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Gbc Explorer 107 Laminator

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EXPLORER 107 OPERATION & MAINTENANCE MANUAL © December 1999 GBC Pro-Tech Do not duplicate without written permission. TE UP PE R MPE HE AT RA TU RE CO LO RO LL NT WE R RO HE AT L RO LL ER ER HOT D COL S. MEA HOT SU B HE AT ER S D COL S. MEA RO LL ER S NIP HOT D COL S. MEA HOT D COL S. MEA F OF N FA ING OL CO ON RE VE RS E F OF ON R TO MO L RO NT CO RO RO LO Revision : A Part number : 930 - 041 WE R TE NS LL UP ER PE R TE NS LL ER ION ION GBC Pro - Tech 4151 Anderson Road DeForest, WI 53532 Ph: ( 608 ) 246 - 8844 Fx: ( 608 ) 246 - 8645 Explorer 107 Operation and Maintenance Manual Read me file Read Me File . . . . . . . . . The information in this publication is provided for reference and is believed to be accurate and complete. GBC Pro - Tech 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. GBC Pro - Tech 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 GBC Pro - Tech or others. GBC Pro Tech assumes no liability arising from infringements of patents or any other rights of third parties. This publication is copyrighted © 1999 by GBC Pro - Tech. All rights 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 GBC Pro - Tech. In the electronic version of this publication, the hand will change to a pointer finger to return to the first identifying hyperlinked. When moving from page to page, use PAGE, use to advance to the last PAGE, use to go back one PAGE and use to advance one PAGE. When moving from view to view, use VIEW and use to return to a previous to advance to the next VIEW. Should you find an error within this publication or would like to make a suggestion, please utilize the fax correspondence sheet following this read me file and fax it to the number provided. Your comments and help will ensure up to date information. Thank you. © GBC Pro - Tech December 1999 Read me file Explorer 107 Operation and Maintenance Manual This page intentionally left blank. © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Read me file Fax Correspondence Fax number : ( 608 ) 246 - 8645 Date : To : Sean Flood @ GBC Pro - Tech 4151 Anderson Road DeForest, WI 53532 From : Company : Address : Phone number : ( ) Fax number : ( Re : Explorer 107 Operations and Maintenance Manual What section ? What needs correcting ? Additional comments: © GBC Pro - Tech December 1999 What Page # ? ) Read me file Explorer 107 Operation and Maintenance Manual This page intentionally left blank. © GBC Pro - Tech December 1999 Explorer 107Operation and Maintenance Manual Table of Contents Table of Contents Section 1: Safety 1.1 Symbols .....................................................................................................1 - 1 1.2 Safety features ...........................................................................................1 - 1 1.3 Installation .................................................................................................1 - 3 1.4 Operations .................................................................................................1 - 8 1.5 Applications .............................................................................................1 - 13 1.6 Troubleshooting ......................................................................................1 - 17 1.7 Maintenance ............................................................................................1 - 18 1.8 Label Explanation ...................................................................................1 - 21 Figure 1.8.1 Label Location ....................................................1 - 22 Section 2: Warranty 2.1 Limited warranty information ...................................................................2 - 1 2.2 Exclusions to the warranty .......................................................................2 - 1 © GBC Pro - Tech December 1999 Page I Table of Contents Explorer 107 Operation and Maintenance Manual Section 3: Specifications 3.1 General .......................................................................................................3 -1 3.2 Consumables..............................................................................................3 - 1 3.3 Function .....................................................................................................3 - 2 3.4 Electrical ...................................................................................................3 - 2 3.5 Dimensions ................................................................................................3 - 3 Figure 3.5.1 Dimensions ..............................................................3 - 3 Section 4: Installation 4.1 Pre-installation check list ..........................................................................4 - 1 Figure 4.1.1 Plug ..........................................................................4 - 2 Figure 4.1.2 Suggested receptacle ...............................................4 - 2 Figure 4.1.3 Suggested floor layout .............................................4 - 3 4.2 Unpacking .................................................................................................4 - 4 Page II © GBC Pro - Tech December 1999 Explorer 107Operation and Maintenance Manual Table of Contents 4.3 Shrink wrapped .........................................................................................4 - 4 4.4 Crated ........................................................................................................4 - 5 4.5 Safety check ..............................................................................................4 - 7 4.6 Control panel check ................................................................................4 - 10 4.7 Main roller handle ...................................................................................4 - 15 4.8 Pull roller handle .....................................................................................4 - 16 4.9 Lateral film adjustment ...........................................................................4 - 17 4.10 Film brake adjustment ..........................................................................4 - 18 4.11 Inline slitters ..........................................................................................4 - 19 4.12 Rear cut-off blade .................................................................................4 - 23 Section 5: Operations 5.1 Control panels ...........................................................................................5 - 1 5.1.1 Operations control panel .......................................................................5 - 1 © GBC Pro - Tech December 1999 Page III Table of Contents Explorer 107 Operation and Maintenance Manual Figure 5.1.1 Operations control panel ........................................5 - 4 5.1.2 Temperature control panel .....................................................................5 - 5 Figure 5.1.2 Temperature control panel ......................................5 - 8 5.2 Emergency .................................................................................................5 - 9 5.3 Set up .......................................................................................................5 - 10 5.3.1 Power ....................................................................................................5 - 11 5.3.2 Film loading ..........................................................................................5 - 11 Figure 5.3.1 Film centering chart ..............................................5 - 14 5.3.3 Roller handles ......................................................................................5 - 15 5.3.4 Heating ................................................................................................5 - 16 5.4 Lateral film adjustmentt ..........................................................................5 - 18 5.5 Film brake adjustment ............................................................................5 - 20 5.6 Using inline slitters...................................................................................5 - 20 5.7 Rear cut-off blade ...................................................................................5 - 23 Page IV © GBC Pro - Tech December 1999 Explorer 107Operation and Maintenance Manual Table of Contents 5.8 Front safety shield .....................................................................................5 - 24 5.9 Pressure plate ..........................................................................................5 - 25 5.10 Feed table ..............................................................................................5 - 26 5.11 Feed guides ............................................................................................5 - 29 Section 6: Applications 6.1 Initial webbing ...........................................................................................6 - 1 6.2 New film to existing film ..........................................................................6 - 10 6.3 Unwebbing ...............................................................................................6 - 12 6.4 Parameter charts .......................................................................................6 - 13 Chart 6.4.1 Nap-Lam II ( SAE ) ..................................................6 - 14 Chart 6.4.2 Nap-Lam I ( SAE ) ...................................................6 - 14 Chart 6.4.3 Premium ( SAE ) ......................................................6 - 15 © GBC Pro - Tech December 1999 Page V Table of Contents Explorer 107 Operation and Maintenance Manual Chart 6.4.4 Nap-Lam II ( Metric ) ..............................................6 - 15 Chart 6.4.5 Nap-Lam I ( Metric ) ................................................6 - 16 Chart 6.4.6 Premium ( Metric ) ...................................................6 - 16 Chart 6.4.7 Temperautre conversion chart ................................6 - 17 Section 7: Troubleshooting 7.1 Wave problems .........................................................................................7 - 1 7.2 Output problems .......................................................................................7 - 4 7.2.1 Problems/ Cause/ Hints...........................................................................7 - 4 7.3 Machine problems .....................................................................................7 - 5 7.3.1 Problem/ Hints ........................................................................................7 - 5 7.3.2 Clearing a jam .........................................................................................7 - 6 7.4 Glossary .....................................................................................................7 - 7 Page VI © GBC Pro - Tech December 1999 Explorer 107Operation and Maintenance Manual Table of Contents Section 8: Maintenance 8.1 Maintenance schedule ...............................................................................8 - 1 8.2 Cleaning the rollers ..................................................................................8 - 2 8.3 Clean the cabinets and covers ....................................................................8 - 7 8.4 Cleaning the control panels ........................................................................8 - 7 © GBC Pro - Tech December 1999 Page VII Table of Contents Explorer 107 Operation and Maintenance Manual This page intentionally left blank. Page VIII © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Safety Section 1 Safety WARNING CAUTION Indicates a potentially hazardous situation which, if not avoided, could result in serious injury. Do not attempt to operate your Falcon 160 laminator until you have read this section carefully! Your safety, as well as the safety of others, is important to GBC Pro - Tech. This section contains important safety information. DANGER Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury. The following symbols are used throughout this manual to indicate Information, Caution, Warning, Danger and Electrical Shock conditions. ELECTRICAL SHOCK 1.1 Symbols Indicates an electrical shock situation which, if not avoided, could result in serious paralyzation of the body or death. INFORMATION Indicates helpful information that should be considered before, during, or after an action, step or procedure is given. 1.2 Safety features CAUTION Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury, or alerts against unsafe practices or alerts against actions which could damage the product. © GBC Pro - Tech December 1999 The Explorer 107 laminator has been designed with safety as a primary consideration; however, you must become thoroughly familiar with the controls, proper operation, proper service procedures and safety features of the laminator before using or servicing the unit. Page 1 - 1 Safety Explorer 107 Operation and Maintenance Manual In addition, the heating components of the Explorer 107 can reach temperatures of over 200oF ( 100oC ). An important feature of the Explorer 107 laminator are the safety latches and the interlocks. The front safety shield and the feed table are both equipped with safety latches. When a safety latch is not in the locked position, the motor is disabled. Refer to Figure 1.2.1 DANGER At these temperatures there is a danger of severe burn if the rolls are touched during setup, operation or servicing. WARNING Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! INFORMATION Only a qualified service technician should perform any procedure requiring the cabinet doors to be opened. Figure 1.2.1 Safety latches The word qualified is defined below; Safety latches Qualified ; • Any engineer that has experience with electrical and mechanical design of lamination equipment.The engineers should be fully aware of all aspects of safety with regards to lamination equipment. RE ATU PER TEM L TRO CON HOT S.CO MEA LD HOT S.CO MEA LD HOT S.CO MEA LD HOT S.CO MEA LD OFF FAN LING COO ON E ERS OFF REV ON OR MOT L TRO CON LER ROL SION TEN ER LER UPP ROL SION ER TEN LOW • Any commissioning or service engineer must be of competent nature, trained and qualified to GBC ProTech standards to fulfill that job. This person will have completed and passed the full service training course from GBC Pro-Tech. • Any GBC Technician, GBC Specialist, and / or GBC Pro-Tech Technician that has been through the GBC Pro-Tech service training course. Page 1 - 2 Safety latches Under the feed table © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual The laminator is equipped with two EMERGENCY STOPS ( E-STOP ).One is located above the TEMPERATURE CONTROL panel and the second is located above machine POWER. Refer to Figure 1.2.2 Safety To continue operation, both E-STOPS must be in the up position. To reset the E-STOP, twist the button 1/4 turn clockwise. Rotate Figure 1.2.2 Emergency stops Emergency stops L TRO RE CON ATU PER TEM HOT D COL S. MEA HOT D S. COL MEA HOT D COL S. MEA HOT D COL S. MEA INFORMATION OFF FAN ING COOL ON RSE OFF REVE ON ROL R CONT MOTO ER ROLL ION R TENS UPPE ER ROLL ION R TENS LOWE To engage the EMERGENCY STOP feature, press down. Either of these, when engaged, removes power to the motor. Push down The laminator will operate only when all safety latches are in the fully latched position. 