Primera FX1000 Manual

Operator’s Guide
© 2012 All rights reserved.
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Notices: The information in this document is subject to change without notice. NO WARRANTY
OF ANY KIND IS MADE WITH REGARD TO THIS MATERIAL, INCLUDING, BUT NOT
LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. No liability is assumed for errors contained herein or for incidental or
consequential damages in connection with the furnishing, performance, or use of this material.
This document contains proprietary information that is protected by copyright. All rights are
reserved. No part of this document may be photocopied, reproduced, or translated into another
language without prior written consent.
Trademark Acknowledgments: Primera is trademark of Primera Technology Inc. Windows is a
registered trademark of Microsoft Corporation. All other trademarks are the property of their
respective owners.
Printing History
Edition 1.0, #511341, Copyright 2012, All rights reserved.
FCC Compliance Statement: This device complies with part 15 of the FCC rules. Operation is
subject to the following two conditions: (1) this device may not cause harmful interference, and
(2) this device must accept any interference received, including interference that may cause
undesired operation.
For Users in the United States: This product is intended to be supplied by a UL listed Direct
Plug-In Power Supply marked "Class 2"or a UL listed ITE Power Supply marked "LPS" with
output rated 19v, 3.42 amps or higher. 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. In a domestic
environment this product may cause radio interference, in which case the user may be required
to take adequate measures. This equipment generates, uses, and can radiate radio frequency
energy and, if not installed and used in accordance with the instructions, may cause harmful
interference to radio communications. However, there is no guarantee that interference will not
occur in a particular installation. If this equipment does cause harmful interference to radio or
television reception, which can be determined by turning the equipment off and on, the user is
encouraged to try to correct the interference by one or more of the following measures:
•Re-orient or relocate the receiving antenna.
•Increase the separation between the equipment and receiver.
•Connect the equipment into an outlet on a circuit different from that to which the receiver
is connected.
•Consult the dealer or an experienced radio/TV technician for help.
Use of shielded cables is required to comply with the Class A limits of Part 15 of the FCC Rules.
You are cautioned that any changes or modifications not expressly approved in this manual
could void your authority to operate and/or obtain warranty service for this equipment.
For Users in Canada: This digital apparatus does not exceed the Class A limits for radio noise
for digital apparatus set out on the Radio Interference Regulations of the Canadian Department
of Communications. Le present appareil numerique n'emet pas de bruits radioelectriques
depassant les limites applicables aux appareils numeriques de la class A prescrites dans le
Reglement sur le brouillage radioelectrique edicte par le ministere des Communications du
Canada.

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Table of Contents
Section 1: Warnings, Cautions and Notes…………………………………………………. 4
Section 2: Setup……………………………………………………………………………..… 5
2.1 What is Included ……………………………………………………………………. 5
2.2 Unpack and Assemble……………………………………………………………… 6
2.3 Identifying the Parts………………………………………………………………… 8
Section 3: Run a Job…………………………………………………………………………… 9
3.1 Load Printed Roll …………………………………………………………………… 9
3.2 Set Up the Weeder………………………………………………………………….. 10
3.3 Foam Weeder Roller Installation (Optional)……………………………………… 12
3.4 Set Up the Slitter……………………………………………………………………. 14
3.5 Set Up the Take Up Mandrel………………………………………………………. 17
3.6 Run Job, Evaluate Tension and Adjust Guides………………………………….. 20
3.7 Adjust Guides……………………………………………………………………….. 22
Section 4: Maintenance and Troubleshooting……………………………………………...23
4.1 Replacing Blades…………………………………………………………………… 23
4.2 Paper Path Diagram ………………………………………...…………………….. 24
4.3 Cleaning and Maintenance ……………………………………………………….. 25
4.4 Problem - Solution Table ………………………………………………………….. 26
Section 5: Specifications……………………………………………………………………….27

