GMP EXCELMASTER-1600 User Manual

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Page 1

USER'S GUIDE

EXCELMASTER-1600

Before operating the unit, please read this manual thoroughly and retain it for future reference.

Page 2

TABLE OF CONTENT

Cover 1

Table of Content 2

Important Safety Instructions 3

Specifications 4

Pre-Installation 5

Installation 6

Control Guide 7

Power ON/ OFF 7 Control Panel Display 7 Control Panel 7 Rewinder Selection Switch 8 Upper Rewinder Direction Switch 9 Lower Rewinder Direction Switch 9 Rear Control Switch 9 Foot SW Enable 9

Features Guide

E-Stop 10 Safety Shield Interlock Latch 10 Safety Shield 10 Feed Table 10 Heat Rollers 10 Pull Rollers 10 Roller Handle 11 Idler Bar 11 Chill Idler 11 Cooling Fans 11 Film Shaft 11 Lower Shaft Lock 11 Rewind Shaft 12 Rewind Tube 12 Unwind/ Rewind Tension 12 Core Adaptors 12 Rewind Adaptors 12 Rear Table 12 Rear Slitter 12 Film Web 12 Nip Point 12 Foot Switch 12 Print Unwind Basket 12 Options 12

Separator Bar 12 Rewind Kit 12

Film Loading and Threading 13 Load a Roll of Film 13 Loading Top Thermal Film 14 Loading Top PSA Film 14 Loading Top Mount Adhesive 15 Loading Bottom Thermal Film 15 Loading Bottom PSA Film 16 Loading Bottom Mount Adhesive 16 Threading Card Procedure 17 Start Laminating 18 Tacking New Film To Existing Film 19 To Unweb The Laminator 20 Clearing A Film Jam 20

Applications 21

Pre-Coating Boards 21 Using Rear Rollers 21 Mounting Pre-Coated Boards 21 Single Sided Lamination 22 Creating a Decal 22 Mounting a Decal 22 PSA Encapsulation 23 Thermal Encapsulation 23 Micronex 23

The Art Of Lamination 24

Basic Rules 24 Film Tension 24 Heat 25 Output 25

Maintenance 26

Troubleshooting Guide 27

Page 3

IMPORTANT SAFETY INSTRUCTIONS

YOUR SAFETY AS WELL AS THE SAFETY OF OTHERS IS IMPORTANT T O GBC. IN THIS INSTRUCTION MANUAL AND ON THE PRODUCT , YOU WILL FIND IMPORT ANT SAFETY MESSAGES REGARDING THE PRODUCT . READ THESE MESSAGES CAREFULL Y . READ ALL OF THE INSTRUCTIONS AND SAVE THESE INSTRUCTIONS FOR LATER USE.

THE SAFETY ALERT SYMBOL PRE-

CEDES EACH SAFETY MESSAGE IN THIS INSTRUCTION MANUAL. THE SYMBOL INDICATES A POTENTIAL PERSONAL SAFETY HAZARD TO YOU OR OTHERS, AS WELL AS PRODUCT OR PROPERTY DAMAGE.

THE FOLLOWING WARNINGS ARE FOUND UPON THIS PRODUCT .

ADVERTENCIA

o de choque

Ries eléctrico No abra: Adent r o no ha piezas r epar ables por el us uar io. Mantenimiento solament e por personal calificado

ATTE N TI ON

Ris

ue de

secousse

ue.

électri Ne pas ouvrir. Pas de pièces réparables par l'utilisateur. Entretien seulement par personnel

ualifié.

THIS SAFETY MESSAGE MEANS THAT YOU COULD BE SERIOUSL Y HURT OR KILLED IF YOU OPEN THE PRODUCT AND EXPOSE YOURSELF TO HAZARDOUS VOLT AGE.

ADVERTENCIA

RODILLOS CALIENTES. PUNT O DE PINCHAMIENTO.

Mantener manos ropa a d is t anc i a.

ATTENTION

ROULEAUX CHAUDS. POINT DE PINCEMENT.

Tenir mains et vêtements à l'écart.

THIS SAFETY MESSAGE 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.

ADVERTENCIA

NAVAJA FILOSA.

Mant ener m a nos y dedos a dist anc ia.

ATTENTION

LAME COUPANT E.

Tenir mains et doigts à l'écart.

THIS SAFETY MESSAGE MEANS THAT YOU COULD CUT YOURSELF IF YOU ARE NOT CAREFUL.

WARNING: THE SAFETY ALERT

SYMBOL PRECEDES EACH SAFETY MESSAGE IN THIS INSTRUCTION MANUAL. THE SYMBOL INDICATES A POTENTIAL PERSONAL SAFETY HAZARD TO YOU OR OTHERS, AS WELL AS PRODUCT OR PROPERTY DAMAGE.

WARNING: DO NOT A TTEMPT TO

SERVICE OR REPAIR THE LAMINATOR.

WARNING: DO NOT CONNECT THE

LAMINATOR TO AN ELECTRICAL SUPPLY OR A TTEMPT T O OPERA TE THE LAMINAT OR UNTIL YOU HAVE COMPLETELY READ THESE INSTRUCTIONS. MAINTAIN THESE INSTRUCTIONS IN A CONVENIENT LOCATION FOR FUTURE REFERENCE.

WARNING

Elect ric al s hock hazard. Do not open. No user serviceable part s in side.

