25" ProSeal
Contents
1. 8 3 2 Assembly Drawings amp Exploded Views The next pages contain assembly drawings and exploded views Huntgraphics 8 13 November 19992. 8 1 8 1 2 Schematic Installation Diagram ProSeal 44 110V 60Hz 8 2 8 1 3 Schematic Diagram Control PCB 110V 50 60HZz 8 3 8 1 4 Schematic Diagram COniroDBanel l U UL U L u u u u 8 4 8 1 5 Schematic Installation Diagram ProSeal 25 230V 50Hz 8 5 8 1 6 Schematic Installation Diagram ProSeal 44 230V 50Hz 8 6 8 1 7 schematic Diagram Control PCB 230V 50 60Hz 8 7 Certified Electrical Components Lists amp Spare Part Codes 8 8 8 2 1 VA OOR FC EG 8 8 8 2 2 ZADVALUIBOH S MACHIN ON esie eski pO aaa eka p d ke ak ak pa a a bad e DA 8 9 Mechanical Spare Parts List Assembly Drawings 8 Exploded Views 8 10 8 3 1 Mechanical Spare Paris LAG E 8 10 8 3 2 Assembly Drawings 8 Exploded Views 8 11 December 1999 ProSeal Section 1 Machine Characteristics 1 1 Machine Description Machine Characteristics The ProSeal 25 and ProSeal 44 laminators are electro mechanical devices containing two silicone rollers a heating element for the top roller an electronic PIZ controller for a fixed temperature and a synchronous drive AC motor to maintain a constant process speed The ProSeal laminators have been designed to be used with ProSeal Pouch Boards and ProSeal Flexible Pouches When used with these products one is able to mount
3. Huntgraphics 4 5 February 2000 Pro Seal Disassembly Reassembly Procedures 4 5 Software The Control System of the ProSeal Laminator is software driven The software resides in a small embedded controller mounted on the Control PCB Necessary tools small flat head screwdriver Approximate time 3 minutes Note To change upgrade the software it is necessary to perform the Plastic Side Covers Procedure described in Section 4 3 Make sure that the power cord is disconnected from the mains 1 Insert the small screwdriver between the processor and it s socket mounted on the PCB See figure 20 Carefully remove the processor 2 To insert the new processor make sure that the small pins are not bent and that their pin to pin distance matches the hole to hole distance on the socket 3 Carefully insert the new processor Make sure that the pins do not bend Make sure as well that the small notch on the side of the processor matches the symbol printed on the PCB The notch must be on the left side arrow fig 20 in figure 20 4 Discard the old processor Huntgraphics 4 6 February 2000 Pros eal Disassembly Reassembly Procedures 4 6 Rear Panel Necessary tools Phillips crosshead screwdriver medium open ended spanner 8mm knife Necessary materials two tie wraps 2 5 3 mm wide Approximate time 10 minutes Note To remove the rear panel it is necessary to perform the Plast
4. eal Adjustment Procedures Section 5 Adjustment Procedures 5 1 Laminating Pressure Adjustment Note To perform the following adjustments it is necessary to remove both plastic side covers first See Section 4 3 Disassembly Reassembly Plastic Side Covers e Note the top roller must be at room temperature before this procedure is being performed e Next the heating element including both heater brackets has to be removed See the Heating Element Procedure described in Section 4 4 e After completion of the Laminating Pressure Adjustment procedure it is mandatory to continue with the Nip Adjustment Procedure described in Section 5 2 Necessary tools 10mm open ended spanner small flat head screwdriver Allen key 2mm Approximate time 15 minutes To adjust or set the laminating pressure the following special devices are required The Pressure Display Unit PDU This unit has to be plugged in a wall socket the two pressure sensors can be plugged in at either side of the PDU The pressure actually force display reads in Kilograms See figure 25 pressure Sensors fig 25 Together with the PDU a set of sensor supports has to be used Each machine type needs a different set of sensor supports For the ProSeal 25 a set shown in figure 26 is necessary figure 27 shows the set for the ProSeal 44 Note each figure shows only half the set fig 26 support set for ProSeal 25 fig 27 support set for
5. strip fig 35 Note The figures above show the adjustment strips on the ProSeal 25 the adjustment strips on the ProSeal 44 are positioned under the bearing housing they are larger and mounted with two bolts 3 Make sure that there is some space between the adjustment strips and the bearing housings see figure 37 4 Place the adjustment sheet between the rollers Make sure that the sheet covers the bottom fig 37 roller completely Huntgraphics 5 4 February 2000 Pro eal Adjustment Procedures 5 Push and rotate the nip setting knob fully counter clockwise until the pin mounted in the knob reaches its lowest position in the indent bracket See figure 38 The top roller is now applying pressure on the adjustment sheet lowest position 6 Push the adjustment strip against the top roller bearing housing Whilst holding the strip in this position fasten the M5 bolt s firmly using the Allen key 4mm See figure 39 7 Perform the previous step at either side of the machine 8 Open the roller nip again to remove the adjustment sheet fig 39 Hunteraphics 5 5 February 2000 ProSeal 5 3 Temperature Adjustment Note To perform the following adjustments it is necessary to remove the right hand plastic side cover first see Section 4 3 Disassembly Reassembly Plastic Side Covers To measure the temperature of the top roller it is necessary to have the interlocking bolts