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Section 1: Warnings, Cautions and Notes
Thank you for purchasing the FX1000 Matrix Removal System. Please read the following
Warnings, Cautions and Notes before operating your FX1000.
Note: Notes are used to notify of installation, operation, or maintenance information that is
important but not safety related. Notes will be found throughout this manual.
Caution: Caution is used to indicate the presence of a hazard, which if ignored may result in
damage to the unit.
Warning: Warning means that a potential safety hazard exists and indicates procedures that
must be followed exactly to avoid serious personal injury.
Warnings
•Do not operate the FX1000 while wearing loose fitting clothing or neck ties. Serious
injury may result. If clothing or fingers are caught in the rollers, immediately press the
STOP button on the front of the unit.
•Keep your hands away from the FX1000 at all times while it is running. The electric
motors in the FX1000 are extremely powerful and are capable of crushing fingers at the
nip point in the paper path. The nip point is where the paper is compressed so it can be
pulled or pushed through printer. If fingers are caught in the nip point, press the stop
button immediately and open the nip points by pushing the levers to the right.
•To prevent fire or shock hazard, do not expose the unit to rain or moisture. To reduce
the risk of electric shock, do not remove exterior panels. No user-serviceable parts are
inside. Refer to qualified service personnel. Operate the unit with only proper electrical
specifications as labeled on the unit and the AC adapter.
Caution
•Do not use media that is wider than specified in the specifications section of this manual.

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Section 2 Setup
Section 2.1: What is Included
The FX1000 includes everything you need to remove the matrix and slit a roll of printed
material. The following items are included.
•Euro and USA/Japan power cord located in supply box.
•7 Slitter Blades. These are preinstalled in the slitter station.
•Assortment of Cardboard Cores. (Located in the media box)
•2 mm Hex Driver.
•3mm Hex Driver.
•Foam Weeder Rollers.

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Section 2.2: Unpack and Assemble
1. Disassemble the top and sides of the crate by removing the screws from the red
dots. Remove the supply box and the input mandrel box.
2. Using the yellow nylon lifting straps, lift the FX1000 out of the crate and onto the
floor. Using an M5 Allen wrench remove the straps and replace the bolts. The straps
are not useful for lifting to heights above the knees.
3. Lift the FX1000 on to a sturdy table or bench capable of holding at least 250 lbs (114
Kg). You will need 4 people, one at each corner, to comfortably lift the FX1000 from
the floor onto a table. The back right corner has the most weight.
3.LiftHere
2.LiftHere
1.LiftHere
4.LiftHere

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4. In the supply box, locate the supply mandrel, 3mm Allen wrench and the bottle of
Loctite.
5. Partially remove the two set screws on the mandrel so that approximately ½ inch (1
cm) is exposed. Crack the top off the Loctite container and place two drops on each
set screw. Reset each screw until it is flush with the outside of the mandrel. Attach
the mandrel to the unwinder (left side) drive shaft. Line up the holes in the chuck with
the flat edges on the drive shaft. The holes must correspond with the flats or the set
screws will not hold the chuck in place.
6. Tighten the set screws using the 3mm Allen
wrench. Once they are tight, attempt to rotate
the mandrel forward and backward while
watching the drive shaft. The drive shaft should
move with the mandrel. If it does not move with
the mandrel, loosen the set screws slightly and
turn the mandrel until the set screws are even
with the flats. The Loctite will dry in 24 hours.
7. Connect the power cable and switch on the
unit.

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Section 2.3: Indentifying the Parts
FX1000 Overview
Nip Point
Take Up Mandrel
Unwinder / Supply Mandrel
Control Panel
Nip Lever
Slitter Station Core Engagement Knobs
Waste Matrix
Take Up Mandrel
(Weeder)
Media Guides
Upper Take Up Mandrel
(Optional)
Emergency Stop Button

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Section 3 Run a Job
Section 3.1: Load a Printed Roll
1. On the unwinder/supply mandrel loosen the core engagement knob and remove the
remaining portion of the previous roll, if any.
2. Place the new roll on the unwinder/supply mandrel. Push it back until it touches the core
stop.
3. Be sure that the edge of the media corresponds with the edge of the core. If the media is
coning in or out you will want to attempt to straighten the media on the core. If the core is
shorter than the media width, pull the roll out so that the edge of the media is even with
the core stop. If the core is wider than the media you may need to adjust the guide
collars (Section 3.6) to accommodate the altered position of the web.
4. Turn the core engagement knob clockwise to lock the roll in place.
Core Stop
Unwinder
Knob

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Section 3.2 Set Up the Weeder
1. Push the Nip Lever into the “Nip Open” position.
2. Feed the media OVER the first guide roller and UNDER the second guide roller.
3. Continue feeding the media through the nip point.
4. Once you reach the peel roller, peel the matrix from the liner.
5. Place an empty core on the Matrix mandrel and tighten the core engagement knob.
6. Pull the matrix from the liner and attach it to the Weeder. Manually turn the mandrel
one full revolution.
Matrix
Peel
Roller
Slitter Station
Nip Lever
First Guide Roller Second Guide Roller

