44/62 Ultra Plus
Laminator
User manual
Manuel de l’utilisateur
Betriebsanleitung
Manual de uso
Manuale d’uso
7001507
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44/62 Ultra Plus
Laminator
User manual
7001708, Rev.A
July 2007
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INTRODUCTION
We would like to thank you for purchasing a Seal 44/62 Ultra Plus, designed to give you
many years of reliable service. By following the guidelines outlined in this manual for
proper care and use, you can depend on many years of trouble-free profitability from your
investment.
Your 44/62 Ultra Plus laminator meets the CE Machinery Safety Directive (89/392/EEC,
including 91/368/EEC, 93/44/EEC and 93/68/EEC) and is ETL listed (UL 1950/EN60950).
Statement of intended use.
The 44/62 Ultra Plus laminator has been designed to be used with Seal materials. When
used with this products, you are able to mount, mount and laminate, and encapsulate
prints in one step. Your machine has not been tested with any other materials and is not
recommend for use with products other than Seal supplies.
WARNING:
THIS MACHINE IS DESIGNED FOR MOUNTING AND LAMINATING. ANY
USE OTHER THAN THE INTENDED MAY CAUSE DAMAGE TO THE
MACHINE OR PHYSICAL HARM TO THE USER.
Liability Statement
The details given in this manual are based on the most recent information available to us.
They may be subject to change in the future. We retain the right to make changes to the
construction or the design of our products without accepting any responsibility for
modifying earlier versions previously delivered.
Standardized Symbols
Passages marked this way offer an idea / tip or other information on the
efficient use of this unit.
WARNING:
PLEASE PAY ATTENTION TO ALL PASSAGES MARKED THIS WAY.
THIS INFORMATION IS VITAL TO PREVENTING USER INJURY AND /
OR DAMAGE TO THE UNIT. FAILURE TO FOLLOW THIS
INFORMATION COULD VOID THE USER’S WARRANTIES AND
TRANSFER ALL SAFETY OBLIGATIONS TO THE USER.
2
Introduction
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TABLE OF CONTENTS
Introduction
2
3
Table of Contents
1
Specifications
5
1.1
1.2
Technical Specifications
5
Electrical specifications
6
6
6
1.2.1
1.2.2
US versions
EU versions
2
Safety / Important Safeguards
Safety symbols used on the equipment.
Emergency stop-buttons
7
7
7
2.1
2.2
3
Unpacking and Installation
Ambient Conditions
8
8
8
8
8
3.1
3.2
3.3
3.4
3.5
Surroundings
Power supply
Workspace Requirements
Setting up the laminator in 4 steps.
9
11
3.5.1
Adjustable feet
4
Unit description
Control panel
12
4.1
4.2
13
Motor control
13
14
14
4.2.1
4.2.2
Slow-mode
Reversing the machine
4.3
4.4
4.5
Unwind brakes
15
15
15
Roller nip settings
Image guide storage place.
5
Process Control Sheet
16
Table of Contents
3
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6
Application Processes
17
6.1
Loading the machine
17
17
18
18
18
6.1.1
6.1.2
6.1.3
6.1.4
Loading film onto a machine equipped with the interlock bracket.
Loading film onto a machine equipped with the cam lock system.
Loading the unwind shaft into a machine equipped with the interlock bracket.
Loading the unwind shaft into a machine equipped with the cam lock system.
6.2
6.3
Webbing the films
Feeding images
19
21
21
6.3.1
How to feed images:
6.4
6.5
6.6
Laminating and adhesive coating (Decaling)
Decaling without liner
22
23
Mounting
24
24
6.6.1
To mount decals onto a substrate
6.7
Encapsulating
25
26
26
27
6.8
Pre-Coating
6.9
Mounting using a ProSEAL® Mounting Board
Mounting and Lamination using a ProSEAL®pouch Board.
Encapsulating with a ProSEAL® Flexible Pouch using a ProSEAL® Carrier
6.10
6.11
Board 28
7
8
9
Maintenance & Cleaning
29
30
31
32
33
Troubleshooting
Glossary of Terms
10 Limited Warranty
11 Index
4
Table of Contents
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1 SPECIFICATIONS
1.1 Technical Specifications
Imperial
Metric
Max. Working Width
processes up to 50°C
44 Ultra Plus 44” maximum
62 Ultra Plus 62” maximum
44 Ultra Plus 42” maximum
62 Ultra Plus 60” maximum
1118 mm max.
1574 mm max.
1067 mm max.
1523 mm max.
processes up to 125°C
7 ft/min
2.13 m/min.
Max. Speed
Off (ambient temp.)
125°F, 195°F, 250°F
Off (ambient temp.)
