StarLam 1600R Liquid Laminator Operation
Contents
1. on the outside and facing upwards Please see Figure 8 2 Repeat step 1 to load an empty take up core on the front of the machine Rotate the core slightly once in place to lock 1t into position Supporting bush Wind up roll A 7 E ri E tle li x re EN ADE 4 TN ki E TES 7 A ET P a 7 ee Pi Re rj AAA Bor E Fi T E y T 12 StarLam 1600R User Manual 3 Lift the heating box assembly and gently lean it against its mainstays located on the two sides of the machine body boxes as shown in figure 9 Figure 9 4 Feed the media through the laminator according to Figure 11 a Leave a 1 8 meter long blank leader at the front of the printed material to be coated and a 1 5 meter long blank at the end of the printed roll media This will ensure consistent coating of the printed area b Straighten up the material to be coated webbing and stretch it tightly c Use adhesive tape to stick the leading edge of the media to the empty paper core on the opposite side of the machine from the main control console 13 StarLam 1600R User Manual Figure 11 A To ensure even film thickness and proper coating please stretch the material tightly and evenly 5 The substrate must be spooled onto strait and without variance from side to side 6 Switch the main power supply to the on position Next switch the machine power to the on position so that the power light illu2. 8 6 5mm ID Rigid Fluid Tube o Peristalic Pump Assembly o 33 StarLam 1600R User Manual p20 Female Panel 3 8 Coupler 10 0 0 0 ooo 121 Male 3 8 Coupler fF A rr O AE Lo 127 ee O O PE SE Ko BP ES Po o pe pM EE nt 34 StarLam 1600R User Manual Appendix A3 e 9 O E e e e a 35 StarLam 1600R User Manual Appendix A4 Tips and Tricks for the StarLam 1600R G3 Start up Check List 1 Make sure machine power 1s on 2 Make sure substrate 1s properly tensioned to take up core Pull tension and tape in the center first then pull tension on each side and tape Substrate should be tight and not loose and sagging Use the Que green button to pull tension on the substrate and hold it after taping 3 Make sure heater is in the raised position Turn heater on and let it preheat to at least 100 Deg Celsius 4 Open fluid flow valve so that liquid laminate is dispensed onto substrate Wait until the laminate 1s flowing off the sides of the substrate 5 Start motor at the 2 speed 6 Lower Heater 7 Switch cooling fans on Let machine run until job is coated Clean Up and Shut Down Check List 1 Shut off the fluid feed valve 2 Stop the machine before the vinyl spools off of the feed roll There should be approximately 2 to 3 wraps still on the core 1 5 meters total from the metering rod to the end
3. Use only water based liquid laminate Using certain solvent based flammable liquids may increase the chance of a fire or explosion Please use caution to select and use a liquid laminate compatible with this equipment The machines power source shall be connected to a sufficient proper safety breaker with nominal current rating Breaker operating current shall be no less than 40 Amps If the laminator needs service only authorized personnel should open the electrical boxes A qualified professional or the manufacturer shall be asked to take responsibility for the maintenance and repair Switch off the main power supply when performing maintenance to the equipment When it is necessary to open the electrical apparatus box the main power supply to the machine should be shut off This includes the main power supply line Maintenance to the machine while in a live electrical working environment should not be allowed Do not touch the circuit controlling part in the electrical control box StarLam 1600R User Manual AN Only authorized personnel should open the machine s electric control box This electric control box 1s equipped with a key lock and key A designated person in charge should keep the key A Switch off the power to the external power line when not using the machine for long periods of time StarLam 1600R User Manual Machine Diagram O Sy LE U U 1 1 i i
