Seal Image 6100 Ultra
Contents
1. 350002 Laminate Cutting Razor Blades 270600 Zippy Cutter Blades Grease Gun 350021 Bearing Maintenance Gun Adapter 350022 Bearing Maintenance High Temp Grease 350007 Bearing Maintenance Edge Wrap Tool 350003 Image Mounting Door Keys 052032 Cabinets Maintenance O Rings 4 169007 Clutch Drives Female Air Coupler 246701 Air Compressor 2 Amp Fuse 1421 12 Electrical 3 Amp Fuse 1421 10 Electrical Also enclosed Installation Acceptance Form 314010 Hunt Graphics offers a comprehensive line of mounting and laminating equipment and supplies to add to your creative potential Contact your nearest sales office see rear cover for location nearest you B amp REPLACEABLE PARTS PART DESCRIPTION 34 Shaft Collar Zinc 3035 DCTN Nice Ball Bearing 7516 DLGTN Nice Ball bearing Air Clutch Mach III Air Compressor Air Cylinder Kit 1 Stage Pull Air Cylinder Kit 2 Stage Main Air Filter Kit Air2. WHT R ti DI WHT BLU SLOT J4 POWER ru RELAY BOARD SUPPLY Power RESISTOR A OH inne O bod 2 Od UU Ze a 2 PROCESSOR T MOTOR p b BOARD ES CONTROL O com QA RED LT BLUE se O alo da O TE pe s E Fr T ee m DE 50 eta ACCESSORIES The following list of accessories is included in the Accessory Pack and can be ordered through a Hunt Graphics Sales Office near you Accessories Part Usage Owner s Manual 350061 Instruction Information Quick Reference Guide 350065 Recommended Settings Terry Cloth Towel 35001 1 Roll Cleaning Image Roll Cleaner 350020 Roller Adhesive Removal 5 16 T handle 312001 Brakes Lock Collar 3 16 Allen Wrench 313020 Table Arms Installment Tape Measure 35001 5 Supply Media Alignment Zippy Cutter
3. We recommend using this Periodic Maintenance Sheet to record dates that authorized safety or maintenance personnel perform these laminator maintenance procedures Proper maintenance of your laminator ensures receiving many years of profit from your investment 46 Ea PROCESS CONTROL SHEET Process Application Use Top Unwind Bottom Unwind FRONT CONTROL PANEL SETTINGS Top Roller Temp Motor Speed Setting Bottom Roller Temp Main Roller Pressure Motor Direction Forward Reverse Cooling Fans On Off BACK CONTROL PANEL SETTINGS Pull Rollers Up Down Pull Roller Pressure Pull Roller Tension WEBBING SETTINGS Web Tension Top Light_ Med Heavy Chill Idlers Over Under 17 pre Web Tension Bott Light Med Heavy Sheet Fed Roll Easel Shim Wheel Shim Wheel Front Rear Bottom Main Roller leeved We recommend that you make a photocopy of this page With each successfully run application record the process and settings and a diagram of the webbing procedure NOTE Keep the record so the application can be repeated at a later date HINT If a standard image is made available for each new process then sales materials and samples can be developed for reference 47 e ELECTRICAL DIAGRAMS C 200 240 Vac Single Phase DOOR INTERLOCK D CONFIGURATION IUSA amp CA
4. Rear Roll Easel Top Main Roller BS rr A e Pressure sensitive Over laminate 9 ul Print Guide NV Front Table Main Roller Marking Film Sleeved Tie Bar Sleeved Tie Bar Paper 7 Backing Marking Film Shiny side out 40 i STEP FOUR OF WEBBING PROCEDURE Le i Lower the top main and pull rollers Reduce the amount of tension on the lower rear take up shaft by backing off the adjustment collar This will prevent bubbling that might occur between the two chill idlers when excessive tension from the lower rear take up shaft pulls the film before it can be properly cooled off If during operation this bubbling can not be eliminated by this method raise the top pull roll and then lower again Continue to run and this should remedy this problem Turn the motor on and run the prints through the rollers checking the quality of the output Minimize adjusting the motor speed during the run of the transfer process This may cause wrinkles feeding into the nip of the main rollers It is best to set the desired speed at the start It is recommended that if you want to change the speed drastically during the operation stop the motor and raise the top roller Adjust the speed setting and lower the top roller to reestablish good output Adjust the tension of the brakes on the front top and bottom unwind shafts and the rear roll easel sha
5. PULL ROLL LE AUXILLARY STOPS 24 VDCI EH ENCODER DRIVE MOTOR 10 181 VDCI THERMOSTATS 24 VDCI LT BLUE LINE FILTER 201 260 Vacl EMERGENCY STOPS ILeft Side 200 240 Vacl 1200 240 Vacl TOP 200 240 Vacl RELAY BOARD 1 2 HEATER ELEMENT SKW 1200 240 Vac BOTTOM 200 240 Vacl FOOT SWITCHES 24 VDEI HEATER ELEMENT SKW THIS CIRCUIT BREAKER IS IN D MODELS ONLY RELAY OVERTEMP 49 LT BLUE itle IMAGE 6100 WIRING DIAGRAMS NOTE SDME PHOTO EYES DO NDT HAVE PINK WIRES ue Document Number ev 8 DI A ate Wednesday July 15 1998 heet ol A 8 c H t ELECTRICAL DIAGRAMS FRONT DISPLAY BACK DISPLAY TOP INFRARED SENSOR BOTTOM INFRARED SENSOR 10 11 VOCI SLOT J1 DIO BOARD SLOT J2 AIO BOARD 1 10 VOC 1 10 VOC TTTTTTTTTTTT S BK la se 284 28 OO O BACKPLANE
6. Used for easy loading of laminates and adhesives Allows for rapid changeover between applications Combined with the lock collar the brake easily adjusts the film tension on each unwind shaft 3 ROLL EASEL This digital media supply shaft works in conjunction with the rear wind up tube for roll to roll laminating and smooth square media feeding An optional second media supply shaft is also available 4 HIGH RELEASE SILICONE ROLLERS The high release silicone coatings prevent adhesive build up and make cleaning easy Reinforced steel main rollers minimize roller deflection under high pressures 5 FIVE WIND UP TUBES Used for winding up the release liner off some laminates and adhesives A clutch drive assembly with a clutch adjustment collar allows for the correct amount of tension needed 6 FILM COOLING SYSTEMS Two chill idlers and a cooling fan bank effectively cools the film during encapsulating and heat transfers producing smooth flat output 7 PRINT GUIDE TABLE Allows for easy feeding of cut sheets into the laminator rollers as you feed them under the print guide 8 DIGITAL TOUCHPAD Touchpad control panels on the front and back of the laminator with LED indicators and 9 preset settings for temperature and speed ADDITIONAL FEATURES Electric High Wattage Heating Elements and Independent Temperature Controls with Infrared Temperature Sensors Provide for rapid even heating to 300 F 149 C and maximum accuracy Heavy duty C
7. at our option replaced without charge The applicable warranty shall be one year from date of purchase with the exception of silicone roll coverings that will be six months from date of purchase Original consumer purchaser means the person whom first purchased the product covered by this warranty other than for purpose of resale The warranty extends to and is enforceable by only the original consumer purchaser and only for the period during the applicable term which the product remains in the possession of the original consumer purchaser For more information regarding this warranty please contact your distributor KI WARNING Changes or modifications to this unit not expressly approved by the party responsible for compliance could void the user s authority to operate the equipment EN WARNING Any unauthorized changes or modifications to this unit will void the user s warranty and will transfer health and safety obligations to the user vI WARNING This machine is designed for mounting and laminating Any use other than the intended may cause damage to the machine or physical harm to the user INTRODUCTION SPECIAL MARKINGS M Thank you for purchasing an Image 6100 Ultra laminator a laminator designed to give you years of reliable service As you become familiar with your laminator you will appreciate the high quality of its production and the excellence in engineering stated in its smartly styled design The Im
8. licensed electrician in accordance with electrical codes in your area install your mains power Specifications subject to change without notice IMPORTANT The mains outlet should be fused no higher than 60 Amp Three phase or 100 Amp Single phase The information contained herein is based upon our research and believed to be accurate but the accuracy and completeness of our recommendations are not guaranteed The user shall determine the suitability of the product for their use before using the product and the user assumes all risk and liability whatsoever in connection with the use of the product Neither seller nor manufacturer shall be liable for any injury loss or inability to use product The following is made in lieu of all warranties expressed or implied seller s and manufacturer s only obligation shall be to replace or credit such quantity of the product proved to be defective IMPORTANT SAFEGUARDS AND WARRANTY INFORMATION Your Image 6100 Ultra laminator is designed to be one of the safest laminator on the market Operational safety features have been designed into your laminator with the user s safety of utmost consideration However following safe operating guidelines is still the responsibility of the operator NA Read heed and follow these safety and operating instructions POWER SOURCES Operate the laminator only with the type of power sources indicated in this manual Refer to the Specific
9. 21 e SHIM WHEELS Refer to the product literature supplied with your laminator for the proper shim wheel setting needed for your particular laminating application The correct pressure setting is important to insure that you receive a quality output To Set the Shim Wheels Determine the thickness of the board that you will use for mounting NOTE Adjust the shim wheels on both sides of the laminator to compensate for the mounting board and apply adequate pressure IMPORTANT Whenever you mount onto a board that is thicker than the thin laminate you must create a gap between the top and bottom rollers nearly equal to the thickness of the board being used By doing this you insure the correct amount of pressure neither too little nor too much WARNING Too much pressure can crush the board being used and even damage the top and bottom rolls Normally a press of 025 0 6mm is sufficient Equivalent Press Measurements Inches Metric mm Decimal 1 25 mm 1 000 3 4 19 mm 0 75 1 2 13 mm 0 50 3 8 10 mm 0 375 1 4 6 mm 0 25 3 16 5mm 0 1825 1 8 3mm 0 125 1 16 2mm 0 0625 1 16 2mm 0 0625 0 0 0 207 0 Figure 6 Adjusting the Shim Wheel ei PRESET PROGRAMS Purchasers should individually determine prior to use the suitability of each material for their specific purpose Hunt Graphics does not accept liability for risks associated with the performance of materials in
