DS-60 Heat Press Service Manual
Contents
1. Output E 246 il Voltage As by Q Jumper o0 4 uses Located O Under the z d Main Circuit oC LL Breaker Jumper u oQ u qi ag H Z N O 22 4 ex E 90 z lt 05 4 e 5 x O lt o 2 a 1 5 or 1 8 Horsepower Resistor or VISAV IV 8776H766M g ZK o OF 2x 02 o2 lt ke wo m o gt ali olg a lt 42 gt 22 LKB Figure 5 8 Barrier Board and Motor Controller Board Showing Default Setting 5 8 GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Adjustments Heater Control Programming FUNCTIONS MENU AND PROGRAM MODE GUIDE A 3sec 1 Enter exit program mode PSY Press and hold 7 P 2 Single level navigation 3 View Change Option View Function Option Autotune Option value To change Option value V Ar Release lead UR 4 Changing menu levels Locate level Function Select new level A o S F MENU LEVEL i E a a 4 RS RS S SY gg OA S ES S o Sx S S 5 22. ozo xx Ba 050 X v9 1 o 9 809 x04 ZESES jssjojeQ HO5L OUd c J 9 809 7 27 NOISIA3 oi 9340345 SSTINN L 4 13388 061 250 LSNYHL 902 00 MHL 0607 LSNYHL 5 SLI SC B SXxOZSESE LNN MDOUN 91 8 E X v LX 1 ASM 0D 00G 3ZNOMB 1SO8 ONIHSNE 00v ZEO ISAYHL ONIMV3H 019 250 MHL 0607 LSNYHL YSHSVM Ocv ece0 MHL 0607 1SnHNHL 5 192 100 HOLMIO 9 H231 ONd 289 NOISSINH3d LNOHLM 3504 do4 0351 NI NI 035019510 YO 031909 38 LON TIVHS AINO NOLIVWJOJN SNIM3J3NION3 3ON3GUIJNOO 93155 SI SIHL NO 035019510 AHL Ol SIHONMJ ANvIdIHdOHd SWIVIO HO3l OHd 089 1 GBC Pro Tech 1997 October 9 12 DS 60 Heat Press Service Manual GBC Pro Tech 1997 October Illustrated Parts List 9 13 Illustrated Parts List DS 60 Heat Press Service Manual
3. 1997 October DS 60 Heat Press Service Manual Section 5 Adjustments When a DS 60 Heat Press is not operating properly there are several adjustments you can make to return it to normal operation Some of these adjustments need to be made on a regular basis and are listed in the Maintenance Schedule in Section 6 Maintenance The others only need to be done when the heat press is not functioning properly This section begins with instructions for removing the cabinet covers and includes both mechanical and electrical adjustments to the heat press Mechanical Adjustments There are three main mechanical adjustments for the DS 60 Heat Press e Nip Adjustment for the Main Rolls e Photoelectric Eye Adjustment e Chain Tensioning Removing Drive and Control Side Cabinet Covers A WARNING Always remove power from the heat press before removing the cabinet cover s You could be burned or get your fingers caught in the drive mechanisms Tools required 8 hex wrench GBC Pro Tech 1997 October Adjustments To remove a cabinet cover A WARNING Remove power from the heat press and make sure it won t be reapplied while you are performing this procedure You could be severely shocked electrocuted or get your fingers caught in the drive mechanisms 1 Remove the ten screws attaching the cover to the heat press using the 1 hex wrench See Figure 5 1 2 Lift the cover off
4. 53 9 SIHL Wodi 5 3805 135 3AOW3MH HO3l ONd NOJSSINAJd N3lll4M LNOHLIM 350484 N3HIO 403 YO 404 0361 NO YO NI 03507102510 43909 38 LON TIVHS AINO NOLLVABOJNI ONIHJ3NION3 404 3ON3GIJNOO 03 551 SI ONIMVAC SIHL NO 035010510 JHL 01 AMVI3IMdOMNd SWIVID 084 289 1 GBC Pro Tech 1997 October 9 6 DS 60 Heat Press Service Manual GBC Pro Tech 1997 October Illustrated Parts List 9 7 Illustrated Parts List 9 8 DS 60 Heat Press Service Manual GBC Pro Tech 1997 October Illustrated Parts List T vos F wx xx oso x S 98 p 7 809 805 AEE 18320430 Lol EL IIOS 2 1 S 305 GIMI 089 SD E MJA 31v9S ON NO 33LN3O l3NIBVO 3NIHOVW SM3 3105 NINA 5 OL ALL 001 SGL 0S 939115 SNINSVM MLS LAN OZ 4 1 620 994 100 890 H3HSVM o WONJ NOISSIN3d
5. 5 1 the Main Roll NIP zd se rop ARE m NE ER IR ERR Re 5 3 Thermocouple Positioning and Cleaning 5 3 Photoelectric Eye E ECC E b 5 4 Chai 5 5 Electrical 5 6 Motor Control Board Potentiometers HE obou 5 6 Heater Control Program mln 5 2 5 9 Pressure Sshsel Adjustment asso tior mieten cee cer Secu ticle etis e cu EIUS 5 11 Section 6 Maintenance 6 1 rt oett 6 1 6 2 en t A Lue Lu LUE AM M 6 3 Removing Flat Spots on the Main Rolls cuc ten eph nt 6 3 Disassembly Reassembly 6 4 GBC Pro Tech 1997 October iii DS 60 Heat Press Service Manual Drive and Rewind au xtd verde vex dette da op AA obo 6 4 SDIOGKGIS tomes no can ra envies n DU VIAE ME DU DM EADEM TAM A E 6 5 V SAN ce dudes caus O SN OV S HN BO TET Ida O a 6 7 Control BOAR cain rar TOORA EUR UD ECO 6 7 CIRCUIE Breaker Dosen T ee EUR NESLO G ELO XE L A EUC L G ERL B SOL 6 7 WAAMA UU
