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POLARIS II LAMINATOR

OPERATOR MANUAL

Part Number: 930-115 REV: - REV Date: 7-27-04

Summary of Contents for 930-115

Page 2: ...ithout notice All specifications and information concerning products are subject to change without notice Reference in this publication to information or products protected by copyright or patent does not convey any license under the rights of General Binding Corporation or others General Binding Corporation assumes no liability arising from infringements of patents or any other rights of third pa...

Page 3: ...nstallation 4 1 4 2 Setting up your laminator 4 2 Figure 4 2 1 Paper Guide 4 2 5 0 Operations 5 1 Components on the laminator 5 1 Figure 5 1 1 Power Switch 5 1 Figure 5 1 2 Feed Table Details 5 1 Figure 5 1 3 Catch Table 5 2 Figure 5 1 4 Vacuum Adjustment 5 2 Figure 5 1 5 Air and Vacuum Gauges 5 2 Figure 5 1 6 Guide Wheels 5 2 Figure 5 1 7 Heat Roller and Shield 5 3 Figure 5 1 8 Pull Roll 5 3 Figu...

Page 4: ...l 6 1 Figure 6 1 2 Suction Cups and Paper Stack 6 1 Figure 6 1 3 Film Leader 6 2 6 2 Helpful hints 6 3 6 3 Important points to remember 6 3 Quick Set up 6 5 ApplicationGuide 6 6 7 0 Maintenance and Troubleshooting 7 1 Cabinets and cover 7 1 7 2 Clean the rollers 7 1 7 3 Misc Maintenance 7 2 7 4 Troubleshooting 7 2 Figure 7 3 1 Troubleshooting guide 7 3 ...

Page 5: ...s symbol is to inform you of how to avoid a dangerous situation ELECTRICALHAZARD Thissymbolisusedprior to a step The information following this symbol is to prevent an electrical shock condition that may be caused by an operators action or machine function 1 2 General rules of safety ELECTRICAL HAZARD Do not operate the laminator if power cord is damaged or frayed You can be severely shocked elect...

Page 6: ...erials may cause damage to the rollers or cause poor output quality CAUTION Alwaysobserveallwarninglabelsplaced at various points on the laminator If you do not completely understand a label contact your local service representative for further explanation CAUTION Avoidcontactwiththeheatrollerduring operation or shortly after power has been removed from the laminator CAUTION Whenmovingthelaminator...

Page 7: ...ositionjustinfrontoftheheatrollersnip Electrical hazard Thesafetylabelbelowmeansthatyoucouldbeseriously hurtorkilledifyouopentheproductandexposeyourself tohazardousvoltage This label is located on the rear panel in the center of the laminatorjustbelowthefilmsupplyshaftbetweenthepull rollersanddecurlingbar The safety label below means that you should always replace a fuse with the same size and typ...

Page 8: ...nand sprockets of the drive system Thislabelislocatednearalldrivesprocketsonthemachine Sharp knife Thesafetylabelbelowmeansthatyoucouldcutyourself ifyouarenotcareful This label is located on the rear panel in the center of the laminatorjustabovetheElectricalhazardsafetylabeland below the rear slitter Refer to Figure 1 3 1 Safety label placement for illustration ...

Page 9: ...ns Manual Polaris II 1 Between pull rollers and decurling bar 1 Center rear panel below film unwind 2 One on each side of the laminator 2 One on each side of the laminator Located near Fuse Holder Near all sprockets Figure 1 3 1 Safety label placement ...

Page 10: ...Page 1 6 2004 General Binding Corporation Operations Manual Polaris II ...

Page 11: ...f the laminator has been misused mishandled damaged by negligence by accident during shipment or due to exposure to extreme conditions repaired altered moved or installed by anyone other than GBC or its authorized agents or if incompatible film was used GBC s obligation under this limited warranty does not include routine maintenance cleaning adjustment normal cosmetic or mechanical wear nor freig...

Page 12: ...Page 2 2 2004 General Binding Corporation Operations Manual Polaris II This page intentionally left blank ...

Page 13: ...ons Speed up to 50 ft min 6 m min Temperature 7 Settings 225 240 250 260 270 280 290 deg F 3 3 Weight Unpacked 1870 lbs 850 kilograms ShippingWeight 2156 lbs 980 kilograms 3 4 Dimensions W x H x D Refer to Figures 3 4 1 Dimensions Machine 50 5 in x 54 in x 85 in 128 25 cm x 137 cm x 216 cm 105 longwithdeliverytable 3 5 Electrical requirements INFORMATION Refer to the serial plate located on the re...

