Safetyprecauton

DO NOT OPERATE THIS MACHINE UNTIL YOU HAVE READ AND PULLY UNDERSTOOD THE FOLLOWING SAFETY PRECAUTIONS.

1. Never operate this machine without reminding yourself that a big laminator is a powenful and potentially dangerous tool. If misused, used carelessly. or used without observing the rules of safe operation, very serious injury can result.
2. Never operate this machine without all guards, housings, safety shields, stop switches Or other safety devices in place and fully operational.
3. Never operate this machine unless you have been fuly trained and have received and understood all operating instructions. Make sure you know how the machine works and how it is controlled.
4. Never operate this machine if it is not working properly or if you notice any abnormality in its
5. Never tamper with, rewire, or bypass any control or safety device on this machine.
6. Aways keep all parts of your body clear of the laminating rollers, pul rollers, and heated surfaces of the laminator when the power is on.
7. Remember that even after the machine has been turned off for some time, the laminator's noA ung ol ybnoue joy uewal ueo 'sued bujulofpe pue 'sued paleau
8. Never attempt to clean the heated areas, laminating rollers, or pull rollers while the power is
9. Never remove the machine housing or attempt any kind of maintenance without disconnecting power to the unit.
10. Aways be sure all persons are clear of the machine before advancing or reversing the pressure rollers, especially when multiple operators or observers are present.
11. Never wear loose clothing, ties, jewelry or any item, which could be caught in the rollers or machinery when operating the machine. Operators with long hair must put their hair up before running the machine.

off and you intend to adjust the mechanism or change a blade.

13. Because casters raise the center of gravity and the increase risk of tipping, use casters only when the machine needs to be moved. Use a minimum of two people. Move slowly, and avoid any obstructions. Remove the casters when the machine is in its proper position. NOTICE TO EMPLOYER: A copy of these safety precautions must be given to all operators, set-up personnel, maintenance people, and supervisors of this machine. A copy should also be hung on

IMPoRTANT: Where a language barrier or insufficient schooling would prevent a person from reading and understanding these safety precautions, you should either translate this information or have it read or interpreted to the person, and get assurance that it is understood.

IMPoRTANT: Remember that you cannot Use heat lamination on thenmal paper, Such as typical fax paper, because it is activated by heat and will turn black. Be careful about laminating anything that will be affected by heat. For example, the colors in heavy. Light crayon drawings may not be affected, but test an expendable sample of any item that may not laminate well.

Do not laminate one-of-a-kind documents unless you are sure of your laminating skills and can afford to damage or ruin the document.

Do not laminate valuable items such as stamps, baseball cards, autographs, or other collectibles because the value of such items can be destroyed by lamination. Collectors generally value these items only in their original state.

IMPORTANT: Eviter de plastifier du papier thermo sensible, comme le papier de telecopieur, pusqu'll noircira sous T'effet de la chaleur, et enlever les trombones et les

les dessins au pastel dont les couleurs baver et se melanger, surtout si la couche de

de doute, il est preferable de faire un essai avec un echantillon perdu.

moins de bien malitriser la technique de plastification.

Ne pas plastifier non plus les articles de collection comme les trimbres, les cartes de

collection ne urs s'ls ne sont plus dans leur etat d'origine.

IMPORTANTE: Recuerde que no puede laminar papel termico, tal como el papel de fax tipico, ya que es activado por el calor y se tormara negro. Retire tambien cualquier

cosas sensibles al calor, por ejemplo, los colores de dibujos hechos en lapiz de paste!

que podrian no laminarse bien.

de laminador y pueda permitirse aruinar el documento.

No lamine aniculos de valor, como estampillas, tarjetas de beisbol, autografos, u otros coleccionables, ya que su valor puede ser destruido por la laminaci6n. En general, las coleccionistas valoran este tipo de articulo en su estado original.

Table Of Contents

1L0INTRODUCTION

Safety Symbols 1-2 Features and benefits

Principles of operation Laminating film

2.1UNPACKING AND INVENTORY

3-1 PRODUCT ILLUSTRATIONS & NAMES OF PARTS

Safety Precautions

51SETUP 8& OPERATION

5-2 Threading the laminator Threading diagram Recommended temperature settings Laminating and mounting 5.7 Cold applications Preventing and solving problems

6-1 INSTRUCTIONS FOR OPTIONS

6-2 Release liner takeup 6-3 Roll feed attachment ThermoGlide (Available in 42 " only)

7-1 MAINTENANCE

7-2 Cleaning the heat shoes Cleaning the rubber rollers

1-0 INTRODUCTION The Digital laminator is designed to provide quality lamination of a wide range of papers and materials up to 1/2-inch thick using fim up to ten mil thick. Common applications include, but are not limited to maps, digital imaging. packaging, posters, instructional aids, signs, presentation materials, photographs, copies (B&W or color). prints, flyers, promotional sheets and many other items. Options include a release liner take-up, a roll feed, and a Thermo Glide TM assembly (42" oniy). A slitter assembly, which is also optional, must be factory installed. The stand and casters are standard on the both the Digital 42 & 60.

installation, operation, and maintenance instructions in this manual. Read the manual before using the laminator, keep the manual with the machine, and periodicaly review the instructions. The manual also contains warranty and parts information. We take this opportunity to thank you for selecting the Digital laminator and to assure you of our commitment to your satisfaction with our products. As you unpack your new laminator, please complete the following information. Always have this information ready when calling.

Dealer Where Purchased

Serial #

Installation Date

operating the laminator. MISE EN GARDE: La machine a plastifier produit beaucoup de chaleur et on doit I'utiliser avec prudence. ADVERTENclA: EI plastificador produce tempera tur as muy altas; tenga cuidado al utilizaro.

WARNING: The laminator shouid not be operated without the plexiglass safety shield. MISE EN GARDE: Ne pas utiliser la machine a plastifier sans son ecran protecteur en plexiglass. ADVERTENClA: No utilice el plastificado sin tener el protector de plexiglass en su lugar.

Ledco, Inc. Fax: 585-367-2978 Web: ledcoinc.com 4265 North Main Street

E-mail: ledco@ldconc.com Phone: 585-367-2392 Hemlock, NY 14466

1-1 SAFETY SYMBOLS

Part #

Glossary Of Symbols

Hand Crush/Force from Above

General Danger

Arm Entanglement

Curting of Fingers or Hand/Straight Blade Lab54

Hand Entanglement/Chain Drive

Intemational/Hot Warning Lab100

Electrical Hazard Lab 43

CE Lab06 CE European Electrical

International Ground

12 FEATURES & BENEFITS

Your new laminator has several standard features that set it apart from other models.

