63

OPERATION / MAINTENANCE MANUAL

Rev 10/03/08

Copyright © 2007 Drytac Corporation / Revised © 2008 Drytac Corporation

All rights reserved. No part of this publication may be utilized or reproduced in a retrieval system, or transmitted in any form or by any means; electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from Drytac Corporation.

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Welcome to the World of Drytac

Over the past three decades, Drytac has evolved into one of the world’s most highly regarded manufacturers of products for graphics finishing and display. Our core product line consists of a wide range of pressure-sensitive, heatset and thermal overlaminating films. In addition, we offer an extensive line of mounting adhesives, backing films, inkjet media, finishing equipment, accessories, and banner stands.

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Our “Start To Finish” strategy sums up Drytac’s unique ability to manage all phases of the customer experience: product quality and performance, manufacturing and distribution, training and technical support and the industry’s best customer service.

Thank you for purchasing the JetMounter 63™ .

This 63” wide laminator is equipped with a top heated roller enabling you to process pressuresensitive adhesives and overlaminates (Room Temperature to 140°F/60°C) as well as Heatset adhesives and overlaminates (185°F/85°C) and even t hermal (*) overlaminates (210°F+/99°C+).

Please familiarize yourself with this manual prior to operating it. If you have any questions, contact your nearest Drytac office or customer representative.

(*) Since this is a single top heated roller laminator without pull rollers, thermal (MHL) overlaminates (210°F/99°C) are primarily recommende d when overlaminating an image already mounted to, simultaneously mounted to (Triprint), or supported by, a mount board such as

FoamCore, Gatorboard, etc.

JM63 Features:

Heavy duty, durable metal construction.

Top heated roller (Room Temperature to 230°F/110°C)

Large silicone coated anti-stick rollers

Idler bars to facilitate release paper removal and even tension control

Single pressure-set with pressure read out

Top and bottom auto-grip supply shafts

Top and bottom auto-grip release paper take-up shafts

Extra take-up shaft for rewinding decals and laminated prints

Adjustable speed control

Forward and reverse mode

Adjustable brake tension for unwind/supply shafts

Adjustable speed for rewind/take-up shafts

Heavy duty lockable casters

Fold away front table

Paper in feed guide

Two emergency stops and self checking photo electric safety eyes

Foot pedal control

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Table of Contents

Important Safety Information............................................................................................... 5

Specific Moving Instructions ............................................................................................... 9

Unpacking and Installation.................................................................................................. 9

Positioning and Connecting ............................................................................................... 16

Safety Devices and Control Panel .................................................................................... 17

Preheating the JM 63 for Heated Operation ....................................................................... 20

Pressure Settings, Speed ................................................................................................... 20

Shaft Tensions .................................................................................................................... 21

Auto Grip Shafts ................................................................................................................. 21

Mounting with the JetMounter

TM

Series Laminators ............................................................ 22

Mounting Board Selection ....................................................................................... 22

Adhesive Selection.................................................................................................. 23

Pre-coating the Mounting Board ............................................................................. 23

Mounting a Graphic to a Pre-Coated Board ............................................................ 24

L a m inating with the JetMounter

TM

Serie s Laminators .......................................................... 25

Selecting a Laminate Film ....................................................................................... 25

L a m inating a Single Unmounted Graphic ............................................................... 26

L a m inating a Single Mounted Graphic .................................................................... 27

Laminating Multiple Mounted Images ..................................................................... 28

Using a Leader Board ......................................................................................................... 29

Carrier Boards..................................................................................................................... 30

Preparing Mounting Boards ................................................................................................ 30

Maintenance ....................................................................................................................... 31

Contact Info......................................................................................................................... 32

Technical Specifications ..................................................................................................... 33

Replacement Parts ............................................................................................................. 34

Warranty ............................................................................................................................. 35

Appendix ............................................................................................................................. 36

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Important Safety Information

Before operating this equipment for the first time, it is crucial that you take the time to read and understand all of the following safety-related information. Failure to follow these procedures could result in serious personal injury and/or damage to the equipment and work piece.

Safety Signal Words and Symbols

Danger symbols indicate imminently hazardous situations that, if not avoided, will result in serious injury or death.

!

Pinch

Hazard

Inside

Panel

Warning symbols indicate a potentially hazardous situation that, if not avoided, could result in severe injury or death.

Caution headings indicate a potentially hazardous situation that, if not avoided, may result in minor or moderate injury.

This symbol indicates a statement of company policy directly or indirectly related to the safety of personnel or protection of property.

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!

!

Pinch

Hazard

Inside

Panel

These symbols indicate a dangerous pinch hazard exists.

Pinch point.

Keep hands clear during operation.

This caution label indicates that a heavy object is involved and assistance is needed to avoid injury.

The JetMounter ™ performs mounting and laminating using two rollers to apply uniform pressure to adhesives and overlaminating films. The point where the rollers touch the material is called the Nip. This area creates a potential pinch hazard for fingers or other objects. DO NOT

OPERATE THIS EQUIPMENT IF YOU ARE UNWILLING TO ACCEPT THIS HAZARD! TO

AVOID INJURY, ALWAYS KEEP YOUR FINGERS AWAY FROM THE NIP AREA.

No persons under the age of 16 should be allowed to operate the equipment.

The following safety features are designed to offer a reasonable measure of protection against injury while maintaining an operator-friendly machine. Please do not attempt to disable or alter their functionality in any way. Any modifications will void the warranty and pose a serious risk to the operator.

Contact Drytac Technical Services if any malfunction of the equipment occurs and stop using the machine immediately!

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All JM63 models are equipped with an electric eye in front of the roller Nip which, when interrupted, will sound a buzzer as a warning to indicate that an object is breaking the photocell circuit. Additionally, when the mode switch is set to “Auto” and the buzzer sounds the rollers are stopped. (Note: Be particularly cautious when operating the JetMounter

TM

in the Foot Pedal mode because in this Mode the rollers will NOT STOP when the photocells are interrupted. An audible alarm will sound, but the rollers will continue to be powered at a reduced speed).

Prior to operating the laminator, always check that the photocell and buzzer are working properly. Select the Auto mode and use a piece of cardboard to block the photocells to confirm that the alarm sounds and the rollers stop.

The JM63 JetMounter

TM also equipped with red Emergency Stop buttons located on both sides of the front or on the top on each side of the laminator. The Emergency Stop button will stop the machine instantly. Stopping the machine in the Foot mode can also be accomplished by lifting your foot off the pedal, turning the speed to zero (0) OR turning off the power switch.

DO NOT operate this equipment when you are alone. As with all motorized equipment, it is advisable that other adults be present to assist if required.

DO NOT operate the JetMounter ™ while under the influence of alcohol, prescription drugs or any other substance that could impair your judgment or reaction time.

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Remove any jewelry such as rings, bracelets and necklaces prior to operating the equipment.

Keep loose clothing, neckties, artificial fingernails, long hair and anything else that might easily be drawn into the rollers away from the machine.

Turn the JetMounter ™ power OFF if you are loading adhesives or film, cleaning the rollers or performing other activities that require close proximity of your fingers to the Nip. This will avoid the possibility of inadvertently starting the machine. Keep all safety guards in place and your fingers away from the Nip area when the machine is operating.

Always work at a slow speed until you become familiar with the machine.

Exercise caution when lifting rolls of laminate and adhesive due to their weight. Use assistance to avoid personal injury or damage to the equipment and materials.

Prior to lifting a supply shaft into the laminator, position the T-Slot in the hub on the machine’s right side to receive the shaft. The use of an assistant is strongly recommended.

Always disconnect the laminator from the power supply before removing any panels for service.

When using a large supply roll, be aware that a pinch hazard can exist between the top roller and the supply shaft. When working from the rear of the laminator the operator must be aware of the Nip point of the contacting rollers and exercise extreme caution to avoid injury.

The sound pressure level this machine generates at the operators’ position is less than 70dB.

Keep this manual near the machine for future reference. Also check our website for any additional or updated safety information. (www.drytac.com)

Contact our Technical Services Department if you have any questions about the operation of this equipment. (Contact information can be found on page 31).

