Delta Laminator Operator Manual 1. SAFETY NOTICES 1.1 SAFETY NOTICES – COMPLETE MACHINE The following safety notices pertain to the operation of the machine. WARNING Obey the following precautions. Failure to do so can result in severe personal injury or damage the machine.
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Delta Laminator Operator Manual Important • The machine can be operated only by an operator who has been trained appropriately by a GBC service technician. • The operator should use the primary and secondary stations to operate the machine. See the illustration in Section 1.1.1.
Delta Laminator Operator Manual 1.2 SAFETY NOTICES – LOADING A STACK OF PAPER The machine is designed for feeding and laminating paper. CAUTION Obey the following precautions. Failure to do so could result in minor personal injury or damage the machine.
Delta Laminator Operator Manual 1.3 SAFETY NOTICES – FEEDER HEAD HANDLING The feeder head picks up a sheet of paper and loads it into the feeder rollers. It is necessary to change the position of the feeder head if the sheet size is changed.
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Delta Laminator Operator Manual • To move the feeder head, turn the manual lever counter clockwise to loosen the clamp. Then move the upper arm continuously along the guide bar. Do not get your fingers near the guide bar. (The arm could hit the guide bar holder at the limit position).
Delta Laminator Operator Manual 1.4 SAFETY NOTICES – IN-FEED WHEELS AND GATE ADJUSTMENT CAUTION • Do not handle the units in any way if the machine is in operation. • The weights can be put in and taken out only if the machine is at rest.
The position of the plates can be adjusted with the adjustment screw while the machine is in operation. • The adjustment can be done only by an operator trained by GBC Service. • The operator should wear tight fitting clothes to prevent possible trapping with the gate or feeder rollers.
Delta Laminator Operator Manual 1.6 SAFETY NOTICES – LAMINATING AND PRESSURE ROLLER ZONE The operating laminating roller temperature, depending on the type of laminating film, is 210 to 300 °F (100 to 150 °C). In order to maintain the machine function, it is not possible to cover all the zones near the laminating and pressure rollers.
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Delta Laminator Operator Manual Side view from the operator’s side A – Warning: Roll surface with a high temperature B- dangerous place - contact surface B – Warning: Crush hazard of laminating roll and pressure roll View of the laminating roller and pressure roller from the separator...
Delta Laminator Operator Manual 1.7 SAFETY NOTICES – DECURLING BAR ADJUSTMENT During laminating there is an internal tension between the paper and laminating film causing it to curl up. The sheets are straightened by the decurling bar so that they will be straight after laminating.
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Delta Laminator Operator Manual CAUTION Keep fingers away from pinch points between the lever and the cover when opening the cover. Separator (cross section) WARNING Keep fingers away when the machine is in operation. View of the regulating screws from the stacking table WARNING Keep your fingers away when the machine is in operation.
Delta Laminator Operator Manual 1.9 SAFETY NOTICES – TWIN KNIFE The cutting knives are covered with Plexiglas at the top and at the sides. Since the knives are very sharp and they move very fast the following rules must be obeyed.
GBC’s obligation under this limited warranty is limited to replacement or repair, at GBC’s option, of any part found defective by GBC without charge for material or labor.
Delta Laminator Operator Manual 3. MACHINE TECHNICAL SPECIFICATIONS, DIMENSIONS, AND WEIGHTS 3.1 MACHINE TECHNICAL SPECIFICATIONS 3.1.1 PAPER SPECIFICATION US Version EU Version Maximum sheet size 20-1/2 x 28 in. 520 x 720 mm Minimum sheet size 7-7/8 x 7-7/8 in.
Delta Laminator Operator Manual 3.2 MACHINE MAIN DIMENSIONS AND WEIGHTS US Version EU Version Dimensions (Length x width x height) 100.4 x 48.5 x 53.2 in. 2550 x 1230 x 1350 mm Floor space for machine operation 6.7 x 9.7 ft.
Delta Laminator Operator Manual 4. MACHINE CONTROLS 4.1 CONTROL PANEL Refer to the Control Panel illustration on the next page. Machine Start button Machine Stop button Machine speed potentiometer Feeder – movement Up button Feeder – movement Down button Pressure roller – Closed button Pressure roller –...