Thicker films are generally applied better at mid-range to lower speeds, while 1.5 mil

Ease of cleaning. The silicone rubber rollers and the teflon-coated heat shoes of swing away in seconds, making it far easier to clean the laminating rollers and the heat shoes.

their work. It does not conduct heat so they'll be protected from hot areas. It is fixed to the feed tray and the machine wil not run if the feed tray and safety shield is not in place. Lamination pressure. The rubber rollers are spring-ioaded and preset to ensure correct and even lamination pressure. The pressure is easy to adjust if required when performing routine maintenance. Feed tray pressure strip. (Heat Shoe Model Only) This strip on the front of the feed tray holds images flat as they go into the laminator, making it easier to handle the lightweight papers sometimes used in digital imaging. Supply roll tension contrals. Supply roll tension is easy to adjust by simply tightening or loosening the tension control knobs on the supply roll mandrels.

on a laminator do wear out. Even the high-quality silicone rubber used in the rollers will lose flexibility over time. Extensive use may wear out the rollers, or an operator

without disassembling the frame.

Right and left adjustable feed guides. Sillicone rubber laminating rollers. The rollers are flexible enough to provide a

content insures a much longer average roller life. Very strong steel cores. These prevent roller flexing and insure uniform pressure across the width of the laminate, giving you the best quality lamination available in a medium-duty commercial machine.

Controls to open and close the laminating rollers. The controls make threading easier and allow even heating of laminating rollers during warm-up. e100% Made in the U.S.A. 13 OPTIONS

Roll feed tray When laminating a very long item such as a banner, it is just about impossible to feed it in perfectly straight by hand. By roling it up on an empty

helpful for the owners of poster printers, plotters, banner makers, and other digital output devices.

trimming away side scrap during the famination process. The two heads can be adjusted independently with great precision, even while the laminator is running. (Must be factory installed).

Release liner takeup Many cold laminating films and other materials with pressure- sensitive adhesives have release liners that must be removed just prior to applying to a graphic or substrate. This option is motor-driven and controlled with a clutch to automate the release liner removal.

ThermoGlide TM replaces the standard heat shoe with a series of heated idlers for quieter, friction less movement of the filim into the laminating rollers. (Available on the 42" laminator only).

ThermoGlide is a trademark of Graphic Laminating, Inc., and Ledco, Inc.

14 SPECIFICATIONS

42 60

Max laminating width Speed 0-30FPM 0-20FPM

Laminating roller diameter

Supply roll core size

up to 10 mil up to 10mil

Recommended film

Max laminating thickness

Max film roll diameter

Dimensions 71L39H43W Shipping Dimensions 71L39H43W 91L39H43W Weight/shipping weight 500/800lbs 880/1200lbs Motor 1/4 HP D/C 1/4 HP D/C

Standard heat shoe machine: Electrical (single-phase) 208-240V 208-240V

50/60 Hz 50/60 Hz 40 amps 30 amps

Electrical 3 Phase 208-240V 208-240V

18 amps 13 amps

Nema L6-30P Nema L6-50P

Electrical connector Heater 7400 watts 5200 watts

42" ThermoGlide machine: Electrical (single-phase) 208-240V

40 amps 50/60 Hz

Electrical connector NEMA L6-50P

7800 watts

1-5PRINCIPLES OF OPERATON

The Digital laminators operate by pulling filim with a thermally activated adhesive over a

heat shoes to activate a polyethylene adhesive layer on the film. It then passes through rubber rollers to apply pressure and bond the film to the item being laminated. The adhesive is pressed into the ink and fibers on the surface of the paper.

The strength of the lamination bond can be checked by cutting a large "X" on the suface of a laminated sample with a sharp blade. Use the tip of the blade to pry up one corner of the "x'. Grab that corner and pull up the fim. Ink and/or paper fibers coming up with the layer of film indicates a good adhesive bond. If the film comes up too easily. with no ink or paper, the lamination was probably done at too low a temperature. Check the instructions that may have come with your laminating film and/or the lamination temperature chart in section 5-5. Please note that when doing an X-test on glossy (coated) paper, a good X-test will pull up ink only. The film should not come up easily. When laminating material that is not glossy (uncoated), the paper is often more fibrous and a good X-test will yield ink and paper fibers coming up with the film.

16LAMINATING FILM

Most thermal laminating film consists of two layers: a base of polyester and an adhesive layer of polyethylene. The polyester layer forms the harder oufer surface of the film and does not melt at laminating temperature. It provides rigidity and protection for your

the film onto the subject material under the pressure of the laminating rolers. As an X- test demonstrates, the adhesive is pressed into the paper and fills irregularities in the

The proportion of polyester and poly eth yi ene in a film is usually described with polyethylene. The first number refers to the base layer. The second number refers to the adhesive layer. A mil is 1/1000 of an inch. Since polyester is the more costly of the two types of plastic generally used in laminating film, a "3-2" flim will cost more than a "2-3" fim. Both are 5-mil films but the '3-2" version will seem a little thicker on a piece of laminated material because it will be slightly stiffer. Thermal laminating films are available in many different base/adhesive Five mil film, for example, can be found in 1-4, 2-3, 3-2 and 41 combinations. F

In the US laminating trade, the generally accepted practice is to describe two-sided

the film descriptions being used. There is a huge variety of thermal laminating films available to suit many different kinds of application. Here are some of the more

film with low-melt adhesives, also known as co-polymer films; these often have better clarity and are less likely to curl or ripple matte films to eliminate glare or to accept printing or writing: many suppliers offer films with both glossy and matte finishes film with UV inhibitors to protect colors in the laminated material from fading in

thermal film that has a pressure-sensitive adhesive and a release liner on its outer side; for example, a poster with this material laminated on the back could easily be mounted without fasteners or tape "liner films" with a protective liner on the top outer surface...after a piece of material has been laminated, trimmed, packed, and shipped, the person using the materia! can remove the protective liner revealing a surface perfectly free of dust, scratches or abrasion

for a laminated piece iridescent clear films for special visual effects permanently waterproof fims for outdoor, underwater, or special applications; the most common thermal laminating fims are made with water-based primers and will eventually de-laminate if continually exposed to water or weather; truly waterproof films are made with special primers Rolls of filim may be purchased in different widths. The size of the laminator is the only limitation to the width of the film rolls you can use. Make sure the upper and lower rol! widths are the same, and are aligned with each other.

