Ledco Compass Operation Manual

READ ALL PRECAUTIONS & INSTRUCTIONS CAREFULLY

BEFORE OPERATING LAMINATOR

Setup

Instruction

Operation

Lamination

Maintenance

Compass

Hot Roll Laminator

Operation

Manual

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IMPORTANT: Don’t laminate one-of-a-kind documents unless you are sure of your
laminating skills and can afford to damage or ruin the document.

Don’t laminate valuable items such as stamps, baseball cards, autographs, or other

collectibles because the value of such items can be destroyed by lamination. Collectors
generally value these kinds of items only in their original state.

Remember that you cannot laminate thermal paper because it is activated by heat and
will turn black. Also, remove paper clips and staples because they can damage the
rubber rollers. Be careful about laminating anything that will be affected by heat. For
example, the colors in crayon drawings may run together or be smeared, especially if
the crayon layer is heavy. Light crayon drawings may not be affected, but test an
expendable sample of any item that may not laminate well.

IMPORTANT: Éviter de plastifier du papier thermosensible, comme le papier de

télécopieur, pusqu’ll noircira sous l’effet de la chaleur, et enlever les trombones et les

agrafes gul risquent d’endommager les rouleaux de caoutchouc. Prendre certaines

précautions avant de plastifier des articles susceptibles de réagir à la chaleur comme
les dessins au pastel dont les couleurs baver et se mélanger, surtout si la couche de
pastel est épaisse. Les pastels en couche mince peuvent ne pas réagir, mais, en cas
de doute, il est préférable de faire un essai avec un échantillon perdu.

Ne pas plastifier les documents importants dont il n’existe qu’un seul exemplaire, à

moins de bien malitriser la technique de plastification.
Ne pas plastifier non plus les articles de collection comme les trimbres, les cartes de

baseball, les autographes ou autres, qui peuvent perdre leur valeur pour les
collectionneurs s’ils ne sont plus dans leur état d’origine.

IMPORTANTE: Recuerde que no puede laminar papel térmico, tal como el papel de
fax tipico, ya que es activado por el calor y se tornará negro. Retire también cualquier
sujeta-papeles o grapa, puesto que pueden danar los rodillos de goma. Evite laminar
cosas sensibles al calor, por ejemplo, los colores de dibujos hechos en lápiz de pastel
pueden no ser afectados, pero ensaye con alguna muestra descartable, en los ìtemes
que podrían no laminarse bien.

No lamine ningún documento único, a no ser que esté muy seguro de sus habilidades
de laminador y pueda permitirse arruinar el documento.

No lamine artículos de valor, como estampillas, tarjetas de béisbol, autógrafos, u otros
coleccionables, ya que su valor puede ser destruido por la laminación. En general, las
coleccionistas valoran este tipo de artículo en su estado original.

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TABLE OF CONTENTS

1 INTRODUCTION
1-1 Introduction

1-2 Features and benefits
1-3 Specifications
1-4 Principles of operation
1-5 Laminating films
1-6 Warranty

2 UNPACKING AND INVENTORY

3 PRODUCT ILLUSTRATIONS AND NAMES OF PARTS

3-1 Display
3-2 Threading diagram
3-3 Film loading procedure

4 SAFETY PRECAUTIONS

5 SETUP AND OPERATION

5-1 Setup and operation

5-2 Laminating
5-3 Recommended temperature settings
5-4 Laminating

5-5 Preventing and solving problems (hot)

6 CLEANING AND MAINTENANCE

6-1 Cleaning and maintenance

6-2 Cleaning the rubber rollers
6-3 Lubrication

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1-1 INTRODUCTION

The Compass hot roll laminator is designed to provide quality lamination of a wide
range of papers and materials up to 1/8th inch / 3.2 mm thick using film up to 10 mils
thick. Common hot applications include, but are not limited to, maps, digital imaging, ink
jet prints, packaging, posters, instructional aids, signs, presentation materials,
photographs, copies (B&W or color), prints, flyers, promotional sheets, and many other
items.

To assure the best performance from your new laminator, please follow the safety,
installation, operation, and maintenance instructions in this manual. Read the manual
before using the laminator, keep the manual with the machine, and periodically review
the instructions. The manual also contains warranty and parts information.

Thank you for selecting the LEDCO Compass hot roll laminator. We are committed to
your satisfaction.

As you unpack your new laminator, please complete the following information. Always
have this information ready when calling.

Purchased From________________________________________________________

Installation Date ___________________________Serial # ______________________

WARNING: High temperatures are present, and care
should be exercised in operating the laminator.

MISE EN GARDE: La machine à plastifier produit

beaucoup de chaleur et on doit l’utiliser avec

prudence.

ADVERTENCIA: El plastificador produce

temperaturas muy altas; tenga cuidado al

utilizaro.

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WARNING: The laminator should not be operated
without the plexiglass safety shield.

MISE EN GARDE: Ne pas utiliser la machine à

plastifier sans son écran protecteur en plexiglass.

ADVERTENCIA: No utilice el plastificado sin

tener el protector de plexiglass en su lugar.

