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CHEMINSTRUMENTS
HOT ROLL LAMINATOR
MODEL HL-100, HL-101
OPERATING INSTRUCTIONS
PRODUCT DESCRIPTION ................................................................................................2
UNPACKING ......................................................................................................................3
ASSEMBLY ........................................................................................................................4
Location ...................................................................................................................4
Installation of Unwind Stand ...................................................................................4
Assembly of HL-100 ................................................................................................4
Key Components ..................................................................................................... 5
HOT LAMINATOR DIAGRAM.........................................................................................6
SAFETY FEATURES .........................................................................................................7
Trip Wire ................................................................................................................. 7
Emergency Stop Buttom ......................................................................................... 8
TEMPERATURE CONTROLLER OPERATION ..............................................................9
OPERATION .....................................................................................................................10
Theory of Operation ...............................................................................................10
Laminating Procedure ........................................................................................... 10
OPTIONS ...........................................................................................................................11
Gap Adjusters .........................................................................................................11
Chrome Plated Steel pressure Roll (HL-101) ........................................................12
Tension Unwind .....................................................................................................12
Second Face Unwind .............................................................................................12
Pneumatic Foot Control .........................................................................................12
Driven Heated Pressure Roll ..................................................................................12
Heated Drive Roll ..................................................................................................13
MAINTENANCE ..............................................................................................................13
Tightening Belt ......................................................................................................13
Air Connections .....................................................................................................14
Safety Trip Wire Adjustment .................................................................................14
Troubleshooting .....................................................................................................15
WARRANTY ....................................................................................................................16
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PRODUCT DESCRIPTION
The ChemInstruments Hot Roll Laminator is a state of the art laboratory scale pressure
roll laminator. Many of the features were formerly only available in larger floor models. The Hot
Roll Laminator will aide you in the production of quality laminations and provide you with
essential information when scaling up to pilot trials with your product.
The unit has the following features:
Hard coat anodized, Teflon coated aluminum top pressure roller.
Top heated roller is pressure controlled with an easy to read dial indicator.
Bottom drive roll is covered with 80-durometer-silicone rubber.
Variable speed control of the drive rolls in both forward and reverse directions.
Easy to use Fenwal temperature controller
Safety features include a trip wire, which lifts the pressure roller.
Another safety feature is the emergency stop switch that will stop the drive roller.
Optional features include:
Air piston gap adjusters
Chrome plated steel pressure roller (HL-101)
Tension unwind upgrade
Second face stock unwind stand
Pneumatic foot control valve
Driven heated pressure roller
Heated bottom drive roller
240 VAC
Upon receipt of a new ChemInstruments Hot Roll Laminator, there are some steps that
should be followed in setting up the unit. Following these steps will help to extend the life of the
laminator and also aide in achieving superior laminations.
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UNPACKING
ChemInstruments has made every effort to ensure that the HL-100, HL-101 arrives at
your location without damage. Check the unit for any damage that might have occurred in
shipment. Very little damage has been experienced in the past, however, make sure that no air
lines have been disconnected and that the top roll has not been scratched. Check all packaging
material carefully for individually wrapped accessories. If any damage did occur during transit,
notify the carrier immediately.
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ASSEMBLY
Before laminating any samples, follow this procedure to set up the Hot Roll Laminator:
LOCATION
The laminator should be set up on a bench, which allows access to both the front and
back of the machine. Some users have found a cart useful in reaching the front and back and also
allow the unit to be mobile. Whether on a permanent bench top or a cart the weight of the unit (
160 to 185 lbs. ) must be considered.
INSTALLATION OF THE UNWIND STAND
Be sure the roll unwind bar is seated correctly in the mount. If a tension unwind has been
selected be sure the pressure plate is positioned over the pin. (See Photo 1)
ASSEMBLY
Carefully remove the kraft paper from the laminating rolls.
Attach the incoming airline to the machine.
This requires a female quick disconnect. Set the laminator's air pressure regulator at 40
PSI for a midpoint starting pressure.
Plug the Laminator into a 120 VAC outlet or 240 VAC if requested as an option.
The laminator will draw 12 – 15 amps. Check the amp maximum for the circuit and be
sure other electrical devices on the same circuit do not cause an overload.
Remove the wooden blocks between the rollers
Press the red UP button to raise the pressure roll and remove these blocks.
With the optional gap adjusters create a gap by turning the middle portion of the air
pistons in clockwise direction. The gap adjusters can be used to create a gap between the
rollers when the machine is not in use. The gap adjusters can be used to assure the top
pressure roll is not resting on the rubber covered silicone roll when not in use. This will
prevent an indentation or flat spot from occurring on the rubber covered roller. (See
Figure 1)
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IMPORTANT - Save these blocks and insert them between the rollers when the unit is not in use!
This will prevent an indentation or flat spot from occurring on the rubber covered drive roll..
The unit is now set up for laminating see Temperature Controller Operation for heating
instructions.
