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                                                   Phoenix 4400- DHP 

November 2017 

 

1 

 

Table of Contents 

Contents 

 

 

 

 

 

 

 

 

  Page 

1.

 

Introduction …………………………………………………...........................................…..2 

2.

 

Important Safety Instructions…………………………………………………………….…..2 

3.

 

Installation Safeguards …………………………………………………………………........3 

4.

 

General Safeguards…………………………………………………………………….…….4 

5.

 

Operating Conditions …………………………………………………………………….….5 

6.

 

Operating Precautions………………………………………………………………………..5 

7.

 

Packing List …………………………………………………………..………….……..……6 

8.

 

Installation 

a.

 

Uncrate the machine ……………..7      e. Remove auto-grip shafts………..…………..8     

b.

 

Remove stand side frames..……....7      f. Assemble the stand……………..…………...9   

c.

 

Remove the side panels……….….8      g. Attaching the machine to the stand..………..9 

d.

 

Remove plastic cover, Operator’s          h. Install left/right auto-grip shaft brackets......10 
Manual, feed tray, safety shield 
and cross members……………….8  

9.

 

System Components…………………………………………………………………………10 

10.

 

Roller Pressure/Gap Handle……..………………………………………………………......11 

11.

 

Emergency Stop Switch..……………………………………..……………………….….....11 

12.

 

Thermal Film Shaft w/Brake Adjustment 

a.

 

2 ¼” Core Adaptors……………12 

c. Thermal Shaft Brake Assembly…………...13 

b.

 

3” Core Adaptors………………12 

d. Shaft Cradles and Alignment Arrows…......13 

13.

 

PSA Film Unwind/Rewind Shafts w/Brake Adjustment 

a.

 

Drive side alignment…………..14 

c. Unwind/Rewind Brake Assembly………...15 

b.

 

Support Cradle Locking Ring…14 

14.

 

Control Panel…………………………………………………………………………….…..15 

15.

 

Rear Power Panel..………………………………..………………………………….….…..16 

16.

 

Safety Shield and Safety Photo Eye…………………………………………………….…...16 

17.

 

Feed Table w/Side Guides……………………………………………………………….…..17 

18.

 

Standby and Auto Sleep Function……………………………………………………….…..17 

19.

 

Heat Sensor Safety Feature……………………………………………………………….....17 

20.

 

Operation………………………………………………………………………………….....18 

21.

 

Loading Film Rolls…………………………………………………………………………..19 

22.

 

Using 2 ¼” Film Core Adaptors……………………………………………………………..21 

23.

 

Threading Thermal Film……………………………………………………………………..22 

24.

 

Threading Pressure Sensitive Film (PSA)…………………………………………………...24 

25.

 

Mounting 

a.

 

Pre-coating mounting Boards……………………………………………………….....25  

b.

 

Mounting to pre-coated boards………..…………………………………………….....25 

26.

 

Troubleshooting……………………………………………………………………………....26 

27.

 

Specifications............................................................................................................................27 

28.

 

Warranty …………………………………………………………………………………..….28 
 

 

Summary of Contents for 4400-DHP

Page 1: ...Phoenix 4400 DHP November 2017 0 OPERATING MANUAL Please read this manual carefully before operating ...

Page 2: ...le 11 11 Emergency Stop Switch 11 12 Thermal Film Shaft w Brake Adjustment a 2 Core Adaptors 12 c Thermal Shaft Brake Assembly 13 b 3 Core Adaptors 12 d Shaft Cradles and Alignment Arrows 13 13 PSA Film Unwind Rewind Shafts w Brake Adjustment a Drive side alignment 14 c Unwind Rewind Brake Assembly 15 b Support Cradle Locking Ring 14 14 Control Panel 15 15 Rear Power Panel 16 16 Safety Shield and ...

Page 3: ...ty obligations to the user 2 Important Safety Instructions In this operating manual you will find important safety messages regarding the product Read these instructions carefully failure to comply with the following safety procedures could result in serious injury WARNING Do not attempt to service or repair the laminator Only authorized maintenance and service technicians should make repairs WARN...

Page 4: ...st harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or te...

Page 5: ... rollers Do not attempt to laminate items that exceed total recommended material thickness of the unit Do not place foreign object inside the machine Do not cut adhesive films directly on the surface of the rollers to avoid damaging the rubber coating Shut down the machine after laminating to avoid misusing this machine by others Turn off the power switch and unplug the power cord before moving th...

Page 6: ...hine or near it Do not keep the machine in dusty areas or places with strong vibrations 6 Operating Precautions The following objects should not be subject to lamination o Volatile substances or any thermal sensitive substances e g Vinyl chloride o Valuable unique and unrecoverable objects o Objects subject to change of color and nature attributable to heat e g thermal sensitive paper crayons etc ...

Page 7: ...ames for stand 2 Stand cross members for stand 3 Unwind rewind shaft for machine 2 Left bracket for unwind rewind shaft inside accessories box 1 Right bracket for unwind rewind shaft inside accessories box 1 Zippy knife inside accessories box 1 Hex wrench 4mm 5mm 6mm each one Hex screw M8 80 for stand 12 Flat washer 8mm for stand 12 Spring washer 8mm for stand 12 Hex screw M5 12 Unwind rewind brac...

Page 8: ... all parts from shipping crate and boxes Inspect parts and the machine carefully Any missing parts should be reported to the shipper upon receipt of shipment 8a Remove the top lid of the crate 8b Remove the stand side frames and set aside Stand side frames TOP ...

Page 9: ...e panels of the crate 8d Remove plastic cover operating manual safety shield feed tray and stand cross members 8e Remove the Auto Grip supply shafts Plastic cover feed tray safety shield and Operator s Manual Stand Cross Members Auto Grip supply shafts ...

Page 10: ...e machine off the skid and set it on the assembled stand securing it with the locking thumbscrews on both side frames The locking castors go to the front Refer to the Packing List Section 7 for the proper hardware NOTE The machine is heavy use caution and good lifting practices when moving the machine to the stand Locking thumb screws 1 2 3 1 Fastening bolts 2 Side frames 3 Cross members ...

Page 11: ... 3 PSA release liner rewind shaft w tube 4 PSA film supply shaft 5 Top thermal film supply shaft w brake disc 6 Left side cabinet 7 Feed table 8 Left side laminator stand 9 Casters 10 Right PSA supply rewind shaft bracket 12 PSA release liner rewind brake knob 13 PSA film supply shaft brake knob not shown 14 Control panel 15 Safety shield 16 Right side cabinet 17 Bottom thermal film supply w brake...

Page 12: ...n all the way at the top b Four mounting gap settings 1 4 6mm 3 16 5mm 1 8 3mm and 1 16 1 5mm 3 There are two pressure settings Thick Film 5 and 10 mil and Thin Film 1 5 and 3 mil Caution When not in use set the Gap handle to the fully open position 11 Emergency Stop Switch The Emergency Stop Switch is located at the rear of the left side cabinet When depressed it will stop all functions of the un...

Page 13: ...o the desired position When using these adaptors make sure the points are facing the opposite direction of the shaft rotation 12b 3 Core Adaptors The 3 Core Auto Grip Adaptors for thermal films can be positioned on the shaft according to the film width by loosening the set screws and sliding to the desired position These adaptors have a locking collar and should be placed on the outside of the fil...

Page 14: ...on Note Do not overly tighten the brake tension Apply only enough tension to the film web to smoothen out wrinkleless before they enter the laminating nip point 12d Support Cradles and Alignment Arrows The thermal film supply shafts have locking screws and alignment arrows indicating which way they are to be loaded on the machine Always insert the shaft with the arrows aligned on the shaft and the...

Page 15: ...ve tongue and groove drive sides Align the tongue of the shaft with the groove in the cradle Alignment arrows on the shafts indicate the position of the tongue 13b Support Cradle Locking Rings After the shafts have installed rotate the outer locking ring of the cradle to lock the shafts in place Tongue Groove Tongue alignment arrow Outer locking ring ...

Page 16: ...ase liner to be pulled into the rollers or induce curl in the finished product 14 Control Panel 3 1 5 2 9 6 8 7 4 1 MODE Indicator LEDs Speed Top Heat Bottom Heat 2 MODE Selector 3 Temperature Actual 4 Temp Speed Setting Display 5 Speed Heat UP DOWN Adjustment 6 Bottom Heat ON OFF 7 Motor REV FWD 8 Motor RUN STOP 9 Top Heat ON OFF Release liner brake adjustment knob PSA film brake adjustment knob ...

Page 17: ... into support block of the shield 3 Lower safety shield onto side support bar 4 When mounting remove the shield 5 The safety photo eye located just before the heat rollers will protect the operator from becoming entrapped in the rollers If the eye becomes blocked the motor will shut off stopping the rollers To reset the motor remove the blockage and press MOTOR 6 Use the foot pedal to laminate and...

