GBC 44DT User manual

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GBC 44DT Laminator
Installation &
Operation Manual

44DT Laminator
INSTALLATION &
OPERATION MANUAL
Document Number: 930-122 REV: - REV DATE: 11-24-04
Do not duplicate without written permission.

Page i
Operating Instructions 44DT
1. Safety
Warnings .................................................................1-1
General ....................................................................1-1
Electrical ..................................................................1-2
2. Warranty
Limited 90-Day Warranty ...........................................1
3. Specifications
FCC Note ................................................................ 3-2
4. Installation
Prior to Installation ................................................. 4-1
Installation .............................................................. 4-1
5. Feature Guide
Top Film Supply Shaft ............................................ 5-1
Release Liner Take-up .......................................... 5-1
Idler Bar .................................................................. 5-1
Heat Pressure Rollers ............................................ 5-1
Nip Point ................................................................ 5-1
Safety Shield .......................................................... 5-1
Feed Table .............................................................. 5-2
Table Interlock Latch ......................................... 5-2
Bottom Film Supply Shaft ................................ 5-2
Film Web ................................................................ 5-2
Core Adaptors .................................................. 5-2
Roller Pressure Handle ......................................... 5-2
Film and Take-up Tension Adjustment Knobs ... 5-3
Control Panel ..................................................... 5-3
Display .......................................................... 5-3
Functions ....................................................... 5-3
Pull Rollers ......................................................... 5-4
Circuit Breaker ................................................... 5-4
6. Operation
General Operation .................................................. 6-1
Standby Mode ........................................................ 6-2
Loading Film ........................................................... 6-2
Removing and Installing the Safety Shield ........ 6-3
Removing and Installing the Feed Table ........... 6-4
Loading Film Onto the Supply Shafts ................ 6-4
Thermal and AccuShield™ Films Configuration 6-6
Configuration for PSA Films .............................. 6-7
Loading Film with a Threading Card ................. 6-8
Webbing Thermal Films ................................. 6-8
Webbing AccuShield Films ........................... 6-9
Webbing PSA Films ......................................6-10
Tacking New Film to Existing Film ....................6-12
Decaling in Two Passes With PSA Film ................6-13
Tips For Threading Pressure Sensitive Adhesive
(PSA) Film .........................................................6-14
Mounting ...............................................................6-14
Pre-Treating Boards ..........................................6-14
Mounting Only ..................................................6-14
Film Alignment and Tension ..................................6-15
Film Alignment ..................................................6-15
Film Tension ......................................................6-15
Testing the Web ............................................6-15
Clearing a Film Jam (Wrap-up) .............................6-16
Lamination Guide .................................................6-16
7. Operator Maintenance
Caring for the 44DT Laminator ...............................7-1
Cleaning The Rollers ...........................................7-1
Troubleshooting ......................................................7-2
TABLE OF CONTENTS

