HLCL-1000_v11

HOT MELT LABORATORY COATER LAMINATOR
MODEL HLCL-1000
OPERATING INSTRUCTIONS
CHEMINSTRUMENTS
510 COMMERCIAL DRIVE
FAIRFIELD, OHIO 45014
(513) 860-1598
www.cheminstruments.com
Revision 1.1
July 31, 2018

TABLE OF CONTENTS
PRODUCT DESCRIPTION ........................................................................................................ 3
SPECIFICATIONS.......................................................................................................... 3
UNPACKING ............................................................................................................................. 4
ASSEMBLY ............................................................................................................................... 5
THEORY OF OPERATION ........................................................................................................ 7
POWER UP .................................................................................................................... 7
CONTROLLER OPERATION ......................................................................................... 7
COATING HEAD ............................................................................................................ 9
OPERATION .................................................................................................................. 9
SETTING COATING GAP .............................................................................................10
RESERVOIR .................................................................................................................11
CLEANING ....................................................................................................................11
SETTING TEMPERATURE ...........................................................................................12
MICROMETERS (OPTIONAL) ......................................................................................13
BRAKE UNWIND STANDS ...........................................................................................14
LAMINATOR CONTROLS .............................................................................................15
MAINTENANCE ........................................................................................................................16
CLEANING ....................................................................................................................16
TROUBLESHOOTING ..................................................................................................16
REPLACEMENT PARTS ..........................................................................................................19
2|Page
Hot Melt Laboratory Coater Laminator Operating Instructions (HLCL-1000)
PRODUCT DESCRIPTION
Congratulations on the purchase of your new ChemInstruments Hot Melt Coater/Laminator

model HLCL-1000. The HLCL-1000 is designed to produce coated samples of hot melt
adhesives and then laminate a variety of foils, films, and papers. The HLCL-1000 is designed to
consistently coat and laminate on a lab scale with the following featues.
• Brake unwind stands for both the coater and laminator

• Web alignment guides
• Precision ground coating bars
• Independently heated coating bars and reservoir
• Adjustable air pressure for changing laminating pressure
• Variable speed from 0.5 – 7.5 feet per minute (0.15 – 2.25 meters per minute)
Warning: This equipment can cause injury if not used properly. It is the
operator’s responsibility to observe all safety rules and warnings.
SPECIFICATIONS
Electrical 120 VAC, 50/60 Hz, 15 amps or 240 VAC 50/60 Hz, 8 amps
Product Sample Width 3 inches (7 centimeters) to 12 inches (30 centimeters)
Reservoir Capacity Up to 125 mL
Reservoir Temperature Up to 400 degrees Fahrenheit (204 degrees Celsius)
Physical Dimensions Width: 33 inches (84 centimeters)
Depth: 37 inches (94 centimeters)
Height: 22 inches (56 centimeters)
Weight: 160 pounds (73 kilograms)
3|Page
UNPACKING
ChemInstruments has made every effort to ensure that the HLCL-1000 arrives at your location
without damage. Carefully unpack the instrument and check for any damage that may have
occurred during shipment. If any damage did occur during transit, notify the carrier
immediately.
The coating bars are wrapped to protect them during shipment. Carefully remove the wrapping.
DO NOT USE A KNIFE.
Make sure all of these components are present before discarding the packaging material.
The HLCL-1000 consists of the following parts:

• An envelope with this manual.
• Two brake unwind cores.
• Set of Allen wrenches
• Bag Containing:
o Two Teflon side dams
o Two thickness gauges
o Four machine feet & four screws
4|Page
ASSEMBLY
Warning: The HLCL-1000 weighs over 160 pounds. DO NOT attempt to move it
by yourself.
1. Remove the HLCL-1000 from the crate and set on a sturdy surface.
2. The feet on the bottom of the HLCL-1000 may be adjusted by turning clockwise or
counterclockwise. Adjust the feet until the unit is level.
3. Unwrap the two brake unwind cores and place on the top of the unwind stands.
4. Place the two Teflon side dams in the reservoir.
Assembly and installation diagram:
1. Brake unwind core (pictured with roll of film)