6. SWIVIO 084 289 9 15 GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Illustrated Parts List PE EEE Bad JWOS W130 3000 cud 430105 039 E E suc 1 130 SL a 1 084 289 NOISSINH3d ___ 08 193 91 4320008438 38 TIVHS ONY AINO NOILVAOOJNI DNIN33NION3 c aanaz 3000 2 Ni 03055 SI 1 03501350 WAIA aaa 900 8 OL 5 SMIVID 1 084 289 wai lave NOILdIN2S3Q GBC 1997 October 9 16 Illustrated Parts List DS 60 Heat Press Service Manual 9 17 ON WS CU sii 500 AS 6 6 4 Alva 010 XXX 55 313 060 x 79 1 371 Sy98 9vz 809 9 809 HSINIJ 101 NOUS S OAld SAW z NZI CY 3ONV33 IO ON NOISIA33 031512395 5 5591 20 133 5 HIS O8 0491 9 N ETN a
7. Remove power from the heat press before servicing You can be severely shocked electrocuted or cause a fire A WARNING Do not use liquid or aerosol cleaners on the heat press Do not spill liquid of any kind on the heat press You can be severely shocked electrocuted or cause a fire Use only a damp cloth for cleaning A WARNING Exercise care when cleaning the rolls with 80 isopropyl alcohol Use only in a well ventilated area Wear rubber gloves Use only on cool rolls Cleaning heated rolls can ignite the fumes A CAUTION Use only 80 isopropyl alcohol or a rubber cement eraser to clean the main rolls Harsh chemicals like toluene acetone or MEK destroy the silicone covering of the rolls GBC Pro Tech 1997 October 1 2 DS 60 Service Manual A CAUTION Raise the upper main roll when the heat press is not in operation Prolonged contact can damage the rolls A CAUTION Excess pressure can damage the main rolls Always select the minimum roll pressure necessary to complete the task A WARNING The operating environment must be free of dust flammable liquids and vapors You can be injured by inhaling chemical vapors Vapor build up or stored flammable liquids can cause a fire Excessive dust can damage the heat press A CAUTION Do not use a knife or other sharp instrument during installation or while servicing the heat press You can cause irreparable damage to t
8. 3 2 DS 60 Operation and Maintenance Manual GBC Pro Tech 1997 October DS 60 Operation and Maintenance Manual Installation 8 6 1 2 2 6 m 20 2 9 56 84 m 1 Front 8 6 1 2 2 6 m lt 13 4 m Wall Electrical LI lt 3 1 m Figure 3 1 Heat Press Space Requirements GBC Pro Tech 1997 October 3 3 Installation Unpacking NOTE ALL SHIPMENTS ARE EX WORKS At our dock title passes to the buyer Please review your insurance coverage prior to shipment as you are responsible for all subsequent freight charges and risks Before signing the Bill of Lading you should be sure to inspect the crate and or pallet for signs of damage or missing items if applicable make a note of this on the Bill of Lading The DS 60 Heat Press is shipped in a plywood crate A WARNING The unpacking process requires at least two on a skid people You can be severely injured or crushed Tools required e Phillips head screwdriver po open end wrench or adjustable wrench To uncrate the heat press 1 Remove the top of the crate and then the sides in the order shown in Figure 3 2 A CAUTION Do not allow the top to fall into the crate It can damage the heat press Do not put packing screws on the floor They can cause problems when trying to roll the machine into position A second person must support the side labe