10. JET ELECTROSTATIC AND PHOTOGRAPHIC COLD SIDE HOT SIDE FILMS Top Unwind Pressure sensitive over laminate Bottom Unwind Pressure sensitive mounting adhesive unwind Shan LAMINATOR SETTINGS Front Control Panel Top Roller Temp OFF gt Bottom Roller Temp OFF Main Roller E Main Roller Pressure 40 60 PSI te Easel Motor Speed Setting 3 5 FPM 1 1 5 MPM CS Motor Direction Forward Reverse X oim E Ken Cooling Fans On Off X Pull Roller Back Control Panel Pull Rollers Up Down X Pull Roller Pressure 40 60 PSI Pull Clutch Tension 65 70 PSI WEBBING SETTINGS Web Tension Top None X Med Heavy Web Tension Bottom None X Med Heavy Chill Idlers Over Under 1 Over 2 Over Sheet Fed X Roll Easel Covered Shim Wheel Settings 1 16 2mm Zeie 30 ms MOUNTING Mounting involves permanently affixing a previously made decal onto a substrate No laminates or adhesives are needed IMPORTANT Before beginning adjust the four shim wheels to correspond to the thickness of the backing being used Place the mounting board on a flat surface Lay your images face down on the mounting board Fold back approximately one inch of the release liner along one of the edges to expose the adhesive Crease the release paper evenly on this fold pressing with your fingertips from the center out Turn the image over and carefully position the exposed adhesive edge of the image onto the board using t
11. Make a rigid display by face mounting an image to a clear acrylic using an optically clear pressure sensitive adhesive Coat the acrylic and mount the print A diffuser film can be applied to the back as needed Roller Films Temperature Top Optimount Ambient to 113 F 45 C Bottom Ambient to 113 F 45 C Speed 3 5 FPM or 1 1 5 MPM PROGRAM 5 FLOOR GRAPHICS See webbing diagrams P 30 First make a decal by applying a special non slip durable laminating film to the face of the print and a permanent removable pressure sensitive adhesive to the back Then using a hand roller and burnishing tool or squeegee apply the graphic to a clean smooth floor Roller Films Temperature Top Seal s Floor Guard 194 203 F 90 95 C Bottom Floor Grip 1 Ambient to 122 F 50 C Speed 3 5 FPM or 1 1 5 MPM PROGRAM 6 ONEPASS DISPLAY See webbing diagrams P 29 and 30 OnePass Displays are created by taking a printable laminate and using the laminator seal it into a foam board or a rigid board Roller Films Temperature Top Seal s OnePass 220 F 105 C Bottom NA Ambient to 110 F 45 C Speed 3 FPM or 1 MPM pa ENCAPSULATING SET UP WEBBING Select films slightly wider than the image width to allow for a border without film waste A border of 1 8 to 1 4 is adequate Ensure the main rollers temperatures are set according to the recommendatio
12. ROLLERS m Le i IMPORTANT Hunt Graphics recommends that a licensed electrician in accordance with electrical codes in your area install your laminator Refer to the Specifications Table on page 4 for the Electrical Panel Assembly power requirements All domestic laminators will be shipped without a power cord It is required that only a qualified electrician provides power to the Solid State Relay solid State Relay Overtemp Relay Htm laminator or the warranty will be void We recommend a Ground Green Wire Special Instructions The ground green wire should be two inches longer than the black and white wires Current Device RCD RCCD Once power is connected to your laminator press the main power button on the front Fault Interrupter GFI circuit breaker with a 60 amp load rating not Earth Ground exceeding a 100 amp load rating Use 3 6 AWG power Lower Cora cord Type SOW A SO rated to 90 C and 600 Volts as d el control panel once to turn the laminator ON If you have no display refer to the Troubleshooting page for problem solving NN info See the Electrical Connection Diagram for detailed 90 C 600 volts information For European laminators use a Residual Turn clockwise to tighten Recommended plug Nema 6 50P ban Wire White Wire Press the roller UP button once to raise the top ro
13. error has occurred The speed display will show the error level The top temperature display will show the error data These displays are used to find the problem The bottom temperature display shows the current running program number The first time an error occurs on your machine reset your power by depressing and resetting the Emergency stop button If the error occurs again see the chart The chart defines some of the problems that may have caused the error If you cannot define the problem contact your distributor or sales representative for technical assistance Note After an error has shut down the system the power must be turned off for 10 seconds using the Emergency stop button After 10 seconds turn the power on to restore the system re WARNING The machine must be unplugged from the power source before any servicing Speed Display Top Temp Display Problem Error Level 1 0 Error Data 1 The photo eye has failed Error Level 1 0 Error Data 5 The digital I O DIO card is defective Error Level 2 0 Error Data 0 Reset If error occurs again the digital I O DIO card is defective Error Level 2 1 Error Data 1 The Solid State Relay for the top main roll heater is defective Error Level 2 1 Error Data 2 The Solid State Relay for the bottom main roll heater is defective Error Level 2 1 Error Data 3 If the rollers are hot the Digital I O DIO card h
14. he bolom oris Pull Clutch Tension 65 70 PSI AT WEBBING SETTINGS Web Tension Top Light X Med Heavy Web Tension Bottom Light Med X Heavy Chill Idlers Over Under 1 Over 2 Over Sheet Fed X Roll Easel Shim Wheel Settings 3 16 or 5mm Optional Applying a laminate to the bottom of the mounting board adds the benefit of preventing the warping of the foam board An added benefit allows for the quick changeover from encapsulating to one pass mounting 2 a APPLYING AN OVERLAMINATE PROCEDURE An over laminate such as Seal Print Shield pressure sensitive adhesive with a release liner can be applied to your mounted prints photographs or images on photographic papers Use a sled to support unmounted prints during the laminating procedure To create a sled coat a board with Seal Print Mount adhesive and leave the release liner on Sleds can be reused until the surface is marked enough to transfer blemishes through the laminated print Otherwise recoat the board if it is still in good functional condition Use leader boards the same thickness as the sleds boards Place unmounted prints to be laminated face up on the sled as the sled passes through the rollers For over laminating mounted prints follow the same procedures eliminating the use of a sled IMPORTANT Before beginning first adjust the four shim wheels to correspond to the thickness of the board you will use Load a roll of pressure sensitive over lam
15. idler and lay evenly over the mounting adhesive to adhere Top film pressure sensitive First mount a core on the top front wind up tube and adhere a strip of the pressure sensitive adhesive across its width Pull the film down under the top idler and up to the wind up tube Adhere the release liner smoothly to the wind up tube Separate the film from the release liner and lay squarely over the mounting adhesive to adhere Lower the top roller and use a leader board to feed the films into the nip Use the footswitch to feed the films through the rollers From the rear of the laminator use the footswitch to feed the film over the chill idlers and through the pull rollers Keeping film taut hold the leader board up against the top pull roller with one hand and lower the top pull roller Cut off the piece of leader board Return to the front and run the laminator applying light brake tension gradually on both supply shafts until there are no wrinkles in the film as it goes into the nip If wrinkles do not work out within 5 feet or 1 5 m cut the film and repeat the webbing process Once the laminates are tracking correctly feed the image into the nip through the print guide table Apply back tension to the image by holding back on the outer edges Once laminated the image can be mounted to a board or other substrate 28 s DECALING HEAT ACTIVATED PROCESS Creating a decal by applying a hot laminate to the top and a cold backing fil
16. not spill isopropyl alcohol on the laminator WARNING Use only an Image Roll Cleaner or a cotton cloth and isopropyl alcohol to clean the rollers and not other solvents or cleaners Use of other cleaners or solvents may cause roller damage and will void the warranty i ei LOADING A ROLL OF MATERIAL re IMPORTANT Seal pressure sensitive adhesives are wound with the adhesive side on the inside Make certain that you place the roll of film on the unwind supply shaft so that the material will feed with the adhesive side facing away from the rollers With the 5 16 T handle included in your accessory pack loosen the setscrew and remove the lock collar from the unwind shaft Slide the roll of material onto the unwind shaft centering the roll as explained in Setting the Brakes Reapply the lock collar and move the brake and lock collar into place and tighten the setscrews IMPORTANT The position of all films boards rolls of media and cardboard cores for wind ups must be set central in the laminator to ensure optimum quality and correct tracking Use the tape measure included in your accessory kit for alignment Press the unwind supply shafts firmly into the unwind brackets to prevent tension and tracking problems WEBBING THE LAMINATOR One of the most critical aspects of operating your laminator is the process of webbing Mastering webbing is the key to operating the laminator effectively Each particular laminating mounting proce