6. 155 160 C 0 closed nip 1 16 1 5 mm 1 8 3mm 3 16 5 mm W 6 mm 60766 60794 ProSeal 44 12 305 mm 58 1473 mm 15 380 mm 154 Ibs 70 kg 172 Ibs 78 kg 110VAC 60Hz 16A 230VAC 50Hz 9A 44 maximum 1120 mm 0 8 N mm 1 min 305 mm min 311 320 F 155 160 C 0 closed nip 1 16 1 5 mm 1 8 3 mm 3 16 5 mm W 6 mm 60824 60853 Huntgraphics February 2000 ProSeal Installation Section 2 Installation 2 1 Preinstallation The following requirements are applicable 2 1 1 Electrical Requirements This unit should only be connected to a power supply outlet of the voltage amperage and frequency marked on the rear panel The laminator has a grounded plug three prongs To reduce the risk of electrical shock this plug is intended to fit only a grounded outlet of the proper amperage and in only one way The US versions of the ProSeal machines are provided with fixed powercables and NEMA plugs the European versions are provided with Euro appliance inlets see also Section 8 The electrical specifications of the machines are ProSeal 25 ProSeal 44 US version 110VAC 60Hz 12A 110VAC 60Hz 16A EU version 230VAC 50Hz 7A 230VAC 50Hz 9A The ProSeal machines must be installed next to the power outlet extension cords are not to be used The plug and the outlet must be easily accessible by the operator For the US versions there are two types of outlet
7. TOO TI6 dS a N ONADOLS Co Woot IWNIWASL ver A R NA AJVIE elt l UT h L437 3NV 3 EOO9 196 dS ONXIOLS ES SCt vrt dS ONXADOLS IS Z000 T96dS ON2DOLS IS ONJO LS JEV d W Er T vb T di UNZ HI ISL L0 vv T dS ONNOOLS 1200 96 dS JNVd IDJAINDJ ONADOLS 3S 3A 33 d9d IWALNOS 1000 196 d 1 ONX204S I TASS Jv AOU February 2000 8 1 Huntgraphics Diagrams ProSeal Schematic Installation Diagram ProSeal 44 110V 60Hz 8 1 2 IJO 1 388uS rIdoDe AC lec vr I AegunwN AOLI vv W4SOdd AVaSDVI G t IL 009 196 d ONADOLS cS ZSI brT dS ONADOLS ld ZE T vv T1 dS ONSIIDILS IS L 000 196 d ONADOLS Tels S 6000 796 dS ONXDOLS L000 196dS ONSIJOLS TS T200 96 dS ONXIJOLS aJd IUALNUO AU113A7N33381 NIJD dd Jnd 3LIHA r0odq 196 dS ww N ONAJOLS AIO WNIW 3l Vee Wou NADAL AIVA 802 vv1 dS ONAIDLS JEDI a3MDd 7 ELO PYT di DINDIODLLS ANVd UND 393338 JV AOII February 2000 8 2 Huntgraphics ProSeal Diagrams 8 1 3 Schematic Diagram Control PCB 110V 50 60Hz E d Su sch T d SE A SW Ki D an h gt LA ae Ge pe ap 100 2 a m H nj E o v y B W 8 en o d D 8 LY o o GE G m S vrIpNI MOD Lo va vr 115V 9V 2N 9 1r e a3A0d 2 x t g
8. of the top cover in the unlocked position see Section 4 1 Opening Closing the Aluminium Top Cover Adjustment Procedures Necessary tools Infrared Temperature meter small flat head screwdriver Approximate time 30 60 minutes The top roller temperature should be set to 160 C 4 C 320 F 7 5 F Changing the temperature to a higher value in case it is too low goes faster than the other way around as the roller is heating up faster than it will cool down Therefore it is necessary to open the top cover if the roller has to cool down and wait approx 15 20 minutes to assure that the temperature is well under the correct value Before taking a temperature measurement the top cover has to be closed for at least 5 minutes To do the measurement open the top cover and quickly measure the temperature of the top side of the top roller close to the middle of the machine See figure 40 Close the cover again To change the temperature setting insert the screwdriver in the trimpot as shown in figure 41 Rotating clockwise increases the temperature counter clockwise rotation will decrease the temperature A five degree turn of the trimpot will increase decrease the temperature by approximately 10 C 18 F Repeat the previous steps if the temperature is not correct After this adjustment procedure assemble the right hand cover again fig 40 fig 41 Please do not forget to lock the top cove
9. N A SP 963 0020 PH CR power cable UK HS Components 462 418 250VAC 10A SP 961 0017 BS1363A ua CEE 7 VII Feller G1 00 C13 250VAC 10A N A SP 961 0016 tri rated internal wiring i UL1015 N A tri rated internal wiring i UL1015 N A blue tri rated internal wiring i UL1015 N A green yellow VW 1 Type 3 a Sleeving Hellermann Tyton 277 873 10 0 mm Class 105T N A plasticties Insolok TT E23190 ER Precision Engineerin sensor Proseal g 9 TH4075 N A N A SP 144 143 Ltd 25 Herde Precision Engineerin Pd Proseal Ltd g g TH4074 SP 144 137 Cem De Naamplaat BV SP 144 073 Huntgraphics 8 9 November 1999 ProSeal Diagrams Huntgraphics 8 10 November 1999 ProSeal Diagrams 8 3 Mechanical Spare Parts List Assembly Drawings amp Exploded Views 8 3 1 Mechanical Spare Parts List assy bottom roller ProSeal 4d 5P 144 004 assy bottom roller ProSeal 25 SP 144 027 assy sensor TH4074 ProSeal 44 assy sensor TH4075 ProSeal 25 assy control PCB 115V 50 60Hz SP 144 152 heater ProSeal 25 EU 230V 1500W SP 144 160 assy rh arm compl ProSeal25 SP 144 186 assy rh arm pull roller comp SP 144 190 assy rear sheet ProSeal 44 US SP 144 206 assy US Power Cable 154 SP 144 211 assy feed in table ProSeal25 JP 144 230 Hunteraphics 8 11 November 1999 ProSeal Diagrams Huntgraphics 8 12 November 1999 ProSeal Diagrams
10. ProSeal 44 The tools shown above have to be inserted in the roller journals at either side of the machine To insert the tools into the top roller the heating element including both brackets has to be removed first See the disassembly reassembly procedure in Section 4 4 Hunteraphics 5 1 February 2000 ProSeal Next the nip adjustment strips have to be loosened on either side of the machine See figure 28 and 29 the detailed adjustment strip is shown figure 30 Note that the strip must not touch the top roller bearing housing during the pressure adjustment procedure m adjustment strip fig 28 Note The figures shown above show the adjustment strips on the ProSeal 25 the adjustment strips on the ProSeal 44 are positioned under the bearing housing they are larger and mounted with two bolts Make sure that there is some space between the adjustment strips and the bearing housings see figure 30 At the left hand side of the machine the overtemperature switch has to be turned away to the right In order to do this remove the M4 socket screw at the top of the switch and loosen the other M4 socket screw a bit using the Allen key 3mm See figure 31 2 To place the pressure r sensors between the supports it is necessary to open the roller nip fully In order to do this push and rotate the nip adjustment knob situated on the right hand side of the machine inward and fully clo
