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DS-60 Operation and Maintenance Manual

Operation

© GBC Pro-Tech 1998 January

3-7

352&(66&21752/&+$57

Product:_________________________

Process: Roll to Roll Transfer _________

Date:________________

352&(66&21752/',$*5$0$

Roll to Roll Transfer For Non or Mild-Biased Fabrics

FRONT CONTROL SETTINGS

Speed (Ft/min): 1-4 (30-90 cm/min)

Reverse/Forward: Forward

Roll Up/Down: Down

Top Heater On/Off: On

Roll Pressure: 15-40%

Top Temp. Set: 395 ºF (200 ºC)

Paper

Paper
Rewind

Fabric

Fabric
Rewind

Paper Can
Be Webbed
Either Way

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Summary of Contents for PRO-TECH DS-60

Page 1: ...on in opera tion under norm al condi tions and emerg ency situat ions 3 This mach ine is to be servic ed only by traine d and autho rized perso nnel Follow locko ut proce dures before servic ing 4 Never reach into the mach ine for any reaso n unles s the mach ine is at a COMP LETE STOP 5 Never leave the mach ine stopp ed in such a mann er that anoth er worke r can start the mach ine while you are ...

Page 2: ...his 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 o...

Page 3: ...anel 3 2 Setup 3 2 Heat Press Roll Pressure 3 2 Loading the Materials 3 3 Heating 3 3 Process Control Charts 3 3 Roll to Roll Transfer 3 3 Sheet Feed Transfer 3 4 6HFWLRQ 0DLQWHQDQFH DQG 7URXEOHVKRRWLQJ Thermocouple Positioning and Cleaning 4 1 Cleaning 4 2 Adjusting the Main Roll Nip 4 3 Chain Tensioning 4 4 Lubrication 4 5 Contacting Technical Support 4 5 Troubleshooting 4 5 Ghosting 4 5 Wrinkli...

Page 4: ...DS 60 Operation and Maintenance Manual iv GBC Pro Tech 1998 January Blank page ...

Page 5: ...eye protection on both the infeed and outfeed sides of the nipping rolls to prevent objects from entering the nip The heat press is equipped with four emergency stop buttons located on the top front and back of either side of the heat press Any of these if engaged stops the heat press To continue operation all emergency stop buttons must be in the up position and you must press the reset button ab...

Page 6: ...rushed or burned Do not wear ties loose fitting clothing or dangling jewelry while operating or servicing the heat press These items can get caught in the nip and choke you or you can be crushed or burned Do not operate the heat press near water You can be severely shocked electrocuted or cause a fire POW ER Insert Lock Circuit Breakers Secured in Off Position Remove and lockout power see Figure 1...

Page 7: ... or other sharp instrument during installation or while servicing the heat press You can cause irreparable damage to the rolls Do not operate the heat press if the power cord is damaged or frayed You can be severely shocked electrocuted or cause a fire Contact a qualified electrician to replace the cord Do not attempt to move the heat press across anything other than a flat level surface without t...

Page 8: ...CES WHEN OPERATING OR SERVICING THE HEAT PRESS AND KNOW HOW TO REACT QUICKLY IN AN EMERGENCY DXWLRQ DUQLQJ DEHO RFDWLRQV Posted at various locations on your DS 60 Heat Press are important safety labels PAY CAREFUL ATTEN TION TO THESE LABELS AT ALL TIMES Figure 1 3 shows the location of each of these labels ...

Page 9: ...GA RD E NOT AU S E M ERG E N CY ST OP AR R E T D U R G E N C E Inside cabinet Inside cabinet PRO TECH DS 60 SAFETY INSTRU CTIONS SIC HERH EIT S RICH TLINIEN CO NSIGNESDE SÉCU RITÉ NOT AU S E M ERG E N CY ST OP AR R E T D U R G E N C E CAL 3200 100 90 80 70 60 50 40 30 20 10 SEL RST 1 2 3 4 0 0 0 0 WARNING ACHTUNG MISE EN GARDE WARNING ACHTUNG MISE EN GARDE WARNING ACHTUNG MISE EN GARDE SAFETY INST...

Page 10: ...start the machine while you are working on or within the machine 6 Never change or defeat the function of electrical interlocks or other machine shutdown switches 7 Before starting this machine check that All persons are clear of the machine No maintenance work is being performed on the machine All guards are in place All parent rolls are well chucked in the unwind stands The machine is free of pa...