17. wide gap doesn t occur causing the roller to slip But do not overlap e NOTE Thicker laminates and images require slower speeds to allow the heat to properly penetrate the laminate and the image and activate the adhesive on the mounting board e Remove the mounted image from the rear of the laminator trim it to size and display it The one step process takes practice to master Each individual combination of laminate and image requires different speeds and temperature settings Use a copy of the Process Control Sheet to record successful combinations _ amp ONE STEP MOUNTING AND LAMINATING PROCESS The one step process of hot mounting an image to a heat activated board and applying a hot laminate to the top of an image The option of applying a bottom laminate prevents board warping MEDIA INK JET ELECTROSTATIC AND PHOTOGRAPHIC COLD SIDE HOT SIDE FILMS Top Unwind Heat activated Laminate 3 5 Mil Bottom Unwind Opt Heat activated Laminate 3 5 Mil Front Top Unwind Shaft LAMINATOR SETTINGS Front Control Panel Top Roller Temp 210 215 F 99 102 C Bottom Roller Temp OFF See Optional xd Main Roller Pressure 40 60 PSI ae I T Motor Speed Setting 3 5 FPM 1 1 5 MPM awe Motor Direction Forward X Reverse a n Bottom Cooling Fans On On X Maln Roler Back Control Panel E Optional Pull Rollers Up Down X Applying a laminate Pull Roller Pressure 40 60 PSI 1o
18. 3040 708664 REAR COVER Huntgraphics For more information about Hunt Graphics products contact the sales office nearest you Hunt Graphics Americas Hunt Graphics Europe Hunt Graphics Europe Railroad Ave Extension Building 8 Unit 6 Scimitar Park Kanaaldijk O Z 3 Beacon Falls Connecticut USA 06403 0098 Courtalds Road P O Box 29 8100 AA Raaalte Phone 203 729 5201 e 800 257 7325 Basildon Essex England SS13 1ND The Netherlands Fax 203 729 5639 e 800 966 4554 Phone 00 44 1268 591691 Phone 00 31 572 345 500 Fax 0044 1268 727615 Fax 00 31 572 345 501 Hunt Graphics Americas Hunt Graphics Pacific The Information contained herein is 690 Gana Court Unit A 13 Floor Block 1 general and does not constitute any Mississauga Ontario Canada L5S 1P2 Leader Industrial Centre warranties or guarantees Phone 1 905 564 7717 e 800 663 4868 Tsuen Wan New Territories Hong Kong Fax 1 905 564 7079 Phone 00 852 2407 3738 Fax 00 852 2408 0973 PS sunr Hunt Graphics Enhancing the world s images A Subsidiary of Hunt Corporation 53
19. D indicates which direction the laminator is in NOTE The operator can change the heat and speed settings after a program is loaded by use of the adjustment buttons MOTOR ON OFF BUTTON LED is lit when the motor is ON The footswitch can be used when the motor is OFF MOTOR SPEED ADJUSTMENT BUTTON Press arrow to increase Press arrow to decrease T ei CLUTCH CONTROL PANEL DIAGRAM The Clutch Control Panel adjusts the amount of pull tension that is directly applied to pull the laminate through the pull rollers The amount of tension applied affects the output and extreme pull tension will stretch the hot films causing outfeed waves in the finished product This is a factor with films such as Print Guard which stretches easily Excessive tension will also cause downward curl in the finished product The standard setting for normal operation is 65 70 PSI For mounting applications using the pull rollers set the tension for 75 PSI to avoid the pull roller from slipping 1 AIR PRESSURE GAUGE Indicates the PSI reading for the overdrive tension of the bottom pull roller The standard setting for normal operation is 65 70 PSI 2 AIR REGULATOR KNOB This knob adjusts the overdrive tension of the bottom pull roller Pull out the knob and turn to adjust push back in to set 1 e 2 O 16 J d LAMINATOR SET UP CHECKING OPERATION m If a process requires heat press ON the heaters approximately 45 minutes
20. Fitting Three way Air Gauge Kit Air Regulator Kit Air Regulator Kit 1 Analog Board Bearing Flange 1 15 16 Bearing Take up 1 15 16 Brake Kit Breaker 25 Amp Breaker 50 Amp Breaker 6 Amp CBK PMTAOR Button Chain Clutch Chain Main Drive Chain Motor Chill Idler Shaft Chill Idler Plated Clutch Drive Kit Clutch Idler Kit Connecting Link Contact Block Digital IO Board Door Disconnect 63 Amp PART 200065 027420 027425 104550 225020 55043 55042 5507 234010 55069 50607 50607 1 131006 021156 025155 50623 129720 129725 129702 175060 101262 101260 101261 708666 615661 131007 143025 PART DESCRIPTION Electrical Panel Base Kit Electrical Panel Platform Kit Encoder Bracket Encoder Fans Fuse 250V 3Amp Hex Tensioner Center Kit Hex Tensioner Offset Kit Lock Collar Mechanical Transformer Shaft Mini Tensioner Kit Motor Tension Idler Center Kit Motor Tension Idler Offset Kit Motor Omron G7L 2A TUBJ CB DC24 Panel Display Processor Board Rewind Tube Gray Roll Easel Shaft Rollers Main Rollers Pull Solenoid Sprocket 35B15 7 8 Bore Sprocket 35B17 3 4 Bore Sprocket 35BS13 5 8 Bore Sprocket 35BS17 7 8 Bore Sprocket Main Roller Unwind Shaft 52 PART 55066 55065 511624 501624 136600 142110 55101 5510 516004 708604 55112 55103 55102 107550 166040 131002 131001 615461 708660 691690 691694 55053 113115 113015 113030 113057 11
21. NADAI au 6A CONTROL POWER R RED 5 25A BOTTOM HEATER De RED o lt Se got 2 25A TOP HEATER RED E e On N o e i O e GREEN PE SIA LT BLUE ec o COMMON HOT 200 240 Vac Single Phase DOOR INTERLOCK 11 CONFIGURATION IEUROPEI ere 6A CONTROL POWER 7 RED 5 o 25A BOTTOM HEATER In RED o lt e T e 5 6 25A TOP HEATER RED eg eo n N e e NEUTRAL O O e PE GREEN YELLOW LT BLUE eer i d Os NEUTRAL TERMINAL BLOCK IBLUEI 380 415 Vac Three Phase DOOR INTERLOCK 13 CONFIGURATION IEUROPEI ee 6A CONTROL POWER RED e o 2 O e 1 O 25A BOTTOM HEATER e 0 3 O 12 RED o ia 5 O 6 25A TOP HEATER RED ses A e On N ei e NEUTRAL O O BE GREEN YELLOW 1 O 2 NEUTRAL LT BLUE ex TERMINAL BLOCK IBLUEI Title IMAGE 6100 WIRING DIAGRAMS Size Document Number Rev A 6100A A Date Tuesday July 14 1998 Eheet 1 of 4 48 D ELECTRICAL DIAGRAMS LT BLUE CIRCUIT BREAKERS MAIN ROLL COOLING FANS 1200 240 Vacl EMERGENCY STOPS Right Side 200 240 Varl AIR SOLENIODS 124 VDCI RED WHT RED BLK
22. ROBLEM The laminator is not heating up or shows erratic temperature readings SOLUTION Make sure the heaters are ON the LED light is illuminated Make sure the rollers are together with both shim wheel settings set at 0 and turning at a moderate speed when first heating up For technical assistance please contact your sales representative PROBLEM Images or Prints are rippling or jumping as they are fed into the nip SOLUTION Apply tension to Images or Prints as they are fed into the nip Hold cut sheets back by hand PROBLEM The film output is rippled or wavy boat waking SOLUTION Check that you have webbed the laminator correctly Refer to the web diagrams Improper film tension most encapsulating films need a minimal amount of brake tension Run the laminator at a higher speed for photo materials or heat sensitive prints because exposure to heat at low speeds can cause waving PROBLEM e The film is cloudy or mottled SOLUTION Increase the roller temperature or decrease the motor speed Heavier mil films may require increased roller pressure due to the thicker adhesive layer PROBLEM The display is flashing and the controls do not respond SOLUTION See next page for Error Codes ERROR CODES The machine shuts down and the display starts blinking This means that the software has detected an error in the system The numbers on the displays tell you what
23. TABLE OF CONTENTS GETTING STARTED Technical SbeelTIGRU OIN aaa Important Safeguards and Warranty Intormatton Features of the Image 6100 URFa iii Image 6100 Ultra Features Deeg Salet fee T ciiam em Iristallaton or Your LarfillialOt anco oinnia ta nek osx ssa aeiaai WoriNg Ares DISOIAND EE Front Control Panel DISAGI EE Back Gontrel Panel DISgram EEN Cluten control Panel Didgrani EE PROCEDURES FOR USE ene tu Checking Cleaning the RO IGES geegent Loading a Roll of Material Webbing the Laminator Feeding Image ADJUSTMENTS AND SETTINGS Se IN Wile BAKES e TR MR mt Di eM D PE LAMINATING PROCESSES meset Fro IS s E peni EE Double sided RE ale LEG AR A MOUNTING PROCEDURES leslie rr One step Mounting and Laminating ssseessessssessrnsssssssessrnsssssssnnnnnssssssrennnnsssens Applying an OVErtamninate cc aiar TRANSFER PROCESS OnePass Dry Transfer PrOCOSS is ttti ttt ra TROUBLESHOOTING OO Laminating REN e EE MAIA Your ESrillialok TE Periodic Maintenance Sheet Process Control Ee ISP OU Ee E PIE aiea iaa EPUM EE Sd P asai p D DD LIMITED WARRANTY ON IMAGE LAMINATORS Hunt Graphics warrant to the original consumer purchaser that all new Image laminators that prove defective in materials or workmanship within the applicable warranty period will be repaired or
24. ading rolls onto the laminator requires care as the material must meet in such a way as to prevent wrinkling and other abnormalities IMPORTANT The brake setting greatly affects the smooth flow of the laminating film e Center the rolls on top and bottom unwind shafts in relation to each other Measure from the end of each film roll not the core to the side panel of the laminator for both rolls Then adjust the brake and lock collar so that both rolls match e Tighten the rolls by adjusting the brakes and putting on the aluminum lock collars to hold the rolls in place IMPORTANT Do not over tighten the lock collars or the steel screw will strip the aluminum threads of the lock collars e Set the appropriate brake tension Set the brake so that the material doesn t free spin on the shaft yet stills dispenses film without a significant amount of pull IMPORTANT When reloading the rolls of laminate reset the brake to bottom out when no gap appears between the brake collar and tension ring exerting no force on the roll of laminate To increase the brake tensions turn the tension ring counterclockwise Brake Figure 5 Image Brake Diagram E Unwind Shaft 0 B Roll of Laminate When no gap appears between the brake collar To increase brake tension and tension ring the brake turn tension ring counterclockwise has bottomed out and no force is exerted on the roll of laminate
