Pioneer-5000bc Idh e

2006.10.29 Rev.
PIONEER-5000BC/IDH User Guide
"Important Safety Instruction" is for the purpose of User's safety and Prevent the property
loss. Read thoroughly and Use rightly according to the manual
※ Product Design or Specification is subject to change for performance improvement without a prior notice.
page - 1/78
Table of Contents
◐Safety Warning ◐ How to Use the Control Panel
Safety Device 4page Organization of control panel 29page
Emergency switch 5page Setting the display 30~32page
Safety Warning 6~10page Main display 33page
Warning Stickers 11~12page Displaying the amount of work 34page
Ascent and descent of feeding table 35page
◐ Installation of the product ◐ Roller Operation
Checking the Contents of packging 13~14page Setting the operating speed 36page
The name of Main Device 15~17page Roller operation 37page
Unpacking and Moving 18~20page Setting the Driving 38page
Installation of the product 21~25page
Test Operation 26~27page ◐ Emergency alarm and disable
Safety Function 39~41page
◐ Checking the rotation direction of vacuum pump ◐ Sub Display
Vacuum Pump 28page How to set laminating roller temp 42page
Adjusting the bursting motor speed 43page
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Table of Contents
◐ Manual Display ◐ Laminating Method 66~67page
Checking the Functions 44~46page
◐ Main tenance 68~69page
◐ Display of setting
Driving the motor 47page ◐ Troubleshooting Guide
Adjusting the timing 48~50page Paper Feeding 70~72page
Laminating 73page
◐ Paper Loading Bursting 74page
Paper Loading 51~52page Others 75page
◐ How to use feeding device ◐ Product Specification 76page
How to use feeding device 53~56page
Setting of feeding device 57page
◐ How to use the Main Device
How to use Laminating 58~59page
How to use Bursting 60page
Loading & Unloading Film 61~62page
Explanation 63~65page
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Safety Device
Safety Device
☞ External Box
External Box protect inside contents and prevent a injury by drive part at once.
Caution :When external box is opened,the electricity supply is cut off automatically.
Reference : In order to resupply the elctricity, please refer to the electricity reset switch of using main device
Safety Cover
☞ Safety Cover
Safety Cover prevent a burn from high temperature roller and
a injury from throwing part of your hand on high speed rotating roller .
Feeding
Device External Box
Cuation : The roller can't be drived when safety cover is opend

in operation or before.
page - 4/78
Safety Device
Emergency Switch
☞ Emergency Switch
Emergency switch has the function of bringing the system and the spinning and the spinning of motor(roller) to a halt in case of emergency.
Use it only in case of emergency during operation.

☞ Location of Emergency Swich ☞ Emergency stop and Cancellation
Emergency
If you press the red button as shown in the below figure,
switch
emergency switch is activated and every system is stopped.
If you turn the red knob in the direction of arrow as shown in the below
figure, emergency switch is reverted to its original mode.
However, the system can't be reverted to its status prior to emergency stop.
In order to restore the system, please refer to the 'Alarm and Cancellation of
Emergency.
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Safety Warning
"Safety Warning" is for maintaining user's safety and preventing

damage on his/her property.
Please, read it carefully so that you may use the equipment in a correct way.
Warning: If you violate this message, you might be exposed to serious injury or even led to death.
Caution: If you violate this message, you will be exposed to serious injury and property damages.
This symbol indicates a prohibited action. If you take a prohibited action, you will be either wounded or
injured due to the malfunction of the equipment.
This symbol indicates a requested action. Unless the requested action is taken, your safety will not be fully guaranteed.
The request is represented with a figure inside the circle.
Reference: It indicates the solution to prevent an error that might occur in the middle of operation.
page - 6/78
Safety Warning
Electrical Source
Warning
Don't connect or remove the plug with wet hands. You might be electrically shocked.
This product consumes a large amount of electricity during its operation.
If you connect this equipment with a power cable
with insufficient capacity or an old cable, a fire might break out due to electrical leakage.
Do no use a voltage or an electrical source other than indicated. That's a reason for a fire and an electrical shock.
Insert the plug deeply into the socket so that it won't shake. If not, it's a reason for a fire due to the abnormally
heated consent.
Make sure that it's grounded for safety.
In case of malfunction or electrical leakage, there's a possible danger for an electrical shock.
Don't damage or deform the power chord or the plug. That's a reason for a fire or an electrical shock.
Don't bend or pull the power chord too hard. Don't place the power chord under a heavy object.
You might damage the power chord and that's a reason for a fire or an electrical shock.
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Safety Warning
Installation and use
If inflammable or combustible substance is around, it might be a reason for a fire.
Don't use this product in an airtight space.
If you connect the electrical source of external equipment to this product, there's
a possible danger for a fire due to electricity.
Users must not disassemble, repair or remodel this product. That's a reason for a fire and an electrical shock.
Please, get help from the retailer for inspection and repair of the inner main body.
Please, avoid wearing loose outfits such as a necktie, a necklace or shirts with a long lace.
Such an outfit might get stuck into the roller or the rotating part and you might be exposed to fatal injury.
Do not manipulate or remodel the safety device or the safety switch. You might be exposed to fatal injury.
Don't place liquid such as water on the top of the equipment. That's a reason for an electrical shock and malfunction.
Don't use a combustible spray or flammable substance when cleaning the exterior and the interior of the equipment.
A fire might broke out.
Please, keep the equipment away from children. There's danger for an electrical shock or a scald.
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Safety Warning
Electrical Source
Caution
Before moving the product, please turn off the power and remove the plug from the consent.
A damaged chord is the reason for a fire or an electrical shock.
After using the product, the plug must be removed from the consent.
Don't arbitrarily replace the power plug.
You must always obey the voltage and the phase in the specification.
Installation and use
Please, install the product on a flat floor and make sure that the wheel and the height control leg are locked.
After initial installation or moving of the product , make sure that inspect the product according to the basic inspection procedure.
When moving the product outside the room, use the forklift truck.
Except when loading a paper, don't insert a part of your body into the bottom of the loading table
You might be exposed to fatal injury especially in the middle of operation.
Don't go under the bottom of the product.
When replacing a roll film weighing 25kg or more, more than two persons must lift it together.
page - 9/78
Safety Warning
Don't use the product for any other purposes. Obey the procedure and the method in the user's
manual.
page - 10/78
Safety Warning
Only persons who attended the user training session may use this product.
The product is heavy. When unpacking or moving the box, you must be accompanied with many people.
If you don't, that might be the reason for damage on the product or fatal injury.
Be careful not to allow a part of your body or other alien substance wound into the gear or the chain.
That's the reason for injury and malfunction of the machine.
The laminating roller is very hot. If your body contacts it, you might suffer a burn.
Please, avoid installing the product at places listed below.
A place with sudden temperature change - eg. A place with a heater such as a stove, or a place near the ventilation hole of AC
A place with a possible cause of fire
A place exposed to the direct sunlight
A place with lots of dust or vibration
An unstable place such as a dark place, a tilted ground
Don't place an object on the product. The upper part of the main body is hot, objects on the surface will be deformed or the equipment will
malfunction.
During operation, the upper part of the machine and the film right after laminating are very hot. You might suffer a burn injury.
Don't use this equipment for purposes other than laminating. That's the reason for accidents and malfunction.
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Safety Warning
Please, arrange the surrounding during laminating.
page - 12/78
Warning Stickers
Warning Stickers
For the safety of users, warning stickers are attached on the surface of equipment as shown in the below figures.
Please, be careful not to expose yourself to any possible injury during operation.
☞ Warning - Roller ☞ Caution - High Temperature

Be careful not to throw part of your hand or body into the roller. The surface is very hot. Please, avoid a direct contact.
High Temperature and pressure of the roller might
lead to your injury.
☞ Caution - Sharp Blade ☞ Caution -Electricity