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If the matrix does not easily pull, manually turn unwinder to create some slack.
7. At the same time you are pulling the matrix from the liner pull the label slack through
the slitter station over the slitter rollers and under the right guide roller.
8. Continue pulling the labels through the slitter and winding the matrix on the matrix
mandrel until you have enough media to attach to the lower take-up mandrel.
9. Attach an empty label core to the take up mandrel and tighten the core engagement
knob.
10. Attach the media to the core.
11. Manually turn the mandrel until media is tight
Right Guide Roller
Slitter Rollers
Lower take-up
mandrel

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Section 3.3 Foam Weeder Roller Installation (Optional)
Install the Foam Weeder Roller for improved weeding performance when using synthetic
materials such Polyester, Polypropylene and Vinyl. You may also choose to install the weeder
roller to improve weeding performance for non-standard die cuts or any time the labels are
being pulled up with the matrix.
Installation Instructions:
1. The foam roller has a slit along the
entire length so that you can push it over
the weeder roller.
Install Here
Foam Rolle
r
Weeder Rolle
r
Push Foam Over
Weeder Roller
Install Here

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2. Rotate the foam roller so the slit is
facing up. Remove the protective paper
covering the adhesive.
3. Push the foam together along the entire
length of the slit in the foam roller. The
adhesive will hold it together.
Note: Make sure the foam roller freely
rotates on the weeder roller.
The graphic below shows a correctly installed foam roller in use.

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Section 3.4 Set Up the Slitter
1. Seven blades are preinstalled in the retracted position in your FX1000. The FX1000
slitter station allows you retract or engage slitting blades without removing them from
the unit. You will need to decide how many to engage to slit your labels. For example,
depending on what type of applicator will be used you may need to slit and remove
edge waste. Use this table as a guide.
Columns Blades Needed
Remove Edge Waste Leave Edge Waste
1 2 0
2 3 1
3 4 2
4 5 3
5 6 4
6 7 5
7 Not Possible 6
8 Not Possible 7
2. Press the release latches to open the slitter station.
Typical Slitter Configuration for Three Columns.
Slit Here
Edge Waste Edge Waste

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Do NOT push the cover all the way closed! Let it rest on the spring
loaded latches for now. The blades will not cut the media in this position.
3. Loosen the thumbscrew on the blade housings you intend to engage. For optimal
safety, it is recommended to use a pliers to loosen the blade housing thumb and move
them into the engaged position.
4. Pull the thumbscrew toward you to engage the slitter blade. The thumbscrew moves
inside a curved slot.
5. Tighten the thumbscrew once the slitter blade is engaged.
6. Start with the slitter blade furthest from you and repeat steps 2, 3 and 4 for each.
7. Once you have engaged the blades you want to use close the slitter station.
Note: Before deciding which
blades to engage make sure
that the blade can actually be
moved to the intended
position. Each blade housing
has a limited range of
movement. If you cannot
move the blade to the
intended position you will
need to choose a different
blade housing.
View from Back of unit
Slitter blade engaged
Pull

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8. Loosen the thumbscrews for the engaged slitters. Line them up with the correct
positions between the die cut labels.
9. Once the blades are in the correct position, push the slitter station all the way closed.
The blades will puncture the media once the slitter station is locked into place.
Replacing or Rotating Blades
If a blade becomes dull you will need to rotate the blade to one of the four cutting corners. If all
cutting corners have been used, you will need to replace the blade. Follow this procedure:
1. Press the release latches to open the
slitter station.
2. Loosen the thumbscrew on the slitter
blade housing containing the dull
blade. Completely remove the
thumbscrew.
3. The blade and housing will detach
from the opposite side.
4. Rotate or replace the blade.
5. Fit the blade over the locator pin and the thumbscrew capture pin.
Tip! Mark the dull blade corners with a
permanent marker before rotating the blade.
Blade Housing
Slitter Blade