2. Brake unwind stand
3. Reservoir for Teflon side dams
4. Brake unwind core(pictured with roll of film)
5. Brake unwind stand
6. Guard
7. Screw securing guard
8. Screw securing guard
4
1
3
5
6
8
5|Page
OPTIONAL: The laminator portion of the HLCL-1000 can be removed from the unit and placed
further away from the coater if necessary. The laminator is held in place by four screws. These
screws are located on the bottom of the laminator and accessed through the top of the laminator
by removing the front and back guards. Each guard is held in place by two screws on either
side of the top of the guard.
1. Remove the screws and the guards to access the bottom of the laminator.
2. Once the guards are removed, you will expose the screws which mount the laminator to
the coater. Remove the screws. Store the screws in a safe place in case you wish to
reattach the laminator.
3. Remove the laminator for the coater.
4. Replace the guards on the laminator. The laminator should never be operated
without the guards in place.
5. The four extra feet included in with the HLCL-1000 are to be used on the bottom of the
laminator if it is separated from the coater. Using the included screws, mount one foot in
each corner of the laminator.
6|Page
THEORY OF OPERATION
The ChemInstruments HLCL-1000 allows you to produce lab scale simulations of production
processes. The HLCL-1000 has the ability to heat each coating bar and the reservoir
separately, which offers a greater range of control and diversity for your applications. The
reservoir is not designed to melt your coating, only to keep it at set temperature. The following
is a step by step process to create a finished product using the HLCL-1000.
POWER UP
Turn power on with the master switch located on the front panel.
Warning: Operating temperature for this equipment is 0 to 70 Celsius. The

equipment needs to be completely free of condensation, inside and out, before
applying power.
Warning: Make sure the power source matches the requirements of the HLCL-
1000 machine. Damage will occur if this unit is plugged into the incorrect power
supply.
CONTROLLER OPERATION
The heating controllers are preset and tested at the factory before shipment. They are ready to
begin operating as soon as the power switch is turned on. The actual temperature of the
coating bars or back dam are the process values and are displayed on top of each controller
under PV. The desired temperature is the set point and is displayed on the bottom under SP.
The green lamp labeled OUT will light when the coating head is being heated. AL1 and AL2 are
alarms that are not used with this unit. The AT lamp is lit during auto-tuning. This has already
been completed at the factory and should not be repeated.
When the power switch is first turned on, the two displays of each controller will display preset
parameters for the first four (4) seconds. This will include whether the display is set for
Fahrenheit or Celsius and the maximum and minimum set point values. The display will then
automatically change to display the process value and set point. This is the normal operating
mode.
7|Page
After turning on the heater and changing the set points, allow the unit to stabilize. The
factory has tested the unit at 250˚F. It usually takes 45 minutes to 1 hour for the unit to
fully stabilize.
Warning: Once the heater is turned on, the temperature will rise very quickly.
The 45 minutes mentioned above is the time for full temperature stabilization. It
is not the time needed for the coating head to come up to temperature.
NOTE: When you first turn on power, you may notice the smell of burning oil. This is
normal as oil is used as a cooling agent when boring the holes in the coating bars.
NOTE: It is very important to let the machine run for 45 minutes after each adjustment to
allow the temperature to stabilize.
Warning: Allow the coating bars, the back dam, and the heating rods to cool to
room temperature before touching.
TOUCHING HOT COATING BARS, BACK

