Banner American Easy-LAM II Operating instructions

OPERATING
INSTRUCTIONS
EZ27
Roll
Laminator
Revised February 1, 1999
TABLE OF CONTENTS
Safety Messages and Electrical Safeguards .................................. 1-2
Introduction ...................................................................................... 2-3
Laminator Features ............................................................................ 3
Specifications ...................................................................................... 3
Initial Set-up ...................................................................................... 4-5
Unpacking .......................................................................................... 4
Feed Table Assembly ......................................................................... 4
Components .................................................................................... 4,5
Operation .......................................................................................... 5-8
Loading Laminating Film .................................................................. 5,6
Threading Laminating Film .............................................................. 6,7
Roller Tension .................................................................................... 7
Heat Shoe Temperature ..................................................................... 8
Laminating ........................................................................................ 8-9
Troubleshooting ............................................................................. 9-10
Maintenance .................................................................................. 10-11
Cleaning Heat Shoes & Rollers ................................................... 10,11
Warranty & Return Policy ................................................................. 11
Parts List ....................................................................................... 12-13
Parts Illustrations ......................................................................... 14-17
Exploded View .................................................................................. 14
Side Panels ...................................................................................... 15
Motor Assembly ................................................................................ 16
Wiring Diagram ................................................................................. 17
17
POWER
BLACK
GREEN
WHITE
L2
0
HEAT
SWITCH
6
THERMOSTAT
GROUND
HEATER
INDICATOR
BLACK
4
BLACK
L1
5
3
2
1
0
TOP
BLACK
WHITE
HEATER ELEMENT
HEATER ELEMENT
BOTTOM
HEATER ELEMENT
HEATER ELEMENT
0
2
ORANGE
1
8.5
4
5
CAPACITOR
3
MOTOR RUN
INDICATOR
RED
6
0
OFF
RUN
SWITCH
BLACK
RED
ORANGE
MOTOR
IMPORTANT SAFETY MESSAGES AND
ELECTRICAL SAFEGUARDS
For your protection, do not connect the laminator to electrical power or attempt to
operate it until you read these instructions completely. Keep these instructions in
a convenient location for future reference. This instruction manual and labels
affixed to the laminator are important safety messages. Read these messages
carefully.
For your safety...
16
”
Keep hands, long hair, clothing, and other loose articles such as
jewelry and ties, away from laminator’s moving parts.
”
Save these Operating Instructions for later use.
”
Do not touch the heat shoes while the laminator power is turned
on. Allow shoes to cool completely before touching.
”
Do not use the laminator for other than its intended purpose.
”
Place laminator on a sturdy cart, stand, or table. A laminator
placed on an unstable surface may fall, causing serious bodily
injury. Move laminator with caution. Quick stops, excessive
force, or uneven floor surfaces may cause the laminator and cart
to overturn.
”
Never override or attempt to defeat electrical or mechanical
safety interlock devices.
”
Never insert objects or spill liquids in or on the laminator. They
may contact dangerous voltage points or short out components
that could result in fire or electrical shock.
”
The laminator should only be operated from the type of power
source indicated in these Operating Instructions and on the data
plate located on the rear panel of the laminator.
”
The three-pronged grounding plug is a safety feature and will
only fit into a grounding-type power outlet. If you are unable to
insert the plug into an outlet contact a qualified electrician to have
a suitable outlet installed.
”
Do not leave the laminator power on overnight. Unplug the
laminator at the end of the day.
1
”
Unplug the laminator before moving it or when it is not in use for
an extended period of time as a precaution against the possibility
of an internal malfunction that could create a fire hazard.
”
Do not operate the laminator with a damaged power supply cord
or plug, or after it malfunctions or has been damaged in any
manner.
”
Keep the power cord away from hot or wet surfaces.
”
Do not overload electrical outlets beyond their capacity as this
can result in fire or electrical shock. This unit is rated at 15 amps
(12 amps CSA) and should be the only item plugged into a 15 or
12 amp branch circuit. When connected to a 20 amp branch
circuit any items in addition to the EZ27 must not exceed 4 amps.
”
Adjust only those controls that are specified in these Operating
Instructions.
”
Do not attempt to service or repair the laminator yourself. Unplug
the laminator from the electrical outlet and contact an authorized
service representative under any of the following conditions:
• When the power supply cord or plug is damaged or frayed.