50°C, 90°C, 120°C
Temperature settings
Dimensions (HxWxD)
44 Ultra Plus 43.7”x58.3”x22”
62 Ultra Plus 43.7”x76.3”x22”
1110x1480x560 mm
1110x1940x560 mm
Shipping dimensions (HxWxD)
44 Ultra Plus 28.4”x63”x24.8”
720x1600x630 mm
720x2060x630 mm
62 Ultra Plus 28.4”x81”x24.8”
Weight
Net Weight
44 Ultra Plus 222 lbs
62 Ultra Plus 297 lbs
44 Ultra Plus 331 lbs
62 Ultra Plus 416 lbs
101 kg
140 kg
135 kg
189 kg
Shipping Weight
Maximum roll diameter
Unwind
6.3”
4”
160 mm
100mm
Release liner wind-up
Maximum roll weight
Unwind
44 Ultra Plus 40 lbs
62 Ultra Plus 60 lbs
18.1 kg
25.2 kg
0, 1/16”, 1/8”, 3/16”,
1/4”, 5/16”, 1/2”
0, 2, 3, 5, 6, 8, 13mm
Roller Opening (Nip) settings
Roller Pressure
1.32 N/mm.
0.86 N/mm
44 Ultra Plus
62 Ultra Plus
7.52 lbf/in
4.90 lbf/in
Two siliconized steel rollers.
Roller Construction
Keep the area around your laminator clear with adequate space around it so you can feed,
receive and trim mounted and / or laminated images.
Specifications
5
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1.2 Electrical specifications
Push the power button (at least 1 sec.) and the forward (or reverse) button on the control
panel, to run the laminator.
1.2.1EU versions
44 Ultra Plus
62 Ultra Plus
1N/PE 230VAC +/-10%, 50/60Hz, 9A
1N/PE 230VAC +/-10%, 50/60Hz, 13A
For the EU versions, in the UK, the following is applicable:
BS 1363 – 13A
wall receptacle:
Use the provided
BS 1363 plug
For the EU versions, mainland Europe, the following is applicable:
Germany, The Netherlands
Portugal, Spain
France
Belgium
Use the provided Schuko plug.
6
Specifications
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2 SAFETY / IMPORTANT SAFEGUARDS
2.1 Safety symbols used on the equipment.
ROTATING PARTS
MECHANICAL HAZARD. FAILURE TO USE CAUTION NEAR EXPOSED
ROLLERS COULD RESULT IN PHYSICAL INJURY. BE CAREFUL THAT
ITEMS SUCH AS LOOSE CLOTHING, LONG HAIR AND JEWELRY DO
NOT BECOME ENTANGLED IN ROTATING PARTS.
HOT OBJECTS
FIRE HAZARD. THE LAMINATOR CONTAINS A HEATED TOP ROLLER
WHICH MAY REACH TEMPERATURES OF 135°C (275°F). THERE IS A
DANGER OF SEVERE BURNS IF THE HEATED TOP ROLLER IS
TOUCHED DURING USE.
Figure 1
2.2 Emergency stop-buttons
There are two buttons; they are located on the top of the left and right plastic covers of the
machine.
The Emergency-stop buttons shut down the rotation of the rollers and should only be used
in case of an emergency. Once pressed, these buttons lock, and they must be rotated to
be reset before the machine can be used again.
Safety / Important Safeguards
7
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3 UNPACKING AND INSTALLATION
Please read and fully understand the entire manual before proceeding to use your
laminator.
3.1 Ambient Conditions
The following environmental conditions are ideal for the best operation of the laminator.
Ambient Temperature
The best temperature for the 44/62 Ultra Plus is between 16°C and 35°C (50°F and 95°F).
Do not expose the laminator to direct sunlight as output quality may be affected.
Relative humidity
For best results, the ambient relative humidity for the 44/62 Ultra Plus should lie between
70% and 90%.
Water and moisture
If the laminator is installed in a damp room or near water, the electrical power supply must
be in accordance with the standards prevailing in the country concerned.
3.2 Surroundings
Install the laminator in surroundings that are as clean and dust free as possible in order to
obtain the highest quality end product. The materials that are used on this laminator can
have an electrostatic charge and will attract dust, adversely affecting the output.
3.3 Power supply
Connect the machine in accordance with the details given on the identification plate
attached to the rear of the machine. Refer also to the technical specifications in this
section for more information.
3.4 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.
8
Unpacking and Installation
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3.5 Setting up the laminator in 4 steps.
1. Remove the cardboard box and the plastic bag as described on the outside of the box.
2. Pick the box behind the laminator which contains the stand parts.
3. Mount the LH-side part of the stand as shown in next figure. (The LH-part is
recognizable by a spring utility on the bracket.) Use two serrated washers and two
socket screws M6x16 (see fig.2)
Do not tighten the screws completely.
Figure 2
4. Mount the RH-part of the stand onto the laminator as shown in figure 3. Use the
serrated washers and the socket screws M6x16.
Do not tighten these screws completely.
Figure 3
Unpacking and Installation
9
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5. Finally, mount the middle part between the LH- and RH parts.
Use two serrated washers and two socket screws M6x16.
Do not tighten these screws completely
Figure 4
6. Taking care to align the top of the LH stand so that it is parallel with the blue plastic
cover and there is a small gap (1-2 mm) between the blue cover and the stand, tighten
the 2 screws that hold the stand to the machine.
