56FM Laminator INSTALLATION & OPERATION MANUAL Document Number: 930-123 REV: - REV DATE: 11-24-04
56FM Page 2 Operating Instructions
56FM Operating Instructions TABLE OF CONTENTS 1. Safety General Safety ........................................................1-1 Electrical Safety ......................................................1-2 2. Warranty Limited 90-Day Warranty ...........................................1 3. Specifications Prior to Installation ....................................................... Installation .................................................................... FCC Note...................................
56FM Page ii Operating Instructions
6FM Operating Instructions 1. SAFETY Your safety, as well as the safety of others is important. Before you install or use the laminator, read and follow all the safety notices carefully in this chapter. In this instruction manual, and on the laminator, you will find important safety notices regarding the laminator. Read all of the instructions and save these instructions for further use. The safety alert symbol precedes each safety notice in this manual.
56FM ELECTRICAL SAFETY The laminator should be connected only to a source of power as indicated in these instructions and on the serial plate located on the rear of the laminator. Contact an electrician should the attachment plug provided with the laminator not match the receptacles at your location. WARNING: Do not attempt to service or repair the laminator. Failure to observe this warning could result severe personal injury or death.
Operating Instructions 56FM 2. WARRANTY LIMITED 90-DAY WARRANTY The Manufacturer warrants to the original purchaser for a period of ninety days on labor and one year on parts after installation that this laminator is free from defects in workmanship and material under normal use and service. The Manufacturer’s obligation under this limited warranty is limited to replacement or repair, at the Manufacturer’s option, of any part found defective by the Manufacturer without charge for material or labor.
56FM Page 2 Operating Instructions
56FM Operating Instructions 3. SPECIFICATIONS Operating Speed • Variable • Fixed – Safety shield removed 1 to 9 fpm (0.3 to 4 mpm) 3 fpm (0.9 mpm) Dimensions • Width • Height • Depth • Weight 69 in (170 cm) 54 in (140 cm) 30 in (76.4 cm) 300 lbs. (136 kg) Electrical Requirements • Voltage • Current • Power • U.S. Receptacle 220 V 60 Hz 18 Amps 4000 W NEMA 6-30R 54 (140) 69 (170) 30 (76.4) Fig. 3-1. 56FM Dimensions. (Shown in inches (cm).
56FM FCC NOTE This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications.
Operating Instructions 56FM 4. INSTALLATION This chapter describes how to install the laminator. There are no operator serviceable parts to the laminator other than periodic cleaning. Refer to the Operator Maintenance chapter. 4. Connect the attachment plug provided with the laminator to a suitably grounded outlet only. Avoid connecting other equipment to the same branch circuit to which the laminator is connected, as this may result in nuisance tripping of circuit breakers or blowing fuses.
56FM Page 4-2 Operating Instructions
56FM Operating Instructions 5. FEATURE GUIDE This chapter identifies the main components of the 56FM laminator. The laminator is mounted to a floor stand that has locking castor wheels. Release liner take-up Thermal film supply shaft position PSA film supply shaft Top idler bar Heat pressure rollers Safety shield Roller pressure handle Control panel Feed table Bottom film supply shaft Foot switch Fig. 5-1. Component Identification from Front of the 56FM Laminator.
56FM Operating Instructions HEAT PRESSURE ROLLERS BOTTOM IDLER BAR Two silicone coated steel rollers heat the laminating film and press the heated film to the items being laminated. Heat is provided by an internal heating element. Each roller is heated independently. (Not shown) The idler bar directs the film to the roller. It assists in keeping the film flat on the heat rollers. NIP POINT Holds the film or kraft paper on the laminator. (Not shown.
56FM Operating Instructions CONTROL PANEL Display Top heat roller temperature Feed speed Job number Bottom heat roller temperature READY WAIT AUTO-OFF TOP TEMP. ST-BY Operating status MOTOR – STOP and RUN Press the STOP button to stop the laminator. Press and release the RUN button for continuous running. WARNING: Keep your fingers and hands away from the nip point (the point where the heat rollers meet). Failure to observe this warning could result in severe personal injury. BOTTOM TEMP.
