Xyron PRO 2500 User manual

USER’S GUIDE
Adhesive Application &
Laminating System
The XM2500 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
XM2500, 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.

Upper Idler Bar
Upper Supply Roll
Rubber Rollers
Slots for
Supply
Installation
Lower Access Door
Open to install and
remove supplies
Lower Idler Bar
Paddle
Used to lock
document
in place
Lower Supply Roll
Top Cover
Remove to
install/remove
supplies
Crank Handle
Used to advance
documents and
film thru machine
Feed Tray
Used to guide and
align documents
into the machine
Blade
Bars
Cut Blade
Used to trim
output as it exits
the machine
FEATURES & FUNCTIONS
Input Side
Output Side

Step 1:
• Remove the top cover of the machine
by lifting upward
• Grasp the handle on the lower access
door; pull to open.
ASSEMBLY INSTRUCTIONS
1. Place the Crank Handle assembly
onto the D-shaped roller shaft
with the set screw facing upward.
2. Move the handle forward on the
D-shaped shaft until it stops.
3. Use the Hex wrench to secure
the set screw.
Step 2:
• Match the colored 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.
LOADING SUPPLY ROLLS
Remove the XM2500, crank handle assembly and hex wrench from the packaging.

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 lm is
inserted squarely. Rotate
the handle 1/4 turn in the
direction of the arrows.
Step 6:
• Continue to crank lm through the
machine until it is aligned and wrinkle-free.
• Trim off excess lm 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.
Step 4:
• Make certain the lower
lm is tight. If necessary,
rotate the supply roll
in the direction of the
arrows until the film is
taut.
• Grasp the lm 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 lm exits
between the blade bars.
• Just before the top lm
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 blade bars.

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
1 Side Laminate/1 Side Mounting Adhesive.
• 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 ngers across
the leading edge to secure it in lace.
• Turn the handle clockwise to advance
the document through the machine.
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.
Proper Technique
• Remove the protective clear mask layer
and discard.
• Always remove the liner from the
media as shown.
BASIC OPERATION
How to remove document from adhesive

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 4:
• Remove the supply rolls from the
machine. We recommend that
supplies are stored laying flat in a
cool, dry place using the original
packaging.
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.
SUPPLY ROLL REMOVAL

Product Supply Description
Permanent High-Tack Adhesive: Extremely aggressive adhesive instantly creates a
permanent bond on most surfaces. Sets instantly and will not peel. Acid-Free.
Permanent Standard Adhesive: Moderately aggressive adhesive creates a permanent
bond on most surfaces. Can be touched to surface, peeled back quickly, and replaced.
Acid-Free.
Repositionable Adhesive: Allows items to be repositioned over and over. Easy removal
from glass, walls, paper, and most other surfaces. Acid-Free.
Standard Use Laminate: High-gloss film suitable for use on a variety of substrates.
Superior adhesion. Compatible with most media. Acid-Free.
Thermal Print Sensitive Laminate: High-gloss film suitable for use on thermal print
sensitive items. Acid-Free.
Combination – Laminate/Adhesive: One of the laminate products described on the top
surface and one of the acid-free adhesives described on the bottom surface. Acid-Free.
AVAILABLE SUPPLY ROLL
Part Number Product Description Material
Length
Material
Width
Laminate &
Adhesive
Combination
Thickness
(per side)
Mounting
Adhesive
Thickness
Adhesive
PH
Mounting
Adhesive
Strength:
1-10
(10 High)
PAT
Approved
LAT405-300 Standard Use Laminate/
High-Tack Adhesive
300’
(91.4m)
25.3”
(64.3cm)
2.7mil
(67.5mic)
0.6mil
(15.2mic) Acid-Free 10 Yes
LAT409-170 Standard Use Laminate/
Repositionable Adhesive
170’
(51.8m)
25.3”
(64.3cm)
2.7mil
(67.5mic)
0.6mil
(15.2mic) Acid-Free 3 Yes
Combination One Side Laminate / One Side Adhesive Application Roll Set
DL403-300 2-Sided
Standard Use Laminate
300’
(91.4m)
25.3”
(64.3cm)
2.7mil
(67.5mic) N/A Acid-Free N/A Yes
DL404-300
2-Sided
Thermal Print Sensitive
General Use Laminate
300’
(91.4m)
24.9”
(63.4cm)
2.7mil
(67.5mic) N/A Acid-Free N/A Yes
Lamination Roll Set
AT400-300 Permanent High-Tack 300’
(91.4m)
24.9”
(63.4cm) N/A 0.6mil (15.2mic) Acid-Free 10 Yes
AT405-300 Permanent Standard 300’
(91.4m)
24.9”
(63.4cm) N/A 0.6mil (15.2mic) Acid-Free 8Yes
AT406-170 Repositionable 170’
(51.8m)
24.9”
(63.4cm) N/A 1.1mil (27.9mic) Acid-Free 3 Yes
Adhesive Application Roll Set

When properly used, the XM2500 is relatively maintenance-free. Listed below are
safeguards and tips that will produce better results.
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, remove upper cut bar
assembly and gently tap or wiggle a plastic end piece off. Carefully slide the orange
blade holder off cut bar. Replace or clean with light solvent such as isopropyl alcohol.
Carefully slide on new or cleaned blade holder and gently tap the plastic end piece on
and replace cut bar assembly.
Use after storage:
For applications where the appearance of your document is critical, it is highly
recommended that the XM2500 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 4” (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.
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 buildup.
Product Specifications
Footprint .................................................... 18.5” x 28.125” x 15”
(47cm x 71.4cm x 38.1cm)
Weight/Packed Weight ............................. 90lbs (40.8kg) / 105lbs (47.6kg)
Document Thickness (max.) ...................... 0.10” (2.5mm) Up to 3/16” foam core with
tray removed
Finished Document Width (max.) ............. 25” (63.5cm)
Power Requirements ................................. None
Cutter ......................................................... Removable, replaceable cutter
MAINTENANCE, SAFEGUARDS & TIPS

TROUBLESHOOTING
Symptom Cause Solution
Long documents
(such as banners)
are not aligned
with film layers
after laminating.
Feed Tray not installed
correctly or supply roll not
seated at base of groove
in side plate(s).
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).
Cut Blade does not
slide smoothly.
Upper Blade Bar sticking
in side plate groove or
blade sticking on Blade
Bar.
Apply silicon lubricant to all
surfaces of top blade bar.
Film does not exit
machine between
Upper and Lower
Blade Bars.
Material is curled or
adhesive has been
transferred to the Nip
Roller causing the film
to stick.
Reposition material between
upper cut bar and lower guide.
Clean adhesive from nip rollers
if necessary.
Cut Blade does not
cut well.
Blade has accumulated
adhesive buildup or is
dull.
Clean adhesive buildup from
blade using isopropyl alcohol.
Replace blade if necessary.
Thin and/or wide
documents tend
to wrinkle during
lamination.
Paddle not operated
correctly, or tray and/or
paddle are not flat.
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.
Document difficult
to load.
Paddle not pulled back
to load position or has
adhesive buildup on
underside.
Prior to loading document, pull
paddle back to “load” position.
Ensure underside of paddle
is clear of any obstruction or
adhesive buildup.
Film wrinkles don’t
go away as crank is
turned clockwise.
Upper and/or lower
supply roll(s) are not firmly
seated in grooves within
side plate(s).
Verify supply rolls are firmly
seated at base of grooves in
side plates.
Film does not lay
flat, curls and/or
wrinkles.
Adhesive buildup on
lower idler bar.
Clean adhesive buildup from idler
roller using isopropyl alcohol.

Warranty Information
Xyron, Inc. warrants that the XM2500 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, with proof of purchase. If the product is
damaged by neglect or misuse, the warranty is null and void.
To register your product online, please go to www.xyronpro.com and click on the
product registration tab.
*If you purchased this product outside the United States, Xyron will warrant this
product in accordance with the purchasing country’s laws.**
**Excludes Australia
Customer Service
We want you to be happy with your purchase of a Xyron product. If for any reason
you have a problem or a question, please contact Xyron Customer Service toll-free
at 1-800-793-3523 or 1-480-443-9419 for help. You can also e-mail us at:
[email protected]
For customer service outside of the U.S.:
Australia: 61 2 8899 8500; [email protected]
New Zealand: 64 9 272 1600; [email protected]
Europe: 44 845 67801801
Asia: 813 5719 6450
©2011 Xyron, Inc.
8465 N. 90th St. Suite 6
Pima Center
Scottsdale, AZ 85258
Visit www.xyronpro.com for more information.
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