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GBC Ultima 65, Service Manual

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TABLE OF CONTENTS 

          

PAGE 

1.0 

Introduction 

 

 

 

 

 

 

 

      1-1 

 

2.0 

Specifications 

 

 

 

 

 

 

 

      2-1 

 

3.0 

Installation  

 

 

 

 

 

 

 

      3-1 

 

4.0 

Operating Instructions  

 

 

 

 

 

      4-1 

      

5.0 

Troubleshooting  

 

 

 

 

 

 

      5-1 

 

5.1 

Theory of Operation  

   

 

 

5.2 

Theory of Successful Lamination  

5.3 

Electrical system 

5.3.1  Heater Control Circuit  
5.3.2  Motor Control Circuit  

           5.4 

Mechanical Operation 

5.5  General Troubleshooting  
5.6  Testing Electrical Components  
5.7  Troubleshooting Guide Chart 
5.8  Electrical Wiring Diagram and Schematics 

5.8.1  Ultima 65 Wiring Schematic 

5.8.2 Ultima 65 Wiring Diagram  
 

6.0 

Disassembly / Assembly / Adjustments    

 

 

     6-1 

 

6.1 

Film Roll Tension Adjustment  

6.2 

Roller Pressure Adjustment 

6.3 

Main PCB (PCB1) Calibration Procedure  

6.4 

Disassembly/Reassemble Procedures 

 

7.0 

Maintenance  

 

 

 

 

 

 

 

     7-1 

 

7.1 

External Cleaning 

7.2 

Heat Tubes (Rollers) and Pull Rollers 

7.3 

Internal Cleaning  

7.4 

Inspection 

7.5 

Lubrication 

              

Summary of Contents for Ultima 65

Page 1: ...ULTIMA 65 GBC National Service Department Printed in U S A Part Number 1722768 Assembly Number 1711501 Issued 01 02 Revision C Copyright General Binding Corporation Northbrook IL U S A SERVICE MANUAL ...

Page 2: ...THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 3: ...neral Troubleshooting 5 6 Testing Electrical Components 5 7 Troubleshooting Guide Chart 5 8 Electrical Wiring Diagram and Schematics 5 8 1 Ultima 65 Wiring Schematic 5 8 2 Ultima 65 Wiring Diagram 6 0 Disassembly Assembly Adjustments 6 1 6 1 Film Roll Tension Adjustment 6 2 Roller Pressure Adjustment 6 3 Main PCB PCB1 Calibration Procedure 6 4 Disassembly Reassemble Procedures 7 0 Maintenance 7 1 ...

Page 4: ...se and Tray Assembly 8 1 3 Left Side Assembly 8 1 4 Right Side Assembly 8 1 5 Frame Assembly 8 1 6 Roller Assembly 8 1 7 Control Panel Assembly 8 1 8 Safety Lever Assembly 8 1 9 Cutter Assembly 9 0 Recommended Spare Parts List 9 1 9 1 Recommended Spare Parts List 9 2 Explanation of Multiplier 10 0 Additional Information 10 1 ...

Page 5: ...Ultima 65 will give customers a simple to use laminator that has the ability to laminate GBC s latest film product the Ultima 1 mil film Ultima film provides superior adhesion and higher gloss for better clarity Ultima film seals at a lower operating temperature temperature range 200 275 F 93 135 C Ultima 1 mil film is 27 in width not 25 This feature allows a larger border for customers laminating...

Page 6: ...se Single Phase Dimensions 32 5 in 83cm Wide 21 0 in 53cm Long 12 0 in 31cm High Weight 85 lb 39kg Speed Variable from1 5 Feet 45 6cm to10 Feet 3m per minute Warm Up Time Approximately 10 Minutes Laminating 200 F 93 4 C To 290 F 143 4 C Temperature Range Laminating Width 27 68 cm Film 1 Mil 1 5Mil and 3Mil Capacity 1 Poly In Film 1 Core Diameter Allowable Maximum thickness is 1 16 1 59mm Product T...

Page 7: ...aminator should be positioned to allow exiting film to drop freely to the floor Accumulation of laminate immediately behind the laminator as it exits the equipment may cause the film to wrap around the pull rollers wrap up condition 4 Avoid locating the laminator near sources of heat or cold Avoid locating the laminator in the direct path of forced heated or cooled air 5 Connect the attachment plu...