56FM Operating Instructions FILM AND TAKE-UP TENSION ADJUSTMENT KNOBS CORE ADAPTORS Take-up shaft Allows the operator to increase or decrease film web and release liner tension as needed to reduce curl and wrinkles. Core adaptor Supply shaft FOOT SWITCH Starts and stops the laminator when pressed and released. When the safety shield is removed, use the foot switch to move the rollers forward. Gripper POWER SWITCH Fig. 5-6. Core Adaptors on Film and Take-up Shafts.
56FM Operating Instructions 6. OPERATION This chapter describes how to: • Operate the machine • Load films (web the laminator) • Laminate items • Mount items GENERAL OPERATION For thermal processes, the heat rollers need to be brought up to the proper temperature before you load films or run items through the laminator. If the laminator will be idle for more than four hours, lower the temperature of both rollers to 165 °F (75 °C). For PSA films and mounting processes, remove the chill idler.
56FM Operating Instructions REMOVING AND INSTALLING THE CHILL IDLER Chill idler LOADING FILM The 56FM laminator runs poly-in pressure sensitive adhesive (PSA) and thermal films. Poly-in means the adhesive side of the film is on the inside of the web. The shiny side of clear film must contact the heat rollers. The dull side of the film contains the adhesive. Use extreme caution when loading delustered (matte) film as both sides appear dull. Fig. 6-1. Chill Idler in the Laminator.
56FM Operating Instructions IMPORTANT NOTES: • • • The top and bottom rolls of laminating film must be the same width and present simultaneously. A small amount of adhesive will squeeze out during lamination. Hardened adhesive deposits can damage the main rollers. To avoid any damage, rotate the rollers at the slowest speed if READY is not displayed on the control panel. Refer to the Operator Maintenance chapter for cleaning instructions. Always change the top and bottom supply rolls at the same time.
56FM Operating Instructions REMOVING AND INSTALLING THE FEED TABLE LOADING FILM ONTO THE SUPPLY SHAFTS The feed table should not be removed except to install films. The laminator will not operate in the continuous mode when the table is removed or the latch is retracted. Refer to Fig. 6-4. for the following instructions. If you are replacing existing films, perform the following first set of instructions, To remove existing films.
56FM Operating Instructions To load films onto the supply shafts: 1. If the supply shaft is on the laminator, remove it by lifting the right end out of its bearing cradle and then pull the hex end out of the left side. This applies to the top and bottom supply shafts. 2. Slide the new roll on to the shaft and core adaptors, referring to Fig. 6-2 to determine how the film unwinds from the roll.
56FM LOADING FILMS WITH A THREADING CARD Operating Instructions WEBBING THERMAL FILMS The following procedures use a film threading card that is sometimes provided with new rolls of film. If one is not provided, a scrap piece of stiff cardboard or poster board with a straight edge is suitable. Either can be reused. Instructions are given for thermal or PSA films. Prior to loading (webbing) film, remove the safety shield and feed table.
Operating Instructions To web (load the films) the laminator with thermal films: 1. Thread the top film under the top idler and drape the loose end over the top heat pressure roller so that it extends a little past the bottom of the top heat pressure roller. 56FM WARNING: Hot surfaces and pinch points. Keep fingers and hands away from the heat pressure and pull rollers when the laminator is running. Failure to adhere to this warning could result in serious personal injury. 4.
56FM Operating Instructions 7. Stop the laminator when the threading card exits and cut off the card. 8. Check the film alignment and adjust the tension as needed. See the Film Alignment section in this chapter. WEBING ACCUSHIELD™ FILM The threading card for webbing AccuShield film can be any stiff print. IMPORTANT: When starting to laminate, always start the rollers BEFORE applying pressure to the rollers to prevent AccuShield build up on the roller.
56FM Operating Instructions WEBBING PSA FILMS WARNING: Keep your fingers and hands away from the nip point while the machine is running. They could be trapped and crushed in the rollers. Clothing, jewelry, and long hair could be caught in the rollers and pull you into them. 4. Release the card and ensure that the film and card are being pulled into the laminator. The card will guide the film into the rollers. 5. After the threading card exits the laminator, set the roller pressure handle to Release.
56FM Operating Instructions To web (load the films) the laminator with PSA films: 1. Pull the top film down, thread it under the idler bar, and then pull the film back up to the take-up core. 2. Lightly tape both corners of the film to the takeup core. Ensure that the film is pulled evenly and that no bulges exist at either end of the idler bar. 3. Using a very sharp utility knife, lightly score the laminating film approximately 4 in (10 cm) above the upper heat pressure roller.
