Xyron XM2500 User manual

Adhesive Application &
Laminating System
USER’S GUIDE
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 mount-
ing adhesive to a variety of media. The same system is capable of laminating, selec-
tively 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.
2500

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
Features & Functions

Remove the machine from the packaging
and place on a level surface. Locate
the crank handle which is
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 corre-
sponding 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

Step 3:
•On the bottom
supply roll, grasp
the laminated starter
section by the leading
edge film.
•Route over the bot-
tom 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 mini-
mize 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 align-
ing 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 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 docu-
ment 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 fingers across
the leading edge to secure it in
place.
•Turn the handle clockwise to advance
the document through the machine.
Basic Operation
How to remove document from adhesive backing
Proper Technique
•Remove the protective clear mask layer
and discard.
•Always remove the liner from the media as
shown.

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 handle1/2 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. We recommend that
supplies are stored laying flat in
a cool, dry place using the original
packaging.
Supply Roll Removal

Available Supply Roll
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.
Adhesive Application Roll Set
AT400-300 Permanent High-Tack 300’ 24.9” N/A 0.6mil Acid-Free 10 Yes
(91.4m) (63.4cm) (15.2mic)
AT405-300 Permanent Standard 300’ 24.9” N/A 0.6mil Acid-Free 8 Yes
(91.4m) (63.4cm) (15.2mic)
AT406-170 Repositionable 170’ 24.9” N/A 1.1mil Acid--Free 3 Yes
(51.8m) (63.4cm) (27.9mic)
Lamination Cartridges
DL403-300 2-Sided Standard Use Laminate 300’ 25.3” 2.7mil N/A Acid-Free N/A Yes
(91.4m) (64.3cm (67.5mic)
DL404-300 2-Sided Thermal Print Sensitive 300’ 24.9” 2.7mil N/A Acid-Free N/A Yes
Laminate General Use (91.4m) (63.4cm) (67.5mic)
Combination One Side Laminate / One Side Adhesive Application
LAT405-300 1 Side Standard Use Laminate 300’ 25.3” 2.7mil 0.6mil Acid-Free 10 Yes
1 Side High-Tack Adhesive (91.4m) (64.3cm) (67.5mic) (15.2mic)
LAT409-170 1 Side Laminate 170’ 25.3” 2.7mil 0.6mil Acid-Free 3 Yes
1 Side Repositionable Adhesive (91.4m) (64.3cm) (67.5mic) (15.2mic)
Laminate &
Adhesive Mounting
Combination Mounting Adhesive
Material Material Thickness Adhesive Strength PAT
Part Number Product Description Length Width (per side) Thickness Adhesive pH (1:10; 10-high) Approved

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 rec-
ommended that the XM2500 be used and stored in a clean, dust-free environ-
ment. 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 rec-
ommended 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 sol-
vent 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
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

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 clock-
wise.
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 adhe-
sive has been transferred 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. 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.
Troubleshooting
Symptom Cause Solution

Warranty Information
Xyron, Inc. warrants that the XM2500 is free from defects inmaterial and work-
manship 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.
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, so 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
©2009 Xyron, Inc.
8465 N. 90th St. Suite 6
Pima Center
Socttsdale, AZ 85258
Visit www.xyronpro.com for more information