11. at a slow rate instead of being constantly lit Cause The temperature sensor wires are short circuited Solution Check the wires and replace the sensor if necessary See Section 8 3 2 Assembly Drawings 8 Exploded Views drawing no 144 184 144 186 art code 144 137 144 143 Problem The temperature ready LED keeps on flashing at a slow rate after 20 minutes once the heating has been activated Causes The heating element is defective or one of its connectors had not been installed Solution Check by performing the Heating Element assembly reassembly procedure see Section 4 4 Hunteraphics 7 1 February 2000 Pro Seal Troubleshooting The Solid State Relay is defective it has a permanent open state in this case the red LED on the Solid State Relay is constantly on Solution Replace the Solid State Relay see Section 4 1 The overtemperature switch is defective it has a permanent open state in this case the line voltage can be measured between it s connectors Solution Replace the overtemperature switch See Section 8 3 2 Assembly Drawings amp Exploded Views drawing no 144 185 144 187 art code 961 6003 The Control PCB is defective if the previous checks are OK Solution Replace the Control PCB Problem The temperature ready LED starts flashing at a fast rate after some 20 minutes and continues to do so The top cover is warmer than usual Cause The Solid State Relay is defective
12. heating system is active IEC symbol meaning Heating system IEC symbol meaning LED green Temperature controller status F Flashes at a slow rate if the roll temp is too low Steady if the roll temp is OK and machine is ready Flashes at a fast rate if the roll temp is too high IEC symbol meaning Top roller heater Pushbutton function Switching the heating system on off middle LED will indicate if heaters are on LED is on or off IEC symbol meaning gm LED is off toggle function on off j Pushbutton function Reversing the forward movement of the rollers momentary action as long as this button is IEC symbol meaning pressed reverse roller movement fig 7 Huntgraphics 3 2 February 2000 Pro eal Disassembly Reassembly Procedures Section 4 Disassembly Reassembly Procedures 4 1 Opening Closing the Aluminum Top Cover Necessary tools medium flat head screwdriver Approximate time 1 minute To open the cover do the following steps 1 Insert the screwdriver in one of the holes situated on the top of the cover Make sure that the head fits in the screw mounted directly underneath this hole See figure 8 2 Rotate the screwdriver approximately 1 4 turn the direction is not important as the screw is a so called quarter turn snap in screw 3 Repeat this at the other side of the top cover 4 Open the top cover until it rests on the feed in
13. mount and laminate and encapsulate prints in one step Each machine is provided with a User Manual the purpose of this manual is to outline the materials and processes when using ProSeal supplies using this laminator to create signs displays and flexible graphics with professional results The manual includes instructions of various laminating procedures which are meant to give the user comprehensive information needed for the efficient use of his laminator These machines have not been tested with any other materials and are not recommended for use with products other than ProSeal supplies The US versions of the ProSeal machines are provided with fixed powercables and NEMA plugs the European versions are provided with Euro appliance inlets see also Section 8 The ProSeal laminators meet the Machinery Directive 89 392 EEC amp applicable amendments They are ETL and cETL listed per directive UL 1950 3 Edition 1995 and CAN CSA C22 2 No 950 95 1 2 Machine Specifications Mechanical Height Overall Width Depth Net Weight Shipping Weight Electrical US version EU version Process Working width Roller Line Pressure Process speed Process temperature Nip Settings Order Codes US version EU version ProSeal 25 12 305 mm 40 1016 mm 15 380 mm 77 Ibs 35 kg 90 Ibs 41 kg 110VAC 60Hz 12A 230VAC 50Hz 7A 25 maximum 635 mm 1 N mm 1 min 305 mm min 311 320 F
14. of the machine should be as follows ProSeal 25 35 kilograms ProSeal 44 46 kilograms If necessary change these values as described above After the adjustment remove the pressure sensors and the supports fig 34 Assemble all parts in reverse order Now it is mandatory to continue with the Nip Adjustment Procedure described in Section 5 2 Hunt 5 3 February 2000 Pro eal Adjustment Procedures 5 2 Nip Adjustment Note to perform the following adjustments it is necessary to remove both plastic side covers first See Section 4 3 Disassembly Reassembly Plastic Side Covers Necessary tools Allen key 4mm In addition a metal adjustment sheet having a specific thickness is necessary For the ProSeal 25 the thickness of this sheet must be 0 5 mm size 700x250 mm For the ProSeal 44 the thickness of this sheet must be 1 25 mm size 1150x250 mm Approximate time 5 minutes Note the top roller must be at room temperature before this procedure is being performed 1 Setthe roller nip opening to its maximum position by pushing and turning the nip setting knob fully clockwise 2 Next the nip adjustment strips have to be loosened on either side of the machine if not loosened already in case the previous procedure has been performed See figure 35 and 36 the detailed adjustment strip is shown figure 37 Note that the strip must not touch the top roller bearing housing adjustment