4. and the protection conductor shall be connected to protective earth with mark PE LI IN PE A If an abnormal situation occurs and you need to urgently stop the machine in process press the emergency stop switch This machine 1s equipped with a heating and drying system When operating the heating and drying system do not place your hands or any other body part into the heating area The heat generated can scald and burn the skin Use caution when operating the heating and drying system of the machine A When operating and using the machine be careful not to block either of the three fans on top of the heater panel This can damage the heating unit and potentially damage the heater box StarLam 1600R User Manual A Be careful when wearing a necktie necklace wristband or long hair when operating the machine Care should be taking to bind loose clothing secure jewelry and manage hair so as not to get rolled up and bound in the machine Serious injuries can occur 1f proper precautions are not taken Do not insert any material that 1s not intended for use with the machine This can lead to unnecessary damage of the equipment Raise the heating box lightly when lifting the heating box Do not place hands onto the guide roll racks or side of machine to avoid hand injury A The left and right box doors can be removed after opening If the doors need opening take care to lift and remove them to avoid dropping them A
5. i i E a U E E Te oil qi L a 3 S 2 RS 21 Connector For Cleaning 1 Left Side Main Frame Box 8 Positioning Axles for 14 Front Guide Roll Hos 2 Heater Box Heating Box 15 Laminate Drain Trough 24 Door Hinge 3 Liquid Reservoir Bottle Support 9 Emergency Stop Switch 16 Feed Roller Bar 25 Cooling Fan Bank 1 4 Liquid Reservoir Bottle 10 Operating Switch Panel 17 Roll Clutch Assembly 26 Forward Reverse Que 5 Fan Shield 11 Upper Protection Plate 18 Cleaning Trough 27 Power Supply Switch 28 Hi Amp Switch 29 Power Cord 30 Take up Roller Bar 31 Cooling Fan Bank 2 6 Liquid Nozzle Fixture 12 Cross Girder 19 Caster 7 Right Side Main Frame Box 13 Liquid Metering Rod 20 Leveling Foot StarLam 1600R User Manual LIQUID LAMINATOR e 1 Power Light White 7 Fan Switch 10 Cleaning Pump Switch pj jj 6 Motor Switch StarLam 1600R User Manual Technical Specifications Maximum Laminating width 1600mm 63inches Maximum laminating length 300m 984 feet Temperature adjusting range 80 140 C 176 284 F Speed adjusting range 300 1000mm min 11 82inches 3 28 feet per per minute 15 C 59 F 40 C 104 F Contour dimension length x width x height 2030 x 706 x 1250mm 6 6ft x 2 3ft x 4 1ft SL 1600R machine 256Kg 784 8 Lbs Weight 1n transport SL 1600R machine 440Kg 970 Lbs A Noise of machine is rated at 60db Type of fuse ROIS
6. of the substrate 3 Using a foam brush push all the remaining laminate off the substrate and into the reclaiming trough 4 Loosen the fastening screws that hold the metering rod in place and remove the metering rod 5 Place the metering rod into the cleaning trough and rotate it a few times to wet the rod 6 36
7. off position Fill the Laminate reservoir bottle with fresh liquid laminate 2 After the substrate webbing 1s properly fastened onto the rollers of the machine open the main laminate reservoir valve to the on position and then open the dispensing valve to the on position 3 Let the laminate run down and along the front side of the metering rod Let the laminate run off the sides of the substrate webbing and into the laminate reclaiming trough Start the machine motor to begin the lamination process The heater should already be preheated and lowered when the lamination process 1s started The cooling fans should be on as well 4 Once the laminate reclaiming trough has enough laminate that has pooled in the trough and covered the drain spout and filter open the drain valve to the on position then turn the peristaltic pump on by flipping the laminate pump power switch to the up position Position 1 in the diagram 5 Turn the pump speed control knob Diagram point 4 to the 20 25 position The laminate should start moving through the fluid lines The clear filter should fill up with laminate When you see the clear fluid line going up to the laminate reservoir bottle then the laminate has completed the circuit and is recycling properly The laminate recycling pump can be left on during the lamination process of the machine Cleaning the Laminate Pump 1 Drain the laminate from the drain trough into the laminate storage contai
8. 10 3 x 38 Fuse for heating box 32A x 2 Fuse for air drying fans O O gt A Fuse for transformer m Fuse for heating box s fan A 0 4A 2A IA IA StarLam 1600R User Manual Precautions Before Operating Preparation Before Operation e Load liquid laminate into the liquid reservoir bottle and then screw on the reservoir cover e Place the liquid reservoir bottle onto the support for the bottle Use the liquid piping to reliably connect the liquid reservoir bottle to the liquid dispensing nozzle e Put the rolled substrate to be coated onto the appropriate paper cylinder core 10 StarLam 1600R User Manual Operation Instructions Roll to Roll Lamination Instructions 7 Lock Collar Supporting bush for letoff roll Feed roll i na 1 Pome iy pda a n of i xa eee FA E Supporting axle box Positioning axle box 1 Load the media on the laminator a Rotate the jacket of the core roller that is on the same side of the machine as the main control console so that the core roller can be slightly lifted and rotated outward and away from the machine It may be necessary to rotate the shaft collar lock into the unlocked position first 11 StarLam 1600R User Manual b Slide the printed roll of substrate to be coated onto the core holding rod Pay close attention to make sure the face of the material to be coated is on the outside face of the roll to be coated The open flap should be
