Image Image® 600 MD Laminator ® 6500 Owner’s Operation Manual Image ® 600 MD Laminator
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TABLE OF CONTENTS TABLE OF CONTENTS--------------------------------------------------------------------------------------------------- 2 INTRODUCTION ---------------------------------------------------------------------------------------------------------- 3 WORKSPACE / CONNECTING THE LAMINATOR.................................................................................................4 UNPACKING, SET-UP AND INSTALLATION....................................................................................
INTRODUCTION Thank you for purchasing the Image® 600 MD Laminator. The Image 600 MD has been designed to provide you with years of reliable service. As you become familiar with the laminator, you will appreciate the high quality of production and the excellence in its engineering design. The Image 600 MD is a bi-directional laminator designed for full range, high volume requirements. This includes heat or pressure sensitive lamination, encapsulation and hot or cold mounting of images.
W O R K S P A C E / C O N N E C T IN G T H E L A M I N A T O R CONNECTING THE LAMINATOR Connect the laminator in accordance with details as listed on the identification plate attached to the rear of the laminator. Refer also to the Technical Specifications page for additional information. CAUTION: SEAL Graphics recommends installation of a Ground Fault Interrupter (GFI) circuit breaker if operating the laminator near water or in an area of high humidity.
UNPACKING, SET-UP AND INSTALLATION Only skilled personnel should perform installation. Read and comply with all warnings and follow the proper installation procedures and safety guidelines. Refer to the outside of the crate for Uncrating and Recrating instructions. Take into account the weight of the laminator (1850lb./839 kg shipping weight) when moving. Use equipment that can safely lift the weight. The laminator is shipped on a wooden pallet (skid).
UNPACKING THE LAMINATOR 1. Remove the transport packing and the plastic shrinkwrap that the laminator is wrapped in to avoid moisture penetration during shipping. 2. Remove the accessory kit package from the top of the laminator. This kit includes the tools necessary for installation. 3. Remove the two footswitches from the top of the laminator. Remove the foam wrapped around them. 4. Place the footswitches in positions that are readily accessible while feeding images. 5.
IMPORTANT SAFEGUARDS AFTER SWITCHING OFF THE LAMINATOR, THE ROLLERS MAY REMAIN HOT FOR AND ADDITIONAL FOUR OR MORE HOURS. LAMINATOR SAFETY SYMBOLS CAUTION: Read and make sure you understand these safety and operating guidelines. Rotating Parts: Risk Of Injury Electrical Parts – Danger of being injured by electricity DANGER: DANGER: FAILURE TO USE CAUTION NEAR ROTATING PARTS, SUCH AS ROLLERS, COULD RESULT IN PHYSICAL INJURY.
the rollers and to avoid extensive replacement costs. WARNING: When the laminator is not in use, adjust the shim wheels to create a gap between the laminating rollers to prevent flat spots from developing. Flat spots would affect the quality of the output and void the warranty replacement.
PRODUCT FEATURES SAFETY FEATURES The Image® 600 MD Laminator is designed with safety and protective devices with the user’s safety the primary consideration. However, following safe operating guidelines is still the responsibility of the user. Hand-Operated Emergency Stop Buttons Emergency Stop buttons are located on each side of both cabinets for easy access. When pressed, they immediately suspend laminator operations, and raise the rollers.
LAMINATOR FEATURES 6 4 5 3 2 3 7 1 8 5 9 Figure 3: Laminator Features STANDARD FEATURES 1 - Control Panel System For independent control of pressure, temperature, cooling system and read-out of speed and material usage. 2 - Top Motor Control Panel Controls in-feed direction and processing speed.
FRONT CONTROL PANEL SYSTEM 1. Air Pressure Gauge: Indicates the PSI reading for the downward pressure of the top main roller. The standard setting for the normal operation is 35-55 PSI. 2. Air Regulator Knob: Adjusts the downward pressure of the top roller. Turn clockwise to increase the pressure. 3. Roller Up/Down Switch (Front, Top): Press up to raise the roller. Press down to lower the roller. 4. Cooling Fan On/Off Button: Turns On/Off the cooling fan.
PULL ROLLER CONTROLS The Pull Roller controls are located on the right side cabinet when facing the rear of the laminator. 1. Air Regulator Knob: Adjusts the downward pressure of the top pull roller. Turn clockwise to increase the pressure. 2. Air Pressure Gauge: Indicates the PSI reading for the downward pressure of the top pull roller. The standard setting for the normal operation is 35-55 PSI. 3. Roller Up/Down Switch (Rear, Top): Press the switch up to raise the roller.
PULL ROLLER PRESSURE CONTROLS 60 40 1 80 20 0 10 12 2 14 16 Figure 6: Pull Roller Pressure Controls The Pull Roller Pressure Control Panel is located on the left side cabinet when facing the rear of the laminator. The operator can adjust the amount of tension that is directly applied to the laminate between the main and pull rollers. The amount of tension applied affects the output and extreme pull tension will stretch the hot films causing outfeed waves in the finished product.