1.3 Installation The following symbols are positioned at various points in Section 4 Installation. CAUTION Failure to follow the pre-installation check list can result in damage to the laminator. © GBC Pro - Tech December 1999 Page 1 - 3 Safety Explorer 107 Operation and Maintenance Manual WARNING The operating environment must be free of dust, flammable liquids and vapors. You can be injured by inhaling chemical vapors. INFORMATION A L L S H I P M E N T S A R E E X - W O R K S . At our dock, title passes to the buyer. Please review your insurance coverage prior to shipment, as you are responsible for all subsequent freight charges and risks. WARNING INFORMATION Vapor build up or stored flammable liquids can cause a fire. Excessive dust can damage the laminator. Before signing the Bill of Lading, you should be sure to inspect the crate and / or pallet for signs of damage or missing items; if applicable, make note of this on the Bill of Lading. CAUTION Do not locate the laminator where air is blowing directly on the machine. The air flow can cool the rolls unevenly and result in poor quality output. INFORMATION Depending on the destination and customer preference, the Falcon 160 may be shipped in various ways. The laminator may arrive shrink wrapped or in a plywood crate on a skid. Please follow the unpacking procedure that pertains to your method of shipment. WARNING The Explorer 107 Laminator is a large and heavy piece of equipment. It is necessary to employ LICENSED RIGGERS ONLY to move the laminator. The laminator is not designed to be tipped up or sideways in any way. Such action disturbs the exact alignment of the rolling parts of the machine and requires extensive realignment. You can be crushed or seriously injured. Page 1 - 4 WARNING The unpacking process requires at least two people. You can be severely injured, crushed or cause damage to the laminator. © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual CAUTION Do not use a knife or other sharp object to remove the shrink wrap from around the laminator. You can cause irreparable damage to the rollers. Safety CAUTION A second person must support the side labeled 5 in Figure 4.4.1 It can fall and damage the laminator or cause harm to you and others. INFORMATION WARNING Do not attempt to move the laminator across anything other than a flat level surface without trained and qualified riggers. You can be crushed or seriously injured. GBC Pro-Tech's warranty does not cover malfunction of the equipment due to mishandling and / or tipping. GBC ProTech bears no responsibility for personal injury or damage due to moving the laminator improperly. INFORMATION CAUTION Do not allow the top to fall into the crate. It can damage the laminator. INFORMATION Do not put packing screws on the floor. They can cause problems when trying to roll the laminator into position or you can become injured if stepped on. © GBC Pro - Tech December 1999 About recycling: The crate components can be reused for shipping the laminator again or can be disassembled and the wood and screws recycled. The shrink wrap is not recyclable, so it must be discarded. 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. Page 1 - 5 Safety Explorer 107 Operation and Maintenance Manual WARNING If a safety feature is not functioning properly, contact your local service representative immediately INFORMATION When the laminator is first turned on, the control panels display the default settings. INFORMATION Reverse speed can be controlled by Speed Adjust. INFORMATION A second person is needed to assist with the idler tension checks. Default setting; Cooling Fan = Off, Motor Speed = Off, Top Teflon Roller = 32 o F, Nip Rollers = 32 o F, Bottom Teflon Roller = 32 o F and Sub Heaters = 32 o F. INFORMATION Lower film tension idler: gray rubber covered idler located below the lower cooling fan assembly. INFORMATION When any command is pressed ( with the exception of Reverse ) on the Operations Control Panel, a "beep" will sound. If the command is held down, the panel will continually "beep". INFORMATION Upper film tension idler: gray rubber covered idler located above the upper cooling fan assembly. INFORMATION Leave the motor speed adjust at 5 to continue with the function check. Page 1 - 6 © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual INFORMATION HOT When MEAS , or C O L D is pressed once, you will hear one "beep", when pressed and held, you will only hear one "beep". INFORMATION When pressing or , "Beeps" once for every one increment of change. INFORMATION Number indicated is an approximate of room temperature. Your display may differ. WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP. You can be CRUSHED or BURNED! Safety INFORMATION The handle will stop after making initial contact, then can be turned more to apply pressure and will lock into position. WARNING Extreme caution should always be exercised working around the core gripper support, the gripper tabs can cut you! WARNING At no time should the slitter guard be removed! Sharp blades can cut you! INFORMATION The large inner dials on the left and right cabinet doors will lower and raise the slitters. CAUTION INFORMATION Never leave the rollers in the down position without rolling. Prolonged contact in one area can form flat spots on the rollers. © GBC Pro - Tech December 1999 The center slitter can not be lowered without lowering the side slitters. Page 1 - 7 Safety Explorer 107 Operation and Maintenance Manual WARNING Caution should always be exercised when using the rear cut-off blade. Sharp blade can cut you! INFORMATION When any command is pressed ( with the exception of Reverse ) on the Operations Control Panel, a "beep" will sound. If the command is held down, the panel will continually "beep". WARNING Keep hands and fingers away from the path of the rear cut-off blade. Sharp blade can cut you! INFORMATION 1 increment on the Motor Speed Adjust is equal to approximately 3.5 ft./ min. ( 1.1 m/ min. ). 1.4 Operations INFORMATION Reverse speed can be controlled by Speed Adjust. The following symbols are positioned at various points in Section 5 Operations. 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. Page 1 - 8 INFORMATION Always use the minimum film tension necessary to complete the task. © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Safety INFORMATION INFORMATION When the laminator is first turned on, the control panels display the default settings. Default setting; Cooling Fan = Off, Motor Speed = Off, Top Teflon Roller = 32 o F, Nip Rollers = 32 o F, Bottom Teflon Roller = 32 o F and Sub Heaters = 32 o F. "Beeps" once for every one increment of change. WARNING At these temperatures there is a danger of severe burn if the rollers are touched during set up, operation or servicing. INFORMATION The unit of measurement can be set to display o F or o C. INFORMATION When an EMERGENCY STOP is engaged, all motion stops. The nip will not change from the operating setting. INFORMATION It is recommended that you press HOT ( H O T ) first, then adjust for desired temperature setting. INFORMATION "Beeps" once for every one increment of change. © GBC Pro - Tech December 1999 INFORMATION The Temperature control panel settings are not affected when an E-STOP has been pushed. INFORMATION Power to the motor is removed when the safety shield is not in the fully locked position. Page 1 - 9 Safety Explorer 107 Operation and Maintenance Manual WARNING Extreme caution should always be exercised when removing an unwind shaft, the grippers tabs can cut you! INFORMATION For 2-1/4 core film, turning the roll film in the same direction as the gripper tabs while sliding makes loading the film onto the unwind shaft easier. INFORMATION Refer to Figure 6.1.1 under Section 6 Applications for unwind direction for Poly-In and Poly-Out films WARNING Always use safe and proper lifting practices when lifting heavy objects. You can become seriously injured or crushed. INFORMATION The gripper tabs should point in the opposite direction of film rotation. INFORMATION Ensure the roll pins are on top. They should not be in the saddle! CAUTION Ensure the roll of laminate is loaded properly on the unwind shaft. Exposed adhesive should be facing away from the rollers. This will prevent hours of roll cleaning! Page 1 - 10 INFORMATION Use Chart 5.3.1 Film centering chart in Section 5 Operations for measurements. © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual INFORMATION If not exactly centered, lateral film adjustment can be made during the webbing process. WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP. You can be CRUSHED or BURNED! Safety INFORMATION When raising the main roller, the heat platen and the Top Teflon roller ( upper heat assembly ) moves as well. WARNING Keep hands and fingers away from the heating components and the nip of the rollers. You may be CRUSHED or BURNED! INFORMATION INFORMATION When lowering the main roller, the heat platen and the Top Teflon roller ( upper heat assembly ) moves as well. CAUTION Never leave the rollers in the down position without rolling. Prolonged contact in one area can form flat spots on the rollers. © GBC Pro - Tech December 1999 Lateral film adjustments can be made while the laminator is in operation. INFORMATION Quality of the output may be affected during a lateral film adjustment. Page 1 - 11 Safety Explorer 107 Operation and Maintenance Manual INFORMATION Excessive brake tension may cause the output to curl. Always use the minimum brake tension required to complete the task. WARNING At no time should the slitter guard be removed! Sharp blades can cut you! CAUTION Do not webb the laminator with inline slitters in the down position! The leader board can damage the blades. INFORMATION The large inner dials on the left and right cabinet doors will lower and raise both, the left and right, sliiters. Page 1 - 12 INFORMATION The center slitter can not be lowered without lowering the side slitters. INFORMATION The side slitters can not be raised without raising the center slitter. WARNING Caution should always be exercised when using the rear cut-off blade. Sharp blade can cut you! CAUTION Stop the laminator before using the rear cut-off blade. Moving material can damage the rear cut-off blade! © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual WARNING Keep hands and fingers away from the path of the rear cut-off blade. Sharp blade can cut you! Safety INFORMATION Locator latches on the pressure plate are not associated with an interlock switch. The laminator will operate without the pressure plate installed. WARNING Keep hands and fingers away from the bottom of the rear cut-off blade. Sharp blade can cut you! 1.5 Applications The following symbols are positioned at various points in Section 6 Applications. DANGER At no time should you attempt to over ride any of the safety latches on the laminator. WARNING Do not wear ties, loose fitting clothing 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. INFORMATION INFORMATION The laminator will operate only when all safety latches are in the fully latched position. © GBC Pro - Tech December 1999 Proceed to Webbing while waiting for the heaters to come up to temperature. Page 1 - 13 Safety Explorer 107 Operation and Maintenance Manual CAUTION Never leave the rollers in the down position without rolling. Prolonged contact in one area can form flat spots on the rollers. WARNING The following steps are performed while the laminator is HOT! Avoid contact with the heating components! INFORMATION Refer to Figure 6.1.1 under Section 6 Applications for unwind direction for Poly-In and Poly-Out films INFORMATION The gripper tabs should point in the opposite direction of film rotation. Page 1 - 14 WARNING Extreme caution should always be exercised working around the core gripper support, the grippers tabs can cut you! CAUTION Ensure the roll of laminate is loaded properly on the unwind shaft. Exposed adhesive should be facing away from the heated components. This will prevent hours of cleaning! INFORMATION For 2-1/4 core film, turning the roll film in the same direction as the gripper tabs while sliding makes loading the film onto the unwind shaft easier. WARNING Always use safe and proper lifting practices when lifting heavy objects. You can become seriously injured or crushed. © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual INFORMATION Ensure the roll pins are on top. They should not be in the saddle! Safety WARNING Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! INFORMATION Use Chart 5.3.1 Film centering chart in Section 5 Operations for measurements. DANGER At no time should you attempt to over ride any of the safety latches on the laminator. INFORMATION If not exactly centered, lateral film adjustment can be made during the webbing process. INFORMATION The laminator will operate only when all safety latches are in the fully latched position. WARNING INFORMATION The following steps are performed while the laminator is HOT! Avoid contact with the heating components! © GBC Pro - Tech December 1999 The threading card will guide the two films into the pull rollers. Page 1 - 15 Safety Explorer 107 Operation and Maintenance Manual INFORMATION Excessive brake tension may cause the output to curl. Always use the minimum brake tension required to complete the task. INFORMATION The laminator will operate only when all safety latches are in the fully latched position. CAUTION Never leave the rollers in the down position without rolling. Prolonged contact in one area can form flat spots on the rollers. WARNING The following steps are performed while the laminator is HOT! Avoid contact with the heating components! CAUTION Do not use an open blade to cut the web near the rollers. You can put cuts into the rollers! INFORMATION The laminator will operate only when all safety latches are in the fully latched position. WARNING INFORMATION The laminator must be heated for this method of webbing. Page 1 - 16 Keep hands and fingers away from the path of the rear cut-off blade. Sharp blade can cut you! © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Safety 1.6 Troubleshooting WARNING Caution should always be exercised when using the rear cut-off blade. Sharp blade can cut you! WARNING Caution should always be exercised when using the laminator with the safety shield raised. You can be seriously HURT or INJURED! WARNING Extreme caution should be exercised when gripping the film near the heating components. The following symbols are positioned at various points in Section 7 Troubleshooting. 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. INFORMATION For optimal temperature settings of various laminates, contact your supplier or sales representative. WARNING Caution should always be exercised when using the laminator with the safety shield raised. You can be seriously HURT or INJURED! © GBC Pro - Tech December 1999 Page 1 - 17 Safety Explorer 107 Operation and Maintenance Manual 1.7 Maintenance INFORMATION Locator latches on the pressure plate are not associated with an interlock switch. The laminator can operate without the pressure plate installed. The following symbols are positioned at various points in Section 8 Maintenance. WARNING INFORMATION The laminator will operate only when all safety latches are in the fully latched position. 