44DT Laminator
INSTALLATION &
OPERATION MANUAL
Document Number: 930-122 REV: - REV DATE: 11-24-04
Do not duplicate without written permission.
Operating Instructions
TABLE OF CONTENTS
44DT
1. Safety
Warnings .................................................................1-1
General ....................................................................1-1
Electrical ..................................................................1-2
2. Warranty
Limited 90-Day Warranty ........................................... 1
3. Specifications
FCC Note ................................................................ 3-2
4. Installation
Prior to Installation ................................................. 4-1
Installation .............................................................. 4-1
5. Feature Guide
Top Film Supply Shaft ............................................ 5-1
Release Liner Take-up .......................................... 5-1
Idler Bar .................................................................. 5-1
Heat Pressure Rollers ............................................ 5-1
Nip Point ................................................................ 5-1
Safety Shield .......................................................... 5-1
Feed Table .............................................................. 5-2
Table Interlock Latch ......................................... 5-2
Bottom Film Supply Shaft ................................ 5-2
Film Web ................................................................ 5-2
Core Adaptors .................................................. 5-2
Roller Pressure Handle ......................................... 5-2
Film and Take-up Tension Adjustment Knobs ... 5-3
Control Panel ..................................................... 5-3
Display .......................................................... 5-3
Functions ....................................................... 5-3
Pull Rollers ......................................................... 5-4
Circuit Breaker ................................................... 5-4
Decaling in Two Passes With PSA Film ................6-13
Tips For Threading Pressure Sensitive Adhesive
(PSA) Film .........................................................6-14
Mounting ...............................................................6-14
Pre-Treating Boards ..........................................6-14
Mounting Only ..................................................6-14
Film Alignment and Tension ..................................6-15
Film Alignment ..................................................6-15
Film Tension ......................................................6-15
Testing the Web ............................................6-15
Clearing a Film Jam (Wrap-up) .............................6-16
Lamination Guide .................................................6-16
7. Operator Maintenance
Caring for the 44DT Laminator ...............................7-1
Cleaning The Rollers ...........................................7-1
Troubleshooting ......................................................7-2
6. Operation
General Operation .................................................. 6-1
Standby Mode ........................................................ 6-2
Loading Film ........................................................... 6-2
Removing and Installing the Safety Shield ........ 6-3
Removing and Installing the Feed Table ........... 6-4
Loading Film Onto the Supply Shafts ................ 6-4
Thermal and AccuShield™ Films Configuration 6-6
Configuration for PSA Films .............................. 6-7
Loading Film with a Threading Card ................. 6-8
Webbing Thermal Films ................................. 6-8
Webbing AccuShield Films ........................... 6-9
Webbing PSA Films ......................................6-10
Tacking New Film to Existing Film ....................6-12
Page i
44DT
Operating Instructions
Page ii
Operating Instructions
ADVERTENCIA
!
Riesgo de choque
eléctrico
No abra:
Adentro no hay
piezas reparables
por el usuario.
Mantenimiento
solamente por
personal calificado.
ATTENTION
!
Risque de
secousse
électrique.
Ne pas ouvrir:
Pas de pièces
réparables par
l'utilisateur.
Entretien
seulement par
personnel qualifié.
WARNING
!
Electrical shock
hazard.
Do not open.
No user
serviceable
parts inside.
Refer servicing to
qualified service
personnel.
ADVERTENCIA
!
ATTENTION
!
CAUTION
!
RODILLOS
CALIENTES.
PUNTO DE
PINCHAMIENTO.
Mantener manos y
ropa a distancia.
RO
ULEAUX
CHAUDS.
POINT DE
PINCEMENT.
Te
nir mains et
vêtements à l'écart.
HOT ROLLS.
PINCH POINT.
Keep hands and
clothing away.
CAUTION
ATTENTION
CUIDADO
PUNTO DE
PINCHAMIENTO
Keep hands and
fingers away
.
Mantener manos
y
dedos a distancia.
Tenir mains et
doigts a l'écar
t.
PINCH POIN
T
between rollers.
POINT DE
PINCEMENT
entre les rouleaux.
entre rodillos.
1. SAFETY
Your safety, as well as the safety of others is
important. Before you install or use the machine,
read and follow all the safety notices carefully in
this chapter. In this instruction manual, and on the
laminator, you will find important safety notices
regarding the laminator. Read all of the instructions
and save these instructions for further use.
The safety alert symbol precedes each
safety notice in this manual. The symbol indicates a
potential personal safety hazard to you or others, as
well as laminator or property damage.
This safety alert symbol indicates a potential
electrical shock. It warns you to not open the
laminator and expose yourself to hazardous voltage.
The following warnings are found on the 44DT
laminator.
44DT
This safety notice means that your fingers and
hands could be trapped and crushed in the rollers.
Clothing, jewelry and long hair could be caught in the
rollers and pull you into them
WARNINGS
Do not attempt to service or repair the
•
laminator.
Do not connect the laminator to an electrical
•
supply or attempt to operate the laminator
until you have completely read these
instructions. Maintain these instructions in a
convenient location for future reference.
This safety notice means that you could be seriously
hurt or killed if you open the laminator and expose
yourself to hazardous voltage.
This safety notice means that you could be burned
and your fingers and hands could be trapped and
crushed in the hot rollers.
Clothing, jewelry and long
hair could be caught in the rollers and pull you into
them.
To guard against injury, the following safety
•
precautions must be observed when installing
and using the laminator.
Failure to observe these warnings could result in
severe bodily damage or death.
GENERAL
Keep hands, long hair, loose clothing, and
•
articles such as necklaces or ties, away from
the front of the heat and pull rollers to avoid
entanglement and entrapment
The heat rollers can reach temperatures of
•
over 300 °F (166.7 °C). Avoid contact with the
heat rollers during operation or shortly after
power has been removed from the laminator.
Do not use the laminator for other than its
•
intended purpose.
Do not place the laminator on an unstable
•
cart, stand or table. An unstable surface may
cause the laminator to fall resulting in serious
bodily injury. Avoid quick stops, excessive
force and uneven floor surfaces when moving
the laminator on a cart or stand.
Do not defeat or remove electrical and
•
mechanical safety equipment such as
interlocks, shields and guards.
