become familiar with your machine, you will appreciate the high quality output and the excellence in in its ease of use.
THIS MANUAL This manual is intended for the user of the SEAL 65 Pro MD. 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 Warranty and Safety instructions 1.1 Warranty 7 1.1.1 Warranty conditions 1.1.2 Warranty period 7 7 1.2 Safety 8 1.2.1 Safety features 1.2.2 Safety instructions 8 9 1.3 Warnings 9 1.3.1 General ESD-warning 1.3.2 In this manual 1.3.3 On the machine 2. 7 9 9 10 Specifications 11 2.1 Identification 11 2.2 Machine specifications 12 3. 13 Installation 3.1 Unpacking 13 3.2 Installation 16 3.3 Transport 17 4. Description 18 4.1 General description 18 4.
5.3 Loading film rolls 5.3.1 Auto-grip shafts 5.3.2 Use of films with release liner 5.3.3 Loading shaft with film rolls 5.3.4 Presetting the tension 5.3.5 Pressure setting 5.4 Webbing 5.4.1 Upper section only 5.4.2 Upper and lower section 5.4.3 Webbing both upper and lower films. 5.4.4 Roll to roll 5.4.5 Pull rollers 5.5 Processes and settings 5.5.1 Mounting images or decals 5.5.2 Pre-coating panels 5.5.3 Single-sided lamination 5.5.4 Double-sided lamination 5.5.5 Encapsulation 5.5.6 Over-lamination 5.5.
1. WARRANTY AND SAFETY INSTRUCTIONS 1.1 Warranty The warranty period and conditions stated in this chapter are merely a summary of the general SEAL brand laminator warranty conditions. For the exact details on the warranty period and conditions for your machine, please contact Neschen Americas Technical Support or your reseller. English 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. English 1.3 Warnings 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 you will find the following warning symbols in black on a yellow background. HOT OBJECTS DANGER OF GETTING BURN WOUNDS. MAKE SURE NOT TO TOUCH THE MAIN ROLLERS 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, and on the image guide at the input side of the nip. ROTATING PARTS DANGER OF GETTING INJURED BY ROTATING PARTS.
2. SPECIFICATIONS 2.1 Identification The machine identification label 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. English CAUTION: The mains supply must match the values indicated on the machine identification label. Figure 1: Machine identification label (example only – refer to your machine for specific information).
2.2 Machine specifications Technical Specifications Max. Working Width Max. Speed Max. Substrate Thickness (Nip) Max.
3. INSTALLATION WARNING: INSTALLATION MUST BE CARRIED OUT BY SKILLED PERSONNEL. English Note: Make sure that the machine, in its final location, has adequate space. You will need room to feed, receive and trim images. Only skilled personnel should perform installation. Read and comply with all warnings and follow the proper installation procedures and safety guidelines. Refer to the outside of the crate for uncrating and re-crating instructions.
Place the pallet in a space where there is enough room to roll the machine off from the pallet (approx. 3x the length). To unpack, follow the steps below: a. Cut the straps and lift off the carton box. b. Remove the plastic bag. Figure 2: Removing transport parts. c. Put all the loose accessories aside. Accessories Included: d. e. f. g. 14 • Spare Fuses • Snitty Safety Knife • Image Roll Cleaner • Spare Core for Wind-up Shafts Remove the four securing bolts (1). Remove the wooden blocks (2).
English Figure 3: Ramp positioning. h. Place the two ramps (3) against the end of the pallet so that the castors (4) will roll down the ramps without falling off. i. Scew the ramps to the pallet to keep them from moving when unloading the machine. j. Unlock the casters. k. 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.
3.2 Installation a. Move the machine (and the accessories) to its final location. Note: Allow ample working space. See figure 4. . Figure 4: Working space. Working space Width Depth 2x maximum board length + 140 75 in. in. 350 190 cm cm Note: Anti-static clothing and footwear of the operator and an anti-static floor coating will help reduce the build up of electrostatic (dis)charges (ESD). A relative humidity of at least 70% also helps reduce ESD build up. b.
CAUTION: Check the mains values before connecting. See section 2.1 for power supply details d. Connect the machine to the mains using the power cable supplied with the machine. English CAUTION: Only if absolutely necessary, use an extension cable of ample capacity. Unroll the extension cable completely. WARNING: MAKE SURE THE POWER SUPPLY CABLE AND/OR THE EXTENSION CABLE IS NOT BLOCKING YOUR WAY AROUND THE MACHINE. 3.3 Transport The machine can be transported on a smooth surface on its castors.