Delta Laminator Operator Manual 4.2 MACHINE CONTROL DISPLAY 4.2.1 Main Screen Functions The main screen of the machine control displays shows the following functions: • Actual machine speed (ft/min) • Actual machine speed (histogram) • Desired temperature (deg F) •...
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Delta Laminator Operator Manual 4.2.4 Main Screen – Description Hidden button (area) for transfer into Error Machine status - 1st Screen line (STATUS / ERROR) Display of actual Machine status - 2nd temperature - middle line, short of laminating roll...
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Delta Laminator Operator Manual 4.2.5 Screen No. 2 Description Display of actual temperature - middle of Display of actual Area to recall laminating roll temperature - end numeric keyboard to side of laminating roll input preset value on counter of sheets Function switch –...
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Delta Laminator Operator Manual 4.2.6 Screen No. 3 Description Display of number of hours of operation Display of total Button for return to number of sheets in Screen No. 2 thousands 4.2.7 Error Screen Description 1st line of message 2nd line of message...
Delta Laminator Operator Manual 5. MACHINE OPERATION LOADING PAPER AND FILM Set up the side guides and the feeder head position a. Put one sheet of the paper and, according to the width of the sheet, set up the side guides as described in Chapter 7.3.
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Delta Laminator Operator Manual Note: Refer to the illustration on the next page for the remaining steps, which follow the illustration. Check for the film adhesive side "Poly - out" or "Poly – in." One side of the film is coated with an adhesive. It can be checked: •...
Delta Laminator Operator Manual FILM ROLL POSITION ADJUSTMENT ON UNWINDING SHAFT If you insert a new roll of film, which has a different width than the original one, proceed as follows: 1. Adjust the regulating nut of the film lateral movement (a) so that the front edge will be placed with the the white line on the thread.
Delta Laminator Operator Manual LAMINATING ROLL HEATING Each type of laminating film and adhesive have specific temperature range requirements. The required temperature depends upon the thickness of the paper, line speed, film, humidity, ink coverage, type of ink, and other factors. Testing of good film adhesion should be done before production occurs. The laminating temperature range is 210 to 300 °F (100 to 150 °C).
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Delta Laminator Operator Manual ILLUSTRATION 1 - wet paper - brake of laminating film unwinding shaft is too tight ILLUSTRATION 2 - high laminating temperature - wet paper - brake of laminating film unwinding shaft is too tight - excessive pull of pull rollers...
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Delta Laminator Operator Manual Problem: THE SHEETS ARE RAGGED ON THE SIDE BY THE SEPARATOR KNIFE Solution: The problem is caused by: - Too small gap between the sharp blade edge and guide pin Two clamping screws M5 on the knives have to be loosened, the knife turned off the guide pins, and then the screws must be tightened again.
Delta Laminator Operator Manual 7. FEEDER – OPERATION AND ADJUSTMENT FEEDER DESCRIPTION The main sections of the feeder are the lifting mechanism, table, feeder head, front guides, gate I, side guides, in-feed wheels, and gate II. The feeder table is not removable. It is controlled by chains and guided on two guide bars.
Delta Laminator Operator Manual SIDE GUIDES The side guides center the paper stack (c). They are symmetrically adjusted to the machine center. There has to be slight clearance between the side guide strips and paper stack so that the strips will not damage the paper and will not cause improper sheet feeding.
Delta Laminator Operator Manual FRONT LOADING The correct front position of a paper stack on the feeder is assured by the front guides (a) and gate I stops (b). The sheets have to be pressed against the surface of the front guides. Be careful to prevent paper bending, which could cause problems during feeding.
Delta Laminator Operator Manual STACK POSITION When a paper stack is loaded, press the "STACK UP" button. The table (f) will lift and its top position will be determined by the capacity sensor (g). The paper pile should stop 15/64 in. (6 mm) from the top of the gate I.