7. Taking care to align the top of the RH stand so that it is parallel with the blue plastic
cover and there is a small gap (1-2 mm) between the blue cover and the stand, tighten
the 2 screws that hold the stand to the machine.
8. When all of the above steps have been completed in sequence, then tighten the 6
screws that hold the tie bar to the RH and LH stand.
9. Lift the laminator from the pallet and position it onto it’s castors.
10. Make sure that the stand legs do not slide away during lifting.
11. Remove the protecting covers.
Figure 5
10
Unpacking and Installation
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Your 44/62 Ultra Plus must be setup at the place where it will be used. The stand must be
placed on a flat level surface.
12. Cut the tie-wraps and remove the blocks that hold the top roller.
13. Inspect the machine for any physical damage.
14. Plug the power cable into the grounded outlet with appropriate service.
The machine must be installed next to an outlet! Do not use extension cords. The plug
and the outlet must be easily accessible. Please ensure that you plug your laminator into a
grounded, three-prong outlet. Please ensure that the total load of the other items using the
same circuit breaker do not exceed its breaking value.
The laminator should only be connected to a power supply outlet of the voltage and
amperage 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.
3.5.1 Adjustable feet
To secure the stand on the floor, turn the adjustable foot down by hand, until it’s pressed
against the floor. Manually lock the adjustable foot with the nut (figure 6).
Nut
Feet
Figure 6
Unpacking and Installation
11
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4 UNIT DESCRIPTION
Features and benefits of the 44/62 Ultra Plus:
Figure 7
Identification of parts
1
2
3
Wind-up tube
Wind-up for the release-liner
Emergency stop button
Image guide
To help infeed images. It is removable when
mounting.
4
5
6
Upper unwind shaft
Unwind brake
The shaft is suitable for rolls having a 3-inch core
A simple means of setting the unwind tension.
Control panel
Controls rotation of the rolls, temperature and
standby.
7
8
9
Nip knob
To adjust the gap between the rollers
Activates bottom heater (if equipped)
Shows how to preset the machine.
Bottom Heater Switch
Process control sheet
10 Lower unwind shaft
The shaft is suitable for rolls wound onto a 3-inch ID
core
11 Foot switch
To engage slow mode.
The ID-label is located on the rear side of the machine.
12
Unit description
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4.1 Control panel
1
2
1
2
3
4
Drive symbol
area
LED run forward Lit when machine runs
forward
3
Button run
forward
Push button
4
5
6
LED optical
safety system
Lit when light beam is not
blocked.
5
6
Stop button
Push button
LED run reverse Lit when machine runs
reverse
7
7
8
Button run
reverse
Push button
Speed
adjustment
knob
8
9
LED
temperature
setting
9
10 Temperature
setting button
Toggle push button to
preset the temperature.
10
(press 2 seconds to switch
the heating system off)
11
12
11 Power button
12 Power LED
Toggle push-button (press
2 seconds)
Lit when machine is
switched on.
Figure 8
4.2 Motor control
The speed of the rollers is continuously adjustable between 0 and 2.13m/min (0 and
7ft/min) Pressing the ꢀ key runs the rollers in forward direction, pressing the ꢁ key
reverses the direction of the rollers. The stop key stops the roller movement.
Unit description
13
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4.2.1 Slow-mode
The machine has a slow-mode, which can be activated by pressing the foot switch. To
maintain slow-mode, keep the foot switch pressed.
WARNING:
ONCE THE MACHINE IS RUNNING IN SLOW-MODE, INTERRUPTING
THE PHOTOELECTRIC EYES DOES NOT STOP THE MACHINE; AN
AUDIBLE BEEP WILL BE HEARD, AND THE ROLLER SPEED WILL BE
DECREASED. RELEASING THE FOOT SWITCH WILL STOP THE
MACHINE.
Changing from slow-mode to normal running mode without stopping (to prevent
stop marks on the substrate):
• During slow mode (keep the foot switch pressed), press the ꢀ (forward) button on the
control panel. The machine will run at the pre-set speed.
• Next, release the foot switch.
• Finally release the ꢀ (forward) button.
Changing from normal mode to slow-mode without stopping:
• Press the foot switch
Note: Releasing the foot switch will stop the machine.
4.2.2 Reversing the machine
To reverse the rotation of the rollers, press the ꢁ (reverse) button. As long as the button is
pressed, the machine will run in reverse direction, at a speed of 0.6 m/min for heated
machines and 1.2 m/min for cold machines. Releasing the button will stop the machine.
WARNING:
CARE MUST BE TAKEN NOT TO HAVE LOOSE CLOTHING, LONG
HAIR, JEWELLERY AND FINGERS PINCHED BETWEEN THE PULL
ROLLERS AT THE REAR SIDE OF THE MACHINE.
The rotation of the rollers will stop when:
• The photoelectric eyes in front of the main rollers are interrupted
Note: This does NOT happen when the foot switch is used (slow-mode).
• An emergency stop button is pressed
• The foot switch is pressed for a short moment
• Excessive unwind tensions are set (the motor will be shut off electronically, press the
stop button on the control panel to reset).