• If liquid has been spilled into the laminator or it has been
exposed to water.
• If the laminator has been subjected to excessive jarring
through being dropped or bumped.
• If the laminator does not operate normally when following the
operating instructions.
INTRODUCTION
Congratulations on your purchase of the EZ27 Roll Laminator. This unit is
designed to provide years of trouble-free service.
The EZ27 will accept rolls of laminating film up to 27” wide in both 1.5 and 3 mil
thicknesses. Paper and card stock up to 80mm thick may be laminated without
adjusting the feed rollers. Individual temperature controls and indicators provide
uniform temperature on both sides of the item being laminated.
2
15
Your EZ27 is preset at the factory for most applications so any adjustments
should be minor. A thermometer provides continual indication of the Heat Shoe
temperature and may be adjusted as needed.
Laminator Standard Features...
” Preset laminating roller pressure and speed require no adjustment.
” Feed table with adjustable guide.
” External thermometer for ease in monitoring temperature.
” Teflon® coated Heat Shoes for easy cleaning.
” Laminating film widths up to 27”.
” Total thickness up to 86 mils (laminate plus paper).
SPECIFICATIONS
14
Plastic Width
27” (68.6cm)
Plastic Thickness
1.5 mil and 3 mil
Maximum Roll Length
1.5 mil - 1,000 feet (304.8 meters)
3 mil - 500 feet (152.4 meters)
Speed
4 feet per minute
Net weight
66 lbs (29.96 kg)
Power Requirements
120VAC, 60Hz, 1840 watts (UL), 1360 watts (CSA)
220VAC available
3
INITIAL SETUP
Unpacking and assembly...
Before unpacking the unit, inspect the shipping container for signs of damage.
Notify the carrier and your dealer immediately if any damage is noted.
CAUTION! The laminator, without the feed table
and mounting slides installed, weighs approximately 70 lbs. Use two people when removing the
laminator from the shipping container.
16
17
18
19
20
21
22
23
24
25
26
Assemble the Feed Table:
Before you can begin using your laminator, you will have to assemble the Feed
Table and Guides on the laminator. To do this, you will need a #2 Phillips screwdriver.
29
30
31
3. Mount the second Slide to the right side plate using two #8-32 x ½ screws.
Components...
The figure below shows the location of the major components and controls of the
EZ27. You should become familiar with these before operating the laminator.
4
700680
127001
100005
127002
627126
700454
Motor Drive Assembly
Mounting Washers
Motor, Standard
Motor, 90V DC, Variable Speed
Motor, 220V
Motor Support Bracket
Mounting Screws
500002
627104
627306
Capacitor, 7.5µf
Motor Cover
Cover Plate
500401
500512
500516
500513
500204
227607
200002
200001
200606
500601
500701
500706
500703
227107
Fuse Assembly
Fuse Holder
Fuse, 10A, 220V
Fuse, 15A, 120V (UL)
Fuse, 12A, 120V (CSA)
Power Cord
Strain Relief Bushing
Side Cover, Right
Side Cover, Left
Rubber Feet
Indicator Lamp
Heater Power Switch
Machine Drive Switch
Reverse Drive Switch
Safety Shield
1
1
4
2
1
1
1
1
Zippy Cutter
1
32
1. Place the laminator on a sturdy table or stand with clear access to both side
panels.
2. Place one Feed Table Slide on the left side plate and attach the Slide with two
#8-32 x ½ screws.
Laminating & Pull Roll Spur Gear
Roller Sprocket, front, 22 tooth
Roller Sprocket, rear, 21 tooth
Motor Gear
Rubber Rollers, top
Rubber Rollers, bottom
Spacer Washers
Bearing, Roller
Roller Cover
Tie Bar
Terminal Block, 6 position
28
First unpack and identify the following items:
• EZ27 Roll Laminator
• Feed Table with Paper Guide
• Mounting Slides for Feed Table (with screws)
627601
600602
600603
600601
327007
327006
700613
600401
627119
627108
500304
33
34
35
36
37
38
39
40
41
13
2
2
2
2/assy
8/assy
2
1
4
1
1
1
4
1
Machine Drive: This three position (FWD/OFF/REV) switch controls power to the
Laminating Rollers. If the switch is pressed to the FWD position the rollers move
forward, pulling the plastic film and laminated material past the Heat Shoes.