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Specific Moving Instructions

The Drytac JetMounter

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is to be handled with care to avoid personal injury or collateral damage. Whenever the machine is moved, we strongly recommend utilizing at least two people. The adage: “Better safe than sorry,” applies here. The JetMounter

TM

63 is designed with fixed wheels on one side and lockable swivel casters on the other for a very good reason.

When moving the machine, the movers should be positioned at both sides. Do not push the JetMounter

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from the front or back! This eliminates the possibility of having the machine tip over onto the mover or their helper.

Unpacking and Installation

We have taken steps to make your experience with your new JetMounter a positive one.

Please take time to carefully inspect the crate upon arrival for any signs of damage or mishandling. Be sure to note any damage to the deliverer and get the damage recorded in writing and signed by the deliverer prior to accepting the shipment. If there appears to be serious external damage, DO NOT ACCEPT DELIVERY. Contact the shippers’ Damage

Investigation Division and Drytac immediately.

If there is no visible exterior damage to the crate, be aware that there still may be internal damage due to mishandling. In such an event, it is important to follow these instructions carefully to maintain the integrity of the crate for return purposes and to avoid damage to the machine.

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Step 1: Cut off the metal/plastic bands on the crate.

Step 2: Remove the four 8mm hex head screws, 2 on each side, of the crate.

Step 3: Remove the two top metal corner brackets on the front of the crate and any screws that attach the top to the front panel.

Step 4: Remove the screws that attach the remaining metal brackets holding the front and top panel to the ends. It is only necessary to remove the screws from the top and end panels; the brackets can remain attached to the front panel.

Step 5: It is suggested that four people raise the crate shell up a few inches from the pallet base and move it rearward off the base and away from the machine.

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Step 6: Remove the wrapping film from the machine, being careful with any sharp tools near the rollers. (Locate and remove the wrenches in either a box or wrapped in foam in the rail on the pallet base).

Pallet

Base

Ramp

Wrench box

M8X120 mm stud

Caster straps.

M16 rod

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Step 7: Locate the heating element strapped to the pallet base in a blue cable tray. Carefully remove the element before proceeding and set it safely aside.

Step 8: Remove the caster strap on the right rear of the machine, and take out the 2 M8X120 mm studs for use later as pins to hold the ramp into the base.

Step 9: Carefully remove the ramp from underneath the machine.

Step 10: Insert the ramp into the appropriate end of the base pallet, depending on the direction of the swivel casters. (If the brake lever on the swivel casters is to the left as you look at the wheel from the front of the machine, then push the machine off the base to the right- or vice

12

versa). Damage to the casters will result if you attempt to push the machine off the pallet in the wrong direction!

Step 11: Place the 2 M8X120 studs removed in the previous step through the holes in both the base and the ramp to hold the ramp securely in the base.

Caution: Confirm both brakes are set on the swivel casters before proceeding.

Step 12: Disassemble the other three caster fixing straps using the wrenches provided and remove them from the base.

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Step 13: Loosen the four M16 nuts located under each end of the machine. The large bolts can be screwed downward, which will lower the weight of the machine onto it’s’ casters.

Step 14: Remove the support boards from each end, and then the large bolts from their seats and set them aside.

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Step 15: Lift up the caster brake levers on both swivel casters and carefully push the machine down on the ramp. (Use at least two people for this step).

Caution: Damage to the casters will result if you attempt to push the machine off the pallet in the wrong direction!

The swivel caster brake lever, (shown in this photo on the right end of the machine), is to the left- so, in this case, you would push the machine off the pallet toward the right.

If the brake lever on the swivel casters is to the left as you look at the wheel from the front of the machine, then push the machine off the base to the right- or vice versa.

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It is suggested that the specialized crate and packing materials be stored for future shipment purposes.

Positioning and Connecting

1. Move the machine into its final location. ( See illustration on Page 11)

2. Remove all packing material from the machine.

3. Carefully remove the straps securing the in-feed table.

4. Use a level to assure the machine is completely level, front to rear, side to side and diagonally. Once in position, lock the swivel casters.

5. Follow the Heating Element Installation Procedure found in the appendix of this manual.

6. Connect the proper plug to the machines’ power cord that correctly matches the 230 Volt power supply.

7. Route the power supply cable carefully to avoid interference when operating the machine.

The power requirements for your JM63 are marked on the rear panel adjacent to the power connector. Please confirm that you have the correct power source available at the chosen location. If there are any questions about electrical requirements for the equipment, please contact a qualified electrician prior to attempting to power up the machine!

IMPORTED AND DISTRIBUTED BY

www.drytac.com

JETMOUNTER MODEL

SERIAL NUMBER

DATE OF MANUFACTURE

MAX. FEED RATE

WEIGHT

V ~ AC A Hz

Be absolutely certain that the voltage supplied at the outlet corresponds with the voltage marked

on the plate attached to your machine. Do not rely on the cord or outlet configuration to determine the correct power supply voltage!

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ALLOW ENOUGH WORKSPACE AROUND THE MACHINE TO BE ABLE TO

FEED AND REMOVE YOUR WORKPIECE SAFELY! It is recommended that the machine be placed so that at least three feet of space from the front and back beyond the largest piece of material you will use be provided to insure adequate accessibility and safety. For example, if your work piece were a four-foot by eight-foot foam board, you would need to allow a minimum of eleven feet of space in front and eleven feet of space in the rear of your machine. Always consider this rule a necessity prior to beginning your work. (Converted figures in the illustration below in metric are 3 meters and .6 meter).

Safety Devices and Control Panel

Drytac has engineered the JM63 with a number of features to assure safe operation. However, this machine uses pressure and heat and may cause injury if not operated according to instructions and intended use. Please familiarize yourself with the following features and warnings prior to operating the JM63.

Top Mounted Emergency Stops

The JM63 is equipped with two top-mounted Emergency Stop Buttons for ready access from front or rear. When the Emergency Stop Buttons are activated, the power to the motor is shut off immediately and the rollers will come to a complete stop. The Emergency Stop Buttons must then be disengaged and the Reset switch toggled before the machine can be operated again. While an Emergency Stop is activated the photocell LED will flash yellow.

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Automatic Photocell Protection

These optical safety devices are located at the front of the main roller nip and help prevent insertion of fingers or other objects into the nip. Whenever an object comes between the sensors, an audible alarm is sounded and the photocell LED flashes red on the Control Panel.

Auto mode the rollers will come to a complete stop, until the object is removed and the Forward button is pressed.

This feature operates differently in Foot Pedal mode.

When the photoelectric signal is interrupted while in

Foot Mode, the alarm sounds, the LED flashes red and the rollers slow to “jog” mode as long as the operator’s foot remains on the pedal. After the object is removed, the machine will remain in jog mode until the operator takes their foot off of the pedal. When the operator presses the pedal again, the rollers will start in the

Forward direction at the Set speed.

Pressure Meter: Indicates pressure at the roller nip from 0 to 100%.

Photocell LED: Indicates operational status, (see separate Functional Requirements List).

Forward Button: Activates Main Rollers for standard processing.

Stop button: Stops Main Rollers.

Reverse Button: Activates Main Rollers in a reverse direction.

Speed Control: Sets Main Roller speed. Top speed is approximately 6M / minute.

Auto/Foot/Reset Switch: Selects either Foot mode or Auto mode. When the machine is in the

Auto mode, it is controlled by the Forward, Stop and Reverse buttons on the control panel. The photocells are fully operational when in Auto mode. This switch also acts as a Reset when first powering up or after the Emergency Stops are activated. To activate the Reset, toggle the switch from Auto to Foot, and back to Auto. The Photocell LED will change from yellow to green when the Reset has been achieved.

When the machine is in the Foot mode, roller movement is controlled by the Foot Pedal in combination with the FWD and REV buttons. The photocells will slow the rollers to jog speed and sound the alarm when the beam is interrupted.

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Power On/Off: The red indicator light next to the Power Switch indicates that the power is on.

This switch powers up the machine for use. The heating system is controlled independently.