• The stop button on the control panel is pressed
14
Unit description
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4.3 Unwind brakes
Tighten the supply brake so that it applies sufficient tension to laminate. Turning the
knurled collar in a clockwise direction increases the breaking tension applied on the
laminate. Turning the collar counter-clockwise decreases the tension. The best setting for
the brake tension is determinate by the materials you are using and is learned through
experience.
4.4 Roller nip settings
Whenever you mount onto a board, etc., it is important to adjust the rollers to create a gap
nearly equal to the thickness of the board being used. This is done so that anything
passing between the rollers will receive the right amount of pressure and prevent damage
to the roller’s rubber surface (and possibly the board).
How to set the nip:
Determine the thickness of the board that you will use for mounting.
Adjust the nip setting. Grasp the nip-knob with your right hand and push in approximately
¼” (6mm) to the left. Once the knob has disengaged from the stop, it may be rotated
forward or backward (clockwise or counter-clockwise, as viewed from the right hand side
of the unit), until the desired value is opposite the window at the base of the knob.
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 correspond to the ‘Pouch board’ thickness.
There is also fully closed stop for film only applications.
Note:
For non-standard substrate thickness, select the next lowest nip-setting
i.e.; 7mm board – select ¼” (6mm) nip.
4.5 Image guide storage place.
When not in use, the Image Guide can be stored in the stand.
Figure 9
Unit description
15
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5 PROCESS CONTROL SHEET
Pressure Sensitive
Thermal
Application
Recommended SEAL
products
Unwind
Speed
2 - 4ft/min
(0.6 -
1.2m/min)
2 - 4ft/min
(0.6 -
Unwind Recommended SEAL products
Speed
2 - 4ft/min
(0.6 -
1.2m/min) off
2 - 4ft/min
Temp
top
Print Shield
Print Mount
Print Shield
top
Print Guard UV/Jetguard
195 F / 90 C
Rigid Display
bottom
bottom
Print Mount
top
top
Jet Guard
195 F / 90 C
Flexible Display
(0.6 -
bottom
Carrier board/release paper
Print Shield
Floorguard**/Deep
Crystal/Sandtex*
1.2m/min)
bottom
ThermaShield
1.2m/min) 195/250 F / 90/121 C
2 - 4ft/min
(0.6 -
1.2m/min)
2 - 4ft/min
Floor Guard/Jet Guard Deep
Crystal
Pop-Up Display
(0.6 -
1.2m/min)
top
top
195 F / 90 C
bottom
PS Stoplight
bottom
Stoplight 220/320
195/250 F / 90/121 C
Print Shield Floor
Guard**/Sandtex*
2 - 4ft/min
(0.6 -
1.2m/min)
2 - 4ft/min
(0.6 -
1.2m/min)
top
top
Floor Guard
195 F / 90 C
off
Floor Graphic
bottom
Print Mount Removable
bottom
Print Mount Removable
Application
Recommended SEAL
products
Unwind
Speed
Unwind
Speed
Temp
2 - 4ft/min
(0.6 -
1.2m/min)
2 - 4ft/min
(0.6 -
1.2m/min)
top
Print Shield
top
Jet Guard UV/ThermaShield
195/250 F / 90/121 C
Poster - Roll and
Ship
bottom
top
Carrier board/release paper
Print Shield
bottom
top
Jet Guard UV/ThermaShield
Jet Guard UV/ThermaShield
195/250 F / 90/121 C
195/250 F / 90/121 C
2 - 4ft/min
(0.6 -
1.2m/min)
2 - 4ft/min
(0.6 -
1.2m/min)
Presentation
Board
bottom
top
Print Mount
bottom
top
Print Mount
off
2 - 4ft/min
(0.6 -
1.2m/min)
OptiMount Ultra
Backlit Display
Vinyl Banner
bottom
Carrier board/release paper
bottom
top
bottom
Print Shield
top
bottom
Print Guard UV
195 F / 90 C
off
2 - 4ft/min
(0.6 -
1.2m/min)
2 - 4ft/min
(0.6 -
1.2m/min)
Place printed media on
bottom unwind and/or use
release paper
Place printed media on bottom
unwind and/or use release paper
For best results, encapsulation applications are recommended for dual heated roller operation only.
NOTE: in some applications, the performance of pressure-sensitive films & adhesives can be improved by applying them warm (125F (50C)).
* Only available in Europe ** Only available in the US
Figure 10
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6 APPLICATION PROCESSES
6.1 Loading the machine
The following steps outline the basic procedure that have to be used for loading materials,
webbing the laminator and setting the brake tension for the materials you will be using. To
load and unload the material shafts, it is necessary to access the machine from the rear
side.
Select the film(s) that you will use on the top (and bottom) of the images, it is advisable to
use slightly wider width films compared to the print width. This way the print can be
trimmed with a border, so as to reduce waste, but be enough to leave a border.
Always work in the center of the machine.
