GBC Ultima 65 EZload User Manual

GBC Ultima 65 EZload
27 Inch School Roll
Laminator - 1710740B
Instruction Manual
ULTIMA 65
Printed in U.S.A
Part Number 1722768
Assembly Number 1711501
Issued 01/02
Revision: C
Copyright General Binding Corporation, Northbrook, IL U.S.A
SERVICE MANUAL
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TABLE OF CONTENTS
PAGE
1.0 Introduction 1-1
2.0 Specifications 2-1
3.0 Installation 3-1
4.0 Operating Instructions 4-1
5.0 Troubleshooting 5-1
5.1 Theory of Operation
5.2 Theory of Successful Lamination
5.3 Electrical system
5.3.1 Heater Control Circuit
5.3.2 Motor Control Circuit
5.4 Mechanical Operation
5.5 General Troubleshooting
5.6 Testing Electrical Components
5.7 Troubleshooting Guide Chart
5.8 Electrical Wiring Diagram and Schematics
5.8.1 Ultima 65 Wiring Schematic
5.8.2 Ultima 65 Wiring Diagram
6.0 Disassembly / Assembly / Adjustments 6-1
6.1 Film Roll Tension Adjustment
6.2 Roller Pressure Adjustment
6.3 Main PCB (PCB1) Calibration Procedure
6.4 Disassembly/Reassemble Pro cedures
7.0 Maintenance 7-1
7.1 External Cleaning
7.2 Heat Tubes (Rollers) and Pull Rollers
7.3 Internal Cleaning
7.4 Inspection
7.5 Lubrication
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TABLE OF CONTENTS
PAGE
8.0 Parts List
8.1 Ultima 65 Parts List 8-1
8.1.1 Cover Assembly and Film Roll Support Shafts
8.1.2 Case and Tray Assembly
8.1.3 Left Side Assembly
8.1.4 Right Side Assembly
8.1.5 Frame Assembly
8.1.6 Roller Assembly
8.1.7 Control Panel Assembly
8.1.8 Safety Lever Assembly
8.1.9 Cutter Assembly
9.0 Recommended Spare Parts List 9-1
9.1 Recommended Spare Parts List
9.2 Explanation of Multiplier
10.0 Additional Information 10-1
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1.0 INTRODUCTION
Congratulations on your purchase of General Binding Corporation’s latest series of laminators. The Ultima 65 series laminator will provide you with high quality lamination and versatility, at an affordable price.
The Ultima 65 will give customers a simple to use laminator that has the ability to laminate GBC’s latest film product, the Ultima 1 mil film. Ultima film provides superior adhesion and higher gloss for better clarity. Ultima film seals at a lower operating temperature, temperature range 200°-275°F (93°-135°C) Ultima 1 mil film is 27” in width, not 25”. This feature allows a larger border for customers laminating posters that are 24” in width.
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2.0 SPECIFICATIONS
115 VAC MODEL 230 VAC MODEL
Required 120 VAC +/-10% – Two Wire 230 VAC +/-5% Two Wire Power Service Plus Ground Service Plus Ground Supply: 15 Amps, 60 Hz 7.8 Amps, 50 Hz
Single Phase Single Phase
Electrical 120 VAC, 15 Amps 230 VAC, 7.8 Amps Operating 1800 Watts, 60 Hz 1800 Watts, 50 Hz Power: Single Phase Single Phase
Dimensions: 32.5 in. (83cm) Wide
21.0 in. (53cm) Long
12.0 in. (31cm) High
Weight: 85 lb. (39kg)
Speed: Variable from1.5 Feet (45.6cm) to10 Feet (3m) per minute.
Warm Up Time: Approximately 10 Minutes
Laminating 200° F (93.4° C) To 290° F (143.4° C) Temperature Range:
Laminating Width 27” (68 cm) Film 1 Mil, 1.5Mil, and 3Mil Capacity: 1” Poly-In Film, 1” Core Diameter
Allowable Maximum thickness is 1/16” (1.59mm) Product Thickness:
Applications: Teaching Aides
Posters Literature Lightweight materials
Standards: UL, CE, CSA listed
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3.0 INSTALLATION
1. Closely inspect the unit prior to opening. All shipping damage should be brought to the
immediate attention of the delivering carrier.
2. Place the laminator on a stable flat surface capable of supporting at least 95 lbs. The surface should be at least 30 inches high to assure comfortable positioning during operation. All four rubber support feet should be positioned completely on the supporting surface. The supporting surface may also be large enough to hold the material to be laminated.
3. The laminator should be positioned to allow exiting film to drop freely to the floor. Accumulation of laminate immediately behind the laminator as it exits the equipment may cause the film to wrap around the pull rollers (wrap-up condition).
4. Avoid locating the laminator near sources of heat or cold. Avoid locating the laminator in the direct path of forced heated or cooled air.
5. Connect the attachment plug provided with the laminator to a suitably grounded outlet only.
Avoid connecting other equipment to the same branch circuit to which the laminator is connected as this may result in nuisance tripping of circuit breakers or fuses.
Please read the operating instructions thoroughly before operating your laminator.
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GBC Ultima 65 Laminator
Helpful operating hints for safe, quality lamination
LOCATION OF THE LAMINATOR
Position your laminator away from drafts that can affect roller temperature.
FILM LOADING TIPS
It is recommended that LOADING and UNLOADING be performed when the laminator is COLD. After removing the old rolls, check the rollers for adhesive residue. Gently rubbing with Scotch Brite pad, then wiping with a damp cloth can easily remove it. Always change the top and bottom film rolls at the same time. Be sure to use the CORE ADAPTERS from the PREVIOUS ROLL.
Laminating film MUST UNWIND FROM THE BOTTOM OF THE ROLL (dull side up) shiny side must be against the rollers. Use the FILM ALIGNMENT GUIDES on the film shafts to be certain that the top and bottom rolls are aligned properly. When loading, unwind top and bottom film rolls enough to allow film slack for threading. REMEMBER TO: 1) reposition the idler bar in the “J” channel, 2) lower the safety shield, and 3) position the feed tray so the safety latch is engaged.
START SLOW
Turn the power switch ON. Machine will default to the 1 MIL/SPEED 5. If using 1.5 or 3 MIL film, you must press the 1.5/3 MIL button. SELECT lamination SPEED. Default setting is speed 5. Use the SPEED GUIDELINES as a reference or starting point. LOWER SPEED for thicker materials, dark colors and heavy ink coverage. INCREASE SPEED for thinner materials and lighter colors. NOTE: During the initial warm-up period, the roller temperature will rise above the optimum “operating temperature” then fall back. To reduce the effects of excessive heat on your materials when you start, REDUCE THE SPEED TO SETTING 2 FOR THE FIRST FEW FEET OF OPERATION. Once the temperature has stabilized, resume running at the “suggested starting” speeds, indicated on the SPEED GUIDELINES chart which corresponds to the thickness of the material.
READY TO BEGIN
Begin laminating only after READY light is lit. DO NOT RUN the laminator when it is COLD. Damage to the rollers will result. PRESS RUN: While running the laminator, watch the adhesive melt line (the point where the film begins to appear very clear). If the melt line is AT OR ABOVE the point where the film and heat roller meet, the selected SPEED IS OK. If the melt line shifts BELOW the film and heat roller contact point, DECREASE SPEED or stop momentarily until the melt line moves up. DO NOT STOP machine while documents are passing through the heat rollers.
IN THE EVENT OF A WRAP-UP
Cut the top and bottom film webs. Be sure to HOLD DOWN the REVERSE BUTTON while pulling the wrapped film from the pull roll.