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. INFORMATION INFORMATION Rollers only turn in reverse while depressing REVERSE . Improper maintenance, can result in poor output quality. INFORMATION Below is a recommended maintenance schedule. Before performing any of the steps listed, read through the procedures first. Please follow the instructions pertaining to the step you are performing. Page 1 - 18 © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual ELECTRICAL SHOCK Remove power from the laminator before servicing. You can be severely shocked, killed or cause a fire. CAUTION The following procedure is performed while the laminator is HOT! Use extreme caution! Safety CAUTION Harden adhesive deposits on the rollers can cause damage to the rollers. CAUTION Do NOT pick or pull heat activated adhesive off the rolls when they are cold. You can cause irreparable damage to the laminating rolls. WARNING INFORMATION Heating components are HOT! You can become severely burned ! The most efficient time to clean the rollers is after a lamination process is completed. CAUTION Never clean the rollers with sharp or pointed objects. You may put irreparable cuts into the rollers. © GBC Pro - Tech December 1999 INFORMATION The laminator will operate only when all safety latches are in the fully latched position. Page 1 - 19 Safety Explorer 107 Operation and Maintenance Manual INFORMATION If the rolls are heated, proceed to Removing adhesive build up.. WARNING Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! INFORMATION Rollers only turn in reverse while REVERSE depressing . INFORMATION The upper nip roller as well as the Teflon rollers are free spinning. ELECTRICAL SHOCK CAUTION Excessive pressure can destroy the silicone layer by pressing to hard or scrubbing too long in one spot. Remove power from the laminator before cleaning. You can be severely shocked, killed or cause a fire. ELECTRICAL SHOCK INFORMATION Locator latches on the pressure plate are not associated with an interlock switch. The laminator will operate without the pressure plate installed. Page 1 - 20 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. © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual 1.8 Label Explanations ! Posted at various locations on the Explorer 107 Laminator are important safety labels. Pay careful attention to these labels at all times! Figure 1.8.1 illustrates the location of each of these labels. ! MUCHO CUIDADO Riesgo de choque electrico No abra Adentro, no hay piezas reparables para el usuario. Mantenimiento solamente para personal calificado ! MUCHO CUIDADO Risque de secousse electrique. Ne pas ouvrir. Pas de pieces reparables par l'utilisateur. Entretien par personnel qualifie. ! WARNING Electrical shock hazard. Do not open. No user serviceable parts inside. Refer servicing to qualified service personnel. ! WAARSCHUWING Kans op elektrische schok. Niet openen Bevatgeen door gebruik te repareren onderdelen. Door bevoegd service personeel laten repareren ! ATTENZIONE Pericolo di scarica elettrica. Nessuna parte riparabile dall' utente. Chiamare un servizio di riparazioni qualificato. Safety ! CUIDADO ! ATTENTION NAVAJA FILOSA. LAME COUPANTE. Mantener manos y dedos a distancia. Tenir mains et doigts a l'ecant. ! CAUTION ! WARNUNG SHARP BLADE. SCHAREE KLINGE Keep hands and clothing away. Hande und finger ferhalten. ( 1 ) SHARP BLADE: Sharp blade comes down. Keeps hands and fingers away. WARNUNG SpannungsfUhren de Teile. Nicht offnen. Enthalt keine vom Enduerbraucher zu wartende Teile. Fur service bitte an qualifiziertes Service-Personal wenden. ( 3 ) ELECTRICAL SHOCK: Electrical shock hazard. Electrical voltage behind panel. ! CUIDADO RODILLOS CALIENTES. PUNTO DE PINCHAMIENTO. Mantener manos y ropa a distancia. ! ATTENTION ROULEAUX CHAUDS. POINT DE PINCEMENT. Tenir mains et vetements a l'ecant. ! CAUTION HOT ROLLS. ! WARNUNG HEISSE ROLLEN PINCH POINT. Keep hands and clothing away. Klemmgefahr zwischen Rollen Hande und Kleidung ferhalten ( 2 ) Roller Pinch Point: Keep hands and fingers away. You may be crushed and/ or burned. © GBC Pro - Tech December 1999 Page 1 - 21 Safety Explorer 107 Operation and Maintenance Manual Figure 1.8.1 Label locations ! CUIDADO ! ATTENTION ! NAVAJA FILOSA. L A M E C O U P A N T E . Mantener manos y dedos a distancia. Tenir mains et doigts a l'ecant. CAUTION ! WARNUNG SHARP BLADE. SCHAREE KLINGE Keep hands and clothing away. Hande und finger ferhalten. ! MUCHO CUIDADO Riesgo de choque electrico No abra Adentro, no hay piezas reparables para el usuario. Mantenimiento solamente para personal calificado ( center, below the rear cut-off ) ! MUCHO CUIDADO ! Risque de secousse electrique. Ne pas ouvrir. Pas de pieces reparables par l'utilisateur. Entretien par personnel qualifie. WARNING Electrical shock hazard. Do not open. No user serviceable parts inside. Refer servicing to qualified service personnel. ! WAARSCHUWING Kans op elektrische schok. Niet openen Bevatgeen door gebruik te repareren onderdelen. Door bevoegd service personeel laten repareren ! ATTENZIONE Pericolo di scarica elettrica. Nessuna parte riparabile dall' utente. Chiamare un servizio di riparazioni qualificato. ! WARNUNG SpannungsfUhren de Teile. Nicht offnen. Enthalt keine vom Enduerbraucher zu wartende Teile. Fur service bitte an qualifiziertes Service-Personal wenden. ( right cabinet door ) ! CUIDADO ! RODILLOS CALIENTES. PUNTO DE PINCHAMIENTO. Mantener manos y ropa a distancia. ATTENTION ! CAUTION ! WARNUNG HEISSE ROLLEN HOT ROLLS. ROULEAUX CHAUDS. POINT DE PINCEMENT. Tenir mains et vetements a l'ecant. PINCH POINT. Klemmgefahr zwischen Rollen Hande und Kleidung ferhalten Keep hands and clothing away. ( left side frame ) ! ! MUCHO CUIDADO Riesgo de choque electrico No abra Adentro, no hay piezas reparables para el usuario. Mantenimiento solamente para personal calificado ! MUCHO CUIDADO Risque de secousse electrique. Ne pas ouvrir. Pas de pieces reparables par l'utilisateur. Entretien par personnel qualifie. ! WARNING Electrical shock hazard. Do not open. No user serviceable parts inside. Refer servicing to qualified service personnel. ! WAARSCHUWING Kans op elektrische schok. Niet openen Bevatgeen door gebruik te repareren onderdelen. Door bevoegd service personeel laten repareren ! ATTENZIONE Pericolo di scarica elettrica. Nessuna parte riparabile dall' utente. Chiamare un servizio di riparazioni qualificato. ! CUIDADO RODILLOS CALIENTES. PUNTO DE PINCHAMIENTO. Mantener manos y ropa a distancia. WARNUNG ! ATTENTION ROULEAUX CHAUDS. POINT DE PINCEMENT. Tenir mains et vetements a l'ecant. ! CAUTION HOT ROLLS. ! WARNUNG HEISSE ROLLEN PINCH POINT. Keep hands and clothing away. Klemmgefahr zwischen Rollen Hande und Kleidung ferhalten SpannungsfUhren de Teile. Nicht offnen. Enthalt keine vom Enduerbraucher zu wartende Teile. Fur service bitte an qualifiziertes Service-Personal wenden. ( right side frame ) ( left cabinet door ) ! MUCHO CUIDADO Riesgo de choque electrico No abra Adentro, no hay piezas reparables para el usuario. Mantenimiento solamente para personal calificado ! MUCHO CUIDADO Risque de secousse electrique. Ne pas ouvrir. Pas de pieces reparables par l'utilisateur. Entretien par personnel qualifie. ! WARNING Electrical shock hazard. Do not open. No user serviceable parts inside. Refer servicing to qualified service personnel. ! WAARSCHUWING Kans op elektrische schok. Niet openen Bevatgeen door gebruik te repareren onderdelen. Door bevoegd service personeel laten repareren ! ATTENZIONE Pericolo di scarica elettrica. Nessuna parte riparabile dall' utente. Chiamare un servizio di riparazioni qualificato. ! WARNUNG SpannungsfUhren de Teile. Nicht offnen. Enthalt keine vom Enduerbraucher zu wartende Teile. Fur service bitte an qualifiziertes Service-Personal wenden. ( center, below the feed table ) Page 1 - 22 © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Section 2 Warranty GBC Pro-Tech warrants the equipment sold is free from defects in material and workmanship for a period of one ( 1 ) year parts and 90 days labor from the date of installation. This warranty is the only warranty made by GBC Pro-Tech and connot be modified or amended. GBC Pro-Tech’s sole and exclusive liability and the customer’s sole and exclusive remedy under this warranty shall be, at GBC Pro-Tech’s option, to repair or replace any such defective part or product. These remedies are only available if GBC Pro-Tech’s examination of the product discloses to GBC Pro-Tech’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. 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 one year period from the date of delivery. CAUTION Unauthorized customer alterations will void this warranty. © GBC Pro - Tech December 1999 Warranty THE WARRANTY MADE HEREIN IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. GBC PRO-TECH WILL NOT BE LIABLE FOR PROPERTY DAMAGE OR PERSONAL INJURY ( UNLESS PRIMARILY CAUSED BY ITS NEGLIGENCE ), LOSS OF PROFIT OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE THE EQUIPMENT. 2.2 Exclusions to the Warranty This warranty specifically does not cover; 1. 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. Page 2 - 1 Warranty Explorer 107 Operation and Maintenance Manual Qualified • Any engineer that has experience with electrical and mechanical design of lamination equipment.The engineers 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 GBC Pro-Tech standards to fulfill that job. This person will have completed and passed the full service training course from GBC Pro-Tech. • Any GBC Technician, GBC Specialist, and / or GBC Pro-Tech Technician that has been through the GBC Pro-Tech service training course. Page 2 - 2 © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Specifications Section 3: Specifications Specifications provide all of the technical data for the Explorer 107 Laminator. Section 3.1 General Description : A high speed laminator for the graphic arts professional as well as the manufacturer who produces promotional pieces in-house. A laminator with the capability to run even heavy gauge films at higher speeds without scratching. Features : • Tri-Plex heating • Independent control of each heating surface • Top and bottom electronic tension controls • Fan cooled component cabinets • Slip clutch tension for the pull rollers • Easy to use computer interface controls • LCD temperature displays for each heating surface Applications : • Encapsulation - Promotional materials, posters, counter cards, POP displays, calendars, instructional displays, phone/ debit cards, blueprints, menus, placemats, maps, flipcharts, etc. Section 3.2 Consumables Film Types : © GBC Pro - Tech November 1999 • Poly-in films • Poly-out films Page 3A - 1 Specifications Explorer 107 Operation and Maintenance Manual Film Diameters : • Up to a 20 in. outside roll diameter ( 51 cm ) Core Size : • 2-1/4 in. adapters included ( 57 mm ) • 3 in. core standard ( 76 mm ) Film Widths : • 42 in. Thermal films ( 107 cm ) Paper Widths : • 42 in. maximum paper width ( 107 cm ) Section 3.3 Function Speed : • 0 - 35 fpm ( 0 - 10.7 m / min ) Motor : • 2-1/4 horse power drive motor • Bi-directional D.C. motor Heating Capabilities : • 32oF - 290oF ( 0oC - 143oC ) Controls : • Operations control panel • Temperature control panel Roll Design : • High release silicone nip rollers • High release silicone pull rollers • Teflon coated pre-heat rollers Section 3.4 Electrical United States : Page 3A - 2 • 230 - 240 VAC, 50/60 Hz, single phase, 50 amps. © GBC Pro - Tech November 1999 Explorer 107 Operation and Maintenance Manual Specifications B.T.U. output : • 23549 B.T.U. / hour Heater Wattages : • Heat platen = 872 W • Teflon rollers heater = 1040 W ( 55.4 ohms ) • Nip roller heater = 1553 W ( 37.1 ohms ) Amperage Draw : • Drive motor = 3.3 amps • Fan motor = 0.5 amps • Motors and heaters = 13 amps D/C Voltage used : • 36 vdc motor voltage • 24 vdc fan motor A/C Voltage used: • 230 vac ( minimum ) Section 3.5 Dimensions Weight : • Crated : 600 lbs. ( 272 kg. ) • Uncrated : 470 lbs. ( 213 kg. ) Dimensions : • Crated : 90 in. (H) x 72 in. (W) x 46 in. (D) ( 229 cm (H) x 183 cm (W) x 107 cm (D) • Uncrated : 52 in. (H) x 60 in. (W) x 30 in. (D) ( 132 cm (H) x 152 cm (W) x 76 cm (D) Refer to Figure 3.1.1 Nip Height : © GBC Pro - Tech November 1999 35.75 in. ( 91 cm ) Page 3A - 3 Specifications Explorer 107 Operation and Maintenance Manual Figure 3.1.1 Dimensions 27.125 in. ( 69 cm ) 3 in. ( 8 cm ) RE TU RA MPE TE R PE UP AT HE L RO NT CO R WE LO AT HE ER LL RO ER LL RO HOT D COL S. MEA HOT S ER AT B HE SU D COL S. MEA S ER LL RO NIP HOT D COL S. MEA HOT D COL S. MEA 6 in. ( 15 cm ) G IN OL CO N FA OF F ON E RS VE RE OF F ON MO TO R CO NT RO L R WE LO N IO NS TE R PE UP ER LL RO N IO NS TE ER LL RO 45.5 in. ( 116 cm ) 58 in. ( 147 cm ) Page 3A - 4 © GBC Pro - Tech November 1999 Explorer 107 Operation and Maintenance Manual Section 4 Installation GBC Pro-Tech is committed to a program of ongoing product improvement. As a result, we are providing these instructions so that you can insure that your new Explorer 107 Laminator is properly and securely unpacked, moved, and installed. Before an Explorer 107 Laminator can be installed, there are a few requirements that must be met. Make certain that each of the requirements listed in the following pre-installation checklist are met before beginning installation. Installation Is the environment appropriate for the laminator? The laminator requires a clean, dust and vapor free environment to operate properly. It must not be located where there is air blowing directly on the machine. Have you contacted a certified electrician to install a receptacle for the laminator and ensure that adequate power is being supplied, having the appropriate capacity, over current protection and safety lockouts are available. WARNING CAUTION Failure to follow the pre-installation check list can result in damage to the laminator. The operating environment must be free of dust, flammable liquids and vapors. You can be injured by inhaling chemical vapors. 4.1 Pre-installation WARNING Are doorways and hallways wide eneough for the laminator to be moved to the installation site? Vapor build up or stored flammable liquids can cause a fire. Excessive dust can damage the laminator. Is there ample room for the laminator? CAUTION A work area must be established that allows for unrestricted movement around the laminator and provides space for efficient material flow. Figure 4.1.3 illustrates a typical machine area layout. © GBC Pro - Tech December 1999 Do not locate the laminator where air is blowing directly on the machine. The air flow can cool the rollers unevenly and result in poor quality output. Page 4 - 1 Installation Explorer 107 Operation and Maintenance Manual The laminator requires 220 to 240 vac, 50/60 Hz, 30 amps, Single Phase. Figure 4.1.1 Plug WARNING The Explorer 107 Laminator is a large and heavy piece of equipment. It is necessary to employ LICENSED RIGGERS ONLY to move the laminator. The laminator is not designed to be tipped up or sideways in any way. Such action disturbs the exact alignment of the rolling parts of the machine and requires extensive realignment. You can be crushed or seriously injured. Figure 4.1.2 Suggested receptacle G NEMA 6 - 50P Page 4 - 2 © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Figure 4.1.3 Installation Suggested Floor Layout 4' x 6' ( 1.22 m x 2m ) Work table on wheels 8.75 ft. ( 2.67 m ) Table height 35-3/4" ( .94 - .95m ) 58 " ( 147 cm ) 20 ft. ( 6.1 m ) 30 in. ( 77 cm ) 8.75 ft. ( 2.67m ) 3' ( 1 m) 4' x 6' ( 1.22 m x 2m ) Work table on wheels Table height 35-3/4" ( .94 - .95m ) 13' ( 4 m) © GBC Pro - Tech December 1999 Page 4 - 3 Installation Explorer 107 Operation and Maintenance Manual 4.2 Unpacking With regards to your shipping methods, use one of the following procedure described to safely and properly unwrap / uncrate your laminator. INFORMATION A L L S H I P M E N T S A R E E X - W O R K S . At our dock, title passes to the buyer. Please review your insurance coverage prior to shipment, as you are responsible for all subsequent freight charges and risks. INFORMATION Before signing the Bill of Lading, you should be sure to inspect the crate and / or pallet for signs of damage or missing items; if applicable, make note of this on the Bill of Lading. 