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FORMICA CZ, s.r.o.

Machines for single-side paper lamination in printing and copying industry

Separators

FOLIANT 520 FOLIANT 720

Operating instructions

(Version 1/2002)

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CE – DECLARATION CONFORMITY We, FORMICA CZ, s.r.o. , Štefánikova 1347/III, 293 01 Mladá Boleslav Company ID (IČO) 256 34 569 hereby declare, that the design, structure, and construction launched onto the market by us of the equipment named below correspond to the applicable basic safety requirements stipulated in government regulations. If unauthorized changes are made to the equipment, this certificate becomes invalid. Name of the equipment: Machine for automatic sheets separation Type of the equipment: FOLIANT SEPARATOR 520 Manufacturer, place of production: FORMICA CZ, s.r.o., Štefánikova 1347/III, 293 01 Mladá Boleslav

Description and use: The separation machine has been developed to separate one side laminated sheets. When used in connection with a FOLIANT 520T or HP laminators, it forms a semi automatic line FOLIANT 520 for single-sided lamination of paper sheets with polypropylene foil in small and medium printing houses, for lamination of printed book covers, envelopes for booklets and magazines, postcards, file folders and boxes. Applicable government regulations: Order of the government No. 170/1997 Sb. Coll. as amended (Directive 98/37/EC) Order of the government No. 169/1997 Sb. Coll. as amended (Directive 89/336/EEC) Order of the government No. 168/1997 Sb. Coll. as amended (Directive 73/23/EEC) Relevant harmonized standards, national standards and technical specifications: ČSN EN 292-1:1994, ČSN EN 292-2:1994/A1: 2000, ČSN EN 294:1993, ČSN EN 953:1998, ČSN EN 954-1:1998, ČSN EN 1050:1998, ČSN ISO 7000:1996, ČSN EN 60335-1:1997, ČSN EN 61000-3-2+A12:1997, ČSN EN 61000-3-3:1995+A1: 2001 ČSN EN 33 0120:2001, ČSN 1037:1997, ČSN EN 60073:1997, ČSN EN 50081-1:1994, ČSN EN 55014-1:1995, ČSN EN 55014-2:1998 Under conditions for usual and specified use, the product is safe The compliance was inspected pursuant to Section 12, Subsection 4 a) of Act No. 22/1997 Sb.

Compliance was tested in co-operation with ITI TÜV, s.r.o, Modřanská 98, 147 00 Prague 4, Company ID (IČO) 63987 121- Inspection body no. 4002 Certificate (number, date, validity): 2004-05-03 Ing. Ladislav Moc - General Manager ---------------------- Issued in, date Name and position of responsible person Signature

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TABLE OF CONTENTS 1. INTRODUCTION 2. MACHINE USE 3. TECHNICAL DATA 1. INTRODUCTION

The operating instructions deal with the operation of the FOLIANT 520 and FOLIANT 720 separators. These machines have the same design; they differ only in the working width and/or working output. Neither the producer nor the distributor will take responsibility for any damage caused by procedures that do not correspond these instructions and/or safety regulations. Further, they are not responsible for any damage caused by applying improper kinds of films to various kinds of papers. Trying out every material combination is necessary before application. This machine is equipped with various safety devices designed for the operator’s safety as well as for the safety of the machine while being used. These safety precautions cannot cover all safety aspects and thus the operator should read and understand these instructions before using the machine, or s/he should be properly trained by an authorized worker. Errors connected with the machine installation and operation can thus be eliminated. Do not try to put the machine into operation before thoroughly reading all the instructions supplied with the machine and understanding any function and procedure. Three categories of safety regulations are included in these instructions: DANGER Not respecting such instructions can result in loss of life.

WARNING � Not respecting such instructions can result in a serious injury or a

serious machine damage.

NOTICE � Not respecting such instructions can result in a machine damage or an

injury.

