General Binding Mercury Operation/parts And Schematic Book

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The information in this publication is provided for reference and is believed to be

accurate and complete. General Binding Corporation is not liable for errors in this publication

or for incidental or consequential damage in connection with the furnishing or use of the

information in this publication, including, but not limited to, any implied warranty of fitness or

merchantability for any particular use.

General Binding Corporation reserves the right to make changes to this publication

and to the products described in it without notice. All specifications and information concerning

products are subject to change without notice.

Reference in this publication to information or products protected by copyright or patent does not convey any license under the rights of General Binding Corporation or others. General Binding Corporation assumes no liability arising from infringements of patents or any

other rights of third parties.

reserved. The information contained in this publication is proprietary and may not be

reproduced, stored, transmitted, or transferred, in whole or in part, in any form without the

prior and express written permission of General Binding Corporation.

Operations Manual Mercury

Table of contents

1.0 Safety

1.1 Explanation of symbols 1-1

1.2 General Rules of safety 1-1

1.3 Labels 1-3 Figure 1.3.1 Safety label placement 1-4

2.0 Warranty

2.1 Limited warranty 2.1

2.2 Exclusions to the warranty 2-1

3.0 Specifications

3.1 Film and sheet size 3-1

3.2 Functions 3-1

3.3 Weight 3-1

3.4 Dimensions 3-1 Figure 3.4.1 Mercury 3-2

3.5 Electrical requirements 3-1

4.0 Installation

4.1 Placing your laminator 4-1

4.2 Setting up your laminator 4-1

4.3 Know your lamianator 4-2

5.0 Operations

5.1 Components on the laminator 5-1

5.2 Control panel 5-3 Figure 5.2.1 Control panel 5-3

5.3 Feed table 5-4

5.4 Supply shaft 5-6

5.5 Film alignment 5-6

5.6 T ension knobs 5-6

5.7 Separator knife 5-7

6.0 Applications

6.1 Film loading and threading 6-1

6.2 Starting an application 6-3

6.3 Helpful hints 6-4

6.4 Important points to remember 6-5

7.0 Maintenance and troubleshooting

7.1 Cabinets, cover and stand 7-1

7.2 Clean the rollers 7-1

7.3 T roubleshooting 7-2 Figure 7.3.1 T roubleshooting guide 7-3

8.0 Recomended spare parts

8.1 Spare parts list 8-1

9.0 Illustrated parts

9.1 Parts list 9-1

9.2 Parts illustrations 9-8

Operations ManualMercury

Operations Manual Mercury

1.0 Safety

Your safety, as well as the safety of others, is important to General Binding Corporation. This section contains important safety information which must be adhered to while operating, cleaning and performing basic maintenance in and around the machine.

CAUTION: Do not attempt to operate your Mercury Laminator until you completely read and understand this Operations Manual.

1.1 Explanation of symbols

ELECTRICAL HAZARD:This symbol is used prior to a step. The information following this symbol is to prevent an electrical shock condition that may be caused by an operators action or machine function.

1.2 General rules of safety

ELECTRICAL HAZARD: Do not operate the laminator if power cord is damaged or frayed. Y ou can be severely shocked, electrocuted or cause a fire.

INFORMATION: This symbol is used prior to,

during and/ or after a step. Following this symbol is important information pertaining to current subject.

CAUTION:This symbol is used prior to a step. The information following this symbol is to inform you of how to avoid harm to you, others around you or to the equipment.

WARNING: This symbol is used prior to a step. The information following this symbol is to inform you of how to avoid a potentially dangerous situation.

WARNING: Do not operate this laminator if you are not physically , psychologically or emotionally fit. Do not operate this machine until you have been trained and read this manual in its entirety .

WARNING: Do not wear ties, loose fitting clothes or dangling jewelry while operating or servicing the laminator . These items can get caught in the nip and choke you or you can be crushed or burned.

WARNING: Never tamper with the safety devices to increase the laminator’s production capacity . In the event a safety device should fail, never attempt to bypass it for operation. Consult a service representative immediately .

Operations ManualMercury

WARNING: Never use this machine for any other purpose than its intended design and function.

WARNING: Do not make any modifications to this laminator. Unauthorized changes will void your warranty and may cause extensive repairs or create poor output quality.

WARNING: Do not attempt to repair or service the laminator. Disconnect the plug from the power receptacle and contact your local sales/ service representative.

WARNING: Do not place the laminator on an unstable cart, stand or table. An unstable platform may cause the laminator to fall resulting in serious bodily injury .

CAUTION: When moving the laminator on a cart or stand, avoid quick stops, excessive force and uneven floor surfaces.

INFORMATION: Always disconnect the power plug from the receptacle to which it is connected and keep the power supply cord in your possession when moving the laminator .