KEY COMPONENTS ( See Figure 1, Figure 2)
GAP ADJUSTERS
AIR PISTONS
SAFETY TRIP WIRE
HEATED PRESSURE ROLL
RUBBER DRIVE ROLL
AIR PRESSURE REGULATOR
EMERGENCY STOP SWITCH
HEATER CONTROLLER
QUICK AIR CONNECT
BEARING
FINISHED LAMINATION
LAMINATING PLATFORMS
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Figure 1
Figure 2
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Photo 2
SAFETY FEATURES
The Hot Roll Laminator should be considered as any other piece of laboratory
equipment. The safety features will not prevent injury. The safety devices will raise the
top roll or stop the drive roll instantly. The objective is to prevent using these features.
Tuck in ties and roll up sleeves. Loose clothing can be pulled into the laminating rolls
and cause severe injury.
Remove rings and watches. These will only increase your injury if caught in the
laminator.
TRIP WIRE
Located in front of the top laminating roll, when activated this will cause the pressureroll
to rise allowing trapped articles to be freed. Test the trip wire by lowering the pressure roller and
moving the trip wire.( See Photo 2)
Trip Wire
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EMERGENCY STOP BUTTON
Photo 3
This will stop the drive roll from turning in either direction. It WILL NOT release the
pressure, but can prevent further entrapment. To test turn the motor to the ON position, push
down on the red button. The switch should remain locked. Check to be sure the bottom drive roll
has stopped. Turn the switch in the clockwise direction to restart the motor. (See Photo 3)
E-Stop
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TEMPERATURE CONTROLLER OPERATIONS
Photo 4
Heater Switch
The heating controller is set and tested at the factory before shipment. Auto tuning has
been performed at 250° F. It is ready to begin operating as soon as the HEATER switch is
turned on. (See Photo 4)
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Fenwal Controllers
Allow the unit 45 minutes to one hour to fully stabilize to the set temperature. This also
applies when changing temperatures. Fenwal Manual Enclosed.
To change the temperature set point:
Press the SET/ENT button
The brightly lit number is the number that will be changed. Use the left arrow button to
select the number you would like to change.
Use the up and down arrows to change the number.
Once the new set point (SP) has been entered press the SET/ENT button again to save the
new value. If the set enter button is not pushed the controller will continue at the
previous temperature.
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When no buttons are pressed for a period of one (1) minute, the controller returns to
normal operating mode automatically. Press SET/ENT again to continue changing the set
point if desired.
CAUTION Once the heater is turned on, the internal temperature will rise very quickly. The 45
minutes mentioned above is the time for full roll temperature stabilization, not the time needed for
the pressure roll to come up to temperature!!
DO NOT TOUCH THE TOP PRESSURE ROLL AFTER HEATER IS TURNED ON!!
OPERATION
THEORY OF OPERATION
ChemInstruments Hot Roll Laminator canm hot laminate product samples on a laboratory
bench top. The features included in the HL-100/101 provide control to consistently reproduce
samples that are ready for testing.
BEFORE OPERATING THE LAMINATOR, SEE PAGE 8 FOR SAFTEY
PRECAUTIONS.
LAMINATING PROCEDURE
Raise the pressure roller (Red UP button), turn temperature controller on and allow the
temperature to stabilize.
Set the speed as necessary for your material. Turn the motor OFF after the speed is set.
IF the motor will not run, reset the red emergency stop switch on top of the unit. Turn the
outer top portion of the red button clockwise. The switch is not set when it is in the up
position. To use the emergency stop, push straight down on the button. This will stop the
motor and keep it stopped until the switch is reset. (See page 7) for full safety
instructions.
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If the material is in roll form place it on the unwind stand with the heat activated side up
and the uncoated side to the roll. Thread the material over the idler roll and through the
pressure nip gap. Place the other material under heat-activated substrate.
If you are working with hand sheets lay one on top of the other and place one end of the
assembly in the pressure nip gap. Check to be sure the coated side is between the sample
substrates.
After the material is positioned to be laminated, push the DOWN green button and turn
the motor to the ON position.
As the sample moves through the laminating nip, it may necessary guide the sample over
the rear sample platform.
Turn the motor to the OFF positions. Press UP (red) button to release the pressure.
Replace the wooden blocks between the roller shafts when the machine is longer in use.
Do not allow the rolls to rest together. This will cause flat spots to develop on the rubber
roll.
Remove the incoming air pressure hose from the right side of the machine.
OPTIONS
See page 2 for options, which have been selected on this unit.
GAP ADJUSTERS
To create a gap turns the middle section of the air piston clockwise.
To create a specific known gap place feeler gauges between the rollers. For the best
results use 2 sets of feeler gauges (sold separately). Place the gauges at about 6 inches in
from each end of the rolls.
Continue to adjust the air cylinders until the feeler gauges are close-fitting in the nip.
Replace the wooden blocks or create a gap to prevent the rolls from resting together when
the laminator is not in use.
