Castle Edgebanding Machine
Equalizer
Operator Manual
Castle, Inc.
Petaluma, CA
800-282-8338
U.S. Patent No.
6,467,522
Table of Contents
Safety Notification Page 1
Machine Inventory Page 2
Machine Requirements Page 2
Setting Up Page 3
Operating Instruction Page 9
Understanding the LOGO! PLC Page 11
Machine Adjustments Page 15
Definition and Description of Parts Page 19
Maintenance Page 21
Troubleshooting Page 22
Warranty Information Page 26
DO NOT ATTEMPT TO OPERATE THIS
MACHINE UNTIL YOU HAVE READ
THIS MANUAL.
Safety Notification
WARNING: The Castle Equalizer edge banding
machine was designed with operator safety as a
priority. This machine was carefully prepared for
shipment at our factory. Upon receipt of the
machine, inspect for shipping damage. Report any
damage IMMEDIATELY to the freight company,
your Castle dealer and to Castle, Inc. DO NOT
attempt to operate the machine if you observe any
physical damage.
Contact Castle, Inc. at 800-282-8338 for instructions.
1
Inventory
You should have received the following with your Castle Equalizer:
Warranty Card (Please fill out & mail to Castle, Inc. to activate warranty)
Equalizer Operator Manual
Band Reel
Three (3) Glue Hopper Extensions
One (1) 2 ½ lb bag Glue Pellets – CANPLAST Brand
**The Equalizer is sent out with CanPlast brand pellets. If you would like to use a different
brand, DO NOT fill the Glue Pot with the pellets supplied!
One (1) Glue Pot
Two (2) Black Outrigger Beams
Four (4) Outrigger Wheel Cages
Glue Pot Shield with Stock Guide
One (1) Power Cord
One (1) 5/32 Allen Wrench
Machine Requirements
Important: Do not use an extension cord to power the Equalizer
Power: 110 VAC, 20 Amp Circuit
Air Supply: 80 PSI minimum, 150 PSI maximum
2
Setting Up Your Equalizer
Begin unpacking your machine by removing and discarding the cardboard and wood skid
materials.
Loosen the leg locknut and then the set screw on one side of the machine and raise the
Equalizer to the working height of your choice. It may be easier to do this incrementally,
first one side then the other.
There is a retaining bolt inside the legs so that they will not fall out during this adjustment.
Tighten the set screw to hold the chosen height, and then set the angle by pushing the top of
the machine towards the rear of the machine, and then tighten with the jamb nut.
3
Mount the Wheel Cage on the Outriggers. They should be mirror images of each other, left
and right.
Remove the Band Reel from the shipping position. Use the Allen wrench provided to
remove the collar from the shaft. Put the long end of the shaft into the cutout location in the
front bottom center of the machine. It should go all the way through to the rear cutout.
Place the collar on the shaft protruding through the back of the machine and tighten.
Check the action of the Band Reel by grasping the Spokes of the Tape Reel and the Spool
Cover and rotate them back and forth in opposite directions.
Install air supply at the rear of the machine, making sure that the machine is receiving a
minimum of 80 PSI from the compressor. The gauge inside the machine DOES NOT
reflect the PSI coming into the machine.
The Regulator closest to the front of the machine sets how much air is sent through the
pressure sensing tube. The gauge next to it should read between 5 and 15 PSI. The
Regulator closest to the Rear Door of the machine should be set at six full turns to the right
after being completely off (all the way to the left). Both of these Regulators are set at the
factory and should NOT BE CHANGED.
CHANGING THESE REGULATOR SETTINGS WILL VOID YOUR WARRANTY!!
4
Remove your Glue Pot by first loosening the Start Knob directly beneath the Glue Pot on
the under side of the machine.
With the Glue Pot out of the machine, add Glue Pellets directly to the pot until the Transfer
Wheel Axle is covered. **The Equalizer is sent out with CanPlast brand pellets. If you
would like to use a different brand, DO NOT fill the Glue Pot with the pellets supplied!
This addition of Glue Pellets outside the machine is only done when starting with a
completely emptied Pot. The auto-fill mechanism will work for this, but it’s slower this
particular start-up procedure.
Unwrap the Glue Pot Shield with the Castle logo on it (found inside machine). The Glue
Pot Shield sits on the yellow Mechanical Channel with the tabs on the rear of the shield
fitting into the Positioning Holes.
