SERVICE MANUAL

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

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TABLE OF CONTENTS

PAGE 1-1

Theory of Operation Theory of Successful Lamination 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

Disassembly / Assembly / Adjustments

Film Roll Tension Adjustment Roller Pressure Adjustment Main PCB (PCB1) Calibration Procedure Disassembly/Reassemble Procedures

External Cleaning Heat Tubes (Rollers) and Pull Rollers Internal Cleaning Inspection Lubrication

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TABLE OF CONTENTS

PAGE

Ultima 65 Parts List

8.1.1 Cover Assembly and Film Roll Support Shafts 8.1.2 Case 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 Recommended Spare Parts List 9.2 Explanation of Multiplier

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1.0 INTRODUCTION

Congratulations on your purchase of General Binding Corporation’s latest series of laminators. The Ultima 65 series laminator will provide you with high quality lamination and versatility, at an affordable price.

The 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 posters that are 24” in width.

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2.0 SPECIFICATIONS

115 VAC MODEL

230 VAC MODEL

Required Power Supply:

120 VAC +/-10% – Two Wire Service Plus Ground 15 Amps, 60 Hz Single Phase

230 VAC +/-5% Two Wire Service Plus Ground 7.8 Amps, 50 Hz Single Phase

Electrical Operating Power:

120 VAC, 15 Amps 1800 Watts, 60 Hz Single Phase

230 VAC, 7.8 Amps 1800 Watts, 50 Hz Single Phase

Dimensions:

32.5 in. (83cm) Wide 21.0 in. (53cm) Long 12.0 in. (31cm) High

Weight:

Speed:

Variable from1.5 Feet (45.6cm) to10 Feet (3m) per minute.

Warm Up Time:

Laminating Temperature Range:

200° F (93.4° C) To 290° F (143.4° C)

Laminating Film Capacity:

Width 27” (68 cm) 1 Mil, 1.5Mil, and 3Mil 1” Poly-In Film, 1” Core Diameter

Allowable Product Thickness:

Maximum thickness is 1/16” (1.59mm)

Applications:

Teaching Aides Posters Literature Lightweight materials

Standards:

UL, CE, CSA listed

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3.0 INSTALLATION

Closely inspect the unit prior to opening. All shipping damage should be brought to the immediate attention of the delivering carrier.

Place the laminator on a stable flat surface capable of supporting at least 95 lbs. The surface should be at least 30 inches high to assure comfortable positioning during operation. All four rubber support feet should be positioned completely on the supporting surface. The supporting surface may also be large enough to hold the material to be laminated.

The laminator 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).

Avoid locating the laminator near sources of heat or cold. Avoid locating the laminator in the direct path of forced heated or cooled air.

Connect the attachment plug provided with the laminator to a suitably grounded outlet only.

Avoid connecting other equipment to the same branch circuit to which the laminator is connected as this may result in nuisance tripping of circuit breakers or fuses.

Please read the operating instructions thoroughly before operating your laminator.

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GBC Ultima 65 Laminator Helpful operating hints for safe, quality lamination

LOCATION OF THE LAMINATOR

Position your laminator away from drafts that can affect roller temperature.

FILM LOADING TIPS

It is recommended that LOADING and UNLOADING be performed when the laminator is COLD. After removing the old rolls, check the rollers for adhesive residue. Gently rubbing with Scotch Brite pad, then wiping with a damp cloth can easily remove it. Always change the top and bottom film rolls at the same time. Be sure to use the CORE ADAPTERS from the PREVIOUS ROLL.

Laminating film MUST UNWIND FROM THE BOTTOM OF THE ROLL (dull side up) shiny side must be against the rollers. Use the FILM ALIGNMENT GUIDES on the film shafts to be certain that the top and bottom rolls are aligned properly. When loading, unwind top and bottom film rolls enough to allow film slack for threading. REMEMBER TO: 1) reposition the idler bar in the “J” channel, 2) lower the safety shield, and 3) position the feed tray so the safety latch is engaged.

START SLOW

Turn the power switch ON. Machine will default to the 1 MIL/SPEED 5. If using 1.5 or 3 MIL film, you must press the 1.5/3 MIL button. SELECT lamination SPEED. 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 you start, REDUCE THE SPEED TO SETTING 2 FOR THE FIRST FEW FEET OF OPERATION. Once the temperature has stabilized, resume running at the “suggested starting” speeds, indicated on the SPEED GUIDELINES chart which corresponds to the thickness of the material.

READY TO BEGIN

Begin laminating only after READY light is lit. DO NOT RUN the laminator when it is COLD. Damage to the rollers will result. PRESS RUN: While running the laminator, watch the adhesive melt line (the point where the film begins to appear very clear). If the melt line is AT OR ABOVE the point where the film and heat roller meet, the selected SPEED IS OK. If the melt line shifts BELOW the film and heat roller contact point, DECREASE SPEED or stop momentarily until the melt line moves up. DO NOT STOP machine while documents are passing through the heat rollers.

IN THE EVENT OF A WRAP-UP

Cut the top and bottom film webs. Be sure to HOLD DOWN the REVERSE BUTTON while pulling the wrapped film from the pull roll.

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5.0 TROUBLESHOOTING

The laminator uses heat, pressure, tension and speed to continuously apply adhesive coated laminating film to both sides of sheet type materials simultaneously. Both electrical and mechanical properties of this laminator are described in this section. Electrical schematics and wiring diagrams are also provided in this section. A basic understanding of the theory of successful lamination is required for all personnel servicing the Ultima 65.