Refer servicin

ualified s er v ice

personnel.

CAUTION

HOT ROLLS. PINCH POINT.

Keep hands an d clot hin

away.

CAUTION

SHARP BLADE.

Keep hands and clot hing aw ay .

INJURY , THE FOLLOWING SAFETY PRECAUTIONS MUST BE OBSERVED IN THE INSTALLA TION AND USE OF THE LAMINA T OR.

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 over 300° F. Avoid contact with the heat rollers during operation or shortly after power has been removed from the laminator.

Keep hands and fingers away from the path of the sharp film cutter blade located at the film exit.

Do not use the laminator for other than its intended purpose.

Avoid moving the laminator on uneven floor surfaces. Never tilt the laminator.

Do not defeat or remove electrical and mechanical safety equipment such as interlocks, shields and guards.

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.

CAUTION: The receptacle must be

located near the equipment and easily accessible.

Do not operate the laminator with a damaged power supply cord or attachment plug, upon occurrence of a malfunction, or after the laminator has been damaged. Contact GMP’s Technical Service Department or your dealer/distributor for assistance.

Service

Perform only the routine maintenance procedures referred to in these instructions.

WARNING: Do not attempt to service

or repair the laminator.

Disconnect the plug from the receptacle and contact GMP's Technical Department or 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.

WARRANTY

GMP warrants to the original purchaser for a period of ninety (90) days after installation that this laminator is free from defects in workmanship and material under normal use and service. GMP's obligation under this warranty is limited to replacement or repair, at GMP's option, of any part found defective by GMP without charge for material or labor.

This warranty is in lieu of all other warranties expressed or implied. WARRANTIES OF

MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSL Y EXCLUDED. Any representations or promises

inconsistent with, or in addition to, this warranty are unauthorized and shall not be binding upon GMP. In no event shall GMP be liable for any special, incidental or consequential damages, whether or not foreseeable.

This warranty shall be void if the product 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 GMP or its authorized agents; or if incompatible film was used. GMP's obligation under this warranty does not include routine maintenance, cleaning, adjustment, normal cosmetic or mechanical wear, nor freight charges.

Without limiting the generality of the previous paragraph, GMP's obligation under this warranty does not include:

• damage to the pressure rollers or pull rollers caused by knives, razors, or other sharp tool; by any object falling into the working area of the laminator; or by cleaning the rollers with solutions or materials that harm their surfaces;

• damage to Lucite panels or manometer glass caused by mechanical action or by cleaning with solutions or materials that harm those surfaces; nor

• damage to the outer finish caused by mechanical action or by cleaning with solutions or materials that harm the outer finish.

For proper cleaning procedures, see the

“

CARING FOR YOUR LAMINATOR

For European Union Residents Only: This

guarantee does not affect the legal rights which consumers have under applicable national legislation governing the sale of consumer goods.

” chapter.

Page 4

131 cm

211 cm

102 cm

EXCELMASTER-1600

SPECIFICATIONS - EXCELMASTER-1600

Operating Speed:

Up to 5

m/min

Temperature range:

C - 150 OC

Max. Mounting Thickness:

1.3 cm

Max. Film Width:

EXCELMASTER : 165 cm

Dimensions (W x D x H):

Unit alone: (Figure 2)

211 cm x 102 cm x 131 cm

Shipping:

216 cm x 109 cm x 159 cm

Fig. 1

Weight:

Unit alone: Shipping:

Electrical Requirements:

Refer to the serial plate located on the rear of the laminator for the specific electrical rating applicable to the unit.

Voltage: Current: Power: Phase:

1030 lb. (467 kg.)

1250 lb. (567 kg.)

400V/50~60 Hz

8.3A 4000 W Single

Page 5

508 cm

220 cm

101.6 x 152 cm

Work table on wheels

Back

Front

101.6 x 152 cm

Work table on wheels

Electrical cord

drop

91 cm

PRE-INSTALLATION

Before a Laminator can be installed, ensure the following requirements are met;

1. Are door ways and hallways wide enough for the laminator to be moved to the installation site?

2. Is there ample room for the laminator?

– A work area must be established that allows for operation in both the front and rear of the laminator and provides space for efficient material flow. (Figure 3)

3. Is the environment appropriate

for the laminator? – The laminator requires a clean,

dust and vapor free environment to operate properly.

– Avoid locating the laminator near sources of heat or cold. Avoid locating the laminator in the direct path of forced, heated or cooled air.

Fig. 2

330 cm

CAUTION: Air flow can cause uneven heating/ cooling of the rollers and result in poor output quality.

4. Have you contacted a certified

electrician to wire the receptacle and ensure that adequate power is being supplied, having the appropriate capacity, over current protection and safety lockouts available?

EXCELMASTER requires:

°© 400V at 50/60hz with 15 amp service. Use a Nema 6-20R.

Page 6

Fig. 3

INSTALLATION

1. Shipping damage should be

brought to the immediate attention of the delivering carrier.

2. With assistance, carefully roll

the laminator into position over flat and even surfaces.

3. The laminator should be

positioned to allow exiting film to flow freely to the floor or a work table (Figure 4). Accumulation of laminate immediately behind the laminator as it exits the equipment may cause the film to wrap around the pull rollers, resulting in a “jammed” condition.

4. Avoid locating the laminator near

sources of heat or cold. Avoid locating the laminator in the direct path of forced, heated or cooled air.