Heat On/Off: The Heat switch activates the heating system. Be aware that this switch acts independently from the Power switch. The Power switch does not control the heating system, and vice versa. When the Heat switch is turned on, the Power switch should also be on; the rollers should be in contact and moving at a slow speed. Do not activate the heating system with the rollers stationary and in contact. Roller flat spotting can occur.

Motor Overload LED: This LED will light up when the motor is overloaded. When the light is a steady red, the 4 Amp overload breaker on the back of the machine has been tripped. Remove whatever caused the overload condition first, then allow approximately 30 seconds for the breaker to cool down before pushing the button in the center of the breaker on the rear panel to reset. The Reset switch on the control panel will also have to be toggled before starting the machine. If the motor is seriously overloaded, the machine will stop and the Motor Overload

LED will flash red. Correct the cause of the overload before initiating a reset using the Reset switch on the front control panel.

Temperature Controller: Sets and displays the temperature of the upper heated roller. To adjust the temperature, first turn the power switch for the heating system on. The display will show the current roller temperature.

To set the desired temperature, first press the * button on the temperature control.

The display will show S.V, or something similar. Press the up or down arrow on the control to see the present temperature setting. To adjust the setting, simply hold the up or down arrow until the desired temperature setting is achieved. To retain this temperature setting, press the * button again.

The Output light in the upper left corner of the temperature control lights up when power is being supplied to the heating element. It will cycle on and off as the element is powered on and off to maintain the set temperature.

Due to the mass of the rollers, it will take several minutes for the rollers to reach the desired temperature. Likewise, if you change the setting, allow enough time for the roller to achieve the desired temperature before starting to laminate.

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Preheating the JM 63 for Heated Operation

When an application will require the heated upper roller, turn on the Heat Switch and set the desired temperature approximately 15 minutes prior to use. Close the nip gap and run the laminator at a slow speed in order to distribute the heat and avoid hot spots.

Nip Gap Settings

The nip gap is the space between the upper and lower Main rollers. Both the nip gap and processing pressure are controlled by the Pressure Set Hand Wheel, which raises or lowers the upper roller.

Pressure Settings

Overlaminating and encapsulating applications: For one or two-sided application of film to thin output images (poster, photos), turn the hand wheel until the pressure indicator reads about

40%.

Full Width Mounting: For jobs that require processing hard mounting substrates such as

Masonite or Sintra, first set the nip to the thickness of the panel. Next, when the leading edges of the overlaminating film and/or mounting adhesive have passed through the rollers, set the pressure to about 40-60%. Thicker adhesive films or graphics may require greater pressure settings.

Softer Mounting Substrates: Lower pressures should be used for mounting to foam boards to avoid compressing the board. The setting should match the relative density of the board and may range from 10% to 30% for denser materials.

Narrower Graphics: Lower pressure may be used for applications that do not require the full width of the rollers.

Speed

The Main Roller speed is set on the Control Panel. Setting the speed to 0 stops the machine.

For setup, we recommend using slower speed settings.

Processing speeds vary according to the nature and thickness of the materials being processed.

Speed and pressure affects operate inversely, meaning the slower speeds increase the affect of

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pressure and vice versa. Encapsulation and thicker materials may require slower speed settings.

Shaft Tension

All Unwind and Take Up shafts on the JM63 are equipped with Tension Control Knobs on the right side (Control Panel) of the machine. These knobs apply friction to control the speed of the shafts as they unwind or wind up material.

It is important to adjust these settings so that there is an even tension on the adhesive or film during processing. The objective is to apply enough resistance on the film to keep it firm and flat, but not so much as to stretch or distort it. It is also critical to maintain even tension on both sides of the film.

Turn the Tension Control knobs clockwise to increase roll tension and counter-clockwise to reduce tension.

Unwind (Supply) shaft tension: When feeding adhesive or film into the rollers, the primary objective is to maintain the feed at the same rate as the rollers pull the material through the Nip.

The objective is to allow the film to unwind without wrinkles.

Take Up shaft tension: The Release Liner should be pulled away from the adhesive at a steady rate that allows it to “lift” at a point just before the material enters the Nip.

Using Auto Grip Shafts

•

Remove the shafts from the upper and lower Unwind supports.

•

Slide the shaft into the film rolls.

•

Replace the shafts and unwind the film toward the front of the machine.

•

Turn the shaft until the grippers lock.

•

When loading upper and lower Unwinds, makes sure the material rolls are aligned in the same position.

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Mounting with JetMounter

TM

Laminators

Mounting Board (Substrate) Selection:

The selection of a proper mounting board/substrate is very important. Common materials used are:

• Foam Boards: (FomeCor®, GatorBoard®, HartBoard® etc.)

• Illustration Board

• Rag Board

• MDF (medium density fiberboard)

• Corrugated plastic boards: CoroPlast®

• Rigid Plastic Boards (Sintra®, styrene, etc.)

• Tempered hardboard: Masonite®

Adhesive Selection

Once the mounting board has been selected, determine whether to pre-coat the material with adhesive or to purchase pre-cut and pre-coated boards. While the use of pre-cut, pre-coated materials will save time, coating your own mounting board is more economical and allows for maximum flexibility in terms of sizing and substrate selection.

Pre-coating the Mounting Board

Pre-coating a mounting board means applying a mounting adhesive to one side of the board so that a graphic image can be mounted to the board later). The use of a Leader Board is recommended for this process.

1. Adjust rollers for proper pressure (see pages 15-16).

2. Load the roll of PSA (pressure-sensitive adhesive) onto the Supply shaft so that the material can be pulled toward the user from the underside of the roll with the adhesive side facing UP

(the release liner side should be in contact with the roller as shown in the Illustration).

3. Pull the adhesive off of the roll so that about 4” lies flat on the worktable and is draped in front of the rollers.

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4. Lay your Leader Board on top of the exposed adhesive material on the worktable; then push the Leader Board and adhesive into the Nip (the ‘Nip’ of your laminator is the point where the rollers make contact). When pushing the Leader Board into the adhesive, make sure it is parallel to the rollers.

1. Position your first mounting board behind and against the Leader Board. Check for proper alignment, and feed through the rollers (in either AUTO mode or via FOOT switch). Feed one board after another as needed.

Trim the excess adhesive off of the board.

6. Your mounting boards are now pre-coated with pressure-sensitive adhesive, which is still protected by the release paper. The pre-coated boards can be used for immediate mounting or stored for future use.

TIP: When an image is going to be laminated with a gloss overlaminating film, the use of very smooth substrates with glossy surfaces (such as Masonite®) is preferred. This will minimize the effect of board imperfections, (i.e. “orange peel”) in the finished product.

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NOTE: We recommend placing a ‘Tail Board’ behind the last production board (this can be the same board used as a leader board/starting panel). This is especially important when precoating foam board.

Mounting a Graphic to a Pre-Coated Board

1. Adjust the rollers for proper pressure.

2. Expose the adhesive on the board by folding back approximately 1” (2.5cm) of the release liner.

3. Using the folded-back release paper as a temporary support bridge, align the print onto the board and then proceed to “tack” (stick or press down) the leading edge of the print onto the exposed adhesive.

4. Run a Leader Board of the same thickness as your mounting board through the rollers so that the back edge of the Leader Board is at the nip of your machine.

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5. Square your mounting board with the tacked print against the edge of the Leader Board and drape the print over the top roller.

6. Run the mounting board/adhesive/image through the rollers while simultaneously pulling the release liner away from and off of the board.

(The JM63 has automatic Take Up shafts on the front and rear of the chassis. You may choose to unwind the Release Liner onto the Take Up shaft during this process, rather than pulling it by hand.)

L a m inating with JetMounter

™

Laminators

Selecting a Laminating Film

Select an appropriate overlaminating film for the surface of your image based on aesthetics and the conditions under which it will be displayed. Drytac offers a wide variety of films to match your specific output and application. Please consult your Drytac catalog for descriptions of available film choices.

There are several types of laminating jobs that can be performed on JetMounter™ laminators.

The following are the most common applications. To prevent adhesives from sticking to the rollers and to provide a reusable, standard working surface, the use of a silicone-coated board

(also known as a “Carrier Board”) is highly recommended.