Operating Instructions
Page ii
44DT

Page 1-1
Operating Instructions 44DT
Your safety, as well as the safety of others is
important. Before you install or use the machine,
read and follow all the safety notices carefully in
this chapter. In this instruction manual, and on the
laminator, you will find important safety notices
regarding the laminator. Read all of the instructions
and save these instructions for further use.
The safety alert symbol precedes each
safety notice in this manual. The symbol indicates a
potential personal safety hazard to you or others, as
well as laminator or property damage.
This safety alert symbol indicates a potential
electrical shock. It warns you to not open the
laminator and expose yourself to hazardous voltage.
The following warnings are found on the 44DT
laminator.
This safety notice means that you could be seriously
hurt or killed if you open the laminator and expose
yourself to hazardous voltage.
This safety notice means that you could be burned
and your fingers and hands could be trapped and
crushed in the hot rollers. Clothing, jewelry and long
hair could be caught in the rollers and pull you into
them.
This safety notice means that your fingers and
hands could be trapped and crushed in the rollers.
Clothing, jewelry and long hair could be caught in the
rollers and pull you into them
WARNINGS
Do not attempt to service or repair the
laminator.
Do not connect the laminator to an electrical
supply or attempt to operate the laminator
until you have completely read these
instructions. Maintain these instructions in a
convenient location for future reference.
To guard against injury, the following safety
precautions must be observed when installing
and using the laminator.
Failure to observe these warnings could result in
severe bodily damage or death.
GENERAL
Keep hands, long hair, loose clothing, and
articles such as necklaces or ties, away from
the front of the heat and pull rollers to avoid
entanglement and entrapment
The heat rollers can reach temperatures of
over 300 °F (166.7 °C). Avoid contact with the
heat rollers during operation or shortly after
power has been removed from the laminator.
Do not use the laminator for other than its
intended purpose.
Do not place the laminator on an unstable
cart, stand or table. An unstable surface may
cause the laminator to fall resulting in serious
bodily injury. Avoid quick stops, excessive
force and uneven floor surfaces when moving
the laminator on a cart or stand.
Do not defeat or remove electrical and
mechanical safety equipment such as
interlocks, shields and guards.
•
•
•
•
•
•
•
•
1. SAFETY
ADVERTENCIA
!
Riesgo de choque
eléctrico
No abra:
Adentro no hay
piezas reparables
por el usuario.
Mantenimiento
solamente por
personal calificado.
ATTENTION
!
Risque de
secousse
électrique.
Ne pas ouvrir:
Pas de pièces
réparables par
l'utilisateur.
Entretien
seulement par
personnel qualifié.
WARNING
!
Electrical shock
hazard.
Do not open.
No user
serviceable
parts inside.
Refer servicing to
qualified service
personnel.
ADVERTENCIA
!ATTENTION
!CAUTION
!
RODILLOS
CALIENTES.
PUNTO DE
PINCHAMIENTO.
Mantener manos y
ropa a distancia.
ROULEAUX
CHAUDS.
POINT DE
PINCEMENT.
Tenir mains et
vêtements à l'écart.
HOT ROLLS.
PINCH POINT.
Keep hands and
clothing away.
CAUTION ATTENTION CUIDADO
PUNTO DE
PINCHAMIENTO
Keep hands and
fingers away.
Mantener manos y
dedos a distancia.
Tenir mains et
doigts a l'écart.
PINCH POIN
T
between rollers.
POINT DE
PINCEMENT
entre les rouleaux.
entre rodillos.

Operating Instructions
Page 1-2
44DT
Do not insert objects unsuitable for lamination
or expose the equipment to liquids.
ELECTRICAL
The laminator should be connected only to a source
of power as indicated in these instructions and on
the serial plate located on the rear of the laminator.
Contact an electrician should the attachment
plug provided with the laminator not match the
receptacles at your location.
WARNING: Do not attempt to service or repair
the laminator. Failure to observe this warning could
result severe personal injury or death.
Disconnect the plug from the receptacle and contact
your dealer/distributor when one or more of the
following has occurred.
The power supply cord or attachment plug is
damaged.
Liquid has been spilled into the laminator.
The laminator is malfunctioning after being
mishandled.
The laminator does not operate as described
in these instructions.
CAUTION: The receptacle must be located
near the equipment and easily accessible.
Disconnect the attachment plug from the receptacle
to which it is connected and keep the power supply
cord in your possession while moving the laminator.
•
•
•
•
•