15. table fig 8 To close and lock the cover proceed with the following steps 1 Do not close the cover yet but rotate both screws back 4 turn to their original position This is easier when the cover is still open 2 Now close the cover 3 Press using the screwdriver both screws until they snap back into their locks Note When performing the Temperature Adjustment Procedure it is convenient to close the cover without locking the screws This is called the unlocked position Note i Please make sure that after any procedure requiring the top cover to be opened the top cover is closed and locked For safety reasons the operator is not allowed to have free access to the hot roller and roller nip Huntgraphics 4 1 February 2000 Pro eal Disassembly Reassembly Procedures 4 2 Feed in Table Necessary tools medium flat head screwdriver Approximate time 1 minute To remove the feed in table do the following steps Insert the screwdriver in one of the holes situated on the feed in table See figure 9 1 Rotate the screwdriver approximately 4 turn the direction is not important as the screw is a so called quarter turn snap in screw 2 Repeat this at the other side of the top cover 3 Lift the table approximately 20 mm 3 8 by means of the two knurled knobs and slide it straight out of the machine To insert and lock the feed in table proceed with the following ste
16. thickness of the material you will be using with the machine Releasing the knob so that it moves back to the right and clicks into place will set the rollers for use The measurements on the knob 4 3 16 1 8 and 1 16 6 5 3 1 5 mm correspond to Pouch board thickness There is also a fully closed stop for future film only applications To turn the laminator off grasp the control knob and push to the left rotate the knob away from you as far as it will go clockwise This will shut off the machine and open the rollers to permit objects to be removed Internal functionality See figure 5 Inside the machine a rod is mounted 5 between the left and righthand framesheets The knob is mounted on the rod it allows axial movement but no radial movement The knob is provided with a pin 1 that falls in the indents 2 of a bracket 3 The same rod is provided with an eccentric 4 on either side of the machine These eccentrics push or pull the arms 5 where the top roller is mounted 4 in upward or downward The mains switch is mounted in such a way that it switches the power off once the are is in its highest position hunteraphics 3 1 February 2000 Pro eal Theory of Operation 3 2 Control Panel The Control Panel see figure 6 is located on the front right of the machine and has three LED indicators A diagram of the Control Panel is shown in figure 7 1 The top LED when lit indicates the
17. 00719 IVNIWSI3IL Vee w 000 ID6 dS ONADOLS l3 NI JINVI ddy Jv AEC Z0 bFvl dS ONADOLS JNVd IDN February 2000 8 6 Huntgraphics Diagrams ProSeal Schematic Diagram Control PCB 230V 50 60Hz 8 1 7 Sav tynt ota Sgr IENT NAZZ JOU d SITING ANLAII PNU ME VA2 NG A0E2 Ier LU Spr Le SBY DN a Er JVASZc 3V0T y f JVASLE T 1 U C er v0 QZSVH FIN SDISN3S dW3il L SSA sr D ITO a L SSA O S k r m Y d pm eo mo no Dese Ya I L EN e ar 2 MENT RN 21 P LL Ka 2 m SSA a L ANE m Is lt q D a d AG x S LT S amp L AG AS Pou a Q A February 2000 8 7 Huntgraphics ProSeal Diagrams 8 2 Certified Electrical Components Lists amp Sparepart Codes 8 2 1 110VAC 60Hz Machines See also Section 8 1 1 through 8 1 4 DWG Name __ Menufaeturer_ Sparepart peas mag fro SSRI Solid State Relay G3NA 220B 240Vac 20A E64562 SP 961 0001 healing element Tubing Inc 144 158 120 Vac 1500W SP 144 158 Proseal 25 healing element quartz Tubing Inc 144 157 120Vac 1850W N A SP 144 157 Proseal 44 Si DON switch Omron Hartmann V161C5 MAB6 NA microswitch AC250V 16A M1 t SAIA B vid ki 110VAC 60Hz 4W E63316 SP 964 0009 motor Burgess SF33CRN2A Z i connector for P1 5 J2 J3 me Hitaltech HT255005 Imax 17A5 E167473 N A
18. 113 F i Only qualified service technicians should remove the top extrusion in order to clean the rollers if necessary Safety Features The material inlet opening has a height that is in accordance with EN294 clause 4 5 2 the IEC1032 test finger cannot enter this opening The heating system is provided with an over temperature device which will shut off the top roller heating element once a heating system failure occurs Caution Everyone working around the laminator must avoid wearing loose fitting clothing ties or dangling jewelry which could catch in the laminator rollers Technical Service hazards Fire hazard The laminator contains a heated roller which reaches temperatures of 160 C 320 F There is a danger of severe burns if the heated roller is touched during servicing A Mechanical hazard Failure to use caution near exposed rollers could result in physical injury fig 1 Huntgraphics i February 2000 Pr 0 Seal Front Matter Note When performing procedures that require the side covers to be opened ensure that i the power cable is disconnected from the mains Several parts like the mains switch 1 and the overtemperature switch 2 could cause electrical shock if the power is not disconnected fig 2 Huntgraphics ii February 2000 ProSeal Section 1 1 1 1 2 Section 2 2 1 SE Section 3 3 1 3 2 Section 4 4 1 4 2 4 3 4 4