25. age 6100 Ultra is a true bi directional laminator specifically designed for the one pass thermal transfer process Also designed for full range high volume requirements including heat or pressure sensitive lamination encapsulation and hot or cold mounting of images The two sets of symmetrical bi directional rollers speed production running heat activated materials from the front and cold pressure sensitive applications from the back By following the guidelines outlined in this manual for proper care and maintenance you can depend on receiving many years of trouble free profitability from your investment Reading your Owner s Manual will familiarize you with the particular features laminating procedures and operational guidelines of your laminator The manual includes instructions for various laminating processes and diagrams that give you the comprehensive information needed for the safe and efficient use of your laminator This basic knowledge provides the foundation for the creative innovative uses you can build on as you achieve the basic skills through practice WARNING Please pay special attention to all passages marked this way This information is vital to preventing user injury and or damage to the laminator Failure to follow this information could void the user s warranties and transfer all safety obligations to the user IMPORTANT Passages marked this way give recommendations for safety procedures and guidelines and information on
26. am Presets will be visible for a few seconds Use this button to scroll through the programs to put it on Standby On Standby all functions PROGRAM ENTER BUTTON are off but the laminator is still operational Press and release to load program shown in CE o display Press and hold for 3 seconds to save a After an Emergency Stop press to restart new program on the numbered setting shown O O SPEED READOUT NOTE The operator can change the heat and Indicates the speed in feet or meters per Speed settings after a program is loaded by O minute use of the adjustment buttons MOTOR DIRECTION BUTTON O TOP AND BOTTOM HEATERS READOUT ES gt ti E BO TOnWard Displays both the set and actual temperature of TESS SA AINOW TOF Ie Dae the top and bottom rollers The LED indicates which direction the TOP AND BOTTOM HEATERS ADJUSTMENT BUTTONS laminator is in Press once to view the temperature set point Press and hold the arrow to raise the MOTOR ON OFF BUTTON LED is lit when the motor is on The footswitch can be used when the motor is off temperature Press and hold the arrow to Xs I lower the temperature The adjustment will ci diu ais ADJUSTMENT BUTTON begin at a slow pace then more rapidly Le p E cal e dii TOP BOTTOM HEATER ON OFF BUTTONS Y COOLING FANS BUTTON Turns On Off the fans S ei Turns the top or bottom heaters ON or OFF The corresponding LED is lit wh
27. aminated images IMPORTANT When applying films with plastic liners do not stop while laminating as a release separation line will appear in the finished lamination This line may fade over time but initially will be visible especially on dark materials i ei APPLYING AN OVERLAMINATE PROCESS Applying a cold pressure sensitive adhesive with a release liner to mounted prints photographs or images on photographic papers FILMS Top Unwind Bottom Unwind LAMINATOR SETTINGS Front Control Panel Top Roller Temp Bottom Roller Temp Main Roller Pressure Motor Speed Setting Motor Direction Cooling Fans Back Control Panel Pull Rollers Pull Roller Pressure Pull Clutch Tension WEBBING SETTINGS Web Tension Top Web Tension Bottom Chill Idlers Over Under Sheet Fed X Shim Wheel Settings Shim Wheel Shim Wheel COLD SIDE Pressure sensitive Over laminate NA HOT SIDE Rear Top Front Top Unwind Sha Unwind Shag Release Liner 5 Pressure sensitive Over laminate 210 215 F 99 102 C 1 OFF 40 60 PSI 3 5 FPM 1 1 5 MPM Forward X Reverse __ On Off X Sled or Mounted Print Bottom Main Roller Up Down X 40 60 PSI 65 70 PSI Light X Med Heavy Light Med X Heavy 1 Over 2 Over Rol Easel 3 16 or 5mm NOTE For double sided laminations encapsulating over laminate and trim the first side using the preceding procedures and then re
28. application PROGRAM 1 FLEXIBLE DISPLAYS ENCAPSULATING See webbing diagram P 25 Flexible displays are made by encapsulating or sealing a print between two layers of hot laminating film or between a hot laminate and a hot backing film Roller Films Temperature Top Jet Guard Crystal Matte 185 203 F 85 95 C Bottom Jet Guard Gloss 185 203 F 85 95 C Speed 3 5 FPM or 1 1 5 MPM PROGRAM 2 POP UP DISPLAYS See webbing diagram P 29 Pop up display component panels are made by encapsulating or sealing a print between a hot laminate and a hot backing film Roller Films Temperature Top Jet Guard Deep Crystal 195 F 95 C Bottom Stoplight 220 or 370 200 F 105 C Speed 3 FPM or 1 MPM PROGRAM 3 RIGID DISPLAYS See webbing diagram P 30 First you have to make a decal Then apply a laminating film to the face of the print and a pressure sensitive adhesive to the back Then mount the print to a smooth flat substrate of your choice Roller Films Temperature Top Jet Guard Crystal Matte 194 203 F 90 95 C Bottom Print Mount R Ambient to 122 F 50 C Speed 3 5 FPM or 1 1 5 MPM 23 When using a preset program the temperature will automatically activate Settings provided are for optimal performance using Seal s recommended film combinations PROGRAM 4 RIGID BACKLIT DISPLAYS See webbing diagram P 35
29. as failed If the rollers are cold The Analog Card has failed Error Level 2 2 Error Data 1 The top thermocouple is defective or has a bad connection Error Level 2 2 Error Data 2 The bottom thermocouple is defective or has a bad connection Error Level 2 2 Error Data 3 The Analog I O AIO Card is defective 43 eta LAMINATING TERMINOLOGY DECAL An image that has been laminated on top either heat activated or pressure sensitive with an adhesive backing ENCAPSULATING Completely sealing an image between two heat activated films FILM A synonym for laminate The clear material used in the laminating and encapsulating processes HEAT ACTIVATED FILMS Films with a dry adhesive that is activated when heat is applied Once applied to an image the adhesive forms a strong bond locking the laminate and the image together IN FEED The side of the laminator from which images are fed LEADER BOARD A piece of thin foam board about 4 x 2 used to push films into the nip Also used for mounting or pre coating boards to prevent adhesive from getting onto the rollers and sealing edges MIL Refers to the thickness of the laminate film MOUNTING Applying an image onto some kind of foam board or substrate NIP The spot where the top and bottom rollers meet 44 OUT FEED The side of the laminator from which completed images emerge PRE COATING The process of co
30. ating a substrate with an adhesive mounting film onto which an image can be mounted PRESS The amount of force in distance put on anything that passes between the top and bottom rollers Setting the shim wheel adjustment for the top roller at 100 and running an image 125 thick through puts a 025 press on the image PRESSURE SENSITIVE FILMS Films with a wet adhesive which forms a bond between the protective laminate and the surface of the image being laminated Used primarily for fast mounting applications and recommended for heat sensitive thermal and photographic prints RELEASE LINER The backing on a pressure sensitive laminate or mounting adhesive After peeling the release liner off the adhesive layer becomes exposed SLED CARRIER BOARD A piece of smooth non crushable board preferably Masonite coated with a mounting adhesive and leaving the release liner on to provide the necessary non stick surface A piece of foam board can also be used but it will not have the longevity of the Masonite board Sleds are used when laminating one side of an image only SUBSTRATE The material to which an image is mounted or affixed EN MAINTAINING YOUR LAMINATOR CLEANING THE LAMINATOR Clean the exterior painted surfaces of your laminator with a damp cloth Use a household detergent to remove any difficult stains Do not use an abrasive cleaner or it may damage the paint surface M WARNING Do not let water get int
31. ations Table for the proper power requirements WATER AND MOISTURE Install a GFI breaker RCD in Europe if using the laminator near water or in an area of high humidity CLEANLINESS Use your laminator in the cleanest most dust free environment possible to produce the highest quality output SAFETY Keep hair hands and clothing clear of the laminating roller openings at all times Do not wear loose clothing scarves ties and similar garments while operating the laminator PREVENTATIVE MEASURES Do not feed objects such as staples paper clips and rough or abrasive materials through the laminating rollers Keep all objects such as tools rulers pens markers or knives away from the roller opening Refrain from leaving such items on the front table to prevent them from accidentally being fed into the rollers IMPORTANT NEVER cut or slice directly on the rollers as any cuts or gouges will destroy them ALWAYS use cutters with enclosed blades to prevent cutting the rollers and to avoid extensive replacement costs WARNING Always adjust the shim wheels to create a gap between the laminating rollers to prevent flat spots from developing when the laminator is not in use Flat spots will affect the quality of the output and void the warranty replacement WARNING Pull the front table away from the heated rollers when the laminator is not in use or when heating up the rollers Otherwise the front edge of the table will become extremely hot and possib
