Mounter, Laminator and Encapsulator
Contents
1. If not correct as follows e Loosen the clamp 2 with the screw 1 until the cord is free on one side Shorten the cord by approximately 10 mm 4 in Put the end of the cord back underneath the clamp 2 Secure it by tightening the screw 1 6 3 Trouble shooting During processing wrinkles can show up in the image 1 on the in feed table 2 and in the process result 4 on the output table The figures below show some examples where it is caused by the main rollers 3 or the pull rollers 5 and gives a possible solution Wait until a few meters is processed to see results Pressure too high 2 U02 027 Figure 22 Wrinkles due to high pressure e Decrease the roller pressure a little 5 10 Maintenance 41 Pressure too low 4 _ 02 028 Figure 23 Wrinkles due to low pressure a e Increase the roller pressure a little 5 10 Unwind tension too low 2 1 U02 029 Figure 24 Wrinkles due to low unwind tension e 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 2 U02 030 Pull tension too low Figure 25 Wrinkles due to low pull tension e This is a machine adjustment error Contact your dealer and ask for technical assistance 42 User Manual 62Pro Too muc2. KEEP CLEAR OF THE REAR SIDE NIP WHEN RUNNING IN REVERSE MODE When running in reverse the optical safety device at the front side nip is disabled In Normal mode the speed is determined by the speed control In slow mode the speed is fixed at slow mode speed 26 User Manual 62Pro 5 2 3 Slow mode Slow mode is entered and left 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 Normal speed Normal speed in slow mode is still determined by the speed control setting Switching between normal speed and standstill is done by the start and the stop button Slow mode speed Slow mode speed is a fixed low speed see specifications independent from the speed control Slow mode speed can only be selected in slow mode by pressing and holding the footswitch WARNING KEEP CLEAR OF THE NIP WHEN RUNNING IN SLOW FORWARD MODE When running at slow mode speed the optical safety device is disabled When the footswitch is released the forward rotation is stopped Changing to normal speed 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 sl
3. e 5 Connect the machine to the mains using the power cable supplied with the machine Only if absolutely necessary use an extension cable of ample capacity CAUTION 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 18 User Manual 62Pro 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 e breaking if accidentally bumping into an obstacle On rough surfaces use a pallet truck or forklift When moving the machine over long distances use original pallet and packing material and follow the unpacking procedure in the opposite way Installation 19 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 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 11 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 When LED s are blinkin
4. 5 5 4 Double sided lamination 5 5 5 Encapsulation 5 5 6 Over lamination 5 5 7 Decaling 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 62Pro 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 warranty conditions For the exact details on the warranty period and conditions for your machine please contact your dealer 1 1 1 Warranty conditions The manufacturer warrants to the original end user that the machine when proven defective in materials or workmanship within the applicable warranty period will be repaired or at our option replaced without charge Note The main rollers and pull rollers are subject to normal wear and tear and therefore have warranty on material defects only The manufacturer or its representative shall not be liable for any damage caused by the machine nor loss of productivity Warranty is voided when e Changes or modifications are made to this machine not explicitly approved by the manufacturer e The machine is changed or modified by unauthorized persons e The machine is used under other than normal working conditions e The machine is used for purposes other than intended for see page 3 The original end user is the person that first purchased the machi
5. 5 4 2 Upper and lower section A leader panel is needed of the same thickness as the images or panels to process For thin images use the leader panel provided U02 006 Figure 16 Upper and lower section webbed The film in the upper section is webbed first 1 Remove the image guide 2 Feed the film underneath the splitter bar between splitter bar and upper roller e 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 If the film has a release liner e Peel off the release liner e Pull it up and stick it onto the cylinder on the wind up shaft 32 User Manual 62Pro Uo2 005 Figure 17 Webbing lower section 4 Lift the in feed table and put it in the upper position 5 Unwind the film from the lower unwind roll e Feed a pressure sensitive film without release liner underneath the splitter bar A e Feed all other films over the splitter bar B 6 Pull the film forward until the end reaches above the nip and stick it to the film from the upper section If the film has a release liner e Peel off the release liner e Pull it underneath the wind up shaft e Stick it from below onto the cylinder on the wind up shaft 7 Lower the in feed table When encapsulating e Set the top pull roller in the upper position and lock it on both sides 8 Push the fi