Check which temperature setting has to be used for your materials. (see figure 10)
1
Figure 11
6.1.1 Loading film onto a machine equipped with the interlock bracket.
• Remove the desired supply shaft (top or bottom) by pushing the interlock bracket (1) in
the upper position and sliding the autogrip shaft to the right against the spring
pressure.
• Release the interlock bracket when the shaft is completely to the right.
• Lift the shaft out of the laminator.
• Slide the shaft into a material roll. Ensure that the rubber blocking cords are on the top
and bottom of the shaft for easy loading.
Application Processes
17
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1
Figure 12
6.1.2 Loading film onto a machine equipped with the cam lock system.
• Remove the desired supply shaft (top or bottom) by moving the cam handle (1) down
to the open position.
• Lift the autogrip shaft out of the laminator.
• Slide the shaft into a material roll. Ensure that the rubber blocking cords are on the top
and bottom of the shaft for easy loading.
CAUTION
Take care that the ends of the shaft do not become damaged during the
loading and unloading.
6.1.3 Loading the unwind shaft into a machine equipped with the interlock bracket.
• Place the shaft, including the material, into the laminator by inserting it onto the left-
hand supply shaft holder.
• Push the interlock bracket (see figure 11) upward with your finger before sliding the
autogrip shaft further.
• Press against the spring pressure, until you can place the other end of the shaft onto
the RH holder and onto the left-hand side holder.
• Center the material roll in the laminator.
• Rotate the unwind shaft until it locks onto the unwind brake.
6.1.4 Loading the unwind shaft into a machine equipped with the cam lock system.
• Place the shaft, including the material, onto the support blocks on the laminator.
• Move the cam handle up to the closed position.
• Center the material roll in the laminator.
• Rotate the unwind shaft until it locks onto the unwind brake.
18
Application Processes
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6.2 Webbing the films
After the laminator has heated up;
• Remove the infeed table. If applicable, the infeed table can be stored temporarily on
the stand.
• Unroll the film on the top supply shaft, so that an adequate length is hanging over the
top roller (see figures 13 & 14). If necessary, release the supply shaft brake.
• If using a film with release liner, peel back liner and attach it to the wind-up tube.
Figure 13
Figure 14
No release liner
With release liner
• When using a laminate on the bottom, repeat the above procedure for the bottom
supply-shaft.
• Stick the lower web on the upper web (figure 15, 16 or 17)
Figure 15
Figure 16
No release liner
With release liner
Application Processes
19
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Figure 17
Alternative way for webbing film on the bottom unwind.
• Use the provided leaderboard to push the film(s) through the nip (figure 18 or 19).
Figure 18
Figure 19
Refer to the following sections for specific webbing diagrams based on the process you
are performing.
20
Application Processes
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6.3 Feeding images
To aid feeding images, the laminator is
provided with an “Image Guide”. This device
can be positioned in front of the top roller and
it prevents the images from interrupting the
photoelectric eyes. When changing the roller
nip, the Image Guide moves together with the
top roller.
To position the Image Guide, place it on the
brackets, as shown in figure 20 and align the
slots with the screwhead and push it
completely towards the top roller.
Figure 20
6.3.1 How to feed images:
For good results, the process requires that the images be fed through correctly. The
leading edge of each image must be flat all the way across or any wrinkles or creases in
the image will show when encapsulated - perhaps even magnified. To aid feeding, the
leading edge should also be straight.
Feed the image into the machine ensuring that the edge is parallel to the roller. To help
this, the edge of the image can be seen through the windows in the “image guide”, which
is in front of the rollers.
Note:
Do not stop the motor while an image is being finished as this can cause marks in the
output.
Application Processes
21
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6.4 Laminating and adhesive coating (Decaling)
This process involves sandwiching an image between either a hot or cold laminate on the
face of the image and a pressure-sensitive adhesive on the rear. This process can be
used to create self-adhesive images for mounting down onto various substrates.
Once the machine reaches the operating temperature, the top roller may be raised and
webbed as per the following diagrams. Refer to the Temperature/Speed chart on the front
side of the machine and in the manual for settings and recommended film combinations
Decal process with liner;
Over-laminate on top and Pressure-sensitive mounting on bottom.
Linered films:
Pull the film down from the top unwind position.
1. Split the film from the release liner, flip the liner back (fig.21) and pull the film evenly
across the face of the rollers.
2. Place the wind-up idler into the brackets.
3. Place the scrape core on the idler and the top roller.
4. Attach the liner onto the scrape core, using a piece of tape.
5. Push the films all the way through the machine, using the leaderboard.
6. Replace the infeed table.
7. ALWAYS INSTALL THE IMAGE GUIDE.
Figure 21
Figure 22
Figure 23
YOU ARE NOW READY TO FEED IMAGES.
22
Application Processes
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6.5 Decaling without liner
Preparation:
Select the films that you will use on the top and bottom of the images, it is advisable to
use slightly wider width films compared to the print width. This way the print can be
trimmed with a border, so as to reduce waste, but be enough to leave a border. Place the
material rolls into the machine with the adhesive facing you. Web as follows:
Figure 24
Figure 25
Linerless films:
1. Pull the film down from the upper unwind position and place the film evenly over the
top roller.