PARTS LIST AND ILLUSTRATIONS
This section contains reference drawings and parts lists to assist you when
repairing and servicing your laminator. The drawings show only those parts that
may be replaced by the dealer.
Item
Part Number
Description
Qty.
600021
627110
200616
700703
200611
Supply Mandrel Assembly
Core Gripper
Mandrel
End Bushing
Snap Ring
Mandrel Brake Assembly
2
1/assy.
2
1/assy
2/assy
2
6
627112
527104
500804
700304
200602
Heat Shoe Assembly
Teflon Coated Heat Shoe
Heater Element
Thermostat
Heat Shoe Spacers
Thermostat Knobs
2
2
2/assy
2
4/assy
1
7
627305
8
9
600305
600306
Run-off Table
Screw, #6-32 x ¾”
Aluminum Side Plate, Left
Aluminum Side Plate, Right
1
2
1
1
627117
600311
200619
627132
700441
Feed Table Assembly
Feed Table
Feed Table Guide, Right hand
Adjustment Knob
Feed Table Slide
Attaching Screws, 8-32 x ¼”, pan head
1
1
1
1
2
4
327011
200608
700495
Idle Bar Assembly
Idle Bar Rod
Bushings, Idle Bar
Screws, ¼-20 x ½”, Socket, set
2
1/assy
2/assy
2/assy
1
2
3
4
5
10
11
12
13
When this switch is pressed to the REV position the rollers move in the reverse
direction. This is useful for clearing film from the rollers.
Drive Indicator: This light remains on when the Machine Drive is moved to either
FWD or REV positions.
Heater Power: This switch turns power to the top and bottom Heat Shoes on and
off.
Heat Indicator: This light goes on when the Heat Switch is first turned on then
remains on until the Heat Shoe reaches the operating temperature. After that
point, the light will flash briefly as the thermostat controls the Heat Shoe temperature.
OPERATION
This section describes the operation of your EZ27. This laminator is designed for
all widths of plastic up to 27”. However, if narrower widths are used the Heat Shoes
must be cleaned before using a wider roll. Refer to the MAINTENANCE section for
cleaning instructions.
Loading Laminating Film onto Mandrels...
Slide the film onto the mandrel as in Figure 2 below, making sure that the mandrel
spring is in position to compress properly when the film is pushed onto the mandrel. Remove the film in the same direction.
Mandrel Spring
Mandrel
Film
14
15
600202
700504
700478
Roller Tension Assembly
Tension Bar
Screws, #10-24 x ¾” flat head
Screws, #10-24 x ¾” pan head
2
1
2/assy
2/assy
900301
Roller Drive Chain & Master Link
1
12
Figure 2
5
Threading Laminating Film...
These instructions apply to poly-in film rolls (shiny side out, dull side in)
1. For the top supply roll place the mandrel ends into the slots in the top of the
laminator. If you are facing the front of the laminator the film should unwind toward
you from the bottom of the roll as in Figure 3 below.
Note:
The surface of the Heat Shoes is Teflon® coated and must
only be cleaned using a soft cloth. They can easily be
damaged by sharp or abrasive objects.
1. Allow the Heat Shoes to cool.
2. Remove the Feed Table by sliding it toward you to expose the Heat Shoes.
3. Cut the plastic film from the supply rolls and where it exits the rollers. Pull the
film toward you and away from the rollers.
Figure 3
2. Pull 6"-12" of film from the top roll. Pass the film under the idler bar and over the
heat shoes. Make sure the shiny side of the film is against the shoes. See
Figures 5 & 6 below.
3. For the bottom supply roll, remove the run-off table. From the back of the
laminator, place the mandrel ends into position in lower mandrel holder slots.
Return the Run-off Table to its proper position before operating the laminator. If you
are at the back of the laminator the film should unwind away from you at the top of
the roll as in Figure 4 below.
Figure 4
4. Pull 6"-12" of film from the bottom roll. Pass it under the lower idler bar and
drape the film from the bottom roll over the film from the top roll. Since the heat
shoes are hot the bottom film will adhere to the top film. See Figures 5 & 6 below.