4.3 Shrink Wrapped a) Inspect the machine for any obvious shipping damages upon receipt. b) Carefully unwrap the shrink wrap from around the laminator. CAUTION INFORMATION Depending on the destination and customer preference, the Explorer 107 may be shipped in various ways. The laminator may arrive shrink wrapped or in a plywood crate on a skid. Please follow the unpacking procedure that pertains to your method of shipment. Do not use a knife or other sharp object to remove the shrink wrap from around the laminator. You can cause irreparable damage to the rollers. c) With another person, carefully wheel your Explorer 107 Laminator to the installation site. WARNING WARNING The unpacking process requires at least two people. You can be severely injured, crushed or cause damage to the laminator. Page 4 - 4 Do not attempt to move the laminator across anything other than a flat level surface without trained and qualified riggers. You can be crushed or seriously injured. © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Installation Figure 4.4.1 4.4 Crated Disassembling of the crate Tools required • # 2 Phillips head screwdriver • Large adjustable wrench • Crow bar • A second person 1 5 TEMP ERATU RE 3 CONT ROL LOWE R HEAT ROLLE R UPPER HEAT ROLLE R SUB HEATE RS NIP ROLLE RS HOT COL MEA D S. HOT COLD MEA S. HOT COLD MEA S. HOT COLD MEA S. To uncrate the laminator OFF COOL ING FAN ON OFF REVE RSE ON MOTO 4 R UPPE R CONT ROL TENS ION ROLLE LOWE R R TENS ION ROLLE R 2 a) Remove the top of the crate and then the sides in the order shown in Figure 4.4.1 CAUTION Do not allow the top to fall into the crate. It can damage the laminator. Removing the shrink wrap INFORMATION Do not put packing screws on the floor. They can cause problems when trying to roll the laminator into position or you can become injured if stepped on. a) Gently unwrap the shrink wrap from around the laminator. CAUTION CAUTION A second person must support the side labeled 5 in Figure 4.4.1 It can fall and damage the laminator or cause harm to you and others. © GBC Pro - Tech December 1999 Do not use a knife or other sharp object to remove the shrink wrap from around the laminator. You can cause irreparable damage to the rollers. Page 4 - 5 Installation Explorer 107 Operation and Maintenance Manual Moving the laminator b) Remove any plastic strapping and/or packing paper taped to the machine. a) Have the laminator lifted off the skid and placed on the floor by licensed riggers. CAUTION WARNING Do not attempt to move the laminator across anything other than a flat level surface without trained and qualified riggers. You can be crushed or seriously injured. Do not use a knife or other sharp object to remove the shrink wrap from around the laminator. You can cause irreparable damage to the rollers. c) Move all packing materials to a safe distance from the laminator and dispose of properly. WARNING The Explorer 107 Laminator is a large and heavy piece of equipment. It is necessary to employ LICENSED RIGGERS ONLY to move the laminator. The laminator is not designed to be tipped up or sideways in any way. Such action disturbs the exact alignment of the rolling parts of the machine and requires extensive realignment. You can be crushed or seriously injured. INFORMATION GBC Pro-Tech's warranty does not cover malfunction of the equipment due to mishandling and / or tipping. GBC ProTech bears no responsibility for personal injury or damage due to moving the laminator improperly. Page 4 - 6 d) Use two people to carefully roll the laminator to the desired location. INFORMATION About recycling: The crate components can be reused for shipping the laminator again or can be disassembled and the wood and screws recycled. The shrink wrap is not recyclable, so it must be discarded. e) Use Figure 4.1.1 for the suggested floor layout. © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual b) Press POWER to “ I ” . E ME R GE P ! The safety check will ensure that all safety devices and interlock switches are functioning properly. ST O 4.5 Safety check Installation NCY Power ROLL LAMINATOR Model : Input voltage : Input current : Power cunsuption : Temperature range: Current rating of circuit breaker : Max laminating width : Serial No : ############# Made in Korea / Fabrique En Coree Explorer 107 220V~ / 60Hz 27A 5,800 W C 160 Upoto 30 A 1075 mm 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. c) Rotate SPEED to “ 5 ”. MOTOR SPEED WARNING 6 2 REVERSE 9 1 10 If a safety feature is not functioning properly, contact your local service representative immediately 8 3 7 4 5 ON c) Press OFF . ON Feed table MOTOR SPEED 6 2 1 10 © GBC Pro - Tech December 1999 REVERSE 9 a) Ensure an E-Stop is not depressed. If depressed, unlatch the E-Stop. 8 3 7 4 5 ON OFF Page 4 - 7 Installation Explorer 107 Operation and Maintenance Manual d) Under the right side of the feed table, slide the right safety latch to the left. Bottom rollers stop. g) Release the left safety latch. The bottom rollers begin turning. Bottom view of feed table Front safety shield Right safety latch a) Slide the right safety latch of the front safety shield to the left. The bottom rollers stop turning. e) Slide the right safety latch to the right into the interlock, the bttom rollers begin turning. f) Pull the left safety latch to the right. The bottom rollers stop turning Bottom view of feed table Right safety latch Left safety latch Page 4 - 8 b) Slide the right safety latch to the right into the interlock, the bttom rollers begin turning. © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual c) Pull the left safety latch to the right. The bottom rollers stop turning Installation b) Rotate the E-STOP clockwise to reset. Rotate c) Press . Bottom rollers begin turning. ON Left safety latch MOTOR SPEED REVERSE 3 2 8 10 1 9 d) Release the left safety latch. The bottom rollers begin turning. 6 7 4 5 ON OFF Emergency stops a) Press the front emergency stop ( E-STOP ) down. The bottom rollers stop turning. d) Press the rear E-STOP down. The bottom rollers stop turning. Push down Push down © GBC Pro - Tech December 1999 Page 4 - 9 Installation Explorer 107 Operation and Maintenance Manual e) Rotate the E-STOP clockwise to reset. Operations Control panel Rotate INFORMATION When any command is pressed ( with the exception of Reverse ) on the Operations Control Panel, a "beep" will sound. If the command is held down, the panel will continuously "beep". a) Press ON under COOLING FAN. 4.6 Control panel check COOLING FAN ON INFORMATION OFF When the laminator is first turned on, the control panels display the default settings. - Cooling fans turn on. Default setting; Cooling Fan = Off, Motor Speed = Off, Top Teflon Roller = 32 o F, Nip Rollers = 32 o F, Bottom Teflon Roller = 32 o F and Sub Heaters = 32 o F. b) Press OFF under COOLING FAN. COOLING FAN The control panels should be checked to ensure all controls function properly. For a detailed explanation of the control panels, refer to Section 5 Operations. Page 4 - 10 ON OFF - Cooling fans turn off. © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual c) Rotate the motor speed adjust clockwise under MOTOR SPEED. Installation e) Press and hold R E V E R S E SPEED then release. MOTOR SPEED MOTOR SPEED 6 5 REVERSE 4 3 2 2 8 REVERSE 9 9 1 ON OFF - Motor speed indicator illuminates accordingly. 10 10 1 6 7 8 3 7 4 5 under MOTOR ON OFF - Bottom rollers turn in reverse only when pressed. d) Rotate the motor speed adjust counter clockwise under MOTOR SPEED. INFORMATION Reverse speed can be controlled by Speed Adjust. MOTOR SPEED 6 REVERSE 2 8 3 7 4 5 10 1 9 ON OFF f) Press under MOTOR SPEED. ON MOTOR SPEED - Motor speed indicator de-illuminates accordingly. 6 REVERSE 2 8 3 7 4 5 10 1 9 ON OFF INFORMATION Leave the motor speed adjust at 5 to continue with the function check. - Bottom rollers turn in a forward direction. © GBC Pro - Tech December 1999 Page 4 - 11 Installation Explorer 107 Operation and Maintenance Manual g) Press under MOTOR SPEED. OFF - The second person is turning the lower film tension idler from the rear position of the laminator and can feel an increase in resistance while turning. MOTOR SPEED 6 INFORMATION 8 3 7 4 5 2 REVERSE 9 1 10 ON OFF Lower film tension idler: gray rubber covered idler located below the lower cooling fan assembly. i) One person slowly rotates the upper film tension adjust fully clockwise. - Bottom rollers stop turning. INFORMATION 6 4 3 5 2 2 10 1 10 0 1 9 9 0 6 8 8 LOWER FILM TENSION 5 7 3 4 7 A second person is needed to assist with the idler tension checks. UPPER FILM TENSION h) One person slowly rotates the lower film tension adjust fully clockwise. - The second person is turning the upperr film tension idler from the rear position of the laminator and can feel an increase in resistance while turning. 6 2 1 2 1 9 INFORMATION 10 10 0 6 8 9 Page 4 - 12 5 7 8 LOWER FILM TENSION 3 4 0 5 7 3 4 UPPER FILM TENSION Upper film tension idler: gray rubber covered idler located above the upper cooling fan assembly. © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Temperature control panel Installation - Temperature display shows actual temperature of the related component, ( room temperature ) for two seconds. READY INFORMATION 78 HOT When MEAS , or C O L D is pressed once, you will hear one "beep", when pressed and held, you will only hear one "beep". Perform each of the following steps for each heater controller. ( Top Teflon Roller, Nip Roller, Bottom Teflon Roller and Sub Heaters ) o F COLD INFORMATION INFORMATION When pressing or , "Beeps" once for every one increment of change. TEMPERATURE Number indicated is an approximate of room temperature. Your display may differ. b) Press HOT . HOT a) Press MEAS . MEAS COLD HOT MEAS COLD © GBC Pro - Tech December 1999 - Top Teflon Roller indicates 212 oF ( 100 oC ), Nip Roller indicates 176 oF ( 80 oC ), Bottom Teflon Roller indicates 212 oF ( 100 oC ) and Sub Heaters indicates 248 oF ( 120 oC ) in the temperature displays and COLD changes to HOT. Page 4 - 13 Installation Explorer 107 Operation and Maintenance Manual d) Press five times. TEMPERATURE CONTROL TOP TEFLON ROLLER NIP ROLLER READY TEMPERATURE READY TEMPERATURE 212 o 176 F HOT o HOT COLD COLD MEAS BOTTOM TEFLON ROLLER SUB HEATERS TEMPERATURE 212 o READY TEMPERATURE 248 F HOT o F HOT 100 o C / 212 oF 120 o C / 248 HOT MEAS MEAS COLD 80 o C / 176 o F F HOT READY HOT F HOT 100 o C / 212 MEAS o oF HOT COLD MEAS COLD - The temperature display will decrease in single increments for each press. INFORMATION c) Press five times. When pressing or , "Beeps" once for every one increment of change. HOT MEAS COLD - The temperature display will increase in single increments for each press. e) Press COLD . HOT MEAS COLD INFORMATION When pressing or , "Beeps" once for every one increment of change. Page 4 - 14 - All temperature displays will revert to 32 oF ( 0 oC ) and HOT reverts to COLD. © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Installation 4.7 Main roller handle INFORMATION WARNING The handle will stop after making initial contact, then can be turned more to apply pressure and will lock into position. Keep hands and fingers clear of the laminator roller nip when changing GAP. You can be CRUSHED or BURNED! - The upper main roller lowers to make contact with the bottom main roller. CAUTION Never leave the rollers in the down position without rolling. Prolonged contact in one area can form flat spots on the rollers. b) Turn the main roller handle fully counter clockwise. a) Turn the main roller handle fully clockwise. TE LO WE R HE AT MP RO ER AT UR E CO LLE NT R UP PE R HO CO SU B HE AT ER T LD ME AS HO S CO NIP RO HO CO TE LO WE R HE AT MP RO ER AT UR E CO LLE NT R UP PE R HO CO HE AT ER T LD ME AS HO S CO RO HO RO L RO LLE R . . T LDME AS . L RO LLE R . NIP CO HE AT AS RS AS HO B RO T LD ME LLE T LDME CO SU HE AT . T LD ME AS . LLE RS T LDME AS . HO CO T LDME AS . Main roller handle Main roller handle © GBC Pro - Tech December 1999 - The upper main roller raises as it separates from the bottom main roller. Page 4 - 15 Installation Explorer 107 Operation and Maintenance Manual 4.8 Pull roller handle INFORMATION WARNING The handle will stop after making initial contact, then can be turned more to apply pressure and will lock into position. Keep hands and fingers clear of the laminator roller nip when changing GAP. You can be CRUSHED! - The upper pull roller lowers to make contact with the bottom pull roller. CAUTION Never leave the rollers in the down position without rolling. Prolonged contact in one area can form flat spots on the rollers. b) Turn the pull roller handle fully counter clockwise. Pull roller handle a) Turn the pull roller handle fully clockwise. TE LO WE R HE AT MP RO ER AT UR E CO LLE NT R UP PE R HO CO SU Pull roller handle B HE AT ER T LD ME HO CO NIP RO HO CO TE LO WE R HE AT MP RO ER AT UR E CO LLE NT R UP PE R HO SU B HE AT ER T LD ME AS HO CO RO CO RO RO L RO LLE R T LD ME AS . LLE RS T LDME AS . HO T LDME AS . L RO LLE R . S NIP HO HE AT HE AT . S CO CO AS T LD ME AS . LLE RS T LDME AS . HO CO T LDME AS . - The upper pull roller raises as it separates from the bottom pull roller. Page 4 - 16 © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual 4.9 Lateral film adjustment Installation b) Rotate the small outer dial clockwise. Outer dial Perform each of the following steps for the upper and lower unwind shaftswhile standing to the left of the front operating position. Illustrations are for the upper unwind. The lower unwind is identical to the upper unwind withthe excemption of the saddle for the lateral film adjustment assembly. For a detailed explanation of the lateral film adjustments, refer to Section 5.4 Lateral film adjustment. - The unwind shaft moves towards the right of the laminator. c) Rotate the small outer dial counterclockwise. a) Be sure the large inner dial is turned fully counterclockwise. Outer dial Inner dial - The unwind shaft moves towards the left of the laminator. © GBC Pro - Tech December 1999 Page 4 - 17 Installation Explorer 107 Operation and Maintenance Manual 4.10 Film brake adjustment Film brake adjustment Perform each of the following steps for the upper and lower unwind shaftswhile standing to the right of the front operating position. Illustrations are for the upper unwind. The lower unwind is identical to the upper unwind withthe excemption of the saddle for the film brake adjustment assembly. - As you turn the film brake adjustment dial, you feel an increase in resistance while turning the unwind shaft. For a detailed explanation of the film brake adjustment, refer to Section 5.5 Film brake adjustment. b) Rotate the unwind shaft while turning the film brake adjustment dial counter clockwise. WARNING Film brake adjustment Extreme caution should always be exercised working around the core gripper support, the gripper tabs can cut you! a) Use one hand to rotate the unwind shaft while the other hand is turning the film brake adjustment dial clockwisewith the other hand. - As you turn the film brake adjustment dial, you feel a decrease in resistance while turning the unwind shaft. Page 4 - 18 © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Installation a) Rotate the large inner dial clockwise. 4.11 Inline slitters Raise and Lower Dial WARNING At no time should the slitter guard be removed! Sharp blades can cut you! For a detailed explanation of the inline slitters, refer to Section 5.6 Using inline slitters. - The left and right slitters are lowered into the engaged position. INFORMATION Left side slitter controls The large inner dials on the left and right cabinet doors will lower and raise the slitters. Left side slitter control dials b) Rotate the large inner dial counterclockwise. F OF N FA ING OL CO ON RE VE RS E F OF ON R TO MO L RO NT CO RO RO LO WE R TE NS LL ERUP PE R TE NS LL ER ION Raise and Lower Dial ION - The left and right slitters are raised. © GBC Pro - Tech December 1999 Page 4 - 19 Installation Explorer 107 Operation and Maintenance Manual c) Rotate the small outter dial clockwise. - The left slitter moves to the left side of the laminator as you rotate. Left adjust dial Left side slitter - The left slitter moves to the right side of the laminator as you rotate. Right side slitter controls WARNING At no time should the slitter guard be removed! Sharp blades can cut you! Left side slitter Right side slitter control dials c) Rotate the small outter dial counterclockwise. TE MP LOW ER ER HEA AT UR T ROL E LER CO NT RO UPP ER L HEA T ROL LER HOT CO SUB LDMEA S. HEA TER S HOT CO NIP LDMEA S. ROL LER S HOT CO LDMEA S. HOT CO LDMEA S. Left adjust dial Page 4 - 20 © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual a) Rotate the large inner dial counterclockwise. Installation c) Rotate the small outter dial clockwise. Raise and Lower Dial Right adjust dial - The left and right slitters are lowered into the engaged position. INFORMATION - The right slitter moves to the right side of the laminator as you rotate. Right side slitter The large inner dials on the left and right cabinet doors will lower and raise the slitters. b) Rotate the large inner dial clockwise. Raise and Lower Dial - The left and right slitters are raised. © GBC Pro - Tech December 1999 c) Rotate the small outter dial counter clockwise. Right adjust dial Page 4 - 21 Installation Explorer 107 Operation and Maintenance Manual - The right slitter moves to the left side of the laminator as you rotate. INFORMATION The center slitter can not be lowered without lowering the side slitters. Right side slitter a) Rotate the large inner dial clockwise on the left side slitter controls to lower the side slitters. Raise and lower dial Center slitter lever WARNING - The left and right side slitters lower into the engaged position. At no time should the slitter guard be removed! Sharp blades can cut you! b) Push the center slitter lever towards the front of the laminator. Center slitter Center slitter lever Page 4 - 22 © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual ! OP E ME b) Rotate the large inner dial counter clockwise on the right or left side slitter controls to raise all the slitters. a) Slide the rear cut-off blade to one side of the laminator. R G ST - The center slitter is lower into the engaged position. Installation E NCY ROLL LAMINATOR - All three slitters are raised. Model : Input voltage : Input current : Power cunsuption : Temperature range: Current rating of circuit breaker : Max laminating width : Serial No : ############# Made in Korea / Fabrique En Coree Explorer 107 220V~ / 60Hz 27A 5,800 W Up too C 160 30 A 1075 mm Rear cut-off blade 4.12 Rear cut-off blade WARNING Caution should always be exercised when using the rear cut-off blade. Sharp objects can cut you! - The rear cut-off blade moves smoothly from one side to the other side. b) Press down on the blade engage lever. Blade engage lever WARNING Keep hands and fingers away from the path of the rear cut-off blade. Sharp objects can cut you! © GBC Pro - Tech December 1999 - The blade slides down easily as the tip of the blade is exposed. Page 4 - 23 Installation Explorer 107 Operation and Maintenance Manual This page intentionally left blank. Page 4 - 24 © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Section 5 Operations Operations 5.1.1 Operations Control Panel 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. INFORMATION When any command is pressed ( with the exception of Reverse ) on the Operations Control Panel, a "beep" will sound. If the command is held down, the panel will continuously "beep". This section discusses Emergency, Set up and features of the Control panels. ON ( 1 ) Cooling Fan On : When pressed, starts the cooling fans. Cooling fans are not motor circuitry dependent. 