Delta Laminator Operator Manual 8. FEEDER HEAD FEEDER HEAD POSITIONING Loosen the clamp with the handle (a). Move the head to the rear position (off the machine). Lift the table with a paper stack to the working position by pressing the "STACK UP" button. (See the illustration in Chapter 4.1.) Move the head so that the rear stops (b) will touch the rear edge of the...
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Delta Laminator Operator Manual • The brushes (e) should exceed the paper edge by 5/64 to 7/64 in. (2 to 3 mm) and they should sit on the paper only lightly to prevent blowing the paper out. (Use only brushes instead of flat springs for a heavier paper weight.)
Delta Laminator Operator Manual MINIMUM SHEET SIZE FEEDING When the width of a sheet is smaller than the pitch of the internal suction cups (m), it is necessary to loosen the screw (n) and then to turn the internal suction cups forward by 90°. The suction cups will be out of operation.
Delta Laminator Operator Manual 9. GATE I AND IN-FEED ROLLER MECHANISM GATE I FUNCTION Gate I (h) holds the stack of paper vertical to the front edge. If the head moves forward, the gate I turns down in order not to obstruct feeding the sheets into the machine.
Delta Laminator Operator Manual IN-FEED ROLLER MECHANISM The in-feed roller mechanism consists of weight rollers (a), accelerating rollers (b), upper guides (c), and sheet overlap sensor (d). 9.2.1 WEIGHT ROLLERS The weight rollers are always in contact with the paper sheets and press them onto the in-feed roller.
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Delta Laminator Operator Manual 9.2.2 ACCELERATING ROLLERS The accelerating rollers are used to increase the pressure to the in-feed roller when the gate II turns down. The mechanism is driven by the pneumatic roll on the driving side. The amount of pressure is controlled by the control system and is set by the manufacturer.
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Delta Laminator Operator Manual 9.2.3 upper guides The upper guides (c) hold the paper to the bottom guide plate so that sheets will not jump over the gate Position There are three upper guides on the machine. The position of the center one is set by the manufacturer and does not change.
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Delta Laminator Operator Manual Pressure The pressure is determined by the upper (ch) guide position. Refer to the following illustration. The screw (i) should be loosened first. The adjustment should be done as follows: 1. Load one sheet of the paper in the machine.
Delta Laminator Operator Manual 10. GATE II The function of the gate II (a) is to hold a sheet of paper and to release it so that the overlap of the following sheets are within the tolerance of ± 1/16 in. (1.5 mm).
Delta Laminator Operator Manual 13. SEPARATOR 13.1 DECURLING BAR The decurling bar straightens bent paper after laminating the film onto paper. Position the decurling bar according to paper thickness Laminating Laminating Thin paper Laminating roller Thick paper Laminating roll roll...
Delta Laminator Operator Manual 13.2 CHANGING DECURLING BAR RADIUS If a line is apparent on the laminated sheet, radius R3 of the decurling bar (a) can be used for thin paper. The line is caused by the decurling bar edge.
Delta Laminator Operator Manual 13.3 PULL ROLLERS The pull rollers pull the paper between the laminating section and snap rolls in order to level the sheets on the decurling bar. Regulating the paper pull The paper pull can be changed by altering the gap between the rolls with the regulating screw. The size of the gap between the lower and upper drawing rolls is marked on the scale.
Delta Laminator Operator Manual 13.4 TWIN KNIVES The continuous web of laminating film has to be nicked so that the sheets can be separated in the snapping mechanism. A knife with an oscillating motion is used for this. Turn on the “KNIFE” switch to the “START” position to start the knives.
Delta Laminator Operator Manual 13.5 SNAPPING MECHANISM The snapping mechanism separates the individual sheets, which are connected by the laminating film. Controlling the upper snap roll dropping In order to get good separation, the gap between the snapping rollers on the operator side of the rollers must close first before on the drive side of the rollers.
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Delta Laminator Operator Manual Creating the paper wave in front of the snapping rollers Snapping Roller thrust Skewing Wave on Directioning roller regulator wheel the paper safety screw Separation of some films will improve with the use of the skewing wheel. Place the wheel on the drive side of the paper and apply just enough pressure to create a 1/2 in.