5. Once the laminator has been

properly positioned, lock the castors in place. Locking the castors prevent the machine from rolling during set up, operation or servicing.

6. Connect the attachment plug

provided with the laminator to a suitably grounded outlet. 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 7

TOP

  

BOT0℃ 

Release  WAIT 

   



  

 

Fig. 4



SPEED0℃ 

JOB

CONTROL GUIDE

Located at the back left of the machine applies power to the laminator. The control panel display will illuminate when position marked “l” is pushed. The off position, marked “O”, removes power from the laminator.

B. CONTROL PANEL DISPLAY:

(Figure 4) Illuminates when the laminator is plugged in and POWER ON/ OFF is in the on, (I), position. Displays settings for top heater, bottom heater, speed, Job, mode and ready/wait/ positioning indicator.

ROLLER POSITION INDICATOR:

Displays the current main roller position. In figure 7, the roller is shown in the “Release” position. Refer to Roller Handle for more information.

READY/ WAIT INDICATOR:

“READY” appears when actual temperature is equal to (+/- 5) set temperature. “WAIT“ appears when actual temperature is lower than the set temperature. “WAIT” appears when actual temperature is higher than the set temperature.

POSITIONING INDICATOR:

“Positioning...” appears in place of the ready/ wait indicator any time the main rollers are traveling in an upward or downward motion.

C. CONTROL PANEL: (Figure 6)

MASTER DIAL :

or decreases (-) the numeric value for the selected setting when

Increases (+)

Fig. 5

display actual temperature of top and bottom main rollers.

Top Temp. :

When pressed,

permits increasing or decreasing of

TOP

  

  

BOT 0℃ 

Release 

 

WAIT 

   



SPEED0℃ 



JOB

the top temperature by turning the

MASTER DIAL

indicated on the control panel display. Range is 0

and is

- 150OC).

Top Temp.

Bottom Temp.

Press/Release Coolin g

Speed

Job

Bottom Temp. :

pressed, permits increasing or decreasing of the bottom temperature by turning the

and is indicated on the control

When

MASTER DIAL

panel display. Range is 32oF 0OC - 150OC.

Rev. Stop Run

Fig. 6

Page 8

Fig. 7

Press/ Release :

pressed, raises the upper main roller over riding the pull roller handle setting. When pressed again, reverts to current pull roller handle setting.

Cooling :

pressed, turns on the cooling fans. When pressed again, turns off the cooling fans.

JOB :

scrolling of job numbers by turning the indicated on the control panel

display. Range is 1 - 10. Job 10 is reserved for running Accushield material.

To store parameters for a particular job number, select the desired job number location, enter the upper and lower temperatures and

speed, then press

When pressed, permits

MASTER DIAL

When

(Figure 7) When

and is

JOB

Fig. 8

SPEED :

permits increasing or decreasing of speed by turning the

REWINDER

III

(D)

DIAL

control panel display. Range is 1 -

10.

REV :

reverses roller movement to clear film jams and wrap-ups.

STOP :

the rollers.

RUN :

rollers for normal operation.

D. REWINDER SELECTION SWITCH: (Figure 8) This switch

enables the operator to control the function of the upper rewind/ unwind shafts.

I : In this position, turns the power on to the upper front rewind/ unwind shaft.

In this position, neither the

upper front or upper rear rewind/ unwind shaft is selected for motor power.

II : In this position, turns the power on to the upper rear rewind/ unwind shaft.

When pressed,

MASTER

and is indicated on the

When pressed and held,

Stops the movement of

When pressed, activates

Page 9

FWD.

REV.

"REVERSE"



TOP



  

  

BOT0℃ 

Release 

 

Foot SW Enable 



FWD.

SPEED0℃ 

JOB

REV.

E. UPPER REWINDER DIRECTION SWITCH: (Figure 9) This switch

REWINDER

FWD.

STOP

REV.

(E) (F)

enables the operator to control the direction of the upper rewind/ unwind shafts.

“FWD.” : In this position, the motor runs in a forward direction.

“STOP” : Stops the rewinder motor for the rewind/ unwind shaft selected.

“REV.” : In this position, the motor runs in a reverse direction.

REV.

F . LOWER REWINDER DIRECTION SWITCH: (Figure 9) This switch

enables the operator to control the

FWD.

direction of the Lower rewind/ unwind shaft.

“FWD.” : In this position, the motor runs in a forward direction.

Fig. 9

“STOP” : Stops the rewinder motor

for the rewind/ unwind shaft selected.

“REV.” : In this position, the motor runs in a reverse direction.

G. REAR CONTROL SWITCH:

(Figure 10) This switch enables the operator to run jobs from the rear

"RUN"

operating position of the laminator when rear controls are enabled.

“REVERSE” : In this position, the rollers turn from the front operating position towards the rear operating position.

“STOP” : Stops the movement of

the rollers. “RUN” : In this position, the rollers

turn from the rear operating position

(G)

towards the front operating position.

ENABLE REAR CONTROL SWITCH:

To enable the rear control switch,

Fig. 10

press and hold hear a beep, approximately 3

JOB

until you

seconds. REAR CONTROL replaces READY/ WAIT on the control panel display.

Replace the rear slitter with the safety shield properly installed and latched.