Page 14: ...Page 3 2 2004 General Binding Corporation Operations Manual Polaris II 54 inches 105 inches 50 5 inches Figure 3 4 1 Dimensions ...

Page 15: ... a clean dust and vapor freeenvironmenttooperateproperly Itmustnot be located where there is air blowing directly on themachine Haveyoucontactedacertifiedelectriciantoboth wirethelaminatorandensurethatadequatepower isbeingsupplied havingtheappropriatecapacity over current protection and safety lockouts are available CAUTION Too high or too low of an operating position can lead to serious bodily in...

Page 16: ...e legs may have been pre assembled at the factory 4 At this time the feed table legs can be adjusted to desiredheight approx16 Tableheight angle depends onthepaperstockbeinglaminated Tightennuts 5 After the feed table is set to desired height mount the tableonthemachineusingthefronttablehooks Toapply the rear catch table first locate the catch table support bar located at the rear of the machine T...

Page 17: ...E The side guides are adjustable to ensure accurate feeding The Polaris is left justified All settings should be set from left to right See Figure 5 1 2 CAUTION The feed guide should be set outside the width of the film The film should be completely inside the sheet being fed 4 SUCTION CUPS The Feed Table works with a seriesofsuctioncups Thesuctioncupbarcanbeadjusted to allow operator to increase ...

Page 18: ...D BLO W ER ADJUSTM ENT KNO BS 9 AIR GAUGE REGULATOR AND VACUUM GAUGE The air pressure gauge and regulator indicate andcontroltheamountofairbeingblownintothefeeder stack Thevacuumgaugeindicateshowmuchsuctionisapplied to the suction assembly See Figure 5 1 5 Figure 5 1 5 Air and Vacuum Gauges A IR G A U G E A IR R E G U L A T O R V A C U U M G A U G E 10 GUIDE WHEELS The guide wheels assist in the e...

Page 19: ...s a brake to applyfilmtensiontoeliminatefilmwrinkles SeeFigure 5 1 8 15 DECURLING BAR The decurling bar is located inthemiddleofthemachine justpastthemainrolls The decurling bar can be adjusted with the decurling bar adjustment knob to ensure a flat output 16 KNIFEASSEMBLY Theknifeassemblyislocated in the back of the machine The knife automatically cuts and separates the sheets as they are run thr...

Page 20: ...emergency stops are located on top of the laminator They can be located by the yellow hazard stickers and should be used to stop themachineintheeventofanemergency Theemergency stop removes power from the machine 23 NIP POINT The point at which two rollers come into contact The nip point of the heat rollers is the place at which the items for lamination are introduced into the laminator CAUTION Onl...

Page 21: ...ete 3 DECREASE SPEED If the laminator is running pressing this button decreases the speed by 3 ft min 4 BLADE RETURN INCH This is a three position switchwithtwofunctions Whentheswitchisinthevertical position themachinerunsnormally Turningtheswitchto theright clockwise andholdingwillinchthelaminator roll forward at 3 ft min Turning the switch to the left counterclockwise willsendtheknifetothehomepo...

Page 22: ...Page 5 6 2004 General Binding Corporation Operations Manual Polaris II Figure 5 2 1 Control panel 1 2 6 3 5 4 ...

Page 23: ... Pressing thisbuttonwilloverridethealarmandallowthemachine torunwhileallowinggapsbetweenthesheets Whenthe button is black with a white M the misfeed sensor is active and will stop the machine when gaps between the sheetsarelargerthan1 4 Whenthebuttoniswhitewith a black M the misfeed sensor is overridden It is not recommended to laminate while the misfeed sensor is overriddenbecausefilmmaysticktoth...

Page 24: ...ressure for the machine Almost all paper stock can be run at HIGH pressure If you experience wrinkles in the paper stop the machine and select a lower pressure You can not adjust the nip pressure while the machine is running PILE TABLE SCREEN PILE TABLE PILE UP PILE DN 1 2 1 PILE UP Continually pressing the PILE UP button brings the paper pile up This button is only active when thelaminatorisstopp...

Page 25: ...eplace 1 Slidethefilmoverthesupplyshaftadhesivesideaway fromtheroller 2 Tighten core ends to secure film on supply shaft 3 Raise the film support arm 4 ScrewintheSupportLockingPinKnobuntilthelocking pinissecuredintothefilmsupplyshaft 5 Spin roll to insure smooth rotation 5 5 Separator Knife Theintegratedsheetseparatorisabletorunwithcontinuous webflowforhighproductionoutput Theprecisionknife separa...