Page 1-1
44DT
Do not insert objects unsuitable for lamination
•
or expose the equipment to liquids.
ELECTRICAL
The laminator should be connected only to a source
of power as indicated in these instructions and on
the serial plate located on the rear of the laminator.
Contact an electrician should the attachment
plug provided with the laminator not match the
receptacles at your location.
WARNING: Do not attempt to service or repair
the laminator. Failure to observe this warning could
result severe personal injury or death.
Disconnect the plug from the receptacle and contact
your dealer/distributor when one or more of the
following has occurred.
Operating Instructions
The power supply cord or attachment plug is
•
damaged.
Liquid has been spilled into the laminator.
•
The laminator is malfunctioning after being
•
mishandled.
The laminator does not operate as described
•
in these instructions.
CAUTION: The receptacle must be located
near the equipment and easily accessible.
Disconnect the attachment plug from the receptacle
to which it is connected and keep the power supply
cord in your possession while moving the laminator.
Page 1-2
Operating Instructions
2. WARRANTY
LIMITED 90-DAY WARRANTY
The Manufacturer warrants to the original purchaser
for a period of ninety days on labor and one year on
parts after installation that this laminator is free from
defects in workmanship and material under normal
use and service. The Manufacturer’s obligation
under this limited warranty is limited to replacement
or repair, at the Manufacturer’s option, of any part
found defective by the Manufacturer without charge
for material or labor.
THIS LIMITED WARRANTY IS IN LIEU OF ALL
OTHER WARRANTIES EXPRESSED OR IMPLIED.
WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE ARE
EXPRESSLY EXCLUDED. ANY REPRESENTATIONS
OR PROMISES INCONSISTENT WITH, OR IN
ADDITION TO, THIS LIMITED WARRANTY ARE
UNAUTHORIZED AND SHALL NOT BE BINDING
UPON THE MANUFACTURER. IN NO EVENT
SHALL THE MANUFACTURER BE LIABLE FOR
ANY SPECIAL, INCIDENTAL, OR CONSEQUENTIAL
DAMAGES, WHETHER OR NOT FORESEEABLE.
44DT
This limited warranty shall be void if the laminator
has been misused; mishandled; damaged by
negligence, by accident, during shipment, or
due to exposure to extreme conditions; repaired,
altered, moved, or installed by anyone other than
the Manufacturer or its authorized agents; or if
incompatible film was used. The Manufacturer’s
obligation under this limited warranty does not
include routine maintenance, cleaning, adjustment,
normal cosmetic or mechanical wear, or freight
charges.
Without limiting the generality of the previous
paragraph, the Manufacturer’s obligation under this
limited warranty does not include:
Damage to the rollers caused by knives, razors,
1.
or other sharp tools; by any foreign objects
falling into the working area of the laminator;
or by cleaning the laminator with solutions or
materials that harm its surfaces;
Damage caused by adhesives; nor
2.
Damage caused by lifting, tilting or attempting to
3.
position the laminator.
Page 1
44DT
Operating Instructions
Page 2
Operating Instructions
3. SPECIFICATIONS
Operating Speed
Variable
•
Fixed – Safety shield removed
•
Dimensions
Width
•
Height
•
Depth
•
Weight
•
Electrical Requirements
Voltage
•
Current
•
Power
•
U.S. Receptacle
•
Heat Capacity
Max. temperature
•
Warm up from ambient
•
44DT
2.5 to 10 fpm (0.8 to 3 mpm)
3 fpm (0.9 mpm)
55 in (137 cm)
22 in (56 cm)
22 in (56 cm)
222 lbs. (100 kg)
220 V 60 Hz
12.5 Amps
2800 W
NEMA 6-15R
300 °F (167 °C)
10 Minutes to 220 °F (122 °C)
55 (137)
22 (56)
22 (56)
Fig. 3-1. 44DT Dimensions Shown in Inches (cm).
Page 3-1
44DT
FCC 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 the instruction 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 his/her own
expense.
Changes or modifications not expressly approved by
the manufacturer could void the user’s authority to
operate the equipment.
Operating Instructions
This Class A digital apparatus complies with
Canadian ICES-003.
(Cet appareil numérique de las Classe A est
conforme a la norme NMB-003 du Canada.
Page 3-2
Operating Instructions
4. INSTALLATION
44DT
This chapter describes how to install the machine.
There are no operator serviceable parts to the
machine other than periodic cleaning. Refer to the
Operator Maintenance chapter.
WARNING: Do not attempt to service or repair
the laminator. Failure to observe this warning could
result severe personal injury or death.
Disconnect the plug from the receptacle and contact
your dealer/distributor when one or more of the
following has occurred.
The power supply cord or attachment plug is
•
damaged.
Liquid has been spilled into the laminator.
•
The laminator is malfunctioning after being
•
mishandled.
The laminator does not operate as described
•
in these instructions.
INSTALLATION
To set up the laminator for the first time:
Place the laminator on a stable flat surface
1.
capable of supporting the weight of the machine
and any materials. The surface should be at least
30 inches (0.76 m) high to assure comfortable
positioning during operation. All four rubber
support feet should be positioned completely on
the supporting surface. The supporting surface
may also be large enough to hold the material to
be laminated.
The laminator should be located so that exiting
2.
film drops freely to the floor or to a table that
is lower than the exit point of the laminator.
Accumulation of laminate immediately behind the
laminator as it exits the equipment may cause
the film to wrap around the rollers, jamming the
machine.
Avoid locating the laminator near sources of heat
3.
or cold. The laminator should not be in the direct
path of forced heated or cooled air.
PRIOR TO INSTALLATION
Inspect the package for damage. Shipping damage
should be brought to the immediate attention of the
delivering carrier.
Connect the attachment plug provided with the
4.
laminator to a suitably grounded outlet only.
Avoid connecting other equipment to the
same branch circuit to which the laminator
is connected, as this may result in nuisance
tripping of circuit breakers or blowing fuses.
Page 4-1
44DT
Operating Instructions
Page 4-2
Operating Instructions
5. FEATURE GUIDE
This chapter identifies the main components of the laminator.