Be careful not to make a physical contact. A high-voltage electricity is flowing inside. Don't open the
You might get injured by the sharp blade. external box. An electrical shock might lead you to injury or
even death.
☞ Caution - Electricity
Electrical current is flowing inside. ☞ Caution - Chain
Watch out for electrical shocks during operation. Be careful not to throw part of your hand or
body into the chain. It might get cut by the chain.
☞ Caution - Forklift
Don't lift this part with a forklift.
The product might be damaged.
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Warning Stickers
Warning Stickers
page - 14/78
Checking the Contents of Packaging
Checking the Contents
PIONEER-5000BC Item Name Item Specification Quantity
TOOLBOX LARGE (RED) 1
CRICULAR LEVEL RL-32(FSK) 1
WRENCH SET 1
+ , - DUAL PURPOSE DRIVER 1
SETTING DRIVER 1
RING PLIER 1
LONG RODS 1
NIPPER 1
MEASURING TAPE 2M 1
JOGGING TABLE (Option) SPANNER 10mm 1
SPANNER 11mm 1
SPANNER 12mm 1
SPANNER 13mm 1
SPANNER 14mm 1
SPANNER 17mm 1
SPANNER 19mm 1
SPANNER 21mm 1
SPANNER 24mm 1
page - 15/78
Checking the Contents of Packaging
Item Name Item Specification Quantity

SPANNER 27mm 1
SPANNER 32mm 1
SPANNER 33mm 1
SPANNER 36mm 1
SPANNER 40mm 1
BALL WRENCH HEX 12mm 1
PIONEER USER'S GUIDE 1
VACUUM PUMP USER'S GUIDE 1
PLC USER'S GUIDE 1SET
SOCKET SPANNER(BOX SPANNER) 1set (30mm) 1
page - 16/78
The name of Main Device
Feeding Wheel Feeding Device Paper Guide Control Handle Bursting Sub-roller Feeding Device Fixing Handle
Pull Roller Safety Cover Busting Roller Height control Film Trimmer Feeding Table Safety Device Air-exhaust pipe
Decurling Contron Handle Feeding Device Fixed Handle Conveyer Sub-roller Power Reset Switch side slitter
page - 17/78
Explanation of Main Device
Emergency Switch When pressed in emergency, the system is completely stopped.

Bursting Roller This is a roller for separating each laminated paper.
Pull Roller Pressure lever This is a device for adjusting the pull roller pressure and increasing or decreasing the upper/lower separation of the pull roller.
Pull Roller This is a rubber roller for decurling the laminating paper.
Bursting Sub-roller This is a sub-roller for assisting in separating the laminated paper.
Film Trimmer This is a trimmer for separating the laminated paper.
Roll Film This is a laminating film.
Side Slitter This is a cutter for cutting a width of roll film.
Rewinder This is a device for winding the film trimmed by the side trimmer.
Sub-Roller This is for unfolding a film fed by the laminating roller.
Laminating Roller This is for the heating and pressing roller.
Rubber roller This is a rubber roller for pressing.
Feeding roller This is a feeding device for moving the paper into the laminating roller.
Feeding wheel This is for timing the paper feeding and moving the paper into the laminating roller.
Control Panel This is for setting the laminating condition and operating the equipment.
Feeding device This is for feeding the paper one by one.
Feeding device fixing handle This is for fixing the feeding device.
page - 18/78
Explanation of Main Device
Conveyor Belt The belt is used for conveying the paper.

Decurling Device The handle is used for adjusting the curvature of laminated paper. (Refer to page 67)
Laminating Motor The motor is used for starting the laminating roller.
Bursting Roller Motor The motor is used for operating the bursting roller.
Vacuum Pump The pump is used for facilitating inflow/outflow of air for paper feeding.
Table Safety Switch When this switch is turned on,operation of the table stops.
Paper loading table This is used for loading the paper.
Feeding Table This table is used for installing the paper stacker on the feeding parts.
Paper Guide This device is used for aligning the loaded paper.
Paper Guide control handle This device is used for adjusting the location of paper guide to fit the width of paper. (Refer to page 60)
Moving Wheel This wheel is for carrying the product.
Film Shaft This device is used for installing the laminating film.
Power Panel This device is for supplying the power to the equipment
Fan motor This device is used for ventilating the hot air from the inside of the equipment.
Height Control Leg This is for fixing and maintaining the balance of the product.
page - 19/78
UNPACKING and MOVING
☞ Disassembling the packing box of the product

1. In order to prevent corrosions, a vacuum-aluminum packing is used
and the exterior box is made of a veneer board and lumber.
Each veneer board is assembled and fastened with screws in order
to protect the product from the external impacts.
2. You may disassemble the exterior box by removing the screws with
a 11mm box spanner.After disassembling the 5 veneer boards indicated
in figure, take off the vacuum-aluminum packing and move the product.
page - 20/78
MOVING
☞ Conveying and moving the product

◑ Prior to moving the product,
1. Please, remove the electrical power plug and pipes for air and temperature controller from the main body.
2. Please, release the lock of wheels and raise the height control leg.
◑ In the following cases, you must use a forklift as shown in the right figure.
1. When moving the product on the ground which is not flat
2. When you move more than 10 meters
3. When moving to the location of installation after disassembling the box
Caution: The product weighs 1500/2000/3500kg, so be careful not to cause any injury or damage to the property when moving it.
◑ When moving the product with wheels

1. If the moving distance is less than 10 meter, you may use the wheels
2. A minimum of 4 men may push the edges of external box and slowly move the product.
◑ After moving the product,

1. Please, lock the wheels and adjust levelness by lowering the height control legs.
2. Please, reconnect electrical power plugs and pipes of air and temperature controller.
3.Check any defects of the product according to the procedure in the test operation.
Caution: The product weighs 1500/2000/3500kg, so be careful not to cause any injury or damage to the property when moving it.
Make sure that electrical power plugs and pipes of air and temperature controllers are
disconnected from the main body before moving the product.
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MOVING
☞ Explanation of moving-wheels
잠 김 (ON) 풀 림 (OFF)
You may use the moving wheels if you move a short distance at the same place.
There are locks for the moving wheels and you need to release these locks before moving the product.
If you step on the 'On' lever, the wheel is locked. If you step on the 'Off' lever, the lock is released and wheels will turn.
After moving the product, please lock the wheels.
Lock(ON) Unlock(OFF)
☞ Explanation of height control leg

When moving the product, lift the height control legs and after moving it to the desired location,
lower it again to maintain the levelness of the equipment.
You may lift the height control leg by turning it counterclockwise and lower it Fixing Bolt
by turning it clockwise as shown in the right figure.
Height Adjust Leg
page - 22/78
INSTALLATION OF THE PRODUCT
Environment of Installation
☞ Recommended Environment
1. The product must be installed on a flat ground. You must lock the wheels and the height control legs
2. If inflammable or combustible substances are around, they might cause a fire.
3. Good ventilation is required for discharge the heat generated by laminating.
☞ Dimension of Installation
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Connecting to source of electricity
☞ Connecting to the source of electricity ◐ Checking the phases of plug and Consent
◐ Power Specification : Power Scoket(Power
Power Chord
Rated Voltage : 3N(3~phase), 400VAC 1 Consent)
Rated Frequency : 50/60Hz 2
Rated Current : 40A 3
4
◐ Voltage and Phase : 5
20mm
1. Phase of the source of electricity :
G(GROUND) / Earth Power Plug 1
1 G(GROUND)
N(NEUTRAL)
2 N(NEUTAL) 2 3
L1 ( R )
3 L1(R)
L2 ( S )
4 L2(S)
L3 ( T ) 5 4
5 L3(T)
2. Line Voltage)
1
N~L1, N~L2, N~L3 : 230VAC
2 4
L1~L2, L1~L3, L2~L3 : 400VAC 3 5
2 3
4 5
1
Caution : If you make a wrong phase connection with the source of electricity, it will reverse the direction of rotation of motor
and vacuum pump. Consequently, the equipment will suffer from a fatal internal damage.
page - 24/78
◐ In case of connecting the power cable directly to the switchboard
Color and number of wire Color of Wire
Switchboard L1 ( R ) Black 1 Black