19. 4 5 4 6 4 7 Section 5 BL 5 2 5 3 Section 6 6 1 6 2 6 3 Section 7 Fl Section 8 8 1 8 2 8 3 Huntgraphics iv Table of Contents Machine Characteristics JE ele T 7 1 1 db ee R1 1 04 NENNT bk ke a ja ki E T mm 1 1 Installation PC AE A PT pi tk ki 2 1 2 1 1 Electrical Requirements 2 1 2 1 2 Workspace Requirements 2 2 D SPHERE 2 2 Theory of Operation d uie E s oT TORTE EE 3 1 GONW ON Fi TET OTT 3 2 Disassembly Reassembly Procedures Opening Closing the Aluminium Top Cover 4 1 FONW T IR TURNUM mme 4 2 PON ON GAN TR 4 2 ccnl i TT UU 4 4 EE eebe eege 4 6 oE ra EE 4 7 ANTE EE 4 8 Adjustment Procedures Laminating Pressure Feet CETT TE 5 1 PR ALE EE 5 2 Temperature Adjustment sss nemen nemen een nenne 5 6 Maintenance Cn OT Me WEIGHING T m ki k a TT TT 6 1 Regular Cleaning of the Rollers by the COperator 6 1 Cleaning of the Rollers by Service Technicians 6 1 Troubleshooting Bie ee dl NT TT UT Umm 7 1 Diagrams Electrical Scehemgli0S_ u uu aaa sassaaawaqanawasawasaqawpakaqsqkanqsaskakunasanqawa 8 1 8 1 1 Schematic Installation Diagram ProSeal 25 110V 60Hz
20. Pro eal Technical Service Manual Huntgraphics Pro Seal Front Matter ProSeal 25 ProSeal 44 Technical Service Manual REV 2 0 Revision History Amendments will be listed on this page including their descriptions and dates REV Date Description 1 0 Nov 1999 Original version pre release 2 0 Feb 2000 Released version the manual covers US as well as EU machines Page numbering starts with each section Changed pages all The pressure and nip setting procedures have been changed in accordance with the new roller setup uncrowned top roll crowned bottom roll Huntgraphics February 2000 Pro Seal Front Matter Safety Statements The ProSeal laminators have been designed with operator safety as a primary objective however operators must be familiar with the controls as well as the operation before using the unit The electrical and drive system components are isolated from contact with the operator by enclosing them within plastic end covers that are bolted on Only qualified service technicians should remove these protective covers after power to the machine is removed including disconnecting the power cord The heated top roller can reach temperatures of 160C 320 F For operator safety a protective heat shield is mounted over the top roller and attached to the top aluminum extrusion Adequate ventilation is guaranteed because of this the outside temperature of the extrusion will never exceed 45 C
21. Solution Replace the Solid State Relay see Section 4 1 Problem Pouchboards are not drawn in by the machine and the motor is making a louder humming noise it s stalling Only after pushing very hard the boards are accepted Causes The Pouchboard is too thick for the chosen nipsetting Solution Check the nipsetting that corresponds to the boards used Boards of another make are used Solution Use only ProSeal Pouchboards The nip adjustment is not correct Solution Perform the Nip Adjustment procedure see Section 3 2 Problem The quality of the lamination is poor silvery areas on dark surfaces are visible or the edges of the image are not sealed well Causes The roller temperature is too low Solution Perform the Temperature Adjustment procedure see Section 3 3 The roller pressure is too low Solution Perform the Laminating Pressure Adjustment procedure see Section 3 1 Problem The quality of the lamination is poor especially laminated inkjet prints show bubbles Cause The roller temperature is too high Solution Perform the Temperature Adjustment procedure see Section 3 3 Hunteraphics 7 2 February 2000 Diagrams ProSeal Diagrams Section 8 Electrical Schematics 8 1 Schematic Installation Diagram ProSeal 25 110V 60Hz 8 1 1 Wima so uMoJq 66 TI T 3400 Oce vvl 6000 796 ds E Uaquiny ONMIDL1S IND A0IT Se WaSONd Wv DYIQ TW Auge NDAN 11 Il 3d INC 31IHA
22. aps that hold the wire of the heating element to the other two black wires See figure 16 Huntgraphics 4 4 February 2000 Pro eal Disassembly Reassembly Procedures 4 Loosen the screw which attaches the heater wire to the Solid State Relay See figure 17 fig 17 fig 18 5 Remove the heater bracket on the right hand side of the machine see figure 18 and slide the heater wire out of the slot that s in the heater bracket Now the heating element can be taken out of the roller Note When a heating element has to be installed into the roller the quartz tube has to be cleaned first Proceed as follows Insert the heating element with the end having the shortest wire into the roller core Make sure that the wire is bent straight to smoothen the insertion Whilst inserting clean the quartz tube with a lint free cloth lightly dampened with IPA Isopropanol Do not touch the quartz tube with your fingers This is important because fingerprints will burn when the heater is on and can possibly damage the quartz tube See figure 19 Always be very careful when using IPA IPA is very flammable The flash point of IPA is 11 C 51 8 F The self ignition temperature is 400 C 752 F Once the element is placed in the roller reassemble all parts in the reverse order Note Do not forget to attach two new tie wraps and mount them exactly as the two that were fig 19 removed previously
23. ckwise Insert the supports together with the sensor all the way into the roller journals The AT sensor supports should l have their flat sides facing each other see fig 31 1 and the holes in the sensor should fit over the pins in the supports fig 31 Hunt 5 2 February 2000 ProSeal To insert a sensor support into the right hand journal of the bottom roller the belt tensioner assembly has to be removed first already removed in figure 32 Use the small screwdriver to remove the retaining clip from the tensioner arm pivot axis See figure 32 After disassembly of the belt and tensioner the supports can be inserted 1 as previously described fig 32 Now push and rotate the nip adjustment knob until the pin mounted in the knob falls into the first notch relative to top from the indent bracket See figure 33 Pressure will be applied to the pressure sensors and the pressure can be read on the PDU To change the pressure place the 10mm open ended spanner on the M6 nut that s directly under the compression spring so the upper jamnut On the left hand side of the machine it s best to remove the blue connector from the fig 33 overtemperature switch to ease access with the spanner See figure 34 Rotate clockwise to decrease the pressure counter clockwise to increase the pressure seen from above The pressure settings for each PDU display so for either side
24. er 2 1 2 Remove the protective polystyrene foam end covers Remove the polyethylene bag Remove the protective sheet placed between the rollers To do this push the knob situated at the right hand side fully inward and rotate fully clockwise Check for damages Plug the power cable into the grounded outlet as described under 2 1 1 The machine will now start and heat up Hunteraphics 2 2 February 2000 Pro Seal Theory of Operation Section 3 Theory of Operation 3 1 Control Knob The Control Knob see figure 4 is located on the right hand side of the laminator and is operated from the front of the machine The Control Knob has four 4 purposes Turn the power on Turn the heat on Turn the rollers on Adjust the height of the rollers pee J The Control Knob can be operated by pushing it in approximately 1 4 6mm to the left Once the knob has disengaged from the stop it may be rotated forward or backward clockwise or counter clockwise viewed from the right hand side of the unit To switch the power on push the knob in and fig 4 rotate it slowly towards you counter clockwise as viewed from the right side of the unit The top LED will light up to indicate that the power is on Continue to rotate the knob until the desired measurement corresponds with the indicator window at the base of the knob Inside the window the rotation possibilities are shown Select the measurement that indicates the
25. g the power cable into the mains outlet The processor containing the software is not installed Solution Install the software see Software Installation Section 4 5 The processor containing the software is installed the wrong way around Solution Install the software properly see Software Installation Section 4 5 The external mains circuit breaker is tripped Solution Reset the mains circuit breaker The flatcable coming from the control panel in the right hand side cover and the PCB is not connected Solution Perform the Cover Disassembly Reassembly procedure See Section 4 3 The mains micro switch is defective Solution Replace the switch See Section 8 3 2 Assembly Drawings 8 Exploded Views drawing no 144 180 144 182 art code 961 0007 Problem The heating system LED middle LED does not come on when the nip setting knob has been set to one of the nip settings board thicknesses coming from the off position Cause There is a fault in the controlpanel if a loose control panel works fine Solution Replace the right hand cover containing the control panel Perform the Cover Disassembly Reassembly procedure See Section 4 3 Problem The heating system LED middle LED is flashing at a fast rate instead of being constantly lit Cause The temperature sensor wires are not connected properly Solution Check the wires of the sensor Problem The heating system LED middle LED is flashing
26. he original positions into the holes put the blue connector back onto the overtemperature switch and mount the ground wire back to it s position Put the serrated washers back the way they came off one on either side of the two wire eyelets 4 7 Solid State Relay Necessary tools medium flat head screwdriver Allen key 3 mm Approximate time 5 minutes Note To remove the Solid State Relay it is necessary to perform the Plastic Side Covers disassembly procedure see Section 4 3 first Only the right hand cover has to be removed Make sure that the power cord is disconnected from the mains Perform the following steps 1 Loosen all four screws that clamp the wires They are marked 1 through 4 See figure 24 2 Bend the wires a bit away from the Solid State Relay 3 Remove the two M4 bolts that hold the Solid State Relay together with the bent sheet fire enclosure that s mounted behind it 4 Now you can remove the Solid otate Relay together with the bent sheet o When mounting the Relay make sure that the four fig 24 clamping screws and the two M4 bolts are tight Don t forget the serrated washers that belong under the M4 bolt heads Note make sure that the relay is mounted in the proper way the coding on the blue wires should correspond with the numbers on the relay the two black wires on clamp no 1 the wire from the heating element on clamp no 2 Huntgraphics 4 8 February 2000 Pro
27. ic Side Covers Procedure see Section 4 3 first Perform the following steps 1 See figure 21 Cut the two tie wraps arrows at the left hand side of the machine Remove the blue cable connector from the overtemperature switch 1 Remove the nut from the ground connection stud 2 fig 21 fig 22 2 Remove the seven crosshead self tapping screws from the rear panel see figure 22 3 Carefully pull the rear panel backward whilst pulling the two wires the yellow green and the blue one back through the plastic protective bushing that s mounted in the left hand framesheet 4 When the wires are clear from the bushing swing the rear panel a quarter turn away from the machine Take care not to damage the wires 1 going to the motor See figure 23 5 To mount the rear panel back to the machine again swing it far enough towards the machine to insert the two wires into the bushing 6 Whilst pulling the wires through the bushing swing the rear panel further to the machine 7 When mounting the rear panel make sure that the two slots 2 on either side in the panel grab the two bent parts at the underside of the framesheets 8 Next push the rear panel upward to its original position and use the crosshead screws to fig 23 fasten the panel again Do not forget the serrated washers Huntgraphics 4 7 February 2000 ProSeal Disassembly Reassembly Procedures 9 Apply the two new tie wraps exactly on t
