usi CSL2700 User manual

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ROLL LAMINATOR
OWNERS MANUAL
CSL2700

IMPORTANT INFORMATION
PLEASE DO NOT DESTROY THE SHIPPING CARTON!
USI urges you to store the original carton in which your laminator was shipped. Should you ever need to return your laminator to our repair
and service center, it is best repacked in the original carton to avoid damage during transport. Our special foam filled carton ensures
the laminator’s safe transit to our service facility. Failure to use original packaging will result in a repacking fee. If you have any service
inquiries, please contact USI’s Technical Support Hotline, M-F 8am-6pm EST, at 800-752-9131.
Warranty: A Full Two Year Warranty will be issued from date of product shipment. Please supply the model and serial numbers on all
correspondence concerning your laminator.
EQUIPMENT WARRANTY
We warrant to the original purchaser the equipment manufactured to be free from defects in material and workmanship under normal use
and service. Our obligation under this warranty shall be limited to the repair or exchange of any part or parts which may prove defective
under normal use and service within two years from the date of shipment and which our examination shall disclose to our satisfaction to
be defective. Warranty does not include damage due to operator error or general maintenance. When necessary, purchaser shall properly
pack and return the unit to the USI Service Center, freight and insurance prepaid.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE WARRANTIES OF
MERCHANT ABILITY AND FITNESS FOR USE AND OF ALL OTHER OBLIGATIONS OR LIABILITIES ON OUR PART, AND WE NEITHER ASSUME
NOR AUTHORIZE ANY OTHER PERSON TO ASSUME FOR US, ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF THIS LAMINATING
MACHINE OR ANY PART THEREOF WHICH HAS BEEN SUBJECT TO ACCIDENT, NEGLIGENCE, ALTERATION, ABUSE OR MISUSE. WE MAKE
NO WARRANTY WHATSOEVER IN RESPECT TO ACCESSORIES OR PARTS NOT SUPPLIED BY US. THE TERM “ORIGINAL PURCHASER,” AS
USED IN THIS WARRANTY, SHALL BE DEEMED TO THE PERSON OR COMPANY WHO FIRST PUTS THE EQUIPMENT INTO SERVICE. THIS
WARRANTY SHALL APPLY ONLY WITHIN THE BOUNDARIES OF THE CONTINENTAL UNITED STATES.
Note: You will be charged for the replacement of any parts which are damaged as a result of improper packaging.
READ ME FIRST!
This manual contains all the information you need to properly unpack, operate and maintain your USI Laminator. Before unpacking your
laminator we suggest you read and follow the manual step by step. It contains essential information about each and every facet of your
laminator. Pay special attention to the work environment and safety precautions necessary for your laminating unit.
The manual is organized in the following way:
• There are seven major chapters, each covers a different subject heading.
• Each chapter is further broken down into parts.
Each part contains a detailed discussion, including photographs and figures,
covering either an operation or maintenance procedure for your laminator.
• Photographs and figures are numbered on each page for quick reference.
• Please pay special attention to particular notes and caution statements.
These comments alert you to information the we feel essential to operator
safety and damage prevention to the laminator.
Copyright Information:
IMPORTANT: This manual is copyright protected by USI, Inc. in accordance with the laws and requirements of the United States
Government. Any reproduction of this manual, in part or in full, without the written permission of USI, Inc. constitutes a violation of the
U.S. copyright laws and is subject to prosecution.
23

TABLE OF CONTENTS
Chapter 1 — Preparation
PartI LaminatorIntroduction.........................................4,5
Part II Work Area ................................................... 6
Electrical Requirements ......................................... 6
Part III Unpacking ................................................... 7
Part IV Loading Film .............................................. 8-10
Part V Heat Settings ................................................ 11
Part VI Tension ................................................. 12-13
Part VII Reloading A Hot Laminator...................................... 14
Chapter 2 — Care And Cleaning
PartI CleaningTheHeatShoe........................................ 15
Part II Cleaning The Rubber Roller ..................................... 15
Chapter 3 — Common Repair & Accessory Installation
PartI UpperHeatShoeRemoval...................................... 16
Part II Reinstall The Heat Shoe........................................ 17
Part III Removing The Rubber Rollers ................................ 18-20
Part IV Pressure Settings............................................. 21
Part V Lubrication.................................................. 22
Part VI Cleaning Friction Studs ........................................ 23
Part VII Replacing the thermostat .................................... 24-25
Part VIII Sprockets................................................... 26
Chapter 4 — Common Examples Of Poor Laminating And Their Causes
PartI TroubleShooting.......................................... 27-28
Chapter 5 — Diagrams
PartI ThreadingDiagram ........................................... 28
Part II Wiring Diagram .............................................. 29
Chapter 6 — Parts List
PartI PartsList................................................ 30-32
Chapter 7 — Laminating Film
PartI SpecialtyFilm ............................................... 33
23