5
The Stock Guide goes on top of the Glue Pot Shield and is held in place by the two Tri-Arm
Knobs. The Stock Guide should be mounted so that the Laminate faces IN, towards the
machine. The Stock Guide and Glue Pot Shield come from the factory already assembled.
To install the banding onto the Band Reel begin by removing the outer cover. Place the roll
of banding over the Expansion Fingers so that the tape hangs down, ready to travel in a
CLOCKWISE direction.
Replace the outer cover and tighten the Lever.
Working the Spokes in opposite directions will expand the Reel and center the tape roll.
6
Push the tape into the Band Guide until you have more than a couple of inches exposed
above the Glue Pot.
The Band Guide is located just left of the Glue Pot. The banding travels up through the
Band Guide from front to back.
The width can be adjusted with the panhead screw on the front of the Mechanical Channel.
Tighten lightly until you feel a slight increase in drag on the tape. At this point the screw
should be backed off one quarter of a turn.
7
Adjusting the machine for different thicknesses of tape can be done with the screw directly
behind the tape and above the work surface. Loosen the screw and slide the plate right or
left to adjust the amount of drag, so the tape stays in position without falling.
Plug in the machine.
To test, begin by making sure the machine is warmed up and in Run Mode (see page 10 for
Mode definitions). The light should be on solid. Expose the tape to the point where it is
JUST at the bottom of the Guide Rail. Roll a test board across the Glue Pot, and all the way
to the last roller. As you pass the Guillotine, it should cut the banding off.
The bond is best after the glue has had time to cool.
If you pull the tape off it should try to take the wood with it.
8
Operating Instructions
I
MPORTANT NOTE
:
Do not mix glue pellet brands!
Most do not mix well with others!
**The Equalizer is sent out with CanPlast brand pellets. If you would like to use a different brand, DO
NOT fill the Glue Pot with the pellets supplied!
Before running the machine:
Begin by dumping a small amount of glue pellets into Glue Magazine. Do not fill the
Magazine past halfway full. This will ease the process of color changing later, and
also prevents the pellets from getting jammed at the base of the Magaz ine.
Remove the Glue Pot and fill it with pellets up to the top of the Wheel Axle. This is
done by loosening the Star Knob underneath the Glue Pot until the Glue Pot Clamp
raises up off of the Pot.
Install the Glue Pot making sure that the red gasket is well sealed with the tube.
With the machine set-up, turn on the power. The light should begin to strobe
regularly.
The machine will come out of Warm-up Mode (see page 10) after 18 minutes. The
light will change to solid when it is ready. After the machine comes out of warm-up,
the Transfer Wheel can be rotated a half turn to ensure that fresh glue is ready for
application. At that point you can begin running boards. Use CAUTION when
turning the Transfer Wheel because it will be very hot.
9
When running boards be sure that:
The board is sitting flat on the Roller Wheels with the backside flush against the Guide
Rails.
While pushing down with enough pressure to push the Glue Pot down, run the board
through the machine right to left. The pressure required will be met by the weight of a
larger board, but a smaller board may require additional downward pressure.
To ensure a complete application of glue to the board make sure to run the board out to
the end of the machine. Constant pressure needs to be maintained on the board as it is
run.
10
Understanding the LOGO! PLC
Warm-Up Mode
Definition:
The Warm-up Cycle runs for approximately 18 minutes. It is signaled by a 1 second
interval blinking strobe and a non-functional Guillotine. Once the Warm-up Cycle
is complete the Strobe will go solid and the Guillotine will become operational.
HOW TO start Warm-Up Mode:
Make sure the Glue Pot is installed and filled.
Plug in the Equalizer and turn it on.
The Warm-Up screen displays on the LOGO! module. This Screen will have a
timer that counts up the time remaining until operating temperature is r eached.
Guidelines:
Do not attempt temperature adjustment while in the Warm-up Cycle
Do not attempt to apply glue while in the Warm-up Cycle
The Light will blink faster the last 5 minutes of the Warm-up Cycle
Run Mode
Definition:
The Run Mode of the Equalizer is entered when the appropriate glue temperature is
reached. At this point the Strobe goes solid and the Guillotine is operational.
HOW TO start the Run Mode:
The only way to get the Equalizer into Run Mode is to go through the Warm-Up
cycle.
Guidelines:
Temperature will be automatically maintained as long as the Equalizer remains in
use and in Run Mode.