6. example 3 2 Machine dimensions 3 2 1 Uncrated Metric American Width 222 cm 87 4 in Height 143 cm 56 3 in Depth excl in feed table 45 cm 17 7 in Depth incl in feed table 62 cm 24 4 in Working height 90 cm 35 4 in Weight 450 kg 994 Ibs 3 2 2 Crated Width 228 cm 89 8 in Height 162 cm 63 8 in Depth 90 cm 35 4 in Weight 500 kg 1105 Ibs 3 2 3 Working area Width 350 cm 140 in Depth 190 cm 75 in 2x maximum board length Note Anti static clothing and footwear of the operator and an anti static floor coating will help reduce the build up of electrostatic charges ESD A relative humidity of at least 70 also helps reducing ESD build up 14 User Manual 62Pro 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 Maximum panel thickness Roll core inside diameter 3 4 Machine specifications Power supply Europe USA Metric American 1575 mm 62 in 1524 mm 60 in 200 mm 8 in 305 mm 1 ft 305 mm 1 ft 180 mm 6 in 38 mm 1 5 in 76 2 mm 3 in 3N PE 230VAC 10 50 60Hz 25A 1N PE 230VAC 10 50 60Hz 50A For the correct supply voltage version refer to the identification label on the machine Standard number of shaft positions Material unwind Release liner wind up Unwind wind up Optional featur
7. keep the image smooth against the upper roller 5 preventing the image from wrinkling Note For the best result do not stop while feeding an image 5 5 2 Pre coating panels This process is used to coat boards substrates with a pressure sensitive mounting film onto which images can be mounted This process can also be used to create a carrier board Note The mounting film is usually provided with one release liner Place the film and web it as if it has no release liner over the splitter bar Place the roll of mounting film on the shaft of the upper unwind position Set the nip to correspond to the thickness of the panels to be processed Web the film using a leader board of the same material thickness and width Set the pressure while feeding the leader board Before the end of the leader board enters the nip butt up the panel to be pre coated IRON Operating 37 When more panels have to be pre coated feed them in continuously without any gap At the end use a leader board again to finish This prevents the adhesive from touching the bottom roller 6 Butt up and feed the last leader board until the previous panel is out of the nip Do not cut film close to or on the rollers This will damage the silicone CAUTION coating of the rollers and will void the warranty 7 Cut this panel free 8 Back up the leader board using the reverse 9 Cut the film using a blade cutter After removing the release liner
8. mode indicator 7 LED The LED will light when slow mode is selected Stop 8 pushbutton Press to stop the rotation of the rolls Start 9 pushbutton Press to start the rotation of the rolls in the forward direction X Ki Operating 21 3 Forward indicator 10 LED The LED will light when the forward mode is selected P Speed control 11 control knob Sets the speed anywhere in a range between 0 and 10 See specifications for actual speed range Reverse 12 snap pushbutton Press and hold for rotation of the rolls in reverse direction 3 Reverse indicator 13 LED The LED will light when the reverse mode is selected 5 1 2 Heater control The two heater controls above the control panel are equal The upper heater control regulates the temperature of the corresponding upper main roller The lower heater control is for the bottom main roller heater OP U02 002 Figure 10 Heater control section The heater control is turned ON and OFF by the 0 I switch 1 Press to turn the heater ON The actual temperature 3 is now displayed on the temperature control display The heater has a factory defined temperature range Within this range the roller temperature can be regulated The temperature setting is displayed when the up 7 or down 6 button is pressed and changed by pressing the up 7 or down 6 buttons again If the actual te
9. 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 Unwind tension control 4 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 oS Turning the knob counter clockwise will release the brake and therefore release the a tension Operating 23 Unwind wind up tension control 5 knob By turning this knob clockwise an amount of friction is set between the shaft and the frame so this will act as a unwind brake Turning the knob counter clockwise will release the brake Turning the knob further counter clockwise will set an amount of friction between O the shaft and the driving sprocket wheel so this will act as a coupling between motor and shaft The shaft will now act as a wind up shaft OFr Turning the knob clockwise will release the wind up shaft again Wind up tension control 6 knob By turning this knob clockwise an amount of friction is set between the shaft and Os the driving sprocket wheel so this will act as a coupling between motor and wind up shaft Or To release the tension turn the knob counter clockwise Pull roller handle 7 Handle to lever the top pull roller into position Pull roller locking knob 8 S
10. wind up shaft Upper wind up shaft Splitter bar Nip safety bar with optional slitters Pull rollers Output table with optional cooling device Foot switch Identification label Main power switch o ON Oa WDM oS BR a cr ae Co UN oOo a 16 ni wk o A e gt U02 021 g N Figure 2 Main parts identification Figure 3 shows the cross section of the layers in the decal process In this process the largest number of layers is possible 2 LAMINATE 3 ADHESIVE 1 IMAGE 3 ADHESIVE 5 CARRIER 3 ADHESIVE 6 REMOVABLE FOIL Dm U02 028 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 this case the removable foil 6 also functions as carrier The top layer is a normal pressure sensitive laminate in this case with a release liner Heat sensitive laminates in general have no release liners 4 so they just consist of the laminate 2 with a heat activated adhesive layer 3 12 User Manual 62Pro 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 proce