CAUTION: Only use acceptable materials through this laminator. Unacceptable materials may cause damage to the rollers or cause poor output quality .

CAUTION: Always observe all warning labels placed at various points on the laminator. If you do not completely understand a label, contact your local service representative for further explanation.

CAUTION: A void contact with the heat roller during operation or shortly after power has been removed from the laminator .

INFORMATION: Any concerns for safety or operation should be brought to the attention of your local service representative immediately .

Operations Manual Mercury

1.3 Labels

Safety warning labels are placed at various locations on the laminator. Do not remove any of these labels. They are placed for your safety as well as the safety of those working around you.

Below are illustrations of the safety labels and a description of their meanings.

Hot rollers

– The safety label below means that you could be burned and your fingers and hands could be trapped and crushed in the rollers. Jewelry and long hair could be caught in the rollers and you could be pulled into them.

CUIDADO

RODILLOS CALIENTES. PUNTO DE PINCHAMIENTO. Mantener m anos y ropa a dis tancia.

ATTENTION

ROULEAUX CHAUDS. POINT DE PINCEMENT. Tenir mains et vetements a l'ecant.

CAUTION

HOT ROLLS.

PINCH POINT.

Keep hands and clothi ng away.

WARNUNG

HEISSE ROLLEN

Klemmgef ahr zwischen Rollen Hande und Kleidung ferhalten

Pinch point

– The safety label below means use extreme caution when placing your hands in the proximity of the pull rollers nip. You should never place your fingers or other items in this area while the machine is running.

This label is located between the pull rollers and the decurling bar center of the rollers.

Sharp knife

– The safety label below means that you could cut yourself if you are not careful.

CUIDADO

NAVAJA FILOSA.

ATTENTION

LAME COUPANTE.

CAUTION!WARNUNG

SHARP BLADE.

SCHAREE KLINGE

One label is placed on each side from the front operating position just in front of the heat rollers nip.

Electrical hazard

– The safety label below means that you could be seriously hurt or killed if you open the product and expose yourself to hazardous voltage.

Riesgo de choque electrico No abra Adentro, no hay piezas reparables para el usuario. Mantenimiento solamente para personal calificado

MUCHO

CUIDADO

MUCHO

CUIDADO

Risque de secousse electrique. Ne pas ouvrir. Pas de pieces reparables par l'utilisateur. Entretien par personnel qualifie.

WARNING!WAARSCHUWING!ATTENZIONE!WARNUNG

Electrical shock hazard. Do not open. No user serviceable parts inside. Refer servicing to qualified service personnel.

Kans op elektrische schok. Niet openen Bevatgeen door gebruik te repareren onderdelen. Door bevoegd service personeel laten repareren

Pericolo di scarica elettrica. Nessuna parte riparabile dall' utente. Chiamare un servizio di riparazioni qualificato.

SpannungsfUhr end e

Teile. Nicht offnen. Enthalt keine vom Enduerbrauc her zu wartende Tei le. Fur service bitte an qualifizier tes Service-Personal wenden.

Mantener m anos y dedos a distancia.

Tenir mains et doigts a l'ecant.

Keep hands and clothi ng away.

Hande und finger ferhalten.

This label is located on the rear panel in the center of the laminator just above the Electrical hazard safety label and below the rear slitter.

Refer to Figure 1.3.1 Safety label placement for illustration.

This label is located on the rear panel in the center of the laminator just below the film supply shaft between the pull rollers and decurling bar.

Figure 1.3.1 Safety label placement

(1) Between pull rollers and decurling bar

Operations ManualMercury

Riesgo de choque electrico No abra Adentro, no hay piezas reparables para el usuario. Mantenimiento solamente para personal calificado

MUCHO

CUIDADO

MUCHO

CUIDADO

Risque de secousse electrique. Ne pas ouvrir. Pas de pieces reparables par l'utilisateur. Entretien par personnel qualifie.

WARNING!WAARSCHUWING!ATTENZIONE!WARNUNG

Electrical shock hazard. Do not open. No user serviceable parts inside. Refer servicing to qualified service personnel.

Kans op elektrische schok. Niet openen Bevatgeen door gebruik te repareren onderdelen. Door bevoegd service personeel laten repareren

Pericolo di scarica elettrica. Nessuna parte riparabile dall' utente. Chiamare un servizio di riparazioni qualificato.

SpannungsfUhr end e

Teile. Nicht offnen. Enthalt keine vom Enduerbrauc her zu wartende Tei le. Fur service bitte an qualifizier tes Service-Personal wenden.

(1) Center rear panel below film unwind.

CUIDADO

RODILLOS CALIENTES. PUNTO DE PINCHAMIENTO. Mantener m anos y ropa a dis tancia.

