Table of content

General information Overview Warning symbols/safety instructions Installation & assembly Emergency Stop Switch Delivery inspection Transport Wire Locks Air connection Controls Dismounting of the roller gantry Lifting Instructions Operation and application Maintenance and adjustments Troubleshooting Repairs

page 4-5

page 10-11 page 11-12

Congratulations!

You have invested in a Rollover Flatbed Applicator enabling you to do various applications very efficiently and with excellent quality, as well as serving as a very versatile work station. Rollover Flatbed Applicators are very easy to operate and maintain, but you should still take the time to read through this manual carefully. By doing this, you can exploit your Rollover in the optimal way and at the same time you will reduce the possibility for operator- or machine damages. Please also check out www.rollover.no including our YouTube Channel revealing numerous videos on the use of the machine.

General information

The Rollover Flatbed Applicator is built for application of printed vinyl, application tape, laminates and all types of self-adhesive film (i.e. plotter text and digital print) on all types of flat substrates i.e. metal, plastic, glass, foam boards, banners etc. Rollover is designed for dry application of media and produces a result completely free of bubbles and creases. The machine’s main structure includes an illuminated glass bed comprising operation details and an antistatic rubber roller with pneumatic pressure manually activated over the work surface.

Overview

A: Back-lit glass bed B: Activation switch C: Handle for sideways movements D: Rubber Roller E: Reversible brackets/spindle for media F: Tool pocket

Warning symbols

Before you start using your Rollover Flatbed Applicator you should read this manual carefully. This will give you the opportunity to handle the machine in the best possible way so you can avoid damages both to the machine and operator.

See the manual

Contact a technician

Risk of crushing between roller and glass bed

Safety

The pneumatic pressure of the roller against the table may cause crush injury. It is vital to be aware of this when operating the Rollover, especially if there is more than one person involved in the process.

Personal safety equipment

Specific personal safety equipment is not required for normal use of the Rollover.

Testing, control and use of safety functions.

During installation, service and maintenance, the safety functions must be tested. This includes functions such as emergency stop, power failure and loss of pressure. When trigging the emergency stop switch and in the occurrence of power failure, the roller will automatically raise. If the pneumatic pressure lapses, the roll will lower slowly and stop about 3 mm over the working surface. In this situation there is no crushing hazard.

Location of the emergency stop switch:

The emergency stop button is located at the short end of the machine. When the switch is pressed in, the roller will raise immediately.

Other risks

Certain risks cannot be eliminated through technical safety measures alone. There is a risk of crushing and catching when the roller is pneumatically pressed against the flat bed. A warning symbol is displayed on or immediately beside the roller. There is a risk of severe crushing and catching when the roller is pneumatically pressed against the supporting bars. Never pressure-set the roller without first ensuring that the sign material is positioned correctly underneath the roller.

Unauthorized use

The machine must only be used for its intended purpose as specified in this manual. All other use may result in damage or injury, and is at the user’s own risk.

Installation & assembly

Rollover Flatbed Applicator should be assembled and used at normal room temperature with normal humidity levels. This minimizes the occurrence of static electricity. Detailed instructions for mounting of the roller/roller sliding arms is found in this binder.

Lifting instructions

The Rollover must be lifted with a forklift fitted with long forks. The forks must have a minimum length of 7’, and a min. lifting capacity of 1000 kg. Upon arrival in the wooden crate, the pallet itself is the reinforced lifting base, and the lifting positions are well marked. Once on the ground, unscrew the top grid, remove with the forklift and loosen the machine from the pallet by removing the screws holding each leg. When lifting the unit off the pallet for further transport or disassembly, the forks must be positioned as indicated by the yellow stickers found on each of the long sides. It is very important that the roller is close to the lifting point as well as fixed preventing it from sliding which potentially can alter the point of gravity.