9. Version G3 1 00 3 2010 StarLam 1600R Liquid Laminator Operation amp Instruction Manual Marabu StarLam 1600R User Manual Important Please read and understand the operation manual completely Follow all safety information described StarLam 1600R User Manual Introduction Thank you for choosing the StarLam 1600R Liquid Laminator The StarLam 1600R is a new generation liquid laminator designed for post fabrication liquid lamination of posters banners vehicle graphics and paper substrates The StarLam 1600R used in combination with ClearShield liquid laminates will give you the ability to quickly and easily protect your digital output In addition the StarLam is CE approved to further ensure quality and durability The StarLam 1600R utilizes air assisted oven drying to allow the application of liquid laminates in a quick and efficient process The other main advantage of the StarLam 1600R 1s consistency The liquid laminator allows a controlled wet film thickness to be applied so that square footage coverage and dried film thickness can be controlled precisely This ensures accurate lamination with lower production cost The StarLam is designed for production environments where ease of use and reliability are paramount Attention To ensure the safety of the operator and avoid damaging any electrical components please be sure to check the reliability of the earth protective ground of the power receptacle m Please kee
10. anty gives you specific rights Where products 1s sold by a reseller System Supplier as principal the reseller has no authority from Clearstar LP to give any additional warranty or guarantee on Clearstar LP s behalf except as contained or referred to in this document All items carry warranty activated at time of invoice purchase notification to the invoiced Original Recipient Purchaser of the New Equipment a Clearstar LP warrants to the original consumer purchaser that each new StarLam 1600R Liquid Laminator which proves defective in materials or workmanship within the applicable warranty period will be repaired or at our option replaced without charge b The applicable warranty period for new equipment shall be one year parts six months labor from date of purchase c This warranty only extends to and is enforceable by the original recipient purchaser of the equipment and only for the amount of time specified as the period of the warranty Section B which the product must remain in the possession of the Original Recipient Purchaser of the New Equipment Original Recipient Purchaser of the New Equipment is defined as the person or entity that first purchased the product covered by this warranty other than for distributional and resale purposes This warranty is null and void and does not apply if it is found at any time the equipment has not been used for its intended purpose Reseller is defined as a System Suppl
11. bed off in spots The coating can be seen going on as a wet film but does not come out that way when coming out of the heater e Fluid flow from the main dispensing valve has Started coming out slower The fluid doesn t seem to Keep the laminating area supplied e Fluid Reservoir bottle is full but liquid 1s barely FRENDE DUDA Mad vale OL las cropper oul e Flush Fluid connectors in the opposite of flow direction to completely remove dried laminate chunks e Machine heater temperature cannot be controlled e Solid State Heater relay has gone bad and needs to be or adjusted Replaced Contact Clearstar e Liquid seems to run mostly to one side of the l coating rod and barely saturates the other side e Men EEO DE jak e Rod 1s not seated correctly in the holding cradle e Metering rod 1s not rotating properly e Rod is not tightened down sufficiently to allow proper friction between media and rod ER um i e Heater is not getting hot enough when turned up es Nu the machine is getting the required voltage and e Too much tension is on the clutches holding the feed core e Machine is coating but motion 1s jerky or e A small amount of graphite powder lubricant needs to be used Chattering On the clutches where the discs rub against each other and Where the core goes onto the clutches 25 StarLam 1600R User Manual WARRANTY COVER AND CONDITIONS This 1s a limited 12 month warranty please read carefully This warr