DAM, OR HEATING RODS WILL CAUSE
SEVERE INJURY!!!
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COATING HEAD
6 2
4
5
1. Thumbscrews
2. Gap Adjusting Screws
3. Tension Screws (These secure the top coating bar to the crossbar. They are set in the
factory and do not require any adjustment.)
4. Top Coating Bar
5. Bottom Coating Bar
6. Reservoir
7. Crossbar
8. Upright
OPERATION
The machine must be plugged into the appropriate electrical and air source in order to
operate safely and properly.
1. Mount the desired substrate on the brake unwind cores and mount the brake unwind
cores on the unwind stands.
2. Thread substrate from the unwind stand at the left of the machine through the coating
head.
3. Set the coating head to the desired thickness of the coating you would like to produce.
4. Thread the substrate from both unwind stands through the laminator nip.
5. Turn on the coater.
9|Page
6. Program the desired temperature for the top coating bar, bottom coating bar, and
reservoir.
7. Turn on laminator. ON/OFF switch is located on the back of the laminator next to the
plug.
8. Set laminator controls: speed, pressure, and direction. See LL-100 operation manual for
instructions.
9. Place Teflon side dams in reservoir to the desired width you would like to make the
coating, and pour the pre-heated coating into the reservoir.
10. Close laminator nip to produce the coating.
The HLCL-1000 should be run until the reservoir is empty and a coating is no longer being
produced. To stop the HLCL-1000, open the laminator nip. After the HLCL-1000 has cooled to
ambient temperature, disassemble and thoroughly clean the coating head.
SETTING COATING GAP
The following directions will allow you to set the gap on the coating head to create a coating of a
desired thickness.
1. With the power off and the heating elements at room temperature, remove the heating
element from the reservoir. There is a plate that holds the heating elements in place
which must be removed. The plate is held in place by two screws. Remove the screws
and pull out the heating element.
2. Remove the reservoir.
3. Tighten the bottom thumbscrews on either side of the bottom coating bar.
4. Thread the substrate through the coating head in between the top and bottom coating
bar.
5. Move the crossbar up so that the top of the crossbar is level with the uprights. Tighten
the top thumbscrews on either side of the crossbar to secure the crossbar.
6. Follow the steps below to set the gap between the top and bottom coating bars to the
desired thickness of the coating to be produced:
a. The gap adjusting screws can be turned clockwise to lower the top coating bar or
counter-clockwise to raise the coating bar. Raise the top coating bar to create a
gap between the top and bottom coating bars.
b. The thickness gauges have multiple shims with their thickness stamped on them.
Find the desired shim and place each shim between the substrate to insure a
uniform gap along the length of the substrate.
c. Turn the gap adjusting screws clockwise to lower the top coating bar on the
shims of the thickness gauges.
d. Tighten the middle thumbscrews on either side of the top coating bar to secure it
in place, and remove the thickness gauges.
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7. Replace the reservoir.
8. Replace the heating element in the reservoir and reattach the plate holding the heating
elements in the reservoir and coating bars.
RESERVOIR
The reservoir is located on the back of the coating head. The Teflon dam inserts are placed in
the reservoir as shown in the picture. The dam inserts can be positioned anywhere in the
reservoir to create the specified width of the coating you would like to create.
CLEANING
The coating head can be disassembled for cleaning.
NOTE: BE SURE THAT THE MACHINE IS TURNED OFF AND THE COATER IS AT ROOM
TEMPERATURE.
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1. Remove the plate on the right side of the machine that holds the heating elements in
place.
2. Remove the heating elements from the top and bottom coating bars and the reservoir.
NOTE: THE HEATING ELEMENTS MAY BE HOT EVEN IF COATING BARS ARE AT
ROOM TEMPERATURE.
3. Loosen the thumbscrews and remove the top and bottom coating bars and the reservoir.
4. The top and bottom coating bars can be cleaned with a soft cloth and solvent. Be sure
to only use a soft cloth that will not cause scratches to the coating bars.
SETTING TEMPERATURE
Follow the instructions below to set the temperature for the top coating bar, bottom coating bar,
and reservoir. The temperature of the top coating bar, bottom coating bar, and reservoir are all
controlled independently.
1. Turn the machine on.