Page 11: ...le or has a certified electrician been contacted to wire the heat press directly The heat press requires 30A single phase service and a power receptacle that accepts a 30A 250V NEMA L6 30P plug WARNING WARNING WARNING WARNING Failure to follow the preinstallation checklist can result in damage to the heat press The operating environment must be free of dust flammable liquids and vapors You can be ...

Page 12: ...ion DS 60 Operation and Maintenance Manual 2 2 GBC Pro Tech 1998 January Figure 2 1 Heat Press Space Requirements 80 2 m 3 1 m Wall 2 9 84 m 8 6 1 2 2 6 m 8 6 1 2 2 6 m Rear Front 20 6 m Electrical Supply 13 4 m ...

Page 13: ...Have the heat press rolled off the skid and placed on the floor by licensed riggers The ramps included with the heat press can be secured to the edge of the crate bottom using the screws left over from the crate disassembly see Figure 2 2 The unpacking process requires at least two people You can be severely injured or crushed Do not allow the top to fall into the crate It can damage the heat pres...

Page 14: ...er main roll See Maintenance for the proce dure WARNING 6 Replace both cabinet covers Do not attempt to move the heat press across anything other than a flat level surface without trained and qualified riggers You can be crushed or seriously injured The DS 60 Heat Press is a large and heavy piece of equipment It is necessary to employ LICENSED RIGGERS ONLY to move the machine The heat press is not...

Page 15: ...e the following checklist to confirm that the unit is operating properly and that all safety mechanisms are functioning Startup Checklist Start the heat press and go through the following checklist Are the emergency stop buttons working Push down on one of the emergency stop buttons The heat press should stop Pull up on the button and push the reset button on the lower back of the heat press The h...

Page 16: ...Installation DS 60 Operation and Maintenance Manual 2 6 GBC Pro Tech 1998 January Blank page ...

Page 17: ...e system compo nents for the safety of the operator Only a qualified service technician should open these cabinets The heat press is equipped with four emergency stop buttons located on the top front and back of either side of the heat press Any of these if engaged stops the heat press To continue operation all emergency stop buttons must be in the up position and you must press the reset button a...

Page 18: ... main roll on or off 6 TACHOMETER COUNTER DISPLAY Dis plays the operational rate or the amount of material processed 7 MOTION CONTROL FORWARD REVERSE Controls the direction of the drive system forward reverse or stop 8 RUN STOP Turns the drive system on or off 9 PHOTOELECTRIC EYE RESET Resets the photoelectric eye system The photoelectric eye system must be reset any time the heat press is turned ...

Page 19: ...or the basic operations of the heat press GBC Pro Tech Heat Presses respond in a very accurate and repeatable manner The charts provide a way to set up each time every time for repeatable performance by assuring that all controls are set to optimum The process control charts should be kept in this man ual or in a book close to the heat press Encapsulate the popular charts so they can withstand foo...

Page 20: ...he unwind and secure 5 Stop the rolls from turning and raise the upper main roll 6 Web the craft paper through the machine all the way to the rear lower unwind 7 Pivot the idler assembly into its up position and secure it 8 Perform the transfer by inserting the materials into the craft paper main roll nip using the infeed table 9 Start the heat press 10 To stop the transfer stop the machine lower ...

Page 21: ...cess __________________________ Date ________________ 352 66 21752 5 0 IDENTIFICATION DIAGRAM FRONT CONTROL SETTINGS Speed Ft min Reverse Forward Roll Up Down Top Heater On Off Roll Pressure Top Temp Set L U R M F Fixed Idler U Unwind Shaft R Rewind M Upper Main Roll L Lower Main Roll I Infeed Idler In starting up position R F F I U ...

Page 22: ...oll Transfer__________ Date ________________ 352 66 21752 5 0 Roll to Roll Transfer For Biased or Stretchy Fabric FRONT CONTROL SETTINGS Speed Ft min 1 4 30 90 cm min Reverse Forward Forward Roll Up Down Down Top Heater On Off On Roll Pressure 15 40 Top Temp Set 395 ºF 200 ºC Paper Paper Rewind Fabric Fabric Rewind Fabric Can Be Webbed Either Way ...

