Professional Laminating Systems Laminator Operators Manual SERIES II
Record Record Machine Details Distributor Model _______________ Serial #_______________ Date Of Purchase__________________ Date Of Manufacture_______________ Voltage_______________ Inspector______________ 3
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Warnings & Safety................................................................................................................................... 10 Elecrical Requirements ............................................................................................................................. 12 Specifications............................................................................................................................................ 13 Unpacking ........................................
Threading Diagrams............................................................................................................................... 45 Film Tuning .............................................................................................................................................. 48 Film Replacement ..................................................................................................................................... 50 Film Removal.......................................
Professional Laminating Systems, Inc. Hamilton, MT. 59840 406-363-1690 About our company.... The primary goal of PLS is to provide laminating machinery that produces excellent and consistent results at affordable prices. We are able to accomplish this goal through innovative design and engineering practices. The foundation of our system is our patented heated roller, the heart of the lamination process.
CONGRATULATIONS Congratulations on your purchase of a series II heated roll laminator, manufactured by Professional Laminating Systems Inc. Your laminator has been designed with the latest technology to deliver hours of trouble-free operation and quality results. Your new laminator is a very versatile machine capable of laminating 1.2 through 10 mil films on a wide variety of materials through 3/16” thick. With proper care and maintenance, your laminator will offer you many years of dependable service.
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 MALFUNCTION IMMEDIATELY UNPLUG THE MACHINE OR ELECTRICAL NEVER SERVICE THIS MACHINE WITHOUT FIRST DISCONNECTING THE MACHINE FROM THE ELECTRICAL SOURCE. DO NOT TOUCH THE HEATED ROLLERS AS THEIR TEMPERATURE MAY EXCEED 350 DEGREES FAHRENHEIT.
IF THE SLITTERS (SIDE TRIM KNIVES) ARE USED, USE EXTREME CAUTION WHEN HANDLING THE KNIFE BLADES OR MAKING ADJUSTMENTS, AS THE KNIFE BLADES ARE RAZOR SHARP. USE MULTIPLE PEOPLE TO UNPACK AND MOVE THE LAMINATOR AS IT WEIGHS IN EXCESS OF 75 POUNDS. LEAVE REPAIRS AND MAINTENANCE TO A QUALIFIED PERSONNEL. NEVER LEAVE THE MACHINE UNATTENDED WHILE IN USE.
ELECRICAL REQUIREMENTS A GROUNDED RECEPTICAL MUST BE USED, MAKE SURE THAT THE RECEPTICAL MATCHES THE MACHINE REQUIREMENTS MODEL PL1200HP PL227 PL227HP PL238 PL238wf PL244wf VOLTS 120 120 240 120 240 240 AMPS 20 20 20 20 20 25 PLUG * * L6-20 * L6-20 L6-30 WATTS *Conventional plug however the outlet must be dedicated (no other devices on the same circuit). The electrical installation must meet local and federal electrical codes and a qualified person must make the installation.
Specifications Hard specs Model PL 1200 w/o stand PL 1200 w- stand PL 227w/o stand PL 227w stand PL 238wf PL 244wf Film specs: Model PL 1200 w/o stand PL 1200 w- stand PL 227w/o stand PL 227w stand PL 238wf PL 244wf Dry/Ship weight Height Width 40# / 60# 21” 24” 60# / 80# 51” 24” 70# / 100# 21” 39” 90# /120# 51” 39” 140# / 170# 50” 50” 170# / 200# 50” 56” Models shown in their standard configuration Depth 21” 21” 21” 21” 21” 21” Max upper roll Max lower roll Max thickness 11” 6” 10 mil+ 11” 22” 10 mil+
Silicone Vs. Metal A silicone covered heated roller is the most advanced, accurate and highest quality methods of lamination available to day. Producing superior results to nearly any other process, it is the paramount method. However, there are some common sense differences between silicone rollers and the old metal heat shoe technology. Though the silicone rollers are the greatest advantage to other technologies, it is possibly its greatest weakness.
UNPACKING Because the series II laminator is available in several different sizes and configurations, some of the following steps may not be applicable to your specific shipment. However, it may be a good idea to read over the following documentation to familiarize yourself with your machine and the technology involved Typical shipment of the series II laminator is as follows. A. Your laminator was shipped as a tabletop model. B.
LAMINATOR UNPACKING Your laminator is shipped in one box. Some minor assembly is required. You should clear out sufficient space to unpack the laminator. Make sure this area will provide access to both sides of the laminator as well as the front and back of the machine. The laminator is packed in specially designed material for shipping your laminator safely The Packing material should be retained for transportation or for shipping in the event of a warranty or service issue.