2. Push the SET button.
3. The temperature setting under SV will start blinking.
4. Use the < arrow to select which number you would like to change.
5. Use the up and down buttons to select the correct number for the temperature.
6. Once the correct temperature is entered, press the SET button to set the coater to the
programmed temperature.
7. When no entry has been made for a period of one (1) minute, the controller will return to
normal operation with the last recorded set point.
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MICROMETERS (OPTIONAL)
The micrometers for the HLCL-1000 are optional. The micrometers are mounted on the
crossbar of the coating head. The micrometers allow for a faster way to set the gap between
the top and bottom coating bars. Follow the directions below to use the micrometers.
1. With the power off and the heating elements at room temperature, remove the heating
element from the reservoir. There is a plate that holds the heating elements in place
which must be removed. The plate is held in place by two screws. Remove the screws
and pull out the heating element.
2. Remove the reservoir.
3. Tighten the bottom thumbscrews on either side of the bottom coating bar.
4. Thread the substrate through the coating head in between the top and bottom coating
bar.
5. Move the crossbar up so that the top of the crossbar is level with the uprights. Tighten
the top thumbscrews on either side of the crossbar to secure the crossbar.
6. Turn the gap adjusting screws clockwise to lower the top coating bar until it rests on the
substrate between the top and bottom coating bars.
7. Turn the micrometer dial so the hand points to zero.
8. Turn the gap adjusting screws counter-clockwise to raise the top coating bar. The
micrometers will indicate the gap created between the top and bottom coating bar
caused by raising the top coating bar. This gap will be the thickness of the coating
created.
9. Once the desired gap is reached, tighten the thumbscrews on either side of the top
coating bar to lock it in place.
10. Replace the reservoir.
11. Replace the heating element in the reservoir and reattach the plate holding the heating
elements in the reservoir and coating bars.
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BRAKE UNWIND STANDS
The HLCL-1000 has two brake unwind stands. One is located to the left of the coating head
and the other is located on top of the laminator. The brake unwind stands allow for the
substrate you are coating or laminating with to be kept under tension during the
coating/laminating process. Tension is controlled by adding or relieving pressure to the friction
plate.
3 inch core
Set Screw
Friction Plate Nut
Alignment Wheel
Follow the procedure below to load a substrate on the 3 inch core and adjust the amount of
friction on the brake system.
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1. Slide a roll of material onto the 3 inch core. CAUTION: The 3 inch core has knife
blades on it which are used to cut into the core of the roll of material and prevent
it from spinning. These knife blades are very sharp and can easily cut skin.
Caution should be taken when loading or unloading rolls of material to prevent
injury. ChemInstruments recommends wearing cutting gloves to protect hands
during loading and unloading.
2. Place the core and friction brake assembly onto the brake unwind stand.
3. Loosen the set screws using an Allen wrench.
4. Turn the nut clockwise to add tension. Turn the nut counter-clockwise to relieve tension.
5. Tighten the set screw using an Allen wrench.
6. Thread the substrate through the coating head or laminator.
7. Align the substrate through the coating head or laminator using the alignment wheel.
Turning the alignment wheel will move the brake unwind stand clockwise or counter-
clockwise in order to align the substrate to travel straight through the coating head and
laminator nip.
LAMINATOR CONTROLS
Refer to Benchtop Laboratory Laminator’s (LL-100) operating instructions for details on using
and operating the laminator controls.
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MAINTENANCE
The ChemInstruments HLCL-1000 is a very simple machine. It requires very little maintenance.
However, the machine requires a thorough cleaning after every use. The coating bars are
precision ground and must be kept clean to repeatedly provide quality coatings.
CLEANING
After finishing the coating job, turn off the controller and allow the unit to cool. When the coating
bars are cool, disassemble the coating head. The heating rods may still be warm even
though the coating bars are cool!!! If possible, soak the bars, dam, and back dam in solvent
overnight.
NOTE: If it is necessary to scrub the coating bars, use only a soft cloth. The bars are precision