12. e coated is cored and fastened into the machine as previously described in the manual Valve Functions To Perform Lamination Siphon from Cleaning the Drum with Liquid Laminate Peristaltic Pump Circuit of the Machine Valve 1 Position Valve 2 Position Valve 3 Position Lamination Procedure 1 Make sure all three Valves are switched to the laminating position insert Picture 2 Open the fluid reservoir valve 3 Open the fluid dispensing valve 22 StarLam 1600R User Manual 4 Once the laminate has filled up the area in front of the metering rod and starts running off both sides of the media lower the heater switch on the drying fans and then start the drive motor at the 2 5 position Once the media begins to coat and move adjust the speed to the 3 position as the heater reaches 100 deg Celsius 5 Once the laminate reclaiming tray begins to fill up some start the peristaltic laminate pump a Start the laminate pump by switching the toggle switch up to the on position b Turn the pump speed control knob so that 1t clicks on and adjust 1t to the 20 or 1 4 position c It is ideal to have the pump recycle the liquid without entirely draining the reclaiming trough Running the laminate reclaiming trough dry will cause the filter screen to dry out and clog Siphon from Drum with Peristaltic Pump 1 Make sure the fluid reservoir valve is in the off position 2 Switch the top valve to the laminating position Swi
13. erfect cleaning use a pressure washer to remove built up coating and any contaminates b Remove fixed bolts on both sides of the liquid trough this bolt is of a special purpose during machine transportation and is not required to use again once removed 15 StarLam 1600R User Manual The StarLam 1600R liquid laminator uses a peristaltic pump A peristaltic pump is a type of positive displacement pump used for pumping a variety of fluids The fluid is contained within a flexible tube fitted inside a circular pump casing though linear peristaltic pumps have been made A rotor with a number of rollers shoes or wipers attached to the external circumference compresses the flexible tube As the rotor turns the part of tube under compression closes or occludes thus forcing the fluid to be pumped to move through the tube Additionally as the tube opens to its natural state after the passing of the cam restitution or resilience fluid flow is induced to the pump The StarLam incorporates a bi directional type peristaltic pump with a variable speed capability allowing extreme versatility with different liquids and also aids in cleaning out the laminate fluid lines The pumping circuit allows for the fluid to remain in the fluid lines and never contact and impeller or freezable pump part The Laminate pump 1s in the inside of the machine opposite the main control housing 16 StarLam 1600R User Manual The StarLam p
14. eristaltic pump 1s composed of 6 main parts The parts are as follows Pump housing Pump rollers 6 Thumb Screws The Peristaltic pump roller assembly 1s as follows SPRING DOITOM ARACKET PINS ROLLERS E TOP DRACKET SH MOTE THE FIAIS ON WE NRACKETS MUST ALWAYS LIME UP To remove the pump tube for replacement 17 StarLam 1600R User Manual Disconnect power to the pump 2 Disconnect the suction and discharge tubing from the pump tubing 3 Remove four thumb screws and pump cover 4 Pull out old pump tubing and discard 5 Clean roller race removing any particles that could damage tubing amp Use one thumb screw to tempo rarily anchor the housing to the case Connect power and run at slowest speed until roller bracket assembly is in position as shown in figure 7 Push new tubing into inlet port anchoring tubing in grippers If using a 9 piece of tube 1 2 should be extended outside of inlet port figure 2 amp Continue to run at slowest speed carefully feeding tube into race as the rollers turn Figure3 KEEP FINGERS AWAY FROM ROLLERS 9 Insert tubing into outlet port figure 4 and replace cover StarLam 1600R User Manual 4 Pump Speed Control 5 Cleaning Pump On Off Switch Cleaning Pump Power Indicator Lamp 19 StarLam 1600R User Manual Laminate Pump Operation 1 Make sure the laminate reservoir bottle valve is in the shut
