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Professional Laminating Systems Series II Operator's Manual

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Professional Laminating Systems
Laminator Manual
SERIES II
OPERATORS MANUAL

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Summary of Contents for Professional Laminating Systems Series II

  • Page 1 Professional Laminating Systems Laminator Manual SERIES II OPERATORS MANUAL...
  • Page 3 Machine Details Model: ____________ Serial #_______________ Date Of Purchase______________ Date Of Manufacture_______________ Voltage_______________ Inspector_______________...
  • Page 4 __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ _____________________...

  • Page 6: Table Of Contents

    1 - Basics: _____________________________________________11 #1. Feed Table ____________________________________________ 12 Feed Table Installation_____________________________ 12 Feed Table Side Guide Adjustment: __________________ 12 #2. Mandrels ______________________________________________ 13 Mandrel Size:____________________________________ 13 Tension Control Knob: ____________________________ 16 #3 Laminating Roller. _______________________________________ 17 #4 Gapping Handle. ________________________________________ 19 Purpose: ________________________________________ 19 #5 Slitters:________________________________________________ 21 Slitter Warnings: _________________________________ 22...
  • Page 7 Troubleshooting ___________________________________________ 70 Overview _______________________________________ 70 Common Errors __________________________________ 70 Glossary _________________________ Error! Bookmark not defined. Notes____________________________________________________ 76 LIMITED WARRANTY ____________________________________ 77 CLAIM PROCEDURE______________________________________ 78 #6Conversion Tables: ___________________________________79 Temperature: Celsius to Fahrenheit ____________________________ 79 Professional Laminating Systems, Inc. Hamilton, MT. 59840 406-363-1690...
  • Page 8 WARNINGS & SAFETY DO NOT OPERATE THIS LAMINATOR WITHOUT FIRST REVIEWING THIS OPERATORS MANUAL IN ITS ENTIRETY. NEVER OPERATE THIS MACHINE WITH REMOVED, DAMAGED OR MISSING PARTS - SHUTDOWN AND DISCONNECT FROM THE ELECTRICAL SUPPLY. IF THERE WERE TO EVER BE A MECHANICAL OR ELECTRICAL MALFUNCTION IMMEDIATELY UNPLUG THE MACHINE NEVER SERVICE THIS MACHINE WITHOUT FIRST DISCONNECTING THE MACHINE FROM THE ELECTRICAL SOURCE.
  • Page 9 SHUT THE MACHINE DOWN AND ALWAYS KEEP ROLLERS GAPPED WHILE THE MACHINE IS NOT BEING ATTENDED. THIS GREATLY EXTENDS THE LIFE OF THE ROLLERS AS WELL AS SAVING $ IN LOST ENERGY. REMEMBER YOUR NEW LAMINATOR TAKES AS FEW AS 4 TO 5 MINUTES TO WARM UP RATHER THAN 20 OR DO NOT ALLOW THE ROLLERS TO EXCEED 300 DEGREES DOING THIS WILL GREATLY INCREASE THE LIFE OF THE LAMINATING ROLLERS –...

  • Page 10: Basics

    1 - Basics: Name Function Feed tray Guides material into rollers Mandrels Securely Holds laminating film Laminating rollers Heats and nips the laminating film Gapping handle Gaps the rollers when not in use (not shown, see page 33) Slitters Heads Cuts the excess from the side of the web of film Pressure knob Adjusts the roller pressure, see section for proper...

  • Page 11: Feed Table

    #1. Feed Table The feed table is used to correctly position the material in relation to the rollers. Located on the surface of the Feed Table is one (or more by option) feed guide. Feed Table Installation 1. When installing the feed table it should be held level and square in relation with the laminating roller and with the front of the feed tray tilted as shown.

  • Page 12: Mandrels

    #2. Mandrels Mandrel Size: You must match your film core size with the mandrels of your laminator 3”Mandrels: 3” Mandrels are standard equipment when the laminator is supplied with a stand. The 3” mandrel is a unique 3” dual locking, interchangeable, ambidextrous, bidirectional mandrel. This mandrel features a rubber roller cam that carefully locks the film roll in place, laterally and radially.
  • Page 13 1” Mandrels: The 1” mandrels are designed to be used with film that is wrapped adhesive in. They feature a typical steel drive dog to grip the film, this drive dog is sharp and must not be contacted. This drive dog only works in one direction, it is important that the film is properly installed on the mandrels.
  • Page 14 Installation: The mandrels are removable and simply slip into the mandrel towers. The handle typically should be facing the right side of the machine. It may take two people to lift the mandrel onto the laminator because once it has a roll of film on it, it can be quite heavy. It is a good idea to practice installing the mandrel onto the machine without any film on it so that the process is understood.