28. machine is plugged in and the power is on 2 The middle LED indicates if the heat is on Heat is required for ProSeal Pouch Boards and ProSeal Flexible Pouches If lit the laminator is in Hot Operation Mode and will heat up to its factory setting If not lit the laminator is in Cold Operation Mode 3 The bottom LED is the Temperature Ready Indicator If flashing slowly this indicates the laminator is heating up and has not yet reached process temperature A steady light indicates the unit has reached process temperature and fig 6 is ready for use A rapid blinking light indicates that the machine is too hot This occurs when changing from Hot Mode to Cold Mode In this case a steady light indicates the machine has cooled sufficiently for cold processes Below the LED lights are two Push Buttons 1 The top button controls the heating of the roller it switches the heater on or off Pushing this button toggles the machine from Hot to Cold or Cold to Hot Operation The bottom LED light when constantly on will indicate the appropriate temperature as been reached 2 The lower button reverses the direction of the motor The motor will continue to run in reverse until the button is released This is used to clear jams or foreign objects should one be drawn into the laminator ISO symbol meaning LED green Power has been switched on 2 Lit when machine is switched on All electronic functions are OK LED green Lit when
29. move the right hand cover from the frame of the machine Now a flatcable connected to the Control PCB will become visible Hold the cover with one hand whilst removing the flatcable connector from the PCB See arrow in figure 13 5 The procedure for the left hand cover is similar though it s obvious that there s no flatcable on this side Assembly of the cover is in reverse order fig 13 Note Make sure that the flatcable has been placed back onto the PCB connector Take care that the flatcable is not twisted Huntgraphics 4 3 February 2000 Pro eal Disassembly Reassembly Procedures 4 4 Heating Element Necessary tools Allen key 3mm Approximate time 10 minutes Note To disassemble reassemble the heating element it is necessary to perform the Plastic Side Covers Procedure described in Section 4 3 Make sure that the power cord is disconnected from the mains The heating element see figure 14 is a quartz tube having a spiral wound filament mounted inside The quartz tube is fragile take care when handling the element To exchange the heating element perform the following procedure fig 14 1 Remove on the left hand side of the machine the blue fast on connector 1 from the overtemperature switch 2 See figure 15 2 Slide the heater wire out of the slot that s in the heater bracket fig 15 fig 16 3 Cut at the right hand side of the machine the two tie wr
30. ps 1 Insert the table back into the machine and make sure that it goes in straight otherwise it might get stuck 2 Once the table falls into it s position rotate the screws back 4 turn to their original position Use the same screwdriver to press both screws until they snap back into their locks Note Please make sure that after any procedure requiring the feed in table to be removed the feed in table is closed and locked For safety reasons the operator is not allowed to have free access to the hot roller and roller nip 4 3 Plastic Side Covers Necessary tools hexalobular screwdriver TX25 Allen key 4mm Approximate time 5 minutes Note To remove the covers it is necessary to perform the Opening Closing the Aluminum Top Cover Procedure described in Section 4 1 To remove the side covers do the following steps 1 Remove the two self tapping screws using the TX25 driver as shown in figure 10 The right hand cover is shown here fig 10 4 2 February 2000 i ly R ly P Pro eal Disassembly Reassembly Procedures 2 Remove the self tapping screw situated at the rear side of the machine using the TX25 driver as shown in figure 11 fig 11 fig 12 3 Remove using the Allen key 4mm the two M5 socket screws situated at the bottom of the cover It s best practice to slide the machine to the edge of the table or counter where it s placed See figure 12 4 Carefully re
31. r as the user of the machine is not Note Ch allowed to open it Huntgraphics 5 6 February 2000 Pro Seal Maintenance Section 6 Maintenance 6 1 Cleaning of the Machine The laminator may be cleaned by the operator with a lint free cloth lightly dampened with a mild soap and water solution Spray on cleaners are not to be used No part of the machine is to be immersed in water or other liquids 6 2 Regular Cleaning of the Rollers by the Operator The laminating rollers of the machine should be periodically cleaned of adhesive build up that might occur during normal operation This should be performed a few times per day using the ProSeal Cleaning Board ProSeal Cleaning Boards are specially designed to attract and capture any adhesive that may be clinging to the rollers They are made from materials that will not damage or cause excessive wear to the ProSeal Laminator 1 Turn on the unit and set for Hot Temperature Operation Once the machine has reached process temperature set the Control Knob to 3 16 2 Slowly insert the Cleaning Board into the inlet opening Ensure that the board enters centered and straight A gentle push may be required to start the board into the machine Hold the edges of the board until it is engaged in the unit and the laminator begins pulling it on its own 3 The board will feed through the laminator and automatically exit at the rear of the unit THE BOARD WILL BE HOT Allow the board