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1. Important notice

1.1 Machine use 1.2 TECHNICAL DATA 1.3 Regulations

2. Transporting and handling the machine 2.1 Positioning the machine 2.2 Storing the machine 2.3 Machine assembly 2.4 Assembly procedure

3. Working 3.1 Position adjustment 3.2 Working conditions

3.2.1 Requirements for the working environment 3.2.2 Disposing of the machine 3.2.3 Description of the electric appliance and its function

4. Running the separator 4.1 Setting the separation unit position 4.2 Setting the deflection wheel position 4.3 Setting the correct separator speed 4.4 Cleaning the machine

5. Separation trouble 6. Breakdown

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�1. Important notice:

Separators of the FOLIANT series are machines with star (“Y”) connection, and thus must be connected only by trained technicians of distribution or service companies. Follow particularly the safety regulations specified on the machine plates. Do not remove the plates nor tamper with them. If any plate is damaged, contact your supplier. 1.1 Machine use: The separator of the FOLIANT series is designed for automatic separation of laminated sheets. The laminator will cover paper sheets with polypropylene film. The separator will separate laminated sheets, count them, and place them into a tray. The FOLIANT separator is designed to form a semi-automatic production line if connected with the laminator. 1.2 TECHNICAL DATA : The related modifications have the same design; they differ only in the working width. Technical parameters

SEPARATOR FOLIANT FOLIANT ( paper: 115 - 350 gsm ) SEPARATOR 520 SEPARATOR 72 0

Suitable formats B2, B3 B1, B2 Max. working width 520 mm 720 mm Voltage 230 V, 50 Hz 230 V , 50 Hz Power input 600 W 600 W Dimensions ( mm ) 900 x 960 x 160 1400 x 1160 x 160 Weight 75 kg 85 kg Minimum paper dimension (W xL) 35 cm x 25 cm 50 cm x 35 cm Maximum paper dimension (W xL) 52 cm x 74 cm 72 cm x 100 cm

Machine acoustic output : Machine operation without load Lwa in dB(A) 70 Machine operation with load Lwa in dB(A) 73,2 Max. permissible value Lwa in dB(A) 100

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1.3 While the machine was being designed, the following standards and regulations were taken into consideration: Machine parts No. 170/1997 Sb. Government Order (98/37/EC Guidelines) specifying the technical requirements for machinery as amended by No. 15/1999 Sb. Government Order and No. 283/2000 Sb. Government Order. ČSN EN 292-1:1994 (EN 292-1:1991) Machinery safety. Basic terms, general design principles, Part 1: Basic terminology, methodology. ČSN EN 292-2:1994+A1:2000 (EN 292-2:1991+A1:1995) Machinery safety. Basic terms, general design principles, Part 2: Technical principles and specification. ČSN EN 294:1993 (EN 294:1992) Machinery safety. Safe distances to avoid touching dangerous points with arms. ČSN EN 953:1998 (EN 953:1997) Machinery safety. General requirements for the design and construction of protective guards (fixed, movable). ČSN EN 954-1:1998 (EN 954-1:1996) Machinery safety. Safety parts of control systems. Part 1: General construction principles. ČSN EN 1050:1998 (EN 1050:1996) Machinery safety. Principles for risk degree determination. ČSN EN 563:996 (EN 563:1994) Machinery safety. Temperatures of surfaces exposed to touch. Ergonomic data to specify limit values of the hot surfaces temperature. ČSN ISO 7000:1996 (ISO 7000:1989) Graphic marks replacing marks on the machinery. The index and clear table of the marks. Electrical parts No. 169/1997 Sb. Government Order (89/336 EWG Guidelines) specifying the technical requirements for product electromagnetic compatibility as amended by No. 282/2000 Sb. Government Order. No. 168/1997 Sb. Government Order (73/23 EWG Guidelines) specifying the technical requirements for low-voltage electrical devices as amended by No. 281/2000 Sb. Government Order. ČSN EN 60335-1:1997 (EN 60335-1:1994) Safety of electrical appliances designed for household and similar purposes. Part1: General requirements. ČSN EN 61000-3-2+A12:97 (EN 61000-3-2+A12:1996) Electromagnetic compatibility (EMC) – Part 3: Limits – Section 2: Limits for harmonic current emission (appliances with input phase current <=16 A) ČSN EN 61000-3-3:1997 (EN 61000-3-3:1995) Electromagnetic compatibility (EMC) – Part 3: Limits – Section 3: Limitation of voltage swinging and flickering in low-voltage distribution networks, specified for appliances with nominal current <=16 A ČSN 33 0120:2001 (IEC 38:1983)