11. without a release liner can be used gt l A A E OR A Figure 18 Webbing image from roll to roll The laminates are webbed first 1 Web the upper and lower section laminates as described in the previous sections 2 Feed the films with a leader board through the nip 3 When the leader panel is through the nip cut off the leader panel 4 Stick the leading edge of the films at the rear side of the machine onto the cylinder on the wind up shaft 5 Set the tension control for this shaft to wind up tension 6 Set the nip to zero no pressure 7 Pull the image to the front and feed it over the in feed table into the nip Unloading When the image roll is empty and through the nip cut the films at approximately the same length and let the machine run until the end is through the nip 34 User Manual 62Pro 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 e Before webbing set the top pull roller in the upper position and lock it on both sides e Webbing is the same as described before accept the films are now with a leader board pushed through the main roller nip and the pull roller nip i iin A B U02014 Figure 19 Roll to roll with pull rollers engaged Operating 35 5 5 Processes and settings 5 5 1 Mounting images or decals In this process the machine is not webbed with
12. 62Pro Mounter Laminator and Encapsulator eal a a 4 U02 035 User Manual UM102EN Rev 1 0 Jan 2003 User Manual 62Pro INTRODUCTION Thank you for purchasing your Seal 62Pro 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 The machine described in this manual is a multi functional machine that can perform the following processes e high quality lamination panel mounting of images mounting and laminating in one pass decaling encapsulating images A vast number of laminating products are available All of them with their own applications and processing specifications 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 e temperature setting for upper and lower roller separately speed setting pressure setting unwind tension of the film s use of pull rollers Introduction 3 THIS MANUAL This manual is intended for the user of the 62Pro Read this manual carefully before starting the machine This manual contains important information for correct installatio
13. AMINATING ROLLERS WILL CAUSE BUILD UP OF ELECTROSTATIC CHARGES An anti static floor coating and wearing anti static clothing and footwear can reduce the risk of ESD shock 1 3 2 In this manual In this manual you will find 3 levels of warnings WARNING THE WARNING MESSAGE IS USED WHEN A LIFE THREATENING SITUATION MAY ARISE OR PERSONAL INJURY CAN OCCUR FOLLOW THE INSTRUCTIONS CLOSELY CAUTION The caution message is used when there is danger of damage to the machine or materials Follow the instructions to prevent this damage oD Note This message is used to give you useful information for easier operation to prevent waste of material etc Warranty and Safety instructions 9 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 ROTATING PARTS 2 DANGER OF GETTING INJURED BY ROTATING PARTS MAKE SURE THAT THESE ROTATING PARTS DO NOT CATCH YOUR FINGERS CLOTHING HAIR ETC This symbol is placed on in feed table arms on the cabinets just above and below the output table and on the pull roller sa
14. der back into the machine 4 Push both sides of the shaft firmly into their suspensions 5 Turn the shaft until the grippers lock in 28 User Manual 62Pro 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 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 e Inthe 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 e Inthe lower section the adhesive side in contact with the image must be on the bottom when unwinding the film to the front of the machine Put the film roll on a flat surface with enough space on one side to insert the shaft Take the auto grip shaft from the unwind position of the machine 3 Insert the shaft into the core cylinder of the film roll holding the auto grip shaft as in Figure 14 N 2 U02 033 Figure 14 Auto grip shaft position 4 Place the shaft with the film roll in the correct way back into its suspensions see Figure 14 Unwind direction of film towards the front of the machine in the upper section e film with release liner on the outside unwinds from the top 1 e film with release liner on the inside unwinds from the bottom 2 e film without release liner unwinds fro
15. ding 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 Leader panel A piece of stiff cardboard or foam used to lead film into the nip of the main rollers In addition it is used when pre coating to prevent adhesive getting onto the rollers Main rollers A set of two silicone coated rollers that perform the actual process Mounting Permanently affixing an image onto a backing board Mounting film Adhesive backing to make an image self adhesive On the side that is in contact with the image the carrier has an adhesive with or without release liner The carrier can function as release liner or be supplied with a second cold adhesive layer and release liner Nip The area where the top and bottom main rollers meet is called the nip Pre coating Coating a substrate with an adhesive mounting film onto which an image can be mounted Pull rollers Set of rollers used in the encapsulation process to stretch the process result in order to avoid warping Release liner Backing film protecting the adhesive layer of a laminate or mounting film Once the release liner is removed the adhesive layer becomes exposed Roll A shaft with a cylinder loaded with film or release liner Roller One part of the main element