Glue levels will be automatically maintained as long as the Equalizer remains in use
and in Run Mode.
The temperature can be adjusted using the LOGO! interface through the back door
of the Equalizer.
The Equalizer will enter Rest Mode if it remains unused for more than 18 minutes.
11
Rest Mode
Definition:
The Equalizer will enter Rest Mode if it remains
when it is in Run Mode. While the Equalizer is in Rest Mode, the glue will be
maintained at a slightly lower temperature then when in Run Mode and the light will
blink a ½ second on and a ½ second off.
HOW TO start Rest Mode:
Rest Mode will be automatically engaged only after the Equalizer remains un-cycled
for more than 18 minutes when in Run Mode.
Guidelines:
Do not attempt to apply glue while the Equalizer is in Rest Mode.
Do not attempt temperature adjustment while in Rest Mode.
To “wake up” the Equalizer, simply depress the Guillotine Actuator and wait for the
Strobe to stop blinking.
The glue should take less than 10 minutes to warm up from Rest Mode.
Sleep Mode
Definition:
The Equalizer will enter Sleep Mode if it remains
minutes when it is in Rest Mode. While the Equalizer is in Sleep Mode it is
essentially powered down completely. The light will be off and the glue heater will
be off, but it will enter the Warm-Up Mode if the Guillotine Actuator is depressed
just once.
HOW TO start Sleep Mode:
Sleep Mode will be automatically engaged only after the Equalizer remains un-
cycled for more than 18 minutes when in Rest Mode.
Guidelines:
Do not attempt to apply glue while the Equalizer is in Sleep Mode.
Do not attempt temperature adjustment while the Equalizer is in Sleep Mode
To “wake up” the Equalizer, simply depress the Guillotine Actuator and wait for the
Strobe to stop blinking.
The glue can take about 18 minutes to warm up from Sleep Mode.
un-cycled for more than 18 minutes
un-cycled for more than 18
12
Temperature Setting
Definition:
The Equalizer has 10 temperature settings, 10 being the hottest and 1 the coldest.
The machine is factory set for a temperature level of 5.
HOW TO change the Temperature:
Turn on the machine and allow it to go into Run Mode.
During the Warm-Up Mode, the Screen will display the countdown timer.
Once the Running Temperature has been reached the Run Screen will appear.
To navigate from the Run Screen to the Temperature Set Screen press
ESC + UP arrow or ESC + DOWN arrow.
This will adjust the operating temperature by 1 level.
Guidelines:
Once you have found the temperature setting that works best for you, it is unlikely
that you will have to adjust it very often.
Once a change to the temperature has been made, allow the glue 10 to 15 minutes to
reach the new temperature, then run a test board before changing the temperature
again.
Glue-Feed Fault
Definition:
If the machine tests the level of the glue six times in a row without being cycled,
then when the glue cycle is tested a seventh time it will put the machine into a Hold.
The message displayed on the interface readout is “Glue Feed Fault”. This Hold can
also occur if no Glue Pot is in place or if it is damaged or misaligned.
HOW TO clear the Hold:
Check the status of the Glue Pot.
If it is low, simply depress the guillotine actuator to let the machine continue
feeding glue
If the Glue Pot is full or overflowing then make sure that the Glue Pot Clamp is
tight and all the hoses in the Control Box are connected and tight.
Guidelines:
This fail-safe feature is included so that the machine doesn’t over fill the Glue Pot.
This condition is normal if the Glue Pot is especially low.
13
Guillotine Lock-out
Definition
The Guillotine can be set to NOT automatically cut the banding. This setting is
built in to allow the use of Vertical Grade Laminate.
HOW TO Lock-out the Guillotine:
From the Run Screen press ESC + RIGHT arrow and hold for 2 seconds
Guidelines:
The Guillotine Lock-out can be toggled On and Off as need by following the above
instructions.
14
Machine Adjustments
Remove or Replace the Glue Pot
Release the tension on the Glue Pot Clamp by loosening the Star Knob found under
the Glue Pot.
15
With the Clamp released, use a pair of pliers to grab the lip of the Glue Pot. Pull it out
and place it on the Galvanized Shelf.
Reverse this procedure to install the Glue Pot, making sure it is installed all the way
back onto the rear of the Hot Plate. Fill the empty Glue Pot with glue pellets to the top
of the Transfer Wheel Axle prior to installation.
glue color changing instructions
Place a bucket or box under the Equalizer at the Magazine, and pull the Magazine Gate out
about 2 inches or until it stops. The glue pellets will drop out of the bottom of the machine.