9. 6 Never change or defeat the function of electrical interlocks or other machine shutdown switches 7 Before starting this machine check that All persons are clear of the machine No maintenance work is being performed the machine All guards are in place parent rolls are well chucked in the unwind stands The machine is free of paper scraps wraps and jams 8 There is a potential hazard of entanglement in this machine caused by items such as Make sure your clothing and hair fit closely to your body and that all jewelry rings and watches are removed Figure 1 3 Locations of Safety Labels Carefully read Operator s Manual before handling this machine Observe instructions and safety rules when operating 1 4 GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Limited Warranty GBC Pro Tech Engineering Company Inc warrants the equipment sold is free from defects in material and workmanship for a period of ninety days 90 from the date of delivery to the customer This warranty is the only warranty made by GBC Pro Tech and cannot be modified or amended GBC Pro Tech s sole and exclusive liability and the customer s sole and exclusive remedy under this warranty shall be at GBC Pro Tech s option to repair or replace any such defective part or product These remedies are only available if GBC Pro Tech s
10. Problem D waves Hints Check paper tension Check relative moisture content of the paper IS Problem Waves on only one side of the output Hints Check nip settings Check for even paper tension i Sises o Problem D waves Hints Increase clutch tension Check roll pressures Check nip settings Problem Angled waves on the output Hints Check for insufficient clutch tension Check for insufficient main roll pressure DS 60 Heat Press Service Manual Problem Straight waves in the output Hints Decrease clutch tension Check operational settings for materials being used Other Common Problems Feed Direction Problem Blistering in the image Hints Increase speed or lower the operating temperature Problem Longitudinal waves or stuttering jerking or excessive noise from the drive side of the laminator Hints Increase chain tension decrease unwind brake tension GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Illustrated Parts List Section 9 Illustrated Parts List Part Name Part Number Accessory Pack 001 451 See page 3 4 for the list of included accessories Safety Label Kit 001 230 Power Cable Assembly 001 173 Assembly on page 9 4 63 5 Idler Assembly 001 393 Assembly on page 9 5 65 Idler Assembly 001 394
11. GBC Pro Tech 1997 October Illustrated Parts List DS 60 Heat Press Service Manual ON 999 je d 020 3 s fa S AL 9 1 x04 9 809 HSINIJ 45340490 UOSJ PUY IS I gt JONVATIOL ar ALD 23140395 3SMY3HLO L 1 38 0L 13365 91 M 3 SSN a 0086 0220 M3HSVM LSNAHL 981 060 LJVHS 4 ONIN dVNS o 062 c 0 15846 ONIMV38 o MHL 080 LSNYHL H3HSVM 002 680 91 8 1 9 5 071 060 LJVHS 2 ONIN dVNS 8 J3MHSVMLIV 13 8 5065 971 X 91 8 100 629 Q31M40NM HOLM BONY LL0 66X AJOGNVLS ONIM3H LJVHS ZLLO Z6EX HOLNTO 31 08 4 289 WOMJj NOISSIAa3d VALUBM LNOHLIM 5049 404 SO 38NLOVINN W 504 035 NI YO FIOHM NI 035071050 031902 LON TIVHS AINO 404 JONAdI4NO3 Q3nss SI l SIHL NO 0350712519 OL SIH9lM
12. 3 Remove the screws holding the circuit breaker from the fuse panel 4 Pullthe circuit breaker back away from the cabinet 5 Cut the heat shrink tubing from the wires on the circuit breaker 6 Remove the wires using the straight slot screwdriver Remove Wires Figure 6 8 Removing the Circuit Breaker To replace a circuit breaker Reinstall the circuit breaker by following the disassembly instructions in reverse order 6 8 DS 60 Heat Press Service Manual Thermocouple Tools required e 5 hex wrench Screwdriver To remove a thermocouple A WARNING Remove power from the heat press and make sure it won t be reapplied while you are performing this procedure You could be severely shocked electrocuted or get your fingers caught in the drive mechanisms 1 Remove the control side cabinet cover see page 5 1 2 Disconnect the two thermocouple wires attached to the heater controller 3 Remove the two screws securing the thermocouple to the rod 4 Pull the wires out of the tube and remove the thermocouple To replace a thermocouple Reinstall the thermocouple by following the disassembly instructions in reverse order Be sure to realign the new thermocouple using the procedure in Section 5 A CAUTION Thermocouple leads are fragile and can be damaged by kinks or scrapes GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Maintenance Motor Controller Board Barr
13. 350444 404 NO 3BnloVJNVW X04 Lave 31OHM NI 031900 38 TIVHS ONY AINO NOLVAHONI Os 690 589 200 920 ONINVSE 9 9 DS 60 Heat Press Service Manual AS 30100 5 X VIO ZICO ON 1HVd 9530 AINSSI SI iviHalVW AHