Drylam PL1200-HP User Manual
Professional Laminating Systems
Laminator Operators Manual
SERIES II
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Record
Record Machine Details
Model _______________
Serial #_______________
Date Of Purchase__________________
Date Of Manufacture_______________
Voltage_______________
Inspector______________
Distributor
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Warnings & Safety................................................................................................................................... 10
Elecrical Requirements............................................................................................................................. 12
Specifications............................................................................................................................................13
Unpacking................................................................................................................................................. 15
Laminator Unpacking ....................................................................................................... 16
Laminator Removal .......................................................................................................... 16
Lift Points.......................................................................................................................... 17
Stand ......................................................................................................................................................... 18
Stand Unpacking...............................................................................................................18
Stand Assembly ................................................................................................................ 19
Mounting The Laminator.......................................................................................................................... 23
Tower Alignment...................................................................................................................................... 24
Laminator Assembly................................................................................................................................. 25
Mandrel Towers................................................................................................................ 25
Slitter Towers.................................................................................................................... 25
Standard Towers Upper .................................................................................................... 26
Lower Towers................................................................................................................... 26
Feed Table Installation...................................................................................................... 27
Laminator Setup........................................................................................................................................ 28
Laminator Controls................................................................................................................................... 29
Temperature ..................................................................................................................... 29
Motor................................................................................................................................. 29
Fans................................................................................................................................... 30
Gap Control Lever ............................................................................................................ 31
Idler Bars........................................................................................................................... 32
Mandrels ................................................................................................................................................... 33
Installation: ....................................................................................................................... 33
Tension Control Knob....................................................................................................... 34
Mandrel Clip..................................................................................................................... 34
Feed Table................................................................................................................................................. 36
Adjustment........................................................................................................................ 36
Slitters....................................................................................................................................................... 37
Cautions ............................................................................................................................ 37
Slitter Assembly................................................................................................................ 37
Slitter Installation...................................................................................................................................... 38
Slitter Operation............................................................................................................................... 39
Slitter Angle Adjustment ..................................................................................................40
Changing Blades............................................................................................................... 40
Threading Procedure................................................................................................................................. 41
5
Threading Diagrams............................................................................................................................... 45
Film Tuning .............................................................................................................................................. 48
Film Replacement..................................................................................................................................... 50
Film Removal............................................................................................................................................ 50
Operation................................................................................................................................................. 51
Guidelines:........................................................................................................................ 53
General:............................................................................................................................. 54
Wide Format:.................................................................................................................... 54
Mounting / Foam Board:................................................................................................... 54
Single Sided:..................................................................................................................... 54
Fan Use ...............................................................................
One Sided – General:........................................................................................................ 56
Production Run One-Sided Lamination............................................................................ 57
Board Stock:...................................................................................................................... 58
Cold Lamination ............................................................................................................... 59
Shutdown .................................................................................................................................................. 62
Maintenance ............................................................................................................................................63
Roller Cleaning................................................................................................................. 63
Rubbing Pad Compound................................................................................................... 63
Brushes.............................................................................................................................. 64
Cleaning The Slip Ring..................................................................................................... 65
Roller Lubrication............................................................................................................. 66
Chain Lubrication .............................................................................................................66
Cam Lubrication ............................................................................................................... 66
Antistatic........................................................................................................................... 67
Roller Care And Maintenance .................................................................................................................. 69
Precautions:....................................................................................................................... 69
About Your Rollers:.......................................................................................................... 69
Roller Failure:................................................................................................................... 69
Operating Guidelines:....................................................................................................... 70
Film:.................................................................................................................................. 70
Cleaning:........................................................................................................................... 70
Film Wrap......................................................................................................................... 71
Troubleshooting........................................................................................................................................ 72
Glossery .....................................................................................................
Notes......................................................................................................................................................... 77
Warranty ................................................................................................................................................... 78
6
7
Professional Laminating Systems, Inc.
Hamilton, MT. 59840 406-363-1690
About our company....