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Laminating a Single Unmounted Image

Before processing, make sure that the image is clean and free of dust or specks of lint (an Anti-

Static cloth or Anti-Static Wisk is recommended for this purpose).

1. Raise the top roller and insert the Carrier Board. Set roller pressure as described on pages

15-16.

2. Pre-cut a sheet of overlaminating film from the roll. (The sheet should be larger than the image by approximately 1” on each side and bottom, and 2” on the top).

3. Peel and fold back approximately 2” of release liner from the top edge of the overlaminating film. Tack the film on the Carrier Board by pressing the exposed section of film onto the leading edge of the board.

4. Start the Carrier Board into your laminator using the Foot Pedal mode. Stop before the edge of the laminating film reaches the rollers.

5. Lift up the remainder of the overlaminating film (which is still protected by the release liner) and slide the image face up underneath it. Stop before it makes contact with the exposed part of the adhesive. It is important to keep the film adhesive away from the artwork until the

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whole assembly is under pressure and traveling through the JetMounter™ .

6. Lay the laminating film over the top of the upper roller. While holding up the edge of the peeled back release liner with one hand, start the rollers and apply the overlaminating film to the surface of the image. Pull up and away on the release paper as your work piece travels through the laminator. Ensure that the release paper does not reach the point where the image makes contact with the top roller. Be sure to complete this step with a consistent motion and do not stop until the entire image has passed through the rollers.

7. The laminated image can now be easily removed from the silicone-coated Carrier Board for trimming and mounting.

L a m inating a Single Mounted Im age

Before processing, make sure that the images are clean and free of dust or specks of lint (an

Anti-Static cloth or Anti-Static Wisk is recommended for this purpose).

1. Raise the top roller and insert the mounted image into the roller Nip. Adjust the roller pressure as described previously.

2. Pre-cut a sheet of overlaminating film from the roll. The sheet should be larger than the image by approximately 1/4” on the sides and bottom and 3” longer on the top.

3. Peel and fold back 2” of release paper liner exposing the adhesive of the laminating film.

4. Tack approximately 1-1/2” of the laminating film to the Leader Board, but not over the mounted image.

5. Insert the Leader Board with the laminating film tacked to it into the Nip. Advance the Leader

Board and the film through the Nip until the upper laminating roller securely pinches the film.

(The trailing edge of the Leader Board should be at the pinch point of the rollers.)

6. Lay the laminating film over the top of the upper laminating roller. Make sure that the folded release paper liner is easily accessible.

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7. Slide the mounted image into the Nip area and allow its edge to make contact with the edge of the Leader Board.

8. While holding up the folded edge of the peeled back release paper with one hand, start the rollers and apply the laminating film to the surface of the image. Pull up and away on the release liner as you advance to ensure that the liner does not reach the Nip area. Process your work with a consistent motion and do not stop until the entire image has passed through the rollers.

9. Trim excess overlaminating film from the edges of the image.

L a m inating Multiple Mounted Im age s

1. For higher volume jobs, select a roll of laminating film slightly wider than the mounted images you intend to laminate.

2. Install the overlaminating film on the Supply shaft so that the material can be pulled toward the user from the bottom of the roll with the Release Liner side facing up.

3. Adjust the rollers for proper pressure.

4. Pull several inches of the overlaminating film off the roll. Separate the overlaminating film from its release liner (approximately 3-4”) and drape it onto the in-feed table in front of the

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rollers. Keep the release liner away from the film while pushing the Leader Board and film into the roller Nip.

5. Position the first mounted image to be laminated against the back of the Leader Board.

Check for proper alignment, and feed through the rollers of your laminator (in Auto mode or with foot pedal). Feed one print in right after another, as needed.

6. Carefully separate prints with a razor blade or utility knife. Trim off the excess film.

The JM63 has automatic Take Up shafts on the front and rear of the chassis. You may choose to unwind the Release Liner onto the Take Up shaft during this process, rather than pulling it by hand.

Us ing a L eader B oard

A Leader Board (also referred to as a “starting panel”) is recommended for use when mounting and laminating with JetMounter™ laminators. A Leader Board is fed into the roller Nip first, followed by the actual mounting/laminating project to be processed. We highly recommend this tool to help set proper pressure for both mounting and laminating prior to processing your work.

The Leader Board should be the same width and thickness of your production mounting board and about 6-8” long. You should also make a Tail Board, which is used behind the last production board. The Tail Board is especially recommended for mounting to foam board.

29

Carrier Board s

When processing un-mounted images, we recommend you use a silicone-coated board to prevent adhesives from sticking to the rollers. This board is called a Carrier Board, and it provides a re-usable, standard working surface. It will be used when laminating your image prior to mounting it onto a mounting board/substrate. It is common practice for finishing professionals to stock Carrier Boards in several different sizes to accommodate various artwork formats.

Manufacturing Carrier Boards

Making a Carrier Board is basically the same process as pre-coating a mounting board.

Instructions for this process are found on page 22. When the mount board is coated with the adhesive, the silicone-coated release liner provides a slick, non-stick surface on which to laminate images. Be sure to use a “self-wound” adhesive with a silicone treated liner for this purpose.

2:

Preparing

Mounting Boards

Preparing Mounting Boards

Once you have decided on the most appropriate adhesive/mounting board combination for your application, it is important that you properly prepare your board before coating. Although often overlooked, this can be the most important step when mounting a print or artwork for display.

Foam Boards

(E.G. FOME-COR®, ETC.)

The surface of these types of substrates is porous and often contains particles that can spoil an otherwise perfect mount. Clay-coated surfaces such as Fome-Cor®, Foam-X® and similar boards should simply be wiped with a Tac Cloth™ to remove dust particles.

Mat Boards/Mill Boards

To prepare mat board or mill board for mounting, use the Anti-Static Wisk™ brush to remove dust particles and other debris.

Hardboard

(E.G. MEDIUM DENSITY FIBERBOARD, MASONITE, ETC.)

To prepare hardboard substrates for mounting, wipe down the surface with a TacCloth. If the surface contains irregularities, use sandpaper to remove them, and then wipe the surface with a

Tac Cloth.

Please note: Due to their highly absorbent properties, do not wipe down the surfaces of any of these substrates (i.e. foam board, mat/millboard or hardboard) with a moist rag. It is important

30

that you remove dust and other debris from your prints prior to mounting. To prepare hardboard substrates for mounting, wipe down the surface with a TacCloth. Should the surface contain irregularities, use sandpaper to remove them, and then wipe the surface with a TacCloth.

Care and Maintenan c e

Cleaning

In order to perform well, your new J ET M OUNTER ™

63 must be cleaned on a regular basis. The work area should also be as clean as possible, with lint and dirt eliminated to every degree possible.Use a damp cloth for cleaning the exterior of the laminator, as well as the shafts and rubber surfaces. Use a household cleaning solution to remove tough dirt.

It is essential to clean the rollers often in order to prevent build-up of adhesive residue. Not only will this affect the operation of the laminator, it may eventually damage the rollers. Use a damp lint-free cloth to wipe away dust and dirt, and a silicone cleaning block to thoroughly remove adhesive stains. Challenging stains can often be removed by using isopropyl alcohol with a lintfree cloth. Do not pour the isopropyl alcohol directly on the rollers. It is easier to clean adhesive residue when the rollers are hot.

The mechanical service points on the JM 63 are dependant upon the amount the machine is used. Under normal use the chains should be lubricated once a year, more often with severe use. They are located inside the right end panel. Be sure to unplug the machine before removing the panel for service. If you have need of assistance, contact Drytac Technical

Services.

Check the auto grip mechanism on each shaft on a regular basis: The distance between the rubber chords and the edges of the recess should be a minimum of 8mm. The cord should not touch the screw.

31

Contact Information

Drytac Corporation (USA)

5383 Glen Alden Drive

Richmond, VA 23231

Toll Free Phone: 800-280-6013

Toll Free Fax: 800-622-8839 e-mail: [email protected]

Drytac Canada, Inc.

