EXP 62” Plus Laminator
Owner’s Manual
REV 01
MADE IN U.S.A.
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EXP 62” Plus Laminator
Table of Contents
About the Manual…………………………………………………………………………………………………….
Safety Precautions……………………………………………………………………………………………………..
Finding a Work Area………………………………………………………………………………………………..
Unpacking Your Laminator……………………………………………………………………………………..
Loading Film………………………………………………………………………………………………………………..
Operation Instructions for Release Liner Rewind (optional)…………………………
Tension………………………………………………………………………………………………………………………….
Setting Roller Temperature……………………………………………………………………………………
Control Panel Left Diagram……………………………………………………………………………………
Control Panel Right Diagram…………………………………………………………………………………
Nip Adjusters Diagram…………………………………………………………………………………………….
Mounting Using a SuperStick® Pouch Mounting System…………………………….
Mounting and Laminating Using a SuperStick® Pouch Board………………….
Encapsulating with a SuperStick® Flexible Pouch or Release Board….….
Cleaning Your EXP 62” Plus Laminator…………………………..............................................
Specifications … …………………………………………………………………………………………………………
Trouble Shooting……………………………………………………………………………………………………….
Warranty…………………………………………………..…………………………………………………………………..
Webbing Diagrams…………………………………………………………………………………………………..
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About this Manual:
READ ME FIRST!
This manual contains all the information you need to properly unpack, operate
and maintain your Laminator. Before unpacking your laminator we suggest
you read and follow the manual step by step. It contains essential information
about each and every facet of your laminator. Pay special attention to the
work environment and safety precautions necessary for your laminating unit.
Please pay special attention to particular notes and caution statements.
These comments alert you to information that we feel essential to operator
Safety and damage prevention to the laminator.
Copyright Information:
IMPORTANT: This manual is copyright protected by D&K Group Inc.. in
accordance with the laws and requirements of the United States Government.
Any reproduction of this manual, in part or in full, without the written permission
of D&K Group Inc.. constitutes a violation of the U.S. copyright laws and is
subject to prosecution.
Safety Precautions
WARNING: Please review the following safety precautions before unpacking
your new laminator.
Use care in unpacking and lifting the laminator. Keep laminator level when
lifting or moving. Laminator weighs approximately 500 pounds.
Consider work area. A cluttered work space can lead to accidents. The
laminator should be placed on a level sturdy surface. Do not attempt to
operate the laminator in damp or wet environments. Do not operate electrical
devices in the presence of flammable liquids, solvents or in gaseous/explosive
atmospheres. Keep work area well lit. Allow sufficient access to front and back
of machine. See the manual for additional work space requirements.
Respect feed rollers. Keep hands away from feed rollers and any other
moving parts. Turn drive switch OFF before attempting to clear film
wraparounds or jams. Use auto-matic reverse to clear film. Do not wear any
loose clothing, ties, jewelry, etc., which can be caught by feed rollers and draw
any body part into the machine.
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Safety Precautions
Do not operate laminator with any panels or guards removed. Panels and
guards protect operators from such moving parts as the drive chain and
sprockets, roller ends, etc.
Turn the power switch OFF before walking away or leaving the laminator
unattended.
Before lifting or moving laminator, turn power switch OFF, unplug unit and
allow to cool to room temperature. Remove film rolls before lifting or moving
machine. Film is easy to rethread, see the section in this manual.
Keep children away. Make sure visitors are kept well back from an operating
laminator.
Do not abuse electrical cord. Never pull cord to disconnect it from a
receptacle. Do not allow cord to contact heat, oil or sharp edges. Do not cut
off or otherwise bypass the grounding prong on the plug.
If an extension cord is necessary be sure it is properly rated and of the same
wire gauge or smaller as the laminator cord. Capacity of the cord must
prevent loss of power and overheating. Before using, inspect extension cord
for any damage, including loose or exposed wires, broken fittings, damaged
insulation, etc.
For service on your laminator call D&K Group Inc.. Use only D&K Group Inc.’s
parts for service or replacement. Failure to use D&K Group Inc.’s parts could
void manufacturer’s warranty.
Use common sense. Be cautious when operating your laminator. Do not
operate laminator when you are tired or your reactions are impaired in any
way.
Do not allow anyone to operate the laminator who has not received proper
instruction and has not read the safety instructions
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Find a Work Area
A separate work station is required to house your laminator. Ample room is
necessary to access the laminator from all 4 sides. If the laminator is back
against a wall, the laminating film may back up and jam the equipment. Your
laminator must be on a stable, level surface.