LEDCO, Inc.

4265 North Main Street

Hemlock, NY 14466 USA

Phone: [phone]

Fax: [phone]

www.ledcoinc.com

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Glossary Of Symbols Part No.

1. Hand Crush/Force from Above Lab35

2. General Danger Lab52

3. Arm Entanglement Lab51

4. Cutting of Fingers or Hand/Straight Blade Lab54

5. Hand Entanglement/Chain Drive Lab36

6. International/Hot Warning Lab100

7. Electrical Hazard Lab 43

8. CE European Electrical Lab06

9. International Ground Lab79

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1-2 FEATURES AND BENEFITS

Your new laminator has several standard features that set it apart from other models.
 Automatic voltage detection. Automatically detects and adapts to power supply

(100-120 v AC or 200-240 v AC)

 Variable speed. The laminator operates at any speed up to 15 feet / 4.5 meters per

minute. Thicker hot films are generally applied better at mid-range to lower speeds,
while 1.5 mil hot films should be applied at mid-range to higher speeds.

 Precision heat control. The programmable digital heat control prevents the

laminator from operating outside the optimum temperature for your film and provides
consistent heating of the laminating rollers throughout the entire temperature range.

 Ease of cleaning. The heated silicone rubber laminating rollers and the silicone

rubber pull rollers of the laminator should be cleaned regularly. The safety shield
(see below) on the laminator removes in seconds, making it easy to clean the
laminating rollers.

 Attached safety shield. The polycarbonate shield is clear so operators can see

their work and does not conduct heat so they’ll be protected from hot areas. It is
fixed to the feed tray, and the laminator will not operate if the safety shield is not in
place.

 Lamination pressure. The rubber rollers are spring-loaded and preset to ensure

correct and even lamination pressure.

 Film tension controls. Film tension is controlled at the idler roller instead of on the

mandrels like most laminators. It requires virtually no adjustment and makes loading
new film rolls simple.

 Ease of maintenance. The Compass is made to last. However, some items on a

laminator do wear out. Even the high-quality silicone rubber used in the rollers will
lose flexibility over time. Extensive use may wear out the rollers, or an operator may
cut a roller by accident. Rollers and other key parts can be changed quickly without
disassembling the frame. Parts are available by calling the LEDCO Service

Department at 1-800-937-9293 or 1 [phone].

 Reverse. The reverse switch can be invaluable to help avoid problems or clear

misfeeds.

 Right and left adjustable feed guides.
 Silicone rubber laminating rollers. The rollers are flexible enough to provide a

good edge seal and firm enough to offer a good surface seal. A high silicone content
ensures a much longer average roller life.

 Very strong steel cores. These prevent roller flexing and insure uniform pressure

across the width of the laminate, giving you the best quality lamination available in a
medium-duty commercial machine.

 Laminate supply gauge with low film warning system. The information screen

on the laminator displays remaining film supply and flashes a warning symbol when
there is less than 10% remaining, helping to prevent out-of-film wrap-arounds.

 Automatic Standby/Shutdown Mode: Automatically switches to standby after 30

minutes and automatically shuts off after 60 minutes to save energy.

 Designed, assembled, and tested in the USA.

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1-3 SPECIFICATIONS

Max laminating width 27” / 70 cm

Speed 15 FPM / 5 m/min

Laminating/pull roller diameter 2.25”/ 5.715 cm

Supply roll core size 1”/ 2.54 cm

Recommended film up to 10 mil, 0.25 mm

Max laminating thickness 1/8” / 3 mm

Max film roll diameter 6” / 15cm

Dimensions 38”L x 23”W x 16”D
97cm L x 58cm W x 38 cm D

Shipping dimensions 40”L x 24”W x 17”D
101cm L x 61cm W x 41 cm D

Weight/shipping weight 85 lbs / 40kg
105 lbs / 51kg

Motor 1/30 HP D/C

Electrical (single phase) 100-120 VAC 12A
200-240 VAC 6A
50/60 Hz

Electrical connector IEC-C14 (back panel)
mates with IEC C-13 cord connector

Heaters (2 X 750 watts) 1500 watts total

Maximum film capacity

with 1.5 mil 1200 ft / 365 m
with 3 mil 700 ft / 214 m

NOTE: The Compass relies on your building or facility’s electrical system circuit
breaker protection. Please ensure this system is operational to avoid damage to
your machine.

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1-4 PRINCIPLES OF OPERATION

Hot roll laminators operate by pulling film with a thermally activated adhesive through a
heated set of laminating rollers. Film from the supply rolls passes over heated rolls to
activate a polyethylene adhesive layer on the film. It then passes through rubber rollers
to apply pressure and bond the film to the item being laminated. The adhesive is
pressed into the ink and fibers on the surface of the paper (see section 5-3).

The strength of the lamination bond can be checked by cutting a large “X” on the
surface of (but not through) a laminated sample with a sharp blade. Use the tip of the
blade to pry up one corner of the “X”. Grab that corner and pull up the film. Ink and/or
paper fibers coming up with the layer of film indicates a good adhesive bond.