The primary goal of PLS is to provide laminating machinery that produces excellent and consistent
results at affordable prices. We are able to accomplish this goal through innovative design and
engineering practices. The foundation of our system is our patented heated roller, the heart of the
lamination process. This roller design not only produces superior finished product but also results in
considerable cost savings to our customers. We are a vertically integrated company as we utilize our
own fully automated machining facilities, as well as in-house powder coating and roller manufacturing
operation. We strive to keep machine designs as simple as possible while providing superior finished
product results, excellent reliability, and ease of operation and maintenance. We work very hard to find
or design and manufacture components that are precisely matched to their given task. Finally, we
believe that maintenance and repair parts should not be a major profit center for our company.
The Revolution Series heated roller system...
Our patented heated rollers were designed to provide a superior finish, good durability, and ease of
cleaning, while still being affordable. Our roller design exceeds all finish and quality capabilities seen in
competitive heat shoe laminators; such as, but not limited to, superior adhesion, negligible stretch,
exclusion of scratches, faster warm up, more capabilities in film and substrate use, more user friendly
and nylon, polypropylene and vinyl capable. Class for class our technology exceeds all performance
capabilities in competitive heated silicone rollers. Another benefit of this design is ultra-fast warm up
times--from room temperature to 250 deg. “F” in about five minutes--high performance models are
ready to run in less than 4 minutes. This means that you can turn your new machines on when you need
them... and off when not in use. The laminating process utilizes a considerable amount of energy
inherent in all processes requiring considerable amounts of heat. And remember, if a commercial
laminators putting out thousands of Btu*s of heat when not in actual use, your air conditioning system is
putting out even more energy in a futile attempt to cool your facility. This wasted energy can add up to
hundreds of dollars a year in unnecessary utility costs. The Revolution Series rollers are covered with
the finest silicone rubber available that is specifically formulated for our precise application. Final
grinding and polishing is accomplished with computerized equipment to insure absolute accuracy and
consistency of the finished roller.
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CONGRATULATIONS
Congratulations on your purchase of a series II heated roll laminator, manufactured by
Professional Laminating Systems Inc. Your laminator has been designed with the latest
technology to deliver hours of trouble-free operation and quality results. Your new laminator is a
very versatile machine capable of laminating 1.2 through 10 mil films on a wide variety of
materials through 3/16” thick. With proper care and maintenance, your laminator will offer you
many years of dependable service.
Please read this manual in its entirety before operating your laminator.
By reading this manual before operation of the machine, you will become familiar with proper
set up, operation, and maintenance of the machine and potentially avoid common mistakes or
worse.
We stand by our products 100% and welcome your comments and suggestions on how we can
better serve your needs and help your business grow.
If you require service, support or materials NOT found through your local representative, please
locate us on our web site at www.pro-lam.com or fax our Technical Service Department at Prolam 406-363-6145. Include your model number, serial number, date of purchase the dealer
through whom it was purchased, a brief description of the service needed, your name, your
business name, your address your phone number and your fax number. We will then respond
promptly by phone or fax.
We appreciate your continued support and trust that you will receive full satisfaction from your
laminator.
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WARNINGS & SAFETY
DO NOT OPERATE THIS LAMINATOR WITHOUT FIRST REVIEWING THIS
OPERATORS MANUAL IN ITS ENTIRETY.
NEVER OPERATE THIS MACHINE WITH REMOVED, DAMAGED OR
MISSING PARTS - SHUTDOWN AND DISCONNECT FROM THE ELECTRICAL
SUPPLY.
IF THERE WERE TO EVER BE A MECHANICAL OR ELECTRICAL
MALFUNCTION IMMEDIATELY UNPLUG THE MACHINE
NEVER SERVICE THIS MACHINE WITHOUT FIRST DISCONNECTING THE
MACHINE FROM THE ELECTRICAL SOURCE.
DO NOT TOUCH THE HEATED ROLLERS AS THEIR TEMPERATURE MAY
EXCEED 350 DEGREES FAHRENHEIT.