LIFT POINTS Make sure that when the laminator is removed from the box it is only lifted by the ends of the tie bars (as shown). PL 1200 shown, if the laminator is wider this is even more critical and may take two or more people to lift it. ! ! ! DO NOT LIFT THE LAMINATOR BY ANY OF THE COMPONENTS BETWEEN THE FRONT ROLLERS AND THE REAR ROLLERS.
STAND The stand is an optional item on certain models and may or may not have been included with the purchase of your laminator. Your laminator stand is shipped in one box it may require simple assembly. You should clear out sufficient space to unpack the stand. Make sure this area will provide access to both sides as well as the front and back of the stand. The Packing material should be retained for transportation and shipping for warranty or service.
STAND ASSEMBLY These instructions for the stand are correct assuming that the stand frames were delivered with the mandrel towers and feet / wheels installed. If they are not please refer to the included documentation for documentation on this, then refer to the following instructions The hardware for assembling the stand was shipped in a parts box that was included in the laminator box.
Use the diagrams and instruction on the following three pages as a guide to assemble the stand 20
Assembled Stand When finished your stand should resemble this example from our PL 227hp. Also Notice the placement of the mandrel towers.
Stand Assembly Review Normal Procedure For stand assembly is as follows 1. Position the parts for assembly, layout the parts in their respective locations on the floor 2. Identify left frame piece (has the smaller slot in the mandrel tower). 3. Position the frame so that the aluminum mandrel tower is toward the front and on the right side (inside) of the stand frame (feet down). 4. Install a spreader into the lower holes (spreaders are not directional).
MOUNTING THE LAMINATOR The laminator is mounted to the top of the stand using the four thru holes on the top of the stand 1. Set the stand in position on a flat level surface. 2. If the laminator arrived with rubber pads on the feet, these must be removed. Using two people, tilt the laminator back while using a 5/32 Allen wrench loosen the cap screw and remove the pad. 3. Make sure that the mounting bolts and pads are properly placed on the stand.
Tower Alignment If the stand arrived with the towers attached you possibly will not need to follow this alignment procedure however, it is recommended before proceeding make sure that the towers are correctly aligned. Before starting this alignment, procedure makes sure screws are tightened only enough to make moving the towers somewhat difficult. It may be necessary to use a rubber hammer or a block of wood to adjust the towers.
Laminator Assembly Mandrel Towers Typical tower configuration on the laminator is either, slitter towers, which include the slitter assemblies attached to it, or our standard towers, which come with machines void of slitters. Slitter Towers If your laminator was supplied with slitters, it is typical that the tower will be already attached to the machine and they simply need to be pivoted upright. 1. Position the laminator mandrel towers.
Standard Towers Upper If your laminator was supplied without slitters, the towers will be included with the hardware pack. 1. Install left tower (small slot) using two 5/16 x ½” long, hex head bolts. 2. Install right tower (large slot) using two 5/16 x ½” long, hex head bolts. 3. Tighten bolts snug (do not over tighten). Lower towers Your machine is available in two different configurations. A. Without a stand, your towers will have to be installed on the laminator below the feed tray. B.
Feed Table Installation Attach the feed table by introducing the table at a slight upward angle. Engage the semicircular extrusion boss against the 1/4' roll pin protruding from the sides of the feed table brackets. Push and press down until the table snaps into place. Rest On Pin Drop Front Down The feed table is removable and is typically removed for installing new film, roller cleaning and service Remove Protective film There is a protective film on the side panels of your laminator.
Laminator Setup Plug the machine into its respective outlet; make sure that this outlet is dedicated or of sufficient rating (no other electrical devices used at the same time on this circuit). !!!THIS CIRCUIT MUST BE GROUNDED Never Operate The Laminator Without A Ground!!! Refer to “ Electrical Requirements” on page 12.
Laminator Controls Heat Switch This switch, located in the upper left of the right-hand control panel activates the heating and temperature control systems incorporated in the rollers. When activated, you will see a numeric temperature displayed in the process control window, located on the left-hand panel. This indication is the actual temperature of the rollers. Please turn off the heaters and gap the rollers when the laminator is not in use.
Direction Control The direction control switch is located directly above the speed control. This switch is a three-position rocker switch. Forward is the normal setting and the switch will stay engaged after being depressed. Reverse is for clearing jams and cleaning rollers. You must keep the rocker depressed for the duration of time you wish to use this direction. Reverse should only be utilized as a last resort--you can normally clear a jam by gaping the rollers.
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. To remedy this either I. Allow the rollers to stabilize by gaping the rollers and leaving them undisturbed in this position for 5-15 min (with fans off) II.
If it is found that the laminating rollers have flat spots on it due to the rollers not being gapped, simply gap the rollers and allow the laminator to go through several heating and cooling cycles then run the laminator without film until the flat spots disappear. The silicones that we use in our rollers are of an extremely high grade and hold nearly no memory for extended periods. We have never had one roller returned because the rollers did not recover from not being gapped.