When installing film, always center the rolls of film on the supply roll mandrels.

Because it does not hold heat well, 1.5 mil film can be the most difficult gauge of film to adhesive type will run at 280 *F. Even when applied at 310 *F, the 1.5 mil fim will not adhere as consistently as the 3 mil film applied at 280°F, or a 5 mil applied at 250°F.

Ten mil film is suggested for those applications that need the most protection and rigidity. Seven mil films are also available. Rolls of film are sometimes spliced. Most fim suppliers will mark a splice with colored you spot a spliced roll in advance, you can put it on the top supply roll mandrel in order to see the splice coming more easily and avoid putting material under the splice. Or

seen from the back side.

1-7WARRANTY

period. provided the laminator has not been abused, altered or operated contrary to instructions. Ledco, Inc. shall not be liable for any alternations or repairs except those made with its written consent.

The adjustment or replacement of pants which are the normal responsibility of the owner.

(screws, nuts, etc.), or other items that show wear under normal use; i.e. "normal wear

Normal operating adjustments to heat, speed, tension, etc. Parts that are not manufactured by Ledco, Inc.. If the individual manufacturer warrants these items, their warranty is, in turn, passed on to the original purchaser of the laminator. Ledco, Inc. does not incur any obligation or liability as a result of the warranties, which are the sole responsibility of the appropriate individual manufacturer. Any laminator that proves defective during the warranty period may be returned to Ledco, Inc. unless it is decided that the necessary repairs can be made during a service call. Notice of the

or return the machine. Phone: 585-367-2392 Fax: 585-367-2978 If the machine is returned, the following should accompany it. 0 Customer name, address and phone number ? Written particulars regarding the maifunction Date of installation Serial number of the machine.

ON THE OUTSIDE OF THE SHIPPING CONTAINER.

Send all returned equipment freight PREPAID to: Ledco, Inc., 4265 North Main Street, Hemlock, NY 14466

Ledco, Inc. does offer technical support if your dealer is unable to assist. This warranty is expressly in lieu of all other warranties expressed or implied. This includes the warranties of Merchantability and Fitness For Use and of all other obligation or liabilities of Ledco, Inc.. Ledco neither assumes nor authorizes any other person to assume it for any other obligation or liability in connection with the sale of this laminator except as provided for above. Further, this warranty will not apply to any machine or part thereof which has been damaged as a result of an accident or as a result of the abuse, misuse, or neglect of the machine. The warranty is also void if the laminator has been altered or repaired by any other than an authorized repair facility or dealer. If you have any questions about this warranty, contact: Ledco:Phone: 585-367-2392Fax: 585-367-2978

2-1UNPACKING AND INVENTORY The laminator arrives fully assembled, except that some parts such as feed trays and fan assemblies may be packed off the machine to avoid shipping damage. Upon arrival, inspect the unit immediately and thoroughly using the packing list that accompanies the shipment. Please follow these steps to correct any problem with your shipment. Ledco, Inc. cannot accept any responsibiity for damage or loss unless you notify us within ten days of receipt of shipment and follow these procedures:

and a claim is filed with the delivering carrier immediately upon receipt of damaged shipment. The procedure for reporing damage depends on the method of shipment. Please note damage on bill of lading. FREIGHT, EXPRESS, or TRUCK DELIVERY: According to the contract terms and conditions of the carrier, the responsibility of the shipper ends at the time and place of shipment. The carrier then assumes full responsibility for the shipment.

1. Notify Ledco IMMEDIATELY.

agent. Ledco will arrange the inspection.

3. DO NOT RETURN ANY GOODS TO LEDCO PRIOR TO AUTHORIZATION BY LEDCO.
4. Submit a copy of the inspector's report to Ledco. Ledco will file the claim with the

damaged machinery when the claim is processed.

Shortage:

an intentional short-shipped (back-ordered) item.

3. Make certain that unauthorized personnel prior to complete unpacking did not remove the item and inventory.
4. Call us and send immediate written notification of the shortage.

Incorrect Shipment:

1. if the material you receive does rot correspond with your order, notify Ledco immediately. Include the order number and item(s).
2. Hold item(s) until return instructions are received. RETURNS: DO NOT RETURN DAMAGED OR INCORRECT ITEMS UNTIL YOU

Have Received Shipping Instructions And An Authorization

NUMBER FROM LEbCo.

3-1 PRODUCT ILLUSTRATIONS & NAMES OF PARTS The photos below and on the following pages identify major components and operating procedures described in this manual.

Top supply roll manore! Emergeney slop bufons

l1ol Aiddns dol tension knob

shleld Contro!

heot shoe Roll pressure

Botom supply

Bottom rolltension knob

Fecd guides

Emergoncy Siop Butc

disploy (aehuah)

Reverse dr

Forward/reverse swilch

Forward drive buiton

Standard heal shoe

Set tempera control kr

(biue) o1

Heat control power swiich (red)

1. Although this machine can be threaded cold, most operators feel it's easier to thread while it is warming up or already hot. Remove the supply rol! mandrels and the feed tray. The supply roll mandrels are now ready to be loaded with film. (There are four 3" diameter stop collars included with the machine. These components are designed to help you conveniently align your top and bottom rolls of film, and can be used to hold your film rolls in place if
2. Slide a roll of fim onto the top supply roll mandrel. Center the roll on the mandrel and place the mandrel in the top bracket.This is a job best done with two people, even if the roll of film is not very heavy. With a person holding each end of the mandrel, it is easy to put both hexagonal fittings into their respective brackets. Make sure they are both fully seated. Atempting to load the fim on the laminator by yourself may result in a back strain or other injury. Make sure the dull side of the fiim is facing up and the shiny side is facing the heat shoes during the

3. Review the threading diagram one page over. Remember, the shiny side or the fim must always go against the shoe. The oull (adhesive) side must face away from the shoe. With the top roll of fim cenfered on the mandrel and the shiny side facing down, pass the fim under the lower idler, over the top idler, and then drape it over the top heat shoe. You are now ready to load the botom supply roll
4. Load the bottom rol of film onto the mandrel in the same manner as the top roll. Remember, the shiny side of the fim must always go against the shoe. The dull (adhesive) side must face away from the shoe. Make sure the two rolls are aligned with each other before going to the next step. Pass the web under the idler bar near the bottom heat shoe. Use extreme care if the heat shoe is already heated up. Pul the bottom web up and drape it over the top web. When the machine is hot, the wo webs will stick to each other. If threading while coid, use tape to hold the bottom web in place.
5. With both rolls threaded and installed in their respective brackets, unwind the top and botfom supply rolls about a half-tun each. This will provide enough slack in the web to allow the feed tray to sllde on easily.