32. s receptacles shown below G G GE Ly I NEMA 5 15R NEMA 5 20R Using 15 Amp Breaker Using 20 Amp Breaker ProSeal 25 ProSeal 44 Note T slot is not applicable for Canada For both EU versions in the UK the following is applicable n BS 1363 13A wall receptacle D a Use the provided BS 1363 plug For both EU versions mainland Europe the following is applicable 1 N I French German Netherlands Belgium Portugal Spain Use the provided Schuko plug 10A Hunteraphics 2 1 February 2000 ProSeal Installation Wirecolours General EU USA Name Blue White Neutral Yellow Green Yellow Green Ground Brown Black Phase Live 2 1 2 Workspace Requirements This unit should be situated away from heat sources such as heat registers or stoves The laminator s location or position should not interfere with its proper ventilation There should be enough space around the laminator to feed in exit and trim mounted and or laminated images The background dust level must not exceed that found in a typical office computer room environment The work area should be level flat and well lit 2 2 Setup Procedure 1 ros Iw Ho Open the box and lift the machine out at least two persons necessary Grasp the machine 8 10 200mm 250mm from either side at the bottom aluminum extrusions Be careful the polyethylene bag is slippery Place the machine on the work area described und
33. t n 2 4 O tu c 0n CL a e m D d gj LA B a a a a gt ou P E G A 0o Hunteraphics 9 3 February 2000 ProSeal Diagrams 8 1 4 Schematic Diagram Controlpanel 144 224 Title CONTROLPANEL PROSEAL Filename PANEL SU Sheet of cx Sel JA del e gir IS VIC MO dL cl S T 4SO NO S31 V 3H Hunteraphics 8 4 February 2000 Diagrams ProSeal Schematic Installation Diagram ProSeal 25 230V 50Hz 8 1 5 ee LCE 2100 coo vvi Aao unwN AQEc Ge IWVdsLed WVADVIC 2 4000 196 dS UN OI ES LEI dS INDOLS EVI rVI dS ONSDOLS 1000 196 dS UN OI TASS 8000 796 dS tONADOLS LW 1113 Axa 0200 96 dS ONAOOLS dJd IDJINDOU L000 196dS ONXIO1S IS 1 HA N3389 dd nig ETU0 196 dS N ONXDOLS WA 200719 IVNIWSI3IL Vee w 000 156 dS ONADOLS l3 NI JINVI ddy JV Adee Z0 bFvl dS ONADOLS JNVd IDN February 2000 8 5 Huntgraphics Diagrams ProSeal Schematic Installation Diagram ProSeal 44 230V 50Hz 8 1 6 Eec vv I Aao unwN NOEC vv 190ISPAJ d WVADVIC 2 4000 196 dS UN OI ES 6ST rPI dS ONS LI LETl brT dS ONSDOLS 1000 196 dS UN OI TASS 8000 796 dS tONADOLS LW 1113 Axa 0200 96 dS ONAOOLS dJd IDJINDOU L000 196dS ONXIO1S IS 1 HA N3389 dd nig ETU0 196 dS N ONXDOLS WA 2
34. terminal block Famell E76048 Ee esse saan um pren mainplug cable Ayme E41542 m Panes 44 Any make Nema 5 20P SJT 3x12AWG LL14903 tri rated internal wiring Multicomp black tri rated internal wiring Multicomp A A tri rated internal wiring Multicomp C C C r m r O O O C1 C1 C1 Z z e a s 20 B Km no O Co N A VW 1 Type 3 Class 105T BN nut cable gland 587 13 01 polyamid SP 961 0012 plastics nsolok T18 T30 E23190 EE Precision Engineerin TS1 sensor Proseal Ltd 9 9 N A N A N A SP 144 143 25 temperate Precision Engineerin TS1 sensor Proseal Ltd 9 9 SP 144 137 cM De Naamplaat BV SP 144 073 z gt Sleeving Hellermann Tyton 277 873 10 0 mm Huntgraphics 8 8 November 1999 ProSeal Diagrams 8 2 2 230VAC 50Hz Machines See also Section 8 1 4 through 8 1 7 Hp eren T Sparepart p mme s SSR1 Solid State Relay G3NA 220B 240Vac 20A E64562 SP 961 0001 heating element Quartz Tubing Inc 144 160 230 Vac 1500W SP 144 160 Proseal 25 Quartz Tubing Inc 144 159 230Vac 1850W SP 144 159 Proseal 44 AC250V 15A on off switch S1 Omron Hartmann V161C5 MAB6 SP 961 0007 microswitch AC250V 16A e overtemp switch 2511L135 2040 AC 250V 25A MH8267 SP 961 6003 SAIA Burgess GE 230VAC 50Hz 4W SP 964 0008 9 5F25CRN2A iid print control PCB I 230VAC Hunt Graphics 963 0020 see underneath
35. to lie flat while cooling Note This is the only roller cleaning method operators are allowed to do 6 3 Cleaning of the Rollers by Service Technicians Only service technicians are allowed to perform a thorough surface maintenance of the rollers This should be done once or twice per year To perform this cleaning procedure the top cover has to be opened See Section 4 1 Opening Closing the Aluminum Top Cover On the ProSeal 44 the feed in table should be removed as well see Section 4 2 Feed In Table The rollers should be cleaned with a lint free cloth lightly dampened with IPA Isopropanol Always be very careful when using IPA IPA is very flammable The flash point of IPA is 11 C 51 8 F The self ignition temperature is 400 C 752 F Please make sure that the top roller is cooled down before cleaning Hunteraphics 6 1 February 2000 ProSeal Its best practice to clean the top roller first adhesive from the top roller is likely to fall on the bottom roller Maintenance See figure 42 cleaning the top roller and figure 43 cleaning the bottom roller fig 42 Huntgraphics 6 2 February 2000 Pro Seal Troubleshooting Section 7 Troubleshooting 7 1 Troubleshooting Problem The power LED does not come on when the nip setting knob has been set to one of the nip settings board thicknesses Causes The power cable has not been plugged in the mains wall outlet Solution Plu
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