NEVER ALLOW SHARP OBJECTS SUCH AS KNIVES OR SCISSORS TO
CONTACT THE ROLLER SURFACE AS A POTENTIAL SHOCK
HAZZARD EXISTS AS WELL AS THE POTENTIAL TO INFLICT SERIOUS AND
IRREPARABLE DAMAGE TO THE SILICONE ROLL COVERING OR THE
OPERATOR.
CAUTION MUST BE EXERCISED TO KEEP HANDS FROM THE NIP POINT OF
THE LAMINATING AND PULL ROLLERS TO AVOID INJURY DUE TO HIGH
PRESSURE AND HEAT AT THESE POINTS.
FAMILIARIZE YOURSELF WITH THE REVERSE FEATURE, DO NOT WEAR
LOOSE-FITTING CLOTHING AND JEWELRY AND HAIR MUST BE PUT UP
AND KEPT AWAY FROM THE NIP POINT THESE ITEMS COULD BE PULLED
INTO THE LAMINATOR SINCE THE ROLLERS ARE ROTATING.
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IF THE SLITTERS (SIDE TRIM KNIVES) ARE USED, USE EXTREME CAUTION
WHEN HANDLING THE KNIFE BLADES OR MAKING ADJUSTMENTS, AS THE
KNIFE BLADES ARE RAZOR SHARP.
USE MULTIPLE PEOPLE TO UNPACK AND MOVE THE LAMINATOR AS IT
WEIGHS IN EXCESS OF 75 POUNDS.
LEAVE REPAIRS AND MAINTENANCE TO A QUALIFIED PERSONNEL.
NEVER LEAVE THE MACHINE UNATTENDED WHILE IN USE.
SHUT THE MACHINE DOWN AND ALWAYS KEEP ROLLERS GAPPED WHILE
THE MACHINE IS NOT BEING ATTENDED GAPPING GREATLY EXTENDS THE
LIFE OF THE ROLLERS AS WELL AS SAVING $ IN LOST ENERGY. REMEMBER
YOUR NEW LAMINATOR TAKES AS FEW AS 4 TO 5 MINUTES TO WARM UP
RATHER THAN 20 OR 30
DO NOT ALLOW THE ROLLERS TO EXCEED 300 DEGREES DOING THIS
WILL GREATLY INCREASE THE LIFE OF THE LAMINATING ROLLERS –
THOUGH YOUR MACHINE IS PERFECTLY CAPABLE OF RUNNING FILM
RATED AT 300 DEGREES PRO-LAM RECOMENDS USING A FILM THAT IS
RATED AT A LOWER TEMPERATURE - THIS WILL INCREASE YOUR ROLLER
LIFE
DO NOT ADVANCE THE FILM THROUGH THE LAMINATOR WHILE
THE ROLLERS ARE COLD THIS MAY RESULT IN THE SURFACE BEING
TORN FROM THE ROLLERS BY THE AGGRESSIVE LAMINATING FILM
ADHESIVE.
DO NOT PLACE THE LAMINATOR NEAR ANY VENTILATION
SYSTEM AS THIS MAY COOL THE ROLLERS.
USE CARE WHEN CHANGING THE LAMINATING FILM AS THE FILM ROLLS
ARE VERY HEAVY AND MAY REQUIRE AS MANY AS 3 OR MORE PEOPLE TO
LOAD THE SUPPLY ROLLS ALSO USE CAUTION TO AVOID PINCHING HANDS
OR FINGERS WHILE LOADING THE ROLL
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ELECRICAL REQUIREMENTS
A GROUNDED RECEPTICAL MUST BE USED, MAKE SURE THAT THE
RECEPTICAL MATCHES THE MACHINE REQUIREMENTS
MODEL VOLTS AMPS PLUG WATTS
PL1200HP 120 20 *
PL227 120 20 *
PL227HP 240 20 L6-20
PL238 120 20 *
PL238wf 240 20 L6-20
PL244wf 240 25 L6-30
*Conventional plug however the outlet must be dedicated (no other devices on the same circuit).
The electrical installation must meet local and federal electrical codes and a qualified person must
make the installation.
If a laminator is hard wired you must install a “disconnect” switch
!!! These Requirements must be strictly adhered to, as an incorrect installation will void your
warranty!!!
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Specifications
Hard specs
Model Dry/Ship weight Height Width Depth
PL 1200 w/o stand 40# / 60# 21” 24” 21”
PL 1200 w- stand 60# / 80# 51” 24” 21”
PL 227w/o stand 70# / 100# 21” 39” 21”
PL 227w stand 90# /120# 51” 39” 21”
PL 238wf 140# / 170# 50” 50” 21”
PL 244wf 170# / 200# 50” 56” 21”
Models shown in their standard configuration
Film specs:
Model Max upper roll Max lower roll Max thickness Max motor speed
PL 1200 w/o stand 11” 6” 10 mil+ 18fpm
PL 1200 w- stand 11” 22” 10 mil+ 18fpm
PL 227w/o stand 11” 6” 10 mil 16fpm
PL 227w stand 11” 22” 10 mil 16fpm
PL 238wf 10” 22’ 5-10 mil 7fpm
PL 244wf 10” 22” 5-10 mil 7fpm
Standard models in their standard configuration
Laminator capabilities
Your new laminator is possibly one of the most capable and fastest laminators available, in its class, to
the industry today. It is capable of laminating an extremely wide variety of materials, even some deemed
impossible to be laminated. Your laminator is capable of using nearly any film that can be run on a
laminator and even more.
Laminator Limitations
Your new laminator, though exceptionally capable, does have its limitations. You will find these as you
read this manual and through time and experience. One of the most important things in your laminator is
the heated rollers. It is very important that you understand this components capabilities and limitations.
Just the same, as a roller can be damaged by touching it with a sharp knife, the roller may be damaged
by overheating it. This limitation, which we will call a duty cycle, will dictate how long your rollers
will last. The beautiful thing about the technology enveloped in your laminators is the responsiveness
and quickness of the laminating rollers. One does need to make sure (as with any mechanical electrical
device) that you do not exceed the design limitations of your rollers. This is why we stress not to exceed
300 degrees and not to run the laminator more than 20 degrees over the film manufactures
recommendations. In addition to this, one needs to make sure that the rollers are not overheated
internally. Before operating, take record of the temperature range that the display shows when idle.
During operation, one should make sure that the laminator cycles on and off. This can be noted by the
slow rise and fall (up to 1 degree a second) around the recorded temperature. If the rollers are unable to
achieve the recorded temperature, this is an indication that the heaters are always on and do not get a
chance to stabilize internally. This will greatly reduce the life of the rollers. It is highly recommended to
use a laminate that is at least 50% (1/2) the width of the rollers and ideally not less than 75% (3/4) of the
roller width - the laminate must be run at the center of the rollers
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Silicone Vs. Metal
A silicone covered heated roller is the most advanced, accurate and highest quality methods of
lamination available to day. Producing superior results to nearly any other process, it is the paramount
method. However, there are some common sense differences between silicone rollers and the old metal
heat shoe technology. Though the silicone rollers are the greatest advantage to other technologies, it is
possibly its greatest weakness. Review the chapter of roller care and maintenance starting of page 65
Keep in mind the following;
• Do not cut the rollers, as with any rubber, they will slit and they will be destroyed.
• Do not overheat the rollers, this is covered in this manual extensively and should be understood.
• Do not allow heat to build up, use the proper width film and turn the machine off when not in
use.
• Do not use abrasive materials on the rollers, they are silicone rubber there are many things that
are harder than this - they will abrade the rollers - use only the accepted cleaning method.
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UNPACKING
Because the series II laminator is available in several different sizes and configurations, some of the
following steps may not be applicable to your specific shipment. However, it may be a good idea to read
over the following documentation to familiarize yourself with your machine and the technology
involved
Typical shipment of the series II laminator is as follows.
A. Your laminator was shipped as a tabletop model.
B. Your laminator was shipped with a stand and the stand requires minimal assembly
C. Your laminator was shipped separated from the stand and your stand does require assembly
Included with your shipment you should find the following possibly in multiple boxes
.