6. Slide the feed trayinto position. Position the safety shieid foward toward the heat shoe. Remember the drive will NoT engage without the feed table andthe safety shield in their proper positions.
7. Make sure there is still enough slack in the web. Close the laminating rollers with the two large knobs on the right side of the unit. With the fim draped over the two heat shoes, and melted or taped together, push one edge of the threading card between the heat shoes so that the film is firmly positioned against the laminating rollers. Make sure the rubber rollers are in the closed position. f a threading card is not available, any piece of card stock or poster board will
8. Push the forward drive switch. If the film and the card are in the nip (the point where the laminating rollers meet) the film and the threading card will start into the laminator and wil! pass through both sets of rubber rollers. When the threading card has cleared the back of the machine, press the STOP switch. CAUTioN: The laminator is designed to be run with the operator directy facing the control panel and feed tray, not at an angle or from the side of the For operator safety, the safety shield must be in position over the upper heat shoe when the machine is ON, or when the drive switch is in the forward

53Fim Threading Diagrom

2. Plcce the locded supply roll mandrel on the

tor, pleose follow lhese wo steps: manarel on the machine as shown in the

pichure. The polyester slde (usually the shiny

1. Place the fim on the supply roll mcndrel as slde) of the fim must go ogainst the hegt shown in the drawings below and to the shoe. The polyethylene side (he dull side) of night. The posltion of the supply roll tension the flim must face the operator. knob moy vory.

Right Side Vew Of Right Sde View Of

Top Supply Roll Bottom Supply Roll

Adhesive Out Adhesive Out Adhesive In Adhesive In

Shiny Side Of Pily

Dull Side Of Film

Seiny Side Of Filh

Adresivr Right Side View Of Lahinator

5-4LAMINATING

1. If the machine is not already on and warmed up. first make sure the power cord is plugged in. Turn on the machine and set the temperature for whatever fim is being used.
2. The laminator will be ready to operate in about 20 minutes. WARNING: Never permit the temperature to exceed 310* Fahrenheit while film is threaded and the laminator is not running. The flm could disintegrate and require cleaning and rethreading of the machine. When it is necessary to laminate at temperatures in excess of 3io* - such as for poster board When using 1.5 mil fiim - pull some excess film off the film supply rolls to provide slack so the film is not tight against the heat shoes while the machine is heating. This will keep the fim from melting when the laminator is not advancing fiim.
3. The laminating rollers can be kept hot when the laminator is not in production by opening both sets of rollers. Put the drive direction switch in forward and turn on the speed control to the minimum position. This allows the laminating rollers to turn and get evenly heated while the machine is warming up. Evenly heated rollers contribute to the quality of the lamination because this eliminates the

laminating rollers.

4. Position the feed guides if needed for precision feeding. You will get the best results by centering items in the web of film.
5. Check and balance the supply roll tension on both rolls. Start by loosening just begins to press on its spring. For a preliminary adjustment, put three or four turns of tension on each knob.
6. Turn the fans on using the rotary switch located next to the master power

films 3, 5 mil or thicker.

7. Once the machine has come up to temperature, you are ready to make final adjustments of the supply roll tension. With the heat ON, the rollers CLOSED, push the FORWARD button.

Watch the film as it passes over the heat shoes. If there is some waviness in the edge would be the top of the top shoe and the bottom of the bottom shoe, the edges that first contact the film. If there is no waviness in the film at all, there is

too much supply roll tension.Loosen both knobs a smal amount and check

If the waviness or wrinkling extends into the laminating rollers, tension needs to be increased. Always keep the amount of tension the same on both rolls. Waviness

8. When starting the machine to begin lamination, let at least 10 inches of fim go through the rollers before inserting the items to be laminated. This takes out slack in the film and removes the cooler strip of fim that forms just in front of the nip

areas of film with excess adhesive that may have pooled just beneath the shoes. Examine the film coming out the back of the machine. If bubbles or wrinkles appear in the film, this means there is not enough tension to draw the film tight and smooth over the heat shoes. Turn the tension control knobs clockwise to increase the tension. If the film is stretching, and gets narrower as it goes across the shoes, supply roll

that film. Film that is 1.5-mil thickness requires very little tension.

the above section on supply roll tension again and readjust the supply roll tension on both rolls. If the tension appears balanced, but you notice waves or ripples toward the center of the web of film as it comes out the back, the temperature may be too high or

called "heat wrinkies'. These heat wrinkles are formed when the film has not cooled enough before coming out the back of the machine. For the best results, the film should be cooled below melt temperature while it is pulled tight and perfectly flat between the laminating rollers and the pull rollers. If it gets out the back of the machine while still at or above melt temperature, heat wrinkles can form. The major reason for fans on a laminator is to cool the film, not to cool the

9. A unique feature of the laminator is the provision for driving both top and distribution of heat on a continuous basis to the laminating rollers prior to startup. or when laminating production is temporarily halted.
10. The laminator is designed to operate with the operator directly facing the control panels and feed tray assembly.

5.5RECOMMENDEDTEMPERATURE SETTINGS

and operating characteristics should be your flm suppliers. If you do not know the

the following table as a guide.

Film Melt Temperature Chart (All Fahrenheit)

Film Thickness

Flm Type

5-10 mll 3 mil

Monopolymer 310°-320°

Low-temp (copolymer)

Ultra-low temperature

Several important notes about this chart:

1. Your fim vendor must have the primary resp on sib lli ty for providing information about the film that you are using.
2. This chart is to serve as a general guide when better data is not available.
3. If your film vendor cannot provide this and other information about the fim you are using, it may be difficuit to achieve good results.
4. When laminating heavy posters or other thick items with 1.5 to 1.8 mil films, some additional heat may be required to get a permanent bond. Never exceed 340 degrees.
5. While offset printed materials may be laminated at the lower ends of the above ranges, inkjet and other output from digital printers may require the upper end of the range in order to get a good bond.
6. See 1-6 LAMINATING FILM for more information.

