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PREAMBLE On my own behalf and on behalf of the GIRBAU company I would like to congratulate you for the purchase you have just made. I hope this product, the result of several years' experience, will give you complete satisfaction.
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TECHNICAL MANUAL Part 1: General Points, Construction, Operation. Part 2: Electrical diagrams, delivered separately. Part 3: Automation, delivered separately. This technical manual gives detailed of all the Series FL folding machines, all options merged. Translation of original notice FL0610A...
4.2 CROSS FOLDING UX2P.........................42 4.3 CROSS FOLDING UX3P.........................44 4.4 CROSS FOLDING MX2P ........................1 4.5 CROSS FOLDING MX3P ........................49 4.6 OPERATION OF FL SERIES FOLDING MACHINES ..............52 5 MAINTENANCE OPERATIONS ......................54 5.1 General maintenance ........................54 5.2 Air filter/regulator maintenance......................55 5.3 Troubleshooting ..........................57 6 SPARE PARTS .............................58...
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4M05516 FEEDER LU 3000 GIRBAU FLATWORK IRONER PC120 GAS ........113 4M05660 FEEDER LU 3300 GIRBAU FLATWORK IRONER PC120 GAS ........115 4M05661 FEEDER WITH BYPASS 1V/2V LU3000 GIRBAU FLATWORK IRONER PC120 GAS ..119 4M05663 FEEDER LU 3300 GIRBAU FLATWORK IRONER PC120 GAS ........115 4M05659 FEEDER WITH BYPASS 1V/2V LU3300 GIRBAU FLATWORK IRONER PC120 GAS ..121...
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4M05265 OSCILLATING ARM LANE OF 825..................227 4M05266 OSCILLATING ARM LANE OF 750..................227 4M05267 OSCILLATING ARM LANE OF 875..................227 4M05401 GIRBAU LEFT COVER ASSEMBLY PS AND PSN8030.8033.8035 .........229 4M05402 GIRBAU RIGHT COVER ASSEMBLY PS AND PSN8030.8033.8035.......229 4M05309 LAPAUW RIGHT COVER ASSEMBLY ................231 4M05310 LAPAUW LEFT COVER ASSEMBLY.................231...
1 INTRODUCTION 1.1 WARNING Usage conditions: It is IMPERATIVE that all staff who have to work on this machine or maintain it (commissioning, maintenance, dismantling...) read and follow all the instructions contained in this notice, as well as those concerning control (electrical and pneumatic diagrams).
1.2 GENERAL POINTS The FL SERIES of folding machines has been specially designed for the fast, accurate folding of articles such as: Small items: cloths, pillowcases, mats. Large items: sheets, mattress covers, tablecloths, surgical sheets, fitted sheets. The machine integrates the latest technological advances in programmable, pneumatic and mechanical automatons.
DANGER pictograms (yellow and black triangles): General danger Electrical danger Mechanical danger Danger of falling Mechanical maintenance DANGER area (yellow and black strip) 1.4 OPERATION PICTOGRAMS Emergency stop Use the touch screen Start Stop Reset FL0610A...
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Grease using a pump Set the selector to Start Set the selector to Stop and padlock it (padlock not provided) Open the air intake valve Shut the air intake valve and padlock it (padlock not provided) FL0610A...
1.5 TECHNICAL FEATURES The technical features of the FL SERIES vary depending on the options ordered. Several folds can be made, depending on the model: 1, 2, or 3 primary folds in 1, 2 or 4 lanes using an air jet (the item comes out with...
1.6.3 CROSS FOLDING UX2P DISCHARGE ON TO SIDE TABLE 1st fold by mechanical blade 2: 2nd fold by mechanical blade and reversing conveyor Side table fold fold The operator picks up the cross-folded items on the discharge side table DISCHARGE WITH SINGLE ROTATING CLAMP STACKER 1st fold by mechanical blade 2nd fold by mechanical blade and reversing conveyor...
DISCHARGE WITH DOUBLE ROTATING CLAMP STACKER 1: 1st fold by mechanical blade 2: 2nd fold by mechanical blade and reversing conveyor 3: 3rd fold stacker) mechanical blade and rotating clamp fold fold fold The operator picks up the cross-folded and stacked items at the stacker discharge. 1.6.4 CROSS FOLDING UX3P DISCHARGE ON TO TABLE 1: 1st fold by mechanical blade...
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DISCHARGE WITH SINGLE FLAP STACKER 1: 1st fold by mechanical blade 2: 2nd fold by mechanical blade and reversing conveyor 3: 3rd cross fold by mechanical blade fold fold fold The operator picks up the cross-folded and stacked items at the stacker discharge. DISCHARGE WITH DOUBLE FLAP STACKER 1: 1st fold by mechanical blade 2: 2nd fold by mechanical blade and...