44DT
Top film supply shaft
(front supply position)
Safety shield
Feed table
Table interlock latch
(under table)
Release liner take-up
Roller pressure
handle
Control panel
Heat pressure rollers
Bottom supply shaft
Fig. 5-1. 44DT Laminator Identification.
TOP FILM SUPPLY SHAFT
Holds the film supply on the laminator.
RELEASE LINER TAKE-UP
Rewinds the release liner of pressure sensitive films
and AccuShield™.
IDLER BAR
(Not shown.) The idler bar directs the top supply film
to the heat pressure roller.
HEAT PRESSURE ROLLERS
Two heat pressure rollers apply pressure to the film
and the print being laminated or mounted. Heat
is provided by an internal heating element. When
using pressure sensitive adhesive films, the heat is
turned off. The rollers pull the print and films into the
laminator.
NIP POINT
(Not shown.) The point at which the top and bottom
rollers come into contact and the point at which the
items for lamination are introduced into the laminator.
SAFETY SHIELD
The safety shield prevents entanglement,
entrapment, and inadvertent contact with the rollers.
When the safety shield is removed, the laminator
runs at 3 fpm (0.9 mpm) when you press the RUN
button. The safety shield is removed only when you
load films.
WARNING: Keep your fingers and hands away
from the nip point. Failure to observe this warning
could result in severe personal injury.
Page 5-1
44DT
Operating Instructions
FEED TABLE
The feed table is used to position items for
laminating and mounting. When the feed table is
removed, the laminator runs at 3 fpm ( 0.9 mpm)
when you press the RUN button. The feed table is
removed only when you load film.
TABLE INTERLOCK LATCH
(Not shown.) The interlock latch locks the feed table
into position and activates an interlock switch. The
latch is located on the left, underside of the feed
table. Move the latch to the right to release the
table. Then lift the table upwards and away from the
laminator.
BOTTOM FILM SUPPLY SHAFT
Holds the film or kraft paper on the machine.
FILM WEB
(Not shown.) The path the laminating film and/or
mounting film mounted on the machine takes
through the machine.
ROLLER PRESSURE HANDLE
Fig. 5-3. Roller Pressure Handle.
The roller pressure handle adjusts the amount of
roller pressure needed for various laminating and
mounting applications. Pull the handle out of a
position, rotate it to the desired pressure, and press
it into the slot. Three main function settings provided
are.
CORE ADAPTORS
Take-up shaft
Core adaptor
Supply shaft
Gripper
Fig. 5-2. Core Adaptors on the Shafts.
The core adaptors hold and lock the rolls of film
and release liner on the shafts to prevent side to
side shifting. Grippers on the supply shafts ensures
proper tension on the film. The supply shaft core
adaptors lock in place with a set screw. The release
liner take-up core adaptors are held in place by
friction.
Release – Provides the widest opening between the
pressure rollers and takes pressure off the rollers.
This is used when installing new rolls of film. When
the machine is not in use, put the handle in this
position.
Mounting – Used when bonding to a rigid substrate
such as mounting boards. Thickness range is 1/32 to
3/16 in. (1 to 5 mm).
Laminating – Used to adhere materials in multiple
substrates. The two positions are low and high
pressure.
IMPORTANT: Use a pressure setting that is
appropriate for the material you are laminating or
mounting.
Page 5-2
Operating Instructions
TEMP SPEED
BOTTOM
HEAT
FAN
STOP
RUN
TEMPERATURE
REVERSE
MEAS.
OFF
ON
9
SPEED
°F220
READY
44DT
FILM AND TAKE-UP TENSION ADJUSTMENT
K
NOBS
Tension Adjustment
Knobs
Fig. 5-4. Tension Adjustment Knobs.
Allows the operator to increase or decrease film web
and release liner tension as needed to reduce curl
and wrinkles.
CONTROL PANEL
Display
LED
Fig. 5-5. Control Panel.
Display
The LCD shows the following information.
READY – Appears when the heat pressure rollers
have reached the set temperature. It flashes when
the heat is out of range.
TEMPERATURE – Displays the programmed
temperature setting. Also displays current
temperature when the MEAS. button is pressed.
SPEED – Displays the set speed.
Functions
The following describes the buttons on the control
panel. Refer to Fig. 5-5.
BOTTOM HEAT – Press the ON button to turn on the
bottom heat pressure roller heater. Press the OFF
button to turn it off. When the bottom heat is turned
on, an LED illuminates below the OFF button.
Page 5-3
44DT
Operating Instructions
IMPORTANT: To change from a process where only
the top roller is heated to a process that requires
heat on both rollers, you must first turn off the
laminator and allow the top roller to cool to room
temperature. Once the roller is cool, both rollers can
be heated simultaneously. See General Operation in
the Operation chapter.
TEMP – Press the up or down arrow buttons to
increase or decrease the temperature. When the
bottom heat roller is turned off, these buttons set the
top roller temperature only. When the bottom heat
roller is turned on, these buttons set the temperature
for both rollers, if they are heated from room
temperature.
SPEED – Press the up or down buttons to set the
speed It is adjustable from 2.5 to 10 feet per minute
(fpm) (0.8 to 3 mpm).
FAN – Turns the cooling fan on and off. Illuminates
when the fan is on.
REVERSE – Press and hold the REVERSE button
to reverse the direction of the rollers. Release the
button to stop.
RUN – Press and release the RUN button for
continuous running. The safety shield must be
installed.
POWER SWITCH
Power switch
Circuit breaker
Fig. 5-6. Back of Laminator.
The power switch is located at the back of the
machine. Press the “I” on the switch to turn it on.
The LCD will illuminate on the control panel. The off
position, marked “0”, turns the machine off.
CIRCUIT BREAKER
Electrical safety device which can be reset by the
operator if tripped.
WARNING: Keep your fingers and hands
away from the nip point (the point where the upper
and lower rollers meet). Failure to observe this
warning could result in severe personal injury.
STOP – Press the STOP button to stop the laminator.
MEAS. – Press and hold the button to show the
actual temperature of the top heat roller on the LCD.
PULL ROLLERS
(Not shown.) The pull rollers, located at the back of
the laminator, are motor driven. They simultaneously
pull the laminate and improve the quality of the
laminated item.