Theory of Successful Lamination

To obtain the ultimate in a successful laminate, three factors should be present:

1. The product to be laminated should be receptive to, and capable of attaining, a good bond with molten polyethylene adhesive.

Most paper products can be laminated with a high degree of integrity. This is because molten polyethylene cements to individual fibers of the paper surface. The rougher the surface texture, the more fibers are exposed to adhesive and the better the bond between adhesive and product. Many substances are applied to paper products, which impair bond between fibers and the molten adhesive. Ink and other printing products affect this bond. While good adhesion occurs between molten adhesive and ink, poor adhesion may exist between ink and its parent paper. Some ink products are heat sensitive and/or lack the ability to be bonded by certain 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 finished laminate.

Smooth surfaces, especially photographic, metallic, and plastic, are difficult for polyethylene to bond to, since no fibers are exposed for the adhesive to contact. This may require the use of other film products to laminate correctly.

Products containing moisture will not laminate well since the fluid converts to steam, forms bubbles, and impairs lamination.

2. At the moment of lamination, the product - polyethylene interface - both top and bottom, must reach the lamination film’s proper operating temperature. Superficial bonds develop at lower temperatures, and the finished laminate may be adequate for its intended use. However, for proper lamination please consult the lamination guide in section 10.Thickness/color of a product bears heavily on the ultimate integrity of the bond, since the thicker/darker a product; the more heat is extracted from the heat rolls. Thicker/darker products may extract heat faster than the machine can put in, and after 20 feet or so, the interfacial temperature may drop below the critical point. Generally speaking, most card stocks whose thickness is on the order of 0.012” thick can be laminated on a continuous basis.

5.0 TROUBLESHOOTING

Theory of Successful Lamination (continued)

3. Total encapsulation of product, with a complete film-to-film border, is often recommended to prevent an otherwise successful laminate from splitting within itself.

Total encapsulation of product, of course, prevents splitting from casual abuse of a corner or edge of the laminate, and obviously, moisture vapor or liquid cannot enter to weaken the laminated product.

Flush cutting of laminated product, or even slightly into the product, yields a neat, trim appearance but renders the product sensitive to splitting at the edges and particularly at corners. The split occurs within the product and not at the adhesive product interface. Flush cutting also leaves a paper edge exposed to the atmosphere and any moisture vapor it contains. However, this may be of little consequence unless the laminate is exposed to an actual liquid, where upon the fibers within the product loosen from one another and splitting occurs.

5.3.1 Heater Control Circuit

The heater circuit is responsible for the temperature and power regulation of the infrared heater assemblies, working in conjunction 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:

Infrared heater assemblies (IR1 & IR2): Resistor type heaters that generate heat when activated. Resistance for the Ultima 65 = 16 ohms (All values +/- 1 ohm).

Main PCB (PCB1): Main control board responsible for the control of all electrical components in the machine. SV1 on the PCB, sets the ambient temperature of the machine. SV2 on the PCB, sets the high temperature setting and the ready light on the Control Panel PCB. These 2 potentiometers work in conjunction with the other, when you adjust one the other will also be affected.

3. Control Panel PCB (PCB2): Features all the controls and LED indicators for interface with the operator and the laminator.
4. Triac (TR1): Voltage applied to the triac is routed through the Main PCB (PCB1) to the Infrared Heaters (IR1 & IR2). This triac can be tested by removing the red and yellow leads from the Main PCB and taking a resistance reading of open. If you get an indication of a short, then the triac has failed closed.
5. Thermocouple (TSA1): The temperature sensor provides a heat reference for the Main PCB (PCB1). This sensor should read a short when cold. Ultima 65 has 1 wrap capton tape. These sensors should be soldered and have no air pockets.

5.0 TROUBLESHOOTING

5.3.1 Heater Control Circuit (Continued)

6. Thermal cutoff (TCO1): Provides overheat protection of the heater circuit. Earlier versions have a resettable type TCO and the current production models have a nonresettable type TCO. These TCO’s should always read a short and will trip when the TCO reaches a temperature of 248°F (120°C).

WARNING! NEVER OPERATE THE LAMINATOR WITH THE TCO REMOVED FROM THE HEATER CIRCUIT! DAMAGE TO THE LAMINATOR AND A FIRE HAZARD MAY RESULT!

5.3.2 Motor Control Circuit

Power is supplied to the Motor Control Circuit when the RUN button on the Control Panel PCB (PCB2) is depressed. This circuit is comprised of the Control Panel PCB, Main Control PCB, 3 amp SLO-BLO fuse and the motor.

1. Control Panel PCB (PCB2): Features all the controls and LED indicators for interface with the operator and the laminator.

Main PCB (PCB1): Main control board responsible for the control of all electrical components in the machine. Should supply output DC 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.

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 clamped tightly against the respective lower roller by adjustable spring pressure. Both upper heat and pull rollers are driven under pressure by the lower rollers respectfully. The laminating film is compressed by both sets of rollers, however, the primary pressure is applied by the pull rollers and the heat rollers provide only nip pressure. Bronze bushings support the rear rollers and provide smooth even roll during operation. Roller bearings support the front rollers. The two film webs are stretched tight as they leave the supply rolls and enter the nip of the heat rollers. Two adjustable brake assemblies located on the left side frame provide tension. The upper and lower brake assemblies restrict or “drag” the respective supply roll shafts as the shafts revolve.

5.0 TROUBLESHOOTING

Malfunction corrections are based on visual observations by the operator and the technician. The cause of malfunctions are isolated by the symptom of the malfunction and noting at which point in the operating cycle the malfunction occurred. Malfunctions that occur during operation can be pinpointed to a defective electrical circuit or to a mechanical part by referring to the “Theory of Operation” in the preceding paragraphs and to the electrical schematic diagrams and electrical wiring diagrams.

WARNING! POSSIBILITY OF ELECTRICAL SHOCK WHEN TESTING ELECTRONIC COMPONENTS. SERVICE SHOULD BE PERFORMED BY QUALIFIED GBC SERVICE TECHNICIANS ONLY. PLEASE CALL GBC FOR SERVICE 1-800-790-7787.

All electrical components can be tested by using a variety of test equipment to check for continuity, resistance, voltage and amperage.

The Troubleshooting Guide Chart that follows is arranged in order of the normal operational sequence. When a malfunction occurs, read down the SYMPTOM column until you reach the description for your symptom. Read the corresponding PROBABLE MALFUNCTION, and then perform the recommended procedure in the CORRECTIVE ACTION column. Refer to the wiring diagrams to resolve any wiring difficulties that may occur.

5.0 TROUBLESHOOTING

5.7 TROUBLESHOOTING GUIDE CHART

SYMPTOM

PROBABLE MALFUNCTION

CORRECTIVE ACTION

No outlet power. Power cord disconnected. Blown fuse. Tripped circuit breaker. Tripped TCO. Power switch. Bad connections. Bad Main PCB (PCB1).

Check outlet for correct voltage. Connect power cord. Check continuity, replace if needed. Reset circuit breaker. Reset or replace TCO. Replace switch. Inspect for loose connections. Replace board.

Bad connections. Infrared heaters bad.

Triac failed. Heat sensor failed. Bad Main PCB (PCB1).

Inspect for loose connections. Check for 16 Ohms, if not replace heaters. Test triac, replace if needed. Test continuity, replace if needed. Replace board.

Not hot enough, or too hot.

Main PCB (PCB1) not calibrated. Triac failed. Heat sensor failed.

Calibrate Main PCB (PCB1) using current calibration procedures. Test triac, replace if needed. Test continuity, replace if needed.

Power, heat, will not run.

Bad connections. Blown motor fuse. Interlock switches not engaged.

Bad Main PCB (PCB1).

Inspect for loose connections. Check continuity, replace if needed. Ensure tray and shield switches are engaged. Check continuity, replace if needed. Check for 3-32 VDC, replace if needed. Test output, replace if needed.

Runs one speed or reverse only.

Bad Main PCB (PCB1). Bad Control Panel PCB (PCB2).

Replace Main (PCB1). Replace Control Panel (PCB2).

Unit does not go to ready.

Main PCB (PCB1) not calibrated.

Calibrate Main PCB (PCB1) using current calibration procedures. Replace Control Panel (PCB2). Test continuity, replace if needed.

Bad motor. Bad Transformer.

Bad Control Panel PCB (PCB2). Heat sensor failed.

5.0 TROUBLESHOOTING

5.7 TROUBLESHOOTING GUIDE CHART (Continued)

SYMPTOM

Poor lamination quality.

PROBABLE MALFUNCTION

Laminator settings incorrect for product being laminated.

Consistent wrap-ups, Dirty rollers. adhesive marks on product.

CORRECTIVE ACTION

Follow lamination guide in section 10 and the “Theory of Successful Lamination” in section 5.2. Follow Film Tension Adjustment in section 4.0 pg 4-5 Operating Instructions. Adjust roller pressure.

Follow “Caring For Your Laminator” in section 4.0 Operating Instructions.

SERVICE SHOULD BE PERFORMED BY QUALIFIED GBC SERVICE TECHNICIANS ONLY. PLEASE CALL GBC FOR SERVICE 1-800-790-7787.

6.0 ADJUSTMENTS

6.1 Film Roll Adjustment

Proper film tension, known as brake tension, is the minimum amount required to eliminate wrinkles in the finished item. The film tension is set at the factory. Tension adjustments are not necessary if you are using 1.5 or 3-mil GBC film, unless the lamination is curling up or down. Generally, 5 and 10-mil film requires more tension; and, as the film roll becomes smaller, tension increases, requiring more adjustments. Film tension should be checked occasionally to assure the adjustment is correct.

The film should be taut. A properly adjusted roll of film should not require excessive force to turn by hand. Film tension should be enough to introduce a minor amount of drag as the film unrolls. Insufficient tension causes wrinkles, while too much tension causes stretching (necking). Uneven tension between the top and bottom rolls creates curl. Too much upper tension creates upward curl (smile). Too much lower tension causes downward curl (frown).

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. Resistance should be slight, not forced.
3. To adjust the top brake, repeat steps 1 and 2.
4. Laminate some test samples to check for proper tension. Readjust if necessary.

6.2 Roller Pressure Adjustment

The tension on the roller pressure springs determine the pressure between the two top rollers and the associated bottom rollers. Ordinarily, the springs require no adjustment. However, if the springs have been removed or if the tension has been changed, readjustment will be required. Replacement should be considered for those springs that can no longer be adjusted or have little effect. The pressure applied should be enough to enable the rollers to pull the film and product being laminated through, however it should not be so great that it causes marks on the film or product.

6.0 ADJUSTMENTS

6.2.1 Ultima 65 Roller Pressure Adjustment (Continued)

1. Turn machine off.
2. Remove right and left side covers.
3. Adjust 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.

6.0 ADJUSTMENTS

6.3 Main PCB (PCB1) Calibration Procedure

The Main PCB must be calibrated when replaced. To calibrate the PCB use the calibration fixture GBC P/N 706111164, and follow the calibration procedure outlined below. Calibration must be performed with the new board installed in the machine.

1. The following tools are required to calibrate the Ultima 65.

A. Calibration Fixture (GBC P/N# 706111164)

B. Amp Meter (Amp Probe) (GBC P/N# 1999105)

C. Volt Ohm Meter with spring clips

D. Precision Screwdriver

E. Infrared Temperature Sensor (GBC P/N# 1722303)

Calibration must be performed when laminator is cold. Unplug machine from 120V 60Hz outlet. Remove left side cover (facing the front of unit). Disconnect thermal sensor from Main PCB at the (- S/N +) and connect calibration fixture in its place. Set VOM to measure DC voltage. Test points are on 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. Attach the Amp Probe to the infrared heater wires. Plug the laminator into a suitable 120V 60Hz outlet. Turn power switch to the (On) position. Set control panel on (1.5 / 3 mil setting) with film on the unit and threaded. Select SV1 on the Calibration Fixture. Adjust SV1 potentiometer on the Main PCB until you read 1.15 VDC on the Multimeter. Select SV2 on the Calibration Fixture. Adjust SV2 potentiometer on the Main PCB until you read 3.45 VDC on the Multimeter.

NOTE: To properly calibrate the Main PCB, confirm the settings are correct by switching between SV1 and SV2 on the calibration fixture and looking at the measured DC voltage on the VOM. This procedure must be done quickly, because the Laminator is heating up and your DC values will change.

14. Switch the Laminator to the (Off) position. Disconnect meter spring clips, and the Calibration Fixture.

6.0 ADJUSTMENTS

6.4 Main PCB (PCB1) Calibration Procedure

15. Reconnect the thermal sensor to the Main PCB.
16. Turn Laminator on.
17. Place the beaded thermocouple in the center of the nip rollers (or infrared temperature sensor pointed right at the nip). Adjust SV2 until the ready light illuminates and the nip temperature is 290°F. Do not let the temperature exceed 310°F (this could cause the rollers to 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 least 5 minutes for the heat to stabilize. Check temperature with infrared temperature sensor or beaded thermocouple.
20. Your Main PCB is now calibrated. Remove Amp Probe, and replace left side cover.

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.

ALTERNATIVE ULTIMA 65 CALIBRATION CONTINUED

Some P.C. Boards have the trim pot mounted tuner side up. Any reference to clockwise (cw) or counterclockwise (ccw), applies to tuner side up. On a P.C. Board with trim pots mounted tuner side down, the directions of rotation are reverse. See Figure 2.

Set SV2 fully clockwise. You will hear a faint clicking when you pass fully clockwise. Right at the click, turn back one full turn rotation counterclockwise. Install P.C. Board into machine and run it on with an amprobe on the heater circuit wire and a beaded thermocouple 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, showing the circuit is maintaining temperature. Read the nip temperature, at this point, each full rotation counterclockwise will increase the nip by 5° F to 10° F. Or if needed, rotation clockwise will decrease the nip temperature. Do this to reach desired nip temperature.

GBC Lamination Specialist Mike Taylor sent in this Alternative Calibration Procedure.

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6.0 ADJUSTMENTS

The disassembly of the Ultima 65 is described in the following steps. Use section 8.0 as a reference to help you understand the text. Reassemble in reverse order. Note: Disconnect the unit from the 120VAC receptacle before performing any disassembly procedures.

IR Heater and Heater Tube (Roller) Disassembly

Remove Feed Table. Remove (4) Phillips Screws from Right Side Plate and remove Right Cover. Remove

4. Phillips Screws from Left Side Plate and remove Left Cover.

Remove upper and lower right side Heater Wire Phillips Screws that are attached to the white ceramic ends of the Infrared Heaters. Remove upper and lower left side Heater Wire Phillips Screws that are attached to the white ceramic ends of the Infrared Heaters. The Infrared Heaters are inside of the Heater Tube (Roller). Disconnect the (2) Thermal Cutout (TCO) Wires attached to the TCO by Female Connectors. (Left side of machine). Remove the (2) Phillips Screws for the top and (2) Phillips Screws from the bottom green silicone Heater Holders (right side only). Remove upper and lower glass Infrared Heaters from the right side of the removed green silicone Heater Holders by sliding them out of the Heat Tubes (Rollers). Note: Use 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. Remove right Heat Tube (Roller) Pressure Hex Screw and Spring. Note: When reassembling, refer to 6.2 for Heat Tube (Roller) Pressure Adjustment. Remove left Heat Tube (Roller) Pressure Hex Screw and Spring. Note: When reassembling, refer to 6.2 for Heat Tube (Roller) Pressure Adjustment. Remove Control Panel P.C. Board, by loosening (2) Phillips Screws securing it to the Right Side Frame. Remove (2) Phillips Screws securing upper outer right side Heater Holder Bracket and remove. Remove Snap Ring from upper right Heat Tube (Roller) shaft. Remove inner right side Heater Holder Bracket. Remove (2) Phillips Screws securing lower right side Heater Holder Bracket and remove. Loosen the (2) Set Screws on the Chain Sprocket attached to the lower Heat Tube (Roller) and remove from the Roller shaft. Remove (2) Phillips Screws securing the Thermal cut out (TCO) and upper outer left side Heater Holder Bracket and remove. Remove Snap Ring from upper left Heat Tube (Roller) shaft. Remove inner Heater Holder Bracket. Remove (2) Phillips Screws securing lower left side Heater Holder Bracket and remove. Remove (4) Phillips Screws securing the right side Heat Tube (Roller) bearing housing and remove. Slide Heat Tube (Rollers) out of the open side

