CSL2700 ROLL LAMINATOR O W N E R S CALL M A N U A L TOLL F R E E 1-800-282-9290 For USI Education or Government Sales 1-800-243-4565
IMPORTANT INFORMATION PLEASE DO NOT DESTROY THE SHIPPING CARTON! USI urges you to store the original carton in which your laminator was shipped. Should you ever need to return your laminator to our repair and service center, it is best repacked in the original carton to avoid damage during transport. Our special foam filled carton ensures the laminator’s safe transit to our service facility. Failure to use original packaging will result in a repacking fee.
TABLE OF CONTENTS Chapter 1 — Preparation Part I Laminator Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,5 Part II Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Part III Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY PRECAUTIONS WARNING: Please review the following safety precautions before unpacking your new laminator. • Use care in unpacking and lifting the laminator. Keep laminator level when lifting or moving. Larger models weigh 60 pounds or more. • Consider work area. A cluttered work space can lead to accidents. The laminator should be placed on a level sturdy surface. Do not attempt to operate the laminator in damp or wet environments.
CSL 2700 Feature Location: A Tension Adjusting Knobs B Color Coded Supply Mandrel (holds film) C Heat Guard D Side Housing E Temperature Adjustment knob F Built In Handles G Heat On/Off Switch H Motor Drive Switch I Paper Guide J Feed Tray K Heat Shoes (behind heat guard) L C Film Temperature Guide M Thermometer F B D K A L M E G B H 5 I J
FIND A WORK AREA A separate work station is required to house your USI laminator. Ample room is necessary to access the laminator from all 4 sides. If the laminator is back against a wall, the laminating film may back up and jam the equipment. A USI laminator cabinet is an excellent choice for a work area. It can easily be moved and provide sufficient storage for film in the cabinet below.
UNPACKING YOUR LAMINATOR Your laminator comes packed in one carton. It contains (1) laminator, (1) heat guard, (1) top supply mandrel, (1) bottom supply mandrel, (1) threading board, (1) feed table with guide, and this operation and maintenance manual. (See diagram page 5) First, open the box. Using two people, carefully lift the laminator from the carton by grasping the side housings and lifting. Do not lift by the upper idler bar or supply mandrel.
LOADING FILM Color-coded laminators & film: (For more information on this revolutionary system see the back cover) Select the two rolls of laminating film that you wish to use. Both rolls of film should be of the same size, type and thickness. Next, take the bottom supply mandrel (marked with the blue Color-Code) and insert it into the roll of film so the blue end of the mandrel matches the blue end of the film roll.
Note: When loading your laminating film, check for film splices. These rolls will be clearly marked. Splices are not common, but are unavoidable. If you find a spliced roll, place it in the top position on the laminator so that the splice can be monitored carefully. When the splice is ready to come through the laminator, turn the drive and heat off, allow the machine to cool, and rotate the roll of film by hand so the film tension is very loose.
Thread the top roll of film under the idler roller as shown in the threading diagram on previous page (see Figure 9-4). Pull the film down so that the films lead edge is below the lower heat shoe. Next thread the bottom roll of film under the lower idler bar pulling film upward until it is even with the top heat shoe (the film will overlap). Tape it to the top film edge. This creates a film “Web” (Photo 10-1 & 10-2).
HEAT SETTINGS Prior to laminating, allow the machine to pre-heat at least 15 minutes in order to stabilize the temperature. Temperature settings depend on the film type being used. The temperature is preset at the factory, but may require adjustment depending on what type of film you are using. Turn the heat on by depressing the heat power switch on the left side panel. The red indicator light will illuminate and remain lit while the machine is in the “on” position.
SETTING TENSION To adjust tension for upper and lower rollers, the laminator must be loaded and heated. Remove the heat guard and feed tray. Loosen both tension control knobs by turning counterclockwise until there is no tension on upper or lower film rolls. Photos 12-1, 12-2. Film should pull freely. As film runs through it will appear wrinkled and bubbly, as pictured in photo 13-1. Gradually increase tension on both rolls, by turning knobs clockwise, until film is smooth on heat shoes.