4. DESCRIPTION This chapter describes the machine and its operating basics. 4.1 General description The machine described in this manual is a multi-directional machine dedicated for processing pressure sensitive or heat activated laminating materials. While feeding through images and coating films, the two silicone coated main rollers generate the nip pressure. The area where the upper and lower main roller meet is called the “nip”.
English 4.2 Parts identification Figure 5: Parts Idenification. 1. Main roll (top front) 2. Pull roll (top rear) 3. Swing out supply shaft (top rear) 4. Swing out supply shaft (top front) 5. Swing out supply shaft (bottom Front) 6. Take up autogrip shaft (bottom front) 7. Take up autogrip shaft (top front) 8. Emergancy Stop 9. Infeed table 10. Roll trough 11. Roll feed idler 12. Foot switch (front) 13. Supply shaft brakes 14. Combi shaft brake / clutches 15. Take up clutches 16. Power circuit breaker 17.
4.3 Process principle In all processes the materials are fed through the nip from the infeed side to be joined together by pressure and/or temperature. A process that makes maximum use of the machine is shown in figure 6. 5 11 6 2 8 3 1 9 Figure 6 Shown is an image roll to roll process with a heat activated top and bottom layer. The image that has to be coated on both sides is unwound from a roll on an unwind shaft (1) and fed between the main rollers (2) via the in-feed table (3).
The optional slitters (11) can be used to cut off the edges when processing roll to roll. 5 7 4 11 6 English 2 3 1 Figure 7: Creating Pop-up art, including image supply roll trough.
5. MACHINE OPERATION 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 Machine controls 5.1.1 Easy Operator InterfaceTM (EOI) In order to take full advantage of your new SEAL 65 Pro MD, it is important to become familiar with the new Easy Operator InterfaceTM . The Easy Operator InterfaceTM is the first windows-based control panel for a laminator.
English 5.1.1.1 The Home Screen Here is a summary of the Home Screen buttons. These buttons are always visible no matter what screen is active inside the grey box. On the home screen the machine status of all functions are displayed inside the black box outlined in grey. 1. Top Roll temperature button a. Action: Call up “Top Roll Temperature Control” screen – see separate description. 2. Bottom Roll temperature button a. Action: Call up “Bottom Roll Temperature Control” screen – see separate description.
7. Stop button a. Action: Stops running the rolls. Does not change the selected direction. b. Brighter when motor is running, dimmer when motor is stopped. 8. Main Roll nip button a. Action: Call up “Main Roll Nip Control” screen – see separate description. 9. Reverse button a. Action: Sets the machine to reverse direction. b. Black arrow turns to green when direction is active. c. Either reverse or forward button is always selected. d. This button can only be used if the motor is not running. 10.
Machine Operation 25 English 1. Front nip pressure display a. Display a percent of nip pressure (1-100). Updates real time. 2. Front nip opening display a. Display only: show the current nip setting. b. Numbers red when rolls are not at current nip setting. c. Numbers green when rolls are at current nip setting. 3. Top and bottom roll current temperature display a. Current temp displayed independently (top roll on top, bottom roll on bottom) in Fahrenheit or Celsius. b.
5.1.1.2 The Heater Screen Both the top and bottom rollers can be heated. You can set the heat by typing in the temperature. When typing you will see the numbers turn from red to white indicating a valid temperature. Use the “X” to backspace and the green check to apply the temperature. Use the purple arrows to adjust temperature up or down in steps of 1 degree. Click the icon on the right of the slider bar to actually turn on/off the heaters.
Machine Operation 27 English 1. Heater on / off button a. This is a toggle button to turn the heater on or off, the window in the button turns red when the heater is on. 2. Number entry pad a. Actions: Pressing any number first clears the current value in the temperature set point display and then displays the numbers pushed in order from left to right. b. The X symbol is used to clear the temperature set point display one number at a time. c.
Setting the roll temperature Be sure to turn the heater on or off using the icon near the slider bar.