  • Page 15: Tension Control Knob

    Tension Control Knob: The tension control knobs are located on one end of the mandrels that hold the laminating film. They are used to: A. Control film tension Prevent the film rolls from free spooling. Flatten any film curl D. Smooth film lay on the rollers As a rule, for the highest quality lamination, the lighter the tension, the better.

  • Page 16: Laminating Roller

    #3 Laminating Roller. The laminating roller is the heart of the machine. The laminating roller simultaneously heats and encapsulates the product being laminated. We realized the need for a new technology in laminating when we were aware of the old insurmountable limitations.

  • Page 18: Gapping Handle

    #4 Gapping Handle. Purpose: This handle is for separating the rollers when not in use or for helping to clear film wraps. The rollers should remain in the gapped or raised position unless the machine is in operation. (Machine shown with alternate tower, disregard differences) Please keep the rollers in the gapped position when the machine is not in use.
  • Page 19 Operation: Simply turn clockwise, the rollers will raise and lower with every revolution of the handle. Gapped / Ungapped When adjusting the roller pressures make sure that the handle is in the un-gapped position, after making adjustments gap and ungap the rollers to make sure that you did not put too much pressure on the rollers for the cam (gapping handle) to operate.

  • Page 20: Slitters

    #5 Slitters: Name Description Side micro Precise edge margin adjustment adjustment Adjuster lock screw Allows major movement of slitter head Slitter angle and Allows for angle adjustment and removal of lock slitter blade holder Slitter Blade holder Holds Blade Spring and lubricant Holds and lubricates parts...

  • Page 21: Slitter Warnings

    Slitter Warnings: !!!Use caution at all times in the vicinity of the slitter assemblies, as the knives are razor sharp!!! !!!If there is any uncertainty about the operators’ competence, remove the blades immediately!!! !!!REMEMBER THESE BLADES ARE EXTREMELY SHARP AND ARE CAPABLE OF DISMEMBERMENT OR DEATH THEY SHOULD BE USED WITH EXTREME CARE AND REMOVED WHEN NOT ABSOLUTELY NECESSARY!!

  • Page 22: Slitter Setup And Operation

    Slitter Setup and Operation: The slitters that we designed were designed to provide the highest quality slitting possible. Though the design is more complex than most, the quality speaks for the complexity. The slitters are machines of their own, one should realize this and devote some time to understand the correct operation of our slitters.
  • Page 23 Slitter Adjustment 1. Align the feed guides on the feed table to the desired location in relation to the film path. Feed a sample piece of paper into the film path. 2. Stop the film when the paper is between the front and rear rollers. 3.

  • Page 24: Changing Blades

    Slitter angle adjustment The angle of the cut on the edge of the film is fully adjustable allowing the knife to plane the edge of the film resulting in a minimized edge curl. To adjust the blade angle, 1. Loosen the blade angle lock ½ turn. 2.

  • Page 25: Pressure Knob

    #6 Pressure Knob Do not use these pressure adjustment knobs to ungap the rollers, before adjusting the rollers. make sure that the rollers are not gapped (handle on the right side of the laminator) These adjustment knobs are located in each corner on the top of the side frames, two for the rear and two for the front.

  • Page 26: Operator Interface

    #2 Operator Interface: Name Function Page Temperature Adjusts Temperature Set point Control Temperature Shows operating temperature Display Power Switch Main Power Switch Fan Switch Fans On/Off 10 Motor Switch Selects between, off , forward and momentary reverse 11 Speed Control Adjusts the speed of the laminator...

  • Page 27: Temperature Control Dial

    Operator Interface #6. Temperature Control Dial This knob regulates the process temperature of the laminate. Simply line up the line on the knob with the desired temperature. Temperature Recommendations: Operating temperature varies depending on the type, thickness and manufacturer of the laminating film you have selected.

  • Page 28: Fans

    #9. Fans This switch activates the cooling fans. These fans control the temperature of the film as it exits the heat rollers. Their use depends on numerous variables so experimentation and experience is about the only way you can determine their necessity. Do not use the fans to facilitate in cooling the laminator during shutdown.

