SEAL AQUA AS-1600 Owner`s manual

AquaSEAL
AS-1600
Seal Brands … the finishing touch.
Owner’s
Operation
Manual
Important:
Read and understand all safety information before operating.
AquaSEAL AS-1600
Liquid Laminator
Preface
This manual contains the following Sections:
Section 1.
Introduction – provides a basic overview of the AquaSEAL™ AS1600 liquid laminator, and contains illustrations of the basic hardware
components.
Section 2.
Operating Procedures – describes procedures for setting up, starting,
stopping, and controlling the machine.
Section 3.
Troubleshooting/Miscellaneous – describes problems that may be
encountered and lists corrective actions to resolve them. Information
on who to call for after sales support.
1
Table of Contents
General
Warranty Statement
Safety Information
Safety Labels
……………………………………………………….. 3
…………………………………………...…………….
………………………………………………………………
4-5
5
Section 1. Introduction
Hardware Overview
……………………………………………………….
6-10
Section 2. Operating Procedures
Tools / Supplies Needed ……………………………………………………
11
Loading the Sealant …………………………………………………………
11
Loading the Media…………………………………………………………...
11
Pre-heat the Laminator ………………………..……………………………
12
Web the Laminator……………………………………………………...……
13
Run the Laminator ………………………………………………………..….
14-15
Cleaning the Laminator……………………………………………..……….
16
Section 3. Troubleshooting/Miscellaneous
Troubleshooting ……………………………………………………..………
17
After Sales Support……..……………………...……………………………
19
2
Warranty
SEAL® Graphics warrants to the original consumer purchaser that each new SEAL® Image® Laminator, which
proves defective in materials or workmanship within the applicable warranty period, will be repaired or, at our
option, replaced without charge.
Effective November 1st, 2002 the applicable warranty period for New Equipment shall be one year (parts), six
months (labor and rollers) from date of purchase.
This 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.
"Original consumer purchaser" means the person who first purchased the product covered by this warranty other
than for purpose of resale. This warranty does not apply if it is found that at any time the equipment has not
been used for its intended purpose.
Effective November 1st, 2002 the applicable warranty period for Refurbished Equipment shall be ninety days
(parts and labor, excluding rollers). Rollers are not covered under warranty. The applicable warranty period for
Demo Equipment shall vary, not exceeding the maximum warranty period stated herein. All Demo Equipment
comes with a specific warranty, which will be stated at the time of purchase. If warranty period is not detailed in
writing, there is no remaining warranty.
Please ask your dealer, distributor, or sales representative for details.
NOTE: Used and Not Refurbished Equipment is sold on an “AS IS” basis with No Warranty.
For more information regarding this warranty, please contact your distributor.
WARNING! 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.
WARNING! 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
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 which case the user will be required to correct the interference at their own
expense.
©Copyright SEAL® Graphics 2002
All rights are reserved. No part of the document may be photocopied, reproduced, or translated to another
language without the prior written consent of SEAL Graphics.
The information contained in this document is subject to change without notice and should not be construed as a
commitment by SEAL Graphics.
SEAL Graphics assumes no responsibility for any errors that may appear in this document. Nor does it make
expressed or implied warranty of any kind with regard to this material, including, but not limited to, the implied
warranties of merchantability and fitness for a particular purpose.
SEAL Graphics shall not be liable for incidental or consequential damages in connection with, or arising out of
the furnishing, performance, or use of this document and the program material, which it describes.
Trademarks Credits
SEAL® is a registered trademark of SEAL Graphics.
Image® is a registered trademark of SEAL Graphics.
AquaSEAL® is a registered trademark of SEAL Graphics.
ProSEAL® is a registered trademark of SEAL Graphics.
3
Safety Information
Intended Use
The AquaSEAL™ AS-1600 liquid a
l minator is intended for use with medium and
large format graphic output. Graphics can vary in widths up to 1.6M (5 ft.) in width
and can be up to 90M (295 ft.) in length (dependent on thickness of media used).
The AquaSEAL™ AS-1600 liquid laminator is intended for use with AquaSEAL™
water based sealant only. Use of solvent-based or other manufacturers sealants
may damage the machine and may void any warranty.
