Xyron 2500 User manual

AT400-300 Adhesive Application – High Tack
AT402-300 Adhesive Application – Low Tack
AT406-170 Adhesive Application – Repositionable
DL403-300 Two-Sided Lamination
SL403-300 One-Sided Lamination
LAT405-300 Combination Lamination/Adhesive Application - High Tack
LAT406-300 Combination Lamination/Adhesive Application - Low Tack
LAT409-170 Combination Lamination/Adhesive Application - Repositionable
Please follow the attached directions carefully.
The Xyron™2500 is an economical and easy to use document finishing system.
This versatile and non-electric system has been designed to laminate or apply
mounting adhesive to a variety of media. The same system is capable of laminating,
selectively applying adhesive or laminating and applying adhesive at the same time.
With the Xyron 2500, documents are easily laminated or can be transformed into
signs, stickers or labels instantly. The machine and supplies are compatible with all
types of computer-printed media including laser, inkjet, color and thermal in a wide
range of material sizes and thickness.
Supply rolls for 2500
Adhesive Application &
Laminating System
USER’S GUIDE
Adhesive Application and Laminating System
2500
1-800-793-3523
EDNord - Istedgade 37A - 9000 Aalborg - Telefon [phone]

Upper Idle Bar
Lower Idle Bar
Paddle
Used to
lock document
in place
Feed Tray
Used to guide and
align documents
into the machine
Top Cover
Removes to
install/remove
supplies
Crank Handle
Used to advance
documents and film
thru machine
Lower Cut
Guide
Rubber Rollers
Lower Supply Roll
Upper Supply Roll
Lower
Access Door
Open to install
and remove
supplies
Slots for
Supply
Installation
Cut Blade
Used to trim output as it
exits –
the machine will
cut when moved to
either direction
Upper
Cut Bar
Understanding the Xyron 2500’s
Adhesive/Laminating System
Parts and Functions
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Training Video
The Xyron 2500 comes with an instructional video. In addition to explaining how
to load supply rolls, the video also includes tips on how to use the machine. Xyron
recommends watching this video before attempting to load and use the 2500.
Remove the machine from the packaging
and place on a level surface. Locate
the crank handle and training video
which are taped to the bottom
inside of the machine.
Install the crank
handle by carefully
threading clockwise
(direction of the arrows)
into the lower rubber roller.
Cut the tie wraps holding
the upper cut bar and lower
guide together.
Step 1:
•Remove the top cover of the machine
by lifting upward.
•Grasp the handle on the lower
access door; pull to open.
Step 2:
•Match the colored dots on the end of
each supply roll with the corresponding
dots on the side of the machine.
Note which roll is identified as
“top” and “bottom”.
•Slide the supply rolls into the
grooves in the sides of the machine,
making certain that the roll is
inserted completely.
Setting Up
Loading Supply Rolls
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Step 3:
•On the bottom
supply roll, grasp
the laminated starter
section by the leading
edge film.
•Route over the bottom
idler bar adjacent to
the lower rubber roller.
•Make sure the film
is inserted squarely.
Rotate the handle 1/4
turn in the direction of
the arrows.
Step 4:
•Make certain the
lower film is tight.
If necessary, rotate
the supply roll in the
direction of the arrows
until the film is taut.
•Grasp the film from
the upper supply roll
and adhere it to the
film on the lower
supply roll.
By carefully aligning
the edges, keeping the
film tight and avoiding
wrinkles, film waste
will be minimized.
Step 5:
•Rotate the handle to
pull the supplies
through the machine.
•Ensure that the film
exits between the
blade bars.
•Just before the top film
becomes tight again,
insert a small piece of
cardstock between the
rubber rollers. This will
help to minimize waste
and ensure the film
exits between the
upper cut bar and
lower guide.
Step 6:
•Continue to crank film through
machine until it is aligned and
wrinkle-free.
•Trim off excess film by pressing down
on the blade holder and sliding in
either direction.
Step 7:
•Replace the top cover.
•Close the lower access door.
•Install feed tray completely by aligning
the support posts in the grooves
located in the sides of the machine.
When done correctly, the film layers should be aligned and wrinkle-free after 18"
(45cm) of material has exited the machine.
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Step 3:
•Trim the document by pressing down on the
blade holder and sliding it in either direction.
Note: As the document exits the machine,
you may wish to trim the leading edge.
This will avoid a later trimming operation.
Step 1:
•Pull back on the paddle so that it is in
the “up” position.