ground and any scratches to the surface will affect the accuracy of the coatings.
The nature of some adhesives may make it necessary to clean the unit while it is still warm.
Warning: Use extreme caution if it is necessary to clean the unit while it is still
warm.
TROUBLESHOOTING
The troubleshooting chart describes some problems that may occur over time. After
determining the problem, follow one of the following maintenance procedures.
UNPLUG THE MACHINE BEFORE ATTEMPTING MAINTENANCE PROCEDURES!
ELECTRIC SHOCK MAY OCCUR IF THE MACHINE IS PLUGGED IN!
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Troubleshooting Chart
Problem Possible Cause Procedure
Power switch not lit Machine not plugged in. Plug machine into correct
power source.
Fuse blown. Replace with correct fuse.
Controller displays Thermocouple wires loose or Check connections inside
“LBA” disconnected. control box.
(See Below – A)
Heating rod thermocouple is Replace heating rod. Call
bad. ChemInstruments.
Green OUT lamp lit, PV Controller is bad. Replace controller. Call
not increasing, but ChemInstruments.
coating head
temperature is
increasing.
Green OUT lamp lit, PV Heating rod wires loose or Check connections inside
not increasing, coating disconnected. control box.
head temperature not (See Below – B)
increasing.
Relay loose or bad. Check relay and replace if
necessary.
(See Below – C)
Controller is bad. Replace controller. Call
ChemInstruments.
A. THERMOCOUPLE CONNECTIONS
1. Each heating rod cable contains four wires. The thermocouple wires are the small red
and white wire.
a. The red wire should be connected to terminal 9.
b. The white wire should be connected to terminal 8.
2. Replace the back panel making sure not to pinch any wires.
3. If “LBA” is displayed on the front of the heating controller, then there is a break in the
thermocouple connection for that controller. If the above connections are not bad, then
the internal thermocouple must be bad and the entire heating rod must be replaced.
NOTE: The thermocouple wires are solid wire, making it easy to break or crack if bent
too severely. When checking these connections, be gentle with this wire.
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B. HEATING ROD CONNECTIONS
1. Each heating rod cable contains four wires. Two larger wires are hot and neutral. The
hot wires from each of the rods are connected to a red butt splice, which has a yellow
wire running to terminal 6 of the relay sockets.
2. The remaining neutral wire is connected to a blue butt splice, which has a white wire
running to terminal 7 of the relay sockets. This white wire is connected to all heating
rods, all controllers, and all relay sockets through a series of blue butt splices. If one of
these connections is loose, the rods will not heat up.
3. Make sure these connections are tight.
C. REPLACING THE RELAY
1. The relays are the clear plastic boxes. First check to make sure each relay is firmly
seated by pushing down gently.
2. If the relay doesn’t move, continue with replacement. If it does move, firmly seat the
relay, reassemble the unit, and test.
3. To remove a relay, wiggle it in a circular motion while gently pulling it out of the socket.
4. Install a new relay by lining up the tab on the plastic post on the bottom of the relay with
the mating part in the socket. Push it firmly into the socket.
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REPLACEMENT PARTS
Part Number Description
R-HLCL MOTOR Replacement Motor for HLCL
R-HLCL UNWIND CORE Replacement 3" Core for LC, HLC, HLCL Unwinds, Includes Break
R-HL/HLC/HLCL FUSE HOLDER Replacement Fuse Holder for the HL/HLC/HLCL
R-HL/HLC/HLCL HEATING CONTROL Replacement Heating Controller for HL/HLC/HLCL

R-HL/HLC/HLCL RELAY Replacement Relay for the HL/HLC and HLCL series
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HOT MELT LABORATORY COATER LAMINATOR

510 COMMERCIAL DRIVE

FAIRFIELD, OHIO 45014

July 31, 2018

Congratulations on the purchase of your new ChemInstruments Hot Melt Coater/Laminator

• Brake unwind stands for both the coater and laminator

The HLCL-1000 consists of the following parts:

Assembly and installation diagram:

1. Brake unwind core (pictured with roll of film)

Warning: Operating temperature for this equipment is 0 to 70 Celsius. The

TOUCHING HOT COATING BARS, BACK

SETTING COATING GAP

The coating head can be disassembled for cleaning.

1. Turn the machine on.

Friction Plate Nut

UNPLUG THE MACHINE BEFORE ATTEMPTING MAINTENANCE PROCEDURES!

ELECTRIC SHOCK MAY OCCUR IF THE MACHINE IS PLUGGED IN!

C. REPLACING THE RELAY

Part Number Description

R-HLCL MOTOR Replacement Motor for HLCL

R-HL/HLC/HLCL HEATING CONTROL Replacement Heating Controller for HL/HLC/HLCL

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