  • Page 29: Motor Direction Control

    #10. Motor Direction Control The direction control switch is located directly above the speed control. This switch is a three- position rocker switch. Off: The center position of this switch is the off position. This switch should remain in the center or off position when the laminator is not in use.
  • Page 30 Film: Film type and thickness poses the primary consideration when determining your speed setting. Thicker film requires slower speeds than thinner film. The max setting on the motor control may be considered to laminate 1.2 mil nylon film one side to a thin paper, if you use a low melt 3 mil, the speed may be 40% of this setting, if you use a 10 mil film, the speed may be 10%-15% of this setting.

  • Page 32: Laminator Setup

    #3 Laminator Setup Make sure the machine is plugged into a properly grounded circuit Never Operate the Laminator without A Ground Refer to “Electrical Requirements” in the installers guide Check and familiarize yourself with the following functions A. The main power switch must be in the “on” position for any other function to work. When activated, the lamp in the switch will glow red.

  • Page 33: Film Threading Fundamentals

    Film threading fundamentals: Idler Rollers There are two idler rollers on a stand model laminator and three idler bars on a table top model, one for the upper laminate and one or two for the lower laminate. These idler bars help direct the film over the rollers to provide a more consistent heat transfer and a high quality lamination.

  • Page 34: Threading Procedure

    Threading Procedure 1. Load the laminating film on the mandrels (see mandrels on pages ___ for proper use). Never allow the dull (adhesive) side of the film to contact the heated rollers. 2. Insert each mandrel into one of the rolls of film paying very careful attention to the threading diagram with respect to the direction the film unwinds.
  • Page 35 9. Pull about 1-½ feet of film from the lower roll, bring the film below the lower front idler roller (if the laminator includes a stand this idler may not exist as it is not required). With the sliding idler roller in lowered position, wrap the film around the sliding idler roller (below the sliding idler, toward the back.
  • Page 36 18. Continue to advance the laminating film through the machine. The film will begin to "straighten and flatten itself out". Stop the machine and check both side edges of the film to be certain the top and bottom laminates are precisely lined up. You may need to slide one of the supply rolls a bit to obtain perfect alignment.
  • Page 37 26. If you have completed all of your laminating chores, gap the rollers and turn the direction control, fans and power off. For a higher quality lamination A. Always laminate with the film centered on the roller B. When laminating one side, use the top roller. C.
  • Page 38 Film diagram for threading pressure sensitive film Notice the path of the release liner Thread laminate as typical. However, before feeding laminate through machine separate the liner from the laminate and remove it while the film is being threaded. After the film is through the back rollers by about one foot remove the release liner to the upper idler roller.
  • Page 39 Tabletop model shown with adhesive in (reverse wrapped)

  • Page 40: Threading Diagrams

    Threading Diagrams Threading diagram, adhesive OUT, 3” mandrels...
  • Page 41 Threading diagram, adhesive IN, 3” mandrels...

  • Page 42: Film Tuning

    Film Tuning Once the laminator has been set up and the film threaded, the laminator should be fine-tuned to the film that you are using. Once the laminator has been fine-tuned, it is not essential to adjust the machine for succeeding film rolls. It may however be necessary to review this paper when one is having problems with the film.

  • Page 43: Adjust The Mandrel Tension

    Adjust the mandrel tension. A. Typically, the mandrel tension is used to smooth the laminating film as it comes over the rollers into the nip and when to adjust film curl. B. If the film is coming over and through the rollers wrinkled, you may add a small amount of tension to the mandrels in attempt to alleviate this.

  • Page 44: Temperature

    Temperature. Temperature settings are an issue of experience and can affect a wide variety of issues. G. Too high of a temperature can cause problems such as blistering, delamination, over heating of the material, insufficient cooling or distortion of the film. H.

  • Page 45: Film Replacement

    Film Replacement It is recommended to remove or replace the film just before the supply rolls run out of film. This will prevent the film adhesive from inadvertently contacting the rollers. Never advance the film through the laminator without first heating the rollers. This will prevent the possibility of tearing the roller covering from the film being “glued”...

  • Page 46: Film Removal

    Film Removal It is recommended to remove the film just before the supply rolls run out of film. This will prevent the film adhesive from inadvertently contacting the rollers Never advance the film through the laminator without first heating the rollers. This will prevent the possibility of tearing the roller covering from the film being “glued”...

  • Page 47: Cleaning

    2. Never use solvents not specifically recommended for cleaning heated silicone laminating rollers. 3. Professional Laminating Systems recommends using methyl alcohol (methanol) or DX330 manufactured By PPG both of these products are flammable and toxic and should be used with extreme caution in a well-ventilated area with the machine disconnected and no flame source.