L2 ( S ) Black 2 Brown
L3 ( T ) Black 3 Black
N(NEUTRAL) Black 4 Blue
G(GROUND)/Earth Green & Yellow Green & Yellow
Caution : If you make a wrong phase connection with the source of electricity, it will reverse the direction of rotation of motor
and vacuum pump. Consequently, the equipment will suffer from a fatal internal damage.
page - 25/78
Warning
Warning: This product consumes a large amount of electricity during its operation.
If you connect this equipment with a power cable with insufficient capacity or an old cable,
a fire might break out due to electrical leakage.
Caution
Caution : For your safety, please make sure that it's grounded properly. If not, excessive static electricity will occur
during operation and it will even cause the malfunction of the equipment.
Caution : If you arbitrarily replace the power plug attached to the product,
it might cause a serious problem to your safety.
When you would like to replace the plug, ask for help from the retailer or our service center.
Caution : Make sure the power is turned off before connecting to the source of electricity.
If not, there's possible danger for injury due to sudden operation of the equipment.
Caution : Do not connect other equipment simultaneously to the consent which is connected to our product.
Due to the excessive power consumption, a fire might break out.
Caution : If you make a wrong phase connection to the source of electricity,
it might cause the damage to the equipment or start a fire.
Caution : Insert the plug deeply into the socket so that it won't shake.
If not, it's a reason for a fire due to the abnormally heated consent.
page - 26/78
Connecting air-pipes
☞ Connecting air pipes
For pressure of laminating roller and operation of bursting roller, inflow of compressed air from the outside is required.
Please, use a compressor with capacity of 5 horse power or more.
To facilitate inflow of compressed air from the outside, air plug is used.
If an air plug is included in the package, please insert a hose as shown in the fight figure.
Compressed Air Filter
An air plug is installed Remove the front and the Connect an air hose with Assemble the front and Connect the air socket
on the equipment. back part from the air the air socket. the back part of air with the plug.
socket. socket.
Reference : A lot of moisture is generated when the compressor makes compressed air.
Please, install a filter at the outlet of compressor before using the equipment.
A dry filter located at the inlet of the equipment and the outlet of external compressor requires removal of moisture
at least once a day.
page - 27/78
TEST OPERATION
TEST OPERATION
☞ Test Operation after Installation

1.Turn off the power switch and press more than 2 emergency switches.
2. Connect the power and the compressed air to the equipment and turn on the power.
3. Release the emergency switch and also release the emergency/function alarm on the control panel.
4. Using the manual menu, check the direction of rotation of the driving motor and see if there's any malfunction.
1) Start the laminating roller and motor and check the direction of rotation.
2) Start the bursting roller and check the direction of rotation.
3) Start the vacuum motor and check the direction of rotation.

4) Check ascent and descent of the feeding table.
5) Check the pressure of laminating roller and the condition of pressure-release.
6) Check whether the cooling motor's running and stopping properly.
7) Check whether the trimmer runs and reverts properly.
8) Check whether the paper aligner operates and reverts properly.
9) Check whether the vacuum motor runs and stops properly.
10) Check whether pressurization and pressure-release of the bursting roller are proper.
11) Check whether the feeding wheel operates and reverts properly.
page - 28/78
TEST OPERATION
TEST OPERATION
5. For testing, load 30~50 sheets of paper Into the paper loading table
6. Enter the length of paper.
7. Adjust the height of loading table and the loading device.
8. Install a film.
9. Set the origin of paper loading.
10. Start a test drive and check if there's any malfunction of the system.
Warning : Please, avoid wearing loose outfits such as necktie, necklace or shirts with a long lace.
Such an outfit might get stuck into the roller or the rotating part and you might be exposed to fatal injury.
Caution : If you make a wrong connection to the source of electricity, part or all of system will malfunction.
Reference : Start with a low speed below 7m/min for your test driving.
page - 29/78
Checking the rotational direction of vacuum pump
VACUUM PUMP
☞ Checking the rotational direction of vacuum pump

Start the system and you can check the rotational direction of vacuum motor by observing injection and suction of air in the blast foot, the blower and the sucker.
Start the system and check the rotational direction of vacuum motor. If everything is normal, it looks like as follows.
At every cycle of the feeding device (1 lap, 1 rotation, 1 roundtrip), air is injected from or sucked into the blower, the blast foot and the sucker once.
⊙ Main Display ⊙ Main Display
1. Starting the system 2. Air-injection from the blow 3. Suction by the sucker 4. Air-injection from the blower foot 5. Stopping the system
Reference : If you made a wrong connection to the source of electricity, you can find out about the rotational
direction of vacuum motor by observing the direction of air as described above.
or more details, please refer to the vacuum pump manual included in the package.
(If the connection is wrong, the blowing air direction is reversed.)
page - 30/78
HOW TO USE THE CONTROL PANEL
Organization of control panel
☞ The control panel consists of 5 different displays that present the status of equipment and input of use-condition as shown in the following figure.
1. Main Display 2. Sub Display 3. Manual Display 4. Display of setting
5. Display of input
The control panel consists of HMI(HUMAN MACHINE INTERFACE) and TOUCH SCREEN.
1. Main Display It consists of the basic menu for laminating process.
2. Sub Display It displays the current status of system and the amount of work.
3. Manual Display It consists of the manual menu for checking the system.
4. Display of setting It's for fine-tuning the system.
5. Display of input It's for entering the condition of process.
☞ How to use the control panel.

If you press the character inside 'ㅁ', then your order is executed.(hereinafter referred to as selection of menu)
The selected menu or the screen before/after the selection of menu is displayed as shown on the figure.
The menu selected or being executed is indicated by the dotted lines.
The menu is disabled while emergency or safety function is running.
In such a case, you may only use the menu to release the safety function.
Caution : If you press the control panel too hard, the panel might get damaged.Press it lightly with your fingertip.
page - 31/78
Setting the display
☞ Setting of main display

Please select the menu indicated in each of the below figures.
1. Main display 2. Selecting a menu in the sub display 3. Selecting a menu in the display of setting 4. Selecting a menu in the manual display
As shown in the above figure, after setting is as the sub display or the display of setting, you may set it to the main display.
5. Selecting a menu in the display of input
Setting-values are entered into the main display.
page - 32/78
Setting the display
☞ Setting of sub display

1. Sub display 2. Selecting a menu in the main disp 3. Selecting a menu in the manual displa4. Selecting a menu in the display of setting
☞ Setting of manual display

1. Manual display 2. Selecting a menu in the sub display 3. Selecting a menu in the display of setting 4. Selecting a menu in the main display
page - 33/78
Setting the display
☞ Setting the display of setting

1. Display of setting 2. Selecting a menu in the main display 3. Selecting a menu in the manual display 4. Selecting a menu in the sub display
page - 34/78
How to use the control panel
Main display
☞ Setting the length of paper

If you want to set or change the length of paper, select a menu in the sequence indicated in the below figure.
As shown in the figure, select the 'LENGTH' menu in the main display and enter the desired length of paper.
Please, enter the value 3~5mm less than the actual paper length.
Because multiple sheets of paper might get fed from the feeding device, you need to set the length of paper shorter than its actual length.
⊙ Main Display ⊙ Input Display
☞ Setting the origin of the paper feeder

⊙ Main Display
By selecting the 'FEEDER(Z)' in the main display, locate the 'blast foot'
and the 'sucker' in the home position described in the left figure.
Setting the origin of the paper feeder is an important function of
determining the initial timing of paper feeding.
Please, make sure that the 'FEEDER(Z)' menu is selected before operation
page - 35/78
Displaying the amount of work
☞ Setting the number of sheets

1. Number of sheets for operation
⊙ Main Display
The 'OP' SHEET' menu in the left figure represents the total number of sheets that can be laminated
in an hour according to the current drive speed and the condition of paper to be laminated.
⊙ Main Display
2. Counter
The 'COUNTER' menu in the right figure represents the total amount of work done as of now.
Represents the total hours of operation as the number of sheets.
Represents the amount of work per unit time. You may initialize it.
☞ Initializing the amount of work

⊙ Sub display
As shown in the left figure, press 'RESET' in the 'DAILY COUNTER' menu of the sub display to initialize
the amount of work.
page - 36/78
Ascent and descent of feeding table
☞ Ascent and descent of the feeding table

⊙ Main Display 1. Ascent/descent of feeding table
As shown in the left figure, press the 'UP' or the 'DW' button in the 'TABLE' menu of the main display
so that the feeding table goes up or down.
The feeding table will be either ascending or descending while the button is being pressed.
If you release the button, it stops.
2. Limit for the height of table
There are preset values for the max. and min. heights of the table.
If you keep pressing the 'UP/DW' button, the table will stop as soon as it reach the limit.
⊙ Feeding table 3. In the following cases, the feeding table won't move
(1) The table won't ascend:
> if the origin of the paper feeding was not set
> if there is no paper in the feeding table (it is detected by the paper sensor shown in the right figure)
> if the height adjustment handle for the table is too tight
> if the table has already reached its max. height (upper limit)
(2) The table won't descend:
⊙ Height adjustment handle for > if the table has already reached its min. height (lower limit)
table (3) The table won't move in any direction
> if the emergency switch is on
> if the signal line is disconnected from the automatic feeding table
> if the control system initiates an alarm (emergency) due to a malfunction during operation
Caution : Be careful so that no part of your body is in the upper or lower part of the table
while the table is moving upward or downward.
You might be exposed to fatal injury.
page - 37/78
Roller Operation
Setting the Operating Speed