1.6.5 CROSS FOLDING MX2P DISCHARGE ON TO SIDE TABLE In 1 lane 1 lane 1-lane operation: 1: 1st fold by mechanical blade 2: 2nd fold (if operating in 1 lane) by mechanical blade and reversing conveyor Side Side table table fold fold in 2 lanes...
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DISCHARGE WITH SINGLE ROTATING CLAMP STACKER 1-lane operation: in 1 lane 1: 1st fold by mechanical blade 2: 2nd fold by mechanical blade and reversing conveyor 3: 3rd fold (in the stacker) by mechanical blade and rotating clamp fold fold fold in 2 lanes 2-lane operation:...
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DISCHARGE WITH DOUBLE ROTATING CLAMP STACKER in 1 lane 1-lane operation: 1st fold by mechanical blade 2nd fold by mechanical blade and reversing conveyor 3: 3rd fold (in the stacker) by mechanical blade and rotating clamp fold fold fold in 2 lanes 2-lane operation: 1st fold by mechanical blade 2: 3rd fold (in the stacker) by...
1.6.6 CROSS FOLDING MX3P DISCHARGE ON TO SIDE TABLE 1-lane operation: in 1 lane 1st fold by mechanical blade 2nd fold by mechanical blade and reversing conveyor 3rd fold by mechanical blade Side table in 1 lane in 1 lane fold fold fold...
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DISCHARGE WITH SINGLE FLAP STACKER in 1 lane 1-lane operation: 1: 1st fold by mechanical blade 2: 2nd fold by mechanical blade and reversing conveyor 3: 3rd fold by mechanical blade fold fold fold in 2 lanes 2-lane operation: 1st fold by mechanical blade 2nd fold by mechanical blade fold fold...
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DISCHARGE WITH DOUBLE FLAP STACKER 1-lane operation: 1: 1st fold by mechanical blade 2: 2nd fold by mechanical blade and reversing conveyor 3: 3rd fold by mechanical blade in 1 lane fold fold fold 2-lane operation: 1st fold by mechanical blade 2nd fold by mechanical blade in 2 lanes fold...
2 HANDLING INSTALLATION The machine must only be handled by qualified personnel. During handling no one must place themselves below a load. 2.1 HANDLING Check that the lifting slings allow the weight of the machine to be lifted. TAKE CARE not to damage the covers. FL0610A...
2.2 PUTTING THE MACHINE IN POSITION Preparation and positioning FL series folding machines: see following pages. The floor must be horizontal and capable of bearing the weight of the machine. Note: Carry out these operations strictly in order. - Screw up the four adjustment jacks so that the machine rests on its four transport wheels.
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If the machine has been sent in plastic film, carry out the following operations: - Raise the primary fold discharge table. - Slightly loosen the screw and pivot the table. - Add the bottom screw, allowing the table to remain horizontal. FL0610A...
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- Raise the feeder conveyor (Feeder) Go to stage 8 If the machine has been sent in a wooden crate, carry out the following operations: Machine folded up Turn the OPG FL0610A...
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Pivot the service bridge assembly Loosen the screw slightly FL0610A...
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Make it pivot Replace the fixing screw Dismantle the flap so you can adjust the service bridge horizontally FL0610A...
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- Place the folding machine in the best possible position behind the ironer. The folding machine and the ironer must be perfectly aligned. The folding machine's roller must be level and parallel with the ironer bed discharge. - Unscrew the four adjustment jacks enough to lift the four transport wheels off the ground (resting on the folding machine).
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CHECKING AND LEVELLING Check that the 2 lower crossbeams are level. Check that the folding machine's 2 cabinets are level. Check the positioning of the feeder roller with respect to the ironer bed and make sure it is level. Make sure the service bridge is level. Once the cylinders have been adjusted, lock them with their lock nuts.
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CONNECTION TO SUPPLIES: Connection to the air supply The machine is equipped with an air treatment unit: Filter/Regulator, see chapter 5 Maintenance operations. The customer must provide the air supply to the machine's on/off valve. This air must be dry and dust-free. Pipes of minimum diameter 15/ 21 (1/2 inch) must be used to supply the machine.
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Connection to the power supply: The electrical installation of the machine must be carried out by qualified, authorised staff . - Make sure that the power supply is correct and that the power of your installation is sufficient before connecting the machine. The power cable must be protected at the head of the line.