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6.0 ADJUSTMENTS

Remove Feed Table. Remove (4) Phillips Screws from Right Side Plate and remove Right Cover. Remove

4. Phillips Screws from Left Side Plate and remove Left Cover.

Remove (3) Phillips Screws from Right Side Plate securing Upper Rear Cover. Remove (3) Phillips Screws from Left Side Plate securing Upper Rear Cover and remove Upper Rear Cover. Remove Socket Cap Screw and Metal Sleeve from the end of Upper Right Pull Roller. Remove Socket Cap Screw and Metal Sleeve from the Lower Left Pull Roller. 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. Remove (3) Phillips Screws from the right Idler Gear Support and remove Support and Idler Gear. Loosen (2) Set Screws on the Upper Right Chain Sprocket attached to the Pull Roller shaft. Loosen (2) Set Screws on the Motor Chain Sprocket attached to the Motor shaft. Remove Upper Right Chain Sprocket and Motor Chain Sprocket. Remove Pull Rollers by tilting one side up and pulling straight out.

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7.0 Maintenance

DISCONNECT POWER PRIOR TO CLEANING EXTERNAL SERVICES.

Clean external surfaces of the laminator with a soft cloth moistened with a mild solution of detergent (such as dish washing liquid) and warm water. Do not use chemical cleaners or solvents, as these have a harmful effect on painted surfaces. Removal of the films is recommended prior to extensive cleaning. Use detergent solution sparingly to avoid contact with internal electrical parts.

Heat and Pull Rollers

Clean both sets of rollers periodically to remove the adhesive extruded from the edges of the film. The adhesive may be removed most easily when the heat rollers are warm. Clean the adhesive from the rollers periodically and after each wrap-up, to insure clear laminations. Use a somewhat abrasive pad such as a 3M Brand No. 96 green commercial 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.

No periodic internal cleaning is required. However, when the side 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 lubricant as possible. Do not use any solvent or other cleaning agent since these would tend to dilute or wash away the lubricant from parts where it is needed. Use a small brush to remove dust from non-lubricated parts such as wiring, switches, motor and structural parts.

Whenever the side plates have been removed for corrective maintenance, inspect for defects such as loose screws or nuts, abraded wire insulation, loose terminals, and binding of mechanical parts. Correct any defects before returning the laminator to service.

No periodic lubrication is required. However, when parts have to be replaced, lubrication may be required at reassembly.

8.0 PARTS LISTS

All parts in each illustration are keyed with an index number for reference to the respective part number, part name, and quantity in the parts list.

When ordering service parts, always include the following information:

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.

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8.1.1 COVER ASSY. AND FILM ROLL SUPPORT

ITEM

GBC #

GMP #

DESCRIPTION

QTY

RETAINING RING

ROLLER COVER

TAKING BAR FOR ROLL COVER

BUSHING

FILM GUIDE SCREEN/UPPER

HEX FILM SHAFT

THUMB SCREW

1” CORE ADAPTER

CENTER PIN FOR ROLL COVER

ROLL PIN

(USE GMP PART NUMBERS WHEN ORDERING PARTS)

8.1.2 CASE AND TRAY ASSEMBLY

ITEM

GBC#

GMP#

DESCRIPTION

QTY

RIGHT SIDE COVER

FIXING KNOB FOR PAPER GUIDE

PAPER GUIDE

LEFT SIDE COVER

FRONT TABLE

LEVER CAP FOR FRONT TABLE

SCREW FOR PAPER GUIDE

FRONT TABLE SUPPORTS

SPEED GUIDELINES LABEL (Not Shown)

COVER SCREWS (Not Shown)

(USE GMP PART NUMBERS WHEN ORDER PARTS)

8.1.3 LEFT SIDE ASSEMBLY

ITEM

GBC#

GMP#

DESCRIPTION

QTY

FILM TENSION LEVER

BRAKE PAD

TENSION PLATE FRICTION DISC

FIBER TENSION PLATE

ADJUSTMENT BOLT FOR FILM TENSION

BRAKE HUB

MICRO SWITCH (FILM ADJUSTMENT)

TENSION ADJUSTMENT PLATE

SPRING PIN

POWER CORD (USA)

POWER CORD (JAPAN)

POWER CORD (UK)

POWER CORD (AUST)

STRAIN RELIEF

POWER SWITCH

POWER PANEL

MAIN PCB (115V)

MAIN PCB (230V)

BRACKET (CIRCUIT BREAKER)

CIRCUIT BREAKER, 15 AMP

MICRO SWITCH BRACKET

MICRO SWITCH, FEED TABLE

BRAKE SPRING WASHER

RETAINING RING

ROLL PIN

(USE GMP PART NUMBERS WHEN ORDERING PARTS)

8.1.4 RIGHT SIDE ASSEMBLY

ITEM

GBC# GMP#

DESCRIPTION

QTY

DC MOTOR

STEEL SPROCKET, 12T * F12

STEEL SPROCKET, 12T * F10

CENTER PIN FOR IDLER GEAR

CHAIN

IDLE GEAR SUPPORT

COIL SPRING (TENSION PLATE)

TENSION PLATE FOR MANDREL

(NOT SHOWN) 3A SLO-BLO MINI FUSE (PCB)

(NOT SHOWN) 3A SLO-BLO REGULAR FUSE (IN-LINE)

(USE GMP PART NUMBERS WHEN ORDERING PARTS)

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8.1.5 FRAME ASSEMBLY

ITEM

GBC#

GMP#

DESCRIPTION

QTY

TRIAC

SUPPORT BAR

TRANSFORMER, (OUTPUT 3-32 VDC)

TRANSFORMER (EUROPE)