Page 8: ... Default setting is speed 5 Use the SPEED GUIDELINES as a reference or starting point LOWER SPEED for thicker materials dark colors and heavy ink coverage INCREASE SPEED for thinner materials and lighter colors NOTE During the initial warm up period the roller temperature will rise above the optimum operating temperature then fall back To reduce the effects of excessive heat on your materials when...

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Page 19: ...n lamination processes This may require the use of pressure sensitive adhesive PSA NAP LAM II Vinyl Premium or HI TAC type film products Some paper and card stocks are coated with silicones wax or varnish which inhibit the ability of molten polyethylene to stick tightly to individual paper fibers In such cases a superficial bond develops which may be adequate depending upon intended use of the fin...

Page 20: ...on with the Main PCB Control Panel PCB triac thermocouple temperature sensor assembly and the thermal cutoff TCO The Heater Control Circuit is comprised of the following electrical components 1 Infrared heater assemblies IR1 IR2 Resistor type heaters that generate heat when activated Resistance for the Ultima 65 16 ohms All values 1 ohm 2 Main PCB PCB1 Main control board responsible for the contro...

Page 21: ...C voltage to the motor of 7 30 VDC depending on speed the faster the speed the more voltage present 3 3 amp SLO BLO fuse F1 Overload protection of the motor 4 Motor M1 35 VDC Motor windings 4 5 8 ohms 5 4 Mechanical Operation The chain driven lower rollers are powered by the drive motor and the Control Panel PCB PCB2 speed selector During operation the upper heat roller and upper pull roller are c...

Page 22: ...LECTRICAL SHOCK WHEN TESTING ELECTRONIC COMPONENTS SERVICE SHOULD BE PERFORMED BY QUALIFIED GBC SERVICE TECHNICIANS ONLY PLEASE CALL GBC FOR SERVICE 1 800 790 7787 5 6 Testing Electrical Components All electrical components can be tested by using a variety of test equipment to check for continuity resistance voltage and amperage 5 7 Troubleshooting Guide Chart The Troubleshooting Guide Chart that ...

Page 23: ...ough or Main PCB PCB1 not Calibrate Main PCB PCB1 using too hot calibrated current calibration procedures Triac failed Test triac replace if needed Heat sensor failed Test continuity replace if needed Power heat will Bad connections Inspect for loose connections not run Blown motor fuse Check continuity replace if needed Interlock switches not engaged Ensure tray and shield switches are engaged Ba...

Page 24: ...Theory of Successful Lamination in section 5 2 Incorrect tension Follow Film Tension Adjustment in section 4 0 pg 4 5 Operating Instructions Incorrect roller pressure Adjust roller pressure Consistent wrap ups Dirty rollers Follow Caring For Your Laminator adhesive marks in section 4 0 Operating Instructions on product SERVICE SHOULD BE PERFORMED BY QUALIFIED GBC SERVICE TECHNICIANS ONLY PLEASE CA...

Page 25: ...ULTIMA 65 ELECTRICAL WIRE SCHEMATIC 120VAC 5 7 ...

Page 26: ......

Page 27: ...5 8 ...

Page 28: ... 6 1 1 Ultima 65 Brake Adjustment Procedure 1 To adjust the bottom brake push and hold the brake lever located on the left side frame by the roll film Rotate the roll of film until the lever engages the internal mechanism Once engaged rotate the film forward to increase the tension and backwards to decrease the tension 2 Release the brake lever and check the tension by rotating the roll of film Re...

Page 29: ...st the rear Pull Rollers The eyebolt on the right and left side should be tightened until only 4 5 threads are showing above the adjusting nut 4 Adjust the front Heat Tube Rollers The Pressure Hex Screw on the right and left side should be flush with the top of the roller bracket 5 Run a test product and readjust if necessary 6 2 ...

Page 30: ...the two pin connector 1 1 located at the top center area of the PCB identified as GND Locate test points on Main PCB and connect spring clips on leads from VOM to test points 8 Attach the Amp Probe to the infrared heater wires 9 Plug the laminator into a suitable 120V 60Hz outlet 10 Turn power switch to the On position 11 Set control panel on 1 5 3 mil setting with film on the unit and threaded 12...

Page 31: ...o blister 18 When the unit is heating monitor the Amp Probe for meter deflection The Amp Probe should deflect to indicate that Laminator is heating and zero out once the unit has gone to ready 19 The temperature can be fine tuned while the Laminator is hot by adjusting SV2 Turn SV2 clockwise to decrease heat and counter clockwise to increase heat Adjust SV2 in small increments and then wait at lea...