15. f necessary use a pressure washer with water e The Metering rod is improperly tightened down Check tightening clamps and adjust as necessary e The material was coated at slightly too high of speed Reduce for same lamination combination in the future eMaterial was coated at slightly too low of a temperature Increase the temperature for same coating combination in the future 24 StarLam 1600R User Manual e It is possible the heater box support tabs have been damaged Replace or repair box supports before using machine again e The heater box heat trap flap may be bent or damaged Replace or repair part as necessary before using machine again e Reduce some of the clutch friction to the core rod e The material being coated seems to coat with a where the material is being pulled from jerky motion somewhat resembles Core rod on same side as main control console a chattering motion e Apply some graphite powder to the clutches where the core Contacts the clutch assembly e One of the fluid connectors is blocked Remove connector And force water the opposite way through the connector or replace connector e Fluid valve is blocked and needs to be cleaned e Fluid reservoir bottle needs to be refilled Not enough Head pressure e Fluid reservoir needs to thoroughly cleaned and scrubbed to remove dried laminate from the walls of the jug e Sections in the middle and sides of the material being coated seem to be rub
16. hose coming through the side of the machine close to the filter housing E rie x re ea A En u 1 pa Le LJ ul B b EN Era lt E a y n o ESL osi T E aa A CA JUS un il ae B gt a gt LOT ni i MM ts q m NEM I j os FA MMS a lt Nitia y Aa Je A I Al gt ca E s A AE A T gt Uu 3 Disconnect the quick connects and connect the supplied short drain hose to the female quick connect Place the open end into a container or five gallon bucket 21 StarLam 1600R User Manual 4 Once the container 1s in place and the hose 1s hanging into 1t then open the laminate trough drain valve 5 Let the trough drain completely Preparation of machine before use 1 Use 4 gallons of room temperature or warm water to fill the wash trough on the bottom of the machine 2 Hook up the cleaning hose to the wash hose connector on the machine Should be located on the front of the machine just under the three valve switches 3 Prime the wash hose by switching on the wash pump motor until a steady stream of water 1s emitted at the end of the hose Be sure to point the cleaning hose into the wash trough Once the hose is primed drape the hose so that the end 1s hanging over the wash trough to avoid leaking water onto the floor 4 Make sure the material to b
17. ier or Distributor A Reseller is also defined as any individual entity or company that purchases and then re sells the New Equipment to another individual entity or company whether or not for profit or for gain Any shell company that processes or facilitates the sale or distribution of the new equipment shall be considered a Reseller Entity 1s defined as any person company corporation organization shell company or trade broker that engages in the reselling or distribution of the new equipment It is the Original Recipient Purchaser of the New Equipment s responsibility to ensure that the equipment is connected to a UPS or similar circuit protector where power failures are common Damage caused by power failure to a system peripherals or structure is excluded from warranty This warranty is void if an incorrect power supply is attached to the unit that does not comply with the product specifications Clearstar LP will not cover under warranty any item that has been connected to a power supply other than that supplied mishandled returned inadequately packed and or otherwise interfered with by unauthorized personnel The removal of any serial numbers will void the warranty Clearstar LP will not repair under warranty damaged caused by operation outside of designed working and storage environments power surges fluctuations and interference and external peripheral devices Clearstar LP accepts no additiona
18. l liability pursuant to this warranty for the cost of traveling insurance or transportation of the product or parts to and from the service agent or reseller system supplier These costs are not 26 StarLam 1600R User Manual included in this warranty This warranty does not cover parts that have been installed by person s that are not registered Clearstar LP Dealer Installer s Equipment Covered StarLam LP technology architecture ONLY this warranty does not cover alterations made to the machine by unauthorized personnel Operating Environment The New Equipment should be operated in a relatively clean dust free environment to ensure optimal performance as dust grime and moisture can contribute to breakdowns that may not be covered under this warranty Geographical Coverage United States qualified distributors within the States and Territories of the United states of America All other territories must be expressed and approved and signed in writing in order to be valid Warranty Response Your system supplier or distributor should be responsible for return of hardware parts and equipment Proof of purchased will be required Contact Clearstar LP Monday through Friday excluding public holidays between the hours of 8am to 5 pm EST Unauthorized Persons No unauthorized person should endeavor to repair or modify the system For all modifications or upgrades please contact your system equipment supplier to ensure that yo