56FM Operating Instructions TACKING NEW FILM TO EXISTING FILM The following describes a method for loading film whereby the existing film on the rollers may be used in place of the threading card to draw the new film through the laminator. Leading edges of the new film will be overlapped onto the adhesive of the existing film. The existing film and the new film will be pulled through the laminator together. To web thermal films: 10.
56FM 9. Pull the laminating film away from the liner and drape it over the existing film. Make sure to carefully align the edges of the films before sticking them together. 10. Install the feed table and safety shield. 11. Set the speed for the slowest speed and press RUN. 12. Observe the film being pulled through the laminator to ensure that the remaining existing film and the new film are advancing concurrently and evenly.
Operating Instructions 7. Remove the laminate and trim out the encapsulated item. To run the second pass: 56FM 7. Press RUN and immediately grasp the release liner for separation as the board is pulled into the rollers. Do not allow the release liner to be pulled into the rollers. Unweb (unload the films) the laminator first. 8. Continue to pull the liner as the item is pulled into the pressure rollers. 9. When the item has cleared the pull rollers, press STOP. Fig. 6-18.
56FM Operating Instructions MOUNTING MOUNTING AND OVERLAMINATION For all mounting processes, remove the chill idler. Refer to Removing and Installing the Chill Idler in this chapter. Mounting and overlamination is where you mount and laminate items in one pass. This can be performed with thermal films or thermal pouch boards. PRE-TREATING BOARDS WITH PSA FILM You may wish to pre-coat mounting boards ahead of time with PSA mounting film.
56FM Operating Instructions To mount and overlaminate with thermal film or pouch boards: 1. Preheat the top heat pressure roller to the desired temperature. 2. Set the speed to 1 fpm (0.3 m). 3. Set the roller pressure handle to the proper setting. 4. Position the item to be laminated on the board. 5. Start a board into the heat pressure rollers. 6. Press RUN and guide the item into the rollers. Fig. 6-20. Configuration for Mounting and Laminating With Thermal Film. 7.
56FM Operating Instructions FILM ALIGNMENT AND TENSION FILM TENSION Proper film alignment and tension contributes to better lamination. Proper film tension, known as brake tension, is the minimum amount required to eliminate wrinkles in the finished item. Tension adjustments are not necessary if you are using 1.5 or 3 mil film unless the lamination is curling up or down. Generally, 5 and 10 mil films require more tension.
56FM Operating Instructions 4. Visually inspect the top and bottom films where they enter the nip. The films should be tight against the rollers at both ends. If they are not, use the tension adjustment knobs to tighten the loose supply film brake and run another test. 5. Ensure that the release liner take-up is keeping the liner tight against the idler bar. If it is loose, use the tension adjustment knob to increase the tension. 6. Run test materials before laminating good materials.
56FM LAMINATION GUIDE Do not attempt to laminate abrasive or metal objects such as staples, paper clips and glitter, as they may damage the rollers. Do not force items into the nip area of the rollers. An item that is not easily drawn into the laminator by the rollers is probably too thick to laminate. Wrinkles may result if an attempt is made to reposition an item once it has been grasped by the rollers. Do not stop the laminator before an item has completely exited the pull rollers.
56FM Operating Instructions 7. OPERATOR MAINTENANCE CARING FOR THE 56FM LAMINATOR The only maintenance required by the operator is to periodically clean the rollers. The following procedure will help keep them free of dirt and adhesive, which has been deposited along the edge of the laminating film. Proper alignment of the rolls of film reduces the amount of adhesive on the rollers. Perform only the routine maintenance procedures referred to in these instructions.
56FM Operating Instructions TROUBLESHOOTING Symptom Control panel does not illuminate when the power switch is in the I position. Rollers do not turn. Possible Cause Laminator not connected to electrical supply. Fuse blown out or breaker open. Safety shield not seated properly or latch not engaged. Feed tray interlock latch not in place. Laminated items are curling. Adhesive deposited on rollers. Unsatisfactory laminate adhesion. Page 7-2 Tension between the top and bottom film roll is unequal.
Operating Instructions 56FM Page 7-3
56FM Page 7-4 Operating Instructions