☞ Setting the operating speed
The job is operated by the speed showing in the display. It is possible to change the speed while the machine is in operation.
If you change the speed during the operation, the speed will be immediately applied to the system.
1. Setting the operation speed in the MainDisplay
As shown in the figure below, select the 'OP SET(RPM)' menu in the Mai display and enter the desired operating speed in the Display of Input.
⊙ Main Display ⊙ Display of Input
2. Setting the operating speed in the display of setting

As shown in the below figure, select the 'MAIN MOTOR SPEED(m/min) in the display and enter the desired operating speed in the Display of Input.
⊙ Display of Setting ⊙ Display of Input
Notice : The maximum speed is 30m/min and incase of the paper length being below 300mm, the maximum speed
is limited by the built-in program.
page - 38/78
Roller Operation
Roller Operation
☞ Operating in the automatic mode
⊙ Main Display
1. Starting the operation
When you want to to start the laminating process, select the "RUN" menu.
As shown in the left figure, if you select the "RUN" menu in the main display, the system starts running at
the speed indicated by the "OP SET(RPM)" window.
Even if you have selected the 'RUN' menu, the trimmer, the burster and the automatic loading table do not start running.
Another menu must be selected to start those devices.
2. Stopping the operation

If you want to stop the laminating process, please select the 'STOP'menu.
If you select the 'STOP' menu as shown in the left figure, the system stops running.
Notice : Activating the 'STOP' menu will terminate the system only if the system was started by activating the 'RUN'menu.
When selecting the 'RUN' or the 'STOP' menu, if the system is running at a high speed,
the system will first either increase or decrease the speed and then starts running at the speed set by the user or stops.
This is for the safety of users and the protection of the system.
If the system was started by selecting the manual menu in the manual display or in the display of setting,
the 'STOP' menu in the main display won't work.
☞ Operating the laminating roller in the Manual Mode

⊙ Display of Setting
As shown in the left figure, if the MAIN MOTOR SPEED 'RUN' menu is selected in the display of setting,
the laminating and the pull rollerr start running.
The roller runs at the speed indicated by the main motor speed window.
If you select the 'STOP' menu, the roller stops running.
If maintenance or repair of the equipment is required, the menu in the display of setting may be used.
Notice :If the roller or the motor was started by activating the 'RUN' menu in the display of setting,
pressing the 'Stop' button in the main display won't stop running.
page - 39/78
Roller Operation
Setting the Driving

☞ Starting and stopping the rewinder
If you select 'RUN' or 'STOP' menu in the main display, the rewinder starts running or stops in conjunction with the laminating roller.
⊙ Main Display
If the system was started by activating 'RUN' menu in the main display, selecting the 'REWINDER' menu as shown
in the left figure will either run or stop the rewinder.
It will stop the rewinder if it was running. It will start the rewinder if it was not running.
☞ Cutting(Bursting)
⊙ Main Display
If the system was started by activating 'RUN' menu in the main display, selecting 'CUTTING' menu as shown in the left figure
will either start or stop the film trimmer, the burstor and the automatic loading table.
It will stop If they were running. It will start if they were not running.
page - 40/78
Emergency alarm and disable
Safety Function
☞ Alarm and emergency stop

This is a function to detect an abnormal situation during operation or power-on and to stop the system for the safety of user and the protection of the product.
When the alarm is on or the emergency stop is activated, a part or all of the system will stop operating.
☞ Emergency stop & disable in the main display

Please, check the following safety menu if you are unable to command the equipment by selecting the menu in the control panel.
⊙ Main Display
The 'FAULT' menu in the left figure is for reminding users of the 'safety' and 'caution.'
In the following cases, you must select this menu shown in the left figure. If not, the system won't work.
1. When the power is on
2. When you pressed the emergency switch - Deactivate the emergency switch and select the menu
3. When a paper feeding error occurs during operation
4. When the paper feeding table is empty or when the paper sensor in the paper feeding table is activated
Select the 'FAULT' menu and then select the 'FEEDER(Z)' menu.
page - 41/78
Safety Function
☞ Emergency stop & release in the sub display

Please, check the following safety menu if you are unable to command the equipment by selecting the menu in the control panel.
Then, select the "EMG' "' and the ' FEEDER(Z)' menus.
◐ Emergency Stop (Sub Display)

If the emergency switch is activated, the " EMG'" menu in the left figure
displays the 'STOP' message .
If the 'STOP' message is being displayed, release the emergency switch
and go on to your next job.
If you have released the emergency switch, the 'STOP' message will change to 'SAFE'
◐ Paper Feeding (Sub Display)

If the paper feeding table is empty, the 'Paper Feeding' menu in the left figure displays the 'Stop' messag
If all of paper in the paper feeding table is used, the paper detection sensor located in the table is activat
and the equipment stops running.
If the 'Stop' message in the 'Paper Feeding' menu is displayed, you may only lower the feeding table
but all the other functions such as ascent of the table or driving are disabled.
To disable the alarm of 'Paper Feeding,' load paper in the paper feeding table
and select the 'Emergency Stop' menu in the main display.
If the alarm is disabled, the 'Stop' message in the window changes to 'Normal.'
page - 42/78
Safety Function
◐ Malfunction of Paper Feeding (Sub Display)
1. Feeding Roller - Feeding Error 2. Feeding Roller - Insert the Paper to the Feed
When a paper feeding error occurs during driving, the 'Malfunction of Paper Feeding' menu shows the 'Stop' message.
When the 'Stop' message is being displayed in the 'Malfunction of Paper Feeding' menu, the equipment stops running completely.
To disable the alarm of 'Malfunction of Paper Feeding,' insert paper into the paper feeding roller and then select the 'Emergency Stop' menu in the main display.
If you want to restart driving after alarm disable, select the 'Origin of Paper Feeding' menu in the main display and then select the 'Drive' menu.
The reason for selecting the 'Origin of Paper Feeding' menu before driving is because you want to facilitate paper feeding.
◐ Loading Table (Sub Display)

The max and min heights of feeding table is predetermined.
If you keep pressing the Ascent/Descent button, it will stop at these limits.
If the feeding table stops at max or min heights, the 'Loading Table' menu
will display either 'Max' or 'Min.'
"Max" : It means that the table is at its maximal height.Only the 'Descent' menu works.
"Min" : It means that the table is at its minimal height.Only the 'Ascent' menu works.
page - 43/78
Sub Display
How to set laminating roller Temp.
☞ Warm up and set the Temperature of Laminating Roller.
As shown in the below figure, press the 'Stop' or the 'Run' button in the 'Heating Roller' menu of the sub display so that the heating
roller temperature goes up and down.
⊙ Sub Display
Set Temp Measure
⊙ Input Display
page - 44/78
Sub Display
Adjusting the bursting motor speed
☞ Bursting Speed
The speed of the bursting roller is automatically changed in connection with the laminating roller.
The 'Bursting Speed' menu is for adjusting the bursting speed in order to improve the bursting performance when working
on a special film such as a nylon or a PET film.
Different values of bursting speed

Type of film Range
POLYNEX (OPP) 0
NYLONEX (NYLON) 10 ~ 20
PERFEX (PET) 15 ~ 25
Above speed is just recommanded.