Make sure to change the Glue Pot (refer to above instructions on how to change the Glue Pot),
and allow time for warm-up.
16
Changing the Hopper Extension
To change the Hopper Extension, remove the Glue Pot (following the above
instructions) and place it on the Galvanized Shelf.
Loosen the lower Philips head screws in the Hopper and slide the old Hopper
Extension off.
Put a new Hopper Extension on so that the Castle logo is visible from the front of the
machine.
Place the Glue Pot back into position, align the Hopper Extension with the hole in the
top of the Glue Pot, and retighten the screw.
Adjusting the Band Guide
The Band Guides can be adjusted for both tape thickness and tape width.
Locate the Philips head bolt to the left of the Glue Transfer Wheel that goes through
the Main Panel. This is where the adjustment takes place.
Adjust it so that there is a slight drag when the tape is pulled through it.
17
Adjust for the width of the tape with the screw on the front of the Mechanical
Channel. It has a spring under its head.
This should also be adjusted until the tape has a slight drag. The spring keeps the
adjustment from changing with use.
Leveling the Outrigger Wheels
Each Outrigger Wheel can be independently leveled.
Loosen the two bolts that hold the Wheel Cage to the Arm
Loosen these to the point that the Wheel Cage moves in its mountings, but has enough
resistance to stay in place when repositioned.
Repeat these steps with each of the Wheels on that particular Arm until they are all
slightly loose.
Place a level (or any true flat surface that is long enough), across the Rollers in the
main body and outward over the Outrigger Wheels.
In this way each Wheel can be positioned to “just touch” the leveling surface.
18
Description of Parts
Glue Pot:
Found in the middle of the yellow Mechanical Channel. The
main part is the Glue Transfer Wheel located in the top of the
Glue Pot. It applies glue as the board is pushed through the
machine.
Guillotine:
Cuts the banding after a board is passed through and glued.
Pushing the white Delrin plate above the Guillotine will also
activate it.
Glue Magazine:
Where the glue pellets are loaded and stored for transfer into the
Glue Pot. To change pellet colors, pull on the Glue Magazine
Gate located near the top of the yellow Mechanical Channel.
The pellets will drop out of the bottom of the machine (near the
indicator) on the bottom edge of the machine.
**NOTE: Do not fill past halfway.
Band Reel:
Used to hold and help feed the roll of banding that will be
applied to the work.
Hopper Extension:
A special brown paper is formed to fit the bottom of the
aluminum chute to better guide glue pellets to the Glue Pot.
Three extra Hopper Extensions are located on the Band Reel
when the machine is shipped.
19
Band Guide:
These stainless steel guides ensure that the tape stays centered
on the board. They are adjustable for both thickness and width.
The thickness is adjusted with the Philips head bolt to the left of
the Transfer Wheel as it goes through the main Front Panel.
The width is adjusted with the Phillips head screw pictured.
Outriggers:
Should be used when longer panels are being banded. They are
simply inserted until they run into the stop bolts inside the
Mechanical Channel. When not in use, the Outriggers can be
stored on the legs of the Equalizer.
Sprung Wheels:
Four of the iron wheels after the Glue Transfer Wheel are spring
loaded to help seal the edges of the banding in place. When
using the Equalizer, hold the panels down firmly to insure that
the wheels are compressed to provide a finished edge on the
banding.
20
Maintenance
WARNING! Electrical Hazard: Do not attempt to service any
Control Box components. Contact a Castle, Inc. service technician for
proper service information.
Machine
The amount of use on the Glue Pot will determine how often it needs to be cleaned
Contact your Castle dealer or Castle, Inc to find Pot Cleaner.
You should periodically check that the Glue Pot and the four Sprung Wheels have
The Hopper Extensions will need to be replaced periodically due to glue build-up.
If any problems develop in cutting the banding, check the Guillotine Blade for
out. A considerable amount of burned glue in the Pot is a good sign that your Pot
requires cleaning.
good spring action.
sharpness.
21
Troubleshooting
Band dispenser is too stiff
The screws may have become too tight. The lock washers should be slightly
compressed, but not fully flattened. Locate and adjust as appropriate.