  • Page 48: Operation

    Operation General Two-sided lamination: It is highly recommended that, the product being laminated is meticulously inspected and tested for compatibility, before running a large job. No one likes surprises. Also be aware that certain items cannot be laminated such as thermal paper printouts often used in things such as faxes receipts sonograms and many labeling devices.

  • Page 49: Temperature

    Temperature: ProLam, Inc recommends following the temperature guidelines consistent with the type film you are using. Since temperature requirements are different from manufacture to manufacture and film to film there are literally thousands of variables out there and ProLam, Inc is unable to publish a list of every film and our recommendations for that film Several guidelines to follow: Start at the manufactures recommendation...

  • Page 50: Speed

    Speed: Speed is once again a function that is very much related to roller temperature, paper temperature, room temperature, laminate thickness or paper thickness however, several guidelines may help. Typically when the film is cold it is somewhat foggy and when it heats up to temperature it becomes clear while laminating, a good guideline for general lamination is to watch the film as it comes over the roller, it should become clear before it hits the nip on the laminating rollers...
  • Page 51 the spring pad when the spring pad is at its uppermost position (when applying pressure make sure that this point is used as a starting point. When the pressure knobs are fully relieved there is a certain amount of preload that still exists on the rollers. Wide Format: The wider laminators 38”...

  • Page 52: Fans

    Fans This switch activates the cooling fans. These fans control the temperature of the film as it exits the heat rollers. Their use depends on numerous variables so experimentation and experience is about the only way you can determine their necessity. Do not use the fans to assist in cooling the laminator during shutdown.
  • Page 53 !!!THE FAN SWITCH MUST REMAIN IN THE OFF POSITION WHEN THE ROLLERS ARE STATIONARY!!! Failure to turn off the fans while the laminator is in an idle state will result in abnormal roller cooling, especially on the bottom roller. This may show as cold spots (foggy areas perpendicular to the film path) or failure of bottom lamination.

  • Page 54: Single Sided Lamination

    Single sided Lamination: The Series II laminators may be used for single side lamination with specifically the smaller models for items such as book covers. These laminators are capable of laminating short-run one- sided applications One sided – general: 1. For good results the laminate that you use should be specifically designed for one-sided...
  • Page 55 Production run one-sided lamination Modification For production run one-sided lamination, the machine requires a simple modification as follows. Make sure to follow all safety procedures as described in this manual. This modification will help in reducing adhesive buildup on the bottom roller, it may reduce film curl and will greatly increase the life of your unused roller.

  • Page 56: Board Stock

    Board Stock: Your series II laminator is capable of laminating and encapsulating a wide variety of materials up to ¼” thick When laminating board stock the roller pressure adjustment knobs must be fully relieved. The speed at which board stock is laminated should be much slower to allow the laminator to heat the board sufficiently.

  • Page 57: Shutdown

    Shutdown The Laminator should be shutdown when not in use for a period longer than five minutes. If the laminator is left on while not in use the roller temperatures may drift and cause poor lamination. The standard shutdown procedure is as follows: 1.

  • Page 58: Maintenance

    Maintenance Before beginning a procedure, always read it thoroughly Never remove any service panels from the machine without first disconnecting the electrical supply. Cleaning the Laminator The surface areas of the machine should be periodically cleaned with a damp cloth and a mild detergent.

  • Page 59: Rubbing Pad Compound

    Rubbing pad compound The only regular lubrication required on your laminator is the rubbing pad assembly. The rubbing pad is located on the right hand side of your laminator, inside the panel on the swing arm near the end of the top laminating roller it consists of a virgin felt pad saturated with a high temperature lubricant The lubricant used on this component is an unique high temperature electrical insulating grease that does not harden it is recommended that this lubricant (rubbing pad compound) be purchased...
  • Page 60 When the brushes are inspected, take note of the condition of the slip ring and that it has not been grooved to badly. If it is seriously grooved and gulled, it should either be polished with scotch brite or replaced. If after replacing the brushes, the condition continues, see temperature fluctuation in troubleshooting.

  • Page 61: Cleaning The Slip Ring

    Cleaning the Slip Ring This procedure must be preformed if there is an erratic and sudden fluctuation in the displayed temperature while the laminator is in operation Follow these steps and all safety precautions. This procedure is only necessary if the temperature fluctuates when the upper roller is rotated by hand and the roller direction is in the off position 1.

  • Page 63: Lubrication

    Lubrication: Roller lubrication The bearings in your laminator are permanently lubricated; they typically require replacement rather than lubrication. Replacement of your bushings is quite unusual, the bearings that are installed into your laminator are rated for a much more severe duty than your laminator could possibly see.