Page 5-4
Operating Instructions
TEMP SPEED
BOTTOM
HEAT
FAN
STOP
RUN
TEMPERATURE
REVERSE
MEAS.
OFF
ON
9
SPEED
°F220
READY
6. OPERATION
44DT
This chapter describes how to use the laminator to:
Operate the machine
•
Load films (web the machine)
•
Laminate items
•
Mount items
•
GENERAL OPERATION
These instructions assume that the films have been
loaded. For information about loading films, see the
Loading Film section in this chapter.
Power switch
To run the laminator:
Turn the laminator On (
1.
located at the back of the machine.
WARNING: Make sure the safety shield and
feed tray are in their proper positions. You could be
burned and your fingers and hands could be trapped
and crushed in the hot rollers. . Clothing, jewelry, and
long hair could be caught in the rollers and pull you
into them.
Set the roller pressure handle for the thickness of
2.
the item that is to be laminated or mounted.
I) with the power switch
Fig. 6-1. Power Switch on the Back of The Machine.
Fig. 6-2. Roller Pressure Handle.
Fig. 6-3. Control Panel.
Do any of the following.
3.
If using thermal films, turn on the bottom
a.
heat if needed, and then use the TEMP
up or down buttons to set the desired
temperature.
If using PSA films, go to the next step.
b.
Page 6-1
44DT
Set the desired speed.
4.
Refer to the Lamination Guide chapter.
Press the RUN button.
5.
The rollers will begin to turn.
If using thermal films, allow the heat lines to pass
the heat pressure rollers before inserting items
into the rollers.
Operating Instructions
LOADING FILM
The machine can perform three functions:
Decaling (laminating and applying a mounting
•
adhesive to the back of the item).
Mounting, using one film.
•
NOTE: Do not press RUN until READY appears on
the display.
Position the item(s) to be laminated or mounted
6.
on the feed table.
Push the item(s) squarely into the roller nip point
7.
(where the two rollers meet). Additional items
can be laminated or mounted without stopping
and starting the machine.
Press the STOP button to stop the laminator
8.
when all of the items have completely exited the
rear of the machine.
IMPORTANT: To change from a process where only
the top roller is heated to a process that requires
heat on both rollers, you must first turn off the
laminator and allow the top roller to cool to room
temperature. Once the roller is cool, both rollers can
be heated simultaneously.
If the laminator will be used within one hour, you may
leave it turned on.
Mounting, using no film.
•
The 44DT laminator runs poly-in and poly-out
pressure sensitive adhesive (PSA) and thermal films.
Poly-in means the adhesive side of the film is on the
inside of the web. Poly-out means the adhesive is on
the outside of the web.
Poly-in
Adhesive surface
Polyester surface
STANDBY MODE
The 44DT automatically goes into a standby mode
after it has been idle for 3 hours. The heat roller
temperature is lowered to 176 °F (80 °C), if they were
on. After another hour of inactivity, the heat is turned
off.
To take the laminator out of standby mode, press the
RUN button. If the heat was lowered or turned off,
you will have to wait until READY is displayed on the
control panel. To run the laminator, press the RUN
button again.
IMPORTANT: Whenever the laminator will be idle
for an hour or more, set the roller pressure handle to
Release.
Page 6-2
Poly-out
Adhesive surface
Fig. 6-4. Poly-in and Poly-out Films.
Polyester surface
Operating Instructions
44DT
IMPORTANT: The top and bottom rolls of laminating
film must be the same width.
Always change the top and bottom supply rolls at
the same time. Near the end of each roll of most
laminating film is a label stating, Warning – End
of Roll. The appearance of this label on either the
top or bottom roll requires that new rolls of film
be installed as soon as the item presently being
laminated completely exits the rear of the laminator.
Do not introduce any additional items into the
laminator when the warning label is visible.
Adhesive will deposit on the rollers if:
One or both rolls of film are allowed to run
•
completely off its core.
Only one roll is used.
•
Different widths of rolls are loaded together.
•
Either roll is loaded with the adhesive side
•
against a roller.
There are two methods of loading film.
Using a threading card.
•
REMOVING AND INSTALLING THE SAFETY
S
HIELD
The safety shield should not be removed except to
install films and when cleaning the rollers. When the
shield is off, the laminator runs at a fixed speed of 3
fpm (0.9 m).
WARNING: Keep fingers and hands away from
the rollers when the machine is running. They could
be burned and trapped and crushed in the rollers.
Clothing, jewelry, and long hair could be caught in
the rollers and pull you into them.
To remove the shield:
Tilt the bottom of the shield out.
1.
Lift shield up and out.
2.
To install the shield:
Align the pins at the back of the shield with the
1.
slots on the machine.
Lower the shield so that it engages the safety
2.
switch.
Tacking new film to existing film.
•
Prior to loading film, the safety shield and feed table
need to be removed.
Page 6-3
44DT
Operating Instructions
REMOVING AND INSTALLING THE FEED
T
ABLE
The feed table should not be removed except to
install films. When the table is off, the laminator runs
at a fixed speed of 3 fpm (0.9 m).
To remove the feed table:
Slide the feed table latch to the right.
1.
Lift the table upwards and away from the
2.
laminator.
To install the feed table:
Place the table on the machine.
1.
Slide the feed table latch to the left.
2.
LOADING FILM ONTO THE SUPPLY SHAFTS
If you are replacing existing films, perform the
following set of instructions,
If you are loading film for the first time, skip these
instructions and start with the next instructions,
load films
To remove existing films:
1.
.
Put the roller pressure handle to Release
To remove existing films
To
.
.
Fig. 6-5. Roller Pressure Handle.
Cut the remaining top and bottom films just
2.
ahead of the heat pressure rollers.
Do not allow the remaining film to pass through
the laminator if there is any exposed adhesive.
Liquefied or tacky adhesive will deposit on the
rollers if the following step is not followed.
Pull the remaining film out the back of the
3.
machine with a quick motion.
CAUTION: Be careful to not cut the heat pressure
rollers. Failure to observe this notice can damage the
rollers.
Page 6-4
Operating Instructions
Remove the release liner from the take-up core
4.
by doing the following.