Safety Instructions
Caution
When handling any chemical products, read the manufacturers’ container labels and
the Material Safety Data Sheets (MSDS) for important health, safety, and
environmental information.
To obtain MSDS Sheets for AquaSEAL™ Products, Please call your local distributor.
In case of emergency, please telephone: +44 (0)1268 530 331 Europe, or
(800) 486-6502 USA
When using any equipment, always follow the manufacturers’ instructions for safe
operation.
Warning
Avoid contact with heat source during use. Wear heat resistant gloves and safety
glasses. Failure to avoid contact with hot surfaces may cause burns. Always
observe manufacturers recommendations when handling chemicals.
4
Safety Information
General
q
Do not operate the machine until it is connected to the proper power source.
Refer to Installation instructions located inside control cabinet.
q
It is strongly recommended that the machine is fed from an “Earth Leakage”
protected electrical outlet – if in doubt, please contact Hunt Technical Services
(contact details in “Miscellaneous” section at the rear of the manual) or consult a
licensed electrician.
q
Familiarize yourself with the layout of the Control Panel, and with the operation of
the sealant delivery system.
q
Do not wear loose clothing, and contain loose hair to avoid becoming entangled
with moving parts of the machine.
q
Comply with all safety warning signs, labels, and instructions.
q
Operators should be trained on the proper use of the machine and all safety
procedures.
q
Provide fresh water, clean towels and rubber gloves for use during cleanup.
q
It is advisable to wear eye protection when filling/emptying sealant tank. Always
Provide an approved emergency eyewash station adjacent to the machine.
Figure 1 shows the safety labels that appear on the AquaSEAL™ AS-1600.
Emergency Stop Labels
High Voltage Warning Label
Rotating Parts Warning Labels
Temperature Warning Labels
Figure 1. Safety Labels
5
Section 1. Introduction
The AquaSEAL™ AS-1600 is a medium to large format media liquid laminator used
to coat graphics with a protective sealant. Operating roll to roll, the media is
threaded under the applicator mechanism, under the drying assembly, and onto the
take-up roller. During operation, the liquid laminator applies sealant onto the printed
graphics and then cures and dries it before winding the media onto the take-up core.
Hardware Overview
Figure 1.1 shows the front view of the liquid laminator. Major components (safety
items shown in red) include the following:
Dam Stop Assembly
Draw Down Assembly
Sealant Tank
Unwind Mandrel
Dryer Panel
Applicator Nozzle
Drip Tray
Figure 1.1 AquaSEAL™ AS-1600 Liquid Laminator Front Views
6
Section 1. Introduction
Hardware Overview (continued)
q
Two Emergency Stop Buttons are fitted to the machine, located prominently on
top of both end cabinets. When pressed, all power is removed from the working
parts of the machine. The machine cannot be used again until the Emergency
Stop Buttons are reset twisting the button ¼ turn clockwise.
When the
emergency stop buttons are reset, the laminator powers up and the power switch
must be reset to begin operation.
q
The Draw Down Assembly is located directly over the Drip Tray and is used to
smooth the coating onto the surface of the media. It is manually raised and
lowered by pivoting the assembly into it’s up or down positions.
q
The Dam Stop Assemblies are used to stop the coating from flowing off the
edges of the media during operation. They are positioned at the edges of the
media and are composed of two separate parts. An inner dam bracket is
positioned on top and at the edges of the media and outer bracket positions up
underneath the media to ensure that the dam stops hold a seal during operation.
q
The Drip Tray is located directly under the Draw Down Assembly and is used to
catch any drips of coating that may fall off the edge or end of the media during
operation. The Drip Tray pulls out the front of the machine for periodic cleaning.