  • Page 64: Copper Antistatic Tinsel

    Copper Antistatic Tinsel Laminator antistatic Anti-Static Tinsel is designed for optimum performance. It eliminates static with the “self energizing” or inductive principle. That is, when sharp points are present in a strong electrostatic field, interchange of electrons occur between the sharp points, thereby ionizing air, and eliminating or neutralizing static electricity.

  • Page 65: Roller Care And Maintenance

    Roller Care And Maintenance This paper is applicable to the revolution series heated laminating rollers built by professional laminating systems only. Using these guidelines on other laminators or rollers could cause serious damage to the roller these guidelines should be used in addition to the instructions and manual provided with your machine. Precautions: •...

  • Page 66: Operating Guidelines

    10. Never use solvents not specifically recommended for cleaning heated silicone laminating rollers. 11. Professional Laminating Systems recommends using methyl alcohol (methanol) or DX330 manufactured By PPG both of these products are flammable and toxic and should...
  • Page 67 be used with extreme caution in a well-ventilated area with the machine disconnected and no flame source. 12. Pro-Lam recommends using a course cotton mechanics cloth (NAPA part # 7601036). 13. Remove the film from the machine 14. Heat the laminator about 10 degrees beyond its normal set point (no hotter than 310 degrees).

  • Page 68: Film Wrap

    Film Wrap 1. DO NOT use an knife or any object that can damage the rollers to remove the film from the rollers 2. Heat the machine to operating temperature. 3. Remove any film, from the machine, that can be removed (supply rolls, tail, etc.), keep track of the end (or beginning) of the film wrap this will be where you start.

  • Page 69: Troubleshooting

    Troubleshooting Overview Before any troubleshooting is made on the quality of the finished film, please confirm the following: 1. The rollers are clean and do not have excessive adhesive deposits. 2. The film used is of the same type, manufacture, thickness and temperature range. 3.
  • Page 70 Rollers Rollers cut, gouged, ripped, blistered, Replace bubbled Erratic Temperature Fluctuation Clean slip ring Rollers cold when laminating Slow down motor Insufficient edge seal Roller pressure Wrinkling film Re-align towers, Add small amount of tension Will not stop heating Unplug+ Contact technical support Will not heat Contact technical support Motor...
  • Page 71 Film Typical problems, Follow list for topic in sequence, the first solution will be the most common. Film is foggy, on rollers and in Decrease speed lamination Increase temperature Defective Film Film is foggy, clear on rollers foggy Decrease temperature in lamination Defective Film Film does not stick / poor bond...
  • Page 72 Blistering / random bubbles on paper Too hot, decrease temperature Paper moisture content too high Incompatible film / temperature for the ink used Defective Film Optical distortion in film / wavy / Too hot for film base, decrease puddles temperature Too slow –...
  • Page 73 Check film alignment Increase rear roller pressure Incompatible paper, paper shrinking excessively Moisture content incorrect, preheat / temper paper Paper shrinking, preheat / temper Moisture content incorrect, let paper stabilize Incompatible film Defective film Waves in film at angles Incompatible paper To hot for paper / ink Check film alignment Incorrect roller pressures, decrease...

  • Page 75: Notes

    Notes _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ ___________________________________________________...

  • Page 76: Limited Warranty

    This warranty is only valid in the USA and for military installation world wide. You must register you machine with Pro-Lam upon receipt of your machine. Professional Laminating Systems Inc. (referred to as “Pro-Lam”) warrants this laminator frame to be free from defects in material and/or workmanship for a period of One (1) year from the date of its original purchase.

  • Page 77: Claim Procedure

    CLAIM PROCEDURE If you discover a defect or malfunction during the period to which this warranty applies, you must follow this procedure: • Contact the Pro-Lam Dealer from whom the laminator was purchased and they will handle your warranty issues for you. •...

  • Page 78: 6Conversion Tables

    #6Conversion Tables: Temperature: Celsius to Fahrenheit Celsius Fahrenheit Celsius Fahrenheit Celsius Fahrenheit...
  • Page 79 Length:EU to SI Unit of measure Inch Inch Inch Inch 0.005 0.255 0.505 12.8 0.755 19.2 0.010 0.260 0.510 13.0 0.760 19.3 0.015 0.265 0.515 13.1 0.765 19.4 0.020 0.270 0.520 13.2 0.770 19.6 0.025 0.275 0.525 13.3 0.775 19.7 0.030 0.280 0.530...

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