Photo 13-1 Feed Tray Photo 13-2 13 Heat Shoe Guard Photo 13-3
RELOADING A NEW ROLL OF FILM ON A HOT LAMINATOR Allow the old film to run to a point just before it pulls off the cardboard cores. Turn the drive switch to “OFF.” Cut the film web with a blade so that approximately 5” of film extends beyond the idler bar. Photo 14-1. CAUTION: When using a sharp object to cut film (blade or shears), avoid contact with heat shoes or rubber rollers. Photo 14-1 Remove the old cardboard cores and replace with new rolls of film. Photo 14-2.
CLEANING THE HEAT SHOES With continuous use the heat shoes and rubber rollers may accumulate adhesive and dirt. It is recommended that you periodically inspect them for adhesive build-up. Use USI’s Laminator Cleaning Kit, which contains cleaning fluid, a coarse scrubbing pad and a mesh covered sponge, for removal of any adhesive build up. Moisten the sponge pad with cleaning fluid and wipe down the heat shoes. NOTE: Be sure to clean the heat shoes only when the laminator is cool.
UPPER HEAT SHOE REMOVAL INSTRUCTIONS 1. Unplug laminator and allow it to cool to room temperature. 2. Remove the left side housing. First remove the thermometer & temperature knob (shown in figure 16-1). The temperature knob has a small Allen head set screw retaining it. Then remove the housing by unscrewing 4 Allen head screws. Set housing assembly aside. 3. Unplug the upper heat shoe wires (A) from the terminal block (B). [Figure 16-2] 4. Gently lift the heat shoe and pull forward.
TO REINSTALL THE HEAT SHOE 1. Be sure laminator is unplugged. 2. Guide heat shoe wires exiting from the left end of the heat shoe through the slot in the left side of frame. 3. Lower the left end of the heat shoe onto its bracket first, then lower the right end and lock in place. 4. Plug the heat shoe wires into the terminal block. 5. Carefully install the left side housing and 4 Allen head screws.
REMOVING THE RUBBER ROLLERS NOTE: Only remove rollers if they are cut or in poor condition. NOTE: The following procedure removes all 4 rollers. In certain instances, it is not necessary to remove all 4 rollers, therefore, remove as required. STEP 1: Remove all film from laminator. Photo 18-1. STEP 2: Unplug laminator. Make sure it is cool. Photo 18-1 STEP 3: Remove the thermometer and heat knob from the left side of laminator. Remove the side housing on both sides of the laminator.
STEP 7: To remove the upper roller, slide the roll shaft out of the roller and then lift the top rubber rollers from the laminator (top laminating roller shown). Photos 19-1 and 19-2 Photo 19-1 STEP 8: Loosen the set screws of the lower roller sprockets (laminating roller shown) Photo 19-3. STEP 9: Loosen the Allen head set screws on the left and right ends of the lower rubber rollers. (Lower laminating roller shown.) Photo 19-4.
STEP 11: To install a new roller or replace the original roller, reverse the removal procedure. Be sure to properly reposition the sprockets and align the chain. All three sprockets should be in line with each other. Since the motor sprocket was not removed, use it as a guide for alignment of the pull roll and laminating roll sprockets. • The pull rollers on this laminator are interchangeable with the laminating rollers. If the laminating rollers have minor damage, each can be replaced by pull rollers.
PRESSURE The pressure settings for the rubber rollers on USI Laminators are preset at the factory and should not require adjusting. In most cases, it is necessary to adjust pressure after the rollers have been removed for service. (Generally this is the only time an adjustment is required.) If an adjustment is necessary, disconnect electrical power and remove both the left and right housings. Photo 21-2 Locate the Slotted Screw holding Compression Spring.
LAMINATOR LUBRICATION Oil the drive chain once every six months with a light weight oil. To avoid binding of the laminating and pull rollers, periodically oil the black plastic bushings. Bushings are located at the end of each roller. To gain access remove side housings. See important information under “Removing Upper Heat Shoe” pg 16. Photo 22-1 Photo 22-2 NOTE: Any type of light oil (i.e. WD40) can be used for the above purposes. Use sparingly.
CLEANING FRICTION STUDS If film rolls begin to shudder or squeak, cleaning of tension assembly is required. STEP 1: Remove the film rolls. STEP 2: Remove the right side housing. STEP 3: Disassemble the friction stud by unfastening and removing the knob. Photo 23-1. Photo 23-1 STEP 4: Remove the spring, metal washer, leather washer and the friction stud. Photo 23-2. STEP 5: To clean, wipe the mounting hole free of excess debris. Use rubbing alcohol. Photo 23-3.