Page 32: ...ALTERNATIVE ULTIMA 65 CALIBRATION Adjust SV1 to 60 ohms at the points shown below Do this with the machine cold and the P C Board removed from machine Figure 1 6 5 ...

Page 33: ...rmocouple in the nip of the heat rollers or infrared temperature sensor pointed right on the nip Heat the laminator until the amprobe registers no pulse deflection Temperature will probably be 225 F to 245 F Turn SV2 8 TO 10 full rotations counterclockwise and let temperature increase until it has held and stopped climbing for at least 5 minutes The amprobe will probably register pulse deflection ...

Page 34: ...e a towel to prevent burns and to prevent oil from getting on the Infrared Heaters from your hands Oil on the Heaters can shorten their life expectancy Set aside the Infrared Heaters in a safe area to prevent breakage 8 Remove right Heat Tube Roller Pressure Hex Screw and Spring Note When reassembling refer to 6 2 for Heat Tube Roller Pressure Adjustment 9 Remove left Heat Tube Roller Pressure Hex...

Page 35: ...ove Socket Cap Screw and Metal Sleeve from the Lower Left Pull Roller 5 Remove Right Hex Nut from Pull Roll Tension Bolt Lift up Tension Lever to release Pull Roll Tension Bolt Remove Left Hex Nut from Tension Bolt Lift up Tension Lever to release Pull Roll Tension Bolt 6 Remove 3 Phillips Screws from the right Idler Gear Support and remove Support and Idler Gear 7 Loosen 2 Set Screws on the Upper...

Page 36: ...scouring pad greenie Cleaning kits are available see sections 8 1 10 and 8 2 12 for part numbers DO NOT CLEAN THESE ROLLERS WITH ANY LIQUIDS OR HARSH ABRASIVES 7 2 Internal Cleaning No periodic internal cleaning is required However when the s ide covers have been removed for corrective maintenance wipe away any dust that may have collected on lubricated parts with a soft cloth leaving as much lubr...

Page 37: ...n the parts list When ordering service parts always include the following information 1 Machine Model Number 2 Machine Serial Number 3 Part Number 4 Part Name 5 Quantity Required Note The Service Parts Department does not stock all hardware to avoid delay standard hardware shown in the parts list should be purchased locally whenever possible 8 0 ...

Page 38: ...8 1 1 COVER ASSY AND FILM ROLL SUPPORT 8 1 ...

Page 39: ...621 603030611 TAKING BAR FOR ROLL COVER 1 4 1711629 613030306 BUSHING 2 5 1711622 601220131 FILM GUIDE SCREEN UPPER 1 6 1711627 613030211 HEX FILM SHAFT 2 7 1720571 613030527 THUMB SCREW 4 8 1711570 604037021 1 CORE ADAPTER 4 9 1711623 603030612 CENTER PIN FOR ROLL COVER 1 10 1711624 1929222 ROLL PIN 1 USE GMP PART NUMBERS WHEN ORDERING PARTS 8 2 ...

Page 40: ...8 1 2 CASE AND TRAY ASSEMBLY 8 3 ...

Page 41: ...2031 PAPER GUIDE 1 4 1711657 604022001 LEFT SIDE COVER 1 5 1711634 604036021 FRONT TABLE 1 6 1711633 613030614 LEVER CAP FOR FRONT TABLE 1 7 1712263 701108133 SCREW FOR PAPER GUIDE 1 8 1711568 613030541 FRONT TABLE SUPPORTS 2 9 N A 803040370 SPEED GUIDELINES LABEL Not Shown 1 10 1712122 701104504 COVER SCREWS Not Shown 8 USE GMP PART NUMBERS WHEN ORDER PARTS 8 4 ...

Page 42: ...8 1 3 LEFT SIDE ASSEMBLY 8 5 ...

Page 43: ...30316 POWER CORD USA 1 10 1711585 704030703 POWER CORD JAPAN 1 10 1711581 704030416 POWER CORD UK 1 10 1711583 704031310 POWER CORD AUST 1 11 1711584 704140403 STRAIN RELIEF 1 12 1712650 704090102 POWER SWITCH 1 13 1711586 601310506 POWER PANEL 1 14 1711650 706011116 MAIN PCB 115V 1 14 1711653 706011112 MAIN PCB 230V 1 15 1711589 601310507 BRACKET CIRCUIT BREAKER 1 16 1711588 704091031 CIRCUIT BRE...

