Page
Read Me File
first
PAGE
last PAGE
go back one PAGE
This page intentionally left blank
Page
Page
Table of Contents
Section 1: Safety
Safety features
Decal Explanation
Figure 1 - 6 Decal Location
Section 3: Specifications
Consumables
Function
Section 4: Installation
Page
Section 5: Operations
Section 6: Applications
Group 1: No heat
Precoating substrates
Single sided lamination ( Sled method )
Single sided lamination ( Craft paper method )
6.10 Parameter charts and diagrams
Figure 6.10.1 Temperature conversion chart
Blank chart
Blank diagram
Chart 1 - Precoating substrates
Page
Diagram 8 - One pass mount
Chart 10 - Thermal decal and mount ( Mount )
Diagram 10 - Thermal decal and mount ( Mount )
Chart 11 - Encapsulation
Section 7: Troubleshooting
Wave problems
Film problems
7.2.1 Thermal laminates
7.2.2 Pressure senstive
Section 8: Maintenance
Maintenance schedule
Cleaning the rollers
8.2.1 Cabinets and covers
8.2.2 Touch screen control panel
This page is intentionally left blank
Section 1 Safety
1.1 Symbols
1.2 Safety features
Figure 1.2.1 Cabinets and covers
Emergency buttons stop
1.3 Installation
that pertains to your method of shipment
Do not allow the top to fall into the crate. It can damage the laminator
Do not put packing screws on the floor
They can cause problems when trying to roll
the laminator into position or you can become injured if stepped on
Improper leveling, will result in poor output quality
Page
1.4 Operations
Footswitch speed is not indicated in the SPEED DISPLAY on the control panel
Twisting the roll of film while sliding
makes loading the film onto the unwind shaft easier
Page
Page
1.5 Applications
Ensure the roll of mount adhesive is loaded properly on the unwind shaft
Page
Page
1.6 Troubleshooting
1.7 Maintenance
Below is a recommended maintenance
schedule. Before performing any of the steps
Excessive pressure can destroy the silicone
layer by pressing to hard or scrubbing too long in one spot
This will prevent anything from
Page
1.8 Label locations
Label locations
Section 2 Warranty
2.1 Limited Warranty
2.2Exclusions to the Warranty
Qualified
Page 2
General
Consumables
Function
Electrical Requirements
Section 3.5 Dimensions
Dimensions
Page
Section 4 Installation
4.1 Pre-installation
Figure 4.1.2 illustrates proper wiring for single phase for the U.S
Figure 4.1.3 illustrates proper wiring for Wye 3 phase for Europe
Figure 4.1.1 Suggested Floor Layout
Figure 4.1. 2 Single phase, U.S
Incoming line voltage
Figure 4.1.3 Wye 3 phase, Europe only
L 3
Correct Configuration
4.2 Unpacking
4.3Shrink Wrapped
4.4 Crated
Moving the laminator
Figure 4.4.2 Positioning of the ramps
b)Remove any plastic strapping and/or packing paper taped to the rolls
4.5 Accessory pack
4.6 Leveling
Figure 4.6.1 Foot bolts
Figure 4.6.2 Front to back
Leveling
Reset
4.7 Safety check
4.7.1Front and rear infeed tables
Page
4.7.2Front and rear safety shields
4.7.3 EMERGENCY STOPS ( E-STOP)
E-STOP
4.8 Function check
4.8.1Control panel
Page
q) Press SPEED t once. SPEED DISPLAY
REV
Figure 4.8.1 Default settings
4.8.3Unwind shafts and unwind brakes
Upper unwind brake
adjustment knob
Page
Section 5 Operations
5.1 Control Panel
Page
1/4
( 15 ) JOB
( 18 ) SAVE :
Section 5.4 Job Programming
( 16 ) JOB
( 19 ) SHUTDOWN :
( 21 ) SPEED
( 24 ) STOP :
( 22 ) SPEED
( 25 ) FORWARD
FORWARD
Panel to Footswitch
Footswitch to Panel
•Press and hold the variable speed footswitch down
•Release the variable speed footswitch
•Release GO. GO should be solid
To raise the safety shield
• Raise the safety shield
Footswitch speed is not indicated in the
SPEED DISPLAY on the control panel
To lower the safety shield
When the safety shield is lowered, speed
reverts to the panel speed setting
SEL
SAV
REV
SAFETY
5.2 Emergency
Set up
5.3.1 Power
5.3.2 Film loading
5.3.5 Heating
Page
5.4 Job programming
Page
5.5.1Main roller manual nip adjustment
5.5 Manual nip adjustment
Page
Figure 5.5.1 Main roller pressure
Proper
pressure
Excessive
g)Press REV tfor a reverse motor direction
5.5.2Pull roller manual nip adjustment
Refer to Figure 5.5.2 for proper roller