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5.0 TROUBLESHOOTING
5.1 Theory of Operation
The laminator uses heat, pressure, tension and speed to continuously apply adhesive coated laminating film to both sides of sheet type materials simultaneously. Both electrical and mechanical properties of this laminator are described in this section. Electrical schematics and wiring diagrams are also provided in this section. A basic understanding of the theory of successful lamination is required for all personnel servicing the Ultima 65.
5.2 Theory of Successful Lamination
To obtain the ultimate in a successful laminate, three factors should be present:
1. The product to be laminated should be receptive to, and capable of attaining, a good bond with molten polyethylene adhesive.
Most paper products can be laminated with a high degree of integrity. This is because molten polyethylene cements to individual fibers of the paper surface. The rougher the surface texture, the more fibers are exposed to adhesive and the better the bond between adhesive and product. Many substances are applied to paper products, which impair bond between fibers and the molten adhesive. Ink and other printing products affect this bond. While good adhesion occurs between molten adhesive and ink, poor adhesion may exist between ink and its parent paper. Some ink products are heat sensitive and/or lack the ability to be bonded by certain lamination processes. This may require the use of pressure sensitive adhesive (PSA), NAP-LAM II, Vinyl, Premium or HI-TAC type film products.
Some paper and card stocks are coated with silicones, wax or varnish, which inhibit the ability of molten polyethylene to stick tightly to individual paper fibers. In such cases, a superficial bond develops which may be adequate, depending upon intended use of the finished laminate.
Smooth surfaces, especially photographic, metallic, and plastic, are difficult for polyethylene to bond to, since no fibers are exposed for the adhesive to contact. This may require the use of other film products to laminate correctly.
Products containing moisture will not laminate well since the fluid converts to steam, forms bubbles, and impairs lamination.
2. At the moment of lamination, the product - polyethylene interface - both top and bottom, must reach the lamination film’s proper operating temperature. Superficial bonds develop at lower temperatures, and the finished laminate may be adequate for its intended use. However, for proper lamination please consult the lamination guide in section 10.Thickness/color of a product bears heavily on the ultimate integrity of the bond, since the thicker/darker a product; the more heat is extracted from the heat rolls. Thicker/darker products may extract heat faster than the machine can put in, and after 20 feet or so, the interfacial temperature may drop below the critical point. Generally speaking, most card stocks whose thickness is on the order of
0.012” thick can be laminated on a continuous basis.
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5.0 TROUBLESHOOTING
5.2 Theory of Successful Lamination (continued)
3. Total encapsulation of product, with a complete film-to-film border, is often recommended to
prevent an otherwise successful laminate from splitting within itself.
Total encapsulation of product, of course, prevents splitting from casual abuse of a corner or edge of the laminate, and obviously, moisture vapor or liquid cannot enter to weaken the laminated product.
Flush cutting of laminated product, or even slightly into the product, yields a neat, trim appearance but renders the product sensitive to splitting at the edges and particularly at corners. The split occurs within the product and not at the adhesive product interface. Flush cutting also leaves a paper edge exposed to the atmosphere and any moisture vapor it contains. However, this may be of little consequence unless the laminate is exposed to an actual liquid, where upon the fibers within the product loosen from one another and splitting occurs.
5.3 Electrical system
5.3.1 Heater Control Circuit
The heater circuit is responsible for the temperature and power regulation of the infrared heater assemblies, working in conjunction with the Main PCB, Control Panel PCB, triac, thermocouple (temperature sensor assembly) and the thermal cutoff (TCO). The Heater Control Circuit is comprised of the following electrical components:
1. Infrared heater assemblies (IR1 & IR2): Resistor type heaters that generate heat when activated. Resistance for the Ultima 65 = 16 ohms (All values +/- 1 ohm).
2. Main PCB (PCB1): Main control board responsible for the control of all electrical components in the machine. SV1 on the PCB, sets the ambient temperature of the machine. SV2 on the PCB, sets the high temperature setting and the ready light on the Control Panel PCB. These 2 potentiometers work in conjunction with the other, when you adjust one the other will also be affected.
3. Control Panel PCB (PCB2): Features all the controls and LED indicators for interface with the operator and the laminator.
4. Triac (TR1): Voltage applied to the triac is routed through the Main PCB (PCB1) to the Infrared Heaters (IR1 & IR2). This triac can be tested by removing the red and yellow leads from the Main PCB and taking a resistance reading of open. If you get an indication of a short, then the triac has failed closed.
5. Thermocouple (TSA1): The temperature sensor provides a heat reference for the Main PCB (PCB1). This sensor should read a short when cold. Ultima 65 has 1 wrap capton tape. These sensors should be soldered and have no air pockets.
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5.0 TROUBLESHOOTING
5.3.1 Heater Control Circuit (Continued)
6. Thermal cutoff (TCO1): Provides overheat protection of the heater circuit. Earlier
versions have a resettable type TCO and the current production models have a non­resettable type TCO. These TCO’s should always read a short and will trip when the TCO reaches a temperature of 248°F (120°C).
WARNING! NEVER OPERATE THE LAMINATOR WITH THE TCO REMOVED FROM THE HEATER CIRCUIT! DAMAGE TO THE LAMINATOR AND A FIRE HAZARD MAY
RESULT!
5.3.2 Motor Control Circuit
Power is supplied to the Motor Control Circuit when the RUN button on the Control Panel PCB (PCB2) is depressed. This circuit is comprised of the Control Panel PCB, Main Control PCB, 3 amp SLO-BLO fuse and the motor.
1. Control Panel PCB (PCB2): Features all the controls and LED indicators for interface
with the operator and the laminator.
2. Main PCB (PCB1): Main control board responsible for the control of all electrical
components in the machine. Should supply output DC voltage to the motor of 7 - 30 VDC: depending on speed, the faster the speed, the more voltage present.
3. 3 amp SLO-BLO fuse (F1): Overload protection of the motor.
4. Motor (M1): 35 VDC. Motor windings 4.5 - 8 ohms.
5.4 Mechanical Operation
The chain driven lower rollers are powered by the drive motor and the Control Panel PCB (PCB2) speed selector. During operation the upper heat roller and upper pull roller are clamped tightly against the respective lower roller by adjustable spring pressure. Both upper heat and pull rollers are driven under pressure by the lower rollers respectfully. The laminating film is compressed by both sets of rollers, however, the primary pressure is applied by the pull rollers and the heat rollers provide only nip pressure. Bronze bushings support the rear rollers and provide smooth even roll during operation. Roller bearings support the front rollers. The two film webs are stretched tight as they leave the supply rolls and enter the nip of the heat rollers. Two adjustable brake assemblies located on the left side frame provide tension. The upper and lower brake assemblies restrict or “drag” the respective supply roll shafts as the shafts revolve.
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5.0 TROUBLESHOOTING
5.5 General Troubleshooting
Malfunction corrections are based on visual observations by the operator and the technician. The cause of malfunctions are isolated by the symptom of the malfunction and noting at which point in the operating cycle the malfunction occurred. Malfunctions that occur during operation can be pinpointed to a defective electrical circuit or to a mechanical part by referring to the “Theory of Operation” in the preceding paragraphs and to the electrical schematic diagrams and electrical wiring diagrams.
WARNING! POSSIBILITY OF ELECTRICAL SHOCK WHEN TESTING ELECTRONIC COMPONENTS. SERVICE SHOULD BE PERFORMED BY QUALIFIED GBC SERVICE
TECHNICIANS ONLY. PLEASE CALL GBC FOR SERVICE 1-800-790-7787.