16. e wooden blocks 3 U02 024 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 Note Save all packing material for later moving over long distances or discard of according to local regulations Installation 17 4 2 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 2 Turn down the four leveling feet until the castors are off the floor 3 Remove all transport material e Cut the straps around the shaft suspensions and remove the foam pads e Cut the straps holding the in feed table arms e Cut the straps around the main roller axis and move up the top main roller to remove the transport blocks from the nip e Cut the straps holding the upper pull roller and open the pull rollers to remove the transport plates 4 Puta spirit level on the upper main roller and level the machine by adjusting the four leveling feet CAUTION Check the mains values before connecting See section 3 4 for power supply details
17. es Slitters Extra plot unwind for 2 and 3 cores Cooling device Nip setting Pressure Process speed Maximum Slow mode Maximum roller temperature Noise level Specifications 1 auto grip 1 auto grip 3 auto grip 0 40 mm 0 1 hein 1 2 5 N mm 5 71 14 28 Ibf in 6 m min 20 ft min 0 6 m min 2 ft min 140 C 284 F lt 70 dB A 15 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 4 1 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 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 refer to Figure 7 1 Cut the straps and lift off the carton box 2 Remove the plastic bag 3 Place the two ramps 4 against the roll off side of the pallet so that the castors 5 will run clear from the edge Figure 6 Ramp positioning 4 Put all the loose accessories aside 16 User Manual 62Pro 5 Remove the four securing bolts 1 6 Turn down the four leveling feet 2 to lift the machine 7 Remove th
18. fety bar 2 ESD SHOCK 3 DANGER OF GETTING AN ELECTRIC SHOCK CAUSED BY ELECTROSTATIC CHARGE BUILD UP IN THIS AREA 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 02 038 U02 037 Figure 1 Warning symbol locations 10 User Manual 62Pro 2 DESCRIPTION This chapter describes the machine and its operating basics 2 1 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 The upper main roller can be moved up or down manually so the nip can be varied to feed materials of various thicknesses A mechanical read out shows the value set The nip setting hand wheel also sets the pressure for the laminating process The lower main roller is motor driven The speed can be manually set between zero anda given maximum value Because both rollers are equipped with a heater heat activated materials can also be processed with these rollers Each roller has its own temperature control unit so t
19. film e When mounting images onto a pre coated board B the adhesive is on the mounting side of the board e When mounting decals A the adhesive is on the back of the image The mounting process is equal for both 1 Remove the shafts from the upper section 2 Preset the nip and the pressure see section 5 3 4 3 Put the board on the in feed table D U02 013 Figure 20 Mounting images or decals 4 Put the image on top of the board image side up Turn back the image at the machine side 1 5 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 36 User Manual 62Pro 6 Apply the image to the board 3 7 Insert the edge with the image adhered to into the nip 8 Lay the loose end of the image smoothly over the upper roller 4 Note Use the footswitch to start stop in slow mode keeping your hands free WARNING KEEP YOUR FINGERS CLEAR OF THE NIP THE OPTICAL SAFETY DEVICE IS NOT FUNCTIONING IN SLOW MODE 9 With your left hand peel back the release liner 6 from the image or board as it is slowly fed into the nip one section at a time without stopping Note Removing the release liner completely exposes the adhesive to dirt and dust that will get trapped under the image 10 With your right hand
20. 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 Operating 25 5 2 Operating modes The machine is either in normal mode or slow mode In both normal and slow mode the rollers can rotate in forward or in reverse direction 5 2 1 Normal forward mode Normal forward mode can be activated from standstill when slow mode is not active The rotation speed of the rollers in normal mode is set via the speed control knob Rotation is started when the start button is pressed and stopped when the stop button is pressed When the footswitch is pressed operation control is taken over by the footswitch and the rollers will rotate forward until the footswitch is released To return control to the control panel without stopping e press and hold the start button e release the footswitch e and then release the start button An interruption of the light beam of the optical safety device will stop the rotation of the rollers After the interruption is removed press the start button to continue the process 5 2 2 Reverse mode Reverse roller rotation can only be started from stand still by pressing the reverse button CAUTION The unwind shafts will not rewind the material they are not motor driven e Rotation is stopped when the reverse button is pressed again WARNING