The Sealant Recovery Trays sit inside the Drip Tray.
q
The Sealant Tank is used to hold the supply of coating (18 liters/5 gallons). It is
positioned on an overhead stand located on the left cabinet of the machine. The
machine has no pump and the coating flows from the tank to the applicator
nozzle by gravity feed and is controlled with flow control valves.
q
The Applicator Nozzle is used to control the flow of coating delivered to the
surface of the media. Coating flows from the Sealant Tank to the Applicator
Nozzle and is flooded onto the surface of the media.
q
The Unwind Mandrel is used to load a roll of media onto the front of the
machine for roll to roll operation. It is a cantilevered assembly located low on the
front of the machine. On the left side of the Unwind Mandrel is located a Tension
Braking mechanism for applying back tension to the web. It is adjusted by
turning the knurled collar. Core alignment is accomplished by sliding the core
onto the mandrel and positioning in the desired position. Once the drive starts
the Auto-grip bands will engage the core and enable the Tension Brake.
7
Section 1. Introduction
Hardware Overview (continued)
q
The Take-up Mandrel is the primary drive for the machine used to pull the
material through the machine and wind it onto the take-up core. It is a
cantilevered assembly located low at the rear of the machine. It pivots from the
left side of the machine and allows for the cores to be loaded and unloaded.
Core alignment is accomplished by sliding the core onto the mandrel and
positioning the core so it is aligned with the unwind core. Once the drive starts
the Auto-grip bands will engage the core and begin pulling the media through the
machine.
q
The Dryer Panel is located on top of the machine running between the two end
cabinets. This assembly is used to dry and cure the coating before it winds up
on the Take-up roller. Lifting the handle located on top of the panel raises the
dryer panel. The Dryer panel should be in the up position during web-up and
heat-up procedures. Once the machine is ready for operation it is lowered into
it’s down position.
Note: The Dryer Panel has fans in the top of it that force air through
perforations in the face of the Heater. These fans are used to push
humidity out of the Dryer Panel compartment and assist in drying the
media.
q
The Control Panel contains all the displays, controls, and indicators required to
operate the laminator. Refer to Figure 1.2 and its accompanying descriptions.
•
Main Power is used to turn power On and Off to the machine. It is also used
to reset the machine after an E-stop switch has been depressed.
•
Heater is used to turn power On and Off to the Heater Assembly.
•
Temperature Controller is used to adjust the set point of the dryer panel.
The temperature is adjusted by holding the set button down and using the UP
and DOWN arrow buttons to scroll to the desired temperature setting. When
power to the machine is ON the controller will display the actual temperature,
and when the SET button is depressed, it will display its desired running
temperature. The display on the controller will be ON regardless of whether
the Heater switch is On or Off.
•
Speed Control is used to adjust the speed setting of the Drive.
8
Section 1. Introduction
Hardware Overview (continued)
Main Power
Heaters
Engaged
Temperature
Controller
Speed
Controller
Figure 1.2 Control Panel
q
The Main Power Circuit Breakers provide over-current protection.
Main Power
Circuit Breakers
Power Cable
Entrance
Figure 1.3 Circuit Breaker / Power Cable Entrance
q
The Power Cable Entrance is the point where the cable connected to the power
source enters the machine. It connects the machine to the following power
sources:
•
228-240VAC, 50/60 Hz, single phase, 30 Amps.
Maximum Power Consumption: 6000 Watts
It is strongly recommended that the machine is fed from an “Earth Leakage”
protected electrical outlet – if in doubt, please contact Seal Graphics Technical
Services (listed at rear of manual) or consult a licensed electrician.
9
Section 1. Introduction
Hardware Overview (continued)
Figure 1.3 shows the rear view of the liquid laminator. Major components (safety
items shown in red) include the following:
Take-up Mandrel
Figure 1.4 Rear View
10
Section 2. Operating Procedures
All operating functions are initiated at the control panel. The following section
outlines general procedures and describes specific functions used to coat media.
This section is divided into the following sub-headings:
1.
2.
3.
4.
5.
Loading Materials
Pre-heat the laminator
Web the laminator
Run the laminator
Cleaning the laminator
Tools/Supplies Required:
•
•
•
•
•
Absorbent towels: soft, lint free, disposable
Lab coat or smock
Rubber gloves
Bucket of water
3M Scotchbrite pad
1. Loading Materials
Loading the Sealant:
1. Disconnect quick-connector fitting in supply line and remove the lid from the
Sealant Tank.
Figure 2.1 Quick Disconnect
2. Pour AquaSEAL™ 110 or AquaSEAL™ 510 into the Sealant Tank. The sealant
tank holds 18 Liters (5 US gallons) of sealant. (Be careful not to add too much
sealant to the tank.)
3. Position Sealant Tank onto the tank pedestal and reattach the quick-connector
fitting in the supply line. (Ensure that the Flow control valve is closed)
4. Using rolled media, position the roll on the Unwind Mandrel. The media must be
oriented to feed into the machine with the image side up.
11
Section 2. Operating Procedures
2. Pre-heat the Laminator
All Pre-heat control operations are controlled from the Control Panel as shown in
Figure 2.2
1. Switch machine to START at the Main Power Switch
• Laminator will power-up
• Dryer Panel is in the UP position.
• Heaters are OFF.
Set Button
Up Button
Down Button
Figure 2.2 Heater Control locations
2. On the Heater Controller, press and hold the SET button to check the set-point
temperature. Adjust the set point by holding the SET button down and using the
UP/DOWN arrows to scroll to the desired temperature setting.
Note: Most vinyl’s run well with a SET POINT temperature of 315°C (600°F)
dependent on speed.
3. Press the Heater Switch to ON to power the Dryer Panel and begin heating.
4. Once the machine reaches its SET POINT it is ready to be operated.
12
Section 2. Operating Procedures
3. Web the Laminator
A Web diagram is provided in Figure 2.3 Below
Figure 2.3 Web Diagram
Method
1. Lift Unwind Assembly to the UP position.
2. Load a take-up core onto the Take-up Mandrel and align with the edge of the
roll of media on the Unwind Mandrel.
3. Pull media up over the web Idler, under the Draw down Assembly and under
the Dryer Assembly to the Take-up Core.
4. Tape material to the Take-up core.
Note: It is important to get the material as straight as possible to ensure a
minimal amount of “telescoping” on the Take-up Roller.
13
Section 2. Operating Procedures
4. Run the Laminator
1. Lower Draw Down Assembly and secure locking pins.
2. Align right and left Dam Stop brackets into position at the edges of the media.
The inner brackets align with the outer edges of the media and lock down by
turning the red knob on top of the bracket. The outer brackets position similarly
next to the inner brackets with the bracket roller sealing against the bottom of the
media. Tighten in place with the red knob on the side of the bracket.
3. Open the Flow Control valves on the applicator Nozzle and begin filling the
reservoir between the Dam Stops.
Figure 2.4 Applicator Nozzle
4. Once coating is spanning between the two dam stops, lower the Dryer Assembly
to the Down position.
5. Turn the Speed Control knob to the desired speed setting.
14
Section 2. Operating Procedures
6. Adjust Brake tension so that the material is pulling through smoothly with no
wrinkles.
Figure 2.5 Unwind Mandrel Brake Adjust
7. When the media being coated comes to an end, the last piece will loose tension;
you will need to manually provide back-tension as the media runs out.
8. Approximately 1.6M (5 ft) prior to the last piece of media going past the Draw
Down Assembly the Flow control valve at the Applicator Nozzle should be
closed.
9. Once the material is through the Dryer Panel, the Dryer switch should be turned
OFF.
10. The finished material is easily unloaded by swinging the Take-up Mandrel out
and slipping the finished roll off the mandrel.
15
Section 2. Operating Procedures
5. Cleaning the Laminator
1. It is important to clean the machine immediately after the end of the material is
completely through the Dryer panel.
2. Switch the machine to Stop on the Main Power Switch.
3. Pull Drip tray out 6 inches and raise the draw down assembly for cleaning.
Figure 2.6 Clean Up View
4. Using a WET cloth, wipe the 2 draw down bars to remove any excess sealant
from them.
Note: Sometimes the tail end of the material will drag a little coating onto the
stainless steel table behind the Draw Down Assembly. It needs to be
cleaned off quickly because the heat from the Dryer Panel will dry it
rapidly.
5. Dry the Draw Down bars with a clean dry cloth.
6. Put cap back on Applicator Nozzle.
16
Section 3. Troubleshooting
The following table lists problems that may occur when using the AS1600 Liquid Laminator.