English Machine Operation 29
The numbers in the front rollers indicate the roller temperature. They will be RED until they reach the desired temperature and then turn green. 5.1.1.3 The Help Screen You can click the Question mark to open the help file. Currently, this allows you to change from Fahrenheit to Celsius, but will include more help as new generations of the EOI are updated. If the button turns red, then the display units will be metric. Click the “S” button to return to the home screen.
5.1.1.4 The Nip Screen The rolls on the 65Pro MD are pneumatically raised and lowered. The position that the rolls move to when they are lowered is controlled by electronically moving a stop that holds the rolls open to any position that the user enters. In order to change the nip setting, the rolls must be in the raised position. • • • • English Similar to heater settings, the nip height can be directly typed into the blue calculator, or you can use pre-sets. One other method is to use fractions.
1. Number entry pad a. Actions: Pressing any number first clears the current value in the nip height display and then displays the numbers pushed in order from left to right. b. The – and / symbols are used for fractional number entry in the form of “1-3/8” to represent 1.375”. c. The X symbol is used to clear the nip height display and reset the “current” set point to the display. d.
English Setting the Nip Height Machine Operation 33
After the check mark is selected you will return to the home screen. The numbers indicating the nip height set point will be updated with the new set point value. They will be RED until the nip reaches the desired position. Then the numbers will turn green. The nip will not go to a new position if the rolls are down. You can change the set point with the rolls down and then raise the rolls when you are ready to have the nip move. Also, the rolls will not lower while the nip is in motion.
5.1.2 Additional controls Emergency stop buttons (1): There are 4 emergency stops on the machine. Two are located on the front of the machine (see section 4.2), and two are in the same locations on the back of the machine. The emergency switches are push button switches. When pressed the rotation of the rolls is stopped immediately, the rolls move to the open position, the heaters turn off, and the button is locked into this stop position. Twist the emergency stop button to unlock it.
Figure 10: Rear Controls Emergency stop buttons (1): There are 4 emergency stops on the machine. Two are located on the front of the machine (see section 4.2), and two are in the same locations on the back of the machine. The emergency switches are push button switches. When pressed the rotation of the rolls is stopped immediately, the rolls move to the open position, the heaters turn off, and the button is locked into this stop position. Twist the emergency stop button to unlock it.
Air water trap (7) The air water trap removes water from the incoming air. Twist the valve on the bottom of the trap to drain the water from the trap. The water should be drained at least once a week. Humid conditions may cause a need to drain the trap more often. Unwind tension control (1) knob: By turning this knob clockwise an amount of friction is set between the shaft and the frame, so this will act as a brake. Tightening the brake will apply more tension to the material on the shaft.
Figure 13: Pendant Controls Speed potentiometer (1): The speed potentiometer increases the speed of the machine as it is turned clockwise. The speed is reduced by turning the knob counter-clockwise. The current speed setting is displayed on the EOI. Stand by switch (2): The machine can be placed into the standby mode by toggling the standby switch. After the switch is toggled, a confirmation message will appear on the EOI. Press the check button to enter the standby mode.
5.2 Operating modes 5.2.1 Normal mode Rotation can be started by pressing the run button and stopped by pressing the stop button. An interruption of the light beam of the in feed photo eye in this mode will stop the rotation of the rollers. After the interruption is removed the rolls will start in the slow mode. Press the slow mode icon on the EOI to resume normal mode. Roll rotation can also be started when the footswitch is pressed.
5.2.3 Slow mode Slow mode is activated when the laminator is running and the photo eyes at the in feed side of either nip are blocked. This is indicated by the snail icon on the EOI screen. Entering slow mode will force the machine to run at 2 ft per minute unless the potentiometer is turn all the way to zero (counter-clockwise). WARNING: KEEP CLEAR OF THE NIP WHEN RUNNING AT SLOW MODE SPEED. When running at slow mode speed, the in feed photo eyes will not stop the roll rotation.
5.3 Loading film rolls All auto-grip shafts operate in the same fashion. Their function is determined by their position in the machine. The drop in shafts fit into the machine in either direction. On the control panel side of the machine the auto-grip shaft gripper snaps into the brake or clutch gripper slot in the shaft holder. At the left-hand side of the machine the drop in shafts have a spring loaded plunger in the shaft holder.