Figure 5.5.2 Pull roller pressure
h)The pull roller nip has now been manually set
i)Press STOP
j)Press REV tfor a reverse motor direction
g)Step on the variable speed footswitch to back the leader board out
5.6 Infeed tables
5.6.1 Removing the table
5.6.2Replacing the infeed table
If the tables are not properly seated, the
laminator will not operate in
"Panel" mode
Figure 5.6.3 Safety roller switch
Safety
Section 6 Applications
6.1 Precoating substrates
Group 1 : No heat
b)Place these two pieces by the laminator for future use
Figure 6.1.1 MAIN POWER / RESET
g)Lift the clevis pin located in the saddle of the upper unwind shaft
c)Turn MAIN POWER to “ ON”. Refer to
d)Press RESET. Refer to Figure
Figure 6.1.2 Unwind shaft
i)Once loaded, swing the upper unwind shaft back into the saddle
j)Push the clevis pin back down to secure the unwind shaft in its saddle
k)Raise the front safety shield
l)Press SEL. SEL will stop flashing
n)Press FWD s
If the board is loose, press
Process
Figure 6.1.3 Leader board
c)Press STOP
d)Press FWD s
Excessive tension will cause the
substrate to bow
g)Have the second person stand at the rear of the laminator
Steps " h " and " i" will be performed
Figure 6.1.4 ( 1/2 in. ) Gap
Figure 6.1.5 Trailer board
Finishing
Do not use an open blade to cut
the web near the rollers. You can put cuts into the rollers
This will prevent any exposed adhesive from contacting the rollers
Section 8.2 Cleaning the rollers
6.2 Mounting only
e)Press SEL. SEL will stop flashing
g)Press FWD s
Figure 6.2.2 Align edges
Figure 6.2.4 Trim the image
Figure 6.2.3 Trim the release liner
Figure 6.2.5 Peel back release liner
f)Press STOP
Figure 6.2.6 Tack leading edge
h)Push the leading edge of the precoated board up to the nip of the main rolls
Figure 6.2.7 Draping the image
1)Press STOP
2)Press REV t
4)Press STOP
5)Press FWD s
Figure 6.2.9 Non conformed print
Steps " l" and " m " will be performed
Yo u ma y b e CRUSHE D o r BURNED
o)The mounted image can now be removed from the rear of the laminator
6.3Single sided lamination ( Sled method )
Figure 6.3.1 MAIN POWER / RESET
Figure 6.3.2 Unwind shaft
g)Once loaded, swing the upper unwind shaft back into the saddle
h)Push the clevis pin back down to secure the unwind shaft in its saddle
i)Raise the front safety shield
k)Press SEL
l)Press FWD s
Y o u c a n C R U S H E D o r B U R N E D
Figure 6.3.3 Laminate to rewind
c)Wrap one full turn of laminate onto the upper rewind tube
Figure 6.3.4 Laminate separation
Steps " i" and " j" will be performed
Figure 6.3.5 Separation point
Page
6.4Single sided lamination ( Craft paper method )
Figure 6.4.1 MAIN POWER / RESET
Page
Figure 6.4.3 Laminate to rewind
Figure 6.4.4 Laminate separation
Figure 6.4.5 Craft paper
k)Press GAP tto enter a 0 in. gap setting
l)Press FWD s
Keep hands and fingers clear of
Steps " m " and " n " will be performed
the laminator roller nip when
adjustin g PRESSURE
If you choose to use the lower rewind tube
make note of the direction of travel
Figure 6.4.6 Finish product rewind
clockwise after you feel the initial contact. Refer to Figure
Do not use an open blade to cut the web near the rollers
Page
Page
6.5 Decal and mount
Saddle
Clevis pin
Figure 6.5.2 Unwind shaft
Figure 6.5.3 Laminate to rewind
Figure 6.5.4 Laminate separation
Figure 6.5.5 Mount adhesive
Page
Page
Figure 6.5.6 Finish product rewind
Page
Pass two : Mount
•Prints ( Decals )
•Substrates
•Leader board ( substrate width x 6” )
a)Replace the front infeed table
h)Press REV t to reverse the direction of the motor
Figure 6.5.8 Setting the decal
Figure 6.5.7 Align edges
Figure 6.5.9 Trim the decal
Figure 6.5.10 Peel back release liner
Figure 6.5.11 Tack leading edge
Steps " j" and " k " will be performed
Figure 6.512 Draping the decal
Figure 6.5.14 Non conformed decal
Figure 6.5.13 Conformed print
Steps " n " and " o " will be performed
Page
Group 2 : Top heat only
6.6 Precoating substrates
Figure 6.6.1 MAIN POWER / RESET
d) Press RESET. Refer to Figure
Figure 6.6.2 Unwind shaft
o)Press SPEED s to set a motor speed of 2 ft. / min. ( .6 m / min. )