Speed should be set depands on the bursted quality.
The 'Bursting Motor' menu is used when you want to operate the bursting roller manually. When the 'Operation' menu is selected,
you cannot change the speed.
⊙ Sub Display
page - 45/78
Manual Display
Checking the function

The manual display consists of manual menus for checking, maintenance and repair of the equipment.
☞ Pressurization and depressurization of laminating roller

If you select 'ON' of the 'PRESS R/L' menu in the manual display below, this will apply as much pressure as preset to the laminating roller.
If you select 'OFF' of the 'PRESS R/L' menu in the manual display below, this will release the pressure applied to the laminating roller.
⊙ Manual Display ⊙ Pressurization of laminating roller ⊙ Depressurization of laminating roller
☞ Runnnig or stopping the cooling fan (Blower)

⊙ Manual Display
If you select 'ON (OFF)' of the 'BLOWER' menu in the manual display shown in the left figure,
the cooling fan is started (stopped).
⊙ Manual Display
☞ Running or stopping the Knicking Knife

If you select 'ON (OFF)' of the 'KNICKING' menu in the manual display shown in the right figure,
the knicking is started (stopped).
page - 46/78
Manual Display
☞ Running or restoring the paper alignment

☞ Running or restoring the paper alignment
If you select 'ON (OFF)' of the 'STOPPER' in the manual display shown in the right figure,
the paper alignment device is started (restored). ⊙ Manual display ⊙ Paper alignment device
☞ Running and restoring the vacuum pump ⊙ Manual Display

If you select 'ON (OFF)' of the 'Vacuum Pump' in the manual display shown in the right figure,
the vacuum pump is started (stopped).
⊙ Manual Display
☞ Running and restoring the bursting roller

If you select 'ON (OFF)' of the 'BURSTING' in the manual display shown in the figure left,
the bursting roller is started (restored).
page - 47/78
Manual Display
☞ Running and restoring the paper feeding device ⊙ Manual Display

If you select 'ON (OFF)' of the 'FEEDING' in the manual display shown in the right figure,
the paper feeding device is started (stopped).
page - 48/78
Display of Setting
Driving the Motor
You can manually operate the laminating roller, the paper feeding device and the bursting roller,
also fine-tune the operational timings of the driving parts of the system.
The default values used in setting of the product are the optimal values set at the time of shipping, and it may require additional adjustment according
to the changes in work conditions.
☞ Driving the laminating roller

Please, refer to the 'Roller Operation' section for driving/stopping and setting/changing the speed of the laminating roller.
☞ Driving the paper feeding device
1) Setting the driving speed
Refer to the 'Setting the Driving Speed'
2) Driving and stopping the device
As shown in the right figure, if you select 'RUN' of the 'FEEDER' in the display of setting, the paper feeding device starts running.
The driving speed of motor is indicated by the FEEDER's speed window.
If you select the "STOP" menu, the motor stops running. You may use this menu when you are required to inspect or repair the equipment.
Notice : If the motor or the roller was started by activating the 'RUN' menu in the display of setting, they can not be stopped by activating the 'STO
in the main display.
☞ Driving the bursting motor
1) Setting the driving speed
Refer to the 'Setting the Driving Speed of the Roller.'
2) Driving and stopping the device
As shown in the left figure, if you select 'RUN' of the 'BURSTER' in the display of setting, the bursting roller starts running.
The driving speed of the motor is indicated by the BURSTER's speed window.
If you select the "STOP" menu, the roller stops running. You may use this menu when you are required to inspect or repair the equipment.
Notice : If the motor or the roller was started by activating the 'RUN' menu in the Dsplay of Setting, they can not be stopped by activating the 'STO
in the Main Display.
page - 49/78
Display of Setting
Adjusting the Timing
☞ Paper feeding alignment

You may adjust the waiting time of the paper feeding alignment device by adjusting the timing of paper feeding of the feeder and the start-timing
of the paper feeding alignment device.
If the paper feeding alignment device opens before paper arrives there, then you must increase the setting values of 'FEEDING' to facilitate the function
of the paper feeding alignment device. If the waiting time of the paper feeding alignment device is too long,
you must decrease the values so that the damage to the printout due to friction with the paper feeding roller.
The paper feeding alignment device and the paper feeding wheel operate simultaneously in the opposite way.
In other words, when the paper feeding alignment device is closed, the paper feeding wheel is opened.
When the paper feeding alignment device is opened, the paper feeding wheel is closed.
The recommended setting values are in the range between 0 and 10.
⊙ Paper Feeding Alignment(Sub Dis⊙ Feeding Roller & Feeding Alignment Device ⊙ Feeding (Sub Display)
Feeding Wheel
Feeding
Paper Feeding Alignment
☞ Paper Feeding
You may adjust the timing of the paper feeding wheel opening for the next paper feeding.(At this time, the paper feeding alignment device is closed.)
If it is too slow and doesn't open before the next sheet of paper arrives at the paper feeding wheel, you must decrease the setting values so that it opens earlier.
On the contrary, if it is too fast and opens before the current sheet of paper arrives at the laminating roller, you must increase the setting value.
The recommended setting value is at 0.
page - 50/78
Display of Setting
☞ Sheet alignment
⊙ Display of Setting ⊙ Paper Feeding Alignment
You may adjust the operational timing of paper alignment device.
If the operational timing is too slow and the device can't have enough time to close in case of a high speed dr
you must decrease the setting value
so that it closes earlier. On the contrary, if the timing is too fast
and the device closes before the paper feeding wheel closes
and paper feeding alignment becomes too difficult, then you must increase the setting value.

☞ Knicking
⊙ Display of Setting ⊙ Film Knicking
Before Film Knicking After Film Knicking
You may adjust the operational timing of the film knicking knife.
Adjust the setting value so that the film knicking knife operates in the area where sheets of paper are underlapped with one another as shown in the above figure.
The smaller the setting value is, the sooner the operational timing is. The larger the setting value is, the later the operational timing is.
It's necessary for you to adjust the setting value according to the changes of angle of the decurling device, the quality and length of paper, and the speed.
The recommended setting value is in the range between -5 and 5.
page - 51/78
Display of Setting

☞ Bursting
⊙ Display of Setting ⊙ Bursting Position
You may adjust the operational timing of the bursting roller.
Bursting Roller
Adjust the setting value so that the bursting roller operates when underlapped parts
of paper are located between the pull roller and the bursting roller.
The smaller the setting value is, the sooner the operational timing is.
The larger the setting value is, the later the operational timing is.
Pull Roller
page - 52/78
Paper Loading
Paper Loading
Paper loading is a very important task for improving the paper feeding and decreasing errors .
☞ Sheet loading
1.Lowering the feeding table 2. Adjusting the sheet width 3. Paper loading
⊙ Main display
Air between the sheets
Adjusting the sheet guides
4. Raising the feeding table 5. Setting the paper feeding device

⊙ 주화면
The reason for blowing air between the sheets of paper is to prevent them from sticking together, minimizing feeding errors due to
adverse printing conditions. The condition of sheet feeding is very important for minimizing feeding errors.
page - 53/78
Paper Loading
Paper Loading
☞ Height adjustment according to deformation of paper

If the top-surface of paper stack is not flat due to deformation of paper, please adjust the height by using a wedge.
Height difference Adjusting with a wedge
Types of unusable paper

1. If the edge and the cutting-side are curled or crumpled
2. If it reacts sensitively to the heat
☞ Paper width adjusting handle