45
SAFETY PRECAUTIONS
WARNING: Please review the following safety precautions before unpacking your new laminator.
• Use care in unpacking and lifting the laminator. Keep laminator level when lifting or moving.
Larger models weigh 60 pounds or more.
• Consider work area. A cluttered work space can lead to accidents. The laminator should be placed on
a level sturdy surface. Do not attempt to operate the laminator in damp or wet environments. Do not
operate electrical devices in the presence of flammable liquids, solvents or in gaseous/explosive
atmospheres. Keep work area well lit. Allow sufficient access to front and back of machine. See the
manual for additional work space requirements.
• Respect feed rollers. Keep hands away from feed rollers and any other moving parts. Turn drive
switch OFF before attempting to clear film wrap-arounds or jams. Use automatic reverse to clear film.
Do not wear any loose clothing, ties, jewelry, etc., which can be caught
by feed rollers and draw any body part into the machine.
• Respect heat shoes. Operating temperatures are hot enough to burn skin. If clearing a film wrap-
around or jam on or near heat shoes, first turn the heat switch OFF and allow laminator to cool to
room temperature. If your laminator is equipped with a heat shoe guard, do not operate without this
guard in place.
• Do not operate laminator with any panels or guards removed. Panels and guards protect
operators from such moving parts as the drive chain and sprockets, roller ends, etc.
• Turn the drive switch OFF before walking away or leaving the laminator unattended.
• Before lifting or moving laminator, turn drive switch OFF, turn heat switch OFF, unplug unit and allow
to cool to room temperature. Remove film rolls before lifting or moving machine. Film is easy to
rethread, see the section in this manual.
• Keep children away. Make sure visitors are kept well back from an operating laminator.
• Do not abuse electrical cord. Never pull cord to disconnect it from a receptacle. Do not allow cord
to contact heat, oil or sharp edges. Do not cut off or otherwise bypass the grounding prong on the plug.
• If an extension cord is necessary be sure it is properly rated and of the same wire gauge or smaller
as the laminator cord. Capacity of the cord must prevent loss of power and overheating. Before using,
inspect extension cord for any damage, including loose or exposed wires, broken fittings, damaged
insulation, etc.
• If you service the laminator yourself, call USI’s Technical Assistance department (1-800-752-9131)
for additional safety recommendations. Use only USI parts for service or replacement.
Failure to use USI parts could void manufacturer’s warranty. Note: Always turn laminator off and unplug
before servicing.
• Use common sense. Be cautious when operating your laminator. Do not operate laminator when
you are tired or your reactions are impaired in any way.
• Do not allow anyone to operate the laminator who has not received proper instruction and has not
read the safety instructions.
LAMINATOR INTRODUCTION
USI roll laminators are uniquely designed and engineered to be user friendly, reliable and virtually trouble free. USI’s
modular construction makes them easy to maintain and repair. All equipment controls are basic in design, functional
and positioned for easy access.

Feature Location:
A Tension Adjusting Knobs
B Color Coded Supply Mandrel (holds film)
C Heat Guard
D Side Housing
E Temperature Adjustment knob
F Built In Handles
G Heat On/Off Switch
H Motor Drive Switch
I Paper Guide
J Feed Tray
K Heat Shoes (behind heat guard)
L Film Temperature Guide
M Thermometer
CSL 2700
45
A
B
C
D
G
HI
J
K
M
E
B
L
F

FIND A WORK AREA
A separate work station is required to house your USI laminator. Ample room is necessary to access the laminator from all
4 sides. If the laminator is back against a wall, the laminating film may back up and jam the equipment. A USI laminator
cabinet is an excellent choice for a work area. It can easily be moved and provide sufficient storage for film in the cabinet
below.
WARNING: Do not place the laminator where the heat shoes will be in the direct path of a room cooling fan, air conditioner
or similar forced draft.
Tools necessary to set up your laminator include cutting shears and any adhesive tape. For future service or maintenance,
an assortment of Allen wrenches, a flat head screwdriver and a Phillips head screwdriver are necessary.
ELECTRICAL REQUIREMENTS
All USI CSL laminators are powered by a standard 115 volt, three prong outlet.
ELECTRICAL SPECIFICATIONS
CSL2700................................................................15amp/1540watts
67

UNPACKING YOUR LAMINATOR
Your laminator comes packed in one carton. It
contains (1) laminator, (1) heat guard, (1) top supply
mandrel, (1) bottom supply mandrel, (1) threading
board, (1) feed table with guide, and this operation
and maintenance manual. (See diagram page 5)
First, open the box. Using two people, carefully lift
the laminator from the carton by grasping the side
housings and lifting. Do not lift by the upper idler
bar or supply mandrel. These are not weight bearing
parts and can cause damage to the machine.
For shipping purposes, white plastic tie straps are
used to hold the power cord, heat shoes, and acces-
sories in place. These straps are approximately 1/8”
wide and should be carefully cut and removed prior
to set up.
Be sure to save the shipping carton…
Should your laminator ever need to be returned for
service, this carton ensures safe transit.
Your new laminator comes pre-loaded and ready to
run. Install the feed table and heat guard as shown
on page 13. Plug the machine in and turn the heat
switch to the “on” position and allow to heat for
approximately 15 minutes. Check the heat setting
and adjust if necessary as shown on page 11.
67
Photo 7-1
Photo 7-2

LOADING FILM
Color-coded laminators & film:
(For more information on this revolutionary system see the back cover)
Select the two rolls of laminating film that you wish to use. Both rolls of film should be of the same size, type and
thickness. Next, take the bottom supply mandrel (marked with the blue Color-Code) and insert it into the roll of film so
the blue end of the mandrel matches the blue end of the film roll. While inserting the mandrel, rotate it in the opposite
direction of which the “gripper dog” points while pressing into the roll of film and center on the mandrel. Place the
loaded mandrel on the machine by matching the blue end with the blue friction stud. To load the top, do the same as
the lower, only match the red ends.
For non-Color-Coded laminators & film:
Select the two rolls of laminating film that you wish to use. Both rolls of film should be of the same size, type and
thickness. Next, take the bottom supply mandrel (labeled “Low”) and insert it into the roll of film until the “gripper dog”
meets the film’s cardboard core (photo 9-1). Rotate the mandrel in the opposite direction from which the “gripper dog”
points. As you rotate, apply pressure to force the mandrel into the roll of film and proceed to center it on the mandrel.
See Figure 8-1.
Place the loaded mandrel on the laminator. Insert the right side first and then lower the left side into the roll bracket.
Take the top supply mandrel (labeled “Top”), insert it into the roll of laminating film, and place it in the top position as
with the lower (process shown in photos 9-1, 9-2 & 9-3).
Note: 1” core laminating film is rolled adhesive side in (”poly in”). When loading fim on mandrel, be sure roll is posi-
tioned correctly to unroll as shown in figure 8-1. If the roll is loaded in reverse, the film could adhere to the laminator
when heated.
89
Figure 8-1
Square
End
TOP
LOW
Round End Gripper
Dog
Square
End
Round
End
Gripper
Dog
RED
BLUE
“Finish”
Side
Adhesive
Side
“Finish”
Side
Adhesive
Side
RED
BLUE

Note: When loading your laminating film, check for film splices.
These rolls will be clearly marked. Splices are not common, but are
unavoidable. If you find a spliced roll, place it in the top position on
the laminator so that the splice can be monitored carefully. When
the splice is ready to come through the laminator, turn the drive and
heat off, allow the machine to cool, and rotate the roll of film by hand
so the film tension is very loose. Turn the drive switch on again and
allow the splice to run through. If necessary, keep turning the roll of
film by hand to keep it slack until the splice has passed through.
Caution: Do not apply excessive force to the ends of the mandrel
(i.e. with a hammer, etc.). Excessive force will damage the mandrel.
When loading the laminator, be sure the heat is turned off and the
machine is cool to avoid chance of burns.
Note: Film rolls must be centered on supply mandrels.
If the rolls are not aligned, hot adhesive will be deposited on the
heatshoes and rubber rollers, necessitating a cleaning operation.
Caution: When loading the laminator, be sure that the heat is turned
off and the machine is cool.
THREADING DIAGRAM
Figure 9-4
89
Photo 9-1
Photo 9-3
Photo 9-2