s)Press STOP
p)Press GAP t to enter a 0 in. gap setting
q)Press GO
r)Continue with step s) when the TOP TEMP DISPLAY stops flashing
Page
Figure 6.6.3 Leader board
Page
Figure 6.6.4 ( 1/2” ) Gap
Figure 6.6.5 Trailer board
6.7One pass mount and laminate
•Leader and trailer board
•Roll of thermal laminate
•Glue stick
( print that are not heat sensitive )
Figure
Page
u) Press on the variable speed footswitch while
guiding the leader board into the nip to confirm
Page
Figure 6.7.4 Leader board
The thin line of glue will assist with holding the layers to the board
h) Press FWD s
j) Apply the minimum amount of brake tension on
the roll of thermal laminate to prevent it from
free spinning
Figure 6.7.5 Trailer board
6.8Thermal decal and mount
Figure 6.8.1 MAIN POWER / RESET
Figure 6.8.2 Unwind shaft
Page
Page
Laminate
Figure 6.8.4 Mount adhesive
The mount adhesive will adhere to the activated adhesive from the laminate
Page
Figure 6.8.5 Finish product rewind
Page
Page
Page
d) Press FWD s
g) Press REV t to reverse the direction of the
motor
e)Press on the variable speed footswitch to back the leader board out
Figure 6.8.6 Align edges
Figure 6.8.9 Peel back release liner
Figure 6.8.7 Setting the decal
Figure 6.8.8 Trim the decal
Figure 6.8.10 Tack leading edge
f)Set the substrate and decal in the center of the rear infeed table
Steps " g " and " h " will be performed
“ i”
i)Drape the loose part of the decal over the upper main roller. Refer to Figure
Figure 6.8.11 Draping the decal
j)Make sure the image is conformed to the upper main roller. Refer to Figure
Figure 6.8.13 Non conformed decal
Figure 6.8.12 Conformed print
motion, keep hands and fingers away from the nip of the rollers
Group 3 : Top / bottom heat
6.9 Encapsulation
Figure 6.9.1 MAIN POWER / RESET
Figure 6.9.2 Unwind shaft
Page
Page
Figure 6.9.3 Laminate
Figure 6.9.4 Lower laminate
Page
Figure 6.9.5 Finish product rewind
Page
6.10 Charts and Diagrams
Figure 6.10.1 Temperature conversion chart
Parameter Chart - Blank
GAP & PRESSURE
MOTOR DIRECTION & SPEED
Web Diagram - Blank
ApplicationsF - 160 Operation and Maintenance Manual
Parameter Chart 1 - Precoating substrates
UPPE R UNWIN D : Pro Mount
SUBSTRAT E : 1/4" Foam Core
LOWE R UNWIN D : N / A
Web Diagram 1 - Precoating substrate
Parameter Chart 2 - Mounting only
Web Diagram 2 - Mounting only
Parameter Chart 3 - Single sided ( Sled )
Web Diagram 3 - Single sided ( Sled )
Parameter Chart 4 - Single sided ( Craft paper )
SUBSTRAT E : N / A
LOWE R UNWIN D : Craft Paper
Web Diagram 4 - Single sided ( Craft paper )
Parameter Chart 5 - Decal and mount ( Decal )
LOWE R UNWIN D : Pro Mount
Web Diagram 5 - Decal and mount ( Decal )
Parameter Chart 6 - Decal and mount ( Mount )
PRINTS : Decals
Web Diagram 6 - Decal and mount ( Mount )
Parameter Chart 7 - Precoating substrates ( Thermal )
Web Diagram 7 - Precoating substrate ( Thermal )
Parameter Chart 8 - One pass mount and laminate
UPPE R UNWIN D : 3 mil Octiva Gloss
PRINTS : Electrostatic images
Web Diagram 8 - One pass mount and laminate
Parameter Chart 9 - Thermal decal and Mount ( Decal )
PRINTS : Any type
Web Diagram 9 - Thermal decal and mount ( Decal )
Parameter Chart 10 - Thermal decal and Mount ( Mount )
Web Diagram 10 - Thermal decal and mount ( Mount )
Parameter Chart 11 - Encapsulation
LOWE R UNWIN D : 3 mil Octiva Gloss
Web Diagram 11 - Encapsulation
Page
Section 7 Troubleshooting
7.1 Wave problems
Page
7.2 Film problems
7.2.2 Pressure sensitive
7.2.1 Thermal laminates
7.3Machine problems
7.4 Glossary
Clutch tension
Encapsulation
Coiling
Cold laminate
Film
Main rollers
Pull rollers
Media
Mount adhesive
Mount tissue
Silvering
Substrate
Tunneling
Unwind
Web
Section 8 Maintenance
8.1 Maintenance Schedule
8.2 Cleaning the rollers
Removing adhesive build up
c)Wipe away the beads with isopropyl alcohol and a cotton terry cloth
Cleaning the beads of
adhesives, dust and dirt from
the rolls
Method
a)Allow the laminator to cool slightly to no higher than 110oF ( 43oC )
Page
8.2.1 Clean the cabinets and
8.2.2 Cleaning the touch
covers
screen