Delta Laminator Operator Manual 14. STACKING TABLE 14.1 STACKING TABLE DESCRIPTION The laminated sheets, coming from the snapping section, accumulate on the stacking table. MIN. MAX. 14.2 STACKING TABLE POSITION ADJUSTMENT The stacking table position must be changed according to the selected sheet size and paper thickness.
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Delta Laminator Operator Manual 15. MACHINE TRANSPORTATION The machine is shipped on a wooden pallet. The machine position on the pallet is shown below. Use only a forklift or pallet truck to transport the machine. The forks must be long enough to reach past the pallet supports of the machine at the further end of the truck, as shown below.
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Delta Laminator Operator Manual 16. MACHINE INSTALLATION A GBC service technician must install the machine, put it into operation, and train the operating personnel. 16.1 PREPARE BEFORE INSTALLATION • Even floor with minimum bearing capacity 512 lb/ft (25kN/m • Pressure pneumatic circuit: Connection with compressed air 90 psi (0.6 MPa) 16.2 ELECTRICAL INSTALLATION REQUIREMENT...
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Delta Laminator Operator Manual BECKER COMPRESSOR ELECTRICAL SUPPLY T4.25DSK 208 - 240 VAC, 3 PH + G 35 AMPS. COMPRESSED AIR 0.6 MPa - 40 L/MIN 35 AMPS. FEEDER STACKING TABLE Machine installation - distance from walls, electric supply, compressed air inlet...
Delta Laminator Service Manual – Mechanical SAFETY NOTICES – FEEDER MAINTENANCE In the automatic operation the feeder table moves upwards in steps. When a new paper stack is loaded, the table moves both upwards and downwards. To assure safe work, the following rules must be observed.
• The power switch must be in the OFF (O) position while tightening the chain or belt. All other activities must be provided by GBC service. Important • As far as maintenance is concerned, the chain lubrication and chain tightening are the only allowed maintenance operations.
• The automatic feeder table lifting is not working reliably. The problem can be removed only by a GBC Service technician. Maintenance consists of regular lubrication of the functional parts according to the lubrication plan and removal of the excess grease and dust.
Delta Laminator Service Manual – Mechanical FEEDER LIFTING MECHANISM DRIVE The feeder table is suspended on the roller chains (h) and driven by the electric motor with a gearbox (j). The chain is clamped to the table on both sides. The torque from the motor is transferred through the drive shaft on both sides of the lifting mechanism, which eliminates binding.
The position of the paper stack when it stops is adjustable with a small screw on the top of the capacity sensor (g). The capacity sensor can be adjusted only by a technician trained by GBC Service. Swing stop I.
If the sensor must be adjusted so that it will not prevent the normal function of the feeder head and will stop the table movement just when the feeder head is slightly lifted around the guide bar after the feeder (stack) hits the feeder head, the adjustment can be performed only by a GBC Service technician.
FEEDER HEAD DRIVE The feeder head drive consists of the main motor (q) and the variator (r). The torque is transferred to the head by the cardan shaft (s). Any adjustment can be done only by a GBC Service technician. FEEDER HEAD All adjustments and repair of the feeder head can be performed only by a GBC Service technician.
If the compressed air is cut off to the pneumatic roll (f), the spring (h) retracts the pressing roller so that it does not contact and deform the feeding roller. Ensure that the spring is in good working order. Only a technician trained by a GBC Service technician can change the pneumatic cylinders or electromagnetic valves.
The main drive roller chains are located under the sheet metal safety cover on the opposite side of the operator. Only a technician trained by a GBC Service technician can change or tighten the roller chains. Maintenance should be performed as follows: 1.
2.14 SNAPPING ROLLER BELT Assembly and disassembly can be performed only by a technician trained by a GBC Service technician. If a belt fails, it must to be changed. The proper belt type is given in the parts catalog and it is also printed on the upper surface of the belt.
Delta Laminator Service Manual – Mechanical 2.15 LUBRICATION AND INSPECTION It is necessary to lubricate and inspect the different parts regularly in order to prolong the machine function and life. Weekly: • Check the condensate quantity in the air treatment unit. If the condensate level in the container exceeds 15/64”...