Note: The shiny side of the film must always go against the Heat
Shoes. If the laminating film is wound with the dull side out, the
Lower Idler Bar must be moved to the lower position. To do this,
remove the side covers and loosen the screws from both ends of the
Idler Bar. Move the bar to the lower position and tighten both screws.
Replace the side covers.
Caution: The Heat Shoes reach a temperature of
up to 350°F. Do not touch the surface of the Heat
Shoes.
4. Lift the film away from the Heat Shoes. Turn the power on and hold the Motor
Drive switch in the REV position while pulling the film forward toward you (from the
front of the laminator).
5. Use a soft cloth moistened with alcohol to remove any residue from the Teflon®
surface of the Heat Shoes and Laminating Rollers.
6. Allow the Heat Shoes and Laminating Rollers to dry before re-threading the film.
Removing Wrap-arounds...
When laminating with thinner gauges of film, there is the possibility of the film
wrapping around the Pull Rollers. Use the same procedure for Cleaning the Heat
Shoes and Laminating Rollers in order to remove a wrap-around. You should
remove any wrap-arounds that occur as soon as possible. If the film is allowed to
cool while wrapped around the rollers it may be more difficult to remove and the
heat shoes may have to be turned on to loosen the film.
Note:
The heat shoes are hot! Use caution when cleaning the
rollers or heat shoes, or when removing wrap-arounds.
WARRANTY AND RETURN POLICY
Warranty
Your laminator is warranted to be free of defects in material and workmanship for a
period of 1 year from the date of original purchase. In the event of a defect in
material or workmanship, the manufacturer or its authorized dealer, will repair or
replace (at their option) the laminator. This does not cover rollers that have been
damaged due to improper cleaning. The manufacturer makes no other warranty
stated or implied except as stated above.
Return Policy
If your laminator is not operating properly, first review the Operating Instructions and
Troubleshooting Guide. If the malfunction cannot be corrected, contact your local
dealer for instructions. Be sure to have your machine serial number and date of
purchase handy. If the laminator must be returned to the dealer, proper packaging
and freight charges are your responsibility. Shipping damage as a result of improper packaging is not covered under the terms of this warranty.
Figure 5
Figure 6
6
11
8. Turn the Machine Drive switch to FWD to start the Laminating and Pull Rollers.
PROBLEM:
ACTION:
Stretch lines appear on laminated items running parallel with
the outside edges.
Increase roller tension on top and/or bottom supply rolls.
Reduce heat shoe temperature.
Clean heat shoes of residual adhesive. See MAINTENANCE
section for cleaning instructions.
9. Feed a piece of thin cardboard about 10” x 25” against the film so that it is
centered between the two Heat Shoes. Push the cardboard and film into the
Laminating Rollers. See figure 4.
10. When the feed card has completely exited the Pull Rollers at the rear of the
laminator turn the Machine Drive Switch off.
11. Insert the Feed Table into the slots located on each side of the unit, between
the Heat Shoes.
PROBLEM:
Blistering of the film appears over the item or along the
edge.
12. If you are not ready to laminate, turn the Heat Switch off.
ACTION:
Reduce temperature on one or both heat shoes. If the indicator
light remains on after the adjustment is made, disconnect the
power supply and contact your dealer.
Adjusting Mandrel/Film Tension...
Clean laminating rollers. See MAINTENANCE section for
cleaning instructions.
There may be moisture in the paper you are laminating. Store
paper in a dry place and be sure that any ink is thoroughly dry
before laminating.
PROBLEM:
Laminated material curls after leaving pull rollers.
ACTION:
Adjust tension. If laminated item curls upwards, reduce top roller
tension. If item curls downward, reduce bottom roller tension.
Clean heat shoes of residual adhesive as it may be causing
“drag” on one side. Refer to MAINTENANCE section for cleaning
instructions.
MAINTENANCE
Each type of laminating film has different characteristics and may require laminator
adjustment. The tension should be set so that the film moves over the Heat Shoes
without wrinkles as the film enters the laminator. Best results are obtained if
tension adjustments are made while the unit is at operating temperature. If any
adjustments are required use the following procedure:
1. Switch the Heaters on. Wait for the Heat Shoes to reach operating temperature. The indicator lamp will go off when the proper temperature is reached. You
can check the temperature by reading the thermometer located on the right side of
the laminator.