This is a device for adjusting the location of paper guide to fit the width of paper.
If you turn it clockwise, the paper guide narrows. If you turn it clockwise, the paper guide widens.
Narrows Narrows
Widens Widens
2
1
page - 54/78
How To Use Feeding Device
Table Height
Adjustment
Device
BLOWER SEPARATOR BACK GUIDE
SUCKER
BLAST FOOT
☞ Cylinder(SUCKER)
PICK UP SUCKER: The function of Pick-up is to maintain condition
of feeding standby suck one sheet and separate it from loaded paper
The height of sucking paper is recommended to 35mm-35mm.
FORWARD SUCKER: The function of forwarder sucker is to move papers
separared by pick-up sucker to the Feeding roller.
Suction cup sticked on each sucker is one of important parts for
the feeding fuction.
Even depending on operation quantity, it is recommended to exchange
the suction cup per 3 months.
page - 55/78
☞ BLAST FOOT
The function of Blast Foot is to blow air between pick-up paper and separate it completely
and is to press piled papers not to go as tray when Forwarder Sucker moves the sheets of paper.
Adjust condition of air-blow from Blast Foot in order that papers are not to be fluttered.
The position of Blast Foot is recommended to be 10-13mm from the edge of papers.
☞ BLOWER
The Blower is to make 10-15 sheets of paper rise over piled papers by blowing air and
is to separate each 1 sheet by blowing air in advance in order that Pick-up Sucker
will suck the upper paper well.
Please set the height of Blower to the position where 10-15 sheets of paper can be rise up.
The Blower will be up when the adjustment handle would be right turned and will be down
when it would be left turned as per figure.
The good distance between papers and Blower is 20-30mm. Please adjust condition
of air-blow from Blower according to papers thickness and size.
☞ SEPARATOR
The Separator is a device to feed the paper from Pick-up Sucker
page by page. Thus, the device makes wide the space between each paper
And also secure the unity of space between the papers.
Adjust the Controller so as the Separator can be positioned within 5mm from the papers.
Turn right the Controller so as the distance between separator
and paper is getting closer.
Turn it left so as the distance is getting wide.
page - 56/78
☞ BACK GUIDE
The Back Guide is a device to line up the papers in order to avoid any propblem
while the procedure for papers feeding.
Both right & left sides of Back Guide should be closed to the sheets of paper and adjust the upper
side should be placed 2-5mm off from the sheets of paper.
Remark : Do not place the sheets of paper so as too much close to the Back guide.
This could be a cause of problem for the feeding procedure.
☞ AIR PRESSURE CONTROLLER
The Air Pressure Controller is a device to control the Air Volume for Vacuum and Blower.
Turn Right the Controller so as Air Volume is reduced.
2 Turn it left so as Air Volume is increased. Adjust the air volume according to paper's thickness and size.
1. Control Air Volume of BLAST FOOT.
1 2. Control Air Volume of BLOWER.
☞ FEEDER HOLDER
The Feeder Holder is a device to lock the feeder.
Install the Feeding device at the proper place and lock the handle.
The place of Blast Foot and Sucker have to be considered when the Feeder Holder is placed.
Turn right the handle, the Feeding device will be locked. Turn it right, the Feeding device
will be moved back and forth.
Remark : Unless lock the Feeding device, it is subject to be backward to the sheets of paper
as well as the Feeding table may go up, running a protection lever for the feeding device.
page - 57/78
☞ HOW TO ADJUST TABLE HIEGHT

It is very important to adjust the table height and to set the feeder in order to insert sheets of paper(Feeding Error and inserted 2 more
sheets) and to run a system. Adjust the Height Adjustment Handle so as the upper side of papers can be positioned below 2mm
from the edge of Paper Alignment as shown Fig.2.
Turn right the Adjustment Handle so as the feeding table goes up. Turn it left so as the feeding table is loewered.
Fig.-1 Height Adjustment Handle Fig.-2 Feeding Device Fig.-3 Distance Between Sheets and Cylinder
page - 58/78
Setting of Feeding Device
☞ Table Height & Setting of Feeding device

After read and understand fully, proceed to work because it is very important to adjust the table height and to set the feeder
in order to insert sheets of paper(Feeding Error and inserted 2 more sheets) and to run a system.
It is required to adjust setting values according to the kind of paper and condition.
1. To Adjust the Table Height 2. To Set the Blower Position 3. To Set the Separator Position 4. To Adjust the Blower Height
1. To Adjust the Table Height

Adjust the Table height so as to be 3~5mm lower than the Paper Alignment device as shown in the Fig.1.
2. To Set the Blower Position
Adjust the Blower foot so as to be positioned within 10mm from the edge of paper as shown in the Fig.2.
3. To Set the Separator Position
Adjust the Separator so as to be positioned within 5mm from the edge of paper as shown in the Fig.3.
4. To Adjust the Blower Height
Adjust the Blower so as to be positioned within 5mm from the piled papers as shown in the Fig.4.
page - 59/78
How To Use Main Devices
How To Use Laminating
☞ Adjustment of Roller Pressure

It is available to adjust the roller pressure with regulator. The pressure of roller air is indicated on the pressure gauge.
Adjust the roller pressure until the needle point to the pressure on the gauge is showing as the below figures.
It is needed to make a different adjustments depending the type of film and paper to be used.
Turn right the regulator, so as the pressure is increased. Turn it left, so as the pressure is lowered.
When turn the press/release lever counterclockwise, the roller is pressurized(pressed). When turn it clockwise, the roller is released.
Pressure Gauge Regulator Pressure Gauge
Regulator
Pressure
Adjustment of laminating Adjustment of Pulling

Pressurization of Depressurized of
roller pressure Roller's Pressure
roller(lock) roller(unlock)
page - 60/78
How To Use Laminating
☞ Adjustment of Decurling
Curling of films after laminating is very natural phenomenon due to the characteristics of single side laminating.
It is not a problem which occurs because of malfunction of the machine. Decurling
Adjustment
Handle
The Decurling device is for preventing the curling of film after single side laminating.
If you adjust the decurling handle as shown in the right figure, the decurling device starts rotating.
Make a proper adjustmnet of the rotational angle of the decurling device depending on
thickness and quality of paper to be used.
If you turn the handle clockwise, the decurling increases and if you turn it counterclockwise, it decreases.
Decurling
The direction of curling when turning the handle counterwise.

The direction of bending when turning the handle clockwise.
page - 61/78
How To Use Bursting

☞ NICKING KNIFE
The film trimmer is a device used to cut a part of film in order to facilitate separation of laminated paper.
If the system was started by selecting the "start" menu in the main display, now, select the "Bursting Setting" menu to start the film trimmer.
Set the operational triming and location so that the film trimmer in the area where sheets of paper are underlapped with one another.
⊙ Knicking the film
Before Knicking After Knicking
☞ Sub-Bursting Roller
The device is for supporting the bursting roller and is so effective to avoid the tear of film
while cut the laminated paper.
The device is located at the right edge of the paper to display the paper speed.
Then the laminating quality is increased. Roller angles have to be adhusted
to avoid the folding of paper.
Warning : When its' position & angle are not adjusted correctly, the paper could be folded.
Remark : Please make sure Sub-Bursting Roller must be in position but not on the conveyor belts.
If it positions on the conveyor belts, they could be taken out of the machine.
page - 62/78
Loading & Unloading Film

☞ Film Shaft(Film Hanger)
3 1. Support of Film Shaft: This device helps to support a film shaft and not to rock from side to side.
4 2
2 1 2. Fixing Pin of Film Shaft: This device is to tighten a shaft.
3. Film Shaft: This device is for loading a roll of laminating film.
4. Compressed air Inlet: inject or exhaust compressed air through this hole.
If inject air into the hold, the film shaft will clench core inside on the film.
☞ Loading a film
Please use a film whose width is 5 to 10mm shorter than that of paper.
Please place the film 5mm away from the edge of paper as shown in the right figure.
1. Remove a Fixing Pin of Film Shaft.
2. Pull a Support of Film Shaft as showing the photo.
3. Load or unolad a film to/from the film shaft.
4. Close the suppoort of film shaft and insert a Fixing Pin.
5. Inject the compressed air into the inlet.
Caution: More that 2 persons are required to load or unload films.

You may get injured or wounded by heavy film.
page - 63/78
Loading & Unloading Film

☞ Setting a film position
Must use a size of paper which is 5 to 10mm wider that that of film because of characteristics of the single side laminating.
If a paper's width is wider than film's one, the rubber may be contaninated or damaged by the glues leaking from the film.
Please the film 3 to 5mm away from the edge of paper as shown in the right figure.
Caution: Please use a film whose width is 5 to 10mm shorter than paper.
If not, it may cause malfunction or breakdown of the equipment.
☞ Side Trimmer & Rewinder

This device is used to cut a roll film which is wider that the width of paper.
Adjust the location of side trimmer properly and cut the film as shown in the figure below.
Caution : Be cautious at mainipulation with the sharp Knife

and during installation or exchange. You may get injured or wounded.
Film Bursting For Using Rewinder
page - 64/78
Explanation of Other Devices
☞ Power Reset Switch

In case of abnormal overload or overcurrent, the power automatically turned off and supplied again.
(For Example:When a side cover is opened while the the machine is in operation)
Once press the Power Reset switch again, Power will be On.
☞ Power Switch
The Power switch is used for switching on or off the machine.
If pull the Power switch (ON "I") up, the power is turned on. If pull it down (OFF "O"), the power will be turned off.
A built-in circuit breaker is included inside the power switch. In case of abnormal overload or overcurrent,
the power will be automatically turned off.
Remark : If such an accident occurs more than twice in a row, please contact the supplier.
☞ Fan Motor
The Fan Motor is to deflate heated air from the inside of machine for the purpose of protecting the system control parts.
This is installed beneath the outer case on back of the machine, securing space which is needed for effective air deflation.
page - 65/78
☞ Paper Detecting Sensor

