Benutzeranleitung / Produktwartung SM110EN des Produzenten SEAL
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44 Ultra Laminator Service Manual SM110EN, Rev. 2.0 May 2003.
Front Matter ii SEAL 44 Ultra Technical Ser vice Manual REV 1.1 Revision History Amendm ents wil l be listed on th is pa ge, incl uding their descripti ons and dates. REV Date Description 1.0 Jan 2001 Origin al vers ion (pre- releas e). 1.1 Mar 2001 Changes i n Spare part list a nd Chapt er 8 (Diagr am s) 2.
Front Matter iii ©2003,2000 SEAL® Graphics Europe BV All tech nica l and t echnolog ic al inform ation include d in t his m anual as well as an y drawin gs and technica l spec ific ations we have m ade a vailable rem ain our pr opert y.
Front Matter iv Safety Stat ements The SE AL 44 U ltra lam inator has been designe d with operat or saf ety as a prim ar y objec tive; ho wever, operator s m ust be f amiliar with the c ontro ls, as well as the oper atio n befo re using the unit.
Front Matter v Note: When performing pr ocedures that require the side covers to be opened, ensure that th e pow er cable is di sconn ected from the mai ns.
Front Matter vi Table of Contents 1 Machine Character istics ...................................................................................................... ............. 7 1-1 Machine Desc ription ..............................................
Front Matter vii 7 Troubles hootin g .............................................................................................................. ................ 37 8 Diagram s .......................................................................
Machine Ch aracteristic s 7 1 Machine Characteristics 1-1 Machine Description The SE AL 44 U ltra lam inat or is an electr o-m echanical device b asical l y containin g two si licon ized laminati ng roll ers, t wo silic oni zed pull r oller s and a t op and bottom film unwind.
Machine Ch aracteristic s 8 1-3 Features Identification of parts 1 W ind-up idler Idler (rem ovab le) to s uppor t the win d-up cor e f or the re lease- liner 2 Emer gency stop buttons Stop the r otatio n of the r oller s imm ediatel y 3 Image guid e To help f eed-in im ages.
Machine Ch aracteristic s 9 1-4 Specificat ions Dimensions & weights Uncrated Crated depth 56 cm (22 in) 63 cm (24.8 in) width 148 c m ( 58.3 in) 160 cm (63 in) height 111 cm (43.7 in) 72 c m (28.4 in) weight 101 k g (222 lbs ) 135 kg ( 297 lbs) Electrica l specif ication s Part no.
Machine Ch aracteristic s 10.
Transport & Install atio n 11 2 Transport & Installati on 2-1 Transport Only use a pall et jack or f orklift to lift and transport the machine. The m achine is tr anspor ted on a wooden pall et, which is an integra l part of the pa ckaging. T he machine is wrapped in plas tic film to avo id m oisture p enetr ation.
Transport & Install atio n 12.
Theory of Op eration 13 3 Theor y of Operation 3-1 Control Knob The Control Knob (s ee f igure 1) is locate d on the right han d side of the lam inator and is opera ted from the front of the m achine. The Control Knob ca n be o perated b y pushi ng it in approxim atel y 6mm (1/4”) to the left.
Theory of Op eration 14 3-3 Control Panel The Control Pane l is loc ate d on the f ront r ight of the m ac hine an d has s even LED indicator s. A diagram of the Contro l Panel is s hown in f igure 3 .
Theory of Op eration 15 3-4 Motor C ontrol The s peed of the r ollers is contin uous ly adjusta ble bet ween 0 a nd 1.5 m /m in. (0 and 4. 9 ft/m in.) Pressing the k e y runs th e rollers in f orward dir ectio n, press ing the k ey rever ses the d irection of the roller s (as long as this b utton is pressed) .
Theory of Op eration 16 3-5 Un w ind Brakes Tighten t he un wind brak e so tha t it ap plies s uff icient tension to lam inate. T urning t he k nurled co llar in a clock wise dir ection increa ses the u nwind t ensio n app lied to the lam inate. T urnin g the c ollar cou nter- clock wise decre ases the tens ion.
