Ledco HRD-443 Operation Manual

Ledco Digital 44" Dual Hot

Roll Laminator & Mounter

Instruction Manual

READ ALL PRECAUTIONS & INSTRUCTIONS CAREFULLY

BEFORE OPERATING LAMINATOR

Setup

Instruction

Operation

Lamination

Maintenance

Hot Roll Digital Laminator

Pressure Sensitive Roll Applicator

Model # HRD-443

Operation

Manual

0

Glossary Of Symbols		Part #
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

1

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, such as typical fax 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.

2

TABLE OF CONTENTS

1-1 INTRODUCTION

1-2 Features and benefits

1-3 Options

1-4 Specifications

1-5 Principles of operation

1-6 Laminating films

1-7 Warranty

2-1 UNPACKING AND INVENTORY

3-1 PRODUCT ILLUSTRATIONS & NAMES OF PARTS

4-1 SAFETY PRECAUTIONS

5-1 SETUP & OPERATION

5-2 Threading the laminator for Thermal (hot) Laminates 5-3 Threading diagram

5-4 Laminating

5-5 Recommended temperature settings

5-6 Laminating and mounting

5-7 Cold applications

5-8 Threading the Laminator for Cold Laminates utilizing the Release Liner Take-up Mechanism

5-9 Cold application notes

5-10 Preventing and solving problems (Hot)

5-11 Preventing and solving problems (Cold)

6-1 INSTRUCTIONS FOR OPTIONS

6-2 Roll feed attachment

7-1 CLEANING & MAINTENANCE

7-2 Cleaning the rubber rollers

7-3 Lubrication

3

1-1 INTRODUCTION

The Hot Roll Digital laminator is designed to provide quality lamination of a wide range of papers and materials up to 1/2-inch thick using film up to ten mil thick in either a hot or cold medium. 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.

The Hot Roll Digital features a built in release liner take-up mechanism to automate the application of transfer tape, and other pressure-sensitive adhesive (PSA) tapes or films. They conveniently & easily apply transfer tape to weeded vinyl, transfer-taped vinyl to sign blanks, and will apply clear PSA overlaminates to finished signs or promotional materials. The Hot Roll Digital Laminator is ideal for mounting applications and can accept substrates up to ½ inch thick .

An optional roll feed (for spooling banners, etc.) is available. The stand is standard with the Hot Roll Digital.

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 Hot Roll Digital 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.

Dealer Where Purchased_________________________________________________

Installation Date ___________________________Serial # ______________________

4

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.

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

Phone: [phone] or 585-367-2392 FAX : [phone]

5

1-2 FEATURES & BENEFITS

Your new laminator has several standard features that set it apart from other models.

•Variable speed. The laminator operates at any speed up to 30 feet per minute. Thicker Hot films are generally applied better at mid-range to lower speeds, while 1.5 mil Hot film should be applied at mid-range to higher speeds. Pre-mask and other cold or PSA applications can be run as fast as the relative skill of the operator.

•Precision Heat Controls. Individual top and bottom heat controls, as used on our other Digital Laminators, allow for even, consistent heating of the laminating rollers throughout the entire temperature range.

•A scrap rewind with an adjustable clutch takes up the release liner found on many pressure-sensitive films.

•Ease of cleaning. The heated silicone rubber laminating rollers, and the silicon rubber pull rollers of the laminator should be cleaned regularly. The safety shield (see below) on the laminator swings away in seconds, making it easy to clean the laminating rollers.

•Attached safety shield. The polycarbonate shield is clear so operators can see their work. It does not conduct heat so they’ll be protected from hot areas. It is fixed to the feed tray and the machine will not run if the feed tray and safety shield is not in place.

•Lamination pressure. The rubber rollers are spring-loaded and preset to ensure correct and even lamination pressure. The pressure is easy to adjust if required when performing routine maintenance.

•Feed tray pressure strip. This strip on the front of the feed tray holds images flat as they go into the laminator, making it easier to handle the lightweight papers sometimes used in digital imaging.

•Supply roll tension controls. Supply roll tension is easy to adjust by simply tightening or loosening the tension control knobs on the supply roll mandrels.

•Ease of maintenance. The Hot Roll Digital laminator 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 Dept. at 800-937-9697.