5.1 Control Panels COOLING FAN ON The control panels of the Explorer 107 Laminator are located at the front operating position of the machine. To the left of the front operating position is the Operations Control Panel. This panel enables the operator to control motor direction, motor speed, cooling fans, Lower idler tension and Upper idler tension. To the right of the front operating position is the Temperature Control Panel. This panel enables the operator to control the temperature settings for the Top Teflon roller, Nip rollers, Bottom Teflon roller and the Sub heaters. © GBC Pro - Tech December 1999 ( 2 ) Cooling Fan Off stops the cooling fans. OFF : When pressed OFF COOLING FAN ON OFF Page 5 - 1 Operations Explorer 107 Operation and Maintenance Manual ( 3 ) Motor Speed Adjust: When rotated fully clockwise, increases the motor speed from 3.5 - 35 ft./ min.. Rotated fully counterclockwise dcreases the motor speed from 35 - 3.5 ft./ min.. ( 5 ) Motor Speed Reverse R E V E R S E : When pressed and held, applies reverse motor power to the laminator. Power is removed when released. MOTOR SPEED MOTOR SPEED 6 4 5 7 2 REVERSE 9 REVERSE 1 10 2 8 3 8 7 3 6 4 5 9 ON OFF 1 10 ON OFF INFORMATION Reverse speed can be controlled by Speed Adjust. INFORMATION 1 increment on the Motor Speed Adjust is equal to approximately 3.5 ft./ min. ( 1.1 m/ min. ). ON ( 6 ) Motor Speed On : When pressed, applies forward motor power to the laminator. ( 4 ) Motor Speed Indicator: Illuminate from left to right when the speed is increased and de-illuminates when speed is decreased. MOTOR SPEED REVERSE 2 8 3 MOTOR SPEED 6 7 4 5 1 ON OFF REVERSE 2 8 3 10 7 4 9 5 6 10 1 9 ON Page 5 - 2 OFF © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual OFF ( 7 ) Motor Speed Off : When pressed removes forward motor power to the laminator. Operations ( 9 ) Upper Film Tension Adjust: Rotated clockwise, increases tension on the upper film tension idler. Rotated counter clockwise decreases tension on the upper film tension idler. MOTOR SPEED 6 8 9 4 10 2 2 10 1 0 6 9 9 LOWER FILM TENSION 5 8 8 1 1 6 7 OFF 5 7 10 ON 3 4 3 2 REVERSE 0 3 7 4 5 UPPER FILM TENSION ( 8 ) Lower Film Tension Adjust: Rotated clockwise, increases tension on the lower film tension idler. Rotated counter clockwise decreases tension on the lower film tension idler. INFORMATION Always use the minimum film tension necessary to complete the task. 6 4 2 2 8 1 9 9 LOWER FILM TENSION 10 10 0 1 6 7 8 0 5 3 5 7 3 4 UPPER FILM TENSION Refer to Figure 5.1.1 for a complete illustration of the Operations Control Panel. INFORMATION Always use the minimum film tension necessary to complete the task. © GBC Pro - Tech December 1999 Page 5 - 3 Operations Explorer 107 Operation and Maintenance Manual Figure 5.1.1 Operations Control Panel 1 2 COOLING FAN ON OFF 4 MOTOR SPEED 5 6 7 4 5 3 8 6 REVERSE 9 2 10 1 3 ON OFF 7 6 2 0 10 0 1 2 9 9 1 6 8 10 Page 5 - 4 5 7 9 LOWER FILM TENSION 3 4 8 8 5 7 3 4 UPPER FILM TENSION © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual 5.1.2 Temperature Control Panel Operations ( b ) Temperature Display: the number 32 is displayed as the default setting. This display setting will change when an alternate value is inputted. b INFORMATION READY When the laminator is first turned on, the control panels display the default settings. TEMPERATURE 32 o F COLD Default setting; Cooling Fan = Off, Motor Speed = Off, Top Teflon Roller = 32 o F, Nip Rollers = 32 o F, Bottom Teflon Roller = 32 o F and Sub Heaters = 32 o F. ( c ) Unit of Measurement Display: Indicates the current unit of measurement. ( 1 ) Temperature control displays: ( Top Teflon Roller, Nip Roller, Bottom Teflon Roller and Sub Heaters ) c READY ( a ) Ready Indicator: Flashes when the actual temperaure exceeds the +/- 10 degrees tolerance. Once the actual temperature falls within the +/- 10 degree tolerance, it changes to solid. TEMPERATURE 32 o F COLD a READY TEMPERATURE 32 o F COLD © GBC Pro - Tech December 1999 Page 5 - 5 Operations Explorer 107 Operation and Maintenance Manual ( d ) Cold Indicator: Is diplayed when C O L D is pressed. If the set point temperature has been increased using , COLD will still be displayed although heat is being supplied. READY ( 2 ) MEAS , H O T , C O L D , and : ( Top Teflon Roller, Nip Roller, Bottom Teflon Roller and Sub Heaters ) TEMPERATURE : When pressed and released, changes the Temperature Display to show current temperature reading for 2 seconds, then reverts to set point reading. MEAS 32 o F COLD d HOT MEAS COLD INFORMATION It is recommended that you press HOT ( H O T ) first, then adjust for desired temperature setting. : When pressed, sets the hot default set point for the corresponding heaters. ( Top Teflon Roller = 212 oF ( 100 oC ), Nip Roller = 176 oF ( 80 oC ), Bottom Teflon Roller = 212 oF ( 100 oC ) and Sub Heaters = 248 oF ( 120 oC )). HOT ( e ) Hot Indicator: Is only displyed when pressed. READY is TEMPERATURE 32 HOT HOT o F HOT MEAS COLD e Page 5 - 6 © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual : When pressed, sets the cold default set point for the corresponding heaters. ( All heaters have a default value of 32 oF ( 0 oC ) for Cold ) COLD Operations : Pressed once, decreases the set point temperature for the corresponding heater by one increment. When pressed and held, automatically decreases the set point value by single increments. HOT HOT MEAS COLD MEAS COLD : Pressed once, increases the set point temperature for the corresponding heater by one increment. When pressed and held, automatically increases the set point value by single increments. HOT INFORMATION "Beeps" once for every one increment of change. Refer to Figure 5.1.2 for a complete illustration of the Temperature Control Panel. MEAS COLD INFORMATION "Beeps" once for every one increment of change. © GBC Pro - Tech December 1999 Page 5 - 7 Operations Explorer 107 Operation and Maintenance Manual Figure 5.1.2 Temperature Control Panel TEMPERATURE CONTROL 1 TOP TEFLON ROLLER NIP ROLLER READY TEMPERATURE READY TEMPERATURE 32 o F 32 COLD HOT 2 COLD MEAS COLD BOTTOM TEFLON ROLLER SUB HEATERS READY TEMPERATURE READY TEMPERATURE 32 o F 32 COLD MEAS COLD 1 F 120 o C / 248 o F HOT 2 o COLD 100 o C / 212 o F Page 5 - 8 F 80 o C / 176 o F HOT MEAS 1 o COLD 100 o C / 212 o F 2 1 HOT MEAS 2 COLD © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Operations E-STOP located above the serial plate on the right side from the rear position of the laminator. Refer to Figure 5.2.2 ! EME GE R Use care in lowering the top laminating roller and know how to react quickly in an emergency. Before lowering the roller, ensure that nothing is in the nip area. Figure 5.2.2 Rear E-STOP P The Explorer 107 Laminator has been designed with safety as a primary consideration; however, you must become thoroughly familiar with the controls, proper operation, proper service procedures, and safety features of the laminator before using or servicing the unit. STO 5.2 Emergency NCY ROLL LAMINATOR Know where the two emergency stop ( E-STOP ) are located before operating the laminator. Model : Input voltage : Input current : Power cunsuption : Temperature range: Current rating of circuit breaker : Max laminating width : Serial No : ############# Made in Korea / Fabrique En Coree Explorer 107 220V~ / 60Hz 27A 5,800 W o C 160 Up to 30 A 1075 mm E-STOP E-STOP located above the Temperature Control Panel on the right side of the front position of the laminator. Refer to Figure 5.2.1 Figure 5.2.1 Front E-STOP In addition, the NipRollers, Teflon Rollers and Sub Heaters of the Explorer 107 can reach temperatures over 200oF ( 93oC ). E-STOP OL TR ON ER LL EC RO UR AT AT HE ER ER W MP LO TE UP PE R HE AT RO LL WARNING ER T HO . AS ME T HO . AS ME LD CO SU B HE AT ER S LD CO NI P RO LL ER S T HO . AS ME LD CO T HO . AS ME LD CO © GBC Pro - Tech December 1999 At these temperatures there is a danger of severe burns if the rollers are touched during set up, operation or servicing. Page 5 - 9 Operations Explorer 107 Operation and Maintenance Manual Reacting to an emergency situation INFORMATION The Temperature control panel settings are not affected when an E-STOP has been pushed. a) In the event of an emergency, press an E-STOP. d) Ensure that the front safety shield is located in the fully locked position. INFORMATION When an EMERGENCY STOP is engaged, all motion stops. The nip will not change from the operating setting. INFORMATION Power to the motor is removed when the safety shield is not in the fully locked position. b) Resolve the emergency situation. c) Reset the E-STOP by rotating 1/4 turn clockwise. The E-STOP will unlatch. 5.3 Set up Unlatch ! Page 5 - 10 EN Y C ST OP EM ER G e) Press ON to resume running. Initial set up of the Explorer 107 laminator is easily attained when instructions are followed exactly. It is suggested and helpful if you take the time to read this section thoroughly before attempting to do any of the steps.A complete understanding of this section will enable you to follow the procedures descibed in Section 6.1 Application. © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual 5.3.1 Power Operations 5.3.2 Film loading a) Clear the area around the laminating rollers and pull rollers. b) Ensure that the laminator is plugged in and no E-STOP is depressed. The Explorer 107 can accommodate Poly-In or Poly-Out films. Each film requires a different loading procedure. Refer to Section 6 Applications for webbing methods. With regards to webbing methods, both require the adhesive side of the film to face away from the heating components. c) Press POWER to the “I ” position to turn on the laminator. WARNING Extreme caution should always be exercised when removing an unwind shaft, the gripper tabs can cut you! ! R STO P EME GE NCY ROLL LAMINATOR Model : Input voltage : Input current : Power cunsuption : Temperature range: Current rating of circuit breaker : Max laminating width : Serial No : ############# Made in Korea / Fabrique En Coree Explorer 107 220V~ / 60Hz 27A 5,800 W Upo C to 160 30 A 1075 mm Power a) Lift the upper unwind shaft from the lateral film adjustment side out of its support saddle. Lateral film adjustment d) Press POWER to “O” position to turn off the laminator. © GBC Pro - Tech December 1999 Page 5 - 11 Operations Explorer 107 Operation and Maintenance Manual b) Pull the upper unwind shaft out from the upper film brake adjustment . Film brake adjustment e) Ensure the core gripper support is properly positioned for the type of film being used and is centered on the unwind shaft. Unwind rotation for Poly-Out films Direction of gripper tabs c) Loosen the thumb screw to the two film core end supports. INFORMATION Thumb screw Refer to Figure 6.1.1 under Section 6 Applications for unwind direction for Poly-In and Poly-Out films INFORMATION d) Slide the Right core end support off of the unwind shaft. The gripper tabs should point in the opposite direction of film rotation. Right core end support WARNING Extreme caution should always be exercised working around the core gripper support, the grippers tabs can cut you! Page 5 - 12 © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual f) Use a 4 mm allen wrench to loosen the two screws if the core gripper support requires adjustment or removal. Operations h) Slide the right core end support onto the unwind shaft. Two screws WARNING g) Slide the roll of film onto the unwind shaft and push the left core end support into the core of the film roll.. CAUTION Ensure the roll of laminate is loaded properly on the unwind shaft. Exposed adhesive should be facing away from the heated components. This will prevent hours of cleaning! Always use safe and proper lifting practices when lifting heavy objects. You can become seriously injured or crushed. i) With the help of a second person, lift the unwind shaft with the roll of film and reinsert the unwind shaft into the open end of the film brake adjustment slot. Film brake adjustment INFORMATION For 2-1/4 core film, turning the roll film in the same direction as the gripper tabs while sliding makes loading the film onto the unwind shaft easier. © GBC Pro - Tech December 1999 Open end Page 5 - 13 Operations Explorer 107 Operation and Maintenance Manual j) Carefully set the lateral film adjustment end of the unwind shaft into its saddle. Lateral film adjustment end k) From the rear position of the laminator, center the film on the unwind shaft. Left core end support Measurement INFORMATION Use Chart 5.3.1 Film centering chart in Section 5 Operations for measurements. INFORMATION Ensure the roll pins are on top. They should not be in the saddle! Chart 5.3.1 Film centering chart Roll pins Common film widths Page 5 - 14 Film widths 12 in. ( 30 cm ) 18 in. ( 46 cm ) 24 in. ( 61 cm ) Measurement 17 in. ( 43 cm ) 14 in. ( 36 cm ) 11 in. ( 28 cm ) 38 in. ( 97 cm ) 4 in. ( 10 cm ) © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Operations Lowering the rollers INFORMATION If not exactly centered, lateral film adjustment can be made during the webbing process. l) Once the roll of film has been centered, tighten the thumb screws to sdecure in place. a) Turn the roller handle clockwise to lower the roller. Pull roller handle TE LO m) For the bottom roll of film, follow the same procedure just described. WE R HE AT MP RO ER AT UR E CO LLE NT R UP PE R HO CO SU B HE AT ER T LD ME AS HO CO NIP RO HO CO HE AT RO L RO LLE R . S T LD ME AS . LLE RS T LDME AS . HO CO T LDME AS . Lower 5.3.3 Roller handles Main roller handle WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP. You can be CRUSHED or BURNED! CAUTION INFORMATION Never leave the rollers in the down position without rolling. Prolonged contact in one area can form flat spots on the rollers. When lowering the main roller, the heat platen and the Top Teflon roller ( upper heat assembly ) moves as well. © GBC Pro - Tech December 1999 Page 5 - 15 Operations Explorer 107 Operation and Maintenance Manual Raising the rollers INFORMATION 5.3.4 Heating When heating the Teflon rollers and the nip rollers, it is recommended that the rollers turn slowly during the heat up process. This allows the heat to evenly distrubute through out the rollers. When raising the main roller, the heat platen and the Top Teflon roller ( upper heat assembly ) moves as well. The heat platens heat quicker than the rollers. With the rollers slowly turning, the