Disassembly / Reassembly Procedu re s 17 4 Disassembly /Reassembl y Procedures 4-1 Plasti c Covers Necessar y tools: hexalobu lar s crewdr iver T X25, Al len k ey 4mm . Approx imate tim e: 5 m inutes To rem ove the s ide cov ers, perf orm the follo wing steps : 1.
Disassembly / Reassembly Procedu re s 18 5. The em ergenc y stop cont actbloc k can be rem oved us ing a little sc rewdri ver whic h can i nserted below the c lamping sprin g and t he contac t block .
Disassembly / Reassembly Procedu re s 19 3. See figur e 11. D isconnec t the white connector 1 , locate d on the right-hand side of the m achine f rom the heater wire. Remove the heater brack et by rem oving the two b olts 2. T ak e care not to l oose the serrate d w ashers.
Disassembly / Reassembly Procedu re s 20 4-3 Rear Panel Necessa ry tools: Phil lips c rosshead s cre wdriver (m edium ), open-ende d spanner 8m m, and k nife. Approx imate tim e: 10 m inutes. Perform the f ollowin g steps : 1. Remove the s ev en self -tapping s crews f rom the rear p anel.
Disassembly / Reassembly Procedu re s 21 4-4 Control System Board & Sof tware 4-4-1 Con trol Syst em Board To c hange the C ontrol S ystem Board, it is nec essar y to disas sem ble Rear Panel, as desc ribed i n section 4-3. 1. Remove al l con nectors.
Disassembly / Reassembly Procedu re s 22 4-5 Solid State R elay Necessar y tools: m edium f lat-head screwdr iver, Allen ke y 3 mm. Approx imate tim e: 20 m inutes. Note: To remo ve the So lid State Relay, it is necess ary to p erform the R ear Pan el disass embly procedur e (see S ection 4- 3) fi rst.
Disassembly / Reassembly Procedu re s 23 4-6 Photoelectric Cells Note: to per form the follo wing a djustm ents , it is neces sar y to remove both p lastic side co vers f irst.
Disassembly / Reassembly Procedu re s 24 4. Remove the two M4 bolts (see the white ar ro ws in figure 20, the le ft hand Photoel ectric Cell is sho wn here).
Adjustment Pr ocedur es 25 5 Adjustment Procedures 5-1 Laminating Pressur e Note: To perform the following adjustments, it is necessary to remove both plastic side covers first. See Sect ion 4-1: Di sasse mbly / R eassembl y Plasti c Side Co vers. There ar e two wa ys to adj ust the lam inating press ure: 1.
Adjustment Pr ocedur es 26 4. Position the load c ells at eit her side of the ro llers , betw een the j ournals , as s hown in figure 24. 5. Push and r otate the nip a djustm ent k nob until the pin, mounted in the k nob, f alls into t he last n otch (relative to top) from the ind ent brack et (see f igure 25, white ar row).
Adjustment Pr ocedur es 27 5-1-2 Adjustment using He at Sensitive Film This pr ocedure ref ers to th e press ure adj ustm ent to be do ne at th e custom er’s site. Note: as th is procedu re is p erformed u sing heat sensit ive film ( JetGuard 5 mil o r Thermashield 5 mil), the top roller temper ature sho uld be set to 120 ° C (2 50 º F).
Adjustment Pr ocedur es 28 • If the roll pr essure i s too high , then th e footp rint looks lik e: This is the case if the e nds of the f ootprint (m eas ured 1’’ f rom either side) are at least 1m m (0.04’’) wider tha n the m iddle. Change t he press ure as de scr ibed belo w.
Adjustment Pr ocedur es 29 5-2 Roller Nip Note: to per form the follo wing a djustm ents, it is neces sar y to remove both p lastic side co vers f irst. See section 4 -1: Di sassembly / Rea ssembly Pl asti c Side C overs. Necessar y tools: Allen Key 4m m, a s et of m etric thick ness gauges .
Adjustment Pr ocedur es 30 5-3 Temperature Necessar y tools: I nfr ared tem peratur e meter, sm all f lat-head sc rewdriver . Approx imate tim e: 30 - 45 m inutes. 1. Set the ro ller n ip to 10m m (3/8’’). 2. Set the t op roll er tem peratur e to the 120°C setti ng on t he contro l panel; the ro ller is being h eated up.