Page 44: ...8 1 4 RIGHT SIDE ASSEMBLY 8 7 ...

Page 45: ...0 1 4 1711573 613030540 CENTER PIN FOR IDLER GEAR 1 5 1711574 701070150 CHAIN 1 6 1711575 601310504 IDLE GEAR SUPPORT 1 7 1720608 701090158 COIL SPRING TENSION PLATE 2 8 1712549 601230802 TENSION PLATE FOR MANDREL 2 1970104 1970104 NOT SHOWN 3A SLO BLO MINI FUSE PCB 1 1970120 1970120 NOT SHOWN 3A SLO BLO REGULAR FUSE IN LINE 1 USE GMP PART NUMBERS WHEN ORDERING PARTS 8 8 ...

Page 46: ...8 1 5 FRAME ASSEMBLY 8 9 ...

Page 47: ... 1711558 610010209 TRANSFORMER UK 1 4 1711561 601230451 UPPER REAR COVER 1 5 1711562 601230452 LOWER REAR COVER 1 6 1711560 601230216 RIGHT SIDE PLATE 1 7 1711652 706040202 HEAT SENSOR THERMO COUPLE 1 8 1711563 601230111 FRONT BASE PLATE 1 9 1711564 601220132 LOWER FILM GUIDE SCREEN 1 10 1711565 703010111 RUBBER FOOT 4 11 1711559 601230215 LEFT SIDE PLATE 1 USE GMP PART NUMBERS WHEN ORDERING PARTS...

Page 48: ...8 1 6 ROLLER ASSEMBLY 8 11 ...

Page 49: ...LLER CENTERED PIN 2 17 1711601 701090157 PULL ROLLER TENSION SPRING 2 18 1711602 603030539 PULL ROLL CENTER PIN 2 19 20 1711647 607040556 UPPER LOWER HEAT TUBE 1EA 21 1711618 701090115 COMPRESSION COIL SPRING 2 22 1712095 701050234 BEARING FLANGE 1 23 1711603 701090718 GRIP RING 2 24 1711609 603030162 LOWER IDLE ROLLER 1 25 1711555 603030151 SUPPORT BAR 1 26 1711648 706025028 INFRARED HEATER 2 172...

Page 50: ...8 1 7 CONTROL PANEL ASSEMBLY 8 13 ...

Page 51: ...ONTROL KEY 1 5 3 MIL GREEN 1 6 N A 703020504 CONTROL KEY FAST BLACK 1 7 N A 703020505 CONTROL KEY SLOW BLACK 1 8 N A 703020506 CONTROL KEY REVERSE BLACK 1 9 N A 703020507 CONTROL KEY RUN GREEN 1 10 N A 703020508 CONTROL KEY STOP BLACK 1 11 1711655 704090313 SWITCH MEMBRANE RUBBER 1 12 1711656 706011113 CONTROL PANEL PCB ASSY 1 13 1711641 701104803 SCREW 1 14 1711659 704161717 CONTROL PANEL CABLE 8...

Page 52: ...2074 613030613 LEVER FOR FRONT TABLE 1 2 1711638 601310511 LEVER GUIDE FOR FRONT TABLE 1 3 1711636 701090721 RETAINING RING 1 4 1712612 701090160 COMPRESSION COIL SPRING 1 5 1911303 1911303 MOUNTING SCREWS NOT SHOWN 2 USE GMP PART NUMBERS WHEN ORDERING PARTS 8 15 ...

Page 53: ...LITTER ASSEMBLY 1 6 1 1 1712134 701110101 NUT 2 2 1720586 604022034 SLITTER LEVER 1 3 1154019 1154019 SLITTER BLADE 1 4 1711641 701104803 SCREW 2 5 1712611 701090159 TENSION COIL SPRING 1 6 1720585 604022033 SLITTER HOUSING 1 USE GMP PART NUMBERS WHEN ORDERING PARTS 8 16 ...

Page 54: ...SENSOR THERMO COUPLE 0 2 1711651 704150107 THERMAL CUT OFF T C O 0 2 1711650 706011116 MAIN P C BOARD 115 VOLT 0 2 1711656 706011113 CONTROL PANEL P C BOARD 0 1 1711655 704090313 CONTROL PANEL MEMBRANE 0 04 1711554 07050703 TRIAC 0 2 1711588 704091031 15 AMP CIRCUIT BREAKER 0 2 1720524 609020200 DC MOTOR 0 04 1711570 604037021 1 CORE ADAPTOR 0 1 1720571 613030527 THUMB SCREW FOR CORE ADAPTER 0 1 1...