21. from the pressure sensitive mounting film the board has an adhesive coating ready to mount an image See section 5 5 1 for mounting images 5 5 3 Single sided lamination Images are laminated single sided using carrier or release boards This laminate can be a heat sensitive laminate or a pressure sensitive adhesive with release liner e The image is put on the carrier board with the image side up e All steps in this process are the same as when pre coating a board section 5 5 2 5 5 4 Double sided lamination Encapsulating images with cold laminates is called double sided lamination and is normally not done with panels 1 Load and web laminating film in the upper and the lower section 2 Stick a leader board to the films and feed it through the nip 3 When the leader board is completely out of the nip lower the upper roller onto the bottom roller nip setting 0 4 Now feed the images into the nip allowing a gap between them 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 38 User Manual 62Pro 5 5 5 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 h
22. g this indicates an error Refer to 5 1 4 for their meaning 11 13 12 Figure 9 Control panel 20 User Manual 62Pro Control ON OFF 1 toggle pushbutton Press 1 second to switch the machine from stand by to active and back WARNING THE MACHINE IS CONSTANTLY POWERED WHEN THE POWER CORD IS PLUGGED IN AND THE MAIN POWER SWITCH IS TURNED TO ON D Power indicator 2 LED The LED will light up when the machine is powered It flashes when the machine is in stand by mode Safety indicator 3 LED The LED will light up when the beam of the optical safety device at the input side of the nip is not interrupted y Pressure indication 4 4 LED s i 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 NIP setting indication 5 Pointer This mechanism is directly coupled with the nip control and indicates the distance nip between the main rollers set by the hand wheel ay Slow mode 6 toggle pushbutton Press 1 second to switch slow mode ON or OFF To run at the fixed slow mode speed the footswitch must be pressed CAUTION When slow mode is active the machine can still run at high speed e Slow mode indication is NOT a speed indication It is a working method Z N V2 a Slow
23. h heat in the final result LETTE l 5j 4 ea Figure 26 Wrinkles due to too much heat The result is still too hot after the pull rollers The bottom pull roller also gets hot e Reduce the heater settings e Check the function of the optional cooling device or have the device installed Roller alignment fault Jjjj 2 VAE AE U02 031 Figure 27 Wrinkles due to faulty roller alignment The wrinkles occur on one side only left or right e This is a machine adjustment error Contact your dealer and ask for technical assistance Material rolls are jumping A regular tick can be heard in the shaft suspension e Adjust the shaft support 1 by turning up or down the screw 2 with an Allenkey U02 078 Figure 28 Shaft support adjustment 6 4 Technical assistance For technical assistance you can contact your dealer or the address on the copyright page in the front of this manual Make a clear description of the problem before contacting technical assistance Please keep the type and 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 Maintenance 43 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 Provi
24. 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 44 User Manual 62Pro
25. ior of the machine with a damp cloth as needed If necessary use a household cleaning solution to remove difficult marks Clean the shafts and the rubber cords on it as required 6 1 1 Cleaning the silicone covered rollers The rollers must be cleaned regularly to prevent a build up of adhesive residue This may eventually damage the rollers Use a damp lint free cloth to remove dust and other dirt Use a silicon cleaning block to remove the adhesive stains from the rollers Note Adhesive is easier to remove when the rollers are hot Put a waste panel between the rollers when cleaning the upper roller to prevent adhesive remnants from falling onto the lower roller WARNING 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 40 User Manual 62Pro 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 e Auto grip shafts with blocking cords 6 2 1 Auto grip shafts Check the auto grip mechanism on each shaft e 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 Figure 21 Auto grip shaft
26. lms with a leader panel into the nip using slow mode 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 9 Stick the front end of the image to the leader panel or butt up the next panel 10 When the leader panel is through the nip set the pressure for optimum result 11 Refit the image guide While feeding the images e Check and adjust the tension on the unwind and wind up shafts e Check and adjust the pressure setting e Now speed can be set to normal Operating 33 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 18 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 The release liner can easily be removed later on Double sided lamination The unwind wind up shaft in the rear of the upper section is used to wind up the processed images Figure 18 B This means the top laminate with or without release liner must be webbed on the top unwind shaft in the upper section and in the lower section only a laminate