Page 18: ...en idle for Three 3 hours without running the machine will go into STAND BY mode The temperature drops to 176 F and the ready light flashes a To resume operation press the MOTOR switch twice b Allow machine to reheat to proper temperature 2 If the motor has been idle for 4 hours without running the machine will go into SLEEP mode and the heaters are turned off a To resume operation turn the ON OFF...

Page 19: ... working voltages before operations Do not use incorrect power supply 2 Turn the main ON Off switch on the front control panel to the ON position the LED display control panel will illuminate 3 The LEDs on the control panel will illuminate 4 Select the desired mode by pressing MODE a The SPEED TOP HEAT and BOTTOM HEAT LEDS will illuminate as you toggle through the MODE button indicating which one ...

Page 20: ...uality of output achieved Excess heat may damage the printed image or cause waves Insufficient heat may result in poor adhesion Thinner stocks can be run faster while thicker stocks or heavy ink coverage should be run slower Some stocks and ink sets cannot be effectively laminated with thermal films Compatibility testing is recommended before laminating long runs Warning Ensure the safety shield i...

Page 21: ...while aligning the arrow on the shaft with the arrow on the machine side frame slide the film roll onto the shafts with the film web coming off the bottom or the top of the roll depending on the poly direction of the film a POLY IN film comes off the BOTTOM of the roll b POLY OUT film comes off the TOP of the roll Note Twisting the roll of film in the direction of the core clip will help slide the...

Page 22: ...shaft is in place c Slide Two 2 core adaptors onto the bottom shaft with the core clips pointing toward the Rear of the machine when the clips are on TOP and the shaft is in place 3 If using POLY OUT film a Select Four 4 2 core adaptors b Slide Two 2 core adaptors onto the TOP shaft with the core clips pointing toward the REAR of the machine when the clips are on TOP and the shafts are in place c ...

Page 23: ...aft 5 Tighten the two 2 core adaptor screws on each core adaptor 23 Threading Thermal Film 1 Upper Film Roll 2 Top Idler Bar 3 Top Heat Roller 4 Feed Table 5 Lower Film Roll 6 Bottom Idler Bar in J channel 7 Bottom Heat Roller 8 Cooling Deck 9 Bottom Pull Roller 10 Exit Tray 11 Top Pull Roller Core Clip 11 10 1 9 8 7 6 2 3 4 5 Locking screws ...

Page 24: ...b through the front rollers and between the rear pull rollers until the threading card can be cut from the web at the rear of the machine Press MOTOR again to stop the rollers or release the foot pedal 10 Refer to Section 12 if you need to adjust the brake tension due to wrinkles in the output Hint If the machine is hot you may slide a piece of poster through the rollers that is large enough so th...

Page 25: ...r 6 Thread the bottom roll of printed media or Kraft paper behind the bottom idler bar and bring it up to the bottom roller If using mounting adhesive DO NOT go behind the bottom idler bar as shown above 7 Push the bottom roll of substrate through the rollers flatten against the roller and tape to the back deck 1 PSA film supply 2 PSA release liner rewind 3 Release liner 4 Top idler bar 5 Top Roll...

Page 26: ...he mounting adhesive between the nip rollers and lower the top roller until it touches the board Pull mounting adhesive down over the idler bar and over the front of the top nip roller and adhere to the leader board Run leader board half way through the roller and stop Insert mounting board to be coated and depress foot switch After the last board insert leader board to keep adhesive from contacti...

Page 27: ...is curled 1 Sheet is curled upward 2 Sheet is curled downward 1 Reduce top roll tension 2 Reduce bottom roll tension LED display id flashing Machine is in Standby Mode Press MOTOR twice allow machine to heat up See section 15 Power is ON but not lights Machine is in Sleep Mode Turn power switch OFF then ON allow machine to heat up See section 15 PSA release liner being pulled into the rollers Not ...

Page 28: ...rmup Time 20 25 min Heating Method Quartz tube Laminating Speed 0 5 to 8 Ft min Film Unwinds PSA Film Top and bottom Top unwind and rewind Film Core Size 2 1 4 and 3 Film Thickness 1 5 to 10 mil Power Supply 240 v 15 Amp Power Consumption 3100 W Net Weight 401 lbs Dimensions 61 x 32 x 53 Shipping Weight Machine 485 lbs Shipping Dimensions Machine 64 x 29 x 26 ...

Page 29: ...or the period during the applicable term which the product remains in the possession of the original consumer purchaser Original consumer purchaser means the person who first purchased the product covered by this warranty It does not apply if it is found that at any time the equipment has not been used for its intended purpose Any unauthorized changes or modifications to this unit without our prio...

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