DISABLE REAR CONTROL SWITCH:

Press and hold

JOB

again to

disable the rear control switch. H. FOOT SW ENABLE: (Figure 11)

In this mode permits operation using the footswitch.

To enable the foot switch, press and hold

STOP

until you hear a

beep, approximately 3 seconds.

FOOT SW ENABLE flashes where READY/ WAIT is indicated.

Press and hold

STOP

again to

disable the foot switch.

Fig. 11

Page 10

(E)

(1)

(C)

(A)

(2)

Fig. 12

Fig. 13

(1)

(B)

(2)

(F)

FEATURES GUIDE

A. E-STOP: (Figure 12) Two E-

STOP buttons exist on the laminator. One on each side of the upper cabinet.

To engage (1), press either push button, roller movement is stopped.

To disengage (2), turn the push button clockwise once the emergency condition has been resolved.

B. SAFETY SHIELD INTERLOCK LATCH: (Figure 13) Used to lock

the safety shield into position and activate an interlock switch. The interlock latch is located on the left side of the safety shield. When pushed to the full left (1), the safety shield is locked. When pushed to the full right (2), the safety shield is unlocked.

C. SAFETY SHIELD: (Figure 13) Prevents entanglement, entrapment and inadvertent contact with the heat rollers. The laminator will

operate only when the Safety Shield is located in the fully locked position.

To remove the safety shield, unlock the safety shield interlock latch and lift the safety shield (1) up and away from the safety shield mounting pins (2).

D. FEED TABLE: (Figure 14) The Feed Table is used to position items for lamination. The laminator will

operate only when the Feed Table and Feed Table Latch are properly installed.

E. HEAT ROLLERS: (Figure 14)

Silicone rubber coated steel tubes heat the laminating film and compress the heated film to the items being laminated. Heat is provided by an internal heating element. The heat rollers are motor driven for ease of loading new film.

F. PULL ROLLERS: (Figure 14) The pull rollers, located at the back of the laminator, are motor driven. They simultaneously pull the film and improve the quality of the laminated item.

(D)

Fig. 14

Page 11

G. ROLLER HANDLE: (Figure 15) The roller handle manually sets the position of the pull rollers while simultaneously electronically setting the main rollers.

Available settings are;

Release

(G)

15mm Mounting

10mm Mounting

5mm Mounting

3mm Mounting

Low-Prs Laminating

Mid-Prs Laminating

High-Prs Laminating

– Release – 15mm Mounting – 10mm Mounting – 5mm Mounting – 3mm Mounting – Low-Prs Laminating – Mid-Prs Laminating – High-Prs Laminating

(Prs = pressure)

H. IDLER BAR: (Figure 16) The idler

Fig. 15

bars, located near each heat roller, are used to direct the film to the heat roller nip.

I. CHILL IDLER: (Figure 16) Assist

(H)

(2)

in the cooling process of the web material as it exits the heat rollers.

(J)

To engage the chill idler, grip the chill idler handles located on each side of the chill idler and lower to

(I)

the web position (1). To disengage the chill idler, move the chill idler to it’s rest position (2).

(1)

J. COOLING FANS: (Figure 16) Assist in the cooling process by pushing unheated air onto the web material as it exits the heated rollers. This feature can be controlled from the control panel.

K. FILM SHAFT: (Figure 17) The film shaft holds the film supply on the machine.

To remove the film shaft, lift up on

Fig. 16

the round end (1) of the unwind/ rewind shaft then pull the hex end (2) of the shaft out and away from the laminator.

(1)

(L)

(K)

L. CORE ADAPTORS: (Figure 17) Hold and lock the rolls of film on the shafts to prevent side to side shifting.

(2)

M. LOWER SHAFT LOCK: (Figure

17) Secures the left side of the lower shafts. To remove a shaft, turn the outer dial (1) opening so it aligns with the inner u-channel (2) opening and lift up and out.

N. UNWIND/ REWIND TENSION:

(Figure 17) Used to apply resistance to the film shaft.

To increase film shaft tension, turn the film shaft tension knob clockwise. Counter clockwise will decrease film shaft tension.

(1)

(2)

(M)

(N)

Fig. 17

Page 12

(1)

(R)

Fig. 18

(1)

Fig. 19

(Q)

(S)

(2)

(O)

(P)

O. REWIND SHAFT: (Figure 18) The rewind shaft holds the rewind tube on the machine.

P. REWIND TUBE: (Figure 18) The two rewind tubes located at the front of the machine are used to rewind release liners. The one located at the rear of the machine is used to rewind the finished product.

Q. REWIND ADAPTORS: (Figure

18) Hold and lock the rewind tube on the rewind shafts to prevent side to side shifting.

R. REAR TABLE: (Figure 19) Provides a working surface when operating the machine from the rear. This table may also be lowered when webbing for roll to roll applications.

To lower, slide the left and right side rear table latches (1) to the unlatched position and lower the rear table.

S. REAR SLITTER: (Figure 19) Used to cut the film web where it exits the rear of the laminator.

To make a cut, push down on the blade engage lever and slide to the apposite side.

T. FILM WEB: Laminating film loaded into the machine.

U. NIP POINT: The point at which the top and bottom rollers come into contact. The Nip Point of the heat rollers is the place at which the items for lamination are introduced into the laminator.

V. FOOTSWITCH: (Figure 20) Used to assist in webbing of the machine and initial feeding of material.

W. PRINT UNWIND BASKET:

(Figure 20) Holds a rolled image. Prevents the image from touching the floor.