5.6 Testing Electrical Components
All electrical components can be tested by using a variety of test equipment to check for continuity, resistance, voltage and amperage.
5.7 Troubleshooting Guide Chart
The Troubleshooting Guide Chart that follows is arranged in order of the normal operational sequence. When a malfunction occurs, read down the SYMPTOM column until you reach the description for your symptom. Read the corresponding PROBABLE MALFUNCTION, and then perform the recommended procedure in the CORRECTIVE ACTION column. Refer to the wiring diagrams to resolve any wiring difficulties that may occur.
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5.0 TROUBLESHOOTING
5.7 TROUBLESHOOTING GUIDE CHART
SYMPTOM PROBABLE MALFUNCTION CORRECTIVE ACTION
No power. No outlet power. Check outlet for correct voltage.
Power cord disconnected. Connect power cord. Blown fuse. Check continuity, replace if needed. Tripped circuit breaker. Reset circuit breaker. Tripped TCO. Reset or replace TCO. Power switch. Replace switch. Bad connections. Inspect for loose connections. Bad Main PCB (PCB1). Replace board.
Power, no heat. Bad connections. Inspect for loose connections.
Infrared heaters bad. Check for 16 Ohms, if not replace
heaters. Triac failed. Test triac, replace if needed. Heat sensor failed. Test continuity, replace if needed. Bad Main PCB (PCB1). Replace board.
Not hot enough, or Main PCB (PCB1) not Calibrate Main PCB (PCB1) using too hot. calibrated. current calibration procedures.
Triac failed. Test triac, replace if needed. Heat sensor failed. Test continuity, replace if needed.
Power, heat, will Bad connections. Inspect for loose connections. not run. Blown motor fuse. Check continuity, replace if needed.
Interlock switches not engaged. Ensure tray and shield switches are
engaged. Bad motor. Check continuity, replace if needed. Bad Transformer. Check for 3-32 VDC, replace if
needed. Bad Main PCB (PCB1). Test output, replace if needed.
Runs one speed Bad Main PCB (PCB1). Replace Main (PCB1). or reverse only. Bad Control Panel PCB (PCB2). Replace Control Panel (PCB2).
Unit does not Main PCB (PCB1) not calibrated. Calibrate Main PCB (PCB1) using go to ready. current calibration procedures.
Bad Control Panel PCB (PCB2). Replace Control Panel (PCB2). Heat sensor failed. Test continuity, replace if needed.
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5.0 TROUBLESHOOTING
5.7 TROUBLESHOOTING GUIDE CHART (Continued)
SYMPTOM PROBABLE MALFUNCTION CORRECTIVE ACTION
Poor lamination Laminator settings incorrect Follow lamination guide in section 10 quality. for product being laminated. and the “Theory of Successful
Lamination” in section 5.2.
Incorrect tension. Follow Film Tension Adjustment
in section 4.0 pg 4-5 Operating Instructions.
Incorrect roller pressure. Adjust roller pressure.
Consistent wrap-ups, Dirty rollers. Follow “Caring For Your Laminator” adhesive marks in section 4.0 Operating Instructions. on product.
SERVICE SHOULD BE PERFORMED BY QUALIFIED GBC SERVICE TECHNICIANS ONLY.
PLEASE CALL GBC FOR SERVICE 1-800-790-7787.
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ULTIMA 65 ELECTRICAL WIRE SCHEMATIC (120VAC)
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6.0 ADJUSTMENTS
6.1 Film Roll Adjustment
Proper film tension, known as brake tension, is the minimum amount required to eliminate wrinkles
in the finished item. The film tension is set at the factory. Tension adjustments are not necessary if you are using 1.5 or 3-mil GBC film, unless the lamination is curling up or down. Generally, 5 and 10-mil film requires more tension; and, as the film roll becomes smaller, tension increases, requiring more adjustments. Film tension should be checked occasionally to assure the adjustment is correct.
The film should be taut. A properly adjusted roll of film should not require excessive force to turn by hand. Film tension should be enough to introduce a minor amount of drag as the film unrolls. Insufficient tension causes wrinkles, while too much tension causes stretching (necking). Uneven tension between the top and bottom rolls creates curl. Too much upper tension creates upward
curl (smile). Too much lower tension causes downward curl (frown).
6.1.1 Ultima 65 Brake Adjustment Procedure
1. To adjust the bottom brake, push and hold the brake lever located on the left side frame by the roll film. Rotate the roll of film until the lever engages the internal mechanism. Once engaged, rotate the film forward to increase the tension and backwards to decrease the tension.
2. Release the brake lever and check the tension by rotating the roll of film. Resistance should be slight, not forced.
3. To adjust the top brake, repeat steps 1 and 2.
4. Laminate some test samples to check for proper tension. Readjust if necessary.
6.2 Roller Pressure Adjustment
The tension on the roller pressure springs determine the pressure between the two top rollers and the
associated bottom rollers. Ordinarily, the springs require no adjustment. However, if the springs have been removed or if the tension has been changed, readjustment will be required. Replacement should be considered for those springs that can no longer be adjusted or have little effect. The pressure applied should be enough to enable the rollers to pull the film and product being laminated through, however it should not be so great that it causes marks on the film or product.
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6.0 ADJUSTMENTS
6.2.1 Ultima 65 Roller Pressure Adjustment (Continued)
1. Turn machine off.
2. Remove right and left side covers.
3. Adjust the rear Pull Rollers. The eyebolt on the right and left side should be tightened until only 4-5 threads are showing above the adjusting nut.
4. Adjust the front Heat Tube (Rollers). The Pressure Hex Screw on the right and left side should be flush with the top of the roller bracket.
5. Run a test product and readjust if necessary.
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6.0 ADJUSTMENTS
6.3 Main PCB (PCB1) Calibration Procedure
The Main PCB must be calibrated when replaced. To calibrate the PCB use the calibration fixture GBC P/N 706111164, and follow the calibration procedure outlined below. Calibration must be performed with the new board installed in the machine.
1. The following tools are required to calibrate the Ultima 65. A. Calibration Fixture (GBC P/N# 706111164)
B. Amp Meter (Amp Probe) (GBC P/N# 1999105) C. Volt Ohm Meter with spring clips D. Precision Screwdriver E. Infrared Temperature Sensor (GBC P/N# 1722303)
2. Calibration must be performed when laminator is cold.
3. Unplug machine from 120V 60Hz outlet.
4. Remove left side cover (facing the front of unit).
5. Disconnect thermal sensor from Main PCB at the (- S/N +) and connect calibration fixture in its place.
6. Set VOM to measure DC voltage.
7. Test points are on the two -pin connector (1+ / 1-) located at the top center area of the PCB, identified as (GND). Locate test points on Main PCB and connect spring clips on leads from VOM to test points.
8. Attach the Amp Probe to the infrared heater wires.
9. Plug the laminator into a suitable 120V 60Hz outlet.
10. Turn power switch to the (On) position.
11. Set control panel on (1.5 / 3 mil setting) with film on the unit and threaded.
12. Select SV1 on the Calibration Fixture. Adjust SV1 potentiometer on the Main PCB until you read 1.15 VDC on the Multimeter.
13. Select SV2 on the Calibration Fixture. Adjust SV2 potentiometer on the Main PCB until you read 3.45 VDC on the Multimeter.
NOTE: To properly calibrate the Main PCB, confirm the settings are correct by switching between SV1 and SV2 on the calibration fixture and looking at the measured DC voltage on the VOM. This procedure must be done quickly, because the Laminator is heating up and your DC values will change.