Tools necessary to set up your laminator include cutting shears and any
adhesive tape. For future service or maintenance, an assortment of Allen
wrenches, a flat head screwdriver and a Phillips head screwdriver are
necessary.
Unpacking Your Laminator
The shipping carton contains:
1 Laminator
1 Top Supply Mandrel
1 Bottom Supply Mandrel
1 Release Liner Rewind Mandrel
1 Feed Table
1 Operating Handbook
Be sure to save the shipping carton . . .
Should your laminator ever need to be returned for service, the foam-filled
carton ensures safe transit.
NOTE: Each laminator is test run after it is assembled. Your laminator may have
a piece of test film in the rollers when you receive it. If so, before threading,
remove the test film by turning the drive switch to “ON”. The test film will exit
the laminator.
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Loading Film
Step 1:
The laminator should be preheated before loading laminating film. To heat the
machine see page 6 “Setting Roller Temperature”.
Step 2:
When the laminator is heating, the rollers should be turning to heat the rubber
rollers evenly. Therefore, turn the drive switch to the forward position and
rotate the speed control knob until the rollers are moving slowly. Heat
approximately 15 minutes.
NOTE: Do not apply excessive force to the ends of the mandrel (i.e. with a
hammer). Force will cause damage. Film rolls must be centered on supply
mandrels. If rolls are not aligned, hot adhesive will be deposited on the heated
rubber rollers, necessitating a cleaning operation.
3” Core Poly out Film
Choose your laminating film. For encapsulating, both types of film should be of
the same size, type and thickness. Take the bottom supply mandrel and insert it
into the roll of film. Place the lower mandrel on the laminator. Take the top
supply mandrel and insert it into the desired roll of film and place it on the
laminator as illustrated above. Follow the same steps to load the top supply
mandrel.
NOTE: When loading your laminating film, check for film splices. These rolls will
be clearly marked. Splices are not common but are unavoidable. If you find a
splice, place that film roll on the top position so the splice can be monitored
carefully. When the splice is ready to come through the laminator, turn the
drive off, and rotate the roll of film by hand so the film is very loose. Turn the
drive switch again and allow the splice to run through. If necessary, keep
turning the roll of film to keep it slack until the splice is out.
Step 3:
Thread the top roll of film under the idler roller. Pull the film down so that the
film’s lead edge is below the lower roller. Next thread the bottom roll of film
under the lower idler bar pulling film upward until it is even with the top roller
shoe and parallel side to side with the top roll of film. “Tack” it to the top film
edge, this creates a film “Web”.
NOTE: Use caution when threading film around rollers.
Step 4:
Loosen tension on both rolls of laminating film. Turn on the “Drive” switch and
using the threading board – push the film web into the laminating rolls. This
process will push the web into the pull rolls and exit. Take extra care to ensure
that the film exits between the rear rollers. Your laminator is now loaded.
Remove the threading board and save for your next use.
NOTE: Slowly run the laminator while threading to help maintain control.
NOTE: Create your own threading board from a piece of poster
board 12”x 60”
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Operation Instructions for Release Liner Rewind (optional)
This laminator is equipped with the features necessary to allow the use of
pressure sensitive film with release for single side lamination. The Release Liner
Rewind will remove the release from the film and wind the waste onto an
empty core, which can then be disposed.
The pressure sensitive film should be mounted on the upper supply roll and
threaded under the idler shaft. An empty film core should be mounted on the
Waste Rewind mandrel, and the mandrel mounted onto the laminator. A
section of scrap media that is at least as wide as the film in use should be
started into the front rollers of the laminator. Separate the release from the
film for a length of about 6 inches, and mount the exposed portion of the film
to the media that has been started into the machine. Bring the end of the
release under and up to the Waste Rewind mandrel, and tape the release to
the spare core that has been installed to the mandrel. The Waste Rewind
mandrel may be rotated by hand to assist in the start up. Slowly advance the
motor of the laminator guiding the film and media to the rear rollers, while
insuring the release is firmly attached to the Waste Rewind core.
The separation point for the film and release should be between the idler shaft
and the point were the film contacts the heat shoe. The separation point can
be adjusted by the tension knob on the Waste Rewind drive shaft. If the
separation point is past the point were the film contacts the heat shoe, tighten
the tension knob slowly until the separation point moves towards the idler
shaft. If the separation point approaches the Waste Rewind mandrel or the
idler shaft, loosen the tension knob slowly until the separation moves towards
the heat shoe. The tension setting should need very little adjustment once set,
but should be monitored during operation.