Cooling Fans. The cooling fans are used during lamination with 3-mil, 5-mil, 7-mil, and 10-mil film. The fans cool the plastic as it leaves the laminating rollers and before it enters the pull rollers. As mentioned earier, the fans prevent heat wrinkling and help insure lamination that is smooth and flat. The pul rollers on a laminator turn a litle faster than the laminating rollers, insuring that the film is perfectly flat whiie It is being cooled.

NOTE: Il is possible that variances from recommended temperature settings may

quality or thickness of the materia! being laminated.

Please note the wide range of temperatures listed, especially for heavier fims. This does not mean any film that thick can be run anywhere within the given

temperature versions of all film thickness. Some low-melt films work at lower temperatures than others do. It is important you buy your film from a vendor who can tell you the following additional information about any film you choose: ?the thickness the clarity suggested melt-temperature range polyester/polyethylene content how well the adhesive will stick to the kinds of images you'll be protecting and

Temperatures may exceed 310° when laminating poster board or other thick items with 1.5 mil film on a continuous basis, but when the machine is stopped, turn the heat off if the setting is in excess of 31o*. Never set the heat above 350? with

6-4Simultaneous Laminating and Moumting

There are several different ways to simultaneously mount and laminate. The one

laminate while mounting with a pressure-sensitive adhesive at the same time. The advantages of pressure-sensitive mounting for digital imaging applications are covered Section 5-7

mounting board with a layer of pressure-sensitive adhesive. OR you can buy board already coated with an adhesive and its release liner.

image. Peel back about 4 inches of the release liner on the edge that will be put into the laminator first (leading edge). Use that exposed adhesive to position and align your image on the board. Being careful to keep the leading edge of the image aligned and wrinkle-free, smooth it down onto the exposed adhesive. The image does not need to be trimmed to final size first, since finish trimming of board and image will be done together after

When the laminator is threaded and up to temperature, put the leading edge of the board with its image under the feed strip on the leading edge of the feed tray. The feed strip should lift easily to accommodate substrates up to 1/2 inch thick.

that film for standard laminating. The fan should be turned off.

shoes yet. Make sure the laminating rollers are closed and locked. The pull rollers should be closed but not locked. Start advancing the film. Once the film

the nip.

Hold onto the release liner. Do not let the release liner go under the safety shield.

close to the laminating nip.

Laminating both sides of the item helps save the setup time that would be wasted in preparing the machine for one-sided lamination. Other problems with one-sided lamination are detailed in section 5-7.

Another advantage of laminating both sides of foam core and some other substrates is that it minimizes the curl that those substrates are subject to over No adjustment of the laminating rollers is required. Because they are spring- loaded, they will open ap prop ni at ely for any board up to 1/2" thick. When using 1/2" thick substrates, close laminating rollers, but do not lock them. After the lamination is complete, trim the board and its now resident image to the finished dimensions. Final finishing steps may include edge grippers for hanging, many types of framing, edging with plastic U-channel, or putting a leg on the back in the case of countertop displays.

57 COLD APPLICATIONS

Cold Mounting

The Digital 42/60 is designed to be a cold laminator and mounting device as we! as a hot laminator/mounter. There are many different methods and sequences for laminating and mounting, but the most common procedure used with digital images is to first hot laminate and then cold mount. Cold adhesives adhere better and more reliably than dry mount (hot) adhesives when it comes to the various plastics, coated papers, and coated mounting boards often used in digital imaging. The Dl-42/60 can be used to apply adhesive film to mounting boards. Boards can also be purchased pre-coated with pressure-sensitive adhesive and a release

Most roils of adhesive have a single release liner. This release liner goes against way so that the liner and adhesive do not touch it. If the stop pins prevent the shoe from completely clearing the web, they may be pulled out with a pair of

This will not affect your Ledco warranty

However, it is not essential that the heat shoe be moved for this application, since it is the release liner side of the product which touches the shoe. If this work is run after a hot laminating job, the heat left in the shoes helps the adhesive to flow. It is not necessary to allow the machine to cool. Cold laminators are one-sided laminators with very few exceptions. Most hot laminators encapsulate or coat both sides. When laminating only one side, you must not allow exposed adhesive to go into the machine. Make sure the material

being coated is at least as wide as the roll of fim. Overap pieces or use sorap paper between pieces to keep adhesive off the rollers.

the open rollers. Stick the adhesive to this threading card, close the rollers, and begin to laminate. Keep feeding scrap paper so that the adhesive does not start a Wraparound on the rollers.

Adjust the unwind tension to remove any wrinkles from the material. Do not use

Begin to feed the mounting boards, butting each up against the one ahead. Cut the boards apart with a utility knife on the back end

Once your boards are coated, or if you buy them pre-coated, you are ready to mount any graphic. There are many methods for sizing and trimming, but most operators pick a board slightly bigger than the graphic and trim board and graphic together after mounting.

Peel back about two inches of the release liner on one end of the board. Use this exposed adhesive to position the laminated graphic on the board. Slide the positioned end of the board into the laminator, holding the graphic up with one hand. Pull off the release liner before it goes into the nip. Pick up the mounted item at the back of the machine. Trim away the unwanted portions of the graphic and the board at the same time.

section of this manual.

Cold Laminating

applications for several reasons:

Cold laminating does not allow true encapsulation It does not offer the same degree of permanent protection Cold flms are several times as costly as hot films Items to be laminated on two sides must be run through the machine twice, so labor is at least doubled

for protecting images printed on vinyi should be made of vinyl themselves so that the flexibiity of the vinyl substrate is not impaired. Polyester films are not recommended over vinyl because of the stiffness.

If a very flexible, conforming substrate is not required for the application, an image is better prinled on paper than on Viny. When cold laminating, the threading process is similar to that described above for mounting adhesives. One difference is that outside surface of the film goes against the top laminating roller, while the adhesive side of the fim should be facing the operator. The release liner should be taped to an empty core on the release liner takeup attachment. When laminating only one side, you must not alow exposed adhesive to go into the machine. Make sure the material being coated is at least as wide as the roll of flm. Overlap pieces or use scrap paper between pieces to keep adhesive off the

Thread the machine by putting a large piece of scrap paper or cardboard through the open rollers. Stick the adhesive to this threading card, close the rollers, and begin to laminate. Keep feeding scrap paper so that the adhesive does not start a Wraparound on the rollers.