platens assist the rollers during the heating process resulting in a faster heat up time. a) Turn the roller handle counterclockwise to raise the roller. WARNING Pull roller handle TE LO WE R HE AT MP RO ER AT UR E CO LLE NT R UP PE R HO CO SU B HE AT ER T LD ME AS . HO S CO NIP RO HO CO T LD ME AS HE AT RO Keep hands and fingers away from the heating components and the nip of the rollers. You may be CRUSHED or BURNED! L RO LLE R Raise . LLE RS T LDME AS . HO CO T LDME AS . The heating components of the Explorer 107 can exceed temperatures of 200 oF ( 93 oC ), at these temperatures severe burn can occur if contacted. a) Clear the area around the laminating rollers and pull rollers nip. Main roller handle b) Ensure the laminator is plugged in and no E-STOP is depressed. Page 5 - 16 © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual c) Turn the POWER to the “I ” position. Operations f) Use motor speed adjust to set a motor speed of 2 on the Operations Control Panel. ! R STO P E ME GE NCY MOTOR SPEED Power 5 6 REVERSE 2 8 3 7 4 ROLL LAMINATOR Model : Explorer 107 Input voltage : 220V~ / 60Hz Input current : 27A Power cunsuption : 5,800 W oC Temperature range: Up to 160 Current rating of circuit breaker : 30 A Max laminating width : 1075 mm Serial No : ############# Made in Korea / Fabrique En Coree 9 1 10 ON OFF d) Press H O T on the temperature control panel for theTop Teflon Roller, Nip Roller, Bottom Teflon Roller and the Sub Heaters. g) Press . The rollers begin turning ON HOT MEAS COLD MOTOR SPEED 6 REVERSE 2 8 3 7 4 5 10 1 9 e) Press or to adjust for desired set point temperature. ON OFF HOT or MEAS COLD © GBC Pro - Tech December 1999 h) Lower the upper heat assembly by turning the roller handle clockwise until the nip rollers contact. Page 5 - 17 Operations Explorer 107 Operation and Maintenance Manual i) When READY stops flashing on the Temperature Displays for all the heating components, proceed with webbing of the laminator. Centering the roll may not always align the top roll of film evenly with the bottom roll of film. The Explorer 107 is equipped with lateral film adjustment devices on the upper and lower unwind shafts. Stops flashing READY 5.4 Lateral film adjustment TEMPERATURE 212 o The lateral film adjusters allow you to shift the the shaft either to the left or to the right without having to recenter the roll of film on the unwind shafts. F HOT j) Raise the upper heat assembly by turning the roller handle counter clockwise. The lateral film adjuster allows for 5/16 of an inch lateral movement from full left or full right position. INFORMATION k) Press OFF . The rollers stop turning. Lateral film adjustments can be made while the laminator is in operation. MOTOR SPEED 6 INFORMATION REVERSE 2 8 3 7 4 5 10 1 9 ON Page 5 - 18 OFF Quality of the output may be affected during a lateral film adjustment. © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Lateral film adjustment right a) Ensure the large inner dial is in the loose position. Turn fully counterclockwise. Inner dial b) Rotate the small outer dial clockwise to shift the unwind shaft to the right. Outer dial c) Once adjusted, secure the lateral film adjuster by turning the large inner dial fully clockwise. © GBC Pro - Tech December 1999 Operations Lateral film adjustment left a) Ensure that the large inner dial is in the loose position. Turned fully counterclockwise. Inner dial b) Rotate the small outer dial clockwise to shift the unwind shaft to the left. Outer dial c) Once adjusted, secure the lateral film adjust by turning the large inner dial fully clockwise. Page 5 - 19 Operations Explorer 107 Operation and Maintenance Manual 5.5 Film brake adjustment Use the film brake adjustments to prevent the roll of film from free spinning. For film tension, use the UPPER FILM TENSION and LOWER FILM TENSION on the Operations control panel. Decrease film brake tension a) Rotate the film brake adjust dial clockwise slowly to gradually decrease tension to the unwind shaft. Film brake adjustment INFORMATION Excessive brake tension may cause the output to curl. Always use the minimum brake tension required to complete the task. Increase film brake tension a) Rotate the film brake adjust dial clockwise slowly to gradually increase tension to the unwind shaft. 5.6 Using inline slitters Film brake adjustment WARNING At no time should the slitter guard be removed! Sharp blades can cut you! Page 5 - 20 © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Inline slitters have three slitting points. Center, left and right. All three may be used simultaneously or independently. Operations Left side slitter control dials The laminator must have film webbed through the rollers before engaging the sliiters. NG OLI CO OFF FAN ON E ERS REV OFF ON OL NTR CO TOR MO ER UPP ER LOW R LLE N RO SIO TEN R LLE N RO SIO TEN CAUTION Do not webb the laminator with inline slitters in the down position! The leader board can damage the blades. INFORMATION Lower the slitters The large inner dials on the left and right cabinet doors will lower and raise both, the left and right, sliiters. a) Turn the large inner dial ( left side clockwise / right side - counterclockwise ) to lower the left and right slitters. Right side slitter control dials Raise and lower dial TE MP LOW ER ER HEA AT UR T ROL E LER CO NT RO UPP ER L HEA T ROL LER HOT CO SUB LD MEA S. HEA TER S HOT CO NIP LDMEA S. ROL LER HOT CO S LDMEA S. HOT CO LD MEA S. Left / right adjust dial © GBC Pro - Tech December 1999 Page 5 - 21 Operations Explorer 107 Operation and Maintenance Manual b) Push the center slitter lever towards the front of the laminator to lower the center slitter. Raise the slitters a) Turn the large inner dial ( left side - counter clockwise / right side - clockwise ) to lower the left and right slitters. Raise and lower dial Center slitter lever INFORMATION The center slitter can not be lowered without lowering the side slitters. Left / right adjust dial b) Lift the center slitter lever towards the rear of the laminator to raise the center slitter. c) Use the small outer dial on the left to adjst the position of the left side slitter. Use the small outer dial on the right to adjust the position of the right side slitter. Right side slitter Center slitter lever Left side slitter Page 5 - 22 © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual INFORMATION The side slitters can not be raised without raising the center slitter. Operations WARNING Keep hands and fingers away from the path of the rear cut-off blade. Sharp blade can cut you! a) Slide the rear cut-off blade fully to one side of the laminator. 5.7 Rear cut-off blade WARNING WARNING Keep hands and fingers away from the bottom of the rear cut-off blade. Sharp blade can cut you! Caution should always be exercised when using the rear cut-off blade. Sharp blade can cut you! b) Press and hold down the blade engage lever while pushing to the opposite side of the laminator. The rear cut-off blade is intended to cut the web output from the laminator and should not be used for any other purposes. Blade engage lever CAUTION Stop the laminator before using the rear cut-off blade. Moving material can damage the rear cut-off blade! © GBC Pro - Tech December 1999 Page 5 - 23 Operations Explorer 107 Operation and Maintenance Manual 5.8 Front safety shield The primary function of the front safety shield is to protect the operator from the heated components and the nip of the rollers. Raise the shield a) Pull both safety latches on the front safety shield toward the center of the laminator. The second function of the front safety shield is to assist the heating components maintain a stable temperature and keep dust away from the activated adhesive. DANGER At no time should you attempt to over ride any of the safety latches on the laminator. Safety latches WARNING Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! WARNING Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! INFORMATION The laminator will operate only when all safety latches are in the fully latched position. Page 5 - 24 b) Raise the safety shield to its full up right position. © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Lower the shield a) Pull both safety latches on the front safety shield toward the center of the laminator and lower. Operations 5.9 Pressure plate INFORMATION Safety latches on the pressure plate are not associated with an interlock switch. The laminator will operate without the pressure plate installed. The pressure plate is provided to assist with keeping the leading edge and trailing edge of a print flat. b) Align the safety latches with their respective interlocks and slide the safety latches outwards. Removing the pressure plate WARNING Caution should always be exercised when using the laminator with the safety shield raised. You can be seriously HURT or INJURED! INFORMATION The laminator will operate only when all safety latches are in the fully latched position. © GBC Pro - Tech December 1999 a) Pull both safety latches on the front safety shield toward the center of the laminator. Page 5 - 25 Operations Explorer 107 Operation and Maintenance Manual b) Raise the safety shield to its full up right position. b) Pull both safety latches on the front safety shield toward the center of the laminator and lower. c) Pull the two locator latches of the pressure plate toward the center of the laminator. c) Align the safety latches with thier respective interlocks and slide the safety latches outwards. INFORMATION The laminator will operate only when all safety latches are in the fully latched position. Locator latches d) Remove the pressure plate and set in a safe place away from the laminator if not used. Replacing the pressure plate a) Pull the two locator latches of the pressure plate towards the center and position so the locator latch pins align with thier respective holes. Page 5 - 26 5.10 Feed table The feed table is equipped with a safety latch and an interlock. These safety devices are in place for your protction and at no time should they be over ridden. DANGER At no time should you attempt to over ride any of the safety devices on the laminator. © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual INFORMATION Operations c) Pull the two locator latches of the pressure plate toward the center of the laminator. The laminator will operate only when all safety latches are in the fully latched position. Removing the feed table WARNING Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! Locator latches d) Remove the pressure plate and set in a safe place away from the laminator if not being used. e) Pull the two safety latches on the feed table toward the center of the laminator. a) Pull both safety latches on the front safety shield towards the center of the laminator. Bottom view of feed table b) Raise the safety shield to its full up right position. Safety latches © GBC Pro - Tech December 1999 Page 5 - 27 Operations Explorer 107 Operation and Maintenance Manual f) Lift the table from the front and pull out away from the laminator. INFORMATION The laminator will operate only when all safety latches are in the fully latched position. Lif tf rom the n fro to b f ta le Replacing the feed table a) Lift the table from the front and set the rear of the table into the rear feed table supprot bolts. d) Pull the two locator latches of the pressure plate toward the center and position the pins with thier respective holes. e) Pull both safety latches on the front safety shield toward the center of the laminator and lower. f) Align the safety latches with thier respective interlocks and slide the safety latches outward. b) Lower the front of the feed table into the front feed table support bolts while pulling the safety latches toward the center of the feed table. INFORMATION The laminator will operate only when all safety latches are in the fully latched position. c) Latch the two safety latches of the feed table into thier respective interlocks. Page 5 - 28 © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Operations 5.11 Feed guides To move the feed guides, loosen the two finger knobs to the guide. Finger knobs Adjust the guides as necessary and secure by tightening the finger knobs. © GBC Pro - Tech December 1999 Page 5 - 29 Operations Explorer 107 Operation and Maintenance Manual This page intentionally left blank. Page 5 - 30 © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Applications Section 6 Applications 6.1 Initial Webbing The Explorer 107 can accommodate Poly-in or Poly-out films. Poly-out means the adhesive is on the outside of the roll. Each film requires a slightly different loading procedure. Follow the procedure below to web the Explorer 107 from a cold. If you are changing film, follow the procedure described in 6.2 New film to existing film. The shiny side of clear film must contact the heating components with the dull sides ( adhesive side ) facing out. Use caution when loading matte or delustered film since both sides appear dull. Materials need The top and bottom rolls of laminating film must be of the same width and be present simultaneously. • 2 rolls of thermal film ( Must be the same in width ) • Threading card ( Film width by 6 inches ) • Enclosed blade ( i.e. Zippy™ knife ) • Second person ( assist with loading the film ) • Images ( i.e. Inkjet, piezo, electrostatic, offset ) WARNING Do not wear ties, loose fitting clothing 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. Set up a) Clear the area around the laminating rollers and pull rollers nip. The procedures and parameters described in this section are reference points only. Parameters will vary with regards to laminate thickness, laminate widths, laminate types, print types, ink or toner types, environment conditions and operator experience. © GBC Pro - Tech December 1999 b) Ensure the laminator is plugged in and no E-STOP is depressed. Page 6 - 1 Applications Explorer 107 Operation and Maintenance Manual c) Turn the POWER to the “I ” position. f) Using motor speed adjust, set a motor speed of 2 on the operations control panel. R G STO EME P ! E NCY ROLL LAMINATOR MOTOR SPEED Power 5 6 REVERSE 2 8 3 7 4 Model : Explorer 107 Input voltage : 220V~ / 60Hz Input current : 27A Power cunsuption : 5,800 W Temperature range: Up to 160 o C Current rating of circuit breaker : 30 A Max laminating width : 1075 mm Serial No : ############# Made in Korea / Fabrique En Coree 9 1 10 ON OFF d) Press H O T on the temperature control panel for theTop Teflon Roller, Nip Roller, Bottom Teflon Roller and the Sub Heaters. g) Press . The rollers begin turning ON HOT MOTOR SPEED MEAS COLD REVERSE 2 8 3 7 4 5 6 10 1 9 ON OFF e) Press or to adjust for desired set point temperature. HOT or MEAS COLD Page 6 - 2 h) Lower the upper heat assembly by turning the roller handle clockwise until the nip rollers contact. © GBC Pro - Tech December1999 Explorer 107 Operation and Maintenance Manual Applications k) Press . The rollers stop turning. OFF INFORMATION Proceed to Webbing while waiting for the heaters to come up to temperature. MOTOR SPEED 6 8 3 7 4 5 2 REVERSE 10 1 9 ON OFF i) When READY stops flashing in the temperature displays for all the heating components, that is your indication to proceed with webbing of the laminator. Webbing Stops flashing READY TEMPERATURE 212 WARNING o F The following steps are performed while the laminator is HOT! Avoid contact with the heating components! HOT j) Raise the upper heat assembly by turning the roller handle counter clockwise. a) Lift the upper unwind shaft from the lateral film adjustment side out of its support saddle. Lateral film adjustment CAUTION Never leave the rollers in the down position without rolling. Prolonged contact in one area can form flat spots on the rollers. © GBC Pro - Tech December 1999 Page 6 - 3 Applications Explorer 107 Operation and Maintenance Manual b) Pull the upper unwind shaft out from the upper film brake adjustment . Film brake adjustment e) Ensure the core gripper support is properly positioned for the type of film being used and is centered on the unwind shaft. Unwind rotation for Poly-Out films Direction of gripper tabs c) Loosen the thumb screw to the two film core end supports. INFORMATION Refer to Figure 6.1.1 