19. minates The fan in the heating box should also begin rotation 7 Switch the power for the electric motor on so that the roll of printed media moves forward slightly Continue this movement until the webbing 1s stretched evenly and tightly Once this is achieved immediately stop the rotation of the machine A When the front end of the webbing moves forward the printed portion does not move pass the metering rod to avoid incompletion of the lamination run 8 Make sure the heating box 1s in the raised position Adjust the heater setting knob on the main control console to the desired temperature position Switch on the heating power switch The machine will begin preheating At this moment it is necessary to wait a few minutes for the heater to preheat 9 Adjust the fluid control valves on the liquid reservoir bottle and the nozzle end so that liquid is injected onto the webbing material to be coated The nozzle should be adjusted to be in the center of the area to be coated 14 StarLam 1600R User Manual 10 When the heater box has reached the preset working conditions the working ready light will illuminate indicating that lamination process may begin 11 Gently lower the heating box down and onto the heater door stop guides 12 Switch on the machine cooling fans Adjust the motor drive speed to the appropriate position This starts the lamination process Upon laminating long rolled material e According to the requiremen
20. ner Shut off the laminate trough drain valve and fill the trough with water until the drain filter screen 1s completely covered up to the top of the filter handle follow trough draining instructions 2 Disconnect the laminate jug from the machine using the quick connects Lift the laminate jug out of the reservoir holder Unscrew the cap and pour the remaining liquid laminate into the laminate storage container 3 Replace the laminate reservoir bottle into the stand and re connect the proper quick disconnects 4 Make sure the laminate reservoir bottle and main dispensing valve are shut off Fill the laminate reservoir with warm tap water 5 Open the drain valve to the laminate trough Open the main dispensing valve and the open the laminate reservoir valve 20 StarLam 1600R User Manual 6 Start the laminate pump and set the speed to about 50 Let the water cycle through the system for a few minutes 7 Stop the laminate pump after cycling plenty of water through the laminate lines 8 Let all the water from the laminate reservoir drain into the laminate trough 9 Drain all the water out of the laminate trough follow trough draining instructions Trough Draining Instructions 1 Make sure the laminate trough valve is switched to the off or closed position 2 Open up the side access panel where the pump and fluid lines are located Locate the laminate drain trough hose and quick connect fittings This should be the
21. ng Bolt PLAM2062 63 Rod Drive Sprocket PLAM2063 64 CSR Drive Shaft Collar PLAM2064 pS CSR Drive Shaft PLAM2065 66 Take Up Core Mandrel PLAM2066 67 Rod Wash Trough PLAM2067 68 Top Fan Assembly PLAM2068 o 69 Bottom Fan Assembly PLAM2069 ooo 70 Push to Connect Elbows PLAM2070 pT Main Support Bracket PLAM2071 p72 Main Support Bracket PLAM2072 73 Drive Motor PLAM2073 pA Control Switches PLAM2074 pS ControlKnobs PLAM2075 o jE O O 77 Main Display Board PLAM2077 Ts Emergency Stop Switch PLAM2078 79 Small Wire Terminal Strip PLAM2079 80 Drive Motor Capacitor PLAM20800 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 61 62 63 64 65 67 70 71 72 73 74 75 76 77 78 79 StarLam 1600R User Manual o 86 DIN Magnetic Breaker PLAM20866 gs Wire Terminal Strip PLAM2089 0 90 Drive Control IC Board PLAM2000 p e 98 Wash Pump Transformer PLAM2098 JJ PTC Swivel LP Elbow amp 0 E y O ee E S Forward Motor Switch PLAM2093 SS 3 8 1 4 connector Nylon 1 4 1 4 connector pS Female Valved 1 4 Coupler 0 0 Female Panel 1 4 Coupler Male Valved 1 4 Coupler oo 8 Male 1 4 Coupler fF Male Valved 3 8 Coupler 0 0 0 1 4 ID Fluid Tubing T strainer filter assembly