•Insert a document so the leading edge
is under the paddle. The document
should extend past the edge of the
paddle 1-2 inches (2.5-5cm).
Note: The side of the document which
is face down will have adhesive
applied when using Front-Side
Lamination/Back-Side Permanent
Adhesive Transfer.
•Align the document parallel to the
edge of the feeder tray.
Step 2:
•Push forward on the paddle to lock the
document in place.
•Ensure that the leading edge of the
document is adhered down evenly.
If necessary slide your fingers across
the leading edge to secure it in place.
•Turn the handle clockwise to advance
the document through the machine.
How to apply Front & Back Lamination
or Front-Side Lamination/Back-Side
Permanent Adhesive Transfer
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•Steps 1, 2 and 3... same as above.
Product Feet
No. Description Applications Per Roll
AT400-300 Adhesive Application – High Tack Paste-ups, comps, storyboards 300
& presentations on foam core
AT402-300 Adhesive Application – Low Tack Paste-ups, comps, storyboards 300
& presentations on foam core
AT406-170 Adhesive Application – Paste-ups, comps, storyboards 170
Repositionable & presentations on foam core
DL403-300 Two-Sided Lamination Posters, inkjet & thermal 300
prints & banners
SL403-300 One-Sided Lamination Indoor applications where protection 300
of the rear side is not needed
LAT405-300 Combination Lamination/Adhesive Paste-ups, comps, storyboards & 300
Application – High Tack presentations on foam core,
provides protection to top surface
LAT406-300 Combination Lamination/Adhesive Paste-ups, comps, storyboards & 300
Application – Low Tack presentations on foam core,
provides protection to top surface
LAT409-170 Combination Lamination/Adhesive Paste-ups, comps, storyboards & 170
Application – Repositionable presentations on foam core,
provides protection to top surface
•Remove the protective clear mask
layer and discard.
•This process removes excess adhesive
from everywhere except the back of
the item run through the machine.
•Remove the document from the white
release liner when you’re ready to
mount it.
How to apply Back-Side Permanent
Adhesive Transfer
Replacement Cartridges
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Step 1 —
•Remove the top cover by lifting
upward.
•Remove the feed tray by lifting and
pulling away from the machine.
Step 2 —
•Make a small hole with a knife about
one inch (2.54cm) from the left edge
of the film.
•Slide the knife towards the right
edge of the film and stop about
one inch (2.54cm) from the edge.
Use caution to avoid cutting into
the rubber rollers.
Step 3:
•Turn the handle 1/2 turn maximum
in the direction of the arrows. This
step will cause the uncut film at the
edges to break, creating a laminated
leader for easy installation at a
later time.
Step 4:
•Remove the supply rolls from the
machine. Xyron recommends that
supplies are stored laying flat in
a cool, dry place using the original
packaging.
Supply Roll Removal
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When properly used, the Xyron 2500 is relatively maintenance-free. Listed below
are safeguards and tips that will produce better results. Refer to the exploded view
diagram for part descriptions.
Importance of a clean document:
For best results when laminating, it is highly recommended that the document be
cleaned with a soft, lint-free cloth immediately prior to lamination. Small dust or lint
particles may cause the laminate to “tent”, producing an appearance similar to a
small air bubble.
Cut blade replacement and cleaning:
The cut blade may accumulate adhesive over time. Cleaning the blade must be
done with great care to avoid personal injury. To remove the blade, slide the orange
blade holder into the notch and lift upwards. Carefully remove the blade holder and
replace or clean with a light solvent such as isopropyl alcohol.
Use after storage:
For applications where the appearance of your laminated document is critical, it is
highly recommended that the Xyron 2500 be used and stored in a clean, dust-free
environment. Airborne dust particles and lint will tend to adhere to the bare adhesive
inside the supply roll. If the machine has not been used for several days or was
subject to a dusty environment, it is recommended that four inches (10cm) of material
be advanced and discarded before inserting your document. It is also recommended
that the feed tray is cleaned with a lint-free cloth. Contact your dealer about a dust
cover as an accessory.
Cleaning adhesive from the nip rollers:
The nip rollers are designed to be self-cleaning under normal use. If adhesive does
accumulate, it can normally be removed by first removing the supply films from
between the nip rollers and advancing a scrap piece of regular bond paper through
the machine. The bare adhesive will tend to attach to the paper. If this method of
cleaning does not work, the nip rollers can be cleaned with a light solvent such as
isopropyl alcohol. Take care not to scratch, cut or chip the rollers. For best results
when laminating, it is critical that the lower idler bar be kept clean of adhesive build-up.