under Section 6 Applications for unwind direction for Poly-In and Poly-Out films Thumb screw INFORMATION d) Slide the Right core end support off of the unwind shaft. The gripper tabs should point in the opposite direction of film rotation. Right core end support WARNING Extreme caution should always be exercised working around the core gripper support, the grippers tabs can cut you! Page 6 - 4 © GBC Pro - Tech December1999 Explorer 107 Operation and Maintenance Manual f) Use a 4 mm allen wrench to loosen the two screws if the core gripper support requires adjustment or removal. Applications h) Slide the right core end support onto the unwind shaft. Two screws WARNING g) Slide the roll of film onto the unwind shaft and push the left core end support into the core of the film roll.. CAUTION Ensure the roll of laminate is loaded properly on the unwind shaft. Exposed adhesive should be facing away from the heated components. This will prevent hours of cleaning! Always use safe and proper lifting practices when lifting heavy objects. You can become seriously injured or crushed. i) With the help of a second person, lift the unwind shaft with the roll of film and reinsert the unwind shaft into the open end of the film brake adjustment slot. Film brake adjustment INFORMATION For 2-1/4 core film, turning the roll film in the same direction as the gripper tabs while sliding makes loading the film onto the unwind shaft easier. © GBC Pro - Tech December 1999 Open end Page 6 - 5 Applications Explorer 107 Operation and Maintenance Manual j) Carefully set the lateral film adjustment end of the unwind shaft into its saddle. k) From the rear position of the laminator, center the film on the unwind shaft. Lateral film adjustment end Left core end support Measurement INFORMATION INFORMATION Use Chart 5.3.1 Film centering chart in Section 5 Operations for measurements. Ensure the roll pins are on top. They should not be in the saddle! Chart 5.3.1 Film centering chart Roll pins Common film widths Film widths Measurement 12 in. ( 30 cm ) 17 in. ( 43 cm ) 18 in. ( 46 cm ) 14 in. ( 36 cm ) 24 in. ( 61 cm ) 11 in. ( 28 cm ) 38 in. ( 97 cm ) Page 6 - 6 4 in. ( 10 cm ) © GBC Pro - Tech December1999 Explorer 107 Operation and Maintenance Manual Applications Figure 6.1.1 Poly-in / Poly-out INFORMATION If not exactly centered, lateral film adjustment can be made during the webbing process. Poly-in l) Once the roll of film has been centered,, tighten the thumb screws to sdecure in place. Poly-in m) For the bottom roll of film, follow the same procedure just described. Threading Poly-out WARNING The following steps are performed while the laminator is HOT! Avoid contact with the heating components! Poly-out a) Start with the upper roll of film. Unwrap about 2-3 feet ( 61-91 cm ) of film from the roll. b) Pull the film under the rubber tension idler and over the metal idler. Refer to Figure 6.1.1 Poly-in / Poly-out © GBC Pro - Tech December 1999 c) Guide the film under the pivot bar of the front safety shield and over the upper heating components Page 6 - 7 Applications Explorer 107 Operation and Maintenance Manual DANGER WARNING Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! d) Raise the front safety shield and remove the pressure plate along with the feed table. At no time should you attempt to over ride any of the safety latches on the laminator. INFORMATION The laminator will operate only when all safety latches are in the fully latched position. e) From the rear of the machine, unwrap about 2-3 feet ( 61-91 cm ) of film from the bottom roll. i) Slide the threading card into the two overlapping filmsand push into the nip rollers. f) Pull the film over the rubber tension idler and under the metal idler. Refer to Figure 6.1.1 Poly-in / Poly-out j) Lower the main roller and pull roller pressure handles to the closed position.and press ON under MOTOR SPEED. g) Guide the bottom film up through the front of the machine and overlap it with the film from the upper roll of film. MOTOR SPEED 6 REVERSE 2 8 3 7 4 5 10 Page 6 - 8 1 9 h) Reinstall the feed table and lower the front safety shield. Slide all safety latches into the interlocks. ON OFF © GBC Pro - Tech December1999 Explorer 107 Operation and Maintenance Manual k) Watch the leading edge of the threading card to ensure that it enters the nip rollers and is being pulled intothe laminator. Applications n) Set a desired working speed by turning the SPEED ADJUST dial clockwise. MOTOR SPEED REVERSE 2 8 3 INFORMATION 7 4 5 6 9 1 10 ON The threading card will guide the two films into the pull rollers. l) Once the threading card has passed completely OFF through the pull rollers, press under MOTOR SPEED. 6 REVERSE 2 8 3 7 4 o) Set the feed guides on the feed table if desired. ON p) Press under MOTOR SPPED when ready to laminate. MOTOR SPEED 5 OFF 10 1 9 ON OFF MOTOR SPEED 6 REVERSE 2 8 3 7 4 5 10 1 9 ON OFF m) Check film alignment and film tention. Adjust as neccessary. INFORMATION Excessive brake tension may cause the output to curl. Always use the minimum brake tension required to complete the task. © GBC Pro - Tech December 1999 INFORMATION The laminator will operate only when all safety latches are in the fully latched position. Page 6 - 9 Applications Explorer 107 Operation and Maintenance Manual r) Once the last image has completely traveled OFF pass through the pull rollers, press under MOTOR SPEED. 6.2 New film to existing film MOTOR SPEED The following describes a method for loading film whereby the existing filmpresent on the heat rollers may be used in place of the threading card to draw the new film through the laminator. 6 8 3 7 4 5 2 REVERSE 10 1 9 ON OFF The adhesive from the existing film must be tacky or activated. The leading edges of the new film will be overlapped onto the tacky adhesive of the old film. s) Raise the main roller and pull roller. The existing film and the new film will be pulled through the laminator together. Refer to Figure 6.1.1 Poly-in / Poly-out. CAUTION Never leave the rollers in the down position without rolling. Prolonged contact in one area can form flat spots on the rollers. INFORMATION g) Press POWER to “ O ” if finished with the laminator. The laminator must be heated for this method of webbing. ! R ST O P E ME GE NCY WARNING ROLL LAMINATOR Model : Input voltage : Input current : Power cunsuption : Temperature range: Current rating of circuit breaker : Max laminating width : Serial No : ############# Made in Korea / Fabrique En Coree Page 6 - 10 Explorer 107 220V~ / 60Hz 27A 5,800 W Uo pC t o 1 6 0 30 A 1075 mm Power The following steps are performed while the laminator is HOT! Avoid contact with the heating components! © GBC Pro - Tech December1999 Explorer 107 Operation and Maintenance Manual a) Once the last image has completely traveled OFF under pass pull rollers, press MOTOR SPEED. Applications e) Unroll eneough film to tack to the existing web of film. f) Using masking tape, attach film from the top roll of film to the existing top web. MOTOR SPEED 6 REVERSE 2 8 3 7 4 5 10 1 9 ON OFF g) Using masking tape, attach film from the bottom roll of film to the existing bottom web. h) Install the feed table and lower the front safety shield. Lock all safety latches into the interlocks. b) Raise the main roller and pull roller. INFORMATION CAUTION Do not use an open blade to cut the web near the rollers. You can put cuts into the rollers! The laminator will operate only when all safety latches are in the fully latched position. i) Rotate the motor speed adjust counterclockwise to 1. c) With an enclosed blade, cut the web of film from the upper and lower supply roll. MOTOR SPEED 6 REVERSE 2 8 3 7 4 5 10 © GBC Pro - Tech December 1999 1 9 d) Replace the current roll of film with the new roll roll of film. ON OFF Page 6 - 11 Applications Explorer 107 Operation and Maintenance Manual j) Raise the main roller and pull roller. k) Press 6.3 Unwebbing under MOTOR SPEED. ON WARNING Keep hands and fingers away from the path of the rear cut-off blade. Sharp blade can cut you! MOTOR SPEED 6 REVERSE 2 8 3 7 4 5 9 1 10 ON OFF WARNING l) Observe the film being pulled through the laminator to assure that the remaining existing film and the new film are advancing concurrently. Caution should always be exercised when using the rear cut-off blade. Sharp blade can cut you! a) Use the rear cut-off blade to separate the finished product from the laminator web. OFF m) Press under MOTOR SPEED once the newly threaded film web has completely exited the laminator. b) With an enclosed blade, cut the web of film from the upper and lower supply roll. MOTOR SPEED 6 REVERSE 2 8 3 7 4 5 10 1 9 ON OFF WARNING Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! n) Adjust motor speed and resume laminating. Page 6 - 12 © GBC Pro - Tech December1999 Explorer 107 Operation and Maintenance Manual Applications c) Raise the front safety shield. 6.4 Parameter Charts d) Remove the pressure plate and feed table. Parameter charts are starting references only. Temperature and speeds will vary. Adjust your settings accordingly for optimal ouput quality.. WARNING Extreme caution should be exercised when gripping the film near the heating components. INFORMATION Temperatures and speeds will vary due to environment conditions, humidity, film ratios, film thickness, film composition, operator experience, line voltage and stock. e) Grip the laminate from the front of the laminator near the nip rollers and pull straight back. f) Clean the heating components as described in Section 8 Maintenance. g) Press POWER to “ O ” if finished with the laminator. For films not listed in the parameter charts, consult your sales representative or the film manufacturer for the recommended temperature and speed settings. Parameter charts for Nap-Lam II, Nap-Lam I and Premium films with respect to 20# bond, 60# bond and 80# bond stock are proveded in SAE and Metric. Refer to Charts 6.4.1 through Charts 6.4.6. ST O EMER GE P ! NCY ROLL LAMINATOR Model : Explorer 107 Input voltage : 220V~ / 60Hz Input current : 27A Power cunsuption : 5,800 W Temperature range: Up to 160 o C Current rating of circuit breaker : 30 A Max laminating width : 1075 mm Serial No : ############# Made in Korea / Fabrique En Coree Power © GBC Pro - Tech December 1999 Use the conversion chart ( Chart 6.4.7 ) provided for temperatures not shown within the parameter charts. Page 6 - 13 Applications Explorer 107 Operation and Maintenance Manual Chart 6.4.1 Nap-Lam II ( SAE ) Stock Nap-Lam II Film Gauge Preset positions Temperatures ( o F ) mil 20# Bond Teflon rollers Nip rollers 1.7 3 5 10 270 250 230 200 - 290 270 250 230 200 - 230 200 - 220 200 - 210 200 60# Bond 1.7 3 5 10 260 240 220 200 - 280 270 240 230 200 210 210 210 - 230 230 220 220 80# Bond 1.7 3 5 10 260 240 220 200 - 280 270 240 230 200 210 210 210 - 230 230 230 230 Control panel Sub heaters Speed Pre- set 7 - 10 5-8 3-5 1-3 Pre- set 7 - 10 5-8 3-5 1-3 Pre- set 6 - 10 4-8 2-5 1-3 * You may have to adjust temperature or speed depending on stock, finish, thickness and ink coverage. ** Turn heat off when not in use. Chart 6.4.2 Nap-Lam I ( SAE ) Stock Nap-Lam I Film Gauge Settings Temperatures ( o F ) mil Teflon rollers Nip rollers 1.5 3 5 290 - 320 270 - 300 240 - 270 250 - 270 240 - 260 230 - 250 60# Bond 1.5 3 5 290 - 320 270 - 300 240 - 270 250 - 270 240 - 260 230 - 250 80# Bond 1.5 3 5 290 - 320 270 - 300 240 - 270 250 - 270 240 - 260 230 - 250 20# Bond Control panel Sub heaters Speed Pre- set 6-9 4-7 2-4 Pre- set 6-9 4-7 2-4 Pre- set 6-9 4-7 2-4 * You may have to adjust temperature or speed depending on stock, finish, thickness and ink coverage. ** Turn heat off when not in use. Page 6 - 14 © GBC Pro - Tech December1999 Explorer 107 Operation and Maintenance Manual Applications Chart 6.4.3 Premium ( SAE ) Stock Premium Film Gauge Settings Temperatures ( o F ) mil Teflon rollers Nip rollers 3 5 10 250 - 270 230 - 250 200 - 230 200 - 220 200 - 210 200 60# Bond 3 5 10 240 - 270 220 - 240 200 - 230 210 - 230 210 - 220 210 - 220 80# Bond 3 5 10 240 - 270 220 - 240 200 - 230 210 - 230 210 - 230 210 - 230 20# Bond Control panel Sub heaters Speed Pre- set 4-7 2-4 1-2 Pre- set 4-7 2-4 1-2 Pre- set 3-7 2-4 1-2 * You may have to adjust temperature or speed depending on stock, finish, thickness and ink coverage. ** Turn heat off when not in use. Chart 6.4.4 Nap-Lam II ( Metric ) Stock Nap-Lam II Film Gauge Preset Positions Temperatures ( o C ) Control panel mic Teflon rollers Nip rollers Sub heaters Speed 38 75 125 250 132 - 143 121 - 132 110 - 121 93 - 110 93 - 110 93 - 104 93 - 99 93 Pre- set 7 - 10 5-8 3-5 1-3 225 gsm 38 75 125 250 127 - 138 116 - 132 104 - 116 93 - 110 93 99 99 99 - 110 110 104 104 Pre- set 7 - 10 5-8 3-5 1-3 300 gsm 38 75 125 250 127 - 138 116 - 132 104 - 116 93 - 110 93 99 99 99 - 110 110 110 110 Pre- set 6 - 10 4-8 2-5 1-2 75 gsm * You may have to adjust temperature or speed depending on stock, finish, thickness and ink coverage. ** Turn heat off when not in use. © GBC Pro - Tech December 1999 Page 6 - 15 Applications Explorer 107 Operation and Maintenance Manual Chart 6.4.5 Nap-Lam I ( Metric ) Stock Nap-Lam I Film Gauge Settings Temperatures ( o C ) mic Teflon rollers Nip rollers 38 75 125 143 - 160 132 - 149 116 - 132 121 - 132 116 - 127 110 - 121 225 gsm 38 75 125 143 - 160 132 - 149 116 - 132 121 - 132 116 - 127 110 - 121 300 gsm 38 75 125 143 - 160 132 - 149 116 - 132 121 - 132 116 - 127 110 - 121 75 gsm Control panel Sub heaters Speed Pre- set 6-9 4-7 2-4 Pre- set 6-9 4-7 2-4 Pre- set 6-9 4-7 2-4 * You may have to adjust temperature or speed depending on stock, finish, thickness and ink coverage. ** Turn heat off when not in use. Chart 6.4.6 Premium ( Metric ) Stock Premium Film Gauge Settings Temperatures ( o C ) mic Teflon rollers Nip rollers 75 125 250 121 - 132 110 - 121 93 - 110 93 - 104 93 - 99 93 225 gsm 75 125 250 116 - 132 104 - 116 93 - 110 99 - 110 99 - 104 99 - 104 300 gsm 75 125 250 116 - 132 104 - 116 93 - 110 99 - 110 99 - 110 99 - 110 75 gsm Control panel Sub heaters Speed Pre- set 4-7 2-4 1-2 Pre- set 4-7 2-4 1-2 Pre- set 4-7 2-4 1-2 * You may have to adjust temperature or speed depending on stock, finish, thickness and ink coverage. ** Turn heat off when not in use. Page 6 - 16 © GBC Pro - Tech December1999 Explorer 107 Operation and Maintenance Manual Applications Chart 6.4.7 Temperature conversion chart o F 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 o = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = C 20 20.6 21.1 21.7 22.2 22.7 23.3 23.9 24.4 25 25.6 26.1 26.7 27.2 27.8 28.3 28.9 29.4 30 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35 35.6 36.1 36.7 37.2 37.8 38.3 38.9 39.4 40 40.6 41.1 41.7 42.2 42.8 43.3 43.9 44.4 o F 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 o = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = C 45 45.6 46.1 46.7 47.2 47.8 48.3 48.9 49.4 50 50.6 51.1 51.7 52.2 52.8 53.3 53.9 54.4 55 55.6 56.1 56.7 57.2 57.8 58.3 58.9 59.4 60 60.6 61.1 61.7 62.2 62.8 63.3 63.9 64.4 65 65.6 66.1 66.7 67.2 67.8 68.3 68.9 69.4 © GBC Pro - Tech December 1999 o F 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 o = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = C 70 70.6 71.1 71.7 72.2 72.8 73.3 73.9 74.4 75 75.6 76.1 76.7 77.2 77.8 78.3 78.9 79.4 80 80.6 81.1 81.7 82.2 82.8 83.3 83.9 84.4 85 85.6 86.1 86.7 87.2 87.8 88.3 88.9 89.4 90 90.6 91.1 91.7 92.2 92.8 93.3 93.9 94.4 o F 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 o = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = C 95 95.6 96.1 96.7 97.2 97.8 98.3 98.9 99.4 100 100.6 101.1 101.7 102.2 102.8 103.3 103.9 104.4 105 105.6 106.1 106.7 107.2 107.8 108.3 108.9 109.4 110 110.6 111.1 111.7 112.2 112.8 113.3 113.9 114.4 115 115.6 116.1 116.7 117.2 117.8 118.3 118.9 119.4 o F 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 o = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = C 120 120.6 121.1 121.7 122.2 122.8 123.3 123.9 124.4 125 125.6 126.1 126.7 127.2 127.8 128.3 128.9 129.4 130 130.6 131.1 131.7 132.2 132.8 133.3 133.9 134.4 135 135.6 136.1 136.7 137.2 137.8 138.3 138.9 139.4 140 140.6 141.1 141.7 142.2 142.8 143.3 = = Page 6 - 17 Applications Explorer 107 Operation and Maintenance Manual This page intentionally left blank. Page 6 - 18 © GBC Pro - Tech December1999 Explorer 107 Operation and Maintenance Manual Section 7 Troubleshooting Troubleshooting Problem: D waves in the image but not in the laminate Cause: Excessive roller pressure. 