Marabu StarLam 1600R Operation & Instruction Manual

Starlam 1600r liquid laminator

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Version G3 1.00 3-2010

StarLam 1600R Liquid Laminator

Operation & Instruction Manual

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Summary of Contents for Marabu StarLam 1600R

Page 1 Version G3 1.00 3-2010 StarLam 1600R Liquid Laminator Operation & Instruction Manual...
Page 2 StarLam 1600R User Manual Important: Please read and understand the operation manual completely. Follow all safety information described.
Page 3 The StarLam 1600R utilizes air assisted oven drying to allow the application of liquid laminates in a quick and efficient process. The other main advantage of the StarLam 1600R is consistency. The liquid laminator allows a controlled wet film thickness to be applied so that square footage coverage and dried film thickness can be controlled precisely.
Page 4: Table Of Contents
StarLam 1600R User Manual Table of Contents Operation Requirements ................. 4 Safety Precautions ................... 4 Machine Diagram ................... 7 Technical Specifications ................. 9 Precautions Before Operating ............... 10 Preparation Before Operation ............... 10 Operation Instructions ................... 11 ...
Page 5: Operation Requirements
StarLam 1600R User Manual Operation Requirements ■ The machine should be used in temperature range of 15˚ C (50˚ F) - 40˚ C (104˚ F). ■ Environmental relative humidity should be 30% - 70%. Avoid using the machine in places with high temperature, humidity and dust. ■...
Page 6 StarLam 1600R User Manual Be careful when wearing a necktie, necklace, wristband or long hair when operating the machine. Care should be taking to bind loose clothing, secure jewelry and manage hair so as not to get rolled up and bound in the machine. Serious injuries can occur if proper precautions are not taken. Do not insert any material that is not intended for use with the machine.
Page 7 StarLam 1600R User Manual Only authorized personnel should open the machine’s electric control box. This electric control box is equipped with a key lock and key. A designated person in charge should keep the key. Switch off the power to the external power line when not using the machine for long periods of time.
Page 8: Machine Diagram
StarLam 1600R User Manual Machine Diagram 21. Connector For Cleaning 1. Left Side Main Frame Box 8. Positioning Axles for 14. Front Guide Roll Hose. 2. Heater Box Heating Box. 15. Laminate Drain Trough 24. Door Hinge 3. Liquid Reservoir Bottle Support 9. Emergency Stop Switch 16.
Page 9 StarLam 1600R User Manual 1. Power Light ( White ) 7. Fan Switch 2. Working Indicator Light ( Green) 8. Temperature Adjusting Knob 3. Fault Indicator Light (Red) 9. Temperature Control Knob 4. Temperature Display Screen 10. Cleaning Pump Switch 5. Speed Adjustment Knob 11.
Page 10: Technical Specifications
StarLam 1600R User Manual Technical Specifications Maximum Laminating width 1600mm (63inches) Maximum laminating length 300m (984 feet) Temperature adjusting range 80-140˚C (176-284˚F) Speed adjusting range 300-1000mm/min (11.82inches-3.28 feet/per per minute) Input power 240 VAC rated / 208 VAC Minimum Nominal input power 9600W @ 240VAC / 7200W @ 208 VAC Nominal input current 40A @ 240 VAC / 36.4A @ VAC Rated Input Frequency...
Page 11: Precautions Before Operating
StarLam 1600R User Manual Precautions Before Operating ■ Please read the instruction manual carefully before operating this machine. ■ Be sure that the power supply system is in compliance with the requirements of this machine before operating. Failure to do so may cause damage from abnormal heat or electrical circuit failure.
Page 12: Operation Instructions
StarLam 1600R User Manual Operation Instructions Roll to Roll Lamination Instructions: 1. Core Holding Rod 2. Webbing / Rolled Media 3. Core 4. Core support Mandrel 5. Clutch discs 6. Lock Collar Tightening Bolts 7. Lock Collar 1. Load the media on the laminator. a.
Page 13 StarLam 1600R User Manual b. Slide the printed roll of substrate to be coated onto the core holding rod. Pay close attention to make sure the face of the material to be coated is on the outside face of the roll to be coated. The open flap should be on the outside and facing upwards.
Page 14 StarLam 1600R User Manual 3. Lift the heating box assembly and gently lean it against its mainstays located on the two sides of the machine body boxes (as shown in figure 9). Figure 9 4. Feed the media through the laminator according to Figure 11. a.
Page 15 StarLam 1600R User Manual Figure 11 ▲ To ensure even film thickness and proper coating please stretch the material tightly and evenly. 5. The substrate must be spooled onto strait and without variance from side to side. 6. Switch the main power supply to the on position. Next, switch the machine power to the on position so that the power light illuminates.
Page 16 StarLam 1600R User Manual 10. When the heater box has reached the preset working conditions the working ready light will illuminate indicating that lamination process may begin. 11. Gently lower the heating box down and onto the heater door stop guides. 12. Switch on the machine cooling fans. Adjust the motor drive speed to the appropriate position.
Page 17 StarLam 1600R User Manual The StarLam 1600R liquid laminator uses a peristaltic pump. A peristaltic pump is a type of positive displacement pump used for pumping a variety of fluids. The fluid is contained within a flexible tube fitted inside a circular pump casing (though linear peristaltic pumps have been made).