Page 1
Operating Instructions 44DT
LIMITED 90-DAY WARRANTY
The Manufacturer warrants to the original purchaser
for a period of ninety days on labor and one year on
parts after installation that this laminator is free from
defects in workmanship and material under normal
use and service. The Manufacturer’s obligation
under this limited warranty is limited to replacement
or repair, at the Manufacturer’s option, of any part
found defective by the Manufacturer without charge
for material or labor.
THIS LIMITED WARRANTY IS IN LIEU OF ALL
OTHER WARRANTIES EXPRESSED OR IMPLIED.
WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE ARE
EXPRESSLY EXCLUDED. ANY REPRESENTATIONS
OR PROMISES INCONSISTENT WITH, OR IN
ADDITION TO, THIS LIMITED WARRANTY ARE
UNAUTHORIZED AND SHALL NOT BE BINDING
UPON THE MANUFACTURER. IN NO EVENT
SHALL THE MANUFACTURER BE LIABLE FOR
ANY SPECIAL, INCIDENTAL, OR CONSEQUENTIAL
DAMAGES, WHETHER OR NOT FORESEEABLE.
This limited warranty shall be void if the laminator
has been misused; mishandled; damaged by
negligence, by accident, during shipment, or
due to exposure to extreme conditions; repaired,
altered, moved, or installed by anyone other than
the Manufacturer or its authorized agents; or if
incompatible film was used. The Manufacturer’s
obligation under this limited warranty does not
include routine maintenance, cleaning, adjustment,
normal cosmetic or mechanical wear, or freight
charges.
Without limiting the generality of the previous
paragraph, the Manufacturer’s obligation under this
limited warranty does not include:
Damage to the rollers caused by knives, razors,
or other sharp tools; by any foreign objects
falling into the working area of the laminator;
or by cleaning the laminator with solutions or
materials that harm its surfaces;
Damage caused by adhesives; nor
Damage caused by lifting, tilting or attempting to
position the laminator.
1.
2.
3.
2. WARRANTY

Operating Instructions
Page 2
44DT

Page 3-1
Operating Instructions 44DT
Operating Speed
Variable
Fixed – Safety shield removed
•
•
2.5 to 10 fpm (0.8 to 3 mpm)
3 fpm (0.9 mpm)
Dimensions
Width
Height
Depth
Weight
•
•
•
•
55 in (137 cm)
22 in (56 cm)
22 in (56 cm)
222 lbs. (100 kg)
Electrical Requirements
Voltage
Current
Power
U.S. Receptacle
•
•
•
•
220 V 60 Hz
12.5 Amps
2800 W
NEMA 6-15R
Heat Capacity
Max. temperature
Warm up from ambient
•
•
300 °F (167 °C)
10 Minutes to 220 °F (122 °C)
3. SPECIFICATIONS
Fig. 3-1. 44DT Dimensions Shown in Inches (cm).
55 (137)
22 (56)
22 (56)

Operating Instructions
Page 3-2
44DT
FCC NOTE
This equipment has been tested and found to comply
with the limits for a Class A digital device, pursuant
to part 15 of the FCC Rules. These limits are
designed to provide reasonable protection against
harmful interference when the equipment is operated
in a commercial environment. This equipment
generates, uses, and can radiate radio frequency
energy and, if not installed and used in accordance
with the instruction manual, may cause harmful
interference to radio communications. Operation of
this equipment in a residential area is likely to cause
harmful interference in which case the user will be
required to correct the interference at his/her own
expense.
Changes or modifications not expressly approved by
the manufacturer could void the user’s authority to
operate the equipment.
This Class A digital apparatus complies with
Canadian ICES-003.
(Cet appareil numérique de las Classe A est
conforme a la norme NMB-003 du Canada.

Page 4-1
Operating Instructions 44DT
This chapter describes how to install the machine.
There are no operator serviceable parts to the
machine other than periodic cleaning. Refer to the
Operator Maintenance chapter.
WARNING: Do not attempt to service or repair
the laminator. Failure to observe this warning could
result severe personal injury or death.
Disconnect the plug from the receptacle and contact
your dealer/distributor when one or more of the
following has occurred.
The power supply cord or attachment plug is
damaged.
Liquid has been spilled into the laminator.
The laminator is malfunctioning after being
mishandled.
The laminator does not operate as described
in these instructions.
PRIOR TO INSTALLATION
Inspect the package for damage. Shipping damage
should be brought to the immediate attention of the
delivering carrier.
•
•
•
•
INSTALLATION
To set up the laminator for the first time:
Place the laminator on a stable flat surface
capable of supporting the weight of the machine
and any materials. The surface should be at least
30 inches (0.76 m) high to assure comfortable
positioning during operation. All four rubber
support feet should be positioned completely on
the supporting surface. The supporting surface
may also be large enough to hold the material to
be laminated.
The laminator should be located so that exiting
film drops freely to the floor or to a table that
is lower than the exit point of the laminator.
Accumulation of laminate immediately behind the
laminator as it exits the equipment may cause
the film to wrap around the rollers, jamming the
machine.
Avoid locating the laminator near sources of heat
or cold. The laminator should not be in the direct
path of forced heated or cooled air.
Connect the attachment plug provided with the
laminator to a suitably grounded outlet only.
Avoid connecting other equipment to the
same branch circuit to which the laminator
is connected, as this may result in nuisance
tripping of circuit breakers or blowing fuses.
1.
2.
3.
4.
4. INSTALLATION