3 SAFETY 3.1 GENERAL POINTS Note: Read and comply with chapter 1 Warning. Machine EMERGENCY STOP: - Press the Emergency stop button: When there is an emergency stop, all movements are stopped. The machine must be started up again by the operator responsible. He/she will press the reset button after making sure there is no further danger.
3.3 INTERVENTION DURING OPERATION It is strictly forbidden to intervene during operation. Before intervening and after the machine has completely stopped, it is essential to: - Set the main switch to OFF and padlock it Padlock not provided - Close the air intake valve and padlock it. Padlock not provided When various movable covers on the machine are opened, it stops.
3.4 POSITIONING OF EMERGENCY STOPS AND SAFETY CONTACTS NEVER REMOVE OR TRY TO ALTER SAFETY ELEMENTS Emergency Emergency stop stop Ref: 13-0787 Ref: 13-0787 Safety sensor Ref: 13-0454 Safety sensor Ref: 13-0454 FL0610A...
4.1 PRINCIPLE Never try to pick up an item that is jammed in the machine. The FL SERIES can deal with large or small items equally well. - The item arrives from the ironer. - It is received on a conveyor called a "feeder".
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4.2 CROSS FOLDING UX2P DISCHARGE ON TO SIDE TABLE 1: 1st fold by mechanical blade 2: 2nd fold by mechanical blade and reversing conveyor Side table fold fold The operator picks up the cross-folded items on the discharge side table DISCHARGE WITH SINGLE ROTATING CLAMP STACKER 1: 1st fold by mechanical blade 2: 2nd fold by mechanical blade and...
DISCHARGE WITH DOUBLE ROTATING CLAMP STACKER 1st fold by mechanical blade 2nd fold by mechanical blade and reversing conveyor 3rd fold (in the stacker) by mechanical blade and rotating clamp fold fold fold The operator picks up the cross-folded and stacked items at the stacker discharge. 4.3 CROSS FOLDING UX3P DISCHARGE ON TO TABLE Side...
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DISCHARGE WITH SINGLE FLAP STACKER 1: 1st fold by mechanical blade 2: 2nd fold by mechanical blade and reversing conveyor 3: 3rd cross fold by mechanical blade fold fold fold The operator picks up the cross-folded and stacked items at the stacker discharge. DISCHARGE WITH DOUBLE FLAP STACKER 1: 1st fold by mechanical blade 2: 2nd fold by mechanical blade and...
4.4 CROSS FOLDING MX2P DISCHARGE ON TO SIDE TABLE in 1 lane 1-lane operation: 1st fold by mechanical blade 2: 2nd fold (if operating in 1 lane) by mechanical blade and reversing conveyor Side table fold fold in 2 lanes 2-lane operation: 1: 1st fold by mechanical blade Side...
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DISCHARGE WITH SINGLE ROTATING CLAMP STACKER in 1 lane 1-lane operation: 1st fold by mechanical blade 2nd fold by mechanical blade and reversing conveyor 3rd fold (in the stacker) by mechanical blade and rotating clamp fold fold fold in 2 lanes 2-lane operation: 1st fold by mechanical blade 3rd fold (in the stacker) by mechanical...
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DISCHARGE WITH DOUBLE ROTATING CLAMP STACKER in 1 lane 1-lane operation: 1st fold by mechanical blade 2nd fold by mechanical blade and reversing conveyor 3rd fold (in the stacker) by mechanical blade and rotating clamp fold fold fold in 2 lanes 2-lane operation: 1st fold by mechanical blade 3rd fold (in the stacker) by mechanical...
4.5 CROSS FOLDING MX3P DISCHARGE ON TO SIDE TABLE 1-lane operation: in 1 lane 1st fold by mechanical blade 2nd fold by mechanical blade and reversing conveyor 3rd fold by mechanical blade Side table fold fold fold in 2 lanes 2-lane operation: 1st fold by mechanical blade 2nd fold by mechanical blade...
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DISCHARGE WITH SINGLE FLAP STACKER in 1 lane 1-lane operation: 1st fold by mechanical blade 2nd fold by mechanical blade and reversing conveyor 3rd fold by mechanical blade in 2 lanes 2-lane operation: 1st fold by mechanical blade 2nd fold by mechanical blade fold fold The operator picks up the cross-folded and stacked items at the stacker discharge.
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DISCHARGE WITH DOUBLE FLAP STACKER 1-lane operation: 1st fold by mechanical blade 2nd fold by mechanical blade and reversing conveyor 3rd fold by mechanical blade in 1 lane fold fold fold 2-lane operation: 1st fold by mechanical blade 2nd fold by mechanical blade in 2 lanes fold fold...