220 Caldari Road

Concord, Ontario

Canada L4K 4L1

Toll Free Phone: 800-353-2883

Toll Free Fax: 877-437-9822 e-mail: [email protected]

Drytac Europe (UK)

Filwood Road, Fishponds

Bristol BS16 3RY, United Kingdom

Phone: +44 (0) 117-958-6500

Toll Free Phone: 0845-070-0660 (UK only) e-mail: [email protected]

32

J ET

Mounter

TM 63

TECHNICAL SPECIFICATIONS

Roller Width 64” (1626mm)

Roller Diameter

Roller Construction

Width

Depth

Height

Weight

Suggested Max. Material Thickness

Maximum Roller Temp.

Max. Material Diameter

Feed Table Height

Power Requirements

Speed Range

5.5” (139.7mm)

Steel with high release silicon covering

Top heated roller.

83” (2108 mm)

29” (737mm) without table up

32” (813mm) with table up

49” (1245mm)

970 lbs. (440 kg)

2” (50.8mm)

248° F (120°C)

9.8” (250 mm)

35.5” (902 mm)

220V 50/60Hz, 13A USA

230V 50/60Hz, 13A UK

0 to 6 M / minute (13ft / minute)

Core Size

Power Consumption

3” (76.2 mm)

2700 Watts (or approx. 12A)

Recommended Plug Type NEMA 6-20P USA

Fuse Specifications

Weight

Width

Depth

Height

(1) 2A, (1) 6A, (2) 0.5A

PACKAGED FOR SHIPMENT

1170lbs (531 kg)

87” (2210 mm)

30” (711mm)

58” (1473 mm)

33

Jet Mounter 63 Replacement Parts

JMS456-01

Emergency stop for JM44/JM54/JM63 Double

Contact

JMS456-02 Foot Switch for JM44/JM54/JM63

JMS6-01H

JMS6-01L

Siliconized Upper Heated Roller Rev B

Siliconized Lower Roller Rev B

JMS6-02

JMS6-03

JMS6-04

Heating Element, including mounting hardware

Idler Bar

JMS6-06

JMS6-07

JMS6-08

JMS6-10

JMS6-11

Supply/Take Up Shaft

Self Check P/Cells, incl. all hardware & Mounting brackets

Supply Shaft Tension Knob

Pressure Set Hand Wheel

Main Circuit Breakers, set

4A ETA Dual Contact O/L Breaker

JMS6-12

JMS6-13

JMS6-14

Omron Solid State Heating Relay

Temperature Sensor – Complete

Motor with drive gears, chain and hardware

JMS6-18 Clix-on temperature sensor with bracket and spring

JMS6-19, C Temperature Control. (Suffix C for Celsius)

JMS6-20

JMS6-24

Pressure Meter

Set of Four casters, Rev. B

JMS6-32

JMS6-33

JMS6-34

JMS6-35

JMS6-36

JMS6-38

Pressure Sensor

Single Idler Bar holder with screws

Double Idler Bar holder with screws

Set of fuses – (2) 0.5A, 1A, 6A

In feed Table Guide

Feed table Lock Pins

JMS6-43 Teflon Disc for Take up brake assembly.

JMS6-Man JM 63 Operator’s Manual

The list above does not include all repair and service parts available. For further parts or service information please contact Drytac Technical Services ( 800-280-6013) .

To assure correct part application, please verify your JetMounter serial number (recorded on the metal plate attached to the rear of the right end case) before ordering parts.

34

WARRANTY POLICY

Thank you for your purchase of the JetMounter

TM

laminator. Every Drytac machine is designed and manufactured to give many years of dependable service. We will do our best to see that your experience with your new machine is a positive one.

To achieve the best results from your JetMounter

TM

, the machine should be set up and operated in accordance with the instructions included in this manual.

Should the original JetMounter

TM

purchaser experience any problem due to faulty materials or workmanship within 12 months of the purchase date, Drytac or their dealer will arrange for the machine to be repaired, replaced or refunded at Drytac’s discretion.

After the warranty period has elapsed, Drytac will provide all reasonable assistance and product support to resolve any problems that may arise.

Please return your warranty card as soon as possible. This will help us more efficiently assist with any problem you may encounter.

Normal wear and tear, any damage to the silicon rollers, damage due to abuse, improper operation or installation is not covered by this warranty. Conditions that will void the warranty include-but are not limited to; failure to follow the instructions contained in this manual, unauthorized changes or modifications to the machine or the stand (where applicable) in any manner, misuse of the machine for purposes other than specified in the Operators Manual.

Drytac will not be responsible for any damage or consequential damage caused by the machine. Please feel free to contact Drytac if you have any questions or problems.

JetMounter

TM

Registration Information

C OMPANY N AME :

A DDRESS :

C ITY / S TATE :

M ODEL #:

S ERIAL #:

P URCHASE D ATE :

W ARRANTY C ARD R ETURNED ON : BY:

35

A. Trouble shooting Guide

B. B Revision Functional Requirements

C. Power UP/Down Memo

D. Heating Element Installation Procedure

E. Roller Adjustment Procedure

F. Technical Services Bulletins

Appendix

36

Appendix A

JetMounter 44/54/63 Photocell Troubleshooting Guide

Photocell LED Status Alarm Additional LED’s Condition Indicated Solution

Green

Green

Steady

Flashing

No

No

No

No

Normal/Ready to Start

Feed Table Switch

Yellow

Yellow

Yellow

Flashing

Flashing/Steady

Flashing

No

No

Yes

No

No

No

E/Stop(s) Activated

Reset Needed **

PCB Fault

Start Work

Secure left table plunger.

Deactivate Stop(s), then toggle Reset switch.

Toggle Reset Switch

Call Tech Services

Red Flashing Yes No Photocell Interrupted Clear Photocells

Yellow Steady No

Motor Overload

LED Steady Red

Thermal Motor Overload

Breaker Tripped

Reset after 20 Seconds and Reduce Load

Yellow Steady No

Motor Overload

LED Flashing Red

Motor Overloaded. PCB

Protection Circuit activated.

Reduce Load and toggle

Reset Switch

No

No Power Supplied to the

Machine

Check: Power Supply,

Circuit Breakers On,

Power Switch On.

Unlit Steady

** Normal condition on power up.

No

ACTION

AUTO MODE

Power Up or E-Stops Reset

FWD button pressed

Photocell interrupted

Photocell cleared

E-Stops Activated

Press and Hold Rev. Button JM63/JM44-54

FOOT MODE

FOOT pedal pressed, FWD mode

Photocell interrupted. FP still depressed

Photocell cleared. FP still depressed.

Photocell cleared. FP dep. Switch to Auto

FOOT pedal released

Restart by FP, no buttons pressed

Press and hold REV in Foot Mode,

Release REV button while depress FP

In Rev. with Foot on pedal- press AUTO

Table Down, FOOT pedal released.

Table Down, FOOT pedal pressed.

JetMounter B Revision Functions

PROGRAMMED SOFTWARE FUNCTIONS

Operation Alarm Photocell LED

Will not Run / Needs Reset No Yellow

Normal oper. @ set speed

Machine stops

Ready to start

Will not Run

No

Yes

No

No

Jog speed Rev./ Will not run Yes

Set speed, FWD

Jog mode

Jog mode

FWD at set speed

Machine stops

Set speed FWD

Jog mode REV

Jog mode REV

Machine Stops,

Ready to start

Will not Run

Jog mode

No

Yes

No

No

No

No

Yes

Yes

No

No

Yes

Green

Flash Green

Flash Green

Green

Flash Red

Green

Flash Yellow

REV Green

Green

Flash Red

Green

Green

Green

Green

REV Green

REV Green

Appendix C

TECHNICAL SERVICES DEPARTMENT

TO:

FROM:

All JM 63 Users

Drytac Technical Services Department, Drytac Corporation

SUBJECT: POWERING DOWN THE JM63

The JM63 has two separate On/Off rocker switches on the front control panel; one for the heating system and one for the roller operation. It is important to remember that the two systems can be powered up or down independently from one another. We are adding the following instruction for safe operation of your

JM63 to be inserted into your Operators Manual and implemented immediately by all users.