14. Switch the Laminator to the (Off) position. Disconnect meter spring clips, and the Calibration Fixture.
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6.0 ADJUSTMENTS
6.4 Main PCB (PCB1) Calibration Procedure
15. Reconnect the thermal sensor to the Main PCB.
16. Turn Laminator on.
17. Place the beaded thermocouple in the center of the nip rollers (or infrared temperature sensor
pointed right at the nip). Adjust SV2 until the ready light illuminates and the nip temperature is 290°F. Do not let the temperature exceed 310°F (this could cause the rollers to blister).
18. When the unit is heating, monitor the Amp Probe for meter deflection. The Amp Probe should
deflect to indicate that Laminator is heating, and zero out once the unit has gone to ready.
19. The temperature can be fine tuned while the Laminator is hot by adjusting SV2. Turn SV2
clockwise to decrease heat, and counter clockwise to increase heat. Adjust SV2 in small increments, and then wait at least 5 minutes for the heat to stabilize. Check temperature with infrared temperature sensor or beaded thermocouple.
20. Your Main PCB is now calibrated. Remove Amp Probe, and replace left side cover.
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ALTERNATIVE ULTIMA 65 CALIBRATION
Adjust SV1 to 60 ohms at the points shown below. Do this with the machine cold and the P.C. Board removed from machine.
Figure 1
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ALTERNATIVE ULTIMA 65 CALIBRATION
CONTINUED
Some P.C. Boards have the trim pot mounted tuner side up. Any reference to clockwise (cw) or counterclockwise (ccw), applies to tuner side up. On a P.C. Board with trim pots mounted tuner side down, the directions of rotation are reverse. See Figure 2.
FIGURE 2
Set SV2 fully clockwise. You will hear a faint clicking when you pass fully clockwise. Right at the click, turn back one full turn rotation counterclockwise. Install P.C. Board into machine and run it on with an amprobe on the heater circuit wire and a beaded thermocouple in the nip of the heat rollers (or infrared temperature sensor pointed right on the nip). Heat the laminator until the amprobe registers no pulse deflection. Temperature will probably be 225° F to 245° F.
Turn SV2 8 TO 10 full rotations counterclockwise and let temperature increase until it has held and stopped climbing for at least 5 minutes. The amprobe will probably register pulse deflection, showing the circuit is maintaining temperature. Read the nip temperature, at this point, each full rotation counterclockwise will increase the nip by 5° F to 10° F. Or if needed, rotation clockwise will decrease the nip temperature. Do this to reach desired nip temperature.
GBC Lamination Specialist Mike Taylor sent in this Alternative Calibration Procedure.
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6.0 ADJUSTMENTS
6.4 Disassembly/Assembly Procedure
The disassembly of the Ultima 65 is described in the following steps. Use section 8.0 as a reference to help you understand the text. Reassemble in reverse order. Note: Disconnect the unit from the
120VAC receptacle before performing any disassembly procedures.
6.4.1 IR Heater and Heater Tube (Roller) Disassembly
1. Remove Feed Table.
2. Remove (4) Phillips Screws from Right Side Plate and remove Right Cover. Remove (4) Phillips Screws from Left Side Plate and remove Left Cover.
3. Remove up per and lower right side Heater Wire Phillips Screws that are attached to the white ceramic ends of the Infrared Heaters.
4. Remove upper and lower left side Heater Wire Phillips Screws that are attached to the white ceramic ends of the Infrared Heaters. The Infrared Heaters are inside of the Heater Tube (Roller).
5. Disconnect the (2) Thermal Cutout (TCO) Wires attached to the TCO by Female Connectors. (Left side of machine).
6. Remove the (2) Phillips Screws for the top and (2) Phillips Screws from the bottom green silicone Heater Holders (right side only).
7. Remove upper and lower glass Infrared Heaters from the right side of the removed green silicone Heater Holders by sliding them out of the Heat Tubes (Rollers). Note:
Use a towel to prevent burns, and to prevent oil from getting on the Infrared Heaters from your hands. Oil on the Heaters can shorten their life expectancy.
Set aside the Infrared Heaters in a safe area to prevent breakage.
8. Remove right Heat Tube (Roller) Pressure Hex Screw and Spring. Note: When
reassembling, refer to 6.2 for Heat Tube (Roller) Pressure Adjustment.
9. Remove left Heat Tube (Roller) Pressure Hex Screw and Spring. Note: When reassembling, refer to 6.2 for Heat Tube (Roller) Pressure Adjustment.
10. Remove Control Pane l P.C. Board, by loosening (2) Phillips Screws securing it to the Right Side Frame.
11. Remove (2) Phillips Screws securing upper outer right side Heater Holder Bracket and remove. Remove Snap Ring from upper right Heat Tube (Roller) shaft. Remove inner right side Heater Holder Bracket.
12. Remove (2) Phillips Screws securing lower right side Heater Holder Bracket and remove.
13. Loosen the (2) Set Screws on the Chain Sprocket attached to the lower Heat Tube (Roller) and remove from the Roller shaft.
14. Remove (2) Phillips Screws securing the Thermal cut out (TCO) and upper outer left side Heater Holder Bracket and remove. Remove Snap Ring from upper left Heat Tube (Roller) shaft. Remove inner Heater Holder Bracket.
15. Remove (2) Phillips Screws securing lower left side Heater Holder Bracket and remove. Remove (4) Phillips Screws securing the right side Heat Tube (Roller) bearing housing and remove.
16. Slide Heat Tube (Rollers) out of the open side
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6.0 ADJUSTMENTS
6.4.2 Pull Roller Disassembly
1. Remove Feed Table.
2. Remove (4) Phillips Screws from Right Side Plate and remove Right Cover. Remove (4) Phillips Screws from Left Side Plate and remove Left Cover.
3. Remove (3) Phillips Screws from Right Side Plate securing Upper Rear Cover. Remove (3) Phillips Screws from Left Side Plate securing Upper Rear Cover and remove Upper Rear Cover.
4. Remove Socket Cap Screw and Metal Sleeve from the end of Upper Right Pull Roller. Remove Socket Cap Screw and Metal Sleeve from the Lower Left Pull Roller.
5. Remove Right Hex Nut from Pull Roll Tension Bolt. Lift up Tension Lever to release Pull Roll Tension Bolt. Remove Left Hex Nut from Tension Bolt. Lift up Tension Lever to release Pull Roll Tension Bolt.
6. Remove (3) Phillips Screws from the right Idler Gear Support and remove Support and Idler Gear.
7. Loosen (2) Set Screws on the Upper Right Chain Sprocket attached to the Pull Roller shaft.
8. Loosen (2) Set Screws on the Motor Chain Sprocket attached to the Motor shaft.
9. Remove Upper Right Chain Sprocket and Motor Chain Sprocket.
10. Remove Pull Rollers by tilting one side up and pulling straight out.
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7.0 Maintenance
7.1 External Cleaning
7.1.1 External Surfaces
DISCONNECT POWER PRIOR TO CLEANING EXTERNAL SERVICES.
Clean external surfaces of the laminator with a soft cloth moistened with a mild solution of detergent (such as dish washing liquid) and warm water. Do not use chemical cleaners or solvents, as these have a harmful effect on painted surfaces. Removal of the films is recommended prior to extensive cleaning. Use detergent solution sparingly to avoid contact with internal electrical parts.