TRANSFORMER (UK)

UPPER REAR COVER

LOWER REAR COVER

RIGHT SIDE PLATE

HEAT SENSOR (THERMO-COUPLE)

FRONT BASE PLATE

LOWER FILM GUIDE SCREEN

RUBBER FOOT

LEFT SIDE PLATE

(USE GMP PART NUMBERS WHEN ORDERING PARTS)

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8.1.6 ROLLER ASSEMBLY

ITEM#

GBC # 1711617

GMP #

DESCRIPTION

SPROCKET

QTY

RIGHT TENSION LEVER FOR PULL ROLLERS

HOUSING FOR DRY BEARING

UPPER IDLER ROLLER

PULL ROLLER

BEARING FLANGE

PULL ROLLER BUSHING

HEATER HOLDER

HEATER HOLDER BRACKET

HEATER HOLDER BRACKET

BEARING

PULL ROLL TENSION BOLT

TENSION LEVER FOR PULL ROLLS

RIGHT INFRARED HEATER SUPPORT

SPROCKET

IDLER ROLLER CENTERED PIN

PULL ROLLER TENSION SPRING

PULL ROLL CENTER PIN

UPPER & LOWER HEAT TUBE

COMPRESSION COIL SPRING

BEARING FLANGE

GRIP RING

LOWER IDLE ROLLER

SUPPORT BAR

INFRARED HEATER

INFRARED HEATER SCREW (NOT SHOWN)

HEAT TUBE BEARING HOUSING

NEEDLE ROLLER BEARING

SCREW (SUPPORT BAR)

THERMAL CUT-OFF (T.C.O.)

SET SCREW

ROLLER BOLT, SOCKET HEAD HEX

INFRARED HEATER BOLT (NOT SHOWN)

OUTER CERAMIC (NOT SHOWN)

INNER CERAMIC (NOT SHOWN)

HEATER JUMPER WIRE (NOT SHOWN)

8.1.7 CONTROL PANEL ASSEMBLY

ITEM#

GBC#

GMP#

DESCRIPTION

QTY

CONTROL PANEL STICKER

PLASTIC SWITCH PANEL

CONTROL KEY, STAND BY, YELLOW

CONTROL KEY, 1 MIL, GREEN

CONTROL KEY, 1.5 & 3 MIL, GREEN

CONTROL KEY, FAST, BLACK

CONTROL KEY, SLOW, BLACK

CONTROL KEY, REVERSE, BLACK

CONTROL KEY, RUN, GREEN

CONTROL KEY, STOP, BLACK

SWITCH MEMBRANE (RUBBER)

CONTROL PANEL PCB ASSY.

SCREW

CONTROL PANEL CABLE (8 PIN)

(USE GMP PART NUMBERS WHEN ORDERING PARTS)

8.1.8 SAFETY LEVER ASSEMBLY

ITEM#

GBC#

GMP#

DESCRIPTION

QTY

LEVER FOR FRONT TABLE

LEVER GUIDE FOR FRONT TABLE

RETAINING RING

COMPRESSION COIL SPRING

MOUNTING SCREWS (NOT SHOWN)

(USE GMP PART NUMBERS WHEN ORDERING PARTS)

8.1.9 CUTTER ASSEMBLY

ITEM#

GBC#

GMP#

DESCRIPTION

QTY

SLITTER ASSEMBLY (1-6)

NUT

SLITTER LEVER

SLITTER BLADE

SCREW

TENSION COIL SPRING

SLITTER HOUSING

(USE GMP PART NUMBERS WHEN ORDERING PARTS)

9.0 RECOMMENDED SPARE PARTS LIST

Use the suggested multipliers as a guideline to maintain your spare parts inventory. This multiplier is based on a six-month’s supply. Multiply the number of machines that you will be required to service in a given territory (your machine base) by the multiplier listed. Refer to 9.1 Explanation of Multipliers for reference. Periodic review of your machine base is recommended. As your machine base grows, your stocking levels will also grow.

NOTE: This is a list of high usage parts only. Less frequently used and incidental parts should be determined and stocked at your discretion.

GBC# 1711647 1711648 1711652 1711651 1711650 1711656 1711655 1711554 1711588 1720524 1711570 1720571 1712140 1711567

GMP#

DESCRIPTION

QTY

UPPER & LOWER HEAT TUBE (ROLLERS)

INFRARED HEATERS HEAT SENSOR (THERMO-COUPLE) THERMAL CUT-OFF (T.C.O.) MAIN P.C. BOARD 115 VOLT CONTROL PANEL P.C. BOARD CONTROL PANEL MEMBRANE TRIAC 15 AMP CIRCUIT BREAKER DC MOTOR 1” CORE ADAPTOR THUMB SCREW FOR CORE ADAPTER BRAKE PAD CUTTER ASSEMBLY

9.1 EXPANATION OF MULTIPLIERS

MULTIPLIER

MACHINE POPULATION

Keep one of these parts for every one unit in your territory Keep one of these parts for every five units in your territory Keep one of these units for every ten units in your territory Keep one of these units for every twenty five units in your territory Keep one of these units for every fifty units in your territory Keep one of these units for every one hundred units in your territory

10.0 ADDITIONAL INFORMATION

This section 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.