•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 insures 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.

•Controls to open and close the laminating rollers. The controls make threading easier and allow even heating of laminating rollers during warm-up.

•100% Made in the U.S.A.

6

1-3 OPTIONS

•Roll feed tray When laminating a very long item such as a banner, it is just about impossible to feed it in perfectly straight by hand. By rolling it up on an empty laminating film roll core and putting that core on the roll feed assembly, laminating the longest item becomes relatively easy. The roll feed assembly is especially helpful for the owners of poster printers, plotters, banner makers, and other digital output devices.

7

1-4 SPECIFICATIONS

Max laminating width	44”
Speed	0-30FPM
Laminating/Pull roller diameter	3 1/8”
Supply roll core size	3”
Recommended film	up to 10mil
Max laminating thickness	1/2”
Max film roll diameter	12”
Dimensions	62”L 34”W 60”H
Shipping Dimensions	72”L 39”W 43”H
Weight/shipping weight	550/850lbs
Motor	1/4 HP D/C
Electrical (single phase)	208-240V single phase
	50-60 cycles 30 amps
	3 Phase 18 amps
Electrical Connector	NEMA 6-30P (Single Phase)
Heaters	5500 watts

8

1-5 PRINCIPLES OF OPERATION

Hot Roll Digital 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 5-5.

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 Hot Roll Digital features a built in release liner take-up mechanism to automate the application of transfer tape, and other pressure-sensitive adhesive (PSA) tapes or films. They conveniently & easily apply transfer tape to weeded vinyl, transfer-taped vinyl to sign blanks, and will apply clear PSA overlaminates to finished signs or promotional materials. Hot Roll Digital laminators are ideal for mounting applications and can accept substrates up to 1/2 inch thick .

Designed for sign and graphics applications, Hot Roll Digital machines are used in many settings, including sign shops, photo-finishing labs, reprographics shops and manufacturing plants.

Jobs such as applying vinyl to sign blanks or putting transfer tape on vinyl signage are very labor intensive. As the material gets wider and longer, the labor costs become disproportionately high. Bubbles and wrinkles are introduced, and waste increases. Some jobs require the additional time and mess of liquid application.

When signage is ruined during the taping or application process, the cost of re-cutting, re-weeding, and reapplying will usually take all the profit out of a job. Whether it’s transfer tape, vinyl, sandblast or acid resist tape, pre-masks, adhesive film, clear polyester, or other pressure-sensitive material, a Hot Roll Digital laminator will put it down effortlessly with no bubbles or wrinkles.

Using a Hot Roll Digital 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. Supply roll

9

tension is controlled with knobs. The laminating roller gap is adjusted with a single knob. Hot Roll Digital laminators are forgiving. They will apply most materials under a wide range of speeds and pressure or tension settings.

The Hot Roll Digital laminators are heavy-duty commercial laminators designed for the most rigorous and demanding jobs and workloads.

10

1-6 LAMINATING FILM

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 film, 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.

11

•“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 revealing a surface perfectly free of dust, scratches or abrasion

•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 to 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 310 °F, while a 3 mil film with the same adhesive type will run at 280 °F. Even when applied at 310 °F, the 1.5 mil film will not adhere as consistently as the 3 mil film applied at 280°F, or a 5 mil applied at 250°F. 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 more 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.

12

1-7 WARRANTY

This laminator is guaranteed against defects in material and workmanship for a period of two years after date of shipment. Defective parts will be replaced without cost within the warranty period, provided the laminator has not been abused, altered or operated contrary to instructions. Ledco, Inc. shall not be liable for any alternations or repairs except those made with its written consent.

This obligation under warranty shall not extend to the following:

•The adjustment or replacement of parts which are the normal responsibility of the owner.

For example, rubber rollers, heat shoe coatings, scratched or chipped paint, loose fasteners (screws, nuts, etc.), or other items that show wear under normal use; i.e. “normal wear parts.”

•Normal operating adjustments to heat, speed, tension, etc.

•Parts that are not manufactured by Ledco, Inc. If the individual manufacturer warrants these items, their warranty is, in turn, passed on to the original purchaser of the laminator. Ledco, Inc. does not incur any obligation or liability as a result of the warranties, which are the sole responsibility of the appropriate individual manufacturer.