X. SEPARATOR BAR OPTION:

(Figure 18) Required if running Micronext® material.

To install, replace the rear slitter with the separator bar.

Y. REWIND KIT OPTION: Enables roll to roll webbing of material. This kit must be installed by a qualified GMP service representative.

(W)

(V)

Fig. 20

Page 13

(1)

Polyester surface

Fig. 21

Fig. 22

Adhesive

surface

Adhesive

surface

Poly-in

Poly-out

OPERATING INSTRUCTIONS

FILM LOADING & THREADING

The top and bottom rolls of laminating film must be of the same width and be present simultaneously. A small amount of adhesive will “squeeze out” during lamination. Hardened adhesive deposits can damage the heat rollers. To avoid any damage, select “Low-Prs Laminating” on the roller handle, rotate the rollers at slowest speed with heat on. Refer to the section entitled

FOR THE LAMINATOR

for instructions regarding removal of the accumulated adhesive.

Adhesive will deposit on the rollers if:

- Only one roll is used.

- Different widths of rolls are loaded together.

- Either roll is loaded adhesive side against a heat roller.

- One or both rolls of film are allowed to run completely off its core.

The adhesive side of the film is on the inner side of the web (Figure

21). The shiny side of clear film

must contact the heat rollers. The dull side of the film contains the adhesive. Use extreme caution when loading delustered (matte) film as both sides appear dull.

Always change the top and bottom supply rolls at the same time. Near the end of each roll of GMP 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.

To load a roll of film; (Figure 22)

1. Lift up on the round end, left side (1), of the unwind/ rewind shaft.

2. Pull the hex end, right side (2), of the shaft out and away from the laminator.

(2)

3. Slide the roll of film onto the film shaft ensuring adhesive side is out.

4. Replace the shaft with the hex end in first then the round end.

5. Center the roll of film.

CARING

Page 14

Fig. 23

Fig. 24

LOADING TOP THERMAL FILM

This procedure describes how to load the upper roll of film onto the laminator. Figure 23 uses poly-in film and the upper rear unwind/ rewind position for illustration purpose.

1. Turn the Power ON/OFF to on (I). Set top heat temperature for the film type you are using.

2. Ensure no brake tension is applied to the film shaft.

3. Remove the safety shield and pivot the feed table down.

4. Pull the top roll of film down under the idler bar and allow to drape over the top heat roller (Figure 23).

5. Reference one of the loading bottom material procedures.

LOADING TOP PSA FILM

This procedure describes how to load the upper roll of film onto the laminator. Figure 24 uses PSA film and the upper rear unwind/ rewind position for illustration purpose.

1. Turn the Power ON/OFF to on (I). If the laminator is already hot, turn POWER ON/OFF to the off (O) position and allow the unit to cool. Once cool, turn the laminator back on.

2. Ensure no brake tension is applied to the film shaft.

3. Remove the safety shield and pivot the feed table down.

4. Set the roll of film in the rear unwind/ rewind position and the rewind tube in the front unwind/ rewind position.

5. Pull the top roll of film down under the idler bar and up the upper front rewind tube.

6. Place one piece of masking tape in the center of the film and secure to the rewind tube.

7. Make two full wraps around the rewind tube, then carefully score the laminate without cutting the release liner.

8. Pull the laminate down allowing it to drape over the upper main roller.

9. Reference one of the loading bottom material procedures.

Page 15

Fig. 25

Fig. 26

LOADING TOP MOUNT ADHESIVE

This procedure describes how to load a roll of mount adhesive using the upper position for pre-coating (Figure 25).

1. Turn the Power ON/OFF to on (I). If the laminator is already hot, turn POWER ON/OFF to the off (O) position and allow the unit to cool. Once cool, turn the laminator back on.

2. Ensure no brake tension is applied to the film shaft.

3. Remove the safety shield.

4. Set the roll of mount adhesive in the upper rear unwind/ rewind position.

5. Pull the mount adhesive over the upper idler and upper main roller allowing the material to rest on the top of the feed table.

6. Reference

PROCEDURE

LOADING BOTTOM THERMAL FILM

This procedure describes how to load a roll of thermal film using the lower unwind position for encapsulation (Figure 26).

1. At this point you should have an upper roll of thermal film loaded onto the laminator.

2. Ensure no brake tension is applied to the film shaft.

3. Guide the bottom film around the lower idler.

3. Adhere the film to the loaded upper roll of thermal film by pulling the film up towards the existing draped thermal film over the main rollers.

NOTE: You may follow this procedure to load a roll of Kraft Paper for single side lamination.

4. Reference

PROCEDURE

THREADING CARD

next.

THREADING CARD

next.

Page 16

Fig. 27

LOADING BOTTOM PSA FILM

This procedure describes how to load a roll of mount adhesive using the lower unwind position for decaling (Figure 27).

1. At this point you should have an upper roll of PSA film loaded onto the laminator.

2. Ensure no brake tension is applied to the film shaft.

3. Pull the lower roll of film around the lower idler bar and towards the lower rewind.

4. Place one piece of masking tape in the center of the film and secure to the rewind tube.

5. Make two full wraps around the rewind tube, then carefully score the laminate without cutting the release liner.

6. Adhere the lower PSA film to the loaded upper roll of film by pulling the film straight up towards the main rollers.

7. Reference

PROCEDURE

THREADING CARD

next.