The Finger Slides may have become dry. Try lubing them with silicone grease or dry
white graphite. Do not use liquid oil as it may drip onto the tape.
Glue pot failing to fill even though fill cycle is activating
repeatedly
The Glue Magazine may have become packed and should be dumped and refilled, or
tapped with the heel of your hand to settle the glue into whatever air spaces may have
developed. To prevent this, make sure that the Glue Magazine isn’t filled over
halfway to the top.
Check the air pressure and confirm that there is a minimum of 80 PSI coming from the
compressor.
Check that the Glue Hopper has not become packed. Castle recommends that the
Hopper be changed periodically because they will gum up after prolonged exposure to
glue fumes.
In the Magazine, check the position of the Shooter Tube above the Shooter Nozzle.
The proper gap is one half an inch.
Check the Shooter Tube for kinks.
Glue pot failing to fill and no fill cycle activated
Check the air supply.
Confirm that the glue is melted.
Check the small black and white Control Tubes for kinks and blockages.
22
Glue pot is overfilling
Check for leaks in the Control Hoses.
Check the small black and white Control Tubes for kinks and blockages.
Glue pot has no heat
Do not attempt to service the controls without guidance. Contact Castle, Inc. before
undertaking any troubleshooting of the Control Box. Attempting to service controls
without authorization will void your warranty.
The Sensor may have failed. Check the wires to the Temperature Sensor, being
careful to notice any broken wires.
Glue Temperature is too low - Poor Bonding Strength and
It strings out during application
Adjust the temperature control up by ONE number, allow 10 minutes for temperature
to stabilize, and then test.
Check Glue Pot for burned glue residue on the bottom of the pot. If excessive residue
is found then clean pot with Glue Pot Cleaner.
Check the bottom outside of the Glue Pot and the Hot Plate for glue residue. Clean if
necessary.
Glue temperature is too high - glue pot is smoking
Adjust temperature control down by ONE number, allow 10 minutes for temperature
to stabilize, and then test.
Guillotine Sticking
The Pivot may be too tight. Locate and loosen the Pivot Screw slightly, allowing for
some free play.
Cutting Wheel has become gummed up. Rotate the Wheel to a clean spot. The
Wheel should be loose enough to turn by hand. The Wheel will need to be cleaned.
Cutting Blade may be chipped. If this is the case the blade needs to be replaced.
23
transfer wheel has a dry line
The Glue Pot may have become contaminated. While the Glue Pot is hot, remove the
top, dump the liquid glue, and scrape out any foreign matter along the bottom of the
Pot.
The Glue Pot may need to be cleaned.
Tape edges not centered enough on board edge
The machine is factory set to place the tape closest to the edge of the board that is
facing IN from the machine when running the board. This means that a larger amount
of excess tape will be sticking over the edge of the board that is facing OUT when
running the board. This excess exists to accommodate thicker stock, and when thinner
stock is run it is simply cut off.
Tape edges not even
The Sprung Wheel Rollers may not be working evenly. It is possible that the springs
may have fallen out. Look in from the back of the machine and confirm that they are
all in place.
24
The Band Guide may not be set properly for the width of tape you are attempting to
use. Check and reset the Band Guide.
Check the Glue Pot to make sure that it is squarely set into machine.
Check Stock Guide to ensure that it is aligned properly.
When running the board, make sure it is fully flush against the Guide Rails and that
pressure is being applied constantly while running the board.
25
Warranty Information
Castle, Inc. uses only the highest quality materials available for the construction of our
machines. Your Equalizer edgebanding machine is warranted for one full year from the date of
purchase against workmanship or material defects under normal use and service. We are not
responsible for negligence, misuse or accidents. We suggest that any and all machine
maintenance or repair be discussed with an authorized Castle Representative prior to any
disassembly. We will gladly answer any questions you may have prior to any part removal.
Castle, at its sole discretion, may either repair or replace machines that are found to be
defective. This shall be the End User’s sole remedy under this warranty. Castle will not,
under any circumstances, be liable to the End User for consequential, incidental, special
or exemplary damages, or for loss of profits, revenue or use. Further, Castle disclaims
any warranty, expressed or implied, as to the merchantability or fitness of a Castle
product for any particular purpose.
For Technical Assistance, Parts & Tooling:
Call 800-282-8338, Monday through Friday, 8:00am - 4:00pm, Pacific Time
Fax: 707-765-0953
26
Loading...