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Electrotechnical regulations. IEC Standardized voltage. ČSN EN 1037:1997 (EN 1037:1995) Machinery safety – Prevention of spontaneous start. ČSN EN 60073:1997 (EN 60073:1996) Electrotechnical regulations. Coding of communicators and controllers by means of colours and additional means.. ČSN EN 50081-1:1994 (EN 55081:1992) Electromagnetic compatibility. General standard dealing with radiation. Part one: Residential, business, and light-industrial buildings. ČSN EN 55014-1:1995 (EN 55014-1:1993) Electromagnetic compatibility – Requirements for household appliances, electrical tools, and similar appliances – Part 1: Radiation –Standard for products groups. ČSN EN 55014-2:1998 (EN 55014-2:1997) Electromagnetic compatibility - Requirements for household appliances, electrical tools, and similar appliances – Part 2: Resistance – Standard for products groups.

�SAFETY DEVICES

This machine is equipped with a safety device protecting both the operator and the machine. These safety devices is made up of the main switch, protective guards, thermal fuse, and overload fuse. Information plates and plates warning about various dangers are placed on the machine.

� Follow particularly the safety regulations specified on the plates on the machine. Do not

remove the plates nor tamper with them. If any plate is damaged, contact the manufacturer.

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Plates list: 1. Type plate; 2. Warning when the cover is removed – danger of an injury caused by electric

current; and 3. Warning when the cover is removed – danger of a mechanical part damage. Electrical installation

The socket (220 - 230V, 50 Hz) designed for connecting the machine must be situated near the machine and must remain easily accessible. The socket and the circuit breaker must be adequately dimensioned – a 10-A circuit breaker. Using extension cables and/or adapters is prohibited. Connecting the machine (in accordance with the national standard) to the electric network can be performed only by a person with appropriate electrotechnical qualification.

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T 6,3 A

T 315 mA

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1011

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Wiring diagram - Separator

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Wiring diagram – Separator

1) Roller – separation unit 2) Main PC Board with transformer 3) Sheets accounting connecting cable (separator – laminator) 4) Sheets accounting sensors 5) Motor 6) Sensors filter 7) Main filter 8) Control panel 9) Main switch 10) Main fuse 11) Sheets accounting connector

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�2. Transporting and handling the machine

Due to the machine’s weight, two persons will be needed to install and handle it. To handle

the machine you can use the spacing rod (A) and the guide strings holder (B). Upon placing the machine behind the laminator, fix the plate guard (C).

2.1 Positioning the machine

The machine must be placed on a firm and flat surface (working plate) – dimensioned for the machine weight – and must not be near other sources of heat and/or in direct sunlight. All control elements must be easily accessible. A minimum one-metre handling space must be kept around the machine. Further, the main switch (4), which serves as the emergency switch in the case of critical events, must be easily accessible.

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2.2 Storing the machine The machine must be placed on a firm and flat surface * Storage temperatures: -10°C up to 60 °C (-10°F up to 140°F) Relative humidity: 20% up to 80%, uncondensing relative humidity

• Recommended accessory : FOLIANT table of appropriate width 2.3 Machine assembly The machine is supplied partly dismantled on a wooden pallet; it is thus necessary to assemble it before putting into operation. Assembling the machine is very easy. Before assembling the machine, ensure that it is disconnected from the power supply. 2.4 Assembly procedure:

1. Place the machine base in the working space; 2. Fix the side protective guard; and 3. Fix the top transparent guard. 1. Top transparent guard 2. Connecting hook 3. Connecting guard 4. Main switch 5. Control panel 6. Counter sensor 7. Cable connectors 8. Belt tightening screws

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�3. Working

3.1 Position adjustment: Laminator – Separator connection

Hang the connecting hook on the laminator spacing shaft.