Once the separation point is set, lamination is performed normally. Care
should be taken to minimize the gap between successive pieces of media
being laminated so that the adhesive from the film is in contact with the lower
roll as little as possible.
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Tension
To adjust tension for upper and lower film rolls, the laminator must be loaded
and heated.
Remove the feed tray. Loosen both tension control knobs by turning
counterclockwise until there is no tension on upper or lower film roll. Film
should pull freely.
Turn the drive switch “ON.”
As film runs through it will appear wrinkled and bubbly. Gradually increase
tension on both rolls, by turning knobs clockwise, until film is smooth on heated
rollers. Once film is smooth, stop tightening knobs.
NOTE: For best results, reset tension with EACH new pair of film rolls.
NOTE: As the film roll supply becomes low it is necessary to decrease tension
on the rolls. Reset at approximately the last 1/3 to 1/4 of a roll.
NOTE: Too little tension on the top or bottom roll causes vertical or diagonal
streaks in the film as it passes around the heated rollers.
NOTE: If the laminator’s speed is set too fast when using thicker films, wrinkling
and bubbling may occur.
WARNING: Excessive tension will lead to increased wear and tear on the
laminator.
Once the laminator is loaded, heated and tension adjusted – reinstall the feed
tray.
Setting Roller Temperature (See Figure 1 and Figure 2 on pg 7)
1.
Press “SEL” green button
2.
Adjust temperature up or down using the up arrow or down arrow.
3.
Press “SEL” green button again to activate temperature.
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Control Panel ( Left )
Figure 1 ( Upper Roller Temperature Control )
Lowers or Raises Upper Heated Roller Temperature
Figure 2 ( Lower Roller Temperature Control )
Lowers or Raises Lower Heated Roller Temperature
Figure 3 ( Upper Roller ON/OFF Switch )
Toggles Upper Heated Roller to ON or OFF
Figure 4 ( Lower Roller ON/OFF Switch )
Toggles Lower Heated Roller to ON or OFF
Figure 3
Upper Roller
ON/OFF Switch
Figure 1
Upper Roller Digital
Temperature Control
Figure 4
Lower Roller
ON/OFF Switch
Figure 2
Lower Roller Digital
Temperature Control
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Control Panel ( Right )
Figure 1 ( Motor Switch )
Toggles Laminator Rollers to Forward or Reverse
Figure 2 ( Fans Switch )
Toggles Laminator fans to ON or OFF
Figure 3 ( Speed Control Knob )
Adjusts the speed of the laminator’s heated rollers
Measured in feet per minute ( FPM )
Note: To Reverse the direction of lamination, switch the Motor & Fan Switches
to “reverse” position
Figure 1
Motor Switch
(Forward/Reverse)
Figure 3
Speed Control
Figure 2
Fans Switch
(ON/OFF)
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Nip Adjusters
The Nip Adjusters are Located on the left hand side of the laminator and are
operated from front and rear of the machine. The Nip Adjusters are used to
adjust the height of the rollers.
To Operate the Nip Adjusters:
ƒ Grasp it with your left hand and pull out approximately 1/4”
ƒ Once the Nip Adjusters have disengaged from the stop, they may be
rotated forward or backward (clockwise or counter-clockwise, as viewed
from the left hand side of the unit).
To Set the Height of the Rollers:
ƒ Continue to rotate the Nip Adjusters until the desired measurement
corresponds with the indicator of the knob.
ƒ Select the measurement that indicates the thickness of the material you
will be using with the machine.
ƒ Release the Nip Adjusters so that it moves back to the right and clicks
into place, this will set the rollers for use.
ƒ The measurements on the Nip Adjusters, ½”, ¼” (6mm), 3/16” (5mm), 1/8”
(3mm) and 1/16” (1.5mm) correspond to board thickness’.
ƒ For additional pressure, stop Nip Adjusters between indicated
thicknesses.
ƒ There is also a fully closed stop, 0” (0mm) for encapsulating applications.
ƒ For additional pressure when rollers are closed, pull knob out & rotate
counter clockwise to increase pressure.
Note: Do not apply additional pressure to rear (Pull) Rollers
Rear Pull Rollers operate best with minimal pressure.
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Mounting using SuperStick Pouch Mounting System
Step One
Insert your print into the SuperStick Mounting & Laminating Pouch.
Step Two
Place the SuperStick Pouch on the surface of virtually any rigid substrate or
foam board – NO ADHESIVE NECESSARY!
Step Three
Pass the SuperStick pouch and board combination through the heated roll
laminator. It comes out done!
Step Four
Display your finished product. That’s it!