The following elements are included when the machine is delivered;

• Rollover Flatbed Applicator
• Cutting mat
• 2 spindles for holding media
• 2 reversible brackets for attaching the spindles on the housings/machine ends
• User Manual/instruction for dismounting/mounting of the roller gantry
• Power cord

These transport wire locks prevent the roller gantry from moving during transport. They are located on each side of the Applicator and clearly marked with labels as shown above. Unscrew (Torx T30) and remove both locks before attempting to move the roller gantry over the glass bed.

Air connection

Compressed Air is supplied through the quick-connector/gauge located at the short end of the Applicator – this is where you also will find the CE-label, switches & controls – see above picture. During operation: recommended 6 – 6,5 bar air pressure, filtered and moisture free air – max pressure 8 bar. The quick connector fixed to the gauge fits an air hose w/clamp coming from the compressor. If needed, the connector can be unscrewed from the gauge to connect with a standard ¼’’ threaded connector of your preference.

Power connection

230V AC 50Hz/120V AC 60Hz or adapted to the local standard

Power plug may only be connected to sockets with 230V AC/120V AC. All other interventions to the electrical system may only be performed by authorized staff. For markets with deviating voltage, the applicator will be adapted to local standard.

Access to internal air- and electrical connections

All internal connections for air and electricity is placed behind the cover at the short end of the table. To access these, loosen the upper two screws and flip the cover outwards. It will stop in a horizontal position, allowing for inspection or repair.

Controls:

Shown in the picture from the left hand side: Main switch, resettable fuse, power inlet, light switch, reset switch (if emergency stop has been activated), emergency stop.

Behind the cover:

Main switch, fuse, power inlet, light switch, emergency stop, printed circuit board.

Flooring

Rollover Graphic Applicators must be placed on a flat, moisture-free and vibration free surface.

Dismounting/mounting of the roller gantry

1. Disconnect the quick-connector for the electrical wires (A) and air tubes (B) underneath the sliding arms on each side of the machine
2. Unscrew the 4 bolts (C)on both sides
3. Lift and place the roller gantry carefully on the floor (requires one person on each side)

Rubber Roller

Attention: To avoid any ‘’flattening’’ of the rubber roller, it is important that the roller is not resting directly on the glass bed for a longer periode of time, i.e. vacations etc. Put a piece of wood or similar underneath the steel roller shaft at each housing to prevent the roller from resting directly on the work surface. If the rubber roller should be deformed, it will normally return to its circular shape after some time, but the best thing is to prevent this from happening. The roller is made from Industrial quality rubber mixed with antistatic fiber, and extremely durable. In case of damages to the roller, please contact your Rollover dealer.

Operation

Operating the Rollover does not require any specific skills of the operator. The operation is performed as described in this manual. Please note: The PVC-cutting mat can be somewhat “uneven” and the surface might after some use be worn out – this can affect the quality of applications negatively. In such cases, application can be done directly on the glass bed until the mat has been replaced. Remember to use only stainless-steel blades if cutting directly on the glass.

Application of self-adhesive vinyl and laminate

1. For application on thicker materials, i.e. sheets which are raising from the glass bed, the substrate is best placed centered on the bed. If the sheet is placed on one side, counterbalance must be achieved by placing material having the same thickness at the opposite side, enabling the roller to hit evenly when lowered onto the substrate.
2. For application on a hollow or box-shaped subject, i.e. road sign or a box lid, a support piece of polystyrene or similar must be placed inside the hollow enabling the subject to resist the pressure from the roller. Please remember to position centered on the tabletop or provide the same build-up on both sides.

• *The thickness of the material can max. be the same as the gap between roller and table top (60mm).

The pressure from the roller when applying will remain unaffected by the thickness of the material within this range.

3. Place the media onto the substrate exactly in the position where you want it to be applied.

4. Lower the roller about a foot or so from one end of the substrate by pressing the activation switch at the end of the handle. This will lock the media in the chosen position.