Lift the right end upward and out of the
a.
support and then pull the hex end out of
the support.
Unwind or cut the liner from the core.
b.
Do not damage or throw away the core.
Put the shaft, with the core, back on the
c.
machine by inserting the left end (hex
end) in the left side of the drive and lower
the bearing into the right side of the
machine.
To remove the film supply shaft, grasp the shaft,
4.
press it to the right until the left end of the hex
shaft clears the brake hub, and raise the left end
of the shaft out of the machine.
Do this for the top and bottom supply shafts.
Slide the core off the shaft and core adaptors.
5.
Tip: Twist the shaft while pulling to remove the
core easier.
44DT
To load films onto the supply shafts:
If the supply shaft is on the machine, remove it
1.
by grasping it, pressing it to the right until the left
end of the hex shaft clears the brake hub, and lift
the left end out of the machine.
This applies to the top and bottom supply shafts.
Use the set screws in the core adaptors to move
2.
the adaptors if needed. The grippers on the core
adaptors should be pointing in the opposite
direction that the film unwinds from the roll.
Supply shaft
Gripper
Take-up shaft
Core adaptor
Clean all rollers and idlers if needed. See the
1.
Operator Maintenance
chapter.
Fig. 6-6. Core Adaptors on the Shafts.
Gripper
Fig. 6-7. Direction of Core Adaptor Gripper on Poly-in Film.
Slide the new roll on to the shaft and core
3.
adaptors. Refer to Fig. 6-4.
Films
to determine how the film unwinds from the
roll.
Poly-in and Poly-out
Page 6-5
44DT
Operating Instructions
Insert the bearing end of the shaft into its
4.
support on the right side of the machine, press
to the right, and then insert the left end of the
hex shaft into the brake hub.
Center each supply roll on the shafts by doing
5.
the following.
Use a ruler to measure from the left edge of
a.
the roll to the left side frame.
Do the same on the right side.
b.
Shift the roll side to side so that both
c.
measurements are equal. It is important that
the edges of the films are aligned so that
adhesive does not get on the rollers.
Center the take-up core on its shaft.
5.
THERMAL AND ACCUSHIELD™ FILMS
C
ONFIGURATION
Thermal and Accushield films are loaded as shown
in Figs. 5-9 and 5-10. The top supply is in the front
unwind position. When loading thermal films, the
bottom supply shaft is also loaded. When loading
AccuShield films, nothing is loaded on the bottom
supply shaft and the separator bar must be in place.
If the top supply shaft is not positioned on the front
position, follow the instructions
properly, the brake assembly will be on the left as
you face the front of the laminator.
To move the supply shaft:
Unscrew the thumb screws on the brake
1.
assembly and the shaft support brackets.
Locating pins
below. When set up
Thumb screw
Fig. 6-8. Top Supply Shaft Brake Assembly in the
Rear Position.
Lift the brake assembly up and out of the
1.
machine.
Lift the shaft support assembly up and out of the
2.
machine.
Go to the opposite side (front or rear) of the
3.
laminator and slide the brake housing over the
pins on the left side as you face the laminator.
Insert the thumb screw into the corresponding
4.
hole and hand tighten.
Slide the shaft support assembly over the pins
5.
on the right side of the laminator.
Insert the thumb screw into the corresponding
6.
hole and hand tighten.
Page 6-6
Operating Instructions
Fig. 6-9. Configuration for Thermal Film.
44DT
CONFIGURATION FOR PSA FILMS
PSA films are loaded with the top supply shaft
assembly in the rear position as shown in Fig. 6-12.
Notice that the supply shaft is mounted on the rear
of the machine.
The brake and support must be positioned in the
rear position for PSA films. To move the supply shaft,
see To move the supply shaft in the Configuration for
Thermal and Accushield
Films section.
Fig. 6-10. Configuration for AccuShield Film
Fig. 6-11. Supply Shaft and Brake Assemblies Mounted
on the Rear Position.
Take-up
PSA Film
Release liner
PSA mounting film or kraft paper
Fig. 6-12. Configuration for Poly-in PSA Film.
Page 6-7
44DT
Operating Instructions
LOADING FILM WITH A THREADING CARD
The following procedure uses a film threading card
that is sometimes provided with new rolls of film. If
one is not provided, a scrap piece of cardboard or
poster board with a straight edge is suitable. Either
can be reused.
To prepare the laminator for loading:
Position the top supply shaft assembly as
1.
appropriate for the process.
Refer to the Configuration for Thermal and
Accushield Films or Configuration for PSA Film
sections in this chapter.
Turn the laminator on and if using thermal films,
2.
turn on the bottom roller heat and set the proper
temperature for the film.
Remove the safety shield and feed tray.
3.
Refer to
Feed Table Removal and Installation
Safety Shield Removal and Installation
and
in this section.
Webbing Thermal Films
Refer to the Configuration for Thermal and Accushield
Films section in this chapter for the proper
configuration.
To web the laminator with thermal films:
Pull the top film down, thread it under the idler
1.
bar and drape it over the top heat roller.
Release the brake tension on the supply shafts.
4.
Note: These instructions are for loading (webbing)
laminating and mounting films for decaling. The top
supply shaft is used for laminating films and the
bottom supply shaft is used for mounting film or
kraft paper. If you are not applying mounting film to a
laminate, kraft paper should be used on the bottom
supply shaft to prevent adhesive from sticking to the
rollers. For more information about loading films for
other processes, refer to the appropriate section in
this chapter
Fig. 6-13. Top Film Draped Over the Top Heat Roller.
Pull the mounting film (or kraft paper) behind the
6.
idler bar and then up to about even with the top
of the top pressure roller without touching the
sticky laminating film.
While pulling evenly, carefully align the edges
7.
of the mounting (or kraft paper) film with the
laminating film, and press the two together. It is
important that the tension is even from one end
of the supply rolls to the other.
Page 6-8
Fig. 6-14. Bottom Film Stuck to Top Film.
Operating Instructions
44DT
Press the straight edge of the threading card into
8.
the two films at the nip (the point between the
two pressure rollers) until the card and films are
slightly past the nip.
Fig. 6-15. Threading Card Inserted Between Films.