Page 55: ...ection contains information released after the manual was published All information pertinent to this unit should be inserted in this section whether it is published in a National Service Bulletin or obtained from any other source 10 1 ...

Page 56: ...the Triac it must be tested out of the circuit and at room temperature Use an Ohm meter to take the readings between the leads as follows RED YELLOW OPEN BLUE YELLOW OPEN RED BLUE CLOSED ROLLER PRESSURE ADJUSTMENT When adjusting the roller pressure on the Ultima 65 keep in mind that the adjustments must be the same on both sides left to right as follows FRONT ROLLERS the setscrew must be flush wit...

Page 57: ... 15 98 Helpful Hints Bulletin The following is a copy of the September 1997 issue vol 1 EAGLE EYE TECHNICAL INFORMATION bulletin published by the Color Finishing Division It offers excellent information and procedures for determining problems associated with GBC s new Color Finishing Laminators Please review and ad this NSB to your Ultima65 and Eagle Series Service Manuals EAGLE EYE TECHNICAL INFO...

Page 58: ...d for this application Thickness of product plays an important part in the laminator s ability to seal at the edge As the thickness of the material increases the chance of achieving a sealed edge decreases Too little or too much heat or roller pressure Excessive heat usually causes waves or warping of the finished product Heat problems may also appear in the form of air bubbles Silvering is a cond...

Page 59: ...test with front heat rollers first Place the strips at an equal distance left center and right 4 Apply full pressure to the rollers and lock the rollers in place 5 Holding the strip at the end centered try to pull the paper out of the nip point at each area 6 If the paper can be pulled from any of these points additional pressure should be added to the right or left side to increase the pressure a...

Page 60: ...ke 2 full turns on each of the four rear pressure roller tension screws After making the roller adjustments apply full pressure to the rollers and run the machine empty allowing components to find a home position Follow the previously stated Paper Pull test and Footprint evaluation ULTIMA65 NOTES We have received several instances of the Ultima65 being too hot or too cold Remember the reset temper...

Page 61: ...S EAGLES INSTALLATION Date 2 28 00 Installation of Eagles and Ultima machines should include removing the side panels and checking for any loose screws and or connections particularly on the P C Boards This should also be a standard procedure when performing service on any of these models 10 7 ...

Page 62: ...ring the Ulitma 65 to current specs are listed below Part Number 1722626 has been assigned to the upgrade kit This upgrade kit should only be ordered for gray roller machines when overheat symptoms occur The technician must then close the call as a 02 warranty using the kit part number Part Description Qty 1711647 Heat Roller 2 1711648 Infrared heater 2 1711650 Main PCB 1 1711656 Control PCB 1 171...

Page 63: ...ion Fixture part number 1700407 Once the inventory has been depleted the Service Parts Dept will be stocking a new Universal Type A Calibration Fixture This Calibration Fixture part number 706111164 can be used on all current GMP Laminators including the Pouch Laminators However the Type A Calibration Fixture will not work with the TITAN 165 110 The TITAN 165 110 Calibration Fixture Type B can be ...

Page 64: ...INFRARED HEATER ASSEMBLY Date 02 11 02 This NSB supersedes and obsoletes NSB 210N dated 4 25 01 Listed below are the individual components for the Ultima 65 Infrared Heater Assembly PART NO DESCRIPTION 701110504 Glass Tube Cap 701108106 Heater Wire Holding Bolt 703050210 Inside Ceramic Insulator 703010309 Silicone Washer 703050205 Outside Ceramic Insulator 6130422 Hexagon Nut R P 10 10 ...

Page 65: ...an start running the machine again There are a number of variables that will cause the machine to turn off while running here is what to check for The 15 Amp Circuit Breaker may have tripped If you have to reset the Circuit Breaker several times in a short period of time the Breaker may have become weak and must be replaced with part number 704091031 Check Safety Shield and Feed Table Tray Interlo...

Page 66: ...5 AND 105 Date 07 18 02 HEATER JUMPER WIRES W CONNECTORES Part number 704161716 is for the Ultima 65 Heater Jumper Wires with Eyelet Connectors Part number 704161803 is for the Eagle 35 65 105 Heater Jumper Wires These wires connect to the ceramic ends of the infrared heaters Please update your Service Manual with this information NOTE Parts are on order and should be in stock within 6 to 8 weeks ...

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