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. As an operator, you can perform simple troubleshooting to correct typical output problems. Use the following guide for assistance. Hints: • Check paper tension • Check relative moisture content of the paper 7.1 Wave problems Problem: D Waves in the laminate Following is a list of common output wave problems you may encounter. Cause: Insufficient roller pressure. The arrow along the length of the web represents the direction of ( travel ). INFORMATION For optimal temperature settings of various laminates, contact your supplier or sales representative. © GBC Pro - Tech December 1999 Page 7 - 1 Troubleshooting Explorer 107 Operation and Maintenance Manual Hints: • Check the roll pressure • Check the main roll nip settings • Check the pull roll nip settings Problem: Straight waves in the output Cause: Excessive heat at the nip rollers Hints: • Check the nip setting of main rolls • Check the nip setting of pull rolls • Check for even paper tension Problem: Angled waves in the output on both sides Cause: Slight amount of insufficient roller pressure. Hints: • Check operational settings for materials being used. Problem: Waves on only one side of the output Cause: Insufficient roller pressureon one side. Page 7 - 2 © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Hints: • Check for insufficient main roller pressure • Check for insufficient pull roller pressure • Check the main roller nip settings • Check the pull roller nip settings Troubleshooting bubble bubble bubble bubble bubble Problem: Indent waves in output after the pull rollers bubble bubble Cause: Handling the web before it has a chance to cool. bubble Hints: • Check for consistent distance between bubbles. • Verifythat bubbles are present with and without paper in the web. Problem: Sparatic bubbles in the web Cause: Excessive moisture Hints: • Insufficient cooling time • Allow output to cool before handling • Check operating temperatures of material Problem: Evenly spaced bubbles in the web. Cause: Bowed rollers Hints: Store prints in a dry place. © GBC Pro - Tech December 1999 Page 7 - 3 Troubleshooting Explorer 107 Operation and Maintenance Manual 7.2 Output problems Following is a list of common film problems you may encounter. Film problems are separate from wave problems. Problem: Coiling or curling of encapsulated images Cause: • Excessive upper film tension • Excessive lower film tension Hints: • Balance the upper and the lower film tension Wave problems are typically caused by machine characteristics. Problem: Silvering in the laminate Output problemsare usually caused from improper operating parameters. Cause: • Short dwell time in the nip • Insufficient heat For definitions of terminologies, please refer to 7.4 Glossary of terminology. Hints: • Decrease the speed • Increase the operating temperature 7.2.1 Problems/Cause/Hints Problem: Delamination Problem: Blistering within the image Cause: • Insufficient temperatures • Speed is too fast • Insufficient roller pressure Cause: • Long dwell time • Set point is too high • Image is wet Hints: • Increase the speed • Decrease the operating temperature • Store images in a dry atmosphere Page 7 - 4 Hints: • Increase operating temperatures • Check operating speed • Laminate compatibility with ink • Ink compatibility with paper • Check roller pressure © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual 7.3 Machine problems Once the Hints are all checked, and your problem still exists, a service call must be placed for a qualified Technician to fix the problem. You may do this by dialing 1 ( 800 ) 790 - 7787. This will connect you with GBC National Service dispatch. You will be required to give the serial number of your machine when placing a service call. Troubleshooting 7.3.1 Problem/Hints Problem : No illumination to the control panels. Hints : • Confirm that POWER is on the “ I ” position. • Ensure that the plug is fully seated in the receptacle. The space below has been provided to keep this number readily available if and when needed. My Explorer 107 Laminator serial number ON under Motor Speed, Problem : Press rollers will not turn.. is : MOTOR SPEED 6 REVERSE 2 8 3 7 4 5 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. © GBC Pro - Tech December 1999 10 WARNING 1 9 At no time does GBC Pro-Tech suggest or recommend that you attempt to fix the machine by opening the cabinets yourself. ON OFF Hints: • Ensure that no E-STOP is depressed. • Ensure that the feed table safety latches are in the fully locked position. • Ensure the safety shield lataches are in the fully locked position.. Page 7 - 5 Troubleshooting Explorer 107 Operation and Maintenance Manual c) Remove the pressure plate. 7.3.2 Clearing a jam Film jams ( wrap-ups ) may occur if the film is loaded backwards or if the area at which film exits the laminator is blocked. The film, when jammed, wraps around the main rollers or pull rollers. To clear a jam it is necessary to rotate the rollers in the reverse direction. OFF under Motor Speed a) Press immediately to stop the laminator. INFORMATION Locator latches on the pressure plate are not associated with an interlock switch. The laminator can operate without the pressure plate installed. d) Remove the feed table. e) Cut the top and bottom film webs. MOTOR SPEED 6 REVERSE f) Grasp the loose ends of the web 2 8 3 7 4 5 10 1 9 ON OFF g) Reinstall the feed table so that the loose ends of the web rest on top and lock the safety latches into the interlocks.. WARNING INFORMATION Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! b) Raise the front safety shield. Page 7 - 6 The laminator will operate only when all safety latches are in the fully latched position. h) Close the front safety shield and lock the safety latches into the interlocks.. © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual i) Press and hold R E V E R S E while guiding the web out of the nip rollers. INFORMATION Troubleshooting Bond strength Refers to one of three conditions; 1) the anchor strength of adhesive to laminate substrate, 2) the anchor strength of the laminating film to the product that has been laminated, or 3) when two layers of film are laminated together, the strength of the adhesive to adhesive bond. Rollers only turn in reverse while depressing REVERSE . Curling j) Thread the film as described in Section 6 Application. A term used to describe an image rolling up on itself. This is caused by differences in the brake tension used between the upper and lower laminates during and application process. D waves A term used to describe a wave pattern caused, generally, by incorrect roller tension. 7.4 Glossary Delamination The glossary can help you understand some of the terminology used when referring to the laminator, applications, or troubleshooting aspects of the machine. Refers to either one of two conditions; 1) the adhesive separating from the laminate substrate, or 2) the laminate separating from the product being laminated. Blistering Dwell time A condition where the paper coating is bubbled up from the image paper causing a “blister”. It is created by using excessive heat during the lamination process. Blistering is most commonly found with photographic and ink jet media. © GBC Pro - Tech December 1999 Dwell time is controlled by the speed of the motor and is defined as the amount of time the film is in contact with the heat rollers. Page 7 - 7 Troubleshooting Explorer 107 Operation and Maintenance Manual Encapsulation Heat platens When an image is completely encased in laminating film, it is encapsulated. The heating component between the nip roller and the Teflon roller. This is also known as a heat shoe. Film Pull rollers A two part material consisting of an adhesive layer and a substrate. The adhesive and the substrate may or may not be clear. This is the material used for lamination. Please refer to laminate. These rollers are used to pull the web through the laminator. Tensioning of the laminated media helps to make it flat and smooth. Laminate Scarring A two part material consisting of an adhesive layer and a substrate. The adhesive and the substrate may or may not be clear. This is the material used for lamination. The visual effect of folding papers or laminates and breaking the surface. When done to a printed material it will be seen as a white crack in the image. Main rollers The main rollers are the laminators primary source Silvering of heat. Media Term used to describe the materials used to print an image, i.e. papers A term used to describe one of two occurrences; 1) air bubbles trapped between the product and a thermal laminate, generally caused by insufficient heat being applied to the film. 2) Film used does not have eneough adhesive for the product being laminated. 3) Excessive amount of Offset powder on the prints. Nip Web The point at which the top and bottom rollers make contact. The material from a supply roll going through the laminator. Page 7 - 8 © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Section 8 Maintenance GBC Pro-Tech 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. Maintenance 8.1 Maintenance Schedule INFORMATION Below is a recommended maintenance schedule. Before performing any of the steps listed, read through the procedures first. Please follow the instructions pertaining to the step you are performing. 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. Daily • Clean the rollers ( See cleaning in this section ) • Inspect the electrical cord for damage. ( If damaged, you should replace or repair it immediately ) INFORMATION Improper maintenance, can result in poor output quality. Monthly • Adjust the nip if needed. ( Performed by a qualified Service Technician ) GBC offers Cleaning kits ( P/N 1711515 ) as well as Extended Maintenance Agreements. • Check the chain tension. ( Performed by a qualified Service Technician ) • Inspect the area around the laminator for possible hazards The only maintenance required by the operator is to maintain clean and adhesive free nip rollers, heat platens and Teflon rollers and overall cleanliness of the laminator itself. © GBC Pro - Tech December 1999 ( dust buildup, combustible items stored too close, etc. ) Page 8 - 1 Maintenance Explorer 107 Operation and Maintenance Manual Semi-Annual • Lubricate the chains, and gears. ( Performed by a qualified Service Technician ) • Check wire termination tightness. CAUTION Never clean the rollers with sharp or pointed objects. You may put irreparable cuts into the rollers. ( Performed by a qualified Service Technician ) ELECTRICAL SHOCK Remove power from the laminator before servicing. You can be severely shocked, killed or cause a fire. CAUTION Harden adhesive deposits on the rollers can cause damage to the rollers. 8.2 Cleaning the rollers CAUTION CAUTION Do NOT pick or pull heat activated adhesive off the rolls when they are cold. You can cause irreparable damage to the laminating rolls. The following procedure is performed while the laminator is HOT! Use extreme caution! INFORMATION WARNING Heating components are HOT! You can become severely burned ! Page 8 - 2 The most efficient time to clean the rollers is after a lamination process is completed. © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual Tools required • Damp cloth ( Use water only to dampen the cloth ) • Rubber cement eraser ( a belt sander dressing block may be used instead ) • Several 100% cotton terry cloths ( best for lint free cleaning ) • 3M™ Scotchbrite™ pad Preparation of the laminator Maintenance b) Ensure no E-STOP is depressed and all safety latches are in the fully locked position. INFORMATION The laminator will operate only when all safety latches are in the fully latched position. c) Press H O T for the Top Teflon roller, Nip Roller, Bottom Teflon Roller and Sub Heaters.. a) Turn the POWER to the “I ”. HOT MEAS COLD ! R ST O P EME G E NCY INFORMATION ROLL LAMINATOR Model : Explorer 107 Input voltage : 220V~ / 60Hz Input current : 27A Power cunsuption : 5,800 W Temperature range: Up to 160o C Current rating of circuit breaker : 30 A Max laminating width : 1075 mm Serial No : ############# Made in Korea / Fabrique En Coree Power If the rolls are heated, proceed to Removing adhesive build up.. d) Lower the main rollers. © GBC Pro - Tech December 1999 Page 8 - 3 Maintenance Explorer 107 Operation and Maintenance Manual e) Set the motor speed adjust to “1”. Removing adhesive build up MOTOR SPEED 6 a) Raise the upper main roller. 8 3 7 4 5 2 REVERSE 9 1 10 ON OFF b) Press f) Press under motor speed. OFF under motor speed. ON MOTOR SPEED 6 REVERSE 2 8 3 7 4 5 10 1 9 ON OFF MOTOR SPEED 6 REVERSE 2 8 3 7 4 5 10 1 9 ON OFF WARNING g) When the READY indicator in the temperature displays stop flashing, proceed with Removing adhesive build up. READY Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! TEMPERATURE ??? o F c) Raise the front safety shield, remove the pressure plate and the feed table. HOT Page 8 - 4 © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual d) Use the 3M™ Scotchbrite™ pad to clean the adheisive off of the top Teflon roller, the two heat platens and the bottom teflon roller. Maintenance f) Replace the feed table and lower the front safety shield. INFORMATION Teflon rollers Locator latches on the pressure plate are not associated with an interlock switch. The laminator will operate without the pressure plate installed. Heat platens TE ER UPP MPE RA TU RE CO NT ER LOW RO L LER T ROL HEA LER T ROL HEA HOT CO LD S. MEA S TER HEA HOT SUB CO LD S. MEA NIP S LER ROL HOT CO LD S. MEA HOT CO LD S. MEA g) Press R E V E R S E to move the bottom roller to an unclean area and release. MOTOR SPEED REVERSE 3 2 8 10 1 9 Nip rollers 6 7 4 5 ON OFF e) Use the rubber cement eraser to clean the nip rollers. INFORMATION Rollers only turn in reverse while REVERSE depressing . CAUTION Excessive pressure can destroy the silicone layer by pressing to hard or scrubbing too long in one spot. h) Repeat steps “a” through “g” until the adhsive is beaded on the rollers. © GBC Pro - Tech December 1999 Page 8 - 5 Maintenance Explorer 107 Operation and Maintenance Manual Cleaning the beads of adhesives, dust and dirt INFORMATION Locator latches on the pressure plate are not associated with an interlock switch. The laminator can operate without the pressure plate installed. a) Press COLD on all temperature controls. HOT d) Press R E V E R S E to move the bottom roller to an unclean area and release. MEAS COLD MOTOR SPEED 6 REVERSE 2 8 3 7 4 5 The upper nip roller as well as the Teflon rollers are free spinning. c) Replace the feed table and lower the front safety shield. Page 8 - 6 10 INFORMATION 1 9 b) Use a damp cloth to clean the beads of adhesives off of the rollers. ON OFF INFORMATION Rollers only turn in reverse while REVERSE depressing . e) Repeat steps “c” and “d” until the rollers are clean. © GBC Pro - Tech December 1999 Explorer 107 Operation and Maintenance Manual i) Replace the feed table, pressure plate and front safety shield. j) Press POWER to “0”. 8.3 Clean the cabinets and covers ELECTRICAL SHOCK Remove power from the laminator before cleaning. You can be severely shocked, killed or cause a fire. Maintenance ELECTRICAL SHOCK 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. 8.4 Cleaning the control panels ELECTRICAL SHOCK Remove power from the laminator before cleaning. You can be severely shocked, killed or cause a fire. a) Use only a slightly damp ( water only ) non abrasive cloth. a) Use a damp cotton terry cloth ( water only ), clean the exterior of the laminator. ELECTRICAL SHOCK b) If water is not strong enough, you may use a mild dishwashing detergent with water and a cotton terry cloth. © GBC Pro - Tech December 1999 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. Page 8 - 7 Maintenance Explorer 107 Operation and Maintenance Manual This page intentionally left blank. Page 8 - 8 © GBC Pro - Tech December 1999

Gbc Explorer 107 Laminator

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