Delta Laminator Service Manual – Electrical 3. ELECTRICAL SERVICE TROUBLESHOOTING – MACHINE CONTROL DISPLAY 3.1.1 Service Screen No. 1 – Pneumatic Cylinders Button for control of snap roll valve Button for return to Button for control of Main Screen No. 1...
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Delta Laminator Service Manual – Electrical The maximum number of the IRC encoder is the maximum caught number, which is proportional to the paper format. This number will reset by switching the “SNAP IMPULSE” button off. It means that if the format is changed to a smaller one, it is necessary to switch the “SNAP IMPULSE”...
Delta Laminator Service Manual – Electrical TROUBLESHOOTING – YELLOW ERROR LIGHT The machine error is signaled by yellow indicator ERROR (lit up continuously or blinking) and the error/status message on the operator's panel in the right at the top. By touching this part of the panel, you get to the Error Screen where the error/status is described in detail.
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Delta Laminator Service Manual – Electrical 3.2.3 Error – fuse FU11 is broken Status indication: • Yellow ERROR indicator is lit up continuously. • Operator's panel, Main Screen, 1st status line: ERROR • Operator's panel, Main Screen, 2nd status line: Fuse FU11 •...
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Delta Laminator Service Manual – Electrical 3.2.6 Error – instrumentation of circuit breaker FA1 for frequency inverter U1 Status indication: • Yellow ERROR indicator is lit up continuously. • Operator's panel, Main Screen, 1st status line: ERROR • Operator's panel, Main Screen, 2nd status line: Circuit Breaker •...
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Delta Laminator Service Manual – Electrical Status correction: • First it is necessary to establish if the error is in the pulse generation or on the main drive. You can check it as follows: Press the “START” button/indicator again to quit the error, if the error persists, it will appear again.
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Delta Laminator Service Manual – Electrical 3.2.10 Status – the loading table is in the bottom limit position Status indication: • Operator's panel, Main Screen, 1st status line: STATUS • Operator's panel, Main Screen, 2nd status line: Feeder bottom •...
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Delta Laminator Service Manual – Electrical 3.2.12 Error of the communication with frequency inverter U2 Status indication: • START button/indicator is blinking. • Yellow ERROR indicator is lit up continuously. • Operator's panel, Main Screen, 1st status line: ERROR •...
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Delta Laminator Service Manual – Electrical 3.2.14 Error – alarm of the heating regulator - on the end sides Status indication: Yellow ERROR indicator is lit up continuously. Operator's panel, Main Screen, 1st status line: ERROR Operator's panel, Main Screen, 2nd status line:...
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Delta Laminator Service Manual – Electrical 3.2:16 Error – temperature sensor Pt100 short – heating in the middle Status indication: • Yellow ERROR indicator is lit up continuously. • Operator's panel, Main Screen, 1st status line: ERROR • Operator's panel, Main Screen, 2nd status line: Pt100 middle •...
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Delta Laminator Service Manual – Electrical 3.2.18 Error – temperature sensor Pt100 short – heating on the end sides Status indication: • Yellow ERROR indicator is lit up continuously. • Operator's panel, Main Screen, 1st status line: ERROR • Operator's panel, Main Screen, 2nd status line: Pt100 end side •...
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Delta Laminator Service Manual – Electrical 3.2.20 Status – the embossing unit attached to the machine is not running (it is stopped) Note: Applicable only in case a embossing unit is attached to the machine. Status indication: • START button/indicator is blinking.
Delta Laminator Service Manual – Electrical TROUBLESHOOTING – PROBLEMS ARE NOT INDICATED ON THE CONTROL PANEL 3.3.1 Error – heating on the laminating roll is not active – end sides or middle Possible indications of statuses: • Bad laminated sheets quality •...
Delta Laminator Service Manual – Service Centers 4. SERVICE CENTERS Please contact the GBC Service Centers if needed: EUROPE GBC National Service GBC Film Group Europe One GBC Plaza Mercuriusstraat 9 NORTHBROOK, IL 60062 6468 ES KERKRADE U.S.A. The NETHERLANDS...
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heat roller not as hot as temperature indicates