1. Your laminator
2. The laminator stand (optional)
3. One set (2) of film supply roll mandrels
4. Mandrel Towers
5. Feed Table
6. Control Handle
7. Slitter assembly (Optional)
8. Release Liner Winder (Optional)
9. Hardware kit
10. Your operators manual
The following pages address each component of your installation individually.
And is outlined as follows
1. Unpack the laminator
2. Unpack the stand
3. Assemble the stand
4. Install stand towers
5. Assemble the laminator
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LAMINATOR UNPACKING
Your laminator is shipped in one box. Some minor assembly is required. You should clear out sufficient
space to unpack the laminator. Make sure this area will provide access to both sides of the laminator as
well as the front and back of the machine.
The laminator is packed in specially designed material for shipping your laminator safely The Packing
material should be retained for transportation or for shipping in the event of a warranty or service issue.
In the box with the laminator you should find the feed tray and enclosed hardware the supply mandrels
will be shipped with the stand if the machine was purchased without a stand the mandrels should be
included with your shipment however in a different box.
!!! SEE THE NEXT PAGE FOR LIFT POINTS ON THE SERIES II LAMINATOR !!!
LAMINATOR REMOVAL
1. Remove the feed tray
2. Remove the center piece of foam
3. Using at least two people pull the laminator and remaining packing, by the lift points, from the
box. Use great care, the laminator may be quite heavy, dropping it will damage it.
4. Set the laminator on the floor and lift one end at a time and remove the foam shipping caps
5. Remove the remaining packing
6. Set the laminator aside and clear sufficient space for the stand and its packing
Please retain original packing in the event that the laminator must be moved or returned to your
dealer for warranty or service.
Use a sufficient number of people to remove the laminator from the box as the machine may weigh
in excess of 200 pounds.
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LIFT POINTS
Make sure that when the laminator is removed from the box it is only lifted by the ends of the tie bars (as
shown). PL 1200 shown, if the laminator is wider this is even more critical and may take two or more people
to lift it.
! ! ! DO NOT LIFT THE LAMINATOR BY ANY OF THE COMPONENTS BETWEEN THE FRONT
ROLLERS AND THE REAR ROLLERS. - - - DAMAGE MAY ACCURE - - - ! ! !
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STAND
The stand is an optional item on certain models and may or may not have been included with the
purchase of your laminator.
Your laminator stand is shipped in one box it may require simple assembly. You should clear out
sufficient space to unpack the stand. Make sure this area will provide access to both sides as well as the
front and back of the stand.
The Packing material should be retained for transportation and shipping for warranty or service.
Shipped with the stand you will find the film supply mandrels for the laminator and possibly any
additional options as you ordered such as a release liner winder.
The hardware used to assemble the stand is packed separately and shipped with the laminator.
The Tools required for assembly are:
1. 1 – 3/16” Allen wrench
2. 1 – 7/16” combination wrench or ratchet
In the box, that the stand is shipped in are the following:
A. 1 - Right side frame, with or without towers attached
B. 1 - Left side frame, with or without towers attached
C. 2 - Spreaders
D. 4 - Feet or caster wheels (as ordered)
Stand Unpacking
Unpacking the stand does not need to be addressed, as it is straightforward.
After the stand is unpacked, consolidate the packing materials and remove it from the assembly area.
If the mandrels are unpacked from their boxes be very careful, they have a sharp protrusion in
the center of the mandrel that can cut if handled carelessly.
Please retain the original packing in the event the laminator must be returned to your dealer for
warranty or service
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STAND ASSEMBLY
These instructions for the stand are correct assuming that the stand frames were delivered with the
mandrel towers and feet / wheels installed. If they are not please refer to the included documentation for
documentation on this, then refer to the following instructions
The hardware for assembling the stand was shipped in a parts box that was included in the laminator
box.
Hardware Identified as:
5/16-18 Button head Socket
Stand parts:
Cap Screw
8 pieces
5/16 Flat Washer
8 pieces
5/16 Split Washer
8 pieces
Stand Frame Left Stand Frame Right Spreaders, 2 typical
19
Use the diagrams and instruction on the following three pages as a guide to assemble the stand
20
Assembled Stand
When finished your stand should resemble this example from our PL 227hp.