Thread the top roll of film under the idler roller as shown in the
threading diagram on previous page (see Figure 9-4). Pull the
film down so that the films lead edge is below the lower heat
shoe. Next thread the bottom roll of film under the lower idler
bar pulling film upward until it is even with the top heat shoe
(the film will overlap). Tape it to the top film edge. This creates
a film “Web” (Photo 10-1 & 10-2).
Using Tension Adjustment knobs, loosen tension on both rolls
of laminating film. Turn on the “Drive” switch and using the
threading board—push the film web into the laminating rollers.
This process will push the web into the pull rollers and exit.
Ensure that the threading board and film exit between the rear
pull rollers (Photo 10-3 & 10-4).
NOTE: If you lose your threading board or if it becomes dam-
aged, you can make your own with a piece of poster board.
Cut poster board 12” wide by
the length of the laminator (27”).
Your laminator is now loaded and ready to be heated. Remove
the threading board and save for your next use.
10 11
Photo 10-1
Photo 10-2: Creating Film Web
Photo 10-4: Threading board and film web exiting pull rollers.
Photo 10-3: Threading board and film web entering.

HEAT SETTINGS
Prior to laminating, allow the machine to pre-heat at least 15 minutes in order to stabilize the
temperature. Temperature settings depend on the film type being used. The temperature is preset at the factory, but
may require adjustment depending on what type of film you are using.
Turn the heat on by depressing the heat power switch on the left side panel. The red indicator light will illuminate and
remain lit while the machine is in the “on” position.
After the machine has been heated for 15 minutes, adjust the heat knob located on the end of the machine, in the
side housing, to the desired temperature setting. Allow the machine to heat for another 5 minutes in order to get an
accurate reading. Check your thermometer to confirm your temperature setting.
TYPE HEAT RANGE
Standard 260-290°F
Opti Clear 210-245°F
Photo Plus 220-250°F
DigiSeal 180-220°F
10 11
Photo 11-1

SETTING TENSION
To adjust tension for upper and lower rollers, the laminator must be loaded and heated.
Remove the heat guard and feed tray. Loosen both tension control knobs by turning counterclockwise until there is no
tension on upper or lower film rolls.
Photos 12-1, 12-2.
Film should pull freely.
As film runs through it will appear wrinkled and bubbly, as pictured in photo 13-1.
Gradually increase tension on both rolls, by turning knobs clockwise, until film is smooth
on heat shoes. Once film is smooth, stop tightening knobs.
NOTE: For best results, reset tension with EACH new pair of film rolls.
NOTE: As the film roll supply becomes low it is necessary to decrease tension on the rolls.
NOTE: Too little tension on the top or bottom roll causes vertical or diagonal streaks in the
film as it passes over the heating shoe.
WARNING: Excessive tension will lead to increased wear and tear on the laminator.
Once the laminator is loaded, heated, tension adjusted—install the Feed Tray and Heat Guard, as shown below in
Photos 13-2 and 13-3.
Photo 12-2
12 13
Photo 12-1 Photo 12-2

12 13
Heat Shoe Guard Photo 13-3
Photo 13-1
Feed Tray Photo 13-2

RELOADING A NEW ROLL OF FILM
ON A HOT LAMINATOR
Allow the old film to run to a point just before it pulls off the cardboard cores.
Turn the drive switch to “OFF.”
Cut the film web with a blade so that
approximately 5” of film extends beyond
the idler bar. Photo 14-1.
CAUTION: When using a sharp object to
cut film (blade or shears), avoid contact
with heat shoes or rubber rollers.
Remove the old cardboard cores and replace with new rolls of film. Photo 14-2.
Loosen the tension on the top film roll.
Thread the new web of film around the
idler bar and tape it to the remaining
segment of the expended roll.
Photo 14-3.
Repeat this procedure for the bottom
film roll. Use caution when threading film
near hot heat shoe.
Run film through the laminator until the
new web of film clears the pull rollers.
Photo 14-4.
Readjust tension.
14 15
Photo 14-1
Photo 14-2
Photo 14-3 Photo 14-4

CLEANING THE HEAT SHOES
With continuous use the heat shoes and rubber rollers may accu-
mulate adhesive and dirt. It is recommended that you periodically
inspect them for adhesive build-up. Use USI’s Laminator Cleaning
Kit, which contains cleaning fluid, a coarse scrubbing pad and a
mesh covered sponge, for removal of any adhesive build up.
Moisten the sponge pad with cleaning fluid and wipe down the
heat shoes.
NOTE: Be sure to clean the heat shoes only when the laminator is
cool.
CAUTION: Teflon coated heat shoes are scratchable.
Periodically inspect the rubber laminating and pull rollers for adhe-
sive build-up.
Remove the upper heat shoe to gain access to the laminating roll-
ers for cleaning.
CLEANING THE RUBBER ROLLERS
NOTE: If indentations begin to appear on the surface of fin-
ished laminations, this may indicate that cleaning of the rollers is
necessary.
Before cleaning be sure the laminator is cool.
Use a dry Scotch Brite®pad to remove excess adhesive from the
rollers. Photo 15-3.
Turn the drive switch on and off to advance the rollers and clean
each section at a time.
Wipe clean with the sponge pad and cleaning solution from USI’s
Laminator Cleaning Kit.
NOTE: Use cleaning solution sparingly. Do not allow to “run”
onto wiring or into “ends” of laminator.
WARNING: Do not use any sharp metallic objects or steel wool to
clean the rubber rollers.
Use of such abrasive objects can damage the rubber surface of the
rollers. USI strongly recommends the Laminator Cleaning Kit for all
of your cleaning needs.
14 15
Photo 15-2
Photo 15-3