32. before use to ensure that the rollers are at the correct operating temperature After you are familiar with the control panel s buttons check all operations Check the Motor and Footswitches Press the motor On Off button once the corresponding LED should be lit Push the motor Up Arrow and the speed readout should increase in number and motor speed Press the Down Arrow and the speed readout should decrease in number and motor speed Check the Heater Controls Press the Top Heater On Off button once the corresponding LED should be lit The readout will display the ambient temperature Press the top heater Up Arrow to see the temperature set point Watch the readout for 5 minutes to verify that the temperature increases Press the top heater On Off button again once the corresponding LED should not be lit Repeat this procedure for the Bottom Heater Check the Emergency Stop Buttons Press one of the Emergency Stop Buttons and the laminator will shut down Rotate the Emergency Stop Button clockwise to reset Press the Power Standby Button The laminator will turn back on Check to make sure the corresponding LED is lit Repeat this procedure with all four Emergency Stop Buttons WARNING If your laminator does not operate correctly contact Technical Service immediately i ei CHECKING THE ROLLERS Your laminator has pneumatic pressure adjustment with fine tune control for a smooth flat finish Correct adjustment of the pres
33. ced on the front table and set aside Remove the protective film wrapped around the laminator s front table that is holding the footswitches and back table Remove the foam from the footswitches and place a footswitch on each side of the laminator for operator use while feeding images Remove the foam from the back table arms Using the 3 16 Allen wrench in the accessory pack reattach these arms to the inside back of the left and right cabinets Once reattached unwrap and insert the back table into position Figure 2 Attaching the Back Table Arms and Inserting Table Table E d On the front table remove the MA ES inert screws through table arms into Cabinets foam from the ends of the roll E easel shaft and the front table s arms Fit the roll easel shaft into place over the front table arms roll easel stubs Unpack the Air Compressor and attach the feet as instructed in the directions We recommend that you use Teflon tape on the fitting ends of the air compressor hose to seal for leaks Insert one end of the hose into the D port of the compressor Attach the female air coupler included in your Accessory Kit Package onto the other end of the hose Connect this end to the male air fitting in the back of the left cabinet Plug the air compressor into a standard AC output 110V in U S 200 240V in rest of world amp BackTable ELECTRICAL FIGURE 3 ELECTRICAL CONNECTION DIAGRAM U S Domestic
34. der the P second chill idler Tape Markingl Film to Cardboard Core A z R Bott e From the back of the laminator pull the film Windup Tube gt through the pull rollers and down to the bottom rear wind up tube Tape the film securely to the cardboard core and rotate a few inches of film around to secure Paper Marking Film Backing Shiny side out e is STEP TWO OF WEBBING PROCEDURE Establish Path of Images Toner and Paper Le i IMPORTANT The images toners on the transfer media are easily scratched so care in handling is necessary Load the roll of Images toner and paper onto the COLD SIDE HOT SIDE top front unwind shaft images facing out Load the roll with the media feeding off the back Rear Top Unwind Sha Adjust and align the images to the roll of Marking Tape Transferred media to cardboard core over film Set the brakes and lock collars as described in center wind up Tube Setting the Brakes Images Toner amp Paper Images Facing Out Rotate the roll of Marking film forward on the front bottom unwind shaft to create slack in the film This will allow for the Scotchprint Images to be webbed through the center chill idlers easier Pull a length of images down around the polished top idler and through the nip of the main rollers Pull forward the roll of Marking Film to create slack 3 in the film for webbing of the Marking Film Images To
35. en the heater is ON BACK CONTROL PANEL DIAGRAM AIR PRESSURE GAUGE Indicates the PSI reading for the O ROLLER UP DOWN BUTTON downward pressure of the top pull roller Press the arrow once to raise the top The standard setting for the normal roller operation is 40 60 PSI Press the arrow once to lower the top roller PROGRAM DISPLAY This display readout will signify the number of the program that is currently being run on the laminator The programs are numbered 1 through 9 with each program having the presets for the speed and the top and bottom roller temperatures PROGRAM SELECTION BUTTON PR Press the arrow to go to the next higher program Press the arrow to go to the next lower program Presets will be visible for a few seconds Use this button to scroll through the programs AIR REGULATOR KNOB Adjusts the downward PSI of the top roller POWER INDICATOR LED Lit when power is ON MAIN POWER STANDBY Press this button to turn on the laminator or to put it on Standby On Standby all functions are OFF After an Emergency Stop press to restart SPEED READOUT Indicates the speed in feet or meters per minute PROGRAM ENTER BUTTON Press and release to load program shown in display Press and hold for 3 seconds to save a new program on the numbered setting shown MOTOR DIRECTION BUTTON Press arrow to go forward Press arrow for reverse The illuminated LE
36. ers Pull Roller Pressure Pull Clutch Tension WEBBING SETTINGS Web Tension Top Web Tension Bottom Chill Idlers Over Under Sheet Fed Shim Wheel Settings Shim Wheel Shim Wheel Heat activated Laminate 3 5 Mil HOT SIDE Heat activated Laminate 3 5 Mil COLD SIDE Rear Top 185 203 F 85 95 C 185 203 F 85 95 C 40 60 PSI 3 5 FPM 1 1 5 MPM Forward X Reverse ___ On X Off _ Top Main Roller Bottom Main Roller Bottom Pull Roller Up Down X 40 60 PSI 65 70 PSI Light X Med Heavy Light X Med Heavy 1 Over 2 Under Roll Ease X 1 16 2mm Covered Foot Switch 27 DECALING SET UP WEBBING Seal recommends its comprehensive line of Print Mount pressure sensitive mounting adhesives Print Shield pressure sensitive over laminating and Print Guard low temperature heat activated over laminating films for your different applications Load and center the films onto the top and bottom supply shafts with the adhesive side facing out Select films slightly wider than the image to allow for trimming If using a heat activated laminate on top set the roller temperature for the type of film being used Raise the top rollers and remove the front table for webbing ease Bottom film Pull the mounting adhesive up in front of the bottom roller and drape evenly over the top roller Top film heat activated Pull the film down under the top
37. ft Make sure the output is free of wrinkles and tracking properly Note Reduce amount of tension on Rear Wind up Tube if bubbling occurs on output between the two center chill idlers IMPORTANT The Cooling Fan Bank must be on for this process because of the high temperatures to ensure quality output Shim Wheel Shim Wheel COLD SIDE HOT SIDE lm Front Top nwind Sha Images Toner amp Paper Images Facing Out Rear Roll Easel Front e dle AA AN A ANA Flows Upward Cooling Output Pressure sensitive Over laminate Marking Film Sleeved Tie Bar Tie Bar Paper 7 Marking Film Backing Shiny side out 41 TROUBLESHOOTING PROBLEM The laminator has no display SOLUTION Check the power cord and the main power button Reset the Emergency stop buttons Unplug the laminator and check the circuit breakers inside the left cabinet Only authorized safety or maintenance personnel should do this Make sure the left side cabinet door is closed and the door interlock is on The door interlock on the left door automatically shuts the laminator off when the door is opened PROBLEM The laminator motor will not run SOLUTION Make sure the Photo eyes are not blocked Check that the motor button is ON or turn the motor speed up Unplug the laminator and check the fuses on motor control board P
38. ges A ei ENCAPSULATING PROCESS Completely sealing a graphic between two heat activated laminates Use a cut sheet or a graphic with trimmed edges since the entire image is finished with a 14 of laminate surrounding each edge MEDIA INK JET ELECTROSTATIC AND PHOTOGRAPHIC FILMS Top Unwind ____ Bottom Unwind LAMINATOR SETTINGS Front Control Panel Top Roller Temp Bottom Roller Temp Main Roller Pressure Motor Speed Setting Motor Direction Cooling Fans Back Control Panel Pull Rollers Pull Roller Pressure Pull Clutch Tension WEBBING SETTINGS Web Tension Top Web Tension Bottom Chill Idlers Over Under Sheet Fed X Shim Wheel Settings Heat activated Laminate 3 5 Mil Heat activated Laminate 3 5 Mil 185 203 F 85 95 C 185 203 F 85 95 C 40 60 PSI 3 5 FPM 1 0 1 5 MPM Forward X Reverse On Off X Up Down X 40 60 PSI 65 70 PSI Light X Med Heavy Light X Med Heavy __ 1 Over 2 Under Roll Easel 1 16 2mm Shim Wheel COLD SIDE HOT SIDE Front Top Unwind Shafj d Se WE Rear Table 25 ms DOUBLE SIDED LAMINATION SET UP Follow the same webbing procedure as Encapsulating Mount the roll of prints on the roll easel attachment so that the images unwind facing up Center the roll of images in alignment with the rolls of film Use the footswitch to feed the images through the print guide table into the ni