Adjust the release line takeup tension so that the release liner is pulled away from the film just after it goes under the idler bar. Adjust the supply roll unwind tension to remove any wrinkles from the material.

them. Be careful no to allow exposed adhesive to go into the rollers to avoid

printed material (one long image or many images) can be put on the roll feed mandrel for lamination in one non-stop process. Or a roll of inexpensive "release" paper can be run under the whole process to keep exposed adhesive out of the nip while laminating a series of pieces.

For those customers who reed cold lamination exclusively, Ledco manufactures the Econocraft line of pressure-sensitive machines 25 to 50 inches wide. They can handle substrates up to 5/8" inch thick and as wide as the particular machine.

5-8PREVENTING AND SOLVING PROBLEMS Please read this section before you have a problem. PROBLEM: Wrinkling of the material as it goes into the laminating rollers. This problem usually occurs when laminating an item that has been folded, rolled, bent Or wrinkled. SOLUTIoN: Make sure the leading edge of the item being laminated is laying flat and is insented parallel to the laminating rollers.

and through the rollers to ensure an even lamination without wrinkles. Smooth from the center of the item, back toward the trailing edges. Once the item starts to feed, you may aiso pull back and to the sides on the corners of the trailing edge. If material has been rolled up, take the curl out of it on a table edge before laminating. If some curl remains, it may be helpful to insert the item with the curl down so the leading edge is pressed against the feed tray until just before the nip. PROBLEM: Wrinkling of the film around the material being laminated.

thicker material. These wrinkles will be trimmed away with the scrap, so they do not affect appearance. Because the rollers are being held apart by the paper or cardboard, they cannot pull equally on the plastic around the paper. This creates wrinkles that tend to look like the bow waves of a boat, radiating out through the clear part of the web from the sheet of material. PROBLEM: When two pieces of material are laminated side by side, the plastic adheres to one piece but not the other.

items into the laminator side by side. However, wrinkling can occur if these items are of unequal thickness, because the laminating rollers are lifted off the thinner items by the thicker items. When laminating items side by side, it is important to arrange them so that the thickness is the same. PROBLEM: Wrinkling of the plastic on a laminated piece of material. SOLUTloNs: Make sure you have enough supply roll tension to take the wrinkles out of the fim before it gets past the heat shoes. (see supply roll tension, section

Make sure the fim is threaded properly (see threading the laminator, section 5-3). The most frequent operator error is threading the film under the bottom stabilizer bar instead of under the bottom idler bar. The threaded film shouid not touch the bottom stabilizer bar. When the bottom web of film is threaded around the

stabilizer bar instead of the idler bar, the fim will tend to wrinkle and often wil not adhere. The top side of the item will not be affected. PRoBlEM: Flim gets wrapped around the pull rollers. SOLUTION: While threading the flm cold, the loose ends of the unlaminated web are particularly susceptible to "wrap-around". To minimize this, pull the threading card after it emerges from the pull rollers until the fim clears the exit table. Use caution when first starting to laminate, being careful that the thin, unlaminated web does not get caught in pull rollers or laminating rollers. If "wrap-around" does occur while the laminator is cold, you can easily correct it by reversing the direction of the rubber rolls, permitting the laminator to release the film from the rolls. PROBLEM: Film gets wrapped around the laminating rollers while the machine is

SOLUTIoN: Leaving the heat on so that the adhesive does not harden, follow the following steps. WARNING: Be very careful not to touch the heat shoes when the machine Is

MISE EN GARDE: No pas toucher Ies sabots chauffants lorsque Ta machine est chaude. ADVERTENCIA: No toque las zapatas cale factor as cuando la maquina esta

1. Remove the feed tray.
2. Cut the film on the top and bottom, just in front of the idler bars.
3. Loosen the fim from the heat shoes and grip the two loose ends, holding them
4. Turn the drive switch to the reverse position.
5. Turn on the drive at a very low speed and allow the laminator to back out the film that is wrapped around the rolls. Pull the film off the roller. WARNING: Keeping the machine in reverse may cause a reverse wrap- around if the film is not getting puled off the roller. You may need to pull on the film with a lot of force while stopping and starting the drive.

marche arriere, le film risque de s'enrouler dans I'autre sens. Appuyer par a-coups sur I'interrupteur et verifier le resultat chaque fois.

ADVERTENCIA: Apretar mucho tempo ef interruptor de marcha atras puede causar hobinado inverso. Aprietelo brevemente, luego sueitelo y observe e! resultado. Aprietelo nuevamente sl se reguierg mas marcha atras. Pare sl nota que el plastico hala hacia atras, volviendo sobre Ios rodlillos. WARNING: Do not try to cut the plastic off the roller with a knife or other sharp instrument. You will end up cutting the rubber rollers and turn an

avec une lame tranchante. Vous entailerez le caoutchouc des rouleaux, ce gui occasion ner a des frais majeurs de reparation gui ne sont pas couverts par la garantie. ADVERTENClA: No intente separar el plastico del rodillo cortando con un cuchillo u otro instrumento filoso. Terminara cortando los rodilos de goma

esta cubierta por la garantia. If this method does not work, let the machine fully coof. Remove the heat shoes and cut the wrap-around off the roller with a small pair of scissors, working the point and the cutting edges away from the rubber to avoid damaging the roller. Then clean the rollers per the instructions in section 7-4.

PRoBlEM: Not noticing that the rolls of film are almost used up (one roll of film always runs out before the other.)

an opposing film, the adhesive exposed to the rubber rollers will stick to the

Wraparound is difficult to clear because the film adheres to the roller and to itself for the entire length of the accumulated film on the roller. It's best to clear this right away, before the adhesive hardens. Follow the steps above to clear. MISE EN GARDE: S'il n'y a gu'un film dans la machine, le cote adhesif, gui se trouvera contre le rouleau de plastification, y adherera, ce qui provoquera un enroulement "monstre: tres difficile a defaire puisque le film adhere d'abord au rouleau, puis a lui-meme a mesure qu'il s'enroule. Il faut agir rapidement avant que la colle durcisse. Proceder de la facon indiquee ci- dessus pour regler le probleme. ADVERTENClA: Si el plastico de uno de los rollos de a baste cimi en to pasa por el plastificador sin ser igualado por una pelicula de plastico del rollo opuesto, el adhesivo expuesto a los rodillos de goma adherira a los rodillos

dificil de deshacer porque el plastico adhiere tanto al rodillo como a si mismo, a lo largo de toda la longituh de la pelicula de plastico acumulada

sobre el rodillo. Es mejor deshacerlo in media ta men te, antes oe que endurezca el adhesivo. Siga los pasos indicados mas arriba para lograrlo. SOLUTloN: To avoid this problem, stop the laminator before either roll runs out, cut the webs of film, and remove the two near-empty rolls of film and then rethread new rolls. When putting film on a laminator, always use two rolls of matched length and width. Experienced users may leave the pieces of film remaining over the shoes and in the rollers to help thread the new film. When the machine is warm, the ends of the new rolls can be easily tacked to the already threaded pieces because the adhesive layer facing outwards will be sticky. Be careful not to burn yourself on the heat shoes. PROBLEM: Fim is not properly adhered or starts to come off sometime after