ATTENTION

ROULEAUX CHAUDS. POINT DE PINCEMENT. Tenir mains et vetements a l'ecant.

CAUTION

HOT ROLLS.

PINCH POINT.

Keep hands and clothi ng away.

WARNUNG

HEISSE ROLLEN

Klemmgef ahr zwischen Rollen Hande und Kleidung ferhalten

(2) One on each side of the laminator

CUIDADO

NAVAJA FILOSA.

Mantener manos y dedos a distancia.

ATTENTION

LAME COUPANTE.

Tenir mains et doigts a l'ecant.

CAUTION!WARNUNG

SHARP BLADE.

Keep hands and clothi ng away.

SCHAREE KLINGE

Hande und finger ferhalten.

Operations Manual Mercury

2.0 Warranty

General Binding Corporation warrants the equipment to be free from defects in material and workmanship for a period of 90 days for parts and labor from the date of installation. This warranty is the only warranty made by General Binding Corporation and cannot be modified or amended.

General Binding Corporation’s sole and exclusive liability and the customer’s sole and exclusive remedy under this warranty shall be, at General Binding Corporation’s option, to r epair or replace any such defective part or product. These remedies are only available if General Binding Corporation’s examination of the product discloses to General Binding Corporation’s satisfaction that such defects actually exist and were not caused by misuse, neglect, attempt to repair , unauthorized alteration or modification, incorrect line voltage, fire, accident, flood or other hazard.

EUROPEAN UNION RESIDENTS ONL Y : This guarantee does not effect the legal rights which consumers have under applicable National Legislation governing the sale of consumer goods.

2.1 Limited Warranty

This warranty specifically does not cover damage to the laminating rollers caused by knives, razor blades, other sharp objects, failure caused by adhesives or improper use of the machine. Warranty repair or replacement does not extend the warranty beyond the initial 90 day period from the date of installation.

CAUTION: Unauthorized customer alterations will void this warranty THE WARRANTY MADE HEREIN IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING ANY WARRANTY OR MERCHANT ABILITY OR FITNESS FOR A P ARTICULAR PURPOSE. GBC FILMS GROUP WILL NOT BE LIABLE FOR PROPERTY DAMAGE OR PERSONAL INJURY (UNLESS PRIMARIL Y CAUSED BY ITS NEGLIGENCE), LOSS OF PROFIT OR OTHER INCIDENT AL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE THE

EQUIPMENT.

Operations ManualMercury

2.2 Exclusions to the Warranty

This warranty specifically does not cover;

Damage to the laminating rolls caused by knives, razor

blades, other sharp objects or failure caused by adhesives.

2. Damage to the machine caused by lifting, tilting and/

or any attempt to position the machine other than rolling on the installed castors on even surfaces.

3. Improper use of the machine.

4. Damage due from unqualified person(s) servicing the

machine.

Qualified;

2.3 FCC Class A Notice

Note: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

Canada Class A Notice- A vis Canada, Classe A

This Class A digital apparatus complies with Canadian ICES-3

Cet appareil numerique de la classe A est conforme a la norme NMB-003 du Canada.

• Any engineer that has experience with electrical

and mechanical design of lamination equipment. The engineer should be fully aware of all aspects of safety with regards to lamination equipment.

• Any commissioning or service engineer must be

of competent nature, trained and qualified to General Binding Corporation standards to fulfill that job. This person will have completed and passed the full service training course from General Binding Corporation.

• Any General Binding Corporation Technician

and/ or General Binding Corporation Specialist that has been through the General Binding Corporation service training course.

Modifications:

Any modifications made to this device that are not approved by General Binding Corporation may void the authority granted to the user by the FCC and/or by Industry Canada to operate this equipment.

Operations Manual Mercury

3.0 Specifications

This section provides specific information regarding the laminator. Any specification not provided must be requested from GBC.

3.1 Film and sheet size

Film – 1 to 3 Mil

Core – 2.25 in. (5.7 cm)

Sheet Size – Min. Width 5.5in.(14 cm)

– Max. Width 18 in. (45.7 cm) – Min. Length 8.5 in. (21.6 cm) – Max. Length unlimited

3.5 Electrical requirements

INFORMATION: Refer to the serial plate located on the rear of the laminator for specific electrical ratings applicable to the unit.

3.2 Functions

Speed – Fixed, dependent on film.

Temperature – Fixed

3.3 Weight

Unpacked – 396 lbs. (180 kilograms)

Shipping W eight – 458 lbs. (208 kilograms)

3.4 Dimensions (W x H x D)

Voltage – 220VAC ~ 60Hz Current – 10A Power – 2200 W

Refer to Figures 3.4.1 Dimensions.