2. Pull the film from the lower unwind position and stick them together on the top roller.
3. Press the laminates into the nip using the provided leader board.
4. Replace the infeed table.
5. ALWAYS INSTALL THE IMAGE GUIDE.
YOU ARE NOW READY TO FEED IMAGES.
Application Processes
23
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6.6 Mounting
This process involves mounting down previously prepared decals onto a substrate. No
films or adhesives are used in this process.
To perform this process, it is necessary to remove the Image Guide, you can store the
Image Guide in the machine stand (See fig. 9)
6.6.1 To mount decals onto a substrate
Place the mounting board on a flat surface. Lay your image face down on the mounting
board and expose approximately 25 mm (1”) of the adhesive by peeling back the release
paper along one of the edges. Fold the release paper back making an even crease.
Turn the image over and carefully position the exposed adhesive edge of the image
squarely onto the board.
Once positioned correctly, press the image firmly down onto the exposed adhesive from
the centre toward the edges to ensure smooth surface. This is the edge that will be fed
into the rollers first.
Ensure that the nip setting of the rollers corresponds to the board thickness.
Push the edge of the board into the rollers and depress the foot switch until the board and
image are just caught by the nip.
Flip the un-tacked portion of the image over the top roller with one hand so that the
release paper can be peeled off the image with the other hand. Depress the foot switch to
feed the board through the rollers. At this point, continuous run can be selected by
pressing one of the speed settings.
Take care that the rollers do not grab the liner
When the end of the board is near the nip, you may want to slow the machine down. To
do this, just press the foot switch to enter slow mode. Releasing the foot switch will stop
the machine.
Remove the mounted image from the rear of the laminator and trim it if necessary. If the
board is accidentally sent in too far at first, the release liner will get caught and will be
impossible to pull back. In this case, stop and reverse the motor until the liner can be
pulled away. The image must be held against the roller while the board feeds through to
prevent wrinkles. As the process becomes more familiar, the speed of the laminator may
be increased to make the process more efficient.
Take care that the release liner does not trip the optical safety system.
Note:
Only hard boards (PVC, Polystyrene, MDF, hard board, etc.) that are of the same
thickness as the nip settings should be used, otherwise damage to the rollers can
occur.
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6.7 Encapsulating
This process involves completely sealing an image between two heat-activated films.
Once the machine reaches the operating temperature, the laminator may be stopped, the
top roller raised and webbed as per the following photographs and diagrams, refer to the
Temperature/Speed chart on page 16 for settings and recommended film combinations.
Preparation:
Note:
Check if the film widths of the lower and upper web are the same!
It is advisable to use slightly wider films compared to the print width. This way the print can
be trimmed with a border and not too much film waste is generated, Mount rolls onto the
unwind shafts with adhesive facing you. Web as follows:
1. Remove the image guide and the infeed table.
2. Pull the film evenly over the top roller and across the face of the rollers.
3. Split the film from the release liner and pull the film evenly across the face of the
rollers.
4. Pull the film up from the bottom unwind station and over the face of the top laminating
roller. The films will then heat and stick together.
Note:
Keep the film under tension (turning the top unwind manually) to prevent the
photoelectric eyes being tripped.
5. Place the feed table into position, and set the roller nip to 1/16” (2mm) to
accommodate for the thickness of the leaderboard.
Note:
Use the 2mm thick leader-board supplied with the machine.
6. Depress the foot switch and then using the provided leader-board push the films into
the nip of the rollers. Using the foot switch, advance the leader between the pull rollers
until the end comes out of the pull-rollers. Release the foot pedal and set the nip knob
to 0mm.
7. Moving to the rear of the laminator, with the film and leaderboard hanging out of the
machine, cut off the leaderboard from the front of the laminator, run the film until the
output is wrinkle free. Best results will be obtained when the film unwind tension is
zero or very light.
Wrinkles, visible on the roller face do not show on the output.
8. Refit the image guide on the infeed table.
YOU ARE NOW READY TO FEED IMAGES.
Application Processes
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6.8 Pre-Coating
This process is used to coat substrates with a self-adhesive coating onto which images
can be mounted. The same process is used to create a carrier board (sled).
Preparation:
Mount the roll of self-wound pressure sensitive adhesive onto the top unwind of the
laminator with the exposed adhesive facing you.
Have a leader board ready of the same thickness as the boards to be coated.
1. Pull the adhesive down from the top unwind station and over the top roller evenly,
and down across the face of both main rollers. Remove the infeed table and the Image
Guide for a moment to do this.
2. Measure the thickness of the board(s) to be coated, and select the correct nip setting.
3. Press the foot switch and, using the leader board, push the adhesive into the roller nip.
Release the foot switch when the rear edge of the leader board is almost leaving the
roller nip.
4. Position the board to be coated into the nip, and choose a speed setting.
Note:
When coating boards, ensure that the next board to be coated follows the previous
board without any gaps.