REPLACING THE THERMOSTAT Step 1: Unplug the laminator. Step 2: Remove the left side housing. See Upper Heat Shoe Removal Instructions (pg 16). Step 3: Loosen, but do not remove the small set screw on the bottom of the lower heatshoe (Photo 25-1). Step 4: Unplug the two blue leads from the bottom of the thermostat. Mark where the leads went to ease reassembly. Step 5: Remove the two screws retaining the thermostat bracket to the laminator.
Photo 25-1 Photo 25-2 Photo 25-3 Photo 25-4 Photo 25-5 Photo 25-6
TIGHTENING SPROCKETS STEP 1: Remove the right side housing. Locate loose sprocket. Each sprocket has a 3/32” Allen set screw located along the outer edge. If the set screw loosens, it will allow the sprocket to spin on the roll shaft, causing the rollers to slip. Laminating Roll Sprocket Pull Roll Sprocket Motor Sprocket STEP 2: Align the set screw with the flat spot on the roll shaft. This can be accomplished by either turning the drive on and off or by using the manual crank (if equipped).
TROUBLE SHOOTING COMMON EXAMPLES OF POOR LAMINATING . . . and their causes. A. FILM NOT BONDING TO SUBJECT OR TO ITSELF AT SEALED EDGES Causes: 1. The heat is set too low. 2. Film tension is too tight. 3. Bottom roll of film is threaded incorrectly. 4. The pressure setting is not correct. B. WRINKLES OR IRREGULAR WAVES RUNNING ACROSS THE LAMINATED WEB (PERPENDICULAR TO THE EDGE) Causes: 1. The heat set is too high. 2. Not enough tension on the supply mandrels. (Large, irregular waves). 3.
TROUBLE SHOOTING COMMON EXAMPLES OF POOR LAMINATING . . . and their causes. (continued) G. HEAT DOES NOT WORK AND RED INDICATOR LIGHT DOES NOT ILLUMINATE 1. Check wiring of the laminator. Refer to wiring diagram on page 29. 2. Replace heat switch and switch wires. NOTE: Switch should not be replaced without also replacing switch wires. H. BOTTOM RUBBER ROLLERS TURN BUT TOP RUBBER ROLLERS DO NOT 1. The tension is too tight. 2. Film has not been threaded correctly. 3. Film was loaded backwards.
CSL 2700 WIRING DIAGRAM CSL Series IV WIRING DIAGRAM
PARTS LIST Part # Component Description Per Machine Left Zone A5510 HEAT SWITCH LIGHTED 2002 1 A5514 DRIVE SWITCH 2002 1 A5846 HEAT CONTROL KNOB (N021) 1 A5888 SET SCREW FOR HEAT CONTROL KNOB 1 A4668 CLASSROOM THERMOSTAT 1 A4678 BRACKET, CLASSROOM THERMOSTAT 1 A4707 TERMINAL BLOCK NUMBERED W/O JUMPER 1 A9800 AUTO SHUT-OFF TIMER/OPTIONAL 1 A4536 BRACKET, AUTO SHUT-OFF/OPTIONAL 1 A4504 STRAIN RELIEF BUSHING (805B) 1 A9906 POWER CORD (806P) 1 A5929 CLASSROOM LEFT SWITCH PANEL LAB
PARTS LIST (continued) Part # Component Description Per Machine Common A4525 1/4 SPLIT LOCK WASHER A4526 BLIND RIVET, GRIPPER DOG, TINNERMAN BRACKET A4528 #8 X 1/4 HEX WASHER HEAD SCREW A4555 #4 FLAT WASHER ZINC PLTD, FOR TINNERMAN BKT A4676 10-32 X 3/8 BUTTON HEAD CAP SCREW A5553 BLIND RIVET AD64BS (14V) A5524 BLIND RIVET FLAT WASHER 3/16 DIA.
USI’s New Color-Code Film System USI Color Codes all of its Roll Film and Roll Laminators! We are the only lamination company to offer this unique troublefree system. That’s right, we are making film loading even easier. We have completely removed the possibility of placing the adhesive side of the film down on the machine. This is a common problem for most laminator users. That problem will no longer be yours.