Operating Instructions
Page 4-2
44DT

Page 5-1
Operating Instructions 44DT
TOP FILM SUPPLY SHAFT
Holds the film supply on the laminator.
RELEASE LINER TAKE-UP
Rewinds the release liner of pressure sensitive films
and AccuShield™.
IDLER BAR
(Not shown.) The idler bar directs the top supply film
to the heat pressure roller.
HEAT PRESSURE ROLLERS
Two heat pressure rollers apply pressure to the film
and the print being laminated or mounted. Heat
is provided by an internal heating element. When
using pressure sensitive adhesive films, the heat is
turned off. The rollers pull the print and films into the
laminator.
NIP POINT
(Not shown.) The point at which the top and bottom
rollers come into contact and the point at which the
items for lamination are introduced into the laminator.
SAFETY SHIELD
The safety shield prevents entanglement,
entrapment, and inadvertent contact with the rollers.
When the safety shield is removed, the laminator
runs at 3 fpm (0.9 mpm) when you press the RUN
button. The safety shield is removed only when you
load films.
WARNING: Keep your fingers and hands away
from the nip point. Failure to observe this warning
could result in severe personal injury.
5. FEATURE GUIDE
Fig. 5-1. 44DT Laminator Identification.
This chapter identifies the main components of the laminator.
Safety shield
Feed table
Top film supply shaft
(front supply position)
Bottom supply shaft
Release liner take-up
Roller pressure
handle
Control panel
Table interlock latch
(under table)
Heat pressure rollers

Operating Instructions
Page 5-2
44DT
FEED TABLE
The feed table is used to position items for
laminating and mounting. When the feed table is
removed, the laminator runs at 3 fpm (0.9 mpm)
when you press the RUN button. The feed table is
removed only when you load film.
TABLE INTERLOCK LATCH
(Not shown.) The interlock latch locks the feed table
into position and activates an interlock switch. The
latch is located on the left, underside of the feed
table. Move the latch to the right to release the
table. Then lift the table upwards and away from the
laminator.
BOTTOM FILM SUPPLY SHAFT
Holds the film or kraft paper on the machine.
FILM WEB
(Not shown.) The path the laminating film and/or
mounting film mounted on the machine takes
through the machine.
CORE ADAPTORS
Fig. 5-2. Core Adaptors on the Shafts.
The core adaptors hold and lock the rolls of film
and release liner on the shafts to prevent side to
side shifting. Grippers on the supply shafts ensures
proper tension on the film. The supply shaft core
adaptors lock in place with a set screw. The release
liner take-up core adaptors are held in place by
friction.
ROLLER PRESSURE HANDLE
Fig. 5-3. Roller Pressure Handle.
The roller pressure handle adjusts the amount of
roller pressure needed for various laminating and
mounting applications. Pull the handle out of a
position, rotate it to the desired pressure, and press
it into the slot. Three main function settings provided
are.
Release – Provides the widest opening between the
pressure rollers and takes pressure off the rollers.
This is used when installing new rolls of film. When
the machine is not in use, put the handle in this
position.
Mounting – Used when bonding to a rigid substrate
such as mounting boards. Thickness range is 1/32 to
3/16 in. (1 to 5 mm).
Laminating – Used to adhere materials in multiple
substrates. The two positions are low and high
pressure.
IMPORTANT: Use a pressure setting that is
appropriate for the material you are laminating or
mounting.
Supply shaft
Take-up shaft
Core adaptor
Gripper