7.1.2 Heat and Pull Rollers
Clean both sets of rollers periodically to remove the adhesive extruded from the edges of the film. The adhesive may be removed most easily when the heat rollers are warm. Clean the adhesive from the rollers periodically and after each wrap-up, to insure clear laminations. Use a somewhat abrasive pad such as a 3M Brand No. 96 green commercial scouring pad (greenie). Cleaning kits are available (see sections 8.1.10 and 8.2.12 for part numbers).
DO NOT CLEAN THESE ROLLERS WITH ANY LIQUIDS OR HARSH ABRASIVES.
7.2 Internal Cleaning
No periodic internal cleaning is required. However, when the side covers have been removed for corrective maintenance, wipe away any dust that may have collected on lubricated parts with a soft cloth, leaving as much lubricant as possible. Do not use any solvent or other cleaning agent since these would tend to dilute or wash away the lubricant from parts where it is needed. Use a small brush to remove dust from non-lubricated parts such as wiring, switches, motor and structural parts.
7.3 Inspection
Whenever the side plates have been removed for corrective maintenance, inspect for defects such as loose screws or nuts, abraded wire insulation, loose terminals, and binding of mechanical parts. Correct any defects before returning the laminator to service.
7.4 Lubrication
No periodic lubrication is required. However, when parts have to be replaced, lubrication may be required at reassembly.
7-1
8.0 PARTS LISTS
All parts in each illustration are keyed with an index number for reference to the respective part number, part name, and quantity in the parts list.
When ordering service parts, always include the following information:
1. Machine Model Number
2. Machine Serial Number
3. Part Number
4. Part Name
5. Quantity Required
Note: The Service Parts Department does not stock all hardware; to avoid de lay, standard hardware shown in the parts list should be purchased locally whenever possible.
8-0
WWW.MYBINDING.COM
8.1.1 COVER ASSY. AND FILM ROLL SUPPORT
8-1
WWW.MYBINDING.COM
8.1.1 COVER ASSY. AND FILM ROLL SUPPORT
ITEM GBC #
GMP #
DESCRIPTION QTY
1 1712109
701090705
RETAINING RING 2
2 1711620
601230453
ROLLER COVER 1
3 1711621
603030611
TAKING BAR FOR ROLL COVER 1
4 1711629
613030306
BUSHING 2
5 1711622
601220131
FILM GUIDE SCREEN/UPPER 1
6 1711627
613030211
HEX FILM SHAFT 2
7 1720571
613030527
THUMB SCREW 4
8 1711570
604037021
1” CORE ADAPTER 4
9 1711623
603030612
CENTER PIN FOR ROLL COVER 1
10 1711624
1929222
ROLL PIN 1
(USE GMP PART NUMBERS WHEN ORDERING PARTS)
8-2
8.1.2 CASE AND TRAY ASSEMBLY
8-3
8.1.2 CASE AND TRAY ASSEMBLY
ITEM GBC# GMP# DESCRIPTION QTY
1 1711658
604022002
RIGHT SIDE COVER 1
2 1720584
604022032
FIXING KNOB FOR PAPER GUIDE 1
3 1720583
604022031
PAPER GUIDE 1
4 1711657
604022001
LEFT SIDE COVER 1
5 1711634
604036021
FRONT TABLE 1
6 1711633
613030614
LEVER CAP FOR FRONT TABLE 1
7 1712263
701108133
SCREW FOR PAPER GUIDE 1
8 1711568
613030541
FRONT TABLE SUPPORTS 2
9 N/A
803040370
SPEED GUIDELINES LABEL (Not Shown) 1
10 1712122
701104504
COVER SCREWS (Not Shown) 8
(USE GMP PART NUMBERS WHEN ORDER PARTS)
8-4
8.1.3 LEFT SIDE ASSEMBLY
8-5
WWW.MYBINDING.COM
8.1.3 LEFT SIDE ASSEMBLY
ITEM GBC# GMP# DESCRIPTION QTY
1 1711592
601310505
FILM TENSION LEVER 2
2 1712140
703070101
BRAKE PAD 4
3 1711577
703070111
TENSION PLATE FRICTION DISC 2
4 1720546
601230702
FIBER TENSION PLATE 2
5 1711637
603030537
ADJUSTMENT BOLT FOR FILM TENSION 2
6 1711635
601230713
BRAKE HUB 2
7 1711593
704090414
MICRO SWITCH (FILM ADJUSTMENT) 2
8 1711643
601310512
TENSION ADJUSTMENT PLATE 2
9 1711644
701091102
SPRING PIN 2
10 1711580
704030316
POWER CORD (USA) 1
10 1711585
704030703
POWER CORD (JAPAN) 1
10 1711581
704030416
POWER CORD (UK) 1
10 1711583
704031310
POWER CORD (AUST) 1
11 1711584
704140403
STRAIN RELIEF 1
12 1712650
704090102
POWER SWITCH 1
13 1711586
601310506
POWER PANEL 1
14 1711650
706011116
MAIN PCB (115V) 1
14 1711653
706011112
MAIN PCB (230V) 1
15 1711589
601310507
BRACKET (CIRCUIT BREAKER) 1
16 1711588
704091031
CIRCUIT BREAKER, 15 AMP 1
17 1711594
601310508
MICRO SWITCH BRACKET 1
18 1711595
704090415
MICRO SWITCH, FEED TABLE 1
19 1711608
701110312
BRAKE SPRING WASHER 2
20 N/A
701090706
RETAINING RING 2
21 N/A
701090832
ROLL PIN 2
(USE GMP PART NUMBERS WHEN ORDERING PARTS)
8-6
8.1.4 RIGHT SIDE ASSEMBLY
8-7
WWW.MYBINDING.COM
8.1.4 RIGHT SIDE ASSEMBLY
ITEM
GBC#
GMP# DESCRIPTION
QTY
1 1720524
609020200
DC MOTOR 1
2 1711571
701080266
STEEL SPROCKET, 12T * F12 1
3 1711572
701080265
STEEL SPROCKET, 12T * F10 1
4 1711573
613030540
CENTER PIN FO R IDLER GEAR 1
5 1711574
701070150
CHAIN 1
6 1711575
601310504
IDLE GEAR SUPPORT 1
7 1720608
701090158
COIL SPRING (TENSION PLATE) 2
8 1712549
601230802
TENSION PLATE FOR MANDREL 2
1970104
1970104
(NOT SHOWN) 3A SLO-BLO MINI FUSE (PCB) 1
1970120
1970120
(NOT SHOWN) 3A SLO-BLO REGULAR FUSE (IN-LINE)
1
(USE GMP PART NUMBERS WHEN ORDERING PARTS)
8-8
WWW.MYBINDING.COM
8.1.5 FRAME ASSEMBLY
8-9
WWW.MYBINDING.COM
8.1.5 FRAME ASSEMBLY
ITEM GBC# GMP# DESCRIPTION QTY
1 1711554
07050703
TRIAC 1
2 1711555
603030151
SUPPORT BAR 1
3 1712594
610010206
TRANSFORMER, (OUTPUT 3-32 VDC)
1
3 1712595
610010207
TRANSFORMER (EUROPE) 1
3 1711558
610010209
TRANSFORMER (UK) 1
4 1711561
601230451
UPPER REAR COVER 1
5 1711562
601230452
LOWER REAR COVER 1
6 1711560
601230216
RIGHT SIDE PLATE 1
7 1711652
706040202
HEAT SENSOR (THERMO -COUPLE) 1
8 1711563
601230111
FRONT BASE PLATE 1
9 1711564
601220132
LOWER FILM GUIDE SCREEN 1
10 1711565
703010111
RUBBER FOOT 4
11 1711559
601230215
LEFT SIDE PLATE 1
(USE GMP PART NUMBERS WHEN ORDERING PARTS)
8-10
WWW.MYBINDING.COM
8.1.6 ROLLER ASSEMBLY
8-11
WWW.MYBINDING.COM
8.1.6 ROLLER ASSEMBLY
ITEM#
GBC # GMP # DESCRIPTION QTY
1 1711617
701080233
SPROCKET 1
2 1711616
601310510
RIGHT TENSION LEVER FOR PULL ROLLERS
1
3 1712049
601230804
HOUSING FOR DRY BEARING 1
4 1711614
603030161
UPPER IDLER ROLLER 1
5 1711596
607040561
PULL ROLLER 2
6 1711597
701050240
BEARING FLANGE 4
7 1711598
613040131
PULL ROLLER BUSHING 4
8 1711613
703010332
HEATER HOLDER 4
9 1711649
601310501
HEATER HOLDER BRACKET 2
10 1711649
601310501
HEATER HOLDER BRACKET 1
11 1711607
701050161
BEARING 2
12 1711599
603030538
PULL ROLL TENSION BOLT 2
13 1711600
601310509
TENSION LEVER FOR PULL ROLLS 2
14 1711610
601310503
RIGHT INFRARED HEATER SUPPORT 2
15 1712606
701080271
SPROCKET 1
16 1712575
603030542
IDLER ROLLER CENTERED PIN 2
17 1711601
701090157
PULL ROLLER TENSION SPRING 2
18 1711602
603030539
PULL ROLL CENTER PIN 2
19 & 20 1711647
607040556
UPPER & LOWER HEAT TUBE 1EA.