Fig. 28

LOADING BOTTOM MOUNT ADHESIVE

This procedure describes how to load a roll of mount adhesive using the lower unwind position for decaling (Figure 28).

1. At this point you should have an upper roll of film loaded onto the laminator.

2. Ensure no brake tension is applied to the film shaft.

3. Adhere the mount adhesive to the loaded upper roll of film by pulling the mount adhesive straight up towards the main rollers. Do not web around the lower idler.

4. Reference

PROCEDURE

THREADING CARD

next.

Page 17

Threading card

Fig. 29

THREADING CARD PROCEDURE

This procedure describes how to feed two loaded films through the main rollers (Figure 29).

1. At this point you should have an upper roll of film and lower roller roll of film loaded onto the laminator with the appropriate material for your application.

2. The table and safety shield must be properly installed.

3. Push the threading card into the main roller nip. The threading card becomes sandwiched between the upper and lower loaded films.

4. Set the roller handle to a laminating position, press the

RUN

5. Once the threading card has exited the laminator, press the

STOP

6. Use the rear slitter to cut the threading card from the web.

7. If you are not running the laminator, set the roller handle to the “RELEASE” position.

8. Now refer to the section entitled

START LAMINATING

button.

Page 18

Fig. 30

START LAMINATING

1. The safety shield and feed table must be in the normal operating position.

2. Select a job mode ( ensure the proper speed and

temperatures are set. Refer to the section entitled

) and

SPEED/

TEMPERATURE GUIDE.

3. Set the roller handle to one of the laminating positions.

4. Press the PRESS/ RELEASE ( ) button. The main rollers gap.

5. Press the RUN ( ) button.

6. Press the PRESS/ RELEASE ( ) button. The main rollers close.

7. Adjust unwind and rewind tensions as necessary.

8. Align the leading edge of the item square to the heat roller nip (Figure 30).

9. With both hands and an outward force push the image slower than the speed of the rollers into the nip of the heat rollers (Figure

31).

CAUTION: Avoid forcing the image into the main roller nip as this action will cause the corners of the leading edge to buckle and create a wave.

Fig. 31

Page 19

Cut here

METHOD FOR TACKING NEW FILM TO EXISTING FILM

The following describes a method for loading film whereby the existing film present on the heat rollers may be used in place of the threading card to draw the new film through the laminator. The adhesive of the existing film must be tacky or liquefied. Leading edges of the new film will be overlapped onto the tacky adhesive of the old film. The existing film and the new film will be pulled through the laminator together.

1. Cut remaining top and bottom film webs between the idler bar and heat rollers (Figure 32).

New film

Fig. 32

Fig. 33

CAUTION: DO NOT CUT THE HEA T ROLLERS WHEN CUTTING THE FILM WEB.

2. Remove the safety shield and tilt the feed table down.

3. Do not allow the adhesive side of the film to contact the heat or pull rollers. Liquefied or tacky adhesive deposited on heat rollers will require the rollers to be cleaned per the section entitled

CARING FOR THE

LAMINATOR

4. Replace both the top and bottom rolls of film with new rolls. Ensure the adhesive side is facing out.

5. Pull the film around the idler bars, with the exception of PSA mounting adhesives without a release liner.

6. Tack the new film to the existing film on the heat rollers. For PSA film, attach the release liner to the rewind tube (Figure 33).

7. Replace the safety shield and feed table.

8. Use the footswitch to advance the film into the heat roller nip.

9. Observe the film being pulled through the laminator to assure that the remaining existing film and the new film are advancing concurrently. Any separation between the films will require stopping the motor immediately and the situation corrected.

10. Press STOP ( ) once the newly threaded film has

completely exited the pull rollers.

Page 20

Pull web

Cut web

Fig. 34

Fig. 35

Cut web

TO UNWEB THE LAMINAT OR

Unweb the laminator if you are changing film widths, cleaning the rollers or have finished using the machine for the day.

1. Using the rear slitter, cut the output from the web (Figure 34).

2. Set the roller handle to the “Release” position.

3. Remove the safety shield and tilt the feed table.

4. Cut remaining top and bottom film webs between supply rolls and heat rollers (Figure 34). Be

careful not to cut any of the rollers!

5. Carefully grab hold of the web (top and bottom film), from the front operating position and pull towards you (Figure 35).

6. Do not allow the adhesive side of the film to contact the heat or pull rollers.

CLEARING A FILM JAM (Wrapup)

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 heat rollers during webbing if a threading card is not used or pull rollers during operation.

To clear a jam:

1. Immediately stop the laminator by pressing STOP ( ).

2. Remove the safety shield and tilt the feed table.

3. Press and hold REVERSE ( ) until the jam has cleared the heat

rollers or pull rollers

4. Set the roller handle to the “Release” position.

5. Manually assist the material through the main rollers and/ or pull rollers.

6. Once the jam has been cleared, set the roller handle to one of the laminating positions.

7. You can now resume laminating.

Page 21

Trailer board

Board

Fig. 36

Fig. 37

Mount

adhesive

Leader board

APPLICATIONS

TIPS FOR PRE-COATING BOARDS (Figure 36)

1. Load the laminator as illustrated in Figure 36.

2. Ensure the chill idler is in the rest position.

3. Set the roller pressure handle to the correct thickness.

4. The width of the roll should not exceed the width of the board by more than 1/2 in. (1.3 cm).

5. Use a leader board to start the run and a trailer board to finish the run.

6. Using the pull rollers will allow you to leave gaps between boards.

7. If not using the pull rollers, have the boards nearby to butt end to end during feeding.

TIPS FOR USING THE REAR ROLLERS (Figure 37)

1. If the front rollers are heated, you may perform certain applications from the rear operating position of the laminator.