Recommended Power Up/Down Procedure

Important: Whenever the machine is not in use, we recommend that the control panel switches and the

MCB (Main Circuit Breaker) be turned off. The correct procedure to Power Up the JM63 is to first confirm all the control panel switches are in their “Off” (O) position (Power, Heat, and Speed). Plug the machine into an appropriate outlet and then turn on the Main Circuit Breaker located on the back of the right end case where the power cord enters the machine.

If the heating system has been activated, before Powering Down the JM63, allow sufficient time for the rollers to cool. Then, stop the rollers by turning off the speed control on the front panel and open the nip so the rollers are no longer making contact. Turn the On/Off rocker switches (located on the front control panel) to the Off (O) position. Finally, turn off the MCB on the back of the right end panel. The JM63 should be powered down in this manner whenever it is not being used or before removing the end panels to perform any service required. If you have any questions or need assistance please contact the Drytac

Technical Services Department.

Appendix D

TECHNICAL SERVICES DEPARTMENT

JM63 HEATING ELEMENT REPLACEMENT/ INSTALLATION

The JM 63 heating element is very fragile and should be handled carefully to avoid damage to the element and harm to the installer. Follow these instructions carefully in the order outlined. Do not

handle the element with your hands. Use clean cotton gloves or cloths when handling to avoid transfer of oils and/or contaminants that could break the element once it is heated up. Unplug the

JM63 from the outlet prior to performing this procedure. Two people are required in order to successfully accomplish this procedure. When you first receive your new JM63, the element comes uninstalled. It is strapped to the base pallet to prevent breakage during shipment. Carefully remove it before the machine is rolled off of the pallet. When the machine is unwrapped and placed in position, proceed with the applicable steps below.

1. Remove both end panels and set them aside.

2. To remove the element, first remove the fiber end caps and electrical connections from each end.

(Keep all parts for reuse.)

3. Loosen the pinch clamps attached to each end of the element, keeping the screw and nuts in the clamp.

4. Remove the two Phillips screws holding the clamp to the “L” bracket that is screwed into the bearing block and then remove the clamp and bracket by sliding it off the end of the element.

5. If the original element was broken inside the roller, you must remove all of the broken glass before installing the new element. Use a shop vacuum with a flexible garden hose adapted to the end of the original large vacuum hose, a strong flashlight and two very patient people for this procedure. Be sure to use eye protection and DO NOT use air to blow the glass out of the roller.

6. To install the new element, carefully remove the top of the cable tray it was shipped in, leaving the element nestled in the tray itself.

7. On initial installations, remove the angle brackets on each end that attach the elements’ pinch clamp to the main support bracket. This will allow access for the element to be inserted into the roller. You will also need to remove the electrical tape from the ends of the wires that supply power to the element. There is one wire on each end, cable-tied to a nearby bracket.

8. Align the new element in the tray with the top roller journal opening. Use cotton gloves or cloths to push the element from the cable tray into the roller. Have a person with a strong flashlight at the far end of the roller guiding the installer as the element is inserted.

1

9. Due to bowing of the element and contact with the metal roller ends, the installer must guide the element carefully through the end journals. A useful tool for this purpose is a piece of PVC pipe with a ¾ inch inside diameter. If you have a piece as long as the machine this installation is much easier, as the pipe can be fed through the roller first without any risk to the element. If not, then using a couple of shorter pieces, one at each end is suggested. Whatever method is used, take care to avoid scratching the glass against the metal roller parts, as this could lead to premature element failure.

10. Once the new element is situated inside the roller, slide the pinch clamp over the left end of the element and reattach the angle bracket to the main support bracket. Position the pinch clamp so it grips the metal portion of the element for at least ¾ of the width of the clamp. This shifts the element to the right end far enough to avoid contact of the element with the left end panel when it is installed.

11. Slide the pinch clamp over the right end of the element and reattach the angle bracket to the main support bracket.

12. Carefully position the element so it is situated in the center of the roller on each end. Use the two screws on the angle bracket and the two screws on the main support bracket for centering purposes. Securely tighten all screws once the element is correctly positioned.

13. Reattach the electrical connections on each end and secure the fiber insulating caps.

14. Power up the machine and test the operation by gradually heating the element from 120-200 degrees Fahrenheit in twenty degrees steps. NOTE: Some smoking from the ends of element will occur; this is normal and is not a cause for concern. NOTE: Properly ventilate the work area during this initial heating phase and avoid inhaling any smoke.

15. If this is a replacement element, record the installation on the Service Record found in the pouch attached to the inside of the left end panel.

16. Once the testing is complete, power down the machine and reinstall the end covers and brake tensioning knobs.

If you have any questions please call the Drytac Technical Services Department.

2

Appendix E

Roller Adjustment Procedure for the JetMounter

™

63

•

Follow the directions carefully. If you do not understand any part of these instructions seek assistance from Drytac Technical Services before attempting the step in question.

•

It is very important to get the greatest thread contact between the spindle threads and the bearing block threads.

•

Once the nip pressure setting is successfully achieved and verified, no further adjustment

to these settings is necessary.

Tools Required:

2- 19mm thin jaw open end wrenches 1- 7” pair of slip joint pliers

2- 8mm open end wrenches 1- 10mm open end wrench

1- Metric Allen wrench set 1- 2mm standard screwdriver

1- 6” Adjustable end wrench Loctite Threadlocker # 242

CAUTION: Power down the machine and disconnect the power supply cord from the outlet before beginning this procedure.

Note: This procedure applies to the fine thread 88 mm hardened spindle with 5 hardened jam nuts, and requires the use of the precision Belleville spring washers of 1.5mm thickness on top (2sets stacked in series with proper backing plates) and four sets of 1.25 mm thickness on the bottom

(stacked in series with proper backing plates).

(Illustration above shows the proper washer stacking configuration).

3

Spring Washer Adjustment

Set the Roller NIP opening to the “Sweet Spot” where the upper roller is resting on the lower roller and the tensioning wheel is loose, neither exerting pressure nor lifting the upper roller. Back off Bolt

A on both sides so the bolts do not contact the bearing blocks and effect the following adjustments.

If possible, the lower threads on the spindle that insert into the bearing block should have Loctite

Thread locker # 242 applied before inserting the spindle into the block.

Important: Thoroughly inspect the both ends of the lift mechanism linkage for any excessive play or loose bolts before beginning this procedure and correct as needed. Loctite Thread locker # 242 should be applied to the threads of the upper height adjusting arm pivot bolt on the right end.

Spindle and Spring Washer Adjustments

Due to the possibility of contact between the left height adjusting arm and the photo cell, it is recommended that the eccentric lobe on be placed in the neutral or center position with the eccentrics’ lobe toward the rear of the machine prior to beginning this procedure. This would correspond with the 9 o’clock position when viewing the bolt from the left end.

(Front of the machine is to the right.)

4

Step 1

Unlock Nut 5 and back it off from the bearing block approximately 10mm. Using Nut 1, tighten the spindle into the bearing block until it is fully seated. Do not exert excessive force to seat the spindle, or damage to the block may occur. Once the spindle is seated, carefully tighten Nut 5 against bearing block. Over tightening Nut 5 can damage the bearing block.

Step 2

Raise the upper roller until there is a slight gap (4-6mm) between the rollers. With the eccentric in its central position as described above, make certain the spindles are fully seated as described in

Step 1. On each side, unlock Nuts 3 and 4 and back them completely down to nut 5. If the roller is not parallel, loosen Nuts 1 and 2 on the side that is highest and back them off to achieve visual parallelism. Decreasing the gap or using three strips of paper inserted in the nip (one an inch in from each end and one in the center) will make this adjustment more precise. The resistance on the paper at each end should be the same when the roller as lowered toward the full rest position or

“sweet spot”. Lock Nuts 1and 2 once the adjustment is complete.

Step 3

The lower spring washers should turn easily by hand. The effort or “feel” should be as similar as possible on each side. This is a critical reference, or starting point for the next step, so use care to make both sides feel the same.

[In some cases, with the spindle fully seated there is not enough clearance to adjust Nuts 3, 4 and 5 without pre-tensioning the spring washers beyond the point described above. In such cases, adjust

Nut 3 until the lower spring stack height is 17/32 “from the bottom bearing block to top of the lower backing washer (actual pre-tensioned stack height of the lower spring washers] Make both sides as equal as possible in this step.