SOLUTIoN: Unless there is something wrong with the film, this problem comes from fim being run at too low a temperature. Check the heat setting on the laminator. (see recommended temperature setings, section 5-5). If the film is not sticking to the item, it is likely that more heat is required. If you are using 1.5 mil film, this problem can occur if you are running the machine too slowiy. Because 1.5 mil film is thin and therefore loses heat easily, it can cool off too much between the heat shoes and the roller nip if it is run too slowly. If you are running thicker films, you may have the problem if you try to go too fast. In this case, the thicker film may not have enough time on the heat shoes to reach

When laminating posters or other thicker material with 1.5 mil film, the paper itself can absorb enough of the heat from the film to drop the adhesive below its melt temperature. The film may start to come off immediately or it may start to fall off

About 320° to 340 *F will usually do the job. Sometimes you may see film detach from an item along one edge (the edge that was put in first). This happens when the material is put all the way into the nip before the machine is started. The area of film between the shoes and the nip can cool off too much while the machine is idle. The adhesive may not be hot enough to stick. The way to prevent this is to let a few inches of film go though before putting in edge of the piece will be properly sealed. lt gives the machine a chance to take up the slack that develops in the film whenever the machine is stopped, and it prevents the following problem as well:

PRoBLEM: A laminated item comes out with a large "oily' spot on or near the leading edge. SOLUTioN: It's not oil that causes this effect, but excess adhesive. When a machine is left heated but idle for a few minutes or longer, the adhesive from the filim over the shoes can form droplets if material is put in immediately. This excess adhesive saturates an area of paper, creating what looks like an oily spot. The solution, as mentioned above, is just to let a few inches of film go through before feeding in your work. Anytime you are laminating unfamiliar or costly items, it is a good idea to start with indication of the results you'll get and also takes care of any pooled adhesive. PROBLEM: A milky, hazy line about an inch wide appears periodicaly across the

SOLuTloN: The rollers are not evenly heated, and the cold side of the rollers is preventing the adhesive from melting. When warming up the machine, keep the rollers open and keep the forward drive on at low speed. The machine produces a continuous squealing noise when

Problem:

it is pulled over the heat shoes under tension. This noise is produced via the same principles that make a violin squeal. Some of the compounds put on flm to keep it from sticking to itself seem to act like resin on the bow of the violin -- they enhance the noise. To minimize squealing, run the laminator with the least amount of supply roll tension that will do the job of removing wrinkles from the web of film. Make sure periodically (see section 7-3). If the noise gets really objectionable, use a different type or different brand of film. PROBLEM: The laminated material seems to have a pitted surface or irregular surface that does not match the texture of the paper being coated. SOLUTlON: This is usually caused by adhesive build-up or dirt on the rubber paper. Inspect the rubber rollers and if they need cleaning refer to section 7-4.

also cause irregularities in the surface of the film. The pull rollers are identical to the laminating rollers and could be substituted if still in good condition.

in the (aminating trade). SOLUTioN: Reduce the heat and/or the supply roll tension. The film is not shrinking so much as it is being stretched by excess heat and tension, causing the web to get narrower as it is pulled over the shoes.

PROBLEM: No power is getting to the laminator.

inside the laminator, but dead outlets and loose power cord connections are the most common causes of this problem. PROBLEM: Wavy or rippled sections in the laminate, especially toward the center of the web.

speed for the fim being used. Slow down the motor and/or use a lower appropriate temperature for that particular film. PROBLEM: General haziness or cloudiness in the flm after lamination.

That cloudiness is a function of

SoLumloN: Increase the temperature.1

incomplete adhesion. On a variable speed machine toaded with thicker film, it

heat shoes.

of an item. SOLUTIoN: This problem can be caused by excessive laminating roll pressure. Putting too much pressure on the laminating rollers actually decreases pressure in the center of the web. The other likely cause of this symptom is worn rollers. For example, if hundreds of thousands of 18-inch wide sheets are laminated on a 38-inch machine, the center of the rollers can get worn down more than the ends of the rollers. In this situation, the laminating rollers should be replaced. The rollers worn in this way are not suitable for use as pull rollers. For problems not listed here, contact your Ledco Dealer. If the Dealer doesn't know the answer, please ask the dealer to contact Ledco and get back to you. You are also welcome to contact us directly with any problem at 585-367-2392. Because of the potential volume of support cails, we do encourage the use of the dealer network as much as possible.

6-1INSTRUCTIONSFOR OPTIONS

6-? RELEASE LINER TAKE-UP

This mechanism provides for the use of cold (pressure sensitive adhesive or PSA) laminating films that require removal of a release liner during application.

1. Place the release liner takeup on the top of the machine so that the motor is on the right side. Plug into a 110 outlet.

3. Load the PSA film onto the top supply roll mandrel. Center the core of film.

4. Feed the film, adhesive and liner side up, over the first idler bar and under the

pieces of tape.

Wide as the film.

6. Attach the release liner with tape to the empty core now on the release liner take-up. Roll the liner unto the core until it is taut.

6. Place the drive switch into the forward position and increase the speed control

the tension as the liner goes through the machine. The film and the liner machine to ensure that the scrap paper and the film are exiting correctly. If a "wrap around" condition exists, simply switch the drive into reverse and press

the drive into forward and assist the leading edge of fim/paper to exit the

Scrap liner wound onto disposable core Scrap liner under tension Separation point Pressure sensitive web (adhesive exposed out) Optional underlay ment paper web Right side view of laminator Digital 42 with release liner take up

6-3 ROLL FEED

When laminating very long items such as banners it is just about impossible to feed it in perfectly straight by hand. With the roll feed mandrel, laminating the longest item becomes relatively easy. The roll feed mandrel is especially helpfu!