2. Ensure the chill idler is in the rest position if using boards.

3. Ensure the safety shield is located in the rear position.

4. Ensure the REAR CONTROLS have been enabled.

5. You may perform mounting applications, pre-coating applications and single side applications from the rear of the machine.

Image

Release liner

Pre-coated board

Fig. 38

TIPS FOR MOUNTING PRECOATED BOARDS (Figure 38)

1. Load the laminator as illustrated in Figure 38.

2. Ensure the chill idler is in the rest position.

3. Ensure the chill idler is removed, the rear slitter is to one side and the inline slitters are not obstructing the path of the boards.

4. Heat, 125 OF (52 OC), may assist the process and increase output quality.

5. Do not stop once you have started the mounting process through the machine.

Page 22

Image

Roll

of Kraft

Paper

Roll of Mount Adhesive

If using PSA Film

Fig. 39

If using PSA Film

of film

Decal

Roll

TIPS FOR SINGLE SIDED LAMINATION (Figure 39)

1. Load the laminator as illustrated in Figure 39.

2. Use kraft paper for one-sided lamination whenever the items to be laminated are narrower than the film you are using.

3. If not using kraft paper, use a scrap piece to finish the run or you will have adhesive on your rollers.

4. Running the web over the chill idler may improve the flatness of the output.

5. A little heat, 125

F (52 OC), may help eliminate silvering effects associated with PSA films.

TIPS FOR CREATING A DECAL (Figure 40)

1. Load the laminator as illustrated in Figure 40.

2. The over laminate may be PSA or thermal type.

3. If using thermal type, pay attention to the Poly-in/ Poly-out rule.

4. Run a test material prior to running the actual image to ensure flat output.

5. Use minimal brake tension to achieve quality output.

6. Do not web the PSA mount adhesive around the lower web idler.

Release liner

Board

Fig. 40

Image

Fig. 41

TIPS FOR MOUNTING A DECAL (Figure 41)

1. Load the laminator as illustrated in Figure 41.

2. The image should not exceed the width of the board by more than 1 in. (2.54 cm) per side.

3. Tack about 1 in. (2.54 cm) of the leading edge of the decal to the leading edge of the board.

4. When tacking the leading edge, start in the center and work to the sides.

5. Use a board that exceeds the size of the decal if inexperienced in the mounting application.

Page 23

Image

Roll

of PSA

Film

Poly-in

Fig. 42

Fig. 43

Roll

of PSA

Film

Poly-in

TIPS FOR PSA ENCAPSULATION (Figure 42)

1. Load the laminator as illustrated in Figure 42.

2. Always use two rolls of the same width.

3. Use minimal brake tension to achieve flat output.

4. The separation of the laminate and the release liner should be maintained close to the heat rollers.

5. A little heat, 125

F (52 OC), may help eliminate silvering effects associated with PSA films.

6. Use of the chill idler may or may not help in the output quality. Try both methods.

TIPS FOR THERMAL ENCAPSULATION (Figure 43)

1. Load the laminator as illustrated in Figure 43 for Poly-in film.

2. Dotted line represents Poly-out film web path.

3. Always use two rolls of film the same width.

4. Use minimal brake tension to achieve flat output.

5. Increase speed gradually to maintain the activating temperature required for the laminate you are using.

6. Length and width of image, ink coverage and paper type may effect the temperature and speed recommended in the SPEED/ TEMPERATURE GUIDE.

Micronex

Image

Roll of

Kraft Paper

Option

Rewind of Kraft Paper

(Must have roll to roll option)

Fig. 44

Rewind of liner

TIPS FOR MICRONEX (Figure

44)

1. Load the laminator as illustrated in Figure 44.

2. You must have the Separator bar option to accurately run this material.

3. Liner rewind tension will be greater than normal operating standards.

4. Do not attempt to run this material greater than a speed setting of 4.

5. To prevent some adhesive adhering to the rollers, you may choose to use a roll of kraft paper for a carrier with the roll to roll rewind option installed.

Page 24

THE ART OF LAMINATION

BASIC RULES Do not attempt to laminate abrasive or

metal objects such as staples, paper clips and glitter, as they may damage the heat or pull rollers.

Do not force items into the nip area of the heat rollers. An item that is not easily drawn into the laminator by the heat 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 heat rollers.

Do not stop the laminator before an item has completely exited the pull rollers. Even a momentary stop will cause a mark (heat line) on the laminated item.

Good, consistent lamination is a result of combining proper heat, 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 heat rollers.

As a general rule, thicker items and film need to run at slower speeds because they extract more heat from the rollers at a quicker rate. 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 lb. bond) and tissue paper, extract less heat from the rollers and can be run at faster speeds.

FILM TENSION

Proper film tension, known as brake tension, is the minimum amount required to eliminate wrinkles in the finished item. The film should be taut. 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 while too much bottom tension causes downward curl.