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CHROME PLATED STEEL PRESSURE ROLL (HL-101)
The top pressure roll is chrome plated not the standard Teflon coated aluminum. This
will create smoother laminations when working with thin gauge films.
The chrome plated roll has been installed at the factory and is ready for use.
TENSION UNWIND
The tension unwind consists of a core insert with a spring-loaded blade that prevents the
face stock from turning and a pressure plate brake.
Load the material over the open end of the core insert. Center the material over the spring
loaded blade. Place the material in the unwind holders, be sure the pressure plate is
aligned over the stop pin.
to increase the tension loosens the setscrews on the large nut on the pressure plate. Then
turn the large nut clockwise. Once the right tension has been established tighten the
setscrews.
Many films require tension to prevent wrinkles from forming.
SECOND FACE UNWIND
This is located below the standard face unwind.
When using this feature the materials are fed through the back of the nip and over the
front sample platform.
PNEUMATIC FOOT CONTROL
This is for the pressure or the motor but not both at the same time.
This feature allows the user to lower the pressure roller while holding samples in place.
Extreme caution should be taken when using this feature to assure that only the sample is
near the nip when lowering the pressure roll. (See page 7 for safety issues).
DRIVEN HEATED PRESSURE ROLL
This feature uses gears on the bottom roll and the top heated roll. These cause both rolls
to turn simultaneously.
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The gear located on the left shaft will engage when the pressure roll is lowered to meet
with the bottom rolls gear.
HEATED DRIVE ROLL
The bottom driven roll is independently heated with a second temperature controller.
Care should be taken when heating the rolls.
Each controller is marked for the roll it is heating.
See page 10 for temperature controller operation.
Maximum recommended temperature is 400o.
MAINTENANCE
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The ChemInstruments Hot Roll Laminator should provide many years of trouble-free
service. However, some maintenance may be necessary. The preceding troubleshooting chart
describes some of the most likely problems and their causes. The following are the maintenance
procedures:
ALWAYS UNPLUG THE UNIT BEFORE OPENING UP THE CONTROL BOX! ELECTRIC SHOCK MAY
OCCUR!
TIGHTENING BELT
1. Remove the six screws holding the faceplate.
2. Remove the four screws holding the side panel.
3. Carefully pull these two panels away from the control box. Make sure not to pull
any wires or air hoses loose!
4. Loosen the four (4) motor mount screws.
5. Pull the motor to tighten the belt.
6. Tighten the motor mount screws.
7. Replace the front and side panels.
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AIR CONNECTIONS
1. Find the source of the leak, then disconnects air pressure from the unit.
2. The tubing is very flexible and is pushed onto a small barb at each connection. This
connection should never leak, but it may.
3. Cut the tubing off the barb.
4. Cut off any bad section of the tubing.
4. Push the tubing back onto the barb.
SAFETY TRIP WIRE ADJUSTMENT
1. If the pressure roller will not lower when the green DOWN button is pressed, the
safety trip wire may need adjustment.
2. Push or pull the wire to verify there are two audible "clicks;" one as the wire is
pushed and the other as it is released.
3. If there is no clicking, loosen the eyebolt on the left side of the safety trip wire by
loosening the set nut, and then turning the eyebolt counter-clockwise.
4. Adjust this so there is a clicking, and the pressure roller operates correctly.
5. Hold the eyebolt securely and tighten the set nut on the eyebolt.
From time to time the rolls may need to be cleaned. The laminating platforms can be
moved to allow easier access to the rolls. To do this, loosen the black plastic thumbscrews, slide
the platform, and then re-tighten the thumbscrews. ALWAYS CLEAN ROLLS WITH
HEATED ROLL AT ROOM TEMPERATURE!!! Mineral spirits may be used to clean both
of the rolls. Do not use toluene, as it will damage the rubber roll. Do not clean the rolls while
they are moving, and always clean the pressure roll while it is in the "up" position. Do not scrape
the pressure roll with any objects! Use only a soft cloth and mineral spirits to clean this roll.
If you have any questions regarding the maintenance or the operation of your Hot Roll
Laminator, or need to order replacement parts, feel free to call ChemInstruments at 513-8601598, Monday - Friday from 8:00 AM to 5:00 PM EST. Or you may fax us at 513-860-1597.
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Problem
Probable Cause
Procedure
Motor switch not
lit.
Machine not plugged in.
Plug machine into 120 VAC outlets.
Blown fuse.
Replace with a 2-amp time delay fuse.
Heater switch not
lit.
Machine not plugged in.
Plug machine into 120 VAC outlets.
Blown fuse.
Replace with a 15-amp fuse.
Rollers do not turn.
Motor speed set at zero.
Increase motor speed.
Gear belt loose.
Tighten gear belt. (SEE BELOW - A)
Air hose leaks.
Loose connection.
Repair connection. (SEE BELOW - B)
Pressure roller will
not lower.
Safety trip wire sticking.
Adjust safety trip wire. (SEE BELOW C)
No air pressure.
Airline not connected.
Connect machine to compressed air line.
TROUBLESHOOTING
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