5. Flip the short end of the media over the roller and remove the back paper

7. Cut off or fold the back paper, leaving about 5 – 6 inches innermost against the roller.

8. If cut, fold a couple of inches of the back paper downwards towards the roller forming a straight fold.

9. Bring the roller over the substrate applying the media in the correct position. When applying on thicker substrates, place a piece of similar thickness against the end preventing the roller to fall off the edge and slam against the glass bed. Please pay attention to keeping the media straight over the roller as you go.

10. Lift and place the roller where the back paper is cut off.

11. Turn the remaining part of the media over the roller.

12. Grab the back paper that you folded earlier, pull it upwards over the roller and hold while moving the roller over the remaining part of the substrate. Please pay attention to holding the media in the center as well as straight over the roller as you go.
13. Please have a look at the videos found on www.rollover.no to have a visual impression of the applications.

How to mount application tape

1. Attach the brackets/spindle to the housing as seen below, and place the roll of application tape (with the glued side facing away from the roller) resting between the roller and the spindle. Fold and glue an inch or so at the end of the tape to avoid it from sticking to the roller or spindle.
2. Grab and pull the application tape, bringing it under the roller with the glued side facing downwards.

Tighten/straighten the tape properly and see to that there are no wrinkles.

3. Lower the roller 2 – 3’’ from the end of the material as a starting point making the application tape stick to the table.
4. Pull the roller across the entire surface of weeded vinyl while applying the tape, then bring the roller to the upper position and cut the application tape with a sharp cutter.

Maintenance and adjustments.

Adjust speed and parallelism - up/down motion of the roller.

Elevation speed of the roller can be adjusted individually on each side of the housings:

1. Use the adjustment screws (Marked A and B in the picture below) to adjust parallel lifting and lowering of the roller on each side. You can use a standard flat screwdriver.
2. Use the same adjustment screws to either increase or reduce the speed of lifting/lowering the roller.

Turn the upper adjustment screws (A) clockwise to reduce speed when lifting the roller. Turn the adjustment screws anti-clockwise to increase speed when lifting the roller.

3. Turn the lower adjustment screws (B) clockwise to reduce speed when lowering the roller. Turn the adjustment screw anti-clockwise to increase speed when lowering the roller.

Daily maintenance

Make sure that the rubber roller is not damaged and has no objects stuck to it. Check the emergency stop function and reset switch. Wipe any dust and make sure that the working surface is clean from particles that can damage the roller or reduce the quality of applications.

Keep the aluminum profile guiding the supporting bearings of the sliding

arms clean!

Once a week:

• Wipe any dust/dirt off the aluminum profiles on each side where the support bearings of the sliding arms run.

Once a month:

• Your Rollover is connected to a compressor. See the maintenance manual for the compressor. It is important that condensation water is emptied as well as using a dryer filter to avoid any humidity in the pneumatic system of the machine, as this can cause corrosion and potential damage.

When necessary:

• Check that there are no damages to the rubber roller.
• Check the surface of the self-healing cutting mat – if worn out and in need of a replacement mat please contact your local dealer or mail us on: rollover@rollover.no

Troubleshooting

The roller will not move up and down:

Reset the emergency stop function Check the air flow Check the power connection Reset the fuse Check that the main switch is in the correct position If this does not help, contact a technician from your local dealer.

The roller runs unevenly over the bed:

Check the parallelism of the roller across the table with the roller in the upper position. This is done by measuring the distance between the roller shaft and the steel edge of the machine. If the distance is not equal on both sides, contact a technician.

Dark areas in the glass bed:

Inspect the underside of the table to check if one or more of the LED-strips are not working. Contact Rollover at rollover@rollover.no or a technician from your local dealer to replace defect LED’s.

Repairs in general:

Contact a technician via the dealer where you purchased your Rollover.

Notice!

The machine must only be used for its intended purpose as specified in this manual. All other use may result in damage or injury, and is at the user’s own risk and liability.

Rollover Flatbed Applicators are made by:

Ramstadløkka 3 N – 1850 Mysen Norway

Mail: Rollover@Rollover.no www.rollover.no Phone: +47 69898888