Follow the last board being coated with the leader board once again to allow the
final board to clear the laminating rollers and then stop the motor and raise the top
roller.
6.9 Mounting using a ProSEAL® Mounting Board
1. Refer to the instruction sheet packed with each box of ProSEAL Mounting Boards for
specific instructions on mounting with a ProSEAL Board.
2. Also, refer to the instruction sheet for information on Compatible Media, Process
Conditions and Technical Information.
3. Place the image to be mounted on the adhesive-coated side of the mounting board
(dull side of the board). Cover your print with the “cover sheet” as marked; (included
with each box of ProSEAL Mounting Boards); please be sure that the board is
completely covered by this sheet.
4. Set the Control Knob to the correct setting that matches the Mounting Board
thickness.
5. Insert the board into the inlet opening. Ensure the board will enter 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.
6. The board will feed through the laminator and automatically exit at the rear of the unit.
CAUTION! The board will be hot! Allow it to lie flat while cooling.
26
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6.10Mounting and Lamination using a ProSEAL®pouch Board.
1. Refer to the instruction sheet packed with each box of ProSEAL Pouch Boards for
specific instructions on mounting/laminating with a ProSEAL Board.
2. Also, refer to the instruction sheet for information on Compatible Media, Process
Conditions and Technical Information.
3. A ProSEAL Pouch Board consists of a SEAL foam board mounting board with a piece
of film on top. The film is sealed to the board along one of the short sides. Carefully
examine the board to deter-mine which edge is sealed. Starting at one of the corners,
opposite the sealed edge, gently lift and peel back the film. Care should be taken not
to break the sealed hinge.
4. Center the image to be laminated on the board and lay the film back over it.
5. Set the Control Knob to the correct setting that matches the Pouch Board thickness.
6. Slowly insert the Pouch Board into the inlet opening. Ensure that the Pouch Board will
enter centered and straight. A gentle push may be required to start the board into the
machine. Hold the edges of the Pouch board until it is engaged and the laminator
begins pulling it on its own.
7. The Pouch Board will feed through the Laminator and automatically exit at the rear of
the unit.
8. CAUTION! The pouch board will be hot!
Allow it to lie flat while cooling.
Note:
If there is any dirt or adhesive on the surface of the board, it can be removed by
dampening a lint free cloth with ISO Propyl Alcohol (IPA) and wiping the surface.
WARNING:
ALWAYS USE CARE 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).
Application Processes
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6.11Encapsulating with a ProSEAL® Flexible Pouch using a ProSEAL®
Carrier Board
1. Refer to the instruction sheet packed with each box of ProSEAL Flexible Pouches for
specific instructions on encapsulating.
2. Also, refer to the instruction sheet for information on Compatible Media, Process
Conditions and Technical Information.
3. The ProSEAL Flexible Pouch consists of two pieces of film that are hinged at one end,
along a short side. Separate the two pieces starting at the end opposite the hinge.
Take care not to break the hinged seal.
4. Insert the article to be laminated in the pouch so there is at least a 1/8" (3.5mm)
border around each of the sides. This ensures that moisture never reaches the
image.
5. Place the pouch with the image on the carrier board included with the Flexible
Pouches or ProSEAL Sled carrier. (The ProSEAL Sled is a carrier board to assist in
the handling of large Flexible Pouches. It is made of materials that will not damage or
cause excessive wear to the ProSEAL Laminators.) Smooth out any wrinkles with the
side of the hand or a soft flexible squeegee.
6. Tape the leading edge of the pouch to the sled using masking tape.
7. Adjust the Control Knob to the 3/16" (5mm) setting for the ProSEAL Sled. Be sure that
the heat is on. (max. temperature)
8. Insert the carrier board with the Flexible Pouch on top into the inlet opening. Ensure
that the carrier board is centered and straight. A gentle push may be required to start
the carrier board into the machine. Hold the edge of the carrier board until it is
engaged and the Laminator begins pulling it on its own.
9. The carrier board will feed through the Laminator and automatically exit at the rear of
the machine.
10. CAUTION! The carrier board will be hot!
Allow it to lie flat and cool before removing the tape.
Note:
If there is any dirt or adhesive on the surface of the board, it can be removed by
dampening a lint free cloth with ISO Propyl Alcohol (IPA) and wiping the surface.
WARNING:
ALWAYS USE CARE 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).
28
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7 MAINTENANCE & CLEANING
Cleaning of the Machine
The equipment must be disconnected from the mains before cleaning.
The laminator may be cleaned by the operator with a lint-free cloth, lightly dampen 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.
Do not use an abrasive cleaner, which can damage the painted surfaces.
Do not allow water or liquids to enter the electrical circuits, which may cause personal
injury and / or damage the equipment when power is applied.
Cleaning the roller procedure: Use the Image roll-cleaner to remove the excess adhesive
from the rollers. This is best done with the rollers hot. When cleaning the upper roller,
place a piece of scrap foam board under the roller to prevent the removed adhesive
remnants from falling onto the lower roller.