Machine – 34.5 in. x 18.5 in. x 69 in.

– (87.6 cm. x 47 cm. x 175.3 cm)

Figure 3.4.1 Dimensions

69 in.

(175.2 cm.)

Operations ManualMercury

34.5 in.

(87.6 cm.)

18.5 in.

(47 cm.)

Operations Manual Mercury

4.0 Installation

This section will guide you through the installation process of the laminator.

INFORMATION: Shipping damage should be brought to the immediate attention of the delivering carrier.

4.1 Placing your laminator

CAUTION: Lifting Hazard. The Mercury laminator weighs 396 lbs. (180kg.) Do not attempt to lift alone.

The supporting surface may also be large enough to hold the material being laminated.

2. . The supporting surface should be large enough to

support the feed table and catch table comfortably.

CAUTION: If feed table or catch table hang over supporting surface, serious injury can occur .

3. Avoid locating the laminator near sources of heat or

cold. Avoid positioning the laminator in the direct path of forced heated or cooling air.

1. Place the Mercury laminator on a stable flat surface

capable of supporting at least 400 lbs. (181 kgs.).

The surface should be at least 30 inches high to assure comfortable positioning during operation. The minimum dimensions are 35 in. (87.6cm.) by 69 in. (175.2cm.).

CAUTION: Too high or too low of an operating position can lead to serious bodily injury and or cause poor output quality.

All seven rubber support feet should be positioned completely on the supporting surface.

INFORMATION: This effects the performance of the heating system and could result in poor output quality.

CAUTION: The stand and laminator should only be moved across even flat surfaces by two or more people. Do not turn the laminator on its side or up side down to move.

CAUTION: The laminator is a heavy piece of equipment and may cause injury and/ or require extensive repair work if it falls.

Operations ManualMercury

4.2 Setting up your laminator

After placing your Mercury laminator on a stable supporting surface, the feed table and catch table must be installed.

CAUTION: The front feed table is heavy and should be installed by two or more people.

1. Loacate front feed table and inspect for any damages

that may have been caused during shipping. Locate gear sprocket on feed table.

2. Carefully line up the gear sprocket on the feed table

with the gear sprocket of the laminator. The notches on the feed table should fit easily onto the laminators table support bar.

4.3 Know your laminator

Drive Side

Front

Heat Rollers

Rear

Control Side

Cabinets

3. At this time the feed table foot pads can be adjusted to

desired height by turning the foot bolts.

4. After the feed table is set to desired position, the feed

belts can be adjusted by loosening thumb screws on each tension pulley. When the tension pulley is at desired position, tighten thumb screw.

5. The final step is to connect the feed table link to the

laminator. Locate the male plug coming off of the feed table and insert it into the female plug of the laminator. To ensure proper fit, tighten threaded fastener finger tight.

6. To apply the rear catch table, first locate the catch

table support bar located at the rear of the machine. The catch table hooks directly to the catch table support bar.

7. Connect the attachment plug provided with the

laminator to a suitable grounded outlet only.

Feed Table

Film Supply

Heat Roller

Safety Shield

Control Panel

Foot Pads

Tension Knob

Refer to Figures 3.5 Electrical requirements

Roller Presure

Handle

Decurling Bar

Knob

Operations Manual Mercury

Fuses

On/Off (I/O)

Switch

Power Cord

Knife Home

Indicator

Rear Guard

Sensor

Thumb Screw

Knife

Assembly

Catch Table Support Bar

Core Adapter

Supply Shaft

Knife Separator

Safety Shield

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Operations ManualMercury

Operations Manual Mercury

5.0 Operation

This section covers the components of the laminator, the control panel, feed table, supply shaft, knife assembly film alignment and tension knobs.

5.1 Components on the laminator

(1) POWER ON/ OFF (I/O): This is located at the back of the control side cabinet. When set to the “I” position, applies power to the laminator. When set to the “O” position, removes power from the laminator.

Fuses

CAUTION: The feed guide should be set outside the width of the film. The film should be completely inside the sheet being fed.

(4) FEED T ABLE FOOT P ADS: The adjustable foot

pads are located in the front of the feed table. By adjusting the foot bolts, you can raise or lower the table.

(5) T ABLE/LAMINA TOR LINK: The table/laminator link is located on the front control side of the laminator. In order to operate the table, the link must be properly installed.

Table/Laminator Link

On/Off

(I/O)

Power Cord

(2) FEED T ABLE: The feed table is semiautomatic to assist operator for an easy feed, and a perfect overlap.

INFORMATION: The feed table will only allow one sheet to enter the machine at a time. The feed table will only work if the table link is connected to the laminator , and is properly installed.

(6) HEAT ROLLER SAFETY SHIELD: Prevents

entanglement, entrapment and inadvertent contact with the heat rollers.