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Mounting and Laminating using a SuperStick® pouch board:
1.
Refer to the instruction sheet packed with each box of SuperStick® pouch
boards for specific instructions on mounting/laminating with a SuperStick®
board.
2.
Also, refer to the instruction sheet for information on Compatible Media,
Process Conditions, and Technical Information.
3.
A SuperStick® Pouch Board consists of a foam mounting board with a
piece of film on top. The film is sealed to the board along one side of the
shorter sides.
4.
Carefully examine the board, determine which edge is sealed. There is a
1/8” tape edge on the sealed end.
5.
Starting at one of the corners opposite the sealed edge, gently lift and
peel back the film. Care should be taken not to break the sealed hinge.
6.
Center the image to be laminated on the board and lay the film back
over it.
7.
Cover your print with the cover sheet packed in each box as marked. This
is required on thick papers to prevent adhesive from sticking to the rolls.
8.
Set the control knob to the correct setting that matches the pouch board
thickness.
9.
Slowly insert the pouch board into the inlet opening. Ensure that the pouch
board will enter centered and straight. A gentle push may be required to
start the board into the machine. Hold the edges of the pouch board until
it is engaged and the laminator begins pulling on its own.
10. The pouch board will feed through the laminator and automatically exit at
the rear of the unit.
11. Support board as it exits the machine to keep heated board from curling
down.
12. THE POUCH BOARD WILL BE HOT! Allow it to lie flat while cooling.
13. If there is any dirt or adhesive on the surface of the board, it can be
removed by dampening a lint free cloth with Poly-Off and wiping the
surface.
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Encapsulating with a SuperStick® Flexible Pouch using a SuperStick® Sled or
release board:
1.
Refer to the instruction sheet packed with each box of SuperStick® Flexible
pouches for specific instructions on encapsulating.
2.
Also, refer to the instruction sheet for information on Compatible Media,
Process Conditions, and Technical Information.
3.
The Flexible Pouch consists of two pieces of film that are hinged at one
end, along a short side. Separate the two pieces starting at the end
opposite the hinge. Take care not to break the hinged seal.
4.
Insert the article to be laminated in the pouch so there is at least a 1/8”
(3mm) border around each of the sides. This ensures that moisture never
reaches the image.
5.
Place the pouch with the image on the release carrier board included
with the flexible pouches or SuperStick® sled carrier. The SuperStick® sled
is carrier board to assist in the handling of large Flexible Pouches. It is
made of materials that will not damage or cause excessive wear to the
EXP 62” Plus Laminators.) Smooth out any wrinkles with the side of the
hand or a soft, flexible squeegee.
6.
Better results may be achieved by taping the leading edge of the pouch
to the sled using masking tape.
7.
Adjust the Control Knob to the 3/16” setting for the SuperStick® Sled or
1/16” for the release carrier board to accommodate its thickness. Be sure
that the heat is on, the middle LED indicator is on and the bottom LED is
constantly on.
8.
Slowly insert the sled or release carrier board with the Flexible
Pouch on top into the inlet opening. Ensure that the sled or release board
is centered and straight. A gentle push may be required to start the sled
or release board into the machine. Hold the edge of the sled or release
board until it is engaged and the laminator begins pulling it on its own.
9.
The sled or release board will feed through the laminator and
automatically exit at the rear of the machine.
10. THE SLED or RELEASE BOARD WILL BE HOT! Allow it to lie flat and cool
before removing the tape.
If there is any dirt or adhesive on the surface of the board, it can be removed
by dampening a lint free cloth with ISO Propyl Alcohol (IPA) and wiping the
surface.
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Cleaning Your EXP 62” Plus Laminator
The laminator may be cleaned with a lint free cloth, lightly dampened with a
mild soap and water solution. Do not use spray-on cleaners. Do not immerse
any part of the laminator in water or other liquids.
Cleaning the rollers with Poly-Off Cleaners & Erasure
1.
2.
3.
4.
5.
6.
Remove Poly-Off kit from Packaging.
Place Latex gloves over hands for protection.
Pour required amount of Poly-Off to sponge and/or abrasive brush.
Scrub affected area until all debris has loosened.
Wipe clean with towel or cloth material.
Place Poly_Off kit back in packaging for storage.
Specifications
Capacity
Height
Width
Depth
Net Weight
Shipping Weight
Electrical
EXP 62” Plus
62”
19 ¼”
80”
28”
500 lbs.
620 lbs.