Page 5-3
Operating Instructions 44DT
FILM AND TAKE-UP TENSION ADJUSTMENT
KNOBS
Fig. 5-4. Tension Adjustment Knobs.
Allows the operator to increase or decrease film web
and release liner tension as needed to reduce curl
and wrinkles.
CONTROL PANEL
Fig. 5-5. Control Panel.
Display
The LCD shows the following information.
READY – Appears when the heat pressure rollers
have reached the set temperature. It flashes when
the heat is out of range.
TEMPERATURE – Displays the programmed
temperature setting. Also displays current
temperature when the MEAS. button is pressed.
SPEED – Displays the set speed.
Functions
The following describes the buttons on the control
panel. Refer to Fig. 5-5.
BOTTOM HEAT – Press the ON button to turn on the
bottom heat pressure roller heater. Press the OFF
button to turn it off. When the bottom heat is turned
on, an LED illuminates below the OFF button.
Tension Adjustment
Knobs
TEMP SPEED
BOTTOM
HEAT
FAN
STOP
RUN
TEMPERATURE
REVERSE
MEAS.
OFF
ON
9
SPEED
°F220
READY
LED
Display

Operating Instructions
Page 5-4
44DT
IMPORTANT: To change from a process where only
the top roller is heated to a process that requires
heat on both rollers, you must first turn off the
laminator and allow the top roller to cool to room
temperature. Once the roller is cool, both rollers can
be heated simultaneously. See General Operation in
the Operation chapter.
TEMP – Press the up or down arrow buttons to
increase or decrease the temperature. When the
bottom heat roller is turned off, these buttons set the
top roller temperature only. When the bottom heat
roller is turned on, these buttons set the temperature
for both rollers, if they are heated from room
temperature.
SPEED – Press the up or down buttons to set the
speed It is adjustable from 2.5 to 10 feet per minute
(fpm) (0.8 to 3 mpm).
FAN – Turns the cooling fan on and off. Illuminates
when the fan is on.
REVERSE – Press and hold the REVERSE button
to reverse the direction of the rollers. Release the
button to stop.
RUN – Press and release the RUN button for
continuous running. The safety shield must be
installed.
WARNING: Keep your fingers and hands
away from the nip point (the point where the upper
and lower rollers meet). Failure to observe this
warning could result in severe personal injury.
STOP – Press the STOP button to stop the laminator.
MEAS. – Press and hold the button to show the
actual temperature of the top heat roller on the LCD.
PULL ROLLERS
(Not shown.) The pull rollers, located at the back of
the laminator, are motor driven. They simultaneously
pull the laminate and improve the quality of the
laminated item.
POWER SWITCH
Fig. 5-6. Back of Laminator.
The power switch is located at the back of the
machine. Press the “I” on the switch to turn it on.
The LCD will illuminate on the control panel. The off
position, marked “0”, turns the machine off.
CIRCUIT BREAKER
Electrical safety device which can be reset by the
operator if tripped.
Power switch
Circuit breaker

Page 6-1
Operating Instructions 44DT
This chapter describes how to use the laminator to:
Operate the machine
Load films (web the machine)
Laminate items
Mount items
GENERAL OPERATION
These instructions assume that the films have been
loaded. For information about loading films, see the
Loading Film section in this chapter.
Fig. 6-1. Power Switch on the Back of The Machine.
Fig. 6-2. Roller Pressure Handle.
•
•
•
•
To run the laminator:
Turn the laminator On (I) with the power switch
located at the back of the machine.
WARNING: Make sure the safety shield and
feed tray are in their proper positions. You could be
burned and your fingers and hands could be trapped
and crushed in the hot rollers. . Clothing, jewelry, and
long hair could be caught in the rollers and pull you
into them.
Set the roller pressure handle for the thickness of
the item that is to be laminated or mounted.
Fig. 6-3. Control Panel.
Do any of the following.
If using thermal films, turn on the bottom
heat if needed, and then use the TEMP
up or down buttons to set the desired
temperature.
If using PSA films, go to the next step.
1.
2.
3.
a.
b.
6. OPERATION
TEMP SPEED
BOTTOM
HEAT
FAN
STOP
RUN
TEMPERATURE
REVERSE
MEAS.
OFF
ON
9
SPEED
°F220
READY
Power switch