If the film comes up too easily, with no ink or paper, the lamination was probably done
at too low a temperature. Check the instructions that may have come with your
laminating film and/or the lamination temperature chart in section 5-3.

Please note that when doing an X-test on glossy (coated) paper, a good X-test will pull
up ink only. The film should not come up easily. When laminating material that is not
glossy (uncoated), the paper is often more fibrous and a good X-test will yield ink and
paper fibers coming up with the film.

The Compass hot roll laminator is ideal for encapsulation and can accept substrates up
to 1/8 inch / 3 mm thick.

Designed for sign and graphics applications, hot roll machines are used in many
settings including schools, sign shops, photo-finishing labs, reprographics shops, and
manufacturing plants.

Using a hot roll laminator is much easier than doing the same work by hand. Fast and
versatile, it requires little instruction for you to be up and running. Film tension is
controlled with slotted wheels. The laminating roller gap is preset. Hot roll laminators will
apply most materials under a wide range of speeds and tension settings.

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1-5 LAMINATING FILMS

Most thermal (hot) laminating film consists of two layers: a base of polyester and an
adhesive layer of polyethylene. The polyester layer forms the harder, outer surface of
the film and does not melt at laminating temperature. It provides rigidity and protection
for your laminated items. The greater the polyester content, the higher the level of
protection, rigidity and luster. The polyethylene layer melts at laminating temperature
and bonds the film onto the subject material under the pressure of the laminating
rollers. As an X-test demonstrates, the adhesive is pressed into the paper and fills
irregularities in the surface.

The proportion of polyester and polyethylene in a film is usually described with
numbers. For example, a “1-2” film consists of one mil of polyester and two mils of
polyethylene. The first number refers to the base layer. The second number refers to
the adhesive layer. A mil is 1/1000 of an inch.

Since polyester is the more costly of the two types of plastic generally used in

laminating film, a “3-2” film will cost more than a “2-3” film. Both are 5-mil films but the
“3-2” version will seem a little thicker on a piece of laminated material because it will be

slightly stiffer. Thermal laminating films are available in many different base/adhesive
combinations. Five mil films, for example, can be found in 1-4, 2-3, 3-2, and 4-1
combinations.

In the US laminating trade, the generally accepted practice is to describe two-sided
lamination, or encapsulation, by the thickness of one layer of film. For example, “3-mil
lamination” should refer to lamination with two layers of 3-mil film. If you are buying or
selling laminating film or lamination services, please make sure both parties understand
the film descriptions being used. There is a huge variety of thermal laminating films
available to suit many different kinds of application. Here are some of the more
commonly used “special” film types or film additives:

 Film with low-melt adhesives, also known as co-polymer films. These often have

better clarity and are less likely to curl or ripple.

 Matte films to eliminate glare or to accept printing or writing. Many suppliers offer a

variety of finishes including glossy, matte, satin (in between glossy and matte)
velvet, and textured (crystal) finishes.

 Film with UV inhibitors to protect colors in the laminated material from fading in

sunlight. Note: All polyester films are inherently UV-protectant.

 Thermal film that has a pressure-sensitive adhesive and a release liner on its outer

side. For example, a poster with this material laminated on the back could easily be
mounted without fasteners or tape by removing the release liner to expose activated
adhesive.

 “Liner films” with a protective liner on the top outer surface. After a piece of material

has been laminated, trimmed, packed, and shipped, the person using the material
can remove the protective liner to reveal a surface perfectly free of dust, scratches,
or abrasion.

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 Opaque or colored films for the back side of a lamination. These can form a border

for a laminated piece to add visual interest or a more finished look.

 Iridescent clear films for special visual effects.
 Permanently waterproof films for outdoor, underwater, or special applications. The

most common thermal laminating films are made with water-based primers and will
eventually de-laminate if continually exposed to water or weather; truly waterproof
films are made with special primers.

Rolls of film may be purchased in different widths. The size of the laminator is the only
limitation on the width of the film rolls you can use. Make sure the upper and lower roll
widths are the same and are aligned with each other.

When installing film, always center the rolls of film on the supply roll mandrels.
Because it does not hold heat well,1.5-mil film can be the most difficult gauge of film to

use. A standard 1.5-mil film will run at about 250 °F / 121°C, while a 3-mil film with the
same adhesive type will run at 240 °F / 115°C. Even when applied at 250 °F/ 121°C,
the 1.5-mil film will not adhere as consistently as the 3-mil film applied at 240°F / 115°C,
or a 5-mil applied at 225°F / 107°C. For many applications, 5-mil film does a much
better job of protecting and enhancing items.

Ten-mil film is suggested for those applications that need the most protection and
rigidity. Seven-mil films are also available.

Rolls of film are sometimes spliced. Most film suppliers will mark a splice with colored
tape. This way, you can see the splice as a “dash” of color on either end of the roll. If
you spot a spliced roll in advance, you can put it on the top supply roll mandrel in order
to see the splice coming easily and avoid putting material under the splice. Or you could
put it on the bottom roll if you plan to be laminating items that will never be seen from
the back side.

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