2. Press the Machine Drive switch to FWD.
3. Locate knob on the right side of Top Supply Mandrel. Turn the knob to adjust
the tension (clockwise to increase, counter clockwise to decrease) until the film
passes over the Top Heat Shoe without wrinkles and the web between the laminating and pull rollers is tight. Note: This adjustment requires only a few degrees of
turn. If the knob is turned too far clockwise, you may stall the drive motor.
This section contains instructions for cleaning and maintaining your laminator.
These procedures should be performed at regular intervals to help ensure the
trouble-free operation of your laminator.
Caution:
Before performing any maintenance on your laminator
first disconnect the power supply. Hazardous voltages
are present when the side panels are removed.
Cleaning the Heat Shoes and Laminating Rollers...
4. Repeat for Bottom Supply Mandrel.
5. If you are not ready to laminate, turn the Machine Drive and Heat Switches off.
The Heat Shoes and Laminating Rollers should be cleaned of any residual adhesive
whenever the film does not pass smoothly over their surfaces.
10
7
Setting Heat Shoe Temperature...
Note:
You may want to run a test lamination first as any item that
passes between the Heat Shoes will be laminated and
cannot be recovered until it exits the rear of the laminator.
The laminator temperature should be adjusted according to the film thickness and
the item being laminated. See Table 1 below for recommended temperature
settings. Keep in mind that the temperatures listed are approximate and different
brands of laminating film may require different temperatures.
1. Turn the Heater switch on.
5. Additional items may be fed in sequence, keeping enough distance between
sheets for trimming.
2. Use the Heater Thermostat Adjustment Knob on the left side of the laminator
to adjust the temperature of the Heat Shoes. Use the temperatures in Table 1
below as a guide.
6. After the last item has exited the Pull Rollers, turn the Machine Drive switch
off.
Material
Temperature Range
1.5 mil (.0015”)
310°F - 325°F
3 mil (.003”)
250°F - 265°F
Table 1
3. Turn the knob counter clockwise to reduce the temperature and clockwise to
increase the temperature. If reducing the temperature, wait several minutes for
the heat to drop to the proper operating temperature. When increasing temperature, the indicator lamp will come on as the laminator is heating up and go off
when it reaches operating temperature.
7. Use the Zippy Cutter to cut across the film to remove the laminated items from
the unit.
TROUBLESHOOTING
The following guide will assist you with most problems that may be encountered
when laminating.
PROBLEM:
Laminator is inoperative. Motor does not turn, indicator
lights are out.
ACTION:
Unit may be unplugged. Connect power supply
Ensure that the circuit breaker has not tripped
4. Check the thermometer to see if the desired temperature has been reached.
You may have to make a few minor adjustments before optimum temperature is
set.
LAMINATING
1. Be sure the heaters have been turned on and are at the proper temperature.
Be sure the film has been properly threaded.
Caution: Do not allow the temperature to exceed
350°F as this could cause the laminating film to
melt on the Heat Shoes.
Fuse may have blown. Replace fuse (front next to power cord)
with 15 amp BUSS (MDA-15) for standard units, or 12 amp
(MDA-12) for CSA units.
PROBLEM:
Laminating film and item being laminated move through
laminator erratically.
ACTION:
Check thickness of item to be laminated. Maximum thickness is
1/16" (1.6mm).
Clean heat shoes of residual adhesive. Refer to MAINTENANCE
section for cleaning instructions.
PROBLEM:
Plastic is not bonding to the item or to itself at the edges.
ACTION:
Make sure heat shoes and rollers are at proper operating temperature and have had time to warm up. See Table 1 for the
suggested temperature ranges.
3. Press the Machine Drive switch to the FWD position. The film will begin
moving through the laminator.
PROBLEM:
Wrinkles on laminated item running parallel with supply
rolls.
4. After clear laminating film exits the Pull Rollers at the rear of the machine you
may slide the first item to be laminated into the laminator with the right edge along
the Paper Guide.
ACTION:
Increase roller tension on top and/or bottom supply rolls; only
small amounts between tests.
2. Adjust the Paper Guide on the Feed Table so that the right edge of the item
will enter the laminator at the desired position.
8
Reduce heat shoe temperature.
9