39. he folded release paper to allow for grasping the release liner Once positioned correctly press firmly with the outer edges of your palms from the center toward the edges to insure a smooth tack This is the edge that will be fed into the rollers first Push the edge into the rollers and step on the foot switch until the board and image are just caught by the nip IMPORTANT Because the foot switch overrides the photo eye be sure to keep your hands clear of the rollers to prevent injury Hold the untacked portion of the image up and against the top roller with one hand Peel the release paper off the image with the other hand while using the foot switch to feed the board through the rollers You must hold the image against the roller while the board feeds through to prevent wrinkles NOTE If the board is accidentally sent in too far at first the release liner will get caught and will be impossible to pull back In this case raise the top roller pull the board out and try again As the process becomes more familiar increase the speed of the laminator to make the process more efficient Remove the mounted image from the rear of the laminator trim it to size and display it amp ONE STEP MOUNTING AND LAMINATING Generally the process of decaling and then mounting is difficult when dealing with larger images because the images must be put through the laminator twice However the availability of mounting boards with heat activated adhe
40. inating film onto the top unwind shaft Set the brake to apply a slight drag but not tight enough to stretch or otherwise pull the film Apply either double stick tape or a strip of the pressure sensitive mounting adhesive film across the width of an empty film core mounted on the front wind up tube Pull the over laminate down from the top unwind shaft under the top idler and up to the front wind up tube Pull the release liner square with the roll of film so that no diagonal wrinkles are apparent Adhere the top release liner smoothly to the adhesive on the core Separate the over laminate from the release liner secured to the take up core and pull the over laminate down evenly so that it rests adhesive side up over the face of the top roller HINT Adhere one end of scotch tape securely to a corner of the film on the wind up tube Pull the other end of the scotch tape down and the film will separate from the release liner Using the foot switch feed a leader board into the nip making sure the film stays adhered to the leader board Wind up any excess release liner by hand onto the wind up tube Set the brake to apply the minimum amount of tension needed to separate the release liner from the film Check that the film and the release liner are tracking correctly with no diagonal wrinkles in either After laminating insert a leader after the last sled so the laminate will adhere properly to the last image Trim mount and display your newly l
41. k and must be turned clockwise to reset Press the laminator main power button to restart the operation The laminator defaults to Program 1 upon restart FOOT OPERATED EMERGENCY TAP SWITCHES Located on both sides of the laminator pressing on these tap switches will immediately cease the laminator s operation and raise the rollers Press the main power button to restart the operation COVERED FOOT SWITCHES One on each side of the laminator allow for complete user control when initially feeding an image into the nip or for feeding a delicate image through the rollers The cover prevents accidentally stepping on the foot switch and starting the laminator MI WARNING The foot switch overrides the photo eyes When the photo eye is blocked the laminator runs in slow mode at a speed of 2 0 feet 0 6M per minute A BUZZER sounds and a light on the left cabinet flashes if an operator blocks a photo eye warning of proximity to the nip Use care to keep hands clear of the rollers while using the foot switch to prevent possible injury PHOTO ELECTRIC SAFETY EYES A light beam path set directly in front and back of the laminating roller openings prevents foreign objects from passing between the rollers The eyes are set for use at the factory and checked by the service representative LOCKING CABINETS The cabinets that house the inner workings of the laminator include locks that maintenance or safety personnel can open only with the supplied
42. keys M WARNING Use of the inside of the cabinets for storage may cause possible personal injury and or damage to the inner workings and will void the warranty DOOR INTERLOCK Located on the left side cabinet facing front of laminator it automatically shuts the laminator off when the door is opened EN WARNING For any servicing ALWAYS turn the laminator and the main power circuit breaker off before opening the side cabinets TE SAFETY INFORMATION WARNINGS The Image 6100 Ultra laminator is equipped with safety equipment to promote safe machine operation You should however take note of the following IMPORTANT Read and make sure you understand these safety and operating instructions Hot Surfaces Danger of getting injured by hot parts Take care when webbing or touching the hot rollers The front rollers can have a surface temperature up to 300 F 149 C Do not touch the rollers IMPORTANT Even after the laminator has been shut off the rollers remain hot for a long time Rotating Parts Danger of getting injured by rotating parts The laminator is equipped with photoelectric eyes to prevent contact with the rotating rollers Make sure that these safety provisions are always in operation installed Follow safety measures to make sure that clothing long hair etc are not caught by the rotating rollers which might result in the risk of being trapped IMPORTANT The laminator operation will cease immedia
43. leading edge of each image is flat all the way across or any wrinkles or creases in the image will show when laminated perhaps even magnified e A straight leading edge will aid in feeding in the image e Feed the image into the nip with the front edge parallel to the roller USING THE ROLL EASEL ATTACHMENT The Roll Easel Attachment is used to encapsulate images digitally reproduced with a color plotter The rolls of images simply slip on and off of the roll easel which lifts on and off the front of the laminator e Mount the roll of prints on the attachment The rolls of images should unwind with the images facing up and should be centered on the attachment so that the laminate covers the images e Leave some blank space at the beginning of the roll of images and in this space a V shaped area should be cut out to allow for an easier and cleaner start to the laminating process e Once the prints are running through the laminator set the brake tension for the roll easel to exert a significant amount of tension so the prints feed through without wrinkles e Set the speed control to 2 3 feet or 0 6 1 0 meters per minute Use the footswitch until the images are tracking correctly Then press the motor ON button and go into auto run mode Don t remove your foot from the footswitch until you have pushed the motor ON button Otherwise the laminator will stop affecting the quality of your image s finish a ei SETTING THE BRAKES The act of lo
44. ll Remove the foam placed between the top and bottom rollers Remove the protective paper from the rolls by using your fingers only to remove the tape and then gently pulling the paper towards you to unwind off the roll WARNING DO NOT USE OPEN BLADES TO REMOVE THE PROTECTIVE PAPER ON THE PRESSURE ROLLERS The pressure rollers are covered with high quality silicone rubber assuring excellent non stick properties Roller damage caused by improper use of cutting tools will void the user s warranty Small cuts and imperfections in the rollers greatly affect the quality of the output and roller replacement costs are expensive IMPORTANT Clean the laminating rollers before using B amp UIPIM WOOY wnwuy Joao G peel GL OPERATING CONDITIONS FIGURE 4 WORKING AREA DIAGRAM An area 15 4 5 m x 11 3 4m is the smallest area recommended We recommended a room size of 20 x 18 or 6 1 x 5 49 m to accommodate a laminator and 2 4 x 8 tables on castors for finishing layout work This area is required for loading unloading rolls of media onto the supply shafts and feeding receiving the maximum mounting board lengths into the laminator correctly A H o o Maximum board length o i Gyo o 1 o 9 30 inch Door clearance ai 4 59 150 cm Room Length 2 x max board length 59 150 cm Minim
45. lutch and Drive Components Provides smoother performance at all speeds and different film thickness e Optional Outfeed Slitter System Provides for convenient outfeed trimming of roll to roll sealing and transferring processes 6 pa IMAGE 6100 ULTRA FEATURES DIAGRAM 2 Rear Top 2 Front Top COLD SIDE Unwind Shaft Unwind Shaft HOT SIDE 1 Shim Wheel 1 Shim Wheel 5 Rear Top 5 Front Top Wind up Wind up Tube Tube 8 Front Digital 4 7 Touchpad 8 Rear Digital Touchpad i 2 GO O Opt 2nd Rear Front Roll Easel Roll Easel One 7 Print Guide Movable 5 Center Top Front Table to Rear 4 Top Wind up S GE i Rear Table Pull Roller Tube ain Roller 6 Chill GO e C 6 Cooling Fan Bank 4 Bottom Main Roller 4 Bottom Pull Roller 5 Rear Bottom 5 Front Wind up Bottom Tube Wind up Tube 2 Rear 2 Front Bottom Bottom Unwind Unwind Shaft Shaft Safety Safety Features Features K Ne a Covered Foot Operated Foot Operated Covered Foot Tap Switches Tap Switches Foot Switch Switch SAFETY FEATURES HAND OPERATED EMERGENCY STOP BUTTONS Emergency Stop buttons are located on each side of the cabinets for easy access Once pressed they immediately cease the laminator s operation and raise the rollers Use these only in the case of an emergency or you may damage an image during a process NOTE Once pressed these buttons loc
46. ly warp the table This will void the warranty replacement SERVICING AND REPLACEMENT PARTS Refer all servicing to an authorized service representative Servicing by any unauthorized technician voids the warranty The service technician must use replacement parts specified by Hunt Graphics Call Technical Service for assistance see the rear cover for the location nearest you IMPORTANT Service technicians must perform safety checks after completing any service or repairs to the laminator WARNING The machines safety photo eye system should be checked every 6 months or after any internal adjustment repair using a tool made from a piece of 12mm 1 2 diameter wood or similar material To test the photo eye system place the tool on the table and slowly move it towards the rotating roller The rotation must stop before the tool touches the roller face This test must be carried out across the whole width of the tables If the photo eye does not operate switch off the machine and do not use until it has been adjusted and checked by an authorized service technician 5 pa FEATURES OF THE IMAGE 6100 LAMINATOR 1 SHIM WHEELS Dial in roller height adjustment for fast and accurate roller nip setting which adjusts for the thickness of the material to be processed Features include pneumatic pressure adjustment with heavy duty air cylinders and fine tune control This allows for optimum pressure at the roller nip 2 FOUR PIVOTING UNWIND SHAFTS