Move the roller pressure handle to where it
9.
applies pressure to the threading card.
Webbing AccuShield Films
The threading card for webbing AccuShield film can
be any stiff print.
IMPORTANT: When starting to laminate, always
start the rollers BEFORE applying pressure to the
rollers to prevent AccuShield build up on the roller.
When stopping, release the pressure on the rollers
BEFORE stopping the motor.
Press the RUN button on the control panel and
10.
guide the threading card into the machine until
the rollers pull the card on its own.
WARNING: Keep your fingers and hands away
from the nip point while the machine is running.
They could be trapped and crushed in the rollers.
Clothing, jewelry, and long hair could be caught in
the rollers and pull you into them.
Release the card and ensure that both films and
11.
card are being pulled into the laminator.
The card will guide the film webs into the rollers.
Replace the safety shield and feed table.
12.
Refer to Safety
Shield Removal and Installation
Feed Table Removal and Installation
Check the film alignment and adjust the tension
13.
as needed.
See the
Film Alignment
section in this chapter.
in this section.
and
Fig. 6-16. Configuration for AccuShield Film.
To web the laminator with AccuShield film:
Pull the film down, thread it under the idler bar
1.
and drape it over the top heat roller.
Fig. 6-17. AccuShield Draped Over the Top Heat Roller.
Press the straight edge of the threading card
2.
into the film at the nip (the point between the two
pressure rollers) until the card and film is slightly
past the nip.
The film should be wrapped around the leading
edge of the card.
Page 6-9
44DT
Operating Instructions
Webbing PSA Films
Refer to the Configuration for PSA Film section in this
chapter for the proper configuration.
Fig. 6-18. Threading Card Inserted Into the Film.
Press the RUN button on the control panel.
3.
Move the roller pressure handle so that it applies
4.
pressure to the threading card and guide the
card into the machine until the rollers pull it on its
own.
WARNING: Keep your fingers and hands away
from the nip point while the machine is running.
They could be trapped and crushed in the rollers.
Clothing, jewelry, and long hair could be caught in
the rollers and pull you into them.
Release the card and ensure that both films and
4.
card are being pulled into the laminator.
The card will guide the film into the rollers.
After the threading card exits the laminator, set
5.
the roller pressure handle to Release.
Poly-in
Fig. 6-19. Configuration for Poly-in or Poly-out PSA Films.
Pull the top film down, thread it under the idler
1.
bar, and pull the film back up to the take-up core.
Lightly tape both corners of the film to the
2.
take-up core.
Turn the take-up one full turn.
3.
Ensure that the film is pulled evenly and that no
bulges exist at either end of the idler bar.
Using a very sharp utility knife, lightly score the
4.
laminating film approximately 4 in (10 cm) above
the upper pressure roller.
Be careful to not cut through the release liner.
Pull the laminating film away from the liner and
5.
drape it over the front of the pressure rollers so
that it extends a little past the bottom of the top
pressure roller.
Poly-out
Press the STOP button.
6.
Separate the release liner from the card.
7.
Pull the film up to the take-up core and tape it to
8.
the core.
Replace the safety shield and feed table.
9.
Refer to Safety
Feed Table Removal and Installation
Check the film alignment and adjust the tension
10.
as needed.
See the
11.
Page 6-10
Film Alignment
Shield Removal and Installation
in this section.
section in this chapter.
and
Fig. 6-20. Top Film Draped Over the Pressure Rollers and
Release Liner Attached to Take-up.
Pull the mounting film (or kraft paper) up to
6.
about even with the top of the top pressure roller
without touching the sticky laminating film.
Operating Instructions
While pulling evenly, carefully align the edges
7.
of the mounting film (or kraft paper) with the
laminating film, and press the two together.
It is important that the tension is even from one
end of the supply rolls to the other.
44DT
WARNING: Keep your fingers and hands away
from the nip point while the machine is running.
They could be trapped and crushed in the rollers.
Clothing, jewelry, and long hair could be caught in
the rollers and pull you into them.
Release the card and watch the leading edge of
11.
the card to ensure that it enters the nip area of
the rollers squarely and is being pulled into the
laminator.
The card will guide the film webs into the rollers.
Fig. 6-21. Bottom Film Stuck to Top Film.
Press the straight edge of the threading card into
8.
the two films at the nip (the point between the
two pressure rollers) until the card and films are
slightly past the nip.
Replace the safety shield and feed table.
12.
Refer to Safety
Feed Table Removal and Installation
Check the film alignment and adjust the tension
13.
as needed.
See the
Film Alignment
Shield Removal and Installation
in this section.
section in this chapter.
and
Fig. 6-22. Threading Card Inserted Between Films.
Move the roller pressure handle to where it
9.
applies pressure to the threading card.
Press the RUN button on the control panel and
10.
guide the threading card into the machine until
the rollers pull the card on its own.
Page 6-11
44DT
TACKING NEW FILM TO EXISTING FILM
The following describes a method for loading thermal
or PSA film whereby the existing film on the rollers
may be used in place of the threading card to draw
the new film through the laminator. Leading edges of
the new film will be overlapped onto the adhesive of
the old film. The existing film and the new film will be
pulled through the laminator together.
Operating Instructions
Remove the safety shield and feed tray.
1.
Refer to
Feed Table Removal and Installation
Cut remaining bottom film web between the
2.
supply roll and rollers.
Remove the existing bottom supply roll and
3.
replace with new film.
Refer to the
section in this chapter.
Unroll enough film from the bottom roll of film to
4.
tack to the existing bottom film.
Make sure to carefully align the edges of the
films before tacking them together.
Cut remaining top film web between the supply
5.
roll and rollers.
Do not allow the adhesive to stick to the rollers
or the bottom film.
Remove the existing top supply roll and replace
6.
with new film.
Safety Shield Removal and Installation
in this section.
Loading Film Onto the Supply Shafts
and
Fig. 6-23. New Thermal Films Attached to Old Films.
Install the feed table and safety shield.
8.
Set the speed for the slowest speed setting and
9.
press RUN
Watch the film being pulled through the laminator
10.
to ensure that the remaining existing film and the
new film are advancing concurrently and evenly.
Any separation between the films will require
stopping the motor immediately and the situation
corrected.