27. m the bottom 2 in the lower section e film with release liner on the outside unwinds from the bottom 2 e film with release liner on the inside unwinds from the top 1 e film without release liner unwinds from the top 1 5 Push both sides of the shaft firmly into their suspensions 6 Turn the shaft until the grippers lock in 7 Position the film and the scrap core in the middle and align them Note When both upper and lower section are used place both films at exactly the same position 8 Make sure the films and scrap cores are set up and aligned properly Operating 29 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 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 counter clockwise 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 On the motor driven wind up shaft it allows the shaft to slip and adapt its rotatio
28. mperature is lower than the set temperature the heater element is turned ON and in the operation display position 2 OP1 is displayed Note The heated roller needs time to reach its set temperature e g from room temperature to maximum takes approximately 1 hour It is recommended to let the machine run at a low speed to avoid uneven hot spots The buttons 4 and 5 are not used Cooling device optional The optional cooling device is automatically switched ON when both heaters are turned on 22 User Manual 62Pro 5 1 3 Additional controls 1 2 Pai i amp 4 UZ 6 O s5 a 8 5 lO hd e 5 3 ak I 02 032 Figure 11 Additional controls Emergency stop buttons 1 push and hold button When pressed the rotation of the rolls 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 Nip setting wheel 2 geared wheel AAO Turn the wheel clockwise to narrow close the nip or counter clockwise to widen open the nip When both rollers touch the materials the pressure is set By turning the wheel clockwise the pressure is increased Turning the nip setting wheel counter clockwise the pressure will decrease The nip setting and the pressure are indicated on the control panel Foot switch 3 snap switch Press and hold the switch to start
29. n 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 If you have any questions or need further details on specific aspects related to this machine please do not hesitate to contact us The address and phone number are stated on the copyright page Chapter 1 will provide you with a summary of the manufacturers warranty information It also describes the safety features installed on the machine and gives a number of safety instruction and warnings Read this chapter carefully Chapter 2 provides a general description of the machine and of the process principles to help first time users to find their way on this machine Chapter 3 specifies the machine machine dimensions and the dimensions of the materials to be used on this machine Chapter 4 guides you through the installation of the machine This chapter also provides information for moving transport and decommissioning of the machine Chapter 5 guides you through the operation in various processes to develop basic knowledge of the machine Chapter 6 provides maintenance procedures for long time efficient and trouble free operation of the machine The trouble shooting section gives a number of sugestions in case the results are
30. n speed to the speed of the film 5 3 5 Pressure setting Thin images When processing thin images thickness same as or less than the film pressure is preset when the upper and lower material is webbed During processing the pressure can be adjusted The best pressure setting for thin films is about 80 Panels When processing panels a leader panel is used to preset the pressure Use a leader panel of the same material thickness and width as the panels to process 1 Set the nip to the thickness of the panel 2 Feed the panel into the nip in slow mode 3 Set the pressure to approximately 80 for full width panels For narrower panels set the pressure proportional to the width between 40 CAUTION and 80 E g half width equals 60 4 Push the reverse button to run the panel back through the machine 30 User Manual 62Pro 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 of the same width as the top film can be used in the bottom section The release liner can easily be removed later on When webbing a film with a release liner the film is always fed over a splitter bar or idler where the release liner is separated f
31. nap lock right hand side seen from the rear of the machine to lock the top pull roller into position Slitters 9 optional Slitters are used to cut off the edges from the laminating result when processing roll to roll The knob A locks the slitter into its horizontal position The knob B locks the vertical position of the slitter knife up is disengaged down is engaged The relative position can be read from the ruler above the slitter rail B Figure 12 Slitter controls 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 24 User Manual 62Pro 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 Press the stop button and check the material flow and the tension setting of the wind up shafts Forward and reverse indicator flashing System error Disconnect and then reconnect the power If the error persists contact your service organization All four pressure indication LED s are