Adjustment Pr ocedur es 31 5-4 Photoelectric Cells Note: to per form the follo wing a djustm ents , it is neces sar y to remove both p lastic side co vers f irst. See secti on 4-1: Disassembly /Reasse mbly Pl astic Sid e Covers. Necessar y tools: s m all flat- head sc rewdriv er.
Adjustment Pr ocedur es 32 5-5 Driv e Chain Necessar y tools: Allen ke y 4mm, m edium flat-head sc rewdri ver. Approx imate tim e: 8 m inutes. Note: to per form the follo wing a djustm ents, it is neces sar y to remove t he right- hand s ide co ver fir st.
Adjustment Pr ocedur es 33 5-7 Image Guide To perf orm the follo wing ad justm ent, it is necessar y to r em ove both plas tic sid e cover s fir st. See Section 4- 1: D isassem bl y/Reassem bly Plasic Side C overs. Necessar y tools: allen k ey 3m m, gauge 2mm .
Adjustment Pr ocedur es 34.
Troubleshooti ng 35 6 Maintenance Cleaning of the M achine The equi pment m us t be disconnec ted fr om the m ains bef ore clea ning. The lam inator m a y be cl eaned by the oper ator with a lint- free c loth, lig htly dam pened with a m ild soa p and water s olution .
Troubleshooti ng 36.
Troubleshooti ng 37 7 Troubleshooti ng Note: The ‘Caus es’, as desc ribed bel ow, are p laced in a log ical or der of occ urrence; pl ease follo w this seq uenc e in ord er to sol ve the problem . Problem: The po wer LED does not c om e on, when the s tandb y pushbu tton is pr essed .
Troubleshooti ng 38 Problem: The po wer LED does com e on, but it is flashin g at a l ow rate. T his is an err or-con dition. Cause: The s upply volt age is t oo lo w. Problem s like thes e occur us ually if extensi on cords a re used; in partic ular exten sion cords , that have a (t oo) lo w rating.
Troubleshooti ng 39 Problem: The For ward LED o n the c ontrol pa nel is f lashing; the m achine has stop ped. Cause: The drive m otor has bee n overl oaded. Solution: Press the s tart butt on. The LED wil l ceas e flashi ng and wil l be lit continuous ly.
Troubleshooti ng 40 Problem: The m otor is not ru nning when t he For ward or R evers e buttons ar e pres sed, the Forwar d or Rev erse LED’s do not com e on eith er; howev er the L ED for the Photoe lectric Cells on the control panel is lit. Cause: One or b oth Em ergenc y Stop b uttons ha ve bee n enga ged.
Troubleshooti ng 41 Problem: The tem peratur e-ready LE D keeps on flashi ng at a sl ow rate ( after 20 m inutes) , once th e heat ing has been acti vated. Causes: The heati ng elem ent is defectiv e, or one of its connec tors had not bee n ins talled.
Troubleshooti ng 42 Problem : The qual it y of the lam inatio n is poor : wrink les and/ or cr eases sho w up in t he outp ut. Cause: The lam inatin g pressur e settin g is wrong. Solution: Perform the Lam inat ing Pre ssur e Adjustm ent Pr ocedur e describ ed in Section 5- 1.
Diagram s 43 8 Diagrams 8-1 Installation Diagram.
Diagram s 44 8-2 Control Panel Diagra m.
Diagram s 45 8-3 Safety Control Sy stem Diagram.
Diagram s 46 8-4 Certified Electrical Components List & Sp arepart Codes DWG Ref. NAME MA NUFA CT URER TYPE TECHNICAL DETA IL S UL LI STI NG S PAREPA RT NO: SSR1 sol id s t ate r el ay Omron G3NA-220B 240Vac / 20A E64562 S P 961- 0001 E1 he ate r 44 U ltra 110V/ 1850W Quar tz T ubi ng I nc.
Diagram s 47 8-5 Mechanical Sp are Parts List , A ssembl y Dra wings & Exploded V iews 8-5-1 Mech anical Spare Part s List Item Sparepart c ode Dwg a dded Ass y bottom roller Pr oS ea l 44 SP 144-.
Diagram s 48 8-5-2 Assemb ly D rawing s & Explod ed View s Thes e assem bly drawin gs ar e availa ble on r equest..
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