INFORMATION: The laminator will operate only when the safety shield is located in the fully down position. Power to the motor is removed when the safety shield is in the raised position.

(3) TABLE SIDE GUIDES: The side guides are

adjustable to ensure accurate feeding. The Mercury is left justified All settings should be set from left to right.

To raise the main roller safety shield, simply lift. Once the safety latch has been retracted, power to the motor is removed.

Operations ManualMercury

To close the safety shield, lower shield until it is in it’s neutral position. The motor will revert to its condition prior to the safety shield being raised.

(7) HEAT ROLLER SAFETY SHIELD LATCH:

Used to ensure that safety shield is in proper position. The safety interlock latch is located on the drive side from the front operating position

Safety Latch

(1 1) DECURLING BAR: The decurling bar is located in the middle of the machine, just past the main rolls. The decurling bar can be adjusted with the decurling bar adjustment knob to ensure a flat output.

(12) KNIFE ASSEMBL Y : The knife assembly is located in the back of the machine. The knife automatically cuts and separates images as they are run through the machine.

(13) KNIFE SEPARATOR SAFETY SHIELD:

Prevents entanglement, entrapment and inadvertent contact with the separator knife. To raise the knife separator safety shield, gently lift. Once the safety latch has been retracted, power to the motor is removed.

To close the safety shield, gently lower shield until it is in it’s neutral position. The motor will revert to its condition prior to the safety shield being raised.

8) HEA T ROLLER: Teflon coated steel tube. Used to heat the laminating film and compress the film to the items being laminated. Heat is provided by an internal infrared element.

WARNING: Avoid contact with the heat roller. Direct contact with the heat roller can burn you.

(9) PULL ROLLERS: The bottom pull roller, located

in the middle of the laminator, is motor driven. When Rollers are in the down position, they simultaneously pull the film and improve the quality of the laminated item.

(10) IDLER BAR: The idler bar, located near the supply roll, is used to direct the film to the heat rollers.

INFORMATION: The laminator will operate only when the knife separator shield is in it’s neutral position and the safety interlock latch is properly engaged. Power to the motor is removed when the safety shield is in the raised position.

(14) KNIFE SEPARATOR SAFETY SHIELD LA TCH: Used to ensure that safety shield is in proper

position. The safety interlock latch is located on the drive side from the front operating position

(15) SUPPL Y SHAFT : The supply shaft holds the film supply and the core adapters hold the rolls of film on the film shaft.

Operations Manual Mercury

(16) CORE ADAPTERS: The film shaft holds the supply

roll while the core adapters hold the rolls of film on the shaft.

Thumb Screw

(17) FILM TENSION KNOB: Allows the operator to increase or decrease film web tension as necessary to reduce curl and wrinkles. Refer to Section 4.6 Adjusting film tension for more information on tension.

Core Adapter

Supply Shaft

(19) EMERGENCY STOPS: The emergency stops are located on top of the laminator. The can be located by the yellow hazard stickers and should be used to stop the machine in the event of an emergency.

(20) GUIDE WHEELS: There are two guide wheels in front of the main rollers that assist in feeding of the images. There are three guide rollers located at the rear of the machine that assist in the exiting of finished images.

(21) NIP POINT : The point at which two rollers come into contact. The nip point of the heat rollers is the place at which the items for lamination are introduced into the laminator.

CAUTION: Only feed acceptable materials through the nip of the rollers. Unacceptable materials may cause damage to the rollers.

Film Tension

Knob

Roller Pressure

Handle

(18) PRESSURE HANDLE: Located on the control side cabinet. Used to adjust the amount of roller pressure needed for various laminating applications.

Emergency Stop

Switch

Decurling Bar

Adjustment Knob

(22) FILM WEB: Laminating film loaded into the machine

(23) CONTROL P ANEL: The control panel is located on the top, control side of the machine. It allows you to select from three deferent job options.

CAUTION: Never force the pressure handle down. If the handle does not move smoothly , contact your local service representative.

Operations ManualMercury

5.2 Control panel

Refer to Figure 5.2.1 Control panel

(1) POWER: Indicates when the laminator has power

supplied to the laminator.

(2) READY : Indicates when the laminator has sufficient heat for the selected film gauge. Flashes when the temperature is close to the set point or overshoots the set point.

(3) OPP: When pressed automatically sets the speed when running polypropylene film

(4) PET :When pressed automatically sets the speed when running polyester film.

Figure 5.2.1 Control panel

MERCURY

POWER

READY

FILM TYPE

OPP

PET

MOTOR CONTROL

RUN

STOP

(5) NYLON:When pressed automatically sets the speed when running nylon film.

(6) RUN: When pressed, activates rollers for normal operation.