47. m to the bottom of a graphic Then remove the release liner from the mounting adhesive and apply the image directly for its intended purpose or later to a mounting board or other substrate for display MEDIA INK JET ELECTROSTATIC AND PHOTOGRAPHIC FILMS Top Unwind Bottom Unwind LAMINATOR SETTINGS Front Control Panel Top Roller Temp Bottom Roller Temp Main Roller Pressure Motor Speed Setting Motor Direction Cooling Fans Back Control Panel Pull Rollers Pull Roller Pressure Pull Clutch Tension WEBBING SETTINGS Web Tension Top Web Tension Bottom Chill Idlers Over Under Sheet Fed X Shim Wheel Settings COLD SIDE Heat activated Laminate 3 5 Mil Pressure sensitive mounting adhesive 215 225 F 102 107 C OFF 40 60 PSI 3 5 FPM 1 1 5 MPM Forward X Reverse On Off X Up Down X 40 60 PSI 65 70 PSI Light X Med Heavy Light X Med Heavy 1 Over 2 Over Roll Easel 1 16 2mm 29 HOT SIDE Front Top Unwind Shaft Bottom Main Roller Bottom Pull Roller DECALING PRESSURE SENSITIVE PROCESS Creating a decal by applying a cold pressure sensitive over laminate to the top and a cold pressure sensitive mounting adhesive to the bottom of a graphic Then remove the release liner from the mounting adhesive and apply the image directly for its intended purpose or later to a mounting board or other substrate for display MEDIA INK
48. ner and Paper Feed the images over the first chill idler and under the second chill idler Sleeved Tie Bar 7 Paper Backing Marking Film lt Shiny side out Pull the toner and paper up to the center wind up tube and either tape them directly to the rewind tube or to a cardboard core over the tube This will automatically wind up the transferred images paper e ies STEP THREE OF WEBBING PROCEDURE Establish Path of Pressure sensitive Over laminate Load the roll of pressure sensitive over laminate onto the rear roll easel shaft with the roll feeding off the bottom of the roll easel shaft Align and adjust the roll of pressure sensitive over laminate to the roll of Marking film Pull a length of over laminate forward and separate the release liner from the over laminate Pass the over laminate over the back of the top pull roller and into the nip of the lower pull roller Pull the over laminate down over the Marking film to the lower rear wind up tube Tape the release liner securely to the rear top wind up tube so that it will be automatically wound up At this point take up the slack of the Marking film roll on the front lower unwind shaft Shim Wheel Shim Wheel COLD SIDE HOT SIDE Rear Top Pressure sensitive Release Liner Images Toner amp Paper Images Facing Out Idler Center Top Wind up Tube
49. ns of the film being used See product literature WARNING The rollers should be down and turning while heating up to provide even heat distribution and prevent roller flat spots from developing Load and center films on top and bottom supply shafts with dull adhesive side facing out and the brake tensions released Press the motor button OFF and raise both top rollers Top film Pull film down and web under the top idler and drape evenly over the face of the top and bottom rollers Bottom film Pull film up and web behind the sleeved tie bar and set evenly over the top film The two films will heat and adhere together Lower the top roller and use a leader board to feed the films into the nip Use the footswitch to feed the films through the rollers From the rear of the laminator use the footswitch to feed the film through the chill idlers and through the pull rollers Keeping film taut hold the leader board up against the top pull roller with one hand and lower the top pull roller Cut off the piece of leader board Return to the front and run the laminator applying light brake tension gradually on both supply shafts until there are no wrinkles in the film as it goes into the nip If wrinkles do not work out within 5 feet 1 5 meters cut the film and repeat the webbing process Once the laminates are tracking correctly feed the image into the nip through the print guide table Apply back tension to the image by holding back on the outer ed
50. o 0 Set the motor direction to forward and the motor speed to 3 fpm or 7 6 cpm This speed can be adjusted slower or faster depending on at what speed you have the best total transfer of the toner into the film The One pass dry transfer process is established by a four step webbing procedure Follow the directions and corresponding webbing diagrams on the following pages to perform the process amp STEP ONE OF WEBBING PROCEDURE DIAGRAM Establish Path of Marking Film EN WARNING Take care reaching over the top main roller since the roller is very hot at the 300 F 149 C temperature Shim Wheel Shim Wheel Load the roll of Marking film onto the bottom front COLD SIDE unwind shaft toner accepting side facing out Load the roll with the media feeding off the front of the unwind shaft HOT SIDE Rear Top Unwind Sha Top Tie Bar Top Idler Center Top Wind up Tube Front Top Unwind Sha Center the roll on the unwind shaft as explained in Setting the Brakes Rear e Place a cardboard core over the bottom rear wind Roll Easel up tube for winding up the finished product Adjust and align the cardboard core to the roll of marking film e Raise both the top rollers for ease of webbing Botta 140 FJ6U C e Pull the Marking film forward behind the tie bar and through the nip of the main rollers Sleeved Tle Bar Feed the film over the first chill idler and un
51. o the control panels of the laminator as they are not sealed Water may enter the electrical circuits and cause personal injury and or damage the equipment when power is applied GREASING THE BEARINGS You must grease the top and bottom roller bearings once each month or every 200 hours M WARNING Failure to lube bearings will cause premature wear which may cause costly repairs and will void your warranty VM WARNING Authorized service technicians must unplug the laminator before any servicing 45 REPLACING FUSES Replace defective fuses with fuses of the same type Replacement fuses are included in your accessory pack and can be re ordered through the Hunt Graphics location nearest you see the rear cover NOTE You must use replacement parts specified by Hunt Graphics The fuses are located inside the left cabinet inside the Electrical Panel Cover RESETTING BREAKERS The breakers are located inside the left cabinet in the center next to the lower infrared sensor Turn the door interlock to the OFF position and open the left cabinet door with door key Reset the tripped circuit breaker to the up position Call Technical Service for further assistance PERIODIC MAINTENANCE SHEET GREASE BEARINGS REPLACE FUSES REPLACE BREAKERS CHAIN TENSION ADJUSTMENT DRAIN WATER AIR SYSTEM FILTER SAFETY CHECK AFTER SERVICING
52. p Once the prints are running through the rollers set the brake tension on the roll easel attachment to exert a significant amount of tension so the prints feed through without wrinkles The type of laminate and graphics being used will determine the amount of tension required Use the bottom rear wind up tube to wind up the laminated prints Tape the front edge of the first finished print to a cardboard core placed over the tube and the prints will continue to automatically wind up Press the motor ON button and set the speed to 3 FPM or 1MPM to go into an effective Auto run operation IMPORTANT Do not remove your foot from the footswitch until the motor is ON or the laminator will stop affecting the finished output NOTE With graphics in roll form the edges are not completely sealed Use an X Acto ST Rotary Cutter to quickly and efficiently trim your laminated images A ei DOUBLE SIDED LAMINATION HEAT ACTIVATED PROCESS Applying a laminate to both the front and back of graphics in roll form The margins between and around the laminated images must be trimmed away for a finished appearance thereby not having completely sealed edges as with encapsulating MEDIA INK JET ELECTROSTATIC AND PHOTOGRAPHIC FILMS Top Unwind Bottom Unwind LAMINATOR SETTINGS Front Control Panel Top Roller Temp Bottom Roller Temp Main Roller Pressure Motor Speed Setting Motor Direction Cooling Fans Back Control Panel Pull Roll
53. peat the process for the second side 35 E s NOTES 36 ONE PASS DRY TRANSFER The One Pass Dry Transfer process involves transferring an image onto a flexible Marking film and applying a high quality pressure sensitive laminate to the image transfer Applying the pressure sensitive laminate to the top of the image transfer increases the longevity of your image transfer and allows for outdoor applications Before webbing for the One Pass Dry Transfer process re Set the top roller temperature to 300 F 149 C and the bottom roller temperature to 140 F 60 C Separate the rollers while heating up to prevent the bottom roller from pulling too much heat from the top roller IMPORTANT We recommend maintaining these temperatures during long runs to ensure the highest quality output Do not allow the top roller temperature to drop below 290 F 143 C Allow the bottom roller to cool down if the temperature exceeds 160 F 71 C before continuing the process Set the Front Main Roller air pressure to 100 psi Set the Back Pull Roller air pressure to 50 psi Set the Air Clutch tension pressure to 40 psi The clutch tension pressure should not exceed 40 psi This will prevent excessive pull on the film affecting the output Set both Front Main Roll shim wheel settings to 1 16 or 2mm The One Pass dry transfer process requires the higher nip pressure for successful transfer Set both the Back Pull Roll Shim Wheel settings t