32. ne from the manufacturer or its representative 1 1 2 Warranty period The standard warranty period on this machine is one year from the date of purchase The main rollers and pull rollers have a warranty period of half a year on material defects only The warranty ends when e The periods stated above have expired e The machine changes possession e Warranty is voided by any of the conditions mentioned above Warranty and Safety instructions 7 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 Safety features Emergency stops The machine has 2 Emergency stops When activated the Emergency stops switch off the power to the motor controller after the machine has come to a complete stop The Emergency stops must be disengaged before a restart is possible Optical safety devices The machine has an optical safety device at the input side of the nip at the main rollers This device performs a check of the operation between transmitter and receiver When an error is detected e g the signal is in
33. not up to expectation Chapter 7 is the glossary and explains a number of terms used in this manual 4 User Manual 62Pro TABLE OF CONTENTS 1 Warranty and Safety instructions 7 1 1 Warranty 7 1 1 1 Warranty conditions 7 1 1 2 Warranty period 7 1 2 Safety 8 1 2 1 Safety features 8 1 2 2 Safety instructions 9 1 3 Warnings 9 1 3 1 General ESD warning 9 1 3 2 In this manual 9 1 3 3 On the machine 10 2 Description 11 2 1 General description 11 2 2 Parts identification 12 2 3 Process principle 13 3 Specifications 14 3 1 Identification 14 3 2 Machine dimensions 14 3 2 1 Uncrated 14 3 2 2 Crated 14 3 2 3 Working area 14 3 3 Material specifications 15 3 4 Machine specifications 15 4 installation 16 4 1 Unpacking 16 4 2 Installation 18 4 3 Transport 19 Table of contents 5 5 5 2 5 3 5 4 5 5 6 2 6 3 6 4 7 Operating Process controls 5 1 1 Control panel 5 1 2 Heater control 5 1 3 Additional controls 5 1 4 Error indications Operating modes 5 2 1 Normal forward mode 5 2 2 Reverse mode 5 2 3 Slow mode Placing 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 Webbing 5 4 1 Upper section only 5 4 2 Upper and lower section 5 4 3 Roll to roll 5 4 4 Pull rollers Processes and settings 5 5 1 Mounting images or decals 5 5 2 Pre coating panels 5 5 3 Single sided lamination
34. op and bottom roller temperature must be set separately In addition to the main rollers a pull roller set is provided to prevent warping of encapsulation results This set is not suited for cold lamination processes An optional cooling device can be installed in front of the pull roller set When both heaters are turned on the cooling device will prevent the pull rollers from warming up too much and therefore prevents the encapsulation result from showing wrinkles Five material shaft positions are standard on the machine Three of these shaft positions can function as both an unwind or as a wind up position which makes the machine more flexible and enables roll to roll processing for some processes The machine can be divided into an upper and a lower section The upper section above the in feed table consists of 3 auto grip shaft positions and a splitter bar idler The top shaft position is for unwinding film the one on the front side for winding e g the release liner The third shaft position is an unwind wind up position which enables more flexibility in the use of this section The 2 shaft positions in the lower section are both unwind wind up positions which gives maximum flexibility for this section Description 11 2 2 Parts identification Nip setting and pressure control wheel Main rollers In feed table with image guide Auto grip shaft Emergency button Heater controls Top unwind shaft Control panel Unwind
35. our It is recommended to let the machine run at low speed to avoid uneven hot spots e Switch ON both heaters set the temperatures see the specifications of the materials used and allow ample time to reach the set temperature e Set the upper pull roller in the upper position before webbing and lock it in position e The procedure is the same as the double sided lamination above section 5 5 4 5 5 6 Over lamination After an image is mounted to a panel a protective laminate can be applied This over laminate can be a heat sensitive laminate or a pressure sensitive adhesive with release liner e This process is the same as to pre coating a board section 5 5 2 5 5 7 Decaling When decaling a laminate is put over the image side and an adhesive backing is put on the backside of the image e The process is the same as double sided lamination section 5 5 4 This decal can later be mounted onto a panel or other substrate Operating 39 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 Do not use abrasive materials for cleaning the machine This can damage CAUTION the painted surfaces or the silicone covering of the rollers Use a damp cloth for cleaning Make sure water does not run into any of the cabinets This can damage the CAUTION electrical circuits when power is applied Clean the exter
36. ow mode speed again Operating 27 5 3 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 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 To position the shaft correctly push it firmly into the suspensions and turn the shaft until it locks in Check the auto grip mechanism on each shaft The rubber cords should just touch the edges of the recess Figure 13A d 8 2 5 mm If not see chapter 6 Maintenance ld ae A B U02 010 Figure 13 Auto grip shaft When the shaft is rotated inside a cylinder the rubber cord will move to the side and gets caught between shaft and cylinder Figure 13B Rotating back will release the cord 5 3 2 Use of films with release liner When using a film with a release liner that must be removed load the wind up shaft with a scrap core empty cardboard cylinder of at least the same width as the film 1 Take the auto grip shaft from the wind up position of the machine 2 Place the scrap core on the shaft holding the shaft as in Figure 14 CAUTION Do not drop the end of the shaft on the floor 3 Put the shaft with cylin