21 1711618
701090115
COMPRESSION COIL SPRING 2
22 1712095
701050234
BEARING FLANGE 1
23 1711603
701090718
GRIP RING 2
24 1711609
603030162
LOWER IDLE ROLLER 1
25 1711555
603030151
SUPPORT BAR 1
26 1711648
706025028
INFRARED HEATER 2
1722775
1722775
INFRARED HEATER SCREW (NOT SHOWN) 4
27 1711604
604037011
HEAT TUBE BEARING HOUSING 2
28 1711605
701020209
NEEDLE ROLLER BEARING 4
29 1720618
701100311
SCREW (SUPPORT BAR) 1
30 1711651
704150107
THERMAL CUT-OFF (T.C.O.) 1
31 1712129
701106603
SET SCREW 2
32 1711569
701107316
ROLLER BOLT, SOCKET HEAD HEX 2
701108106
701108106
INFRARED HEATER BOLT (NOT SHOWN) 4
703050205
703050205
OUTER CERAMIC (NOT SHOWN) 4
703050210
703050210
INNER CERAMIC (NOT SHOWN) 4
704161716
704161716
HEATER JUMPER WIRE (NOT SHOWN) 2
8-12
8.1.7 CONTROL PANEL ASSEMBLY
8-13
WWW.MYBINDING.COM
8.1.7 CONTROL PANEL ASSEMBLY
ITEM# GBC# GMP# DESCRIPTION QTY
1 1711645
802104002
CONTROL PANEL STICKER 1
2 1711646
703020221
PLASTIC SWITCH PANEL 1
3 N/A
703020501
CONTROL KEY, STAND BY, YELLOW
1
4 N/A
703020502
CONTROL KEY, 1 MIL, GREEN 1
5 N/A
703020503
CONTROL KEY, 1.5 & 3 MIL, GREEN 1
6 N/A
703020504
CONTROL KEY, FAST, BLACK 1
7 N/A
703020505
CONTROL KEY, SLOW, BLACK 1
8 N/A
703020506
CONTROL KEY, REVERSE, BLACK 1
9 N/A
703020507
CONTROL KEY, RUN, GREEN 1
10 N/A
703020508
CONTROL KEY, STOP, BLACK 1
11 1711655
704090313
SWITCH MEMBRANE (RUBBER) 1
12 1711656
706011113
CONTROL PANEL PCB ASSY. 1
13 1711641
701104803
SCREW 1
14 1711659
704161717
CONTROL PANEL CABLE (8 PIN) 1
(USE GMP PART NUMBERS WHEN ORDERING PARTS)
8-14
8.1.8 SAFETY LEVER ASSEMBLY
ITEM# GBC# GMP# DESCRIPTION QTY
1 1712074
613030613
LEVER FOR FRONT TABLE 1
2 1711638
601310511
LEVER GUIDE FOR FRONT TABLE 1
3 1711636
701090721
RETAINING RING 1
4 1712612
701090160
COMPRESSION COIL SPRING 1
5 1911303
1911303
MOUNTING SCREWS (NOT SHOWN) 2
(USE GMP PART NUMBERS WHEN ORDERING PARTS)
8-15
8.1.9 CUTTER ASSEMBLY
ITEM# GBC# GMP# DESCRIPTION QTY
1711567
706111049
SLITTER ASSEMBLY (1-6)
1
1 1712134
701110101
NUT 2
2 1720586
604022034
SLITTER LEVER 1
3 1154019
1154019
SLITTER BLADE 1
4 1711641
701104803
SCREW 2
5 1712611
701090159
TENSION COIL SPRING 1
6 1720585
604022033
SLITTER HOUSING 1
(USE GMP PART NUMBERS WHEN ORDERING PARTS)
8-16
9.0 RECOMMENDED SPARE PARTS LIST
Use the suggested multipliers as a guideline to maintain your spare parts inventory. This multiplier is based on a six-month’s supply. Multiply the number of machines that you will be required to service in a given territory (your machine base) by the multiplier listed. Refer to 9.1 Explanation of Multipliers for reference. Periodic review of your machine base is recommended. As your machine base grows, your stocking levels will also grow.
NOTE: This is a list of high usage parts only. Less frequently used and incidental parts should be determined and stocked at your discretion.
GBC#
GMP# DESCRIPTION QTY
1711647 607040556 UPPER & LOWER HEAT TUBE (ROLLERS) 0.2 1711648 706025028 INFRARED HEATERS 0.2 1711652 706040202 HEAT SENSOR (THERMO -COUPLE) 0.2 1711651 704150107 THERMAL CUT-OFF (T.C.O.) 0.2 1711650 706011116 MAIN P.C. BOARD 115 VOLT 0.2 1711656 706011113 CONTROL PANEL P.C. BOARD 0.1 1711655 704090313 CONTROL PANEL MEMBRANE 0.04 1711554 07050703 TRIAC 0.2 1711588 704091031 15 AMP CIRCUIT BREAKER 0.2 1720524 609020200 DC MOTOR 0.04 1711570 604037021 1” CORE ADAPTOR 0.1 1720571 613030527 THUMB SCREW FOR CORE ADAPTER 0.1 1712140 703070101 BRAKE PAD 0.1 1711567 706111049 CUTTER ASSEMBLY 0.04
9.1 EXPANATION OF MULTIPLIERS
MULTIPLIER
MACHINE POPULATION
1 Keep one of these parts for every one unit in your territory
0.2 Keep one of these parts for every five units in your territory
0.1 Keep one of these units for every ten units in your territory
0.04 Keep one of these units for every twenty five units in your territory
0.02 Keep one of these units for every fifty units in your territory
0.01 Keep one of these units for every one hundred units in your territory
9-1
10.0 ADDITIONAL INFORMATION
This section contains information released after the manual was published. All information pertinent to this unit should be inserted in this section whether it is published in a National Service Bulletin or obtained from any other source.