The pull roller clutch is set at the factory. Periodic adjustments may be necessary if after adjusting unwind and rewind brake tensions do not improve your output quality.

Page 25

- A - - B -

Fig. 45

- A - - B -

Fig. 46

HEA T

The “WAIT (Too COLD)” indicator may appear if the speed is set too fast for the material being laminated. Either lower the speed setting or

press STOP “READY” indicator appears.

Operation of the laminator for more than thirty minutes at a time may necessitate a lower speed setting. It is recommended that, during periods of long runs, the items being laminated are alternated between thick and thin. 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. This procedure is recommended because rotating the heat roller prior to lamination will more evenly distribute the heat. Make speed adjustments if necessary.

OUTPUT

1. “D” waves in the image (Figure 45 A).

– Check paper tension. – Paper may be damp or not dry.

2. “D” waves in the laminate (Figure 45 B).

– Change roller handle pressure.

3. Straight waves in output (Figure 46 A).

– Check operational settings for

materials being used.

4. Indent waves in output after pull rollers (Figure 46 B).

– Insufficient cooling time. – Output was handled prior to

cooling.

– Use cooling feature if not on. – Machine was stopped on print.

5. Angled waves in the output (Figure 47 A & B).

– Change roller handle pressure. – Check for even paper tension

(Figure 46 A only)

and wait until the

- A - - B -

Fig. 47

Page 26

MAINTENANCE

CARING FOR THE EXCELMASTER-1600 LAMINATOR

GMP offers Cleaning kits as well as Extended Maintenance Agreements.

Contact your local GMP Service Representative or your dealer/distributor for additional information.

The only maintenance required by the operator is to periodically clean the heat rollers and schedule semi annual maintenance checks.

The following procedure will help keep the heat rollers free of adhesive that has been deposited along the edge of the laminating film. Proper alignment of the rolls of film reduces the amount of “squeeze out”.

WARNING: Do not attempt to laminate adhesives marked

“Flammable”.

• Do not laminate glitter and/ or metallic items. Damage to the rollers may result.

WARNING: Do not apply any cleaning

fluids or solvents to the rollers. Some solvents and fluids could ignite on heated rollers.

• Never clean rollers with sharp or pointed

objects.

• Hardened adhesive deposits on the rollers

can cause damage to the rollers. Rotate the rollers at the lowest speed setting on the control panel.

CAUTION: THE FOLLOWING PROCE-

DURE IS PERFORMED WHILE THE LAMINAT OR IS HOT . USE EXTREME CAUTION.

1. Remove the film from the laminator following

the procedure outlined in steps 1 through 6 of the section entitled

TO UNWEB THE

LAMINATOR.

2. Preheat the laminator until the “READY”

indicator appears.

3. Remove the safety shield and tilt the feed

table.

4. Rub the top and bottom heat rollers with a

3M™ Scotch-Brite™ pad . DO NOT USE

METAL SCOURING P ADS!

5. Use the footswitch to rotate the lower heat/

pull roller to an unclean portion. The upper heat/ pull rollers are free spinning. Continue this process until the complete surface of both rollers are clean.

6. Refer to the beginning of the section entitled

OPERATING INSTRUCTIONS

laminator.

*NOTE: Do not use metal scouring pads to clean the rollers.

to web your

Page 27

TROUBLESHOOTING GUIDE

SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

• The control panel display does not Laminator not connected to Insert attachment plug into receptacle. illuminate when POWER ON/OFF is electrical supply. in the ON, marked “I”, position.

• Heat rollers do not turn when I Safety shield is not properly Remove safety shield and properly replace it. press the RUN ( ) button. installed.

Feed table not properly installed. Tilt feed table and properly replace it. E-STOP is engaged Pull out on the E-STOP push button.

• Heat rollers only turn if I use Laminator is in Footswitch mode. disengage the footswitch mode. the footswitch.

• Rear controls do not operate. Rear controls are not enabled. Enable rear controls.

Safety shield is not installed in Remove the rear slitter and install the safety shield. the rear position.

• Laminated items exhibit curling. Tension between the top and bottom Adjust tension per section

film roll is unequal. Tension on top or bottom roll of Adjust tension per section

film is too loose. Speed setting too slow. Slightly speed up the laminator. Bottom film roll may be improperly Make sure bottom roll of film is around idler bar and the it is in the

loaded. normal operating position. Chill idler not used. Move the chill idler to the web position.

• Adhesive deposited on heat rollers. Top and bottom film webs not Release heat and pull roller pressure, align the rolls of film.

aligned. Laminate improperly loaded. Adhesive (matte) side of laminate film may be against the heat

rollers. Unweb and reload the film properly.

• Unsatisfactory adhesion of laminate. Speed setting too fast for type of Lower speed setting by pressing SLOW button to slower speed

material being laminated. Insufficient heat. Wait for “READY” indicator to appear in the control panel display. Laminate improperly loaded. Adhesive side of film must be facing away from the heat rollers.

Bottom roll of film not threaded behind the idle bar.

Heat rollers require cleaning. Clean heat rollers per procedure in section

FILM TENSION

Laminated item unsuitable for Item may be dirty or may have nonporous surface that is adhesion. extremely difficult to laminate.

• Waves in my output See sub section

Nips may be out of calibration. Place a service call for calibration check.

OUTPUT

. Under section titled

THE ART OF LAMINATION