Press STOP once the newly threaded film
11.
completely exits the laminator.
Check the film alignment and adjust the tension
12.
as needed.
See the
.
Film Alignment
section in this chapter.
Unroll enough film from the top supply roll
7.
shaft to tack to the existing top film. Make sure
to carefully align the edges of the films before
tacking them together.
Page 6-12
Operating Instructions
DECALING IN TWO PASSES WITH
4.
Guide the item into the rollers.
44DT
PSA FILM
Decaling is where you laminate items and then
mount them on other materials such as Foam Core
or mounting board. It is performed in two passes.
The first pass laminates and applies the mounting
adhesive, encapsulating the item. The second pass
mounts it on the other material.
This two pass operation requires pressure sensitive
laminating film on the top supply shaft and pressure
sensitive mounting film on the bottom supply shaft.
Refer to Fig. 6-19 for the proper configuration of
Poly-in or Poly-out film.
Once the item has cleared the back of the
5.
machine, press STOP.
Remove the web and trim out the encapsulated
6.
item.
To run the second pass:
Unweb (unload the films) the laminator before
running the second pass.
Adjust the roller pressure handle to the proper
1.
mounting setting and set the motor speed to 1.
Peel back the leading edge of the release liner of
2.
the laminated item approximately 2 inches
(5 cm).
Place the item on the mount board.
3.
Tack the exposed adhesive edge of the item,
4.
from the center out, to the leading edge of the
board.
Be sure to not introduce wrinkles or air bubbles.
Fig. 6-24. Laminator Loaded for Decaling the First Pass
with Film (Poly-in Shown).
Poly-in Poly-out
Fig. 6-25. Configurations for Poly-in and Poly-out Films.
To run the first pass:
Load the laminator as shown.
1.
Adjust the roller pressure handle to the proper
2.
laminating setting.
Butt the leading edge of the board up against the
5.
rollers.
Drape the encapsulated item over the safety
6.
shield.
Do not allow the print to flop backwards towards
you.
Release liner
Print over safety shield
Fig. 6-26. Laminator Ready for Mounting.
Place the item to be laminated on the feed table,
3.
then press RUN
.
Page 6-13
44DT
Press RUN and immediately grasp the release
7.
liner for separation as the board is pulled into the
rollers.
Do not allow the release liner to be pulled into
the rollers.
After the board has cleared the rollers press
8.
STOP
.
TIPS FOR THREADING PRESSURE
S
ENSITIVE ADHESIVE (PSA) FILM
Use kraft paper for one-sided lamination.
•
Refer to Fig. 6-19
•
configuration.
Whenever possible, pull the remaining web
•
of film out the back of the laminator after the
finished item has been removed.
MOUNTING
for the proper film
Operating Instructions
Fig. 6-28. Laminator Set Up for Pre-treating Boards With
Double Liner Mounting Film.
To pre-treat boards:
Load the laminator as shown in Fig. 6-27 or 28.
1.
Adjust the roller pressure handle to the proper
2.
mounting setting.
PRE-TREATING BOARDS
You may wish to pre-coat mounting boards ahead of
time with PSA mounting film.
PSA mounting film
Board
Fig. 6-27. Laminator Set Up for Pre-treating Boards With
Single Liner Mounting Film.
Start a leader board into the rollers.
3.
Press RUN
4.
Continue feeding one board after another.
5.
Butt the leading edge of the next board up
against the trailing edge of the previous one.
Press STOP when the last board exits the
6.
machine.
.
MOUNTING ONLY
This process requires a decalled item with PSA
mounting adhesive. Refer to the
pass instructions
of this chapter. An alternative method is to use a PSA
pre-treated board, which is described in the
and Overlamination
in the
Decaling In Two Passes
section.
To run the second
section
Mounting
Page 6-14
Operating Instructions
FILM ALIGNMENT AND TENSION
FILM ALIGNMENT
Tension Adjustment
The top and bottom supply rolls must be aligned
as closely as possible. Misalignment can cause
adhesives to be deposited on the rollers.
To align the supply rolls:
Use a ruler to measure the distance between the
1.
left edge of the roll to the side frame.
Measure the distance between the right side of
2.
the roll to the side frame.
Shift the roll side to side to ensue that the two
3. Fig. 6-29. Tension Adjustment Knobs.
measurements are equal.
The machine is equipped with external tension knobs
FILM TENSION
Proper film tension, known as brake tension, is the
minimum amount required to eliminate wrinkles in the
finished item. Tension adjustments are not necessary
if you are using 1.5 or 3 mil (38 or 75 mic) film unless
the lamination is curling up or down. Generally, 5 and
10 mil (125 and 250 mic) films require more tension.
As the film roll becomes smaller, tension increases,
thus the adjustment needs to be loosened. Film
tension should be checked occasionally to assure
that the adjustment is correct.
The film should be taut with no gaps between the
film and pressure rollers. A properly adjusted roll
of film should not require excessive force to turn by
hand. Film tension should be enough to introduce a
minor amount of drag as the film unrolls. Insufficient
tension causes wrinkles, while too much tension
causes stretching (necking). Uneven tension
between the top and bottom rolls create curl. Too
much upper tension creates upward curl. Too much
lower tension bottom causes downward curl.
located on the left side. Turning the knobs clockwise
increases the tension while counterclockwise
decreases the tension.
Testing the Web
After webbing the machine, it is important that the
films run straight and evenly.
To test the web:
Set the roller pressure handle to an appropriate
1.
position.
Press the RUN button and run approximately
2.
6 in. (10 cm) of laminate.
Press the STOP button.
3.
Visually inspect the top and bottom films where
4.
they enter the nip. The films should be tight
against the rollers at both ends. If they are not,
use the tension adjustment knobs to tighten the
loose supply film brake and run another test.
Knobs
44DT
Ensure that the release liner take-up is keeping
5.
the liner tight against the idler bar. If it is loose,
use the tension adjustment knob to increase the
tension.
RUN test materials before laminating good
6.
materials.
Page 6-15
44DT
Operating Instructions
CLEARING A FILM JAM (WRAP-UP)
Film jams (wrap-ups) may occur if the film is loaded
backwards or if the area at which film exits the
equipment is blocked. The film, when jammed, wraps
around the rollers. Jams also occur if something is
too large to pass through the rollers.