(7) LOADING: Allows the operator to run product into heat rolls for the purpose of threading the unit

(8) STOP: When pressed, stops the rotation of the rollers.

(9) REV : When pressed and held, reverses roller direction

to clear film jams and wrap-ups.

REV.NYLON

Operations Manual Mercury

5.3 Feed table

To remove

Remove table/laminator link from machine. This is located just below the control panel. To remove link, turn counter-clockwise. (To the left).

2. Lift the rear of the table upwards and away from the

laminator.

5.4 Supply shaft

To remove

1. Release any tension from the supply shaft, and remove

any excess film.

2. Lift the left side of the supply shaft up and to the left

from the front operating position. Be sure to support both ends of the supply shaft to avoid damage to the laminator.

To replace

Insert the right side of the supply shaft into the supply hexagonal brake hub, located on the right side of the laminator from the front operating position.

To replace

Set the front of the feed table (the side that has gear) into the table brackets making sure that the table gear engages with laminator gear.

2. Adjust table height with adjustable foot pads.

3. Connect the table/laminator link. Insert the plug from

the feed table into the plug of the laminator. Turn clockwise to tighten. (To the right)

2. Lowert the left end of the supply shaft in the supply

shaft saddle.

4. Adjust feeder belts if necessary.

Operations ManualMercury

5.5 Film alignment

The film supply shaft come with pre alignment holes on the right side. The Mercury laminator is a left justified machine. Film should be aligned from the left going to the right. Film should not be centered on the supply shaft.

Mercury- Has pre alignment holes for 9 in. (21 cm)

and 12 in. (31 cm) film widths.

1. Loosen the thumb screw on the right side core adapter.

2. Move to the corresponding hole to match the width of your roll of film.

3. Tighten the thumb screw in the pre drilled hole.

5.6 Tension knobs

Allows the operator to increase or decrease film web tension as necessary to reduce curl and wrinkles. Refer to Page 5-3, Adjusting Film Tension for more information on tension.

To increase film tension

1. Turn the tension knob as indicated below.

Thumb screws

Core adapters

To Increase T en sion Turn Dial Clockwise

To decrease tension

1. Turn the tension knob as indicated below.

To Decrease Tension

Turn Dial Counter Clockwise

Operations Manual Mercury

5.7 Separator Knife:

The integrated sheet separator is able to run with continous web flow for high production output. The precision knife separates sheets while lamination web is moving.

INFORMATION: The laminator will operate only when the knife seperator shield is in its closed position and the safety interlock latch is properly engaged. Power to the motor is removed when the safety shield is in the raised position.

WARNING: When r emoving paper jams, always set the power switch to off “O” to remove power from the laminator . Never reach into the knife separator unit while the machine is powered up.

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Operations Manual Mercury

6.0 Applications

The Mercury will accommodate rolls of film on a 2.25 in. core. This section will describe how to load and thread film and start an application, web diagrams, helpful hints and important points to remember.

WARNING: Do not wear ties, loose fitting clothes or dangling jewelry while operating or servicing the laminator . These items can get caught in the nip and choke you or you can be crushed or burned.

6.1 Film loading and threading

3. Remove the unwind shaft from the laminator. Remove

the core adapters from the unwind shaft.

Poly-in

Adhesive

surface

Polyester surface

Poly-out

Adhesive

surface

Polyester surface

Turn power to ON. (I)

On/Off Switch

(I/O)

2. Ensure the roller nip is open and enter a film type.

NYLON

CAUTION: The dull side of the film contains the adhesive. Use extreme caution when loading delustered (matte) film as both sides appear dull.

4. Slide the roll of laminating film onto the unwind shaft

so the adhesive is facing away from the heat roller when placed on the laminator.

Poly-in film

Adhesive side

Polyester side

Poly-out film

Adhesive side

Polyester side

Operations ManualMercury

5. The Mercury is left justified and the film should be

lined up from the left to the right. Once the film mounted, secure in place by tightening the thumb screws on the core adapters.

CAUTION: The READY indicator on the display should be illuminated. This is your indication that the roller has sufficient heat.

MERCURY

POWER

READY

MOTOR CONTROL

RUN

7. Pull the laminating film down under the idler, and over

the heat roller and allow to drape on the feed table.

Adhesive side

Polyester side

8. Hold the LOADING button on the control panel.

MERCURY

POWER

READY

MOTOR CONTROL

RUN

FILM TYPE

OPP

6. Raise the main roller safety shield for ease of webbing

the film.

FILM TYPE

OPP

9. Slide the threading card ( a piece of heavy stock paper,

card board or similar product) between the feed table and the film resting on the feed table. Push the threading card into the nip of the main rollers.