NATION SERVICE BULLETIN

GBC National Service Department

500 Bond Street Lincolnshire, IL 60069 (800) 790-7787

TO:

SEE DISTRIBUTION

N.S.B. NO: 210D

FROM:

NATIONAL SERVICE DEPARTMENT

Page: 1 of 1

SUBJECT:

ULTIMA 65 TRIAC TEST AND

ROLLER PRESSURE ADJUSTMENT

TRIAC TESTING:

When testing 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 with the block. REAR ROLLERS = leave 4-5 threads showing above the blocks (approx. 6 mm)

JMH

NATIONAL SERVICE BULLETIN

6210 Capitol Drive Wheeling, IL 60090 847/541-4477

TO:

SEE DISTRIBUTION

N.S.B. NO: 210H

FROM:

NATIONAL SERVICE DEPARTMENT

Page: 1 of 4

SUBJECT:

Ultima65 & Eagle Series Laminators 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 INFORMATION, September-1997, vol. 1

IN THE BEGINNING

GBC’s evolution in the laminators has taken the knowledge of lamination to a higher level than ever before. The new GBC Color Finishing Laminators have distinctive characteristics that their older predecessors did not have. With the flexibility to use a wide range of thermal and cold Pressure Sensitive Adhesive (PSA) films, the word lamination takes on new meanings.

Learning the difference between machine malfunction and laminating the different types of printing in today’s market will test your knowledge of lamination and troubleshooting problems. Before assuming the machine to be at fault, ask a few questions to determine “what’s wrong with this picture”.

SEEING THE PROBLEM

• Wrinkling at the edges.
• Excessive wrinkling between two separate laminated sheets running parallel to each other.
• Air bubbles in the lamination.
• Edge of lamination not sealed.
• Warping of product after lamination.
• Cracking of the printed material after lamination.
• “Silvering” on the laminated product.
• Creasing in various areas of the laminated product.

The previous mentioned conditions are not necessarily caused by machine malfunction. are examples of some conditions that may influence the quality of lamination.

Media being laminated - Some prints are made using synthetic materials. This material usually exhibits waves or wrinkles when laminated with thermal films. Pressure Sensitive Adhesive (PSA) films are best suited 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 condition usually caused by insufficient heat. It is mostly noticeable in dark colors. Silvering may also be noticed when laminating with PSA films, which take approximately 24 hours to cure. If the heat is at the recommended temperature for both the film and the product and bubbles, waves, or creasing are still present, this could be caused by differences in roller pressure, front to back or left to right.

Differences in film manufacturing - The preset temperatures for the GBC Eagle are set for GBC NAP-II laminating film, using 20 lb. Bond paper. GBC Eagle laminators usually will laminate a variety of different manufacturer’s film. When laminating with films other than NAP-II, adjustments to the preset temperatures and speed may be necessary.

Ink and toner coverage - Wide format and color prints are made in a variety of ways. The common trend is to use alcohol based inks, called GA ink, or oil based inks, called GO ink. The GA inks usually work very well with thermal films. The GO inks are sensitive designed for vinyl substrates. Another ink type is PIEZO, which is wax based and comes in a “stick” form; it may crack if folded or rolled tightly. Pressure Sensitive Adhesive (PSA) films are great candidates for these applications.

Ink and toner coverage (continued) - Dry toner is commonly used in most copiers and printers in today’s market. Some copiers/printers use water-soluble toner, while others like XEROX use fuser oil to fix the image to the paper. Fuser oil may not allow conventional laminating film to adhere to the paper. In most cases, GBC thermal HI-TAC film solves the problems of excessive fuser oil.

ROLLER PRESSURE BY THE FOOTPRINT

A laminator’s footprint can visually provide a quick assessment of roller pressure. The footprint is the impression made by the heat rollers when the film is allowed to sit idle for three minutes or longer. For best results, use 1.5mil film for this procedure. Run approximately 3 feet of clear film through the heated laminator. Wait approximately 3 minutes for the footprint to form. Run another 3 feet of film and examine the impression. The footprint should be even on both sides and slightly thicker at the center. If this is achieved, run newspaper or lightweight paper through the laminator and check for lamination quality.

Paper Pull Setup Test - This test can be performed to correct roller balance problems. The test must be performed after removing or replacing rollers.

1. Remove all laminating film from front and rear rollers.
2. Cut several 1-inch strips of regular 20lb Bond paper.
3. Gap the rollers and insert the strips starting the 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 at the specific location. The center pressure is affected by adjusting the right and left sides of the rollers. A recommended one full turn should be made to the side where the paper slips.
7. Perform the same procedure for the rear rollers.

LAMINATION PERFORMANCE TEST

After adjusting the roller pressure to the previously recommended starting point, install 1.5 mil film on the laminator, set the temperature to the proper setting, and allow the heat to rise until ready.

Before making any further adjustments, please check the laminated footprint again for the previously stated dimensions. If further adjustment is needed, perform the adjustment with equal full turns at the adjustment point.

EAGLE ROLLER REPLACEMENT

When replacing the rollers, the pressure set up adjustment on the Eagle laminator is crucial to the quality of lamination. This adjustment must be made to the front and rear rollers because the roller brackets support both sets of rollers. Removing The Rollers

1. Disconnect power to the machine.
2. Release pressure on rollers.
3. Remove feed table, left side - film tension knobs, right side pressure handle, and both right and left side covers. 10-5

4. Disconnect heat coil wires attached to ceramic end of the heater tube. The heater tube is inside of the heat roller.
5. Disconnect thermal cutout (TCO) wires attached to the TCO by spade terminals.
6. Remove top and bottom green silicone heater holders (one side only).
7. Remove glass heat coil tubes out of opened side and store in a safe area to prevent breakage.
8. Remove roller pressure screws and springs.
9. Remove Phillips head screws securing heat coil holders brackets, right and left.
10. Loosen Allen screws on the motor gear. Slide gear outward and away from idler gear.
11. Remove screws securing the idler gear bracket. Lift away from machine along the drive chain.
12. Loosen Allen screws on chain sprockets attached to the lower heat and pull rollers and remove from the roller shaft.
13. Remove all snap rings securing the rollers, both right and left.
14. Remove remaining bracket supports.
15. Slide rollers out of the open side.