Page 23: ...oll Transfer _________ Date ________________ 352 66 21752 5 0 Roll to Roll Transfer For Non or Mild Biased Fabrics FRONT CONTROL SETTINGS Speed Ft min 1 4 30 90 cm min Reverse Forward Forward Roll Up Down Down Top Heater On Off On Roll Pressure 15 40 Top Temp Set 395 ºF 200 ºC Paper Paper Rewind Fabric Fabric Rewind Paper Can Be Webbed Either Way ...

Page 24: ...Process Sheet Feed Transfer __________ Date ________________ 352 66 21752 5 0 Sheet Feed Transfer FRONT CONTROL SETTINGS Speed Ft min 1 4 30 90 cm min Reverse Forward Forward Roll Up Down Down Top Heater On Off On Roll Pressure 15 40 Top Temp Set 395 ºF 200 ºC Craft Paper Fabric Image Table Either Unwind Can Be Used Paper Rewind ...

Page 25: ...G To adjust a thermocouple 1 Locate the thermocouple in the middle of the upper main roll on the rear of the heat press 2 Remove the two screws securing the thermocouple to the heat press using the 1 8 hex wrench and take the thermocouple out 3 Inspect the thermocouple If there is any adhesive or dirt on the thermocouple gently clean it off with 80 isopropyl alcohol and a cotton terry cloth Daily ...

Page 26: ...dirt by passing an adhesive coated board through the nip Be sure to set the nip for the thickness of the board used WARNING To clean beads of adhesive from the rolls 1 Allow the heat press to cool completely 2 Set the FWD REV switch to the REV position 3 Clean the upper main roll using a fine soft clean ing pad 4 Clean the lower main roll with either a mild dish washing detergent or a moderate amo...

Page 27: ...ating the lift assembly bolt clockwise to lower the end being adjusted and counterclockwise to raise it Figure 4 3 Nip Setting Assembly Exercise care when cleaning the rolls with 80 isopropyl alcohol Use only in a well ventilated area Wear rubber gloves Use only on cool rolls Cleaning heated rolls can ignite the fumes Use only 80 isopropyl alcohol to clean the lower main roll Harsh chemicals like ...

Page 28: ...chain The tensioner should at this point not be engaging its respective chain 3 Loosen all four motor mount bolts using the 3 16 hex wrench as shown in the figure below The motor should just move freely within the slots Figure 4 5 Adjusting the Chain Tension 4 Using a screwdriver apply a small amount of downward pressure on the motor by prying against the inside of the side frame until there is to...

Page 29: ...mage To help eliminate some of the confusion this guide provides operational parameters for running of the var ious materials These guides are an excellent starting point but there are instances where the suggested oper ational parameters may not produce acceptable output KRVWLQJ This is a term used to describe a shadowing of toner around a transferred image generally caused by exces sive moisture...

Page 30: ...Maintenance and Troubleshooting DS 60 Operation and Maintenance Manual 4 6 GBC Pro Tech 1998 January Blank page ...

Page 31: ...ard 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 ninety day period from the date of delivery CAUTION THE WARRANTY MADE HEREIN IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED IN...

Page 32: ...Warranty DS 60 Operation and Maintenance Manual 5 2 GBC Pro Tech 1998 January Blank page ...

Page 33: ...on a 3 inch 7 6 com inside diameter core maxi mum roll diameter of 10 inches 25 4 cm Speeds 0 to 18 fmp 0 to 5 5 mpm with variable speed reversible action start and stop con trolled either through the instrument panel or with the footswitch Heating Capable of operating tempera tures of up to 475 ºF 235 ºC on the upper chrome roll High output heater to fully replace heat as it is used in the transf...

Page 34: ...Specifications DS 60 Operation and Maintenance Manual 6 2 GBC Pro Tech 1998 January Blank page ...

Page 35: ...dule 4 1 Motor 2 5 4 4 1 Nip 1 2 2 4 2 5 4 1 4 3 2 Options 6 1 3 Photoelectric eye 2 5 Power cord 2 1 Power requirement 2 1 Preinstallation checklist 2 1 Process control charts 3 3 5 Riggers 1 3 2 3 2 4 Roll pressure 3 2 Roll to roll transfer 3 3 6 Safety features 6 1 Safety information 1 1 Safety labels 1 4 Setup procedure 2 4 Sheet feed transfer 3 4 3 8 Specifications Dimensions 6 1 Heating 6 1 ...

Page 36: ...Index DS 60 Operation and Maintenance Manual 7 2 GBC Pro Tech 1998 January Blank page ...

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