Page 26: ...Page 5 10 2004 General Binding Corporation Operations Manual Polaris II Figure 5 7 1 Manual Tension Knob SUPPLY SHAFT MANUAL TENSION ADJUSTMENT KNOB ...

Page 27: ...ll 3 Load the sheet stack on the feed table Make sure to fan the paper when loading to ensure proper feeding Leftjustifythepaperandadjustpaperguidesasrequired 4 Adjust suction cups on the feeder so that only the suction cups needed are being used To adjust turn off the first suction cup that does not come in contact with the paper stack See Figures 6 1 1 and 6 1 2 Figure 6 1 1 Suction Cup Control ...

Page 28: ...eading card between the nip roller and theheatroller Pushthethreadingcardintothenipofthe mainrollersandthroughthemainrollers 14 Guidethethreadingcardundertheidlerrollerinfront of the decurling bar then over the decurling bar 15 Guide the threading card through the pull rolls See Figure 6 1 3 16 Lowerthepullrollerwiththepullrollerknob 17 Insert another sheet into the nip of the main roller andtheni...

Page 29: ...etheadhesivewillliquify Theresultisabetterbond If you are ever unsure that your laminator is set at the proper setting run a test piece scrap of the same or similarmaterialthroughthelaminator Always use the minimum brake tension necessary to achievethedesiredresults Usingthemaximumamount will yield unwanted results after close inspection You may see stretching waves in the laminate distortion of t...

Page 30: ...p of the heat rollers INFORMATION When feeding long items Skewing may occur if the item is not fed into the laminator straight Use the feed guide and guide wheels to help prevent this from happening INFORMATION If the machine is not working always check if the safety shield is closed emergency stops are not engaged or fuses have not blown before placing a service call ...

Page 31: ...to paper path 18 Startmachinewithknifeon 19 Make adjustments according to Operation Tips to follow Operation Tips Feeding Keep the top of the pile 1 8 from the infeed plate by usingwoddenwedges Keep the front of the pile flat within 1 8 Place 10 15 sheets of scrap paper on top of the job for setup and start Place1 ofscrappaperunderthejobtoinsureallsheets are fed Supplyonlyenoughairtothepaperstackt...

Page 32: ...21 ft min OPP Films for Offset Presses Machine Settings Media Top Roll Temp Bot Roll On Off Nip Pressure Speed 24lb Bond 75 gms 225 Deg F OFF Heavy 27 ft min 80lb Cover 218 gms 225 Deg F OFF Medium 40 ft min 90lb Cover 244 gms 240 Deg F OFF Medium 50 ft min LayFlat Films for Offsett Presses Machine Settings Media Top Roll Temp Bot Roll On Off Nip Pressure Speed 24lb Bond 75 gms 240 Deg F OFF Heavy...

Page 33: ... HAZARD Do not use liquid or aerosol cleaners on the laminator Do not spill liquid of any kind on the laminator You can be severely shocked killed or cause a fire Use only a damp cloth for cleaning unless other wise specified 7 1 Cabinets and cover ELECTRICALHAZARD Removepowerfromthe laminator before cleaning You can be severely shocked killed or cause a fire Use a damp use water only to dampen th...

Page 34: ...e laminator Refer to Figure 7 3 1 Troubleshooting Guide on page 7 3 1 Removethefilmfromthelaminator 2 Preheat the laminator to 240 deg F 3 Rub the top and bottom heat rollers with a clean lint freeclothandmineralspirits 4 Usethe Inching funciontorotatetheheatrollerstoa new area for cleaning Continue this process until the complete surface of both rollers are clean 5 Use a damp cloth to clean the t...

Page 35: ...ed Filmtensionnotsetproperly Adhesive or paper on rollers Roller pressureuneven Crooked infeed Pulloutrollerpressureuneven Film stretchingor shrinking Speed too slow Filmtensiontoohigh Filmtensiontoohighoncorechuck Bindingofcorechuckonshaft Filmnotsticking Machine not up to heat Runningtoofast Nip roller pressure not set properly Using incorrectfilm Excessiveupwardcurl Brakeorfilmtensionsettoohigh...

Page 36: ...Page 7 4 2004 General Binding Corporation Operations Manual Polaris II ...

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