10-1
GBC National Service Department NATION SERVICE 500 Bond Street BULLETIN
Lincolnshire, IL 60069 (800) 790-7787
TO: SEE DISTRIBUTION N.S.B. NO: 210D FROM: NATIONAL SERVICE DEPARTMENT Page: 1 of 1 SUBJECT: ULTIMA 65 TRIAC TEST AND Date: 09/ 07/98
ROLLER PRESSURE ADJUSTMENT
TRIAC TESTING:
When testing the Triac it must be tested out of the circuit and at room temperature. Use an Ohm meter to take the readings between the leads as follows.
.
RED & YELLOW = OPEN BLUE & YELLOW = OPEN RED & BLUE = CLOSED
ROLLER PRESSURE ADJUSTMENT:
When adjusting the roller pressure on the Ultima - 65, keep in mind that the adjustments must be the same on both sides left to right as follows.
FRONT ROLLERS = the setscrew must be flush with the block. REAR ROLLERS = leave 4-5 threads showing above the blocks (approx. 6 mm)
JMH
10-2
National Service Department NATIONAL SERVICE
6210 Capitol Drive BULLETIN
Wheeling, IL 60090 847/541-4477
TO: SEE DISTRIBUTION N.S.B. NO: 210H FROM: NATIONAL SERVICE DEPARTMENT Page: 1 of 4 SUBJECT: Ultima65 & Eagle Series Laminators Date: 10/15/98
Helpful Hints Bulletin
The following is a copy of the September 1997 issue, vol. 1, EAGLE EYE TECHNICAL INFORMATION bulletin published by the Color Finishing Division. It offers excellent
information and procedures for determining problems associated with GBC’s new Color Finishing Laminators. Please review and ad this NSB to your Ultima65 and Eagle Series Service Manuals.
EAGLE EYE TECHNICAL INFORMATION, September-1997, vol. 1
10-3
IN THE BEGINNING
GBC’s evolution in the laminators has taken the knowledge of lamination to a higher level than ever before. The new GBC Color Finishing Laminators have distinctive characteristics that their older predecessors did not have. With the flexibility to use a wide range of thermal and cold Pressure Sensitive Adhesive (PSA) films, the word lamination takes on new meanings.
Learning the difference between machine malfunction and laminating the different types of printing in today’s market will test your knowledge of lamination and troubleshooting problems. Before assuming the machine to be at fault, ask a few questions to determine “what’s wrong with this picture”.
SEEING THE PROBLEM
* Wrinkling at the edges. * Excessive wrinkling between two separate laminated sheets running parallel to each other. * Air bubbles in the lamination. * Edge of lamination not sealed. * Warping of product after lamination. * Cracking of the printed material after lamination. * “Silvering” on the laminated product. * Creasing in various areas of the laminated product.
The previous mentioned conditions are not necessarily caused by machine malfunction. The following are examples of some conditions that may influence the quality of lamination.
Media being laminated - Some prints are made using synthetic materials. This material usually exhibits waves or wrinkles when laminated with thermal films. Pressure Sensitive Adhesive (PSA) films are best suited for this application. Thickness of product plays an important part in the laminator’s ability to seal at the edge. As the thickness of the material increases, the chance of achieving a sealed edge decreases.
Too little or too much heat or roller pressure - Excessive heat usually causes waves or warping of the finished product. Heat problems may also appear in the form of air bubbles. “Silvering” is a condition usually caused by insufficient heat. It is mostly noticeable in dark colors. Silvering may also be noticed when laminating with PSA films, which take approximately 24 hours to cure. If the heat is at the recommended temperature for both the film and the product and bubbles, waves, or creasing are still present, this could be caused by differences in roller pressure, front to back or left to right.
Differences in film manufacturing - The preset temperatures for the GBC Eagle are set for GBC NAP -II laminating film, using 20 lb. Bond paper. GBC Eagle laminators usually will laminate a variety of different manufacturer’s film. When laminating with films other than NAP-II, adjustments to the preset temperatures and speed may be necessary.
Ink and toner coverage - Wide format and color prints are made in a variety of ways. The common trend is to use alcohol based inks, called GA ink, or oil based inks, called GO ink. The GA inks usually work very well with thermal films. The GO inks are sensitive designed for vinyl substrates. Another ink type is PIEZO, which is wax based and comes in a “stick” form; it may crack if folded or rolled tightly. Pressure Sensitive Adhesive (PSA) films are great candidates for these applications.
10-4
Ink and toner coverage (continued) - Dry toner is commonly used in most copiers and printers in today’s market. Some copiers/printers use water-soluble toner, while others like XEROX use fuser oil to fix the image to the paper. Fuser oil may not allow conventional laminating film to adhere to the paper. In most cases, GBC thermal HI-TAC film solves the problems of excessive fuser oil.
ROLLER PRESSURE BY THE FOOTPRINT
A laminator’s footprint can visually provide a quick assessment of roller pressure. The footprint is the impressi on made by the heat rollers when the film is allowed to sit idle for three minutes or longer. For best results, use 1.5mil film for this procedure. Run approximately 3 feet of clear film through the heated laminator. Wait approximately 3 minutes for the footprint to form. Run another 3 feet of film and examine the impression. The footprint should be even on both sides and slightly thicker at the center. If this is achieved, run newspaper or lightweight paper through the laminator and check for lamination quality.
Paper Pull Setup Test - This test can be performed to correct roller balance problems. The test must be performed after removing or replacing rollers.
1. Remove all laminating film from front and rear rollers.
2. Cut several 1-inch strips of regular 20lb Bond paper.
3. Gap the rollers and insert the strips starting the test with front heat rollers first. Place the strips at an equal distance, left, center, and right.
4. Apply full pressure to the rollers and lock the rollers in place.
5. Holding the strip at the end, centered, try to pull the paper out of the nip point at each area.
6. If the paper can be pulled from any of these points, additional pressure should be added to the right or left side to increase the pressure at the specific location. The center pressure is affected by adjusting the right and left sides of the rollers. A recommended one full turn should be made to the side where the paper slips.
7. Perform the same procedure for the rear rollers.
LAMINATION PERFORMANCE TEST After adjusting the roller pressure to the previously recommended starting point, install 1.5 mil film on the laminator, set the temperature to the proper setting, and allow the heat to rise until ready.
Before making any further adjustments, please check the laminated footprint again for the previously stated dimensions. If further adjustment is needed, perform the adjustment with equal full turns at the adjustment point.
EAGLE ROLLER REPLACEMENT When replacing the rollers, the pressure set up adjustment on the Eagle laminator is crucial to the quality of lamination. This adjustment must be made to the front and rear rollers because the roller brackets support both sets of rollers.
Removing The Rollers
1. Disconnect power to the machine.
2. Release pressure on rollers.
3. Remove feed table, left side - film tension knobs, right side pressure handle, and both right and left
side covers. 10-5
4. Disconnect heat coil wires attached to ceramic end of the heater tube. The heater tube is inside of the heat roller.
5. Disconnect thermal cutout (TCO) wires attached to the TCO by spade terminals.
6. Remove top and bottom green silicone heater holders (one side only).
7. Remove glass heat coil tubes out of opened side and store in a safe area to prevent breakage.
8. Remove roller pressure screws and springs.
9. Remove Phillips head screws securing heat coil holders brackets, right and left.
10. Loosen Allen screws on the motor gear. Slide gear outward and away from idler gear.
11. Remove screws securing the idler gear bracket. Lift away from machine along the drive chain.
12. Loosen Allen screws on chain sprockets attached to the lower heat and pull rollers and remove from the roller shaft.
13. Remove all snap rings securing the rollers, both right and left.
14. Remove remaining bracket supports.
15. Slide rollers out of the open side.
To reassemble, follow the previous steps in reverse.