To reassemble, follow the previous steps in reverse.

Roller Adjustment - After replacing heat or pull rollers, run the machine, with full pressure, to settle the rollers to a home position. The spring pressure on the rollers should be adjusted to a starting point. To begin:

1. Lower the pressure screws flush with the threaded end of the eccentric bracket.
2. Make 7 full turns on each of the four front heat roller tension screws.
3. Make 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 temperature and speed are set for use with 20lb. Bond paper. The heat temperatures are set for 1 mil “Ultima” NAP-II film and the 1.5 &3 mil setting is for NAP-I film. There is about a 30º F temperature variance between NAP-I and NAP-II films. Make sure the correct film is used for the correct setting.

Another heat related problem that can be often diagnosed as machine malfunction is the use of heavier paper stocks. These materials deplete the preset temperature of the heat rollers or may not bond as expected.

Adjustments to the speed may be necessary to achieve acceptable results. If you do not achieve the desired results, a quick check of the PCB calibration, and adjustment (if needed) may solve the problem.

CARING FOR YOUR LAMINATOR

The new breed of Eagle and Ultima laminators use a softer silicone roller. This type of roller provides for a better-sealed edge. When cleaning these rollers, it is recommended that nonabrasive materials be used. ScotchBrite or eraser type belt cleaners work the best. At the present time we do not have a chemical that is safe for cleaning purposes. Under no circumstances should sandscreeen be used to clean the rollers.

WWW.MYBINDING.COM

TO:

SEE DISTRIBUTION

N.S.B. NO: 210K

FROM:

NATIONAL SERVICE DEPARTMENT

Page: 1 of 1

SUBJECT:

ULTIMAS & EAGLES INSTALLATION

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.

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TO:

SEE DISTRIBUTION

N.S.B. NO: 248A

FROM:

NATIONAL SERVICE DEPARTMENT

Page: 1 of 1

SUBJECT:

ULTIMA 65 UPGRADE

This N.S.B obsoletes N.S.B 248, dated 5/15/00

Ultima 65’s with heat problems (gray roller machines) will no longer be traded in. The parts the technician will need to order to bring 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.

Heat Roller Infrared heater Main PCB Control PCB Control Panel Membrane Heater Holder Bracket (Top) Heat Sensor

WWW.MYBINDING.COM

NATIONAL SERVICE BULLETIN

National Service Department 500 Bond St. Lincolnshire, IL. 60069

TO:

SEE DISTRIBUTION

N.S.B. NO: 243C

FROM:

NATIONAL SERVICE DEPARTMENT

Page: 1 of 1

SUBJECT:

GMP LAMINATION CALIBRATION FIXTURES

GBC Service Parts Dept is currently stocking the Calibration 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 ordered under part number 706111165, and is only to be used on the TITAN 165/110.

WWW.MYBINDING.COM

Professional Support Services 500 Bond St. Lincolnshire, IL. 60069

NATIONAL SERVICE BULLETIN

TO:

SEE DISTRIBUTION

N.S.B. NO: 210P

FROM:

NATIONAL SERVICE DEPARTMENT

Page: 1 of 1

SUBJECT:

ULTIMA-65 INFRARED HEATER ASSEMBLY

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. 701110504 701108106 703050210 703010309 703050205 6130422

DESCRIPTION

Glass Tube Cap Heater Wire Holding Bolt Inside Ceramic Insulator Silicone Washer Outside Ceramic Insulator Hexagon Nut

WWW.MYBINDING.COM

NATIONAL SERVICE BULLETIN

Professional Support Services 500 Bond St. Lincolnshire, IL. 60069

TO:

SEE DISTRIBUTION

N.S.B. NO: 210Q

FROM:

NATIONAL SERVICE DEPARTMENT

Page: 1 of 1

SUBJECT:

ULTIMA-65 TURNING OFF WHILE RUNNING

When you encounter an Ultima-65 turning off while running, here are some things that you should know:

• The Laminator must be plugged into a dedicated grounded outlet. Do not connect other equipment to the same circuit.
• Overloading the motor will cause the Transformer’s TCO to blow. The Transformer does not have a resettable thermal cut off (TCO), so you will have to replace the Transformer.
• There is a resettable fusible link on the Main P.C. Board that replaced the original 3-amp fuse. When the Main P.C. Board gets overloaded (hot), the machine will turn off. Once it cools down, you can 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 Interlock switches and connections. Make sure product thickness does not exceed the maximum of 1/16” (1.59mm). Too much Brake Tension on Film Shafts. As recommended, use the minimum amount of tension to eliminate wrinkles in the finished item. Check for proper pressure/tension between upper and lower Heat Tubes (Rollers) and upper and lower Pull Rollers. The pressure applied should be enough to enable the rollers to pull the film and product being laminated through, however, it should not be so great that it causes marks on the film or product. Motor/Sprocket Chain is too tight. Chain must have some play/slack in it.

WWW.MYBINDING.COM

Professional Support Services 500 Bond St. Lincolnshire, IL. 60069

NATIONAL SERVICE BULLETIN

TO:

SEE DISTRIBUTION

N.S.B. NO: 210R

FROM:

NATIONAL SERVICE DEPARTMENT

Page: 1 of 1

SUBJECT:

ULTIMA 65 & EAGLE 35, 65, AND 105

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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