37. rom the film To increase contact surface with the heated main roller heat sensitive film also runs via this idler splitter bar In this section an unwind or wind up roll can also be an unwind wind up shaft position set as unwind or wind up To feed in the films a leader panel is needed of the same thickness as the panels to process For processing thin images a leader panel is provided When this panel is through the nip is set to zero and the images can be fed 5 4 1 Upper section only B U02 004 Figure 15 Webbing upper section 1 Remove the image guide 2 Unwind the film from the upper or top unwind roll e Feed a pressure sensitive film without release liner from the top unwind roll over the splitter bar A e Feed all other films underneath the splitter bar B Operating 31 3 Pull the film forward until approximately 10 cm 4 in is on the in feed table If the film has a release liner e Peel off the release liner e Pull the release liner up and stick it to the scrap core on the wind up shaft Stick the leader panel to the film Feed the panel into the nip using slow mode Refit the image guide Stick the front end of the image to the leader panel or butt up the next panel During processing e Check and adjust the tension on the unwind and wind up shafts e Check and adjust the pressure setting while feeding through the leader board and images e Now speed can be set to normal NO OSs
38. ss with a heat sensitive top and bottom layer The image that has to be coated on both sides is unwound from a roll on an unwind wind up shaft 1 and fed between the main rollers 2 via the in feed table 3 The upper unwind wind up shaft 6 is set as a wind up to roll up the finished product The top coating film is taken from a supply roll on the top unwind shaft 5 The bottom coating film is taken from a supply roll on the lower unwind wind up shaft 9 When using a pressure sensitive laminate it often has a release liner as shown in the upper section that has to be removed It runs over a splitter bar 7 where the release liner is removed This release liner is rolled up onto a cardboard core placed on the wind up shaft 4 in the upper section When using a pressure sensitive laminate without a release liner it must not run via the splitter bar to avoid getting adhesive residue on it The main rollers can be heated The heat sensitive film is fed under the splitter bar providing maximum contact surface with the heated main rollers When encapsulating hot sealing images an additional set of pull rollers 8 is used to prevent wrinkles after cooling down When continuously encapsulating roll to roll the pull rollers would warm up slowly To prevent this an optional cooling unit can be installed This cooling unit 10 keeps the bottom pull roller at room temperature which in its turn absorbs the heat from the encapsulation re
39. sult The optional slitters 11 can be used to cut off the edges when processing roll to roll U02 023 Figure 4 Creating Pop up art including image supply from roll Description 13 3 SPECIFICATIONS 3 1 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 e identification label EQUIPMENT TO BE CONNECTED TO EARTHED MAINS OUTLET ONLY Il Mill l N TO PREVENT ELECTRIC SHOCK DO NOT REMOVE COVER SEAL 62 PRO EU NO OPERATOR SERVICEABLE PARTS INSIDE 3NIPE 230VAC 50 60H2 25A CoNECTREL PRODUCTOA RED DE ALIMENTACION CONTOWA DE TIERRA PARE EVITAR UNA DESCARGA ELECTRICA N QUITE LA CUBIERTA Serial No 99482806 08 REPARACIONES CONTACTAR CON PERSONAL DE SERVICIO AUTORZADO I THS DEVICE COMPLIES WITH PART 15 OF THE FCC RULES OPERATION IS SUBIECT TO THE FOLLOWING TW CONDITIONS 1 THIS DEVICE MAY NOT CAUSE HARMFULL INTERFERENCE AND THs DEVICE MUSTACCEPT ANY INTERFERENCE REGEWED NUON C EN Ee INTERFERENCE THAT MAY CAUSE UNDESIRED OPERATION Foc Pat 15 Class B SEAL Graphics Europe B V Kanaaldijk O Z 3 P O box 29 MADE IN THE EC 8100 AA Raalte The Netherlands 02 022 Figure 5 Machine identification label
40. terrupted the motor controller will be disabled and the motor will stop The stop signal from the optical device is overruled when e The machine is running in reverse direction e The slow mode has been activated and the footswitch is pressed Safety footswitch The safety footswitch is used as remote control to start and stop the machine in the normal and the slow mode WARNING THE OPTICAL SAFETY DEVICE IS DISENGAGED WHEN USING THE SAFETY FOOTSWITCH IN SLOW MODE SO KEEP CLEAR OF THE NIP WHEN PRESSING THE FOOTSWITCH WHILE SLOW MODE IS ACTIVE The safety footswitch is protected with a safety lock to prevent accidental switching Insert the forefoot completely to disengage this lock Slow mode The slow mode is used when setting up the machine with new films or images 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 8 User Manual 62Pro 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 1 3 Warnings 1 3 1 General ESD warning WARNING A DANGER OF ELECTRIC SHOCK BY ELECTROSTATIC DISCHARGE PROCESSING FILMS THROUGH L
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