Roller Adjustment - After replacing heat or pull rollers, run the machine, with full pressure, to settle the
rollers to a home position. The spring pressure on the rollers should be adjusted to a starting point.
To begin:
1. Lower the pressure screws flush with the threaded end of the eccentric bracket.
2. Make 7 full turns on each of the four front heat roller tension screws.
3. Make 2 full turns on each of the four rear pressure roller tension screws.
After making the roller adjustments, apply full pressure to the rollers and run the machine empty allowing components to find a home position. Follow the previously stated “Paper Pull” test and “Footprint” evaluation.
ULTIMA65 NOTES
We have received several instances of the Ultima65 being too hot or too cold. Remember, the reset temperature and speed are set for use with 20lb. Bond paper. The heat temperatures are set for 1 mil “Ultima” NAP-II film and the 1.5 &3 mil setting is for NAP-I film. There is about a 30º F temperature variance between NAP-I and NAP-II films. Make sure the correct film is used for the correct setting.
Another heat related problem that can be often diagnosed as machine malfunction is the use of heavier paper stocks. These materials deplete the preset temperature of the heat rollers or may not bond as expected.
Adjustments to the speed may be necessary to achieve acceptable results. If you do not achieve the desired results, a quick check of the PCB calibration, and adjustment (if needed) may solve the problem.
CARING FOR YOUR LAMINATOR
The new breed of Eagle and Ultima laminators use a softer silicone roller. This type of roller provides for a better-sealed edge. When cleaning these rollers, it is recommended that nonabrasive materials be used. ScotchBrite or eraser type belt cleaners work the best. At the present time we do not have a chemical that is safe for cleaning purposes. Under no circumstances should sandscreeen be used to clean the rollers.
10-6
WWW.MYBINDING.COM
TO: SEE DISTRIBUTION N.S.B. NO: 210K FROM: NATIONAL SERVICE DEPARTMENT Page: 1 of 1 SUBJECT: ULTIMAS & EAGLES INSTALLATION Date: 2/28/00 Installation of Eagles and Ultima machines should include removing the side panels and
checking for any loose screws and/or connections, particularly on the P.C. Boards. This should also be a standard procedure when performing service on any of these models.
10-7
WWW.MYBINDING.COM
TO: SEE DISTRIBUTION N.S.B. NO: 248A FROM: NATIONAL SERVICE DEPARTMENT Page: 1 of 1 SUBJECT: ULTIMA 65 UPGRADE Date: 5/15/00 This N.S.B obsoletes N.S.B 248, dated 5/15/00
Ultima 65’s with heat problems (gray roller machines) will no longer be traded in. The parts the technician will need to order to bring the Ulitma 65 to current specs are listed below. Part
Number 1722626 has been assigned to the upgrade kit. This upgrade kit should only be ordered for gray roller machines when “overheat” symptoms occur. The technician must then close
the call as a 02 warranty using the kit part number.
Part # Description Qty
1711647
Heat Roller 2
1711648
Infrared heater 2
1711650
Main PCB 1
1711656
Control PCB 1
1711655
Control Panel Membrane 1
1711649
Heater Holder Bracket (Top) 2
1711652
Heat Sensor 1
10-8
WWW.MYBINDING.COM
NATIONAL SERVICE
National Service Department BULLETIN
500 Bond St. Lincolnshire, IL. 60069
TO: SEE DISTRIBUTION N.S.B. NO: 243C FROM: NATIONAL SERVICE DEPARTMENT Page: 1 of 1 SUBJECT: GMP LAMINATION CALIBRATION FIXTURES Date: 05/09/01
GBC Service Parts Dept is currently stocking the Calibration Fixture part number 1700407. Once the inventory has been depleted, the Service Parts Dept will be stocking a new Universal Type “A” Calibration Fixture. This Calibration Fixture part number 706111164 can be used on all current GMP Laminators, including the Pouch Laminators. However the Type “A” Calibration
Fixture will not work with the TITAN 165/110. The TITAN 165/110 Calibration Fixture Type “B” can be ordered under part number 706111165, and is only to be used on the TITAN 165/110.
10-9
WWW.MYBINDING.COM
NATIONAL SERVICE
Professional Support Services BULLETIN
500 Bond St. Lincolnshire, IL. 60069
TO: SEE DISTRIBUTION N.S.B. NO: 210P
FROM: NATIONAL SERVICE DEPARTMENT Page: 1 of 1
SUBJECT: ULTIMA-65 INFRARED HEATER ASSEMBLY Date: 02/11/02
This NSB supersedes and obsoletes NSB 210N, dated 4/25/01.
Listed below are the individual components for the Ultima-65 Infrared Heater Assembly.
PART NO. DESCRIPTION
701110504 Glass Tube Cap 701108106 Heater Wire Holding Bolt 703050210 Inside Ceramic Insulator 703010309 Silicone Washer 703050205 Outside Ceramic Insulator
6130422 Hexagon Nut
R.P.
10-10
WWW.MYBINDING.COM
NATIONAL SERVICE
Professional Support Services BULLETIN
500 Bond St. Lincolnshire, IL. 60069
TO: SEE DISTRIBUTION N.S.B. NO: 210Q
FROM: NATIONAL SERVICE DEPARTMENT Page: 1 of 1
SUBJECT: ULTIMA-65 TURNING OFF WHILE RUNNING Date: 6/21/02
When you encounter an Ultima-65 turning off while running, here are some things that you should know:
The Laminator must be plugged into a dedicated grounded outlet. Do not connect other
equipment to the same circuit.
Overloading the motor will cause the Transformer’s TCO to blow. The Transformer does not
have a resettable thermal cut off (TCO), so you will have to replace the Transformer.
There is a resettable fusible link on the Main P.C. Board that replaced the original 3-amp fuse.
When the Main P.C. Board gets overloaded (hot), the machine will turn off. Once it cools down, you can start running the machine again.
There are a number of variables that will cause the machine to turn off while running; here is what to check for:
The 15 Amp Circuit Breaker may have tripped. If you have to reset the Circuit Breaker several
times in a short period of time, the Breaker may have become weak and must be replaced with part number 704091031.
Check Safety Shield and Feed Table Tray Interlock switches and connections.
Make sure product thickness does not exceed the maximum of 1/16” (1.59mm).
Too much Brake Tension on Film Shafts. As recommended, use the minimum amount of tension
to eliminate wrinkles in the finished item.
Check for proper pressure/tension between upper and lower Heat Tubes (Rollers) and upper and
lower Pull Rollers. The pressure applied should be enough to enable the rollers to pull the film and product being laminated through, however, it should not be so great that it causes marks on the film or product.
Motor/Sprocket Chain is too tight. Chain must have some play/slack in it.
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NATIONAL SERVICE
Professional Support Services BULLETIN
500 Bond St. Lincolnshire, IL. 60069
TO: SEE DISTRIBUTION N.S.B. NO: 210R
FROM: NATIONAL SERVICE DEPARTMENT Page: 1 of 1
SUBJECT: ULTIMA 65 & EAGLE 35, 65, AND 105 Date: 07/18/02
HEATER JUMPER WIRES W/CONNECTORES
Part number 704161716 is for the Ultima 65 Heater Jumper Wires with Eyelet Connectors. Part number 704161803 is for the Eagle 3
5, 65, 105 Heater Jumper Wires. These wires connect to the ceramic ends
of the infrared heaters. Please update your Service Manual with this information.
NOTE: Parts are on order and should be in stock within 6 to 8 weeks.
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