CAUTION: The threading card should exceed the width of the film to prevent activated adhesive from adhereing to the bottom roller .

10. Lower the main roller pressure handle to the related

film setting position.

Operations Manual Mercury

11. While the threading card is being taken through the

rollers, use this time to adjust film tension.

12. Once the threading card has entered the laminator,

let the card procede until the card is almost completely through the nip,, release “Loading” button. Set the next sheet of paper on the feed table and press “Run” button. As the threading card travels throught the nip, it passes a paper sensor. When the paper passes the paper sensor, it allows the next image to be laminated to enter the laminator. This feature allows feeder to automaticly set an overlap. Remembering that overlaping is necessary, continue with next sheet. Repeat.

13. When the job is completed. Trim the threading card

off and release roller pressure using the roller pressure handle.

6.2 Starting an application

CAUTION: Ensure the safety shield is in the fully closed position and the feed table is properly installed. .

1. Turn the laminator on by pushing On/Off to the “I”

(On) position.

CAUTION: Exercise extreme caution when using an open blade around the laminator . A sharp knife can cut you and/ or the rollers.

On/Off Switch

(I/O)

2. Select the type of film you are running.

INFORMATION: Different settings may become necessary as the warm up time, lamination time and materials change.

3. You must manually press the Film Type button. The

laminator will set the speed and temperature for the respective film and 20 lb. bond paper (copier paper).

INFORMATION: Do not begin laminating until the READY indicator illuminates. Normal warm up time is approximately ten minutes.

Operations ManualMercury

4. Position the first item on the feed table to be laminated.

CAUTION: Anything obstructing the path of the film exiting the rear of the laminator may cause a film jam (wrap-up).

5. Set the roller pressure handle to the appropriate position

and press “RUN”. The rollers will begin to turn.

6. Once the last item laminated has completely exited the

rear of the laminator, press the “STOP” button.

7. Turn the laminator off by pushing On/Off to the “O”

(Off) position.

6.3 Helpful hints

Good consistent lamination is a result of combining proper heat, speed, tension and dwell time. Dwell time is the amount of time the material to be laminated is compressed between the heat rollers and is controlled by the speed of the laminator.

Operation of the laminator for more than thirty minutes at a time may necessitate a lower speed setting. It is recommended that during periods of long runs the items being laminated are alternated between thick and thin.

If you are ever unsure that your laminator is set at proper setting, run a test piece (scrap) of the same or similar material through the laminator.

Always use the minimum brake tension necessary to achieve the desired results. Using the maximum amount will yield unwanted results after close inspection. You may see stretching, waves in the laminate, distortion of the image and/ or curling.

INFORMATION: You do not need to un-web the laminator after turning power off except to clean the rollers. Refer to Section 5.1 Cleaning the rollers.

Operations Manual Mercury

6.4 Important points to remember

CAUTION: Do not stop the laminator before an item has completely exited the pull rollers. Even a

momentary stop will cause a dwell line (heat line) on CAUTION: Do not press RUN until READY has illuminated.

CAUTION: T o cut film or web, only use an enclosed blade around the laminator .

the laminated item.

INFORMA TION: W rinkles may result if an attempt

is made to reposition an item once it has entered

the nip of the heat roller

CAUTION: Do not force items into the laminator. An item that is not easily drawn into the laminator is probably to thick to laminate.

CAUTION: Do not attempt to laminate abrasive or metal objects such as staples, paper clips and glitter as they may damage the heat rollers.

WARNING: Do not attempt to laminate adhesives marked “FLAMMABLE”.

INFORMATION: When feeding long items,

skewing may occur if the item is not fed into the

laminator straight. Use the feed guide to help prevent

this from happening.

INFORMATION: If the machine is not working,

always check that the safety shield is properly

closed, the feed table is properly installed and the

circuit breaker has not tripped before placing a

service call.

CAUTION: A void direct contact with the heat rollers when changing the supply roll after the laminator has been running.

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Operations Manual Mercury

7.0 Maintenance &

Troubleshooting

General Binding Corporation laminators require minimal maintenance. However, regular maintenance is essential to keep any piece of precision machinery at peak performance. A maintenance schedule and a section of procedures are included in this section.

WARNING: Do not wear ties, loose fitting clothes or dangling jewelry while operating or servicing the laminator . These items can get caught in the nip and choke you or you can be crushed or burned.

7.1 Cabinets and cover

WARNING ELECTRICAL HAZARD: Remove

power from the laminator before cleaning. You can

be severely shocked, killed or cause a fire.

1. Use a damp ( use water only to dampen the cloth )

white terry cloth towel to wipe dust from the cabinets and

cover.

7.2 Clean the rollers

INFORMA TION: Impr oper maintenance can result in poor output quality.