Determine the best course of action to clear the
jam. It may be necessary to rotate the rollers in the
reverse direction. Set the speed to 1. Press and hold
the REVERSE button on the control panel.
CAUTION: Be careful to not cut the pressure rollers
when cutting the film. Failure to observe this notice
can result in damage to the rollers.
To clear a jam:
Immediately press the STOP button to stop the
1.
machine.
Remove the safety shield and feed tray.
2.
Do one of the following.
3.
Pull one of the webs while running the
a.
laminator in reverse.
Cut the film near the rollers, set the
b.
pressure adjustment to Release, and pull
the film out the back of the machine.
Cut the film near the rollers, set the
c.
pressure adjustment to Release, grasp
the loose ends of the web, and pull
straight out the front of the machine.
Replace the safety shield and feed tray.
4.
Re-load the film if necessary. See the
5.
Film
section in this chapter.
Loading
LAMINATION GUIDE
Do not attempt to laminate abrasive or metal objects
such as staples, paper clips and glitter, as they may
damage the rollers.
Do not force items into the nip area of the rollers. An
item that is not easily drawn into the laminator by the
rollers is probably too thick to laminate.
Wrinkles may result if an attempt is made to
reposition an item once it has been grasped by the
rollers.
Do not stop the laminator before an item has
completely exited the pull rollers. Even a momentary
stop may cause a mark on the laminated item.
Good, consistent lamination is a result of combining
proper tension and dwell time. Dwell time is
controlled by the speed of the motor and is defined
as the amount of time the material to be laminated is
compressed between the rollers.
As a general rule, thicker items and film need to run
at slower speeds. Setting the speed control at slower
settings gives the laminator longer dwell time thus
allowing proper lamination of thick items. Thinner
items, such as standard copier paper (20 Ib. bond)
and tissue paper can be run at faster speeds.
Do not combine thick and thin items at the same
time, as this will result in a poor edge seal around
the thinner material. If you are unsure that the
laminator is set at the proper speed for the item to
be laminated, run a test piece (scrap) of the same or
similar material through the laminator. Make speed
adjustments if necessary.
This manual provides general guidelines and is only
a general reference guide. Different settings may be
suitable as the lamination time and materials change.
Test materials before running good materials through
the machine.
Page 6-16
Operating Instructions
7. OPERATOR MAINTENANCE
44DT
CARING FOR THE 44DT LAMINATOR
The only maintenance required by the operator
is to periodically clean the rollers. The following
procedure will help keep them free of dirt and
adhesive, which has been deposited along the edge
of the laminating film. Proper alignment of the rolls of
film reduces the amount of adhesive on the rollers.
Perform only the routine maintenance procedures
referred to in these instructions.
WARNINGS:
Do not attempt to service or repair the laminator.
•
Do not apply any cleaning fluids or solvents to the
•
rollers. Some solvents and fluids could ignite on
heated rollers.
Keep fingers and hands away from the rollers
•
when the machine is running. They could be
trapped and crushed in the rollers. Clothing,
jewelry, and long hair could be caught in the
rollers and pull you into them.
Failure to observe these warnings could result in
severe personal injury or death or damage the
machine.
To clean the rollers and idler bar:
Remove the safety shield and feed table.
1.
Refer to
and
Operation
Remove the film from the laminator.
2.
Refer to
Operation
Gently rub the heat and pull rollers, and idlers
3.
with a 3M Scotch-Brite pad.
DO NOT USE METAL SCOURING PADS! Do
not use any abrasives to clean the rollers.
Use the dampened rag to remove any dust, dirt,
4.
and other foreign materials from the rollers.
Press and release the RUN button to rotate the
5.
rollers to an unclean portion.
Keep your hands, fingers, the pad, and rag away
while running the machine. Be sure to remove all
adhesive and dirt.
Install the feed table and safety shield.
6.
Removing and Installing the Safety Shield
Removing and Installing the Feed Table
chapter.
Loading Film Onto the Supply Shafts
chapter.
in the
in the
CLEANING THE ROLLERS
Keeping the rollers clean ensures that your finished
items will not be damaged by dirt and adhesives.
You will nee a 3M™ Scotch-Brite™ pad and a clean
rag moistened with water and dish soap.
Never clean rollers with abrasive, sharp, or
•
pointed objects.
Do not use any other cleaning agents other
•
than those listed above.
Accumulated adhesive deposits on the rollers
•
can cause damage to the rollers. Rotate the
rollers at the lowest speed setting on the
control panel.
Page 7-1
44DT
TROUBLESHOOTING
Symptom Possible Cause Corrective Action
Operating Instructions
Power lamp does not
illuminate (next to the
stop button when the
power switch is in the
position.
Rollers do not turn. Safety shield not seated properly. Lower safety shield.
Laminated items are
curling.
Adhesive deposited on
rollers.
ON
Laminator not connected to electrical
supply.
Fuse blown out. Replace fuse or contact your dealer/
Feed tray interlock latch not in place. Slide interlock latch all the way to the left
Tension between the top and bottom film
roll is unequal.
Tension on top or bottom roll of film is too
loose.
Grippers on core adaptors pointing in the
wrong direction.
Speed setting too slow. Slightly speed up laminator.
Top and bottom film webs not aligned. Align film webs per
Laminate improperly loaded. Load film per
Insert attachment plug into receptacle.
distributor for assistance.
into the side frame.
Adjust tension per
Adjust tension per
Load film per
Shafts
section.
Loading Film Onto the Supply
Loading Film
Film Tension
Film Tension
Film Alignment
section.
section.
section.
section.
Unsatisfactory laminate
adhesion.
Speed setting too fast for type of material
being laminated.
Laminate improperly loaded. Load film per procedure outlined per
Rollers require cleaning. Clean rollers per
Laminated item unsuitable for adhesion. Item may be dirty or may have non-
Lower speed setting by turning the speed
knob to slower Speed.
Loading Film
section.
porous surface that is extremely difficult
to laminate.
section
Cleaning the Rollers
Page 7-2
Operating Instructions
44DT
Page 7-3
Loading...