Note:
For adhesive that is difficult to remove, allow the rollers to cool and use isopropyl
alcohol (IPA) and a clean, lint-free cloth. Never pour isopropyl alcohol (IPA) directly
onto the unit.
WARNING:
ALWAYS USE CARE 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).
Maintenance & Cleaning
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8 TROUBLESHOOTING
List of common problems and solutions that the user can correct:
Problem
cause
solution
The power LED does not
come on, when the machine
is switched on.
there is no power
check if the power cable is
plugged into the mains wall
outlet.
check the fuse located on the
rear side.
LED power is flashing
the voltage from the
supplier is too low
Machine voltage 115V:
the incoming voltage must be
between 90-130V AC.
Machine voltage 230V:
the incoming voltage must be
between 200-250V AC.
LED Forward and reverse
are flashing
Drive-motor is in
overload
the machine is in overload
restart the machine
For technical assistance, please contact your technical service representative (see front
cover)
30
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9 GLOSSARY OF TERMS
Decal
An image that has been laminated on top (either heat-activated or pressure-sensitive)
with an adhesive backing.
Heat-Activated Laminates
Laminates with a dry adhesive that is activated when heat is applied. Once applied to
an image the adhesive forms a strong bond adhering the laminate and the image
together.
In-Feed
The side of the laminator from which images are fed.
Leader Board
A piece of foam board (about 4’ x 2 inches) used to push films into the nip. Also used
for mounting or pre-coating boards to prevent adhesive from getting onto the rollers and
sealing edges.
Mil
Refers to the thickness of the laminate in 1/1000ths of an inch.
Mounting
Applying an image onto some kind of foam board or substrate.
Nip
The spot where the top and bottom rollers meet.
Out-Feed
The side of the laminator from which completed images emerge.
Pre-Coating
The process of coating a substrate with an adhesive mounting film onto which and
image can be mounted.
Press
The amount of force in distance put on anything that passes between the top and
bottom rollers. Normally a press of .025 is sufficient.
Pressure-Sensitive Laminates
Laminates with a wet adhesive, which forms a bond between the protective laminate
and the surface of the image being laminated. Used primarily for fast mounting
applications and recommended for heat-sensitive thermal and photographic prints.
Release Liner
The backing on a pressure-sensitive laminate or mounting adhesive. After peeling the
release liner off, the adhesive layer becomes exposed.
Sled (Carrier Board)
A piece of smooth, non-crushable board (preferably Masonite) coated with a mounting
adhesive and leaving the release liner on to provide the necessary non-stick surface. A
piece of foam board can also be used, but it will not have the longevity of the Masonite
board. Sleds are used when laminating one side of an image only.
Substrate
The material to which an image is mounted or affixed.
Glossary of Terms
31
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10 LIMITED WARRANTY
SEAL Graphics warrant to the original consumer purchaser that all new Seal® laminators
that prove defective in materials or workmanship within the applicable warranty period will
be repaired or, at our option, replaced without charge. The applicable warranty shall be
one year from date of purchase with the exception of silicone roll coverings that will be six
months from date of purchase. This warranty does not apply if it is found that at any time
the equipment has not been used for its intended purpose.
"Original consumer purchaser" means the person whom first purchased the product
covered by this warranty other than for purpose of resale. The warranty extends to and is
enforceable by only the original consumer purchaser, and only for the period (during the
applicable term) which the product remains in the possession of the original consumer
purchaser.
For more information regarding this warranty, please contact your distributor.
ATTENTION!
CHANGES OR MODIFICATIONS TO THIS UNIT NOT EXPRESSLY APPROVED BY
THE PARTY RESPONSIBLE FOR COMPLIANCE COULD VOID THE USER'S
AUTHORITY TO OPERATE THE EQUIPMENT.
ATTENTION!
ANY UNAUTHORIZED CHANGES OR MODIFICATIONS TO THIS UNIT WITHOUT
OUR PRIOR WRITTEN APPROVAL WILL VOID THE USER'S WARRANTY AND
WILL TRANSFER HEALTH AND SAFETY OBLIGATIONS TO THE USER.
Note:
This equipment has been tested and found to comply with the limits for a class A digital
device, pursuant to part 15 of the FCC rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates uses and can radiate radio
frequency energy and, if not installed and used in accordance with Owner’s Manual,
may cause harmful interference to radio communications. Operation of this equipment
in a residential area is likely to cause harmful interference in a residential area is likely
to cause harmful interference in which case the user will be required to correct the
interference at his own expense.
32
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11 INDEX
A
L
Application Processes .....................17
Liability Statement .............................2
B
M
Board Thickness................................5
Maintenance....................................29
Max. Speed........................................5
Max. Working Width ..........................5
C
Cleaning...........................................29
N
D
Nip .....................................................5
Dimensions........................................5
R
E
Roller Pressure..................................5
Environment Conditions.....................8
S
G
Speed ................................................5
Standardized Symbols.......................2
Glossary of Terms............................30
T
I
Technical Specifications.....................5
Image Guide....................................16
Interlock backet................................19
W
Weight ...............................................5
Workspace Requirements .................8
Index
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