230V Single Phase 30 amps
Technical Service:
There are no end user serviceable parts in a EXP 62” Plus Laminator! If the
machine does not reach temperature or you do not get the results you desire,
please contact D&K Group Inc.. Your machine is covered by a Full One-Year
Warranty as described in this manual. Contact D&K Group Inc. for warranty
and chemical related questions.
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Trouble Shooting
TROUBLE SHOOTING
COMMON EXAMPLES OF POOR LAMINATING . . . and their causes.
A. FILM NOT BONDING TO SUBJECT OR TO ITSELF AT SEALED EDGES
Causes:
1. The heat (on either or both rollers) is set too low.
2. Film tension is too tight.
3. Bottom roll of film is threaded incorrectly.
4. The pressure setting is not correct.
B. WRINKLES OR IRREGULAR WAVES RUNNING ACROSS THE LAMINATED WEB
(PERPENDICULAR TO THE EDGE)
Causes:
1. The heat set is too high.
2. Not enough tension on the supply mandrels. (Large, irregular waves).
3. Too much tension on the supply mandrels. (Small, fine wrinkles - “orange
peel” effect).
4. The rubber laminating rollers are not clean.
5. The pressure adjustment for the laminating and pull rollers is out of
adjustment.
C. STRETCH LINES RUNNING WITH WEB (PARALLEL TO THE EDGE)
Causes:
1. Too much tension on the supply mandrels.
2. The heat is set too high on either or both heated rollers.
3. The heating rollers are not clean.
D. BLISTERS ON SURFACE OF SUBJECT OR ALONG EDGE OF SUBJECT
Causes:
1. The heat is set too high on either or both heated rollers.
2. Excessive moisture in the paper being laminated. (If inks are not dry,
this may also cause blisters). For high moisture content substrates,
use D&K’s low temperature films with a bonding temperature of
185 - 190F
3. The rubber laminating rollers are not clean, or are damaged.
Trouble Shooting (Continued)
E. CURLING OF THE FINISHED LAMINATION
Causes:
1. Unbalanced tension on the supply rolls. Too much tension on the top
supply roll will cause the web to curl up. Too much tension on the bottom
roll will cause a downward curl in the web.
2. Bottom roll of film has been threaded incorrectly.
3. Heat is unbalanced in the top or bottom heated rollers. If the subject
curls up, there is too much heat in the top roller. If it curls down, there
is too much heat on the bottom roller.
F. WRINKLING AROUND EDGE OF LAMINATED ITEM
Causes:
1. Item to be laminated is too thick or
not enough adhesive in type of film being used.
Possible Solutions:
a. Loosen tension
b. Use thicker film (Higher adhesive content)
c. Flush cut item
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Terms & Conditions
D&K Group, Inc., warrants to the original consumer purchaser that each new
EXP 62” Plus Laminator which proves defective in materials or workmanship
within the applicable warranty period will be repaired or, at our option,
replaced without charge upon its return as outlined below. The applicable
warranty shall be one year from date of purchase with 3 months limited
warranty on the rollers. “Original consumer purchaser” means the purchaser
who first purchased the product covered by this warranty other than for
purpose of resale.
Liability for breach of any warranty express or implied shall be limited to the
repair or replacement, at D&K Group, Inc., option, of the defective item. D&K
Group, Inc. shall not be liable for damages arising out of, or in connection with
the use or performance of any SuperStick® product. Any implied warranty
shall be limited in duration to the duration of this warranty. Some states do
not allow limitations on how long an implied warranty lasts for the exclusion or
limitation of consequential damages, so the above limitation may not apply to
you.
There are no consumer serviceable parts in the EXP 62” Plus Laminator. If you
require service under this Warranty, contact D&K Group Inc. to obtain Return
Authorization (RA), pack the product in its original packaging (or request the
same from Technical Service when requesting the RA), and include a
description of the malfunction and proof of date of purchase. Technical
Service will arrange to have a technician contact your for onsite service.
The Warranty extends to and is enforceable only by the original consumer
purchaser, and only for the period which the product remains in the possession
of the original equipment purchaser. This Warranty does not cover any defect
or malfunction due to the use of faulty non- EXP 62” Plus Laminator materials,
unreasonable use or abuse of the machine, or failure to provide reasonable
and necessary maintenance. This Warranty gives you specific legal rights and
you may have other rights, which vary, from state to state.
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Webbing Diagrams
1.
Encapsulating
2.
Mounting & Laminating Print to pre-coated board
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Webbing Diagrams (continued)
3. One Step Decal
4. Two Step Decal
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Webbing Diagrams (continued)
5. Pre-Coating Boards
6. Mounting Decal Print
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Webbing Diagrams (continued)
7. Laminating with PSA and release liner
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