4.6 OPERATION OF FL SERIES FOLDING MACHINES Make sure that no-one has their hands in the machine. Check that all covers are in place and that no-one is working on or under the machine. Before starting the machine, check: - The direction the motors are turning, - The air pressure, which must be 6 bars.
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- Press the Stop button. - Set the main switch to OFF. - Close the general compressed air valve. FL0610A...
5 MAINTENANCE OPERATIONS - Before any intervention on the machine: - Set the main switch to the OFF position and padlock it. - Close the connection valve to the compressed air supply and padlock it. 5.1 General maintenance Every day or every 10 hours: - Visually check the machine.
5.2 Air filter/regulator maintenance GENERAL USAGE CONDITIONS: Control fluid : Air I.S.O.8573, minimum class 3.5.3. Ambient temperature : -20°C to 50°C Maximum supply pressure : 10 bars. FILTER AND REGULATOR-FILTER equipped with a safety device preventing dismantling under pressure. Assembly Dismantling Clean the tank with soapy water only.
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A key locking system is possible using a padlockable cap. PADLOCKABLE VALVE: When carrying out manual actions on the machine, always lock the valve with at least one padlock so that no-one can turn the pressure on during a manual action. CLOG-FREE SILENCER For safety reasons, never replace the clog-free silencer with a device using a technology that means it could clog up.
5.3 Troubleshooting MALFUNCTIONS CAUSES SOLUTIONS Reset the circuit breaker concerned One of the motor-circuit brakers The folding machine will not start. and check why it was set off. or a safety device is engaged. Remove the emergency stops. Check that the movable covers are properly closed.
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Discharge on table UX3P Pos. Type 2C01853 Grey spur strap LA60/LG530 2C01854 Grey spur strap LA60/LG550 2C01729 PVC strap LA60/LG910 2C01892 PVC strap LA50/LG3440 2C01890 Grey spur strap LA 50 LG825 2C01891 Grey spur strap LA 50 LG1290 - Cross fold section straps MX2P Discharge on to table Pos.
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Discharge on 1 Stacker (ROT. STA.) MX2P Pos. Type Qty. 2C01853 Grey spur strap LA60/LG530 2C01854 Grey spur strap LA60/LG550 2C01729 PVC strap LA60/LG910 2C01950 LU 3000 PVC strap LA50/LG 8520 2C01951 LU 3300 PVC strap LA50/LG 8670 2C01952 LU 3500 PVC strap LA50/LG 8770 Discharge on 2 Stackers (ROT.
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Discharge on side table MX3P Pos. Type 2C01853 Grey spur strap LA60/LG530 2C01854 Grey spur strap LA60/LG550 2C01729 PVC strap LA60/LG910 2C01903 LU 3000 PVC strap LA50/LG4925 2C01904 LU 3300 PVC strap LA50/LG5080 2C01905 LU 3500 PVC strap LA50/LG5175 2C01890 Grey spur strap LA50/LG825 2C01891 Grey spur strap LA50/LG1290...
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4M05660 Feeder LU 3300 Girbau flatwork ironer PC120 gas............115 4M05661 Feeder LU 3500 Girbau flatwork ironer PC120 gas............115 4M05663 Feeder with bypass 1V/2V LU3000 Girbau flatwork ironer PC120 gas ......119 4M05659 Feeder with bypass 1V/2V LU3300 Girbau flatwork ironer PC120 gas ......121 4M05662 Feeder with bypass 1V/2V LU3500 Girbau flatwork ironer PC120 gas ......123...
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4M05160 1st primary fold 2 lanes LU 3300 ..................143 4M05161 1st primary fold 2 lanes LU 3500 ..................143 4M05162 1st primary fold 4 lanes LU 3000 ..................145 4M05163 1st primary fold 4 lanes LU 3300 ..................145 4M05164 1st primary fold 4 lanes LU 3500 ..................145 4M05186 2nd primary fold 2 lanes LU 3000..................147 4M05187 2nd primary fold 2 lanes LU 3300..................147 4M05188 2nd primary fold 2 lanes LU 3500..................147...
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4M05265 Oscillating arm lane of 825 ....................227 4M05266 Oscillating arm lane of 750 ....................227 4M05267 Oscillating arm lane of 875 ....................227 4M05401 Girbau left cover assembly PS and PSN8030.8033.8035 ..........229 4M05402 Girbau right cover assembly PS and PSN8030.8033.8035..........229 4M05309 Lapauw right cover assembly .....................231 4M05310 Lapauw left cover assembly ....................231...
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