54. sive on one side such as the Hunt Manufacturing s Single Step Heat Activated Foam Board makes it possible to laminate and mount an image with one pass IMPORTANT Before you can begin first adjust the four shim wheels to correspond to the thickness of the backing you will use e Set the four shim wheel settings to 3 16 or 5mm e Set the top heater temperature at 210 F or 99 C e Pull the top laminate down from the top unwind shaft under the top idler and drape it evenly over the face of the top roller e Use apiece of standard 3 16 foam board to hold the laminate under the top roller as the roller is lowered e Use the footswitch with the motor speed setting at 2 FPM or 0 6 MPM e Check the adhesion of the laminate by sending a piece of foam board through first The laminate must be free of wrinkles and bubbles e Set the brake tension so that the laminate is taut coming off the roll EN WARNING Too much brake tension could cause the laminate to stretch and not adhere properly e Trim the actual adhesive mounting boards slightly larger than the image a 3 border is sufficient Use the excess for leader boards e Tape the leading edge of the image onto the mounting board to secure its position as you feed the board through the rollers e Feed the leader board into the nip with the image to be mounted right behind For more than one image send them through one after another IMPORTANT Send the images fairly close together so that a
55. ss discusses loading the laminator with the appropriate materials Refer to the web diagrams and instructions corresponding to each process for the correct way to web the laminator Even if you feel you have loaded the laminator correctly given the directions you ve read it is important to check your results against the diagrams Cooling System The majority of processes do not require the use of the cooling fan bank but for extensive running time it is recommended to use the cooling fans to cool off the chill idlers quicker Always web the film over the first idler to cool the backside of the print first thus preventing marks on the hot front side of the print which could affect the finished appearance When using Mounting Adhesive on the back of images it is best to run over both idlers Running the film under the second idler may cause the backing to separate from the release liner Hint Use of thicker films will enhance the colors of the images to be laminated A ei FEEDING IMAGES q IMPORTANT Do not stop the motor or block the photo eyes while an image is being laminated as this can cause marks in the output USING THE PRINT GUIDE TABLE Your laminator is equipped with a Print Guide Table to assist in feeding images into the nip Feeding images under the print guide directly into the nip prevents the images from lifting up and interrupting the photo eyes e Feed images through correctly to ensure good results e Make sure the
56. sure rollers height is essential for safe and proper operation Check this prior to every use To check the vertical movement of the top rollers Press the Roller UP arrow button once The top roller should rise smoothly and evenly on both ends Press the Roller DOWN arrow button once The top roller should lower smoothly and evenly on both ends Repeat this procedure for both front and back top rollers IMPORTANT The silicone covering of the rollers is soft Do not scratch the surface with a sharp object or fingernail CLEANING THE ROLLERS IMPORTANT Clean the laminating rollers every day to prevent adhesive build up and to ensure quality output Adhesive build up may eventually damage the rollers When laminating a small amount of adhesive will squeeze out between the laminate films and onto the top and bottom rollers This residue accumulates through normal use and can be easily cleaned off the rollers Use the Image Roll Cleaner catalog 960 included in your accessory pack to remove the excess adhesive The adhesive is easier to remove with the rollers hot HINT Place a scrap piece of foam board or cardboard under the top roller when cleaning to prevent the waste adhesive from falling onto the bottom roller For a more thorough cleaning allow the rollers to cool and then use a clean lint free cloth and isopropyl alcohol to wipe the roller clean WARNING Isopropyl alcohol is flammable use only when the rollers are cold Do
57. tely when the photo electric eyes set directly in the path of the front and back of the rollers are blocked THIS WILL NOT HAPPEN when using the footswitch in which case a BUZZER will sound with a flashing light and the laminator runs in slow mode at a rate of 2 0 feet 0 6M per minute IMPORTANT The laminator has four emergency stop buttons which may be pressed in dangerous situations The rotating parts of the laminator will then be immediately stopped Electrical Parts Danger of getting injured by electricity Do not open the locked cabinet doors because of the risk of being injured by voltage Only authorized maintenance and service technicians or safety personnel should have access to the keys for mechanical upkeep or repair WARNING Make sure the door interlock on the left side cabinet is disengaged when opening the right side cabinet door for any maintenance The door interlock automatically shuts the laminator off when the door is opened IMPORTANT Do not place heavy objects on the power supply cord 9 a INSTALLATION OF YOUR LAMINATOR TRANSPORT Only skilled personnel should perform installation Heed all warnings and follow the proper installation procedures and safety guidelines Refer to outside of crate for Uncrating Recrating instructions NOTE We recommend that you save the transport bolts nuts and plates of the shipping crate for any major moves that you plan to make with the laminator in the future Remo
58. the proper use and maintenance of the laminator TECHNICAL SPECIFICATIONS LAMINATOR IDENTIFICATION Each Image laminator has a Serial Number Label located on the right side cabinet when facing the rear This label indicates the model type the electrical requirements and the laminator serial number important for reference if any servicing is required IMAGE 6100 ULTRA SPECIFICATIONS TABLE Maximum Working Width 61 inches 155 cm Maximum Speed 20 feet per minute 6 1 mpm Maximum Air Pressure 125 psi Maximum Roller Opening 2 inches 5 cm Maximum Roller Temperature 300 F 149 C Roller Surface Construction High release silicone coating Supply Shaft Capacities Core Inner Diameter 3 inches 7 6 cm Maximum Substrate Thickness Tinch 25 4 mm Dimensions Width 80 203 cm Depth 59 150 cm Height 57 145 cm Net Weight 1900 Ib 864 kg Shipping Weight 2300 Ib 1045 kg Mechanical Requirements 2 CFM compressed air 100 psi 0 25 0 6 cm ID flexible line Electrical Requirements USA and Canada Single Phase International Three Phase 120 240 VAC 50 60 Hz Single phase 50 Amp 380 415 VAC 50 60 Hz Three phase 25 Amp 4 wire plus Earth Maximum Power Consumption 12 000 Watts NOTE Airborne Noise Less than 70DB A IMPORTANT Hunt Graphics recommends that a
59. um Room Length 11 feet 3 4 meter 13 TEMPERATURE 50 to 122 F 10 to 50 C IMPORTANT Do not expose the laminator to direct sunlight as output quality may be affected MOISTURE 30 95 non condensing Ideal Humidity 55 Too much humidity will affect the prints the operator is laminating causing problems with film adhesion DUST Avoid a dusty environment Because the films used are slightly static they will attract dust and the output will be affected Working in a clean and tidy manner will minimize poor quality output and production waste FRONT CONTROL PANEL DIAGRAM AIR PRESSURE GAUGE Indicates the PSI reading for the downward pressure of the top main roller The standard d ROLLER UP DOWN BUTTON setting for the normal operation is 40 60 psi Press the arrow once to raise the top roller lb Press the ze arrow once to lower the top roller AIR REGULATOR KNOB Adjusts the downward PSI of the top roller PROGRAM DISPLAY This display readout will signify the number of the program that is currently being run on the laminator The programs are numbered 1 through 9 with each program having the presets for the speed and the top and bottom roller temperatures PROGRAM SELECTION BUTTON POWER INDICATOR LED Press the arrow to advance to the next EES PROG higher program MAIN POWER STANDBY F TEOS Hio alow 10 Geo UI MENI owe Press this button to turn on the laminator or progr
60. ve the transport bolts from the skid s transport plates with 2 34 open end wrenches or afjustable wrenches Loosen the top lock nut on the bolt and back the bolt up into the cabinet enough to clear the cabinet castors for ease in moving Remove the air compressor and ramp from the skid Position the ramp at the end of the skid and gently roll the laminator off the skid NOTE In the UK and Holland Hunt Europe supplies the air compressor Your laminator has castors to allow for easy moving Roll the laminator into its working space area see Working Area Diagram Lock the castors once it is in place and remember to unlock them before moving the laminator again Take into account the weight of the laminator 1900 1b 864 kg net weight when moving Use equipment with which the weight can be safely lifted The laminator is transported on a wooden pallet skid If your laminator is still on its skid you can move it with a forklift to put it near its place of use re IMPORTANT Set the forks of the forklift to the maximum lifting width of the laminator so the laminator s center of gravity is central between the forks Figure 1 Moving the laminator with a forklift i ei UNPACKING Remove the transport packing and the plastic shrink wrap the laminator is wrapped in to avoid moisture penetration Remove the accessory kit package from the top of the laminator which includes the necessary tools for installation Remove the back table pla
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