The Paper Detecting Sensor detects whether the paper loading table or the feeding table is empty.
If press the "Start" button, the system wouldn't respond.
After loading the papers, disable the emergency/malfunction alarm on the control panel and then start the system.
☞ Safety Device In the Feeder

The Safety Device is to protect the feeder against the feeding table which is loaded the papers.
If the Lever goes up, as shown at the left picture, the system will not work.
If the Lever goes down, the system will work.
☞ Vacuum Pump
We recommend that you should use the pressure of vacuum pump which was present at the time of shipment.
If generates suction and exhaustion air for sheet feeding. You may adjust the pressure according to the type and the size of the paper.
Vacuum Air Control Vacuum Air Control BLOWER Air Control
page - 66/78
☞ Air Exhausting Pipe in the Feeder

It helps to laod and exhaust the laminated sheets of paper.
It is available to adjust air volume using air adjustment handle as shown the red circle.
Adjust the pipe according to the status of loading & exhausting of the laminated sheets of paper.
☞ Conveyor Support Roller

It helps to load and exhaust the laminated sheets of paper.
When it is difficult to load and exhaust by much statics, it is necessary to position the Support Roller on the conveyor belts.
Remark : If the Support Roller is not positioned on the conveyor belts, it might be not fine to load and/or push out the laminated she
☞ Bursting Roller Height Adjustment Knob

The Bursting Roller Height Adjustment Knob is used for adjusting the pressure(Height) of the Bursting Roller. (Number 1)
Turn right the knob so as the roller's pressure is lowered. Turn it left so as the roller's pressure is increased.
1
If it is not bursting by modified width of paper, it is necessary to adjust the knob - the roller's pressure.
2 Tighten the locking washer after adjusting the height. (Number 2)
page - 67/78
Laminating Method
Warning : Please avoid wearing loose clothing such ties, necklaces, dangling jewelry or shirts with a long lace.
Loose clothing can get caught in a roller or a rotating part and you might be exposed to fatal injury.
☞ Work procedure
1. Load the paper and adjust the pa : Stack the paper onto the paper loading table (Refer to the 'Paper Guide Control Handle')
2. Check the height of paper stack : Compare the height of the paper stack to that of the paper alignment device.
(Refer to 'Setting the Feeding Device')
3. Set the paper feeding device : Check the condition of parts installed on the paper feeding device.
4. To load a film : Equipped a film shaft with a roll of film
5. Check the setting on the control p: Check the settings such as the length of paper, the speed and the bursting.
6. Check the condition of the lamina: Check whether the surface of the roller is polluted or covered with alien substances.
7. To load a film : Load a roll of film between the rollers (Refer to the 'Film Loading'.
8. Test Operation : Test run 5~10 sheets of paper and check the condition of lamination and work output.
9. Check the start timing of Nicking : Adjust the start timing so that the nicking knife is aligned with the underlap of paper.
10. Adjust the Bursting(cutting) timin: Adjust the start timing of bursting roller
11. Start operation : Start full operation
☞ Installation of film(film loading)- Normal Laminating Mode
3 4
Please use a film with width's 5 to 10mm narrower than the width of the paper. 3
The films should be located 5mm away from the edge of the paper perforating side.
5
1. By turning the decurling device, adjust the position as shown in the right figure.
2. Push the sheet of paper from the laminating roller to the Pull roller.
3. Push the film until it reaches the mid-point over the laminating roller. 1
4. As the roller's temperature rises, the surface of the film begins to melt. 2
At this point, stick the sheet of paper to the film(overlap).
page - 68/78
Laminating Method
5. Insert the next sheet upto the feeding roller.

☞ Test Operation
When the roller reaches the preset temperature, start a test operation in order to check the pressure setting and
the condition of lamination.
When you press the "RUN" button, the vacuum pump is turned on and pressurization starts.
The system begins to operate.
1.Underlap of the paper: It is ideally 3 to 5mm.
2.Condition of decurling: After checking the cutting of paper, adjust it by the decurling device.
(Refer to the 'Adjusting the decurling")
3.Laminating condition: Change the condition of pressure and temperature and check the resulting finish.
4.Cutting: Check the start timing of Nicking and bursting roller.
After test operation, start the laminating.
page - 69/78
Maintenance
☞ Maintenance of the product
1800Hour 3600Hour 7200Hour

300Hours 900Hours
CHECKING PARTS CHECKING STATUS DAILY s s s REMARKS
1 Month 3 Months
6 Months 1 Year 2 Years
HYDRAULIC PASUCTION CUP WORN, DAMAGE CHECK EXCHANGE

SUCTION CYLINDER(FEEDING) UP/DOWN CHECK EXCHANGE
FEEDING PARTS CYLINDER DRIVING CHECK EXCHANGE
FEEDING WHEEL CYLINDER DRIVING EXCHANGE
NICKING CYLINDER DRIVING CHECK EXCHANGE AFTER 18MONTHS
BURSTING CYLINDER DRIVING EXCHANGE

STACKING CYLINDER DRIVING EXCHANGE
REGULATOR LEAKAGE AIR EXCHANGE
AIR FILTER REMOVE MOISTUREREMOVE MOISTURE CLEAN
AIR HOSE LEAKAGE AIR EXCHANGE
VACUUM PUMP BRUSH & FILTER CHECK & CLEAN REFER TO USER'S MANUAL
FEEDING PARTCAM GREASE CHECK
SPRING SCRATCH CHECK
LEG GREASE CHECK
TIMING BELT WORN, DAMAGE EXCHANGE
TENSION CHECK
SUCTION CUP WORN, DAMAGE CHECK EXCHANGE
SUCTION CYLINDER(FEEDING PARUP/DOWN CHECK EXCHANGE
page - 70/78
Maintenance
DRIVING PARTTABLE & STACKER CHAIN GREASE CHECK

MAIN ROLLER GEAR GREASE CHECK
BEARING OF MAIN ROLLER GREASE CHECK INJECT HIGH HEATING
TIMING BELT WORN, DAMAGE CHECK
TENSION CHECK
PLATE BELT SCTATCH CHECK
TABLE & STACKER GUIDE COVER SURFACE & WORN CHECK
OIL, GREASE CHECK
NIP ROLLER POLLUTION CLEAN OFTEN
NIP ROLLER WORN CHECK EXCHANGE GRINDING, EXCHANGE
RUBBER ROLLER SURFACE & WORN CLEAN CHECK
FEEDING WHEEL SURFACE & WORN CLEAN CHECK
ELECTRIC, CO FAN MOTOR DRIVING CHECK
TABLE, STACKER LIMIT SWITCH DRIVING CHECK
page - 71/78
Troubleshooting Guide
Paper Feeding
Symptom Reasons for malfunction and troubleshooting

When intervals of paper 1. If the forward sucker operates too slowly, paper feeding error increases with
feeding are inconsistent the increasing operational speed(over 30M/min.).
If you turn the speed control counterclockwise, the response time gets shorter.
If you turn it clockwise, the response time get longer.
1) Please check for paper feeding error after turning the control(1) to the left.
2) If the problem still exists, check for paper feeding error after turn the control(2) to the right.
2. It might be because of the slow operational timing of the forward sucker.

3. Ideally, paper fed by the paper feeding device should stop on the paper feeding roller
for a moment and then proceed.
Please refer o the "Paper Alignment" and "Paper Feeding" menu in the display of setting on page 54.
4. It might occur because the timing belt of the feeding roller is damaged.
Please preceed with troubleshooting after checking the condition of the timing belt as shown in the figure.
5. It's because the condition of the paper stack in the loading table is poor.
page - 72/78

6. Because the paper length is set wrong
Misalignment of paper fed by the feeding de 1. Because the condition of paper stack in the paper loading table is poor
2. The paper guide is too close to the paper stack
3. Because the pressure of the feeding sub roller is inconsistent
When the table doesn't either ascend or des1. When the table is empty, it doesn't ascend.
2. If the red light of the sensor located under the table is on, the table doesn't ascend.
Please request support from the seller or Service center.
3. Please check the protection fuse for the motor. It's near the power switch of the product.
Disable the emergency switch or the emergency status of the control panel.
4. If the Blast foot(Paper Feeding device) is stopped on a location other than it's home position,
the table won't ascend.
5. When opened safety cover.
When more than two sheets of paper are ins1. It might be because of the wrong setting used on the feeding device.
Please refer to the "Setting of Paper Feeding Device" on page 59 and 65.
2. It might occur because parts of paper is stuck to the print.
When have bits of roller trace on the paper. 1. It might occur because sub roller's pressure near by the feeding roller is too much.
Please contact the supplier.
page - 73/78
Paper Feeding