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3.5 Set Up the Take Up Mandrels
Before you can configure the take up mandrel you will need to run the media through the unit
until the slits reach the lower take-up and wrap around at least once.
1. Switch on the Matrix.
2. Switch on the Lower Rewind.
3. Set the tension on the Matrix, and Lower Rewind to 0%.
4. Set the Master Speed to the lowest value.
5. Switch on the master switch.
6. Slowly turn up the master speed until the media starts to move. Stop once the slits reach the
lower take up/rewind and wrap around at least once.
Lower Rewind ONLY Model Instructions:
1. Manually turn back the take up mandrel until the first good labels are visible.
2. Cut between the labels at the same point for each roll. Remove the waste label core
from the lower take up mandrel.
3. Place new cores on the lower take up mandrel. Standard sizes are included. Additional
sizes can be purchased from Primera. The core width should equal the width of the
finished roll. It can be a little smaller in some cases depending on what type of
applicator will be used to apply the labels.
4. Attach the labels to the core using waste label or tape. Make sure the tension on both
rolls is even. If they are not even and you have already attached them to the core you
can easily equalize them by loosening the core engagement knob on the mandrel just a
little. Now turn each core on the mandrel until both label rolls are taut. Tighten the
knob again.
5. Feed the edge trim waste over the lower takeup mandrel and into a waste bin.

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Upper and Lower Rewind Model Instructions:
You may configure the take up mandrels in many ways. The instructions below illustrate the
recommended method assuming a two column cut wrapped onto two separate rolls on the
upper take up mandrel with the edge waste trimmed and rolling over the lower take up mandrel.
Edge Waste over Lower Take Up (Recommended). This method is recommended if edge trim
is required. It does not require additional guides or a vacuum system.
Follow these instructions to use the method above:
1. Manually turn back the take up mandrel until the first good labels are visible.
2. Cut between the labels at the same point for each roll.
3. Place cores on the upper take up mandrel. Standard sizes are included. Additional
sizes can be purchased from Primera. The core width should equal the width of the
finished roll. It can be a little smaller in some cases depending on what type of
applicator will be used to apply the labels.
4. Attach the labels to the core using waste label or tape.
Note: Make sure the tension on both rolls is even. If they are not even and you have
already attached them to the core you can easily equalize them by loosening the core
engagement knob on the mandrel just a little. Now turn each core on the mandrel until
both label rolls are taut. Tighten the knob again.
5. Switch on the upper rewind.
6. Remove the waste label core from the lower take up mandrel.
7. Place a new core on the lower take up mandrel.
8. Switch OFF the Lower Rewind.
9. Feed the edge trim waste over the new core and into a waste basket.
Top View
Upper Take Up Lower Take Up
Edge waste to
trash receptacle
over cardboard core
Finished Rolls

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Additional configurations include:
Edge Waste Wrap. Wrap the edge waste on small cores on the upper mandrel and wrap
finished labels on the lower take up mandrel. This requires additional label guides (sold
separately). You must wrap both sides of edge trim on the same mandrel to maintain even
tension.
Alternating Finish Rollers. This method would prevent finished rolls from interleaving as they
are wrapping. However, if edge waste is trimmed this method would probably require a vacuum
system to remove the edge waste.
Edge Waste to Weeder. This involves running the waste directly from the Take Up
Guide Roller to the underside of the Waste Matrix Take Up roll. This method will increase the
size of the waste matrix more quickly and can cause problems for some types of cuts that
require very even pulling force to properly pull the matrix.
Top View
Finished Rolls
Lower Take Up
Upper Take Up
Edge Waste Additional Label Guides
Top View
Lower Take Up
Upper Take Up
Edge waste to
vacuum system
Finished Rolls
Finished Rolls

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3.6 Run Job and Evaluate Tension and Guides
You are now ready to run your job.
1. Switch on the Matrix.
2. Switch on either the Upper Rewind, Lower Rewind or both.
3. Set the tension on the Upper Rewind and Lower Rewind to 50%.
4. Set the tension on the Matrix to 0%.
5. Set the Master speed to the lowest value.
6. Switch on the master switch.
7. Slowly turn up the master speed.
Once the system is running you should evaluate the tension and the roller guides.
Evaluate Tension. The web should be tight at all points along the paper path. You can increase
the tension of any of the mandrels. While the system is running, slowly turn the knob to increase
tension
•Too little tension will cause the web to gather slack. Over time this will cause a jam and
stop the job. It will also create loose finished rolls.
•Too much tension can cause a web break. The most likely place for this to occur is at
the weeder.
If the web breaks the job stops. Web break detection occurs when a sudden change in
web tension is detected on any of the 3 or 4 media mandrels.
Note on label curling: If finished labels are curling or peeling up or under on the edges this is
an indication that tension on the web is not balanced. Decrease tension on the supply mandrel
or lamination mandrel if labels are curling up. Increase tension if they are curling under.