Step 4

Where the spring washers can be turned by hand, adjust each side to achieve the same feel or resistance. To give the spring washers the correct pre-tension, tighten Nut 3, one full turn, which is

360 degrees or six flats of Nut # 3. There are several ways to calculate the number of turns. Mark the nut and use whichever method works for you, but be as accurate as possible. Use a 19 mm thin jaw open end wrench. Do not allow the spindle to turn during this process by holding Nut 1 with another 19 mm thin jaw open end wrench. Try to be as exact as possible when performing this procedure. After adjusting the washer preload as described above, lock Nuts 3 and 4 by tightening

Nut 4 against Nut 3. Be sure that Nut 3 does not turn, to maintain the correct tension on the spring washers. Perform this procedure on both sides.

Pressure setting of the spring washers is complete and should not be altered.

5

Step 5

Raise the upper roller slightly and then lower it until it just makes contact with the lower roller at the extreme right edge. There should be the same amount of roller contact on the left end. If not, then use the eccentric to adjust the left end of the roller higher or lower to make the contact the same on both ends. Be as precise as possible to get the rollers visually aligned before proceeding.

Pressure Meter Calibration

Step 6

Set the rollers to the “sweet spot” where the weight of the top roller is resting on the lower

roller. With the machines’ power off, adjust the pressure meter with the plastic dial at the bottom of the meter’s face until the needle rests at zero. Remove the right end panel and the protective cover over the PCB to gain access to the potentiometers. The two potentiometers are small square blue boxes, located at the bottom of the PCB. The following adjustments require the machine to be powered up. DUE TO LIVE VOLTAGE, USE EXTREME CAUTION WHEN ADJUSTING THE

POTENTIOMETERS!

Step 7

Turn on the main breakers, which are located on the back of the right end panel, and then the power switch on the front control panel. Using a small standard screwdriver, adjust both potentiometers by turning the one nearest the front of the machine counter clockwise to contact the rest or stop. Then turn it clock wise very slightly, just off the stop or rest. Adjust the other potentiometer nearest the rear of the machine by turning it clock wise to its’ rest position. Then back it off slightly counter clock wise. (The meter reading is not pertinent in this step.)

Step 8

Adjust the pressure sensor actuating arm to achieve the correct meter reading. The pressure sensor is located above the photocell in the right end case. The adjusting rod must be set so that

any movement of the roller will cause the needle to move. To make this adjustment, locate the

8mm adjusting bolt at the end of the sensor rod. Loosen the nuts on either side of the mounting bracket and turn the bolt in or out to achieve movement of the needle on the meter as soon as the rod is moved. Position the rod to achieve a meter reading between 4-12% with the rollers at the sweet spot, and then secure it in that position with the lock nuts.

Step 9

Raise the upper roller off of the lower roller by approximately 8mm. Adjust the left potentiometer to achieve a zero reading on the meter. Lower the top roller to the “sweet spot”, where the weight of the top roller is resting on the lower roller, with no additional pressure applied. The meter should

6

read between 4-12 %. Raise and lower the upper roller repeatedly to see if the meter is immediately responsive to roller movement, returns to zero when raised, and reads 4-12% when at the sweet spot. Make adjustments to achieve this condition by repeating the previous steps as needed.

Step 10

Beginning from the sweet spot; turn the hand wheel 3 ½ to 4 turns clock wise. The meter should read very close to 100 % pressure. Adjust the right potentiometer slightly to achieve a 100% reading on the meter. Lift the upper roller and confirm the meter reading drops to zero and is responsive to roller height movement before proceeding. (See previous steps to adjust as needed).

Testing and Fine Tuning the Pressure Settings

Step 11

Perform the paper test. Put a roll of 10-12 mil thick paper as wide as possible in the center of the table and feed the leading edge into the NIP (see drawing below). Be certain the paper is running straight through the rollers by squaring up a tight roll of paper against the top roller. Once you have confirmed that the roll is square with the upper roller and the paper is tight in the nip, you should draw the roll away from the top roller, keeping the roll of paper on the in feed table. In order to keep the paper taut, apply some resistance to the roll during this alignment process. Mark the in feed table with a piece of tape or erasable pen or pencil approximately one foot from the nip where the right edge of the paper meets the table. Set the speed control to maximum. Apply 40 % pressure to the roller and begin to run the roll of paper through the machine. Stop the machine as soon as you detect any deviation.

Measure the direction and amount of deviation from the starting position, using the mark on the table as a reference. (The maximum allowable paper shift is 3mm per 5 meters of paper). If the paper is running to the right it means that the pressure on the right side is greater than the pressure on the left. If it is running to the left, then the pressure on the left is greater. It is important that all adjustments be made on the left end using the eccentric only, to avoid altering the previous pressure meter settings.

Locate the eccentric on the upper pivot bolt on the left height adjusting arm. Back off the pressure setting and raise the upper roller slightly until you can see a visible but slight gap between the rollers on the left end. While holding the inner nut in place, (which is the eccentric), with a 19 mm open end wrench loosen the bolt (the bolt head nearest the outside of the machine). By turning the eccentric in one direction or the other you can raise or lower the upper roller 4mm in either

7

direction. Note the gap and adjust according to the above instructions. Very slight movement of the eccentric is all that is necessary. Make certain you realign the roll of paper with the roller

before performing each check. Repeat the above steps until the paper travel is no greater than 3 mm per 5 meters of paper.

Secure the pivot bolt while holding the eccentric in place after making the slight corrections needed.

Do not over tighten the eccentric hold down bolt! When satisfactory results are achieved from the paper test, confirm that the eccentric bolt is secure. No further spring washer adjustment is necessary.

Rechecking the Visual Parallelism of the Rollers

Step 12

Position the upper roller so the extreme right edges of the upper and lower rollers just contact each other visually, as you look into the nip. There should be the same amount of roller contact on the left end. If a slight adjustment is needed, use Bolt A on the left side to make the correction. On the left side, back off the lock nut on Bolt A, and use an Allen wrench to bring Bolt A into contact with the bearing block. As you tighten Bolt A, the roller lifts on the left end and you may find it necessary to re-adjust the upper roller with the hand wheel to the position described at the beginning of this step. When the correct setting is achieved, hold Bolt A while securing the lock nut against the bearing block. Bring Bolt A on the right side into contact with the bearing block and then secure the lock nut. This should only be a very minor adjustment using Bolt A on the left side only to avoid having to reset the pressure meter.

8

Final Inspection

The paper test described in the steps above should be performed at a variety of pressure settings to verify even spring rate compression. If there is a variance or shift when applying more or less pressure, first check the paper alignment and reset as needed. If the tracking still deviates at different pressure settings, inspect the spring washer stacks for any irregularities and correct as needed. The procedure must be repeated if any alteration is made to the spring washers. Paper run out that occurs at different pressure settings indicates uneven spring washer settings. The spring washer settings must be repeated carefully to remove any differences in the washer preload.

If there is any concern about the rollers, use Kraft paper as wide as possible to clearly reveal any irregularities. If you have questions, call for help from Drytac Technical Services.

Rev. by DJW 9/2/2008

9

Appendix E

TECHNICAL SERVICES DEPARTMENT

Technical Service Bulletin JM 63- 2008-001P

Date of Issuance:

2/08/08

Equipment Affected:

All JM63’s released prior to the date of this bulletin.

Description of the Condition:

In the event the glass portion of the heating element breaks (either in shipping or during use) when the machine is powered up, the exposed heating coil could come in contact with the inside of the roller. This would provide an electrical path to ground allowing current to continue to flow through the coil. If this occurs unnoticed by the operator (or while the machine is left powered up and unattended) it is possible that a portion of the roller could continue to heat regardless of the settings on the Control Panel. If the breakage occurred on the opposite end from where the overheating sensor is located, heating could continue and the roller could be seriously damaged as a result.