Also Notice the placement of the mandrel towers.
21
Stand Assembly Review
Normal Procedure For stand assembly is as follows
1. Position the parts for assembly, layout the parts in their respective locations on the floor
2. Identify left frame piece (has the smaller slot in the mandrel tower).
3. Position the frame so that the aluminum mandrel tower is toward the front and on the right side
(inside) of the stand frame (feet down).
4. Install a spreader into the lower holes (spreaders are not directional). Use a 3/16 Allen wrench,
do not tighten the screws all the way.
5. Install second spreader onto the left frame piece, in the upper holes
6. Install right frame piece to the spreaders, this should be positioned so that the aluminum mandrel
tower is forward facing and inward.
7. Place the stand upside down on a flat level surface, tighten all 8 Allen screws
8. Install any other optional items that may have been included with your laminator using the
instructions supplied, if necessary
9. Once the stand is setup make sure that it is sturdy and all screws are tight
The screw holes on the top of the stand for mounting the laminator are off center. This should be
of no concern; this must be this way for correct laminator alignment (the hole should be justified to
the right).
Please retain the original packing in the event the laminator must be returned to your
Dealer for warrant or service.
22
MOUNTING THE LAMINATOR
The laminator is mounted to the top of the stand using the four thru holes on the top of the stand
1. Set the stand in position on a flat level surface.
2. If the laminator arrived with rubber pads on the feet, these must be removed. Using two people,
tilt the laminator back while using a 5/32 Allen wrench loosen the cap screw and remove the pad.
3. Make sure that the mounting bolts and pads are properly placed on the stand. The rubber pads
should hold the bolts in position securely.
4. Carefully set the laminator on the stand while aligning the legs on the laminator with the pads on
the stand.
Make sure that at least one person holds the laminator from moving or falling until the
laminator is completely secured to the frame.
5. Install the ¼ ” bolts from the bottom side of the tube, Align holes and start the threads in all four
holes do not tighten until all four bolts are started, then tighten until snug. Do not over tighten
and crush the rubber feet as this may result in laminator misalignment. Typically, tightened the
bolt just enough that it just starts to flatten the lock washer.
23
Tower Alignment
If the stand arrived with the towers attached you possibly will not need to follow this alignment
procedure however, it is recommended before proceeding make sure that the towers are correctly
aligned. Before starting this alignment, procedure makes sure screws are tightened only enough to make
moving the towers somewhat difficult. It may be necessary to use a rubber hammer or a block of wood
to adjust the towers.
The following procedure is a preliminary adjustment and it should not be the final adjustment
The final adjustment is done with the machine running see page 48.
The following instructions on the next several pages and page 48 are more critical on our wide format
machines and more care should be taken when following them.
1. Measure between the top, rear corner of the mandrel tower to the rear corner of the laminator this
measurement should be made the same from the left tower and the right tower. Tighten the top
bolt until snug
2. Measure from the lower front corner of the towers to the lower front corner of the laminator
these should be made the same.
3. Tighten the lower mandrel tower bolts. Until snug.
4.
Recheck alignment then tighten the towers to the frame.
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Laminator Assembly
Mandrel Towers
Typical tower configuration on the laminator is either, slitter towers, which include the slitter assemblies
attached to it, or our standard towers, which come with machines void of slitters.
Slitter Towers
If your laminator was supplied with slitters, it is typical that the tower will be already attached to the
machine and they simply need to be pivoted upright.
1. Position the laminator mandrel towers. Do this by grabbing both towers and at the same time,
turn them upright until the holes in the towers are aligned with the holes in the panels
2. Install two 5/16 x ½” long, hex head bolts one in each tower
3. Take note that on the right tower the bolt must be oriented so that the side of the bolt is parallel
to the side of the slitter-actuating handle (see diagram.). Do not over tighten bolt it is better that it
be looser rather than over tightened.
Correct
Notice both bolt and arm lay flush and parallel
4. Check that the ball plunger on the tower rests in its indent in the slitter handle
5. Tighten all remaining attaching hardware
Notice tip on bolt is preventing arm from seating
Incorrect,
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