Mandrels !!!Caution: Use Extreme Care When Handling The Mandrels Located in the center of the mandrel is the mandrel clip, it is very sharp!!! Mandrels: The 3” mandrels are designed to be used with film that is wrapped adhesive out The 1” mandrels are designed to be used with film that is wrapped adhesive in.
Tension Control Knob The tension control knobs are located on the right side of the mandrels that hold the laminating film. They are used to: A. Control film tension B. Prevent the film rolls from free spooling. C. Flatten any film curl D. Smooth film lay on the rollers As a rule, the lighter the tension, the better. The mandrel tension may also be used to assist in keeping the lamination flat.
Mandrel Clip The following diagrams show the proper use of the mandrel clip for film wrapped with the adhesive out only if a film is being used that is wrapped with the adhesive in you must reverse the cores for the clip to grip Take note of the direction of the mandrel clip in relation to the film path and that it would allow the film to slip Though this is shown as incorrect, it is the correct film path (adhesive touching idler not roller) for adhesive in IT IS IMPERATIVE THAT THE ADHESIVE SIDE OF THE F
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 are two (or more by option) feed guides. These guides help keep the material being laminated square and aligned with the film edge and, in effect, correctly locate it for slitter operation. These feed guides are adjustable for both angle and position.
SLITTERS !!!Use caution at all times in the vicinity of the slitter assemblies, as the knives are razor sharp!!! !!!If there exists 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!! When the slitters are removed, make sure that they are stored in a safe location as to prevent injury.
Slitter Installation Disconnect the laminator from the electrical supply before proceeding 1. Remove old towers (if applicable). 2. Assemble the slitter assembly in the order and direction shown on the previous page do not install the razor knifes at this time. 3. Install the shaft collar and the expansion spring (locate the expansion spring of spring washer between the tower and shaft collar) on the left side of the assembly (not shown). 4.
Slitter Operation !!!Use care while using the slitters, as they are sharp!!! Never load film on the laminator with the slitters in the down or trim position Always use sharp blades for slitting operations this will increase the quality of the lamination and prevent damage to the rear rollers due to blade binding and breakage Do not use the slitters to cut materials thicker than 3/64”(approximately .
Slitter angle adjustment We have provided the following adjustment on our deluxe slitter sets for a higher quality-finished product. (At the time of publication the only type available) 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.
Film Film Selection For best results, Professional Laminating Systems Inc. recommends using a film that is; • Manufactured in the USA or name brand and of good quality. This is due to apparent complexity in the film manufacturing process and the compromise of quality by foreign manufactures that offers no repercussion to their profits.
Film Threading Procedure 1. Load the laminating film on the mandrels. The mandrels are marked T and B on each end of the mandrels to indicate top and bottom placement (see mandrels on pages 32 thru 34 for proper use). It is imperative that the dull (adhesive) side of the film never be allowed to contact the heated rollers. 2. Insert each mandrel into one of the rolls of film paying very careful attention to the threading diagram drawing with respect to the direction the film unwinds.
12. Raise the lower idler roller to its upper position (if the film is correctly installed, the adhesive should be facing and in contact with the idler rollers – not the laminating rollers). 13. Now you are ready to complete the threading process. Using a threading card, (included with some laminating film) or a piece of light card board at least 65% as wide as the laminating film and at least 10" long 14.
23. Once you have everything adjusted and working well, please take a moment to mark the film roll location on the film mandrels with tape or a marking pen. This step will save you a lot of time and wasted film next time you change the film When you replace your film rolls you will be able to slide the new film up to this mark if it is the same width roll as the last.
Threading Diagrams Threading diagram, adhesive OUT, 3” mandrels 45
Threading diagram, adhesive IN, 3” mandrels 46
Tabletop model shown with adhesive in (reverse wrapped) 47
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 as crucial to adjust the machine for subsequent film rolls. It may however be necessary to review this paper when one is having problems with the film. The following may be best accomplished by using the thinner films available, such as 1 – 2 mil films but should easily be performed with a thicker film. 1.
E. Use the mandrel tension to cancel film curl. If the film is curling down loosen the bottom mandrel knob and vice versa, If this cannot be reduced by loosening the mandrel knob it may be counter-acted by tightening the mandrel knob that is opposite of the curl (in this scenario the top idler). 3. Temperature. A. Temperature settings are an issue of experience and can affect a wide variety of issues. B.
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.
Laminator Operation Fans / Cooling 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.
!!!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. To remedy this either: I. Allow the rollers to stabilize by gaping the rollers and leaving them undisturbed in this position for 5-15 min (with fans off) II.
Temperature: ProLam, Inc recommends following the temperature guidelines consistent with the type film you are using.
Roller Pressure: General: Roller pressure is adjusted by turning the cap screws on the top of the laminator. More pressure may be needed if a thicker stock is being used, and an edge seal is desired. Keep in mind that there are limitations to what your laminator can do. These limitations depend on film thickness and paper thickness. Our PL1200 hp, which is our 12” model, is capable of putting an edge seal on index stock with 1.8-mil film.
Laminating 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. Valuable one of a kind items, also offer a high risk.
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.
Production run one-sided lamination 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. 1. Unplug the machine. Never work on the laminator while it is energized. 2. Remove the right-hand side panel 3. Remove the lower roller brushes these are located inside the machine on the end of the lower roller. On the end of the roller is a slip ring.
Board Stock / Mounting 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. Wide format printer paper may shrink when laminated depending on the type and moisture content this may cause a wide variety of problems.
Cold Lamination / Pressure Sensitive Your laminator is very capable of laminating one-sided cold lamination using either the machine itself or the optional release liner winder. The instruction for threading your laminator using the machine itself is on the next page. The instructions for the use of the optional liner winder should be supplied with the kit.
Film diagram for threading pressure sensitive film without the use of a release liner winder Left view Right view 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.
Rotary Press Your laminator is capable of being used as a rotary press this process is very similar to cold laminating / mounting or pressure sensitive laminating. Pls Inc. manufactures a laminator that is cold capable only. the model number will start with a “R” this will designate a cold press only and this model will be void of most functions except speed control.
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. Clear the laminated material from the laminator (paper not film). 2. Shut off the fan switch. 3. Shut off the heat switch or reduce temperature below 160 degrees. 4. Reduce roller pressure if needed. 5. Gap the rollers. 6.
Regular 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. Do not spray any cleaning solution on or near the laminator as this may cause irreparable damage to the rollers.
The equivalent of a ¼” bead of compound should be applied perpendicular to the rollers onto the slip ring once applied run the machine without any film on it for about 10 minutes. If the temperature does not stop to fluctuate, inspect the brushes. Brushes Power brushes only need to be replaced when damaged; it is very unusual for these to wear out Temperature sensor brushes periodically need to be replaced. These brushes are made of a copper alloy and will wear with time.
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. Disconnect the laminator from the electrical supply and allow it to cool. 2. Gap the rollers. 3. Remove the left-hand side panel. 4.
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. If you must, you may oil the bushings on the laminator using a 10-weight synthetic high temperature oil. Unplug the machine.
Slitter Assembly Lubrication The slitter assembly requires lubrication when any adjustment is difficult Use a graphite – lithium high temperature grease Lubricate all surfaces subject to friction - - Adjustment screws, slitter shaft, slitter knobs slitter blade holders and pivot points Do not lubricate the towers or actuating arm Use grease sparingly Adjustment knob Do not remove the adjustment screw to lubricate, turn the screw out, lubricate, and then turn it in until the screw is seen on the other side
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. The tinsel does not have to touch the film. Replacement Anti-Static Tinsel is constructed of finer copper strands to obtain a sharper point.
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.
Operating Guidelines: Temperature: 1. Never exceed 300 degrees set temperature or displayed temperature when operating the laminator. 2. Do not set the temperature control more than 20 degrees above the recommended temperature of the film and never above 300. 3. Remember, since your laminator takes about 5minutes to warm up it is unnecessary to leave the laminator turned on while it is not in use. 4.
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. 4. Pro-Lam recommends using a course cotton mechanics cloth (NAPA part # 7601036). 5. Remove the film from the machine 6. Heat the laminator about 10 degrees beyond its normal set point (no hotter than 310 degrees).
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. Allow the laminator to cool to room temperature with the rollers gapped and then reheat - this will dissipate any cold or hot spots or rollers of unequal temperatures. 4.
Rollers Rollers cut, gouged, ripped, blistered, bubbled Erratic Temperature Fluctuation Rollers cold when laminating Insufficient edge seal Wrinkling film Will not stop heating Will not heat Replace Clean slip ring Slow down motor Roller pressure Re-align towers, Add small amount of tension Unplug+ Contact technical support Contact technical support Motor Erratic speed, low Erratic speed, mid, Erratic speed, All Will not run Noise Noise / runs at minimum Set too slow, Contact tech support Reduce mandrel
Film Typical problems, Follow list for topic in sequence, the first solution will be the most common.
Film cont.
Glossary FPM Feet per minute, typical measurement used to rate laminator speed 76
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LIMITED WARRANTY THE WARRANTY 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 for use. All electrical parts and rubber rollers are warranted free from defects in a material and/or work-man ship for a period of ninety (90) days from the date of its original purchase for use.
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. • Or, contact Pro-Lam 1806 hwy. 93 Hamilton MT 59840 or fax 406-363-1690 and explain the reason why you believe there is a defect or malfunction in the laminator including the date and conditions under which the defect or malfunction occurred.