When the system stops suddenly during the 1. The system is stopped if the last sheet of paper loaded in the table has been fed into the roller.
2. The system is stopped if the interval between each sheet of paper is too long due to paper feeding error.
3. The emergency switch might have been pressed.
When the table won't move after adjusting th1. It might be because the origin of paper feeding is wrongly adjusted. Start the paper feeding motor in
the display panel. Stop the Blast foot on the down point and then proceed with your work.
2. It might be because it is currently at the home position of paper feeding.
Start the paper feeding motor in the display panel. Stop the Blast foot on the down point and then with your work.
page - 74/78
Laminating

When the condition of adhesion is poor(silve1. The color of printout is dark solid.
2. The pressure of the laminating roller is too lower.
3. The temperature of the laminating roller is too lower.
4. The operational speed is too quick compared to the temperature of the laminating roller.
When the paper gets creased 1. Paper is too wet or because you are working on paper which has been printed recently.
2. The laminating rubber roller is damaged.
3. The pressure of laminating roller is inconsistent.
Curling of laminated paper 1. Please refer to the "Adjusting the Decurling" section.
When the work is seperated in the middle of 1. You are using a perforator.
We do not recommend a perforator when using a film below 25㎛.
2. It might happen because the width of film is to narrow(below 400mm) or the temperature is too high.
Please lower the temperature.
When the film is stuck to the rubber roller 1. If paper feeding error occurs (in the early stage of operation or when the paper stack is changed),
the film might get stuck to the rubber roller. (No paper is fed.)
Please clean the surface of rubber roller with a cleaning agent.
2. Please insert waster paper under the feeding roller and the laminating roller before starting your laminating work.
라미네이팅 결과물에 주름이 발생되는 현상 1. It might happen when you laminate paper of 120g/㎡.
If depends on the texture of paper.
It depends on the moisture on paper.
It can happen if the temperature is too high for that type of paper.
When the rewinder(recoiler) won't rotate 1. If the shaft is misalighned, then the rewinder may not operate.
2. The setting on the control system is wrongly adjusted.
page - 75/78
Bursting

When the nicking of the film doesn't work. 1. The nickng knife won't work unless you select the "Nicking" function in the menu after selecting the "RUN" key.
If the operational timing of the nicking knife is incorrect, it may not be able to risk the film.
3. If the amount of decurling is too big, you may not be able nick the film.
4. If you use a 'sticker' type of paper, you might not be able to nick the film because of the characteristics of the paper.
5. You may not be able to the film if the cylinder for the nicking knife has stopped working.
Please turn off the power and eliminate the compresed air injected from the outside.
Then check the condition of the cylinder/blade.
When you can not burst(cut) the film 1. If happens because the nicking of the film did not occur.
2. If the left & right side of bursting roller(top) is disconnected, you may not be able to burst(cut) the film.
Please adjust the control bolt located on the left side of roller as shown in the below figure.
3. Please refer to the "SKEWING WHEEL" on page 70.

4. It might happen because the bursting position(timing) is improper.
5. You might not be able to burst the film if you use a type of film other than OPP.
Please inquire to the seller or service center.
page - 76/78
Others

When a power does not turn on. 1. Please check the power switch.
2. Please check whether the side cover is opened or not.
After closed the side cover, please make sure that you should press Power Reset Switch.
When the pressurization(air) device does no1. Please remove the water in the filter collected in the equipemnt.
2. Please open the drain valve of compressor and drain the water.
3. Please check the pressure on the pressure gauge of compressor and of the input section of the equipment.
The recommended range of pressure is between 0.5~0.7MPa(5~7bar).
page - 77/78
Product Specification
Classification PIONEER-5000BC
DIMENSION OF LAMINATOR (Width*Length*Height)(mm) 1300*3000*1340
MAX. LAMINATING SPEED(m/min) 40 m/min
MAX. SHEET FORMAT(mm) 500(W)*700(L)mm
MIN. SHEET FORMAT(mm) 210(W)*250(L)mm
PAPER THICKNESS(g/㎡) 120g/㎡~400g/㎡
LOADING HEIGHT OF FEEDER(mm) 480mm
OUT-PUT STACKER HEIGHT(mm) N/A
LAMINATING FILM POLYNEX,NYLONEX,PERFEX
POWER REQUIREMENTS AC 380V, 3N, 60Hz
POWER CONSUMPTION(kw) 13kw
WARM UP TIME(min) 10min.
HEATING SYSTEM Induction Heating System
ROLLER TEMPERATURE(℃) 140℃
OPERATING SYSTEM Siemens PLC(PROGRAMMABLE LOGIC CONTROLER)
MAIN MOTOR Siemens Induction Motor with Vector Driver
FEEDING MOTOR Siemens Servor Motor with Servo Driver
BURSTING MOTOR Siemens Inverter Motor with Vector Driver
REWINDER MOTOR Siemens Inverter Motor with Vector Driver
NP ROLLER PNEUMATIC AIR CYLINDER
FILM SHAFT AIR SHAFT(3")
COOLING SYSTEM Blower
LAMINATOR WEIGHT(kg) 1100kgs
CUTTING BURST CUTTING WITH NICKING KNIFE AND PERFORATOR
※ Cosmetic design or product specification is subject to change in order to improve the product performance without a pre-notice.
page - 78/78

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2006.10.29 Rev.

PIONEER-5000BC/IDH User Guide

◐Safety Warning ◐ How to Use the Control Panel

Safety Device 4page Organization of control panel 29page

Emergency switch 5page Setting the display 30~32page

Safety Warning 6~10page Main display 33page

Warning Stickers 11~12page Displaying the amount of work 34page

Ascent and descent of feeding table 35page

◐ Installation of the product ◐ Roller Operation

The name of Main Device 15~17page Roller operation 37page

Unpacking and Moving 18~20page Setting the Driving 38page

Installation of the product 21~25page

Test Operation 26~27page ◐ Emergency alarm and disable

Safety Function 39~41page

◐ Checking the rotation direction of vacuum pump ◐ Sub Display

Vacuum Pump 28page How to set laminating roller temp 42page

Adjusting the bursting motor speed 43page

◐ Manual Display ◐ Laminating Method 66~67page

Checking the Functions 44~46page

◐ Main tenance 68~69page

Driving the motor 47page ◐ Troubleshooting Guide

Adjusting the timing 48~50page Paper Feeding 70~72page

◐ Paper Loading Bursting 74page

Paper Loading 51~52page Others 75page

◐ How to use feeding device ◐ Product Specification 76page

How to use feeding device 53~56page

Setting of feeding device 57page

◐ How to use the Main Device

How to use Laminating 58~59page

How to use Bursting 60page

Loading & Unloading Film 61~62page

Cuation : The roller can't be drived when safety cover is opend

Use it only in case of emergency during operation.

"Safety Warning" is for maintaining user's safety and preventing

The request is represented with a figure inside the circle.

Make sure that it's grounded for safety.

Installation and use

If inflammable or combustible substance is around, it might be a reason for a fire.

Don't use this product in an airtight space.

Don't arbitrarily replace the power plug.

Installation and use

You might be exposed to fatal injury especially in the middle of operation.

Don't go under the bottom of the product.

Please, avoid installing the product at places listed below.

A place with a possible cause of fire

A place exposed to the direct sunlight

A place with lots of dust or vibration

An unstable place such as a dark place, a tilted ground

Please, arrange the surrounding during laminating.

☞ Warning - Roller ☞ Caution - High Temperature

☞ Caution - Sharp Blade ☞ Caution -Electricity

Checking the Contents

PIONEER-5000BC Item Name Item Specification Quantity

TOOLBOX LARGE (RED) 1

CRICULAR LEVEL RL-32(FSK) 1

+ , - DUAL PURPOSE DRIVER 1

JOGGING TABLE (Option) SPANNER 10mm 1

Item Name Item Specification Quantity

BALL WRENCH HEX 12mm 1

PIONEER USER'S GUIDE 1

VACUUM PUMP USER'S GUIDE 1

PLC USER'S GUIDE 1SET

SOCKET SPANNER(BOX SPANNER) 1set (30mm) 1

The name of Main Device