Recommended corrective actions are provided for all commonly encountered problems.
Problem / Symptom
Causes
Very thin coating
Sealant is diluted with water
Heavy coating
Weight of coating in application
area causes material to sag and
not get wiped off properly
Dirty Draw Down Bar
Overly thinned coating can dry
quickly and streak
Contaminated coating can
clump up and streak
Media has been overheated
Streaked finish
Media wrinkles
Unwind to take-up alignment is
poor
Insufficient back-tension
Telescoping media
Coated Media is wet coming
out of the dryer panel
Non-wets (areas where the
sealant has not adhered to the
film or paper)
Distortions in media
Cracking effect in the coating
Surface impressions occur at
the take-up roll
Sealant in tank develops a
skin over its surface
Roll-feed to take-up alignment is
poor
Insufficient drying
Media surface is contaminated
Sealant is contaminated
Media or inks and sealant are
incompatible
Media is too hot and is
beginning to melt
Media is hot and back tension is
too high
With thick coatings a high heat
setting can cause evaporation to
occur too rapidly causing this
effect
Insufficient drying
Sealant has been left without
agitation for too long and has
begun to dry out
Corrective Action
Remove old coating and refill
with new
Increase break tension on the
Transition and Tension Idlers
Clean the Draw Down Bar
Remove old coating and refill
with new
Remove old coating and refill
with new
Cool down heaters or speed up
drive
Realign the media
Increase brake tension on
Transition and Tension Idlers
Realign the media
•
•
Reduce web speed
Increase the heat panel
temperature
Ensure media is free form
contaminates
Remove old coating and refill
with new
Use a compatible media
Cool down the heaters and/or
speed up the drive
Decrease back tension
•
Lower heat controller
o
setting to 600 F
•
Check web temperature
with IR gun
• Reduce web speed
• Increase heater panel
temperature
Pull skin off the top of the
sealant and add a small amount
of water (1 cup) and mix into
sealant thoroughly.
17
Section 3. Troubleshooting
18
Section 3. After Sales Support
SEAL Brands Technical Service
(For technical assistance & service)
SEAL Brands Technical Service – Europe and
Asia Pacific
(For technical assistance & service)
For UK: Tel: +44 1268 722 400
Fax: +44 1268 729 442 or +44 870 125 5798
For NL: Tel: +31 572 345 500
Fax: +31 572 345 501
Tel: 1-800-486-6502
Fax: 1-800-966-4554
SEAL Brands Customer Service
(For information and placing orders)
Tel: 1-800-257-7325
Fax: 1-800-966-4554
SEAL Brands Customer Service - Europe
(For information and placing orders)
Tel: +31 572 345 500
Fax: +31 572 345 501
Note: SEAL Graphics recommends that your main power be installed by a licensed electrician in accordance with electrical codes in your area.
Specifications subject to change without notice.
Seal Graphics
Americas Corporation
7091 Troy Hill Drive
Elkridge, MD 21075
Tel: 410-379-5400
Fax: 410-579-8960
Seal Graphics
Canada
1601 Matheson Blvd. E
Unit #4
Mississauga, Ontario
Canada, L4W 1H9
Tel: 905-212-9232
Fax: 905-212-9313
Seal Graphics
U.K. Ltd
Unit 1, 1 Watkins Close
Burnt Mills Industrial Estate
Basildon, Essex SS13 1BJ
United Kingdom
Tel: +44 1268 722 400
Fax: +44 1268 729 442
Seal Graphics
Europe BV
Kanaaldijk O.Z.3
P.O. Box 29,
8100 AA Raalte
The Netherlands
Tel: +31 572 345 500
Fax: +31 572 345 501
Seal Graphics
Pacific Limited
Unit A, 13th Floor, Block 1
Leader Industrial Centre
Tsuen Wan,
New Territories, Hong Kong
Tel: +852 2407 3738
Fax: -852 2408 0973
www.sealbrands.com
© 2002 SEAL Graphics
SEAL and Image are registered trademarks of SEAL Graphics
Part #OM1600-E Rev. 8
(11/02)
19