Recommended Action:

1. See attached memo describing the recommended Power Up/Down Procedure to assure the machine is properly powered up and down by the operator(s). Following the procedure eliminates the possibility of the above condition occurring when the machine is left unattended. This information is to be included in the manual and brought to the attention of all the operators.

2. To further address the condition described above a UL/CSA/CE Equipment Leakage

Current Interrupter (E.L.C.I.) will be installed on the machine. There will be two types available; either will shut off power to the machine if any abnormal grounding condition exists.

3. This T.S.B. will be sent to all JM63 customers explaining the issue and the resolution.

4. We will provide and arrange for the installation of either a replacement circuit breaker or an in-line device that can be easily installed without opening up the machine.

Part Required:

Either an in-line E.L.C.I. device or a replacement Main Circuit Breaker with the function built in.

10

Appendix F

TECHNICAL SERVICES DEPARTMENT

JM63 PCB INSTALLATION

The JM 63 PCB is ESD sensitive and should be handled carefully to avoid damage to the board. Do not handle the PCB with your hands without being grounded. Follow these instructions carefully in the order outlined. Unplug the JM63 from the outlet prior to

performing this procedure.

1. Remove the right end panel and set it aside. Locate the schematics attached to the inside of the end panel and remove them to use for reference during the installation.

2. The PCB is located inside the large protective cover that houses the electrical components. Remove the four screws that secure the cover and set the cover aside.

3. The connections to the PCB have yellow identifying labels that correspond with the

Controller diagram included with the schematics. Carefully remove each connection and pull each one back from the board to ease removal of the PCB.

4. Unscrew and remove the four mounting screws that secure the PCB to the plate, being careful to remove the ground from the top left screw.

5. Orient the new PCB so the ground eyelet on the board is at the top on the left, and reattach the ground wire and secure the mounting screws with the spacers between the board and mounting plate.

6. Follow the diagram to correctly reattach the connections. Double check all connections and that the control panel switches are off.

7. The pressure meter must be recalibrated at this point. Set the rollers to the “sweet spot” where the weight of the top roller is resting on the lower roller. With the power off, adjust the pressure meter with the plastic dial at the bottom of the meter’s face until the needle rests at zero. Identify the two potentiometers (small square blue boxes) located at the bottom of the PCB. The following adjustments require the machine to be powered up. DUE TO LIVE VOLTAGE, USE EXTREME CAUTION WHEN ADJUSTING

THE POTENTIOMETERS!

8. Turn on the main breakers, which are located on the back of the right end panel, and then the power switch on the front control panel. Using a small standard screwdriver, adjust the potentiometers by turning the screw located in the top of each. Adjust the left or zero potentiometer completely counter clockwise, then turn it very slightly clockwise.

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Next, turn the right potentiometer completely clockwise, and then turn it very slightly counter clockwise.

9. Adjust the pressure sensor actuating arm. The pressure sensor is located above the photocell in the right end case. The adjusting rod must be set so that any movement of the roller will cause the needle to move.

10. To make this adjustment, locate the 8mm adjusting bolt at the end of the sensor rod.

Loosen the nuts on either side of the mounting bracket and turn the bolt in or out to achieve movement of the needle on the meter as soon as the rod is moved. Position the rod to achieve a meter reading between 5-10%, and then secure it in that position with the lock nuts.

11. Raise the upper roller off of the lower roller by approximately 8mm. Adjust the left potentiometer to achieve a zero reading on the meter. Lower the top roller to the “sweet spot”, where the weight of the top roller is resting on the lower roller, with no additional pressure applied. The meter should read between 5-10 %. Raise and lower the upper roller repeatedly to see if the meter is immediately responsive to roller movement, returns to zero when raised, and reads 5-10% when at the sweet spot. Make adjustments to achieve this condition by repeating the previous steps as needed.

12. Beginning from the sweet spot; turn the hand wheel 3 ½ turns clock wise. This is 100

% pressure. Adjust the right potentiometer to achieve a 100% reading on the meter. Lift the upper roller and recheck the meter readings and responsiveness before proceeding.

(See previous steps to adjust as needed).

13. Complete the Functional Requirements Checklist.

Upon achieving satisfactory results, power down the machine and unplug from the outlet to reinstall the protective cover and end panel.

14. Revise the serial number on the machine’s serial label with the appropriate revision level and also record the installation on the service record in the pouch on the inside of the right end panel.

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Appendix G

JetMounter 63 Temperature Control and Display

The JetMounter 63 laminator has a heated top roller. The heating element is controlled by a thermostat and display system, linked to an infrared sensor. Because the control system is a multi-purpose thermostat, there are a number of functions that are not needed in the JM63. By default, the controller is locked, and set at the correct temperature, but it may be necessary to make adjustments. The flowchart on the next page includes information and values for all default JM 63 settings.

The control system has a four-digit display, and three buttons: , , and . All functions are accessible through these controls. To power on the control system, turn the Heat switch on. The display will show the current temperature of the roller. Pressing will display , and allow the set temperature to be adjusted. Press or to adjust the set temperature, then press to save the set temperature.

It may be necessary to change the offset on the thermostat if the displayed temperature does not match an external measurement of the temperature of the top roller. If this is the case, do the following:

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Press and hold for three seconds to bring up the Settings menu.

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If the display flashes , then you will need to: o Press and hold both and together for three seconds. o This will make the become solid. Press to set the o Press and hold for three seconds to save the

value to 0.

setting and return to base display.

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If the display shows

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When the option

, press to scroll through the setting options.

is displayed, press or to adjust the offset up or down. This number is added to the measured temperature, so if the machine were reading 180° F when the temperature was actually 160° F, the offset would be decreased by 20. Because the sensor is very close to the roller, the offset is typically negative. So in the case above, the offset might have to be decreased from -35 to -55.

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Once the offset has been entered, press and hold for three seconds to save the change.

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Recheck to make sure that the displayed temperature now matches the external measurement.

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Either readjust the offset, or relock the setting menu by setting the value to 1 as above.

For normal use, no other setting options will be necessary. If any settings are accidentally changed, however, the following flowchart should provide enough information to restore the defaults. If you have any trouble, please contact Drytac Technical Services.

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Base Display

(Current Temperature)

Press and Hold for three seconds. Press to bring up set temperature.

Press or to adjust set temperature, then press to save.

This brings up , which is the first entry in the setting menu.

Setting 0: will set the thermostat to either cool or heat. Be sure this remains set to in the JM63.

Press to cycle between setting types. Press and hold

for three seconds to save settings and return to the base display.

Setting 1: is the deviation setting. This is not used on the JM63, and should remain set to 1.

Setting 2: is the delay time setting. This is not used on the JM63 and should remain set to 1.

Press and hold and together for three seconds to be able to lock and unlock the settings menu.

Press to cycle between setting types. Press and hold

for three seconds to save settings and return to the base display.

is the lock setting. Select 1 to lock the setting menu, and 0 to unlock the setting menu.

sets the decimal point. This is not adjustable on the

JM63 and should remain at 0.

Setting 3: is the input compensation. This is used to adjust the readout to match the actual temperature, if more than a 5 degree difference is determined. Use or to adjust the display to match the proper temperature. Press and hold to lock in the temperature adjustment and leave the setting menu.

Setting 4: is the upper limit of the temperature setting range. This should not be changed on the JM63 and should remain at 250.

activates proportional control. This is not used on the JM63 and should remain set to 0.

Return to lock setting. Press and hold for three seconds to save settings and return to the base display.

Setting 5: is the lower limit of the temperature setting range. This should not be changed on the JM63 and should remain at 68.

Setting 6: is the auxiliary output selector. This is not used on the JM63 and should remain set to 0.

If settings 7, 8, or 9 select for , , or , this means that setting 6 is set to 1. While this should not affect operation of the JM63, you may want to set the auxiliary output selector (setting 6) to 0.

Setting 7: is the alarm temperature setting. This is not used on the JM63 and should remain set to 270.

Setting 8: is the deviation setting for the alarm. This is not used on the JM63 and should remain set to 4.

Setting 9: is the delay time setting for the alarm.

This is not used on the JM63 and should remain set to 1.

Return to Setting 0. Press and hold for three seconds to save settings.

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