5.3.3 Loading shaft with film rolls The way the roll of film is put on the shaft depends on the type of film used and whether you are placing it in the upper or lower section of the machine. In general, film with release liner is rolled up with the liner (and adhesive) to the outside, whereas film without release liner has its adhesive layer to the inside of the roll. • In the upper section, the (adhesive) side in contact with the image must be on the top when unwinding the film to the front of the machine.
5.3.4 Presetting the tension Note: The unwind/wind-up (combi) shafts have a split tension setting: Turn clockwise for unwind tension and counter clockwise to release the unwind tension. Turning further counter clockwise will set wind-up tension (see also section 5.1.2). 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 from unwinding 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. 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 or craft paper of the same width as the top film can be used in the bottom section. The release liner or craft paper can be removed later on.
The film in the upper section is webbed first a. Remove the image guide. b. 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. c. Pull the film forward until it almost reaches the in-feed table and apply it to the upper roller. If the film has a release liner: • Peel off the release liner. • Pull it up and stick it onto the cylinder on the wind-up shaft.
5.4.4 Roll to roll When webbing for the 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. 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.
5.4.5 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. • 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. 5.5.1 Mounting images or decals In this process the machine is not webbed with film.
d. Put the image on top of the board (image side up). Turn back the image at the machine side (1). e. Turn back approx. 25 mm (10 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. f. Apply the image to the board (3). g. Insert the edge with the image adhered to into the nip. h. Lay the loose end of the image smoothly over the upper roller (4).
d. Set the pressure while feeding the leader board. e. Before the end of the leader board enters the nip, butt up the panel to be pre-coated. CAUTION: Do not cut film close to or on the rollers. This will damage the silicone coating of the rollers and will void the warranty. g. Cut this panel free. h. Back-up the leader board using the reverse. i. Cut the film using a Zippy cutter with a covered blade.
• • • 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. 5.5.6 Over-lamination After an image is mounted to a panel, a protective laminate can be applied. This overlaminate can be a heat activated laminate or a pressure sensitive adhesive with release liner.
Process Control Sheet Note: We recommend that you make a photocopy of this page. With each successfully run application, record the process and settings and a diagram of the webbing procedure. Keep the record so the application can be repeated at a later date. Hint: If a standard image is made available for each new process then sales materials and samples can be developed for reference.
Figure 1: Blank Webbing Diagram 52 7003338 - User Manual 65 Pro MD
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. English 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 Preventative maintenance Our machines are designed in such way that they need little (preventative) maintenance in addition to the cleaning. The following checks have to be performed: • Auto-grip shafts with blocking cords. 6.2.1 Auto-grip shafts 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).
6.3.2 Pressure too low. • English Figure 4: Wrinkles due to low pressure. Increase the roller pressure a little (5-10%). 6.3.3 Unwind tension too low. Figure 5: 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. 6.3.4 Pull tension too low. Figure 6: Wrinkles due to low pull tension • This is a machine adjustment error.
6.3.5 Too much heat in the final result. Figure 7: 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 or have the device installed. 6.3.6 Roller alignment fault. Figure 8: Wrinkles due to faulty roller alignment. The wrinkles occur on one side only (left or right). • This is a machine adjustment error.
6.3.8 Machine operation issues Solution • Check if the power cable is plugged into the wall outlet. • Check that the Stand-by switch is ON. • Make sure the main circuit breakers and machine circuit breakers are flipped up or ON. • Make sure that the photo-eyes are not blocked. • Make sure that the Emergency Stop buttons were not activated. Rotate to reset. • Turn the motor speed up. • Unplug the laminator and check the fuses. Only authorized safety or maintenance personnel should do this.
6.3.10 Technical assistance For Technical assistance contact Neschen Americas Technical Support at 1-800-4866502. Make a clear description of the problem before contacting Technical assistance. Please have the Model number and the Serial Number of your machine at hand. You can find this data on the identification plate of your machine, which can be found on the rear side of the right cabinet.
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 (ex. 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.
Contact Us: Seal Brands Technical Service – US & Canada Ph: 1-800-486-7325 Fax: 1-800-966-4554 Email: service@neschenamericas.com parts@neschenamericas.com SEAL Brands Technical Service – Europe & Asia Pacific Ph: +49 5722 207 354 Fax: +49 5722 207 255 Email: technical@neschen.de SEAL Brands Customer Service – US & Canada Ph: 1-800-257-7325 Fax: 1-800-966-4554 Email: csorders@neschenamericas.