Operating Instructions
Page 6-2
44DT
Set the desired speed.
Refer to the Lamination Guide chapter.
Press the RUN button.
The rollers will begin to turn.
If using thermal films, allow the heat lines to pass
the heat pressure rollers before inserting items
into the rollers.
NOTE: Do not press RUN until READY appears on
the display.
Position the item(s) to be laminated or mounted
on the feed table.
Push the item(s) squarely into the roller nip point
(where the two rollers meet). Additional items
can be laminated or mounted without stopping
and starting the machine.
Press the STOP button to stop the laminator
when all of the items have completely exited the
rear of the machine.
IMPORTANT: To change from a process where only
the top roller is heated to a process that requires
heat on both rollers, you must first turn off the
laminator and allow the top roller to cool to room
temperature. Once the roller is cool, both rollers can
be heated simultaneously.
If the laminator will be used within one hour, you may
leave it turned on.
STANDBY MODE
The 44DT automatically goes into a standby mode
after it has been idle for 3 hours. The heat roller
temperature is lowered to 176 °F (80 °C), if they were
on. After another hour of inactivity, the heat is turned
off.
To take the laminator out of standby mode, press the
RUN button. If the heat was lowered or turned off,
you will have to wait until READY is displayed on the
control panel. To run the laminator, press the RUN
button again.
IMPORTANT: Whenever the laminator will be idle
for an hour or more, set the roller pressure handle to
Release.
4.
5.
6.
7.
8.
LOADING FILM
The machine can perform three functions:
Decaling (laminating and applying a mounting
adhesive to the back of the item).
Mounting, using one film.
Mounting, using no film.
The 44DT laminator runs poly-in and poly-out
pressure sensitive adhesive (PSA) and thermal films.
Poly-in means the adhesive side of the film is on the
inside of the web. Poly-out means the adhesive is on
the outside of the web.
Fig. 6-4. Poly-in and Poly-out Films.
•
•
•
Poly-in
Adhesive surface Polyester surface
Adhesive surface
Poly-out
Polyester surface

Page 6-3
Operating Instructions 44DT
IMPORTANT: The top and bottom rolls of laminating
film must be the same width.
Always change the top and bottom supply rolls at
the same time. Near the end of each roll of most
laminating film is a label stating, Warning – End
of Roll. The appearance of this label on either the
top or bottom roll requires that new rolls of film
be installed as soon as the item presently being
laminated completely exits the rear of the laminator.
Do not introduce any additional items into the
laminator when the warning label is visible.
Adhesive will deposit on the rollers if:
One or both rolls of film are allowed to run
completely off its core.
Only one roll is used.
Different widths of rolls are loaded together.
Either roll is loaded with the adhesive side
against a roller.
There are two methods of loading film.
Using a threading card.
Tacking new film to existing film.
Prior to loading film, the safety shield and feed table
need to be removed.
•
•
•
•
•
•
REMOVING AND INSTALLING THE SAFETY
SHIELD
The safety shield should not be removed except to
install films and when cleaning the rollers. When the
shield is off, the laminator runs at a fixed speed of 3
fpm (0.9 m).
WARNING: Keep fingers and hands away from
the rollers when the machine is running. They could
be burned and trapped and crushed in the rollers.
Clothing, jewelry, and long hair could be caught in
the rollers and pull you into them.
To remove the shield:
Tilt the bottom of the shield out.
Lift shield up and out.
To install the shield:
Align the pins at the back of the shield with the
slots on the machine.
Lower the shield so that it engages the safety
switch.
1.
2.
1.
2.