To laminate with the roll feed:

1. Roll up the item on an empty laminating fim roll core making sure it's not telescoped. This insures it is rolled up perfectly straight.

up or not, since both sides of the item will get the same lamination. Adjust for moderate amounts of unwind tension with the tension knob.

3. Feed the leading edge of the item under the feed assembly idler bar into the nip rollers just as if you were feeding an individual sheet. If you have enough point. This makes it easier to feed the item in without wrinkling. An optional technique is to feed a sheet of scrap paper into the nip as a leader. Stop the leader when there is about two or three inches remaining outside the safety shield. Place the banner edge on the edge of the leader and tape it securely. Then stant to laminate.

64ThermoGlide 42y When warming up the ThermoGlide unit, keep the rollers closed and barely creeping. This will run off 8'-10" of film but it is highly advantageous to evenly warm the idlers. This will help to eliminate potential film waste from unevenly heated idlers. When running a ThermoGlide machine set the ThermoGlide temperature 40*-50° hotter than the bottom heat shoe. Upon initial start and warm up, a good deal of temperature overshooting is to be expected. A twenty minute time frame will help stabilize the heating process and thoroughly heat the rubber rollers and/or ThermoGlide heat shoe assembly.

71MAINTENANCE DANGER: Always use extreme caution when performing maintenance on

No power to the machine when working on or cleaning any part of the unit. Use extreme caution to avoid Hot Surfaces, which may remain hot for a period of time even if there is No PoWER to your machine.

Use extreme caution to avoid pinch points at the nip of rubber rollers. NEVER have rubber rollers turning while performing maintenance to your

NEVER wear loose clothing, ties or jewelry (which may become entangled in gears or rubber rollers) while performing maintenance on your machine.

S'assurer que le cordon d'alimentation est debranche et que la machine est mise hors tension avant de toucher a des pleces internes.

Prendre garde aux surfaces chaudes. Ces surfaces demeurent chaudes longtemps apres que le courant a ete coupe. Tenir les doigts et les objets loin des roulequx de caoutchouc. Ne jamais faire tourner les rouleaux pendant I'entretien de la machine. Ne jamais porter de vetements amples, de cravate ou de bijoux, etc. (ces articles peuvent etra happes par les engrenages ou les roulequx de caoutchouc). ADVERTENClA: sea extremadamente cuidadoso siempre que realice tareas de manten i mien to en su maquina.

energia aplicada a la misma mientras este trabajando con partes internas de la

Sea extremadamente cuidadoso en evitar super if ici es callentes, que pueden permanecer calientes curante clerto tiempo, aun despues de astar cortada la

rodillos de goma. Nunca tenga los rodillos de goma en movimiento mientras realiza trabajos de manten i mien to en su maguina.

sefeue/bua Jod sepedeyle Jes uapnad anb) se/of o eleqjos 'eyans edo/ elsin eounN 0 rodilos de goma) mientras esta realizando trabajos de manten i mien to en la

7.2 GENERAL CLEANING Cleaning the laminator daily or weekly will help prevent dirt or adhesive build-up on the rubber rollers and heat shoes and will improve the performance of the unit. 7 -3 CLEANING THE HEAT SHOES During normal use, excess adhesive from the fim will often cling to the heat

shoes, and will tend to increase friction between the film and the shoes. This type of build-up may not be visible, and it may adversely affect lamination in a number

symptom of this problem. Some films naturally tend to squeal, with or without coating powder build-up, but cleaning the shoes usually helps reduce squealing and heips prevent more serious problems. To clean the shoes, heat the machine to full laminating temperature to soften the

clean, soft, dry cloth, gently rub the adhesive or other contaminants off the shoes. Never use any abrasive material or rub too hard on the shoes, because you may remove the Teflon coating.

You may dampen your cleaning cloth with soapy water or a mild water-based cleaning solution, but make sure you carefully insulate your hands from possible steam burns if you do this. The steam formed when water hits the hot surface can penetrate both the cleaning cloth and your gloves. 7 .4 CLEANING THE RUBBER ROLLERS Both the laminating rollers and the pull rollers need regular cleaning. Collectively

To clean the laminating rollers:

1. Remove the film from the laminator and allow the machine to heat up with the rollers open and turning slowly. By getting the laminating rolers hot, it will be easier to remove any adhesive buit-up on the rollers.
2. Turn off the master power switch and unplug the machine.
3. Using a potholder or oven glove, lift the top heat shoe up and back and then lower it onto the stop pins or the top of the pull roll cover (if the pins have been

Loosen the two bolts that hold up the bottom heat shoe and lower the bottom

if the heat shoes were in the way.

WARNING: Never clean the rollers while they are turning. While turning, the

cleaning materials and damage the laminator. Unplug the power cord while cleaning the rollers or performing other maintenance on the machine. Turn the rollers by hand.

MISE EN GARGE: Ne jamais nettoyer les rouleaux pendant qu'ils tournent afin d'eviter de se blesser et d'empecher que le produit de nettoyage

Debrancher le cordon

n'endommage I'interieur de la machine. d'alimentation avant le nettoyage ou tout autre travail d'entretien. Nettoyer d'abord la partie apparente des rouleaux, puis, a' I'aide de la commande de marche arriere, les faire tourner de facon a pouvoir en nettoyer toute la

AVERTENcIA: Nunca limpie los rodillos de goma mientras esten girando. Al estar girando, los rodillos pueden atrapar sus dedos y lastimarlos, 0 pueden atrapar sus articulos para limpieza y danar el plastificador. Desenchufe el cord6n electrico mientras esta limpiando los rodillos, o realizando otras tareas de manten i mien to en la maquina. Gire los rodillos por mano.

Clean the rubber rollers with a mildly abrasive cleaning pad such as a white section of your grocery store (the green pads are too abrasive). Use "CoOL CLEAN" to clean the rollers (available through your local LEDcO dealer). Rub

firmly but do not scrub the rollers vigorously as this might mar the suface. Do not use sharp metal objects or steel wooi as these will also mar the rollers.

and tum the rollers by hand. Be sure to reposition and secure the upper heat shoe before beginning to laminate.

7.5LUBRICATION

Drive Chaln Drive chain and sprockets on all models should receive a light coat