Any laminator that proves defective during the warranty period may be returned to Ledco, Inc. unless it is decided that the necessary repairs can be made during a service call. Notice of the defect should be submitted in writing or by phone to Ledco before any steps are taken to repair or return the machine. Phone: [phone] or 585-367-2392 Fax: [phone]

If the machine is returned, the following should accompany it.

•Customer name, address and phone number

•Written particulars regarding the malfunction

•Date of installation

•Serial number of the machine.

ΚRETURNS MUST HAVE A RETURN AUTHORIZATION NUMBER ON THE OUTSIDE OF THE SHIPPING CONTAINER.

Send all returned equipment freight PREPAID to:

Ledco, Inc., 4265 North Main Street, Hemlock, NY 14466

If your machine needs servicing after the warranty has expired, please contact your dealer. Ledco, Inc. does offer technical support if your dealer is unable to assist.

This warranty is expressly in lieu of all other warranties expressed or implied. This includes the warranties of Merchantability and Fitness For Use and of all other obligation or liabilities of Ledco, Inc. Ledco neither assumes nor authorizes any other person to assume it for any other obligation or liability in connection with the sale of this laminator except as provided for above.

Further, this warranty will not apply to any machine or part thereof which has been damaged as a result of an accident or as a result of the abuse, misuse, or neglect of the machine. The warranty is also void if the laminator has been altered or repaired by any other than an authorized repair facility or dealer. If you have any questions about this warranty, contact: Ledco: Phone: [phone] or 585-367-2392 Fax: [phone]

13

2-1 UNPACKING AND INVENTORY

The laminator arrives fully assembled, with the exception of the stand which requires assembly (instructions are included).Some parts such as feed trays may be packed off the machine to avoid shipping damage. Upon arrival, inspect the unit immediately and thoroughly using the packing list that accompanies the shipment. Please follow these steps to correct any problem with your shipment. Ledco, Inc. cannot accept any responsibility for damage or loss unless you notify us within ten days of receipt of shipment and follow these procedures:

BREAKAGE OR DAMAGE: It is imperative that any shipping damage is reported and a claim is filed with the delivering carrier immediately upon receipt of damaged shipment. The procedure for reporting damage depends on the method of shipment. Please note damage on bill of lading. If possible take photos of the damage immediately.

FREIGHT, EXPRESS, or TRUCK DELIVERY: According to the contract terms and conditions of the carrier, the responsibility of the shipper ends at the time and place of shipment. The carrier then assumes full responsibility for the shipment.

1.Notify Ledco IMMEDIATELY.

2.Hold damaged goods with container and packing for inspection by the examining agent. Ledco will arrange the inspection.

3.DO NOT RETURN ANY GOODS TO LEDCO PRIOR TO AUTHORIZATION BY LEDCO.

4.Submit a copy of the inspector’s report to Ledco. Ledco will file the claim with the carrier. Ledco will replace your machinery if necessary. You will be credited for the damaged machinery when the claim is processed.

SHORTAGE:

1.Check the packing list notations. The apparent shortage may have been marked as an intentional short-shipped (back-ordered) item.

2.Reinspect the container and packing material, particularly for smaller items.

3.Make certain that unauthorized personnel prior to complete unpacking did not remove the item and inventory.

4.Call us and send immediate written notification of the shortage.

INCORRECT SHIPMENT:

1.If the material you receive does not correspond with your order, notify Ledco immediately. Include the order number and item(s).

2.Hold item(s) until return instructions are received.

RETURNS: DO NOT RETURN DAMAGED OR INCORRECT ITEMS UNTIL YOU HAVE RECEIVED SHIPPING INSTRUCTIONS AND AN AUTHORIZATION NUMBER FROM LEDCO.

14

3-1 PRODUCT ILLUSTRATIONS & NAMES OF PARTS

The photos below and on the following pages identify major components and operating controls. Refer to them as you study the installation, operating and maintenance procedures described in this manual.

Emergency stop buttons		Top supply roll mandrel

Release liner

take up tension

control knob

Safety

shield

Control panel

Release liner

take up shaft &

Roll

core grippers

pressure

knobs

Feed tray

Bottom supply

roll mandrel

Stand assembly

W/casters

15