TOP MOTOR CONTROL PANEL 1 2 4 3 Figure 7: Top Motor Control Panel MOTOR CONTROL PANEL OPERATION 1. Speed Adjustment Knob Use this knob to adjust the speed of the roller rotation. Turn the knob clockwise to increase the speed of the roller rotation and counter-clockwise to decrease its speed. The speed of the rollers is continuously adjustable between 0 and 15 ft /min. (0 and 4.6M/min.). Roller speed can be viewed in the top display readout on the front control panel. 2.
SET-UP AND OPERATION After you have reviewed the operational details provided and prior to operations check all controls to become familiar with their operation and function. PRESTART CHECKS CHECK THE MAIN POWER 1. Position the Stand-by Power Switch in the up position and verify that the front displays on the control panel light up. 2. The center red switch on the top cabinet control panel should be illuminated. CHECK THE EMERGENCY STOP BUTTONS 1.
BASIC OPERATING PROCEDURES WARNING: Too much pressure can crush the board being used and even damage the top and bottom rollers. Normally, a press of .025 in. (0.6mm) is sufficient. / 19 3 SHIM WHEEL 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.
LOADING ROLLS OF MATERIAL LOADING A ROLL OF MATERIAL Turn the unwind brake fully towards you so there is no brake tension on the unwind shaft- (until no gap is visible between the unwind brake knurled collar and the retaining ring). Swing out the desired unwind shaft towards you and slide a roll of material onto the unwind shaft. Ensure that the rubber blocking cords are on the top and bottom of the shaft for easy loading (see below).
UNWIND SHAFT CORD ADJUSTMENT Over time the rubber blocking cords will stretch and need to be shortened slightly. To adjust the cord, 1. Unfasten the cord at one end 2. Cut off 0.39 in. (1 cm). 3. Refasten the cord under the cord retainer clip.
TABLE OPERATION PIVOTING TABLE USE FOR WEBBING To facilitate webbing, remove the top wind-up idler and set it aside. 1 Figure 11: Table Release Handle Grasp and pull the table release handle located UNDER the center of the table (Figure 11, Item 1) which pulls the table plungers towards the center of the table. Pivot the table down, away from the rollers (Figure 12).
U N W I N D B R A K E / C O O L IN G S Y S T E M O P E R A T I O N SETTING THE UNWIND BRAKE TENSION NOTE: The brake tension greatly affects the smooth flow of the laminating film. Adjust the unwind brake (Figure 15, Item 2) so that it applies sufficient tension to the laminate. 2 Figure 16: Inserting Cooling Tube To remove the cooling tube from the bottom location: 1. Press the cooling tube towards the left cabinet, compressing the spring to clear the cabinet opening. 2.
A U T O - R U N / F O O T S W I T CH O P E R A T I O N AUTO-RUN OPERATION The continuous-run operation allows the user to set the direction of the roller rotation and adjust the roller speed by turning the Speed Control knob on the top of the left side cabinet. This feature is useful for long runs that don’t require much user control, and when used with the rear wind-up shafts can be efficient in an auto-run mode. 1. Press the motor direction switch for the processing direction desired. 2.
FEEDING IMAGES BASIC STEPS TO FEEDING IMAGES 1. Make sure the leading edge of each image is flat all the way across or any wrinkles or creases in the image will show when laminated – perhaps even magnified. Feeding images under the print guide, directly into the nip, prevents the images from lifting up and interrupting the photo eyes. 2. A straight leading edge will aid in feeding in the image. 3. Feed the image into the laminator ensuring that the leading edge is parallel to the roller.
WEBBING FILMS WITHOUT A RELEASE LINER The following are the basic webbing procedures for webbing films without a release liner: 1. Select films slightly wider than the image to allow for a border without film waste. A border of 1/8 in. to ¼ in. (3 - 6 mm) is adequate. 2. Ensure the main roller’s temperatures are set according to the recommendations of the laminates being used (see literature enclosed in your material box).
WEBBING FILMS WITH A RELEASE LINER The following are basic webbing procedures for webbing films with a release liner: 1. Select films slightly wider than the image to allow for a border without film waste. A border of 1/8 in. to ¼ in. (3 – 6 mm) is adequate. 2. Load and center the films on top and bottom unwind shafts with the dull adhesive side facing out and the unwind brake tension released. NOTE: Check if the film widths of the lower and upper web are the same! 3.
DECALING (HEAT - ACTIVAT ED) This process involves applying a hot film to the top and a cold backing adhesive to the bottom of the graphic. This process can be used to create self-adhesive images for mounting down onto various substrates. After performing this process, follow the Mounting Instructions in the manual to apply the decal to a substrate.
DECALING (PRESSURE-SENSITIVE) This process involves applying a cold pressure-sensitive over-laminate to the top and a cold pressure-sensitive mounting adhesive to the bottom of a graphic. This process can be used to create self-adhesive images for mounting down onto various substrates. After performing this process, follow the Mounting Instructions in the manual to apply the decal to a substrate.