General Binding Corporation offers Cleaning kits ( P/N 1711515 ) as well as Extended Maintenance Agreements.

The only maintenance required by the operator is to maintain clean and adhesive free nip rollers and overall cleanliness of the laminator itself.

WARNING ELECTRICAL HAZARD: Do not use liquid or aerosol cleaners on the laminator. Do not spill liquid of any kind on the laminator . You can be severely shocked, killed or cause a fire. Use only a damp cloth for cleaning unless other wise specified.

CAUTION: This procedure is performed while the

laminator is HOT! Use extreme caution. Direct

contact with the rollers can burn you!

CAUTION: Hardened adhesive deposits on the

rollers can cause damage to the rollers. Rotate the

rollers at the lowest speed setting on the control

panel.

WARNING: Do not apply cleaning fluids or solvents

to the rollers! Fluids and solvents will have a direct

effect on the rubber coated rollers and will require

replacement.

CAUTION: Do not use metal scouring pads to clean

the rollers! Scouring pads will damage the rollers

and require replacement.

7.3 Troubleshooting

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CAUTION: Never clean the rollers with sharp or pointed objects.

1. Remove the film from the laminator.

2. Preheat the laminator until the READY indicator

illuminates.

3. Rub the top and bottom heat rollers with a 3M

Brite

pad.

Scotch-

4.Lower the safety shield.

5. Press RUN to rotate the heat rollers to a new area for

cleaning. Press STOP. Continue this process until the complete surface of both rollers are clean.

As an operator, you can perform some basic troubleshooting before contacting your local service representative.

WARNING: Never remove the cabinets in attempt to troubleshoot the laminator . Y ou may cause damge to other components or injury to yourself.

WARNING ELECTRICAL HAZARD: Do not remove the cabinets. You will be exposed to dangerous voltage which can shock or paralyze you.

6. Follow the procedure in Section 4.6 Film loading and

threading to reload the laminator.

7. Use a damp cloth to clean the teflon roller.

WARNING: Only trained technicians should perform service related work on the laminator .

Refer to Figure 7.3.1 T roubleshooting Guide on page

7.3.

Operations Manual Mercury

Figure 7.3.1 Troubleshooting guide Symptom

•POWER lamp does not illuminate when ON/ OFF (I/O) is in the ON (I) position.

• Heat rollers do not turn.

• Laminated items exhibit

curling.

Possible cause

Laminator not connected to the electrical supply. Blown fuse

Emergency stop is depressed

Safety shield in upright position.

Decurling bar setting is incorrect

Tension on the top film is to tight.

Tension on top roll of film is too loose.

Top film roll may be improperly loaded.

Corrective action

Insert attachment plug into receptacle.

Replace with proper rated fuse

Unlock Emergency stop

Lower safety shield.

Select a differant side of the decurling bar.

Adjust tension per section Film Tension Adjustment.

Make sure top roll of film is around idler bar.

• Adhesive deposited on the

heat rollers.

• Unsatisfactory adhesion of

laminate.

Heat rollers were lowered with no paper stock between them.

Laminate improperly loaded.

Insufficient heat.

Laminate improperly loaded.

Heat rollers require cleaning.

Laminated item unsuitable for adhesion.

Avoid running the laminator without paper stock.

Adhesive (matte) side of laminate film may be against the heat rollers. Load film per procedure outlined in section Film Loading and

Threading.

READY must be illuminated.

Adhesive side of film must be facing away from the heat rollers.

Clean heat rollers per section T o Clean The Rollers.

Item may be dirty or may have non-porous surface that is extremely difficult to laminate.

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Operations ManualMercury

Operations Manual Mercury

8.0 Recommended spares

8.1 Spare parts list

Part Number Item Description

607050141 UPPER HEAT ROLL 607050142 LOWER HEAT ROLL 607050143 PULL ROLLER 609060113 DC GEARED MOTOR 609060115 DC CUTTER MOTOR 610011706 TRANSFORMER 613020627 CUTTER BLADE 703070363 TABLE BELT 703070364 CUTTER BELT 704090805 PHOTO SENSOR MIRROR TYPE 704090810 PHOTO SENSOR 704130116 FUSE 704130122 FUSE 704150111 BI-METAL THERMOSTAT 120V 705030503 BRIDGE DIODE 705090302 SOLID STATE RELAY 705200201 INFRARED SENSOR 706011193 MOTOR PCB 706011708 CUTTER MOTOR DRIVE PCB 706011721 MAIN PCB 706011722 POWER SUPPLY PCB 706011723 DISPLAY PCB 706025082 INFRARED HEATER ASSY”

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Operations ManualMercury

General Binding Mercury Operation/parts And Schematic Book

Specifications and Main Features

Frequently Asked Questions

User Manual