Maintenance, Safeguards & Tips
If You Have Additional Questions, Contact the Xyron Technical Hotline:
800-793-3523 in the U.S.A. and [phone] in Europe
E-mail address in the U.S.A.: [email protected]
E-mail address in Europe: [email protected]
Also, check out our website at www.xyron.com
EDNord - Istedgade 37A - 9000 Aalborg - Telefon [phone]

Long documents (such as
banners) are not aligned
with film layers after
laminating.
Cut Blade does not slide
smoothly.
Film does not exit machine
between Upper and Lower
Blade Bars.
Cut Blade does not
cut well.
Thin and/or wide
documents tend to wrinkle
during lamination.
Document difficult to load.
Film wrinkles don’t go
away as crank is turned
clockwise.
Film does not lay flat, curls
and/or wrinkles.
Feed Tray not installed
correctly or supply roll not
seated at base of groove
in side plate(s).
Upper Blade Bar sticking in
side plate groove or blade
sticking on Blade Bar.
Material is curled or
adhesive has been trans-
ferred to the Nip Roller
causing the film to stick.
Blade has accumulated
adhesive buildup or
is dull.
Paddle not operated
correctly, or tray and/or
paddle are not flat
Paddle not pulled back
to load position or
has adhesive buildup
on underside.
Upper and/or lower supply
roll(s) are not firmly seated in
grooves within side plate(s).
Adhesive buildup on lower
idle bar.
Verify tray is completely
installed such that it is
approximately level and
square. Also, verify supply
rolls are completely seated
at base of grooves in
side plate(s).
Apply silicon lubricant to all
surfaces of top blade bar.
Reposition material between
upper cut bar and lower
guide. Clean adhesive from
nip rollers if necessary.
Clean adhesive buildup
from blade using isopropyl
alcohol or Xyron Adhesive
Cleaner #990. Replace
blade if necessary.
Ensure paddle is pushed
forward completely after
document is loaded and
aligned. Ensure document
is extended approximately
1-2" (16mm) past edge of
paddle before pushing
paddle forward. Also, check
that the leading edge of
document is evenly adhered
(“locked”) to lower supply
film by temporarily pulling
paddle back after it has
been completely pushed
forward. Check paddle
and tray for flatness.
Prior to loading document,
pull paddle back to “load”
position. Ensure underside
of paddle is clear of any
obstruction or adhesive
buildup.
Verify supply rolls are firmly
seated at base of grooves
in side plates.
Clean adhesive buildup
from idler roller using
isopropyl alcohol or Xyron
Adhesive Cleaner #990.
Troubleshooting
Symptom Cause Solution
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Mechanical Manual crank driven cold lamination
Supplies Replaceable supply roll sets
Document size 25 in. (63.5cm) wide x length of supply
(maximum) 300 ft. (91.4m)
Document thickness 0.0 to 0.10 in. (2.54mm) Up to 3⁄16" (4.76mm)
range foam core mounting board with tray removed
Machine size/ (W) 31.5 in. x (L) 28.25 in. x (H) 18.5 in.
dimensions (W) 80cm x (L) 72cm x (H) 47cm
Footprint (L) 15 in. x (W) 27.75 in. (L) 38cm x (W) 71cm
Machine weight Approx. 90 lb. (40.8Kg)
Xyron Technical Hotline
1-800-793-3523 – USA
[phone] – Europe
Notice
The information in this manual is subject to change without notice. Xyron shall not be liable for
errors contained herein or for incidental or consequential damages in connection with the
furnishing, performance or use of this material.
The purchase or acquisition of this product does not confer the right or license to use the machine
and cartridges in the retroreflective field or to make or sell machines or cartridges for use in the
retroreflective field.
Xyron, Inc. warrants that the Xyron 2500 is free from defects in material and workmanship for a
period of one (1) year from the date of purchase. Xyron, Inc. will repair or replace a defective
product or part without charge provided it is returned to the address below, freight prepaid with
proof of purchase. If the product is damaged by neglect or misuse, the warranty is null and void.
Xyron, Inc.
15820 N. 84th Street,
Scottsdale, AZ 85260
Xyron Europe A/S
Snaremosevej 190 B,
Fredericia, 7000, Denmark www.xyron.com
Technical Specifications
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