Page 18 StarLam 1600R User Manual The StarLam peristaltic pump is composed of 6 main parts. The parts are as follows: 1 Pump housing Pump tube 3 Plastic washer Pump rollers Pump cover 6 Thumb Screws The Peristaltic pump roller assembly is as follows: To remove the pump tube for replacement.
Page 19 StarLam 1600R User Manual ...
Page 20 StarLam 1600R User Manual Pump Switch Forward Pump Switch Reverse Pump Switch Off Pump Speed Control Cleaning Pump On/Off Switch Cleaning Pump Power Indicator Lamp...
Page 21 StarLam 1600R User Manual Laminate Pump Operation: 1. Make sure the laminate reservoir bottle valve is in the shut (off) position. Fill the Laminate reservoir bottle with fresh liquid laminate. 2. After the substrate/webbing is properly fastened onto the rollers of the machine, open the main laminate reservoir valve to the "on"...
Page 22 StarLam 1600R User Manual 6. Start the laminate pump and set the speed to about 50%. Let the water cycle through the system for a few minutes. 7. Stop the laminate pump after cycling plenty of water through the laminate lines. 8. Let all the water from the laminate reservoir drain into the laminate trough. 9.
Page 23 StarLam 1600R User Manual 4. Once the container is in place and the hose is hanging into it then open the laminate trough drain valve. 5. Let the trough drain completely. Preparation of machine before use: 1. Use 4 gallons of room temperature or warm water to fill the wash trough on the bottom of the machine.
Page 24 StarLam 1600R User Manual 4. Once the laminate has filled up the area in front of the metering rod and starts running off both sides of the media lower the heater, switch on the drying fans and then start the drive motor at the 2.5 position. Once the media begins to coat and move adjust the speed to the 3 position as the heater reaches 100 deg.
Page 25: Troubleshooting
StarLam 1600R User Manual Troubleshooting Problem Possible cause and remedy ● Be sure that the main power supply switches are switched on ● Power light does not turn on. ● Check internal Breakers to make sure they are not tripped. ● The light shows that the machine is increasing in temperature. Be patient and wait for awhile, and it should illuminate.
Page 26 StarLam 1600R User Manual ● It is possible the heater box support tabs ● Sections in the middle and sides of have been damaged. Replace or repair box supports the material being coated seem to be before using machine again. rubbed off in spots. The coating can be ●...
Page 27: Warranty
All items carry warranty activated at time of invoice/purchase notification to the invoiced Original Recipient Purchaser of the New Equipment a. Clearstar LP warrants to the original consumer purchaser that each new StarLam 1600R Liquid Laminator which proves defective in materials or workmanship within the applicable warranty period will be repaired or, at our option, replaced without charge.
Page 28 StarLam 1600R User Manual included in this warranty. This warranty does not cover parts that have been installed by person(s) that are not registered Clearstar LP Dealer Installer(s). Equipment Covered: StarLam LP technology architecture ONLY – this warranty does not cover alterations made to the machine by unauthorized personnel. Operating Environment: The New Equipment should be operated in a relatively clean dust free environment to ensure optimal performance, as dust grime and moisture can contribute to breakdowns that may not be covered under this warranty.
Page 29: Maintenance
StarLam 1600R User Manual Maintenance After using the StarLam 1600R the machine must be cleaned immediately, otherwise the liquid laminate will solidify which is not beneficial. Before cleaning always switch off the power coming into the machine. 1. Remove the metering rod and clean the laminate off the surface.
Page 30: Appendixes
StarLam 1600R User Manual Appendixes Appendix A…………………………………………………………………………………………A1 Exploded view parts diagram Appendix B…………………………………………………………………………………………A2 Parts list with part numbers Appendix C…………………………………………………………………………………………A3 Electrical Schematic...
Page 31 StarLam 1600R User Manual Appendix A1...
Page 32 StarLam 1600R User Manual Appendix A2 Drawing No. Part Description Clearstar Part No. Metering Rod Cradle PLAM2001 #25 Metering Rod PLAM2002 Nozzle Support Rod PLAM2003 Fluid Nozzle Holder PLAM2004 Fluid Dispensing Nozzle PLAM2005 Heat Deflection Shield PLAM2006 Laminate Drain Trough PLAM2007 Large Tension Roller PLAM2008 Drain Filter Screen PLAM2009...
Page 33 StarLam 1600R User Manual Drawing # Part Description Clearstar Part No. R.S. Fan Track Screw PLAM2041 Core Rod Support Hinge PLAM2042 Core Rod Hinge Plates PLAM2043 Laminate Trough Mount PLAM2044 Idle Roller 2 PLAM2045 Bushing PLAM2046 Heat Shield PLAM2047 Mid Main Support Bracket PLAM2048 Left Support Plate PLAM2049...
Page 34 StarLam 1600R User Manual Drawing # Part Description Clearstar Part No. Safety Relay System PLAM2081 Heater Control IC Board PLAM2082 40A Solid State Relay PLAM2083 SSR Heat Sink PLAM2084 DIN Magnetic Breaker PLAM2085 DIN Magnetic Breaker PLAM2086 DIN Magnetic Breaker PLAM2087 DIN Magnetic Breaker PLAM2088 Wire Terminal Strip PLAM2089...
Page 35 StarLam 1600R User Manual Drawing # Part Description Clearstar Part No. Female Panel 3/8" Coupler Male 3/8" Coupler Coating Rod #18 Mayer Coating Rod #25 Mayer Coating Rod #32 Mayer...
Page 36 StarLam 1600R User Manual Appendix A3...
Page 37 StarLam 1600R User Manual Appendix A4 Tips and Tricks for the StarLam 1600R G3 Start -up Check List 1. Make sure machine power is on. 2. Make sure substrate is properly tensioned to take up core. Pull tension and tape in the center first then pull tension on each side and tape.