22. p this instruction manual for reference in the future m Please follow the safety precautions and operational guide lines when operating this machine StarLam 1600R User Manual Table of Contents Operation Regue MENS ao 4 SAA y He er LU LD 107 Is ee eee a IN A 4 Macias DI a 7 Technical SpeclHiedtlofiS uiae einen d dob ui Eh doti end ia Da ei 9 Precautions Betore ODETANNE siii an 10 Preparation Before Opera ali 10 Operation TS UIC HOP RSS de tads 11 THOU IES OO WING ic a at eee des 24 A mmen 26 MAINISNANCE eo pides 28 ZAST Sale SCIVO sana Sl LA A SJA 28 ADDEN IKES ur lei 29 StarLam 1600R User Manual Operation Requirements m The machine should be used in temperature range of 15 C 50 F 40 C 104 F m Environmental relative humidity should be 30 70 Avoid using the machine in places with high temperature humidity and dust m Don t place the equipment in direct sunlight m Place the machine on a flat floor and properly level it Never set it on an irregular floor to avoid tipping over the machine leading to personal damage or property loss Safety Precautions Ensure that the machine is properly connected to an electrical ground The power cord should be connected in conformity with IEC 60245 regulations and in compliance with local electrical code requirements The phase line should be connected to live wire with mark L The neutral line shall be connected to zero line with mark N
23. rical Schematic 29 StarLam 1600R User Manual Appendix Al 30 StarLam 1600R User Manual Appendix A2 Clearstar Part No Meana Rod Cradle PLAM2001 N 25 Metering Rod PLAM2002 3 Nozzle Support Rod PLAM2003 4 Fluid Nozzle Holder PLAM2004 pS Fluid Dispensing Nozzle PLAM2005 6 Heat Deflection Shield PLAM2006 8 Large Tension Roller PLAM2008 9 DraFilerSceen PLAM200 PLAM2011 Un dU 3l StarLam 1600R User Manual Part Description Clearstar Part No Core Rod Support Hinge PLAM2042 Core Rod Hinge Plates PLAM2043 Laminate Trough Mount PLAM2044 Idle Roller 2 PLAM2045 4 RS Fan Track Screw PLAM2041 a nn nn UNE o 4M o 45 46 Bushing PLAM2M6 M Heat Shield PLAM2047 48 Mid Main Support Bracket PLAM2048 49 Left Support Plate PLAM2049 580 Support Plate Bolts PLAM2050 _ _ _ _ _ o 51 DINRaD PLAM2 8 2 Control Board PLAM202 S Safety Relay Bracket PLAM203 o 54 Main Frame Box Left PLAM2034 p55 DC Transformer Bracket PLAM2055 56 DCTransformerCover PLAM2056 _______ 57 Left Frame Box Door PLAM2057 58 Drive Chain PLAM2058 9 Grounding Bus Bar PLAM2059 p60 Drive Chain Cover PLAM2000O p61 Drive Motor Sprocket PLAM2061 62 Sprocket Retaini
24. tch the bottom two remaining valves to the cleaning position 3 Hook the siphoning hose to the inlet connector on the inside bottom left of the machine when facing the cleaning trough just behind the cleaning trough 4 Connect the other end of the siphoning hose to the siphoning drum connector in the drum and loosen the other drum bung so air can ventilate through into the drum 5 Turn the laminating power switch to the up forward position Adjust the pump to the desired speed using the rotary knob Speed Controller 6 Switch the rotary knob Speed Controller to the off position once the fluid reservoir is filled to just under the fluid inlet port 23 StarLam 1600R User Manual Troubleshooting Possible cause and remed s Power lides toto e Be sure that the main power supply switches are switched on i e Check internal Breakers to make sure they are not tripped e The working indicator light does not illuminate even after heating for some time e Surface of the webbing crumples e Surface of the coated substrate 1s not dry e Coated material is not drying or is not dried uniformly e I am in the middle of a long run and I have figured out my roll is not stretched evenly What can I do to save my job run with the machine in motion e I have clear streaking going in the same direction as the wires on my metering rod e I am getting an uneven coating result in just certain areas of the job The areas seem
25. to be a pattern or repetitious with some sort of symmetry to it e The coated job feels dry coming out of the machine but when I go to unroll the coated roll I hear a slight peeling sound as it unrolls e The light shows that the machine is increasing in temperature Be patient and wait for awhile and it should illuminate e If the working indicator light does not illuminate after a long time then the system is in failure Stop immediately and have the machine repaired before use e Temperature is too high Need to decrease temperature e Speed is too slow Need to increase speed e Temperature 1s too low Need to increase the temperature e Speed is too high Need to decrease speed eHeater is not on e Too much liquid has leaked to the other side of the coating rod e Rolled substrate may have not been stretched tightly Need to enhance the damping of the material roll in the front part of the machine e Rolled substrate has not been stretched evenly Stretch again tightly and evenly according to the above said steps eYou can try tensioning the clutches tighter e If all the environmental requirements of the machine are being met then the liquid laminate may be too high in viscosity Reduce the liquid laminate as per its instructions to get the required viscosity to run on the machine e The metering rod has built up material in the grooves and on the surface Clean the Metering rod very well with appropriate cleaner and 1