MOUNTING This process involves mounting previously prepared decals onto a substrate. No films or adhesives are required for this process. TO MOUNT DECALS ONTO A SUBSTRATE 1. Place the mounting board on a flat surface. 2. Lay your image face down on the mounting board and expose approximately 1 in. (25 mm) of the adhesive by peeling back the release liner along one of the edges. 3. Fold the release liner back making an even crease. 4.
ENCAPSULATING This process involves completely sealing an image between two films.
PRE-COATING BOARDS This process is used to coat substrates with a self-adhesive coating onto which images can be mounted.
LOW -TEMP VINYL TRANSFER This process involves transferring an image onto a flexible vinyl. Top roller temperature and amount of main roller downward pressure is dependent on the type of toners. Use the minimum amount of pressure required for successful transfer.
PROCESS CONTROL SHEET NOTE: We recommend that you make a photocopy of this page. With each successfully run application, record the process and settings and a diagram of the webbing procedure. Keep the record so the application can be repeated at a later date. HINT: If a standard image is made available for each new process then sales materials and samples can be developed for reference.
C L E A N I N G / M A I N T A I N IN G Y O U R L A M I N A T O R WARNING: Ensure the main circuit breaker on the rear left side cabinet is flipped down or OFF before cleaning or greasing the bearings. CLEANING THE LAMINATOR 1. The laminator may be cleaned with a lint-free cloth, lightly dampened with a mild soap and water solution. Do not use spray-on cleaners. Do not immerse any part of the laminator in water or other liquids. 2. Do not use an abrasive cleaner, which can damage the painted surfaces. 3.
PERIODIC MAINTENANCE SHEET Grease Bearings Chain Tension Adjustment / Oil Chain ** Drain Water (Air Filter)*** Safety Check After Servicing NOTE: Enter dates of service and initials of service personnel. We recommend that you make a photocopy of this page, tape it to the inside of the cabinet door and use this to record dates that authorized safety or maintenance personnel perform these laminator maintenance procedures.
T R O U B L E S H O O T I N G G U ID E Problem Solution The laminator will not turn on. • Check if the power cable is plugged into the wall outlet. • Check that the Stand-by switch is ON. • Make sure the main circuit breakers are flipped up or ON. • Unplug the laminator and check the circuit breakers and fuses in the left cabinet. Only authorized safety or maintenance personnel should do this. • Make sure that the photo-eyes are not blocked.
ERROR CODES Error Messages In Speed Display Cause Solution • One of the Emergency stop push buttons is pressed • Reset the Emergency stop pushbutton • There is no power to the Main board • Check the Fuses • Check the Emergency Stop Buttons’ wiring • Remove the obstruction • Rear Photo-eye is interrupted • Front Photo-eye is interrupted • One of the Auxiliary Stop Switches has been pressed DANGER: • Adjust the Photo-eye sensor • Remove the obstruction • Adjust the Photo-eye sensor • Check to see
Error Messages In Temperature Display Cause Solution • Reset Stand-by On/Off Switch • Contact Technical Service (See rear cover) • Check brake tension. Too much tension is the primary cause of this error E3.0 • Motor drive is overloaded • Verify correct settings are being used for rollers • Contact Technical Service (See rear cover) E3.1 • Main motor drive is getting no encoder pulses • Check fuses F1 and F2 on main board E3.
GLOSSARY OF TERMS Decal: An image that has been laminated on top (either heatactivated or pressure-sensitive) with an adhesive backing Film: A synonym for laminate. The material used in the laminating and encapsulating process Heat-Activated Films: Films with an 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.
SPARE PARTS LIST PART DESCRIPTION Accessory Pack Air Clutch Air Cylinder Kit Air Filter Kit Air Gauge Kit Air Regulator Kit Chain, 35-Connecting Link PART # 1160 104500 55055 55056 50609 50607 101036 PART DESCRIPTION Heater Anti-sag Spring Heater Element Heater, Bracket w/o collar Heater, Bracket w/ collar Heater, Bracket, Drive Motor107500 Photo-electric Eye PART # 275215 148610 511391 511394 511507 Chain, Clutch Drive Chain, Main Drive Chain, Lovejoy Tensioner Kit Chill Idler Kit Circuit Breaker, 40A
TECHNICAL SPECIFICAT IONS Mechanical Dimensions (H x W x D) Net Weight Shipping Weight Roller Construction 56 in. x 85 in. x 57 in. (1423 mm x 2159 mm x 1448 mm) 1,300 lbs. ( 590.1 kg) 1,850 lbs. ( 841 kg) Main: (2) 6 in. (15.24 cm) Aluminum Crowned Rollers Pull: (2) 4 in. (10.16 cm) Steel Flat Rollers. Process Max. Working Width Max. Roller Speed Core Inner Diameter Maximum Board Thickness Nip Settings 61 in. maximum (1550 mm) 15 ft/min. (4.5 m/min.) 3 in. (76 mm) 1 in. (25.
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LIMITED 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.