UPPER HEAT SHOE REMOVAL INSTRUCTIONS
1. Unplug laminator and allow it to cool to room temperature.
2. Remove the left side housing. First remove the thermometer & temperature knob
(shown in figure 16-1). The temperature knob has a small Allen head set screw retaining it.
Then remove the housing by unscrewing 4 Allen head screws. Set housing assembly aside.
3. Unplug the upper heat shoe wires (A) from the terminal block (B). [Figure 16-2]
4. Gently lift the heat shoe and pull forward. Be careful not to damage the wires.
Lift from the right side first.
Figure 16-1
Figure 16-2
1
23
4
B
A
Thermometer
Temp. Knob
16 17

TO REINSTALL THE HEAT SHOE
1. Be sure laminator is unplugged.
2. Guide heat shoe wires exiting from the left end of the heat shoe through the
slot in the left side of frame.
3. Lower the left end of the heat shoe onto its bracket first, then lower the right end
and lock in place.
4. Plug the heat shoe wires into the terminal block.
5. Carefully install the left side housing and 4 Allen head screws. Replace the
temperature knob and thermometer
16 17

REMOVING THE RUBBER ROLLERS
NOTE: Only remove rollers if they are cut or in poor
condition.
NOTE: The following procedure removes all 4 rollers.
In certain instances, it is not necessary to remove all 4 rollers,
therefore, remove as required.
STEP 1:
Remove all film from laminator. Photo 18-1.
STEP 2:
Unplug laminator. Make sure it is cool.
STEP 3:
Remove the thermometer and heat knob from the left side
of laminator. Remove the side housing on both sides of the laminator.
STEP 4:
Remove the top heat shoe. Photo 18-2.
Refer to diagram and instructions on page 16.
STEP 5:
Unfasten and remove the pressure adjusting screws on
both sides of the laminator. Photos 18-3, 18-4.
STEP 6:
Loosen the Allen head set screws on the left and right ends
of the top rubber rollers. Photo 18-5.
18 19
Photo 18-1
Photo 18-2
Photo 18-3 Photo 18-4 Photo 18-5

STEP 8:
Loosen the set screws of
the lower roller sprockets
(laminating roller shown)
Photo 19-3.
STEP 9:
Loosen the Allen head set
screws on the left and right
ends of the lower rubber
rollers. (Lower laminating
roller shown.) Photo 19-4.
STEP 10:
Slide the roll shaft out of the rubber
roller and the roll sprocket. (laminat-
ing roller shown.) Photo 19-5.
NOTE: The chain can now be
removed without loosening
the motor mounting screws. Photo
20-1.(next page)
STEP 7:
To remove the upper roller, slide
the roll shaft out of the roller and
then lift the top rubber rollers from
the laminator (top laminating roller
shown). Photos 19-1 and 19-2
18 19
Photo 19-2 Photo 19-3
Photo 19-4 Photo 19-5
Photo 19-1

STEP 11:
To install a new roller or replace the original roller, reverse the removal procedure. Be sure to properly reposition
the sprockets and align the chain. All three sprockets should be in line with each other. Since the motor sprocket
was not removed, use it as a guide for alignment of the pull roll and laminating roll sprockets.
• The pull rollers on this laminator are interchangeable
with the laminating rollers. If the laminating rollers have
minor damage, each can be replaced by pull rollers. If
the laminating rollers are too badly damaged, they must
be replaced. The condition of the laminating rollers is
very important for a good lamination.
• If the chain feels too loose, it may be tightened as follows:
Loosen the motor mounting screws. Push down on the
motor sprocket and refasten the motor mounting screws.
Photo 20-2.
NOTE: Be sure to adjust the pressure on both pressure adjusting screws. 2-3 threads should show through the
adjusting screw mounting bracket. See page 21.
20 21
Photo 20-1
Photo 20-2