26. to the machine 1 Remove the metering rod and clean the laminate off the surface 2 Take away the liquid trough If there 1s waste liquid left after laminating pour back the waste liquid into a liquid container Clean the laminate off the surface and clean after filling up with water Soak and clean with a brush the remaining laminate left in the trough Clean the front and back guide rolls 5 After air drying all parts should be reinstalled into their original position mn A In order to protect this machine do not expose it to the weather When storing the machine for a long time switch off power supply for the external line and cover it with machine cover After Sale Service Thank you for your faith with our company s product As our client you will obtain our company s sincere technical service and support When you need us just contact your equipment supplier or contact Clearstar LP directly If you have any questions please call our reseller agents distributors or contact us directly through our customer service or sales department The products of our company are subject to change without prior notice Clearstar LP P O Box 390 North Charleston SC 29423 1 888 253 2778 Fax 1 843 886 3701 V 1 843 886 0094 www clearstarcorp com StarLam 1600R User Manual Appendixes A PDEDODE Arca daria Dra Al Exploded view parts diagram ZD DEI dio A UE A2 Parts list with part numbers APDEDOIDE Carias A3 Elect
27. ts of the lamination job be sure to pay close attention to when more liquid laminate should be added to the liquid laminate reservoir e The external diameter of the drive roller will continually increase along with the process of liquid laminating The linear speed may also increase as the diameter of roll increases Keep in mind to adjust the settings properly to decrease linear speed as required thus insuring optimal lamination effect 13 If an urgent situation arises and it is needed to stop the machine immediately simply press down on the available emergency stop button located at the top and on either side of the machine 14 Once the liquid lamination process is finished switch off the motor speed switch the heater power switch and cooling fan switch A Do not switch off the main power supply switch if it is within 5 minutes after ending the liquid lamination process This can damage the heater if it is not allowed to cool properly after being used 15 Rotate the locking sleeve jacket to the take up core roller drive roller so that the core holder rod can be lifted up and out of the machine gently The coated and rolled material on the paper core can be removed at this point 16 Immediately clean the liquid metering rod liquid trough to avoid drying and hardening of the liquid laminate a Loosen the metering rod retaining bolts on both side of the liquid metering rod and take it out and clean it immediately For precise and p
28. ur warranty remains intact All requests for warranty assistance should be directed to Clearstar LP Failure to do so will void the warranty Not Warranty works Should Clearstar LP be called upon under the warranty and the fault found to be not the new equipment or its parts you will be invoiced for the cost associated with such works SUMMARY OF WARRANTY EXCLUSIONS We shall not be liable under this warranty for 1 Loss or damage caused by fire explosion direct lightening power surge and the like storm tempest flood water damage rainwater earthquake accident impact burglary theft or attempts thereof malicious damage 2 Loss ofuse of your equipment or other consequential loss damage or consequential liability of any description 3 Damage or liability arising out of a willful act or your willful negligence 4 Damage caused by the fair wear and tear accidental and malicious damage or misuse or attachment of unauthorized additional components 1s excluded from the warranty 5 Gradual deterioration including corrosion or other ongoing effects caused by environmental conditions 6 Loss or damage caused by interference by another party and or attempted remote alterations by any means 27 StarLam 1600R User Manual Maintenance After using the StarLam 1600R the machine must be cleaned immediately otherwise the liquid laminate will solidify which 1s not beneficial Before cleaning always switch off the power coming in
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