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�3.2 Working conditions

3.2.1 Requirements for the working environment: 1. Operation temperatures: 15° up to 40°C (41°F up to 104°F); 2. Dust-free working environment; 3. Air relative humidity 20% up to 80%, uncondensing relative humidity.

MACHINE SAFETY DEVICES

• Side guards; • Top guard – transparent.

3.2.2 Disposing of the machine An unserviceable product will become waste which must be dealt with in accordance with the stipulation of the waste law valid in the operator’s country. You can dispose of an unserviceable product only by passing it to the authorized representative specified in the waste law. Do not dispose of the product in any other way; do not dispose of it in municipal waste. 3.2.3 Description of the electric appliance and its function

The electric circuits are situated under the side guards – on the right side are all the regulation circuits, the main switch with a fuse, motor switches and the speed regulator. The circuits with a transformer and fuses are located in the connecting tunnel, under the feeder. These circuits are accessible by lifting the machine front part, placing a suitable and firm prism underneath (thus securing the front part), and dismantling the bottom protective guard. Pushing the main switch (4) will result in activating the power and control circuits of the machine. You can turn on the machine with the "START" button (15), the drive speed can be changed with "SPEED" – the rotary potentiometer (19). "STOP" – the red button (16) is designed to stop the drive.

15. Start button

16. Stop button 17. Motor operation indicator 18. Machine connection indicator 19. Speed regulator

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�4. Running the separator

�4.1 Setting the separation unit position

9. Deflection wheel

10. Revolving arm 11. Wheel position arrestment screw 12. Valves thrust adjustment screws 13. Valves position arrestment screw 14. Paper

• Lift the top guard, pos. 1. The suitable position of the separating unit – Loosen the screws (pos. 13) on both sides of the unit. Next, position the unit according to the formula: Q = sheet length + 5 – 15 %. Last, secure the unit by the screws, pos. 13.

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� 4.2 Setting the deflection wheel position

The correct deflection wheel (9) position is on the edge of the laminated sheets;

approximately in the position where the paper edge is before the deflection (20), on the other side than the film is perforated.

�4.3 Setting the correct separator speed

The separator is always faster than the laminator; the difference is always plus 10% – 20%.

The speed can be regulated with the potentiometer (19), found on the control panel (5). If you set a higher lamination speed, first set a higher separator speed accordingly, and only then increase the laminator speed.

Never use the separator without protective guards!

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� 4.4 Cleaning the machine

Keep the machine clean – remove dust regularly. Check regularly whether residues of consumer material (paper, film, etc.) have not stuck in the working space. Disconnect the machine from the electrical supply before cleaning or handling it. To best clean the rubber valve, use the rough side of a washing sponge (SOKE, etc.) – the laminator must first be disconnected. Solvent must not come into contact with the machine plastic guards (sides). The plastic guards (sides) can be cleaned with a damp cloth with a small amount of common furniture detergent – as always the machine must be disconnected first.

�5. Separation trouble

The separator does not separate laminated sheets or does not separate them evenly:

• Too small adjustment angle of the deflection wheel; • Poor valves thrust – WARNING: do not strain the thrust springs!!! It causes abrasion of the

rubber-coated valve; • Insufficient film perforation – check the laminator perforation wheel, add a load on the

laminator perforation arm; • Set the optimal tearing valves distance (Q); • Insufficient separator speed. • Counter doesn’t work (!!!CHECK THAT THEY ARE NOT EXPOSE ON THE STRONG

DIRECT LIGHT (SUN, REFLECTOR, etc…)!!!

� 6. Breakdown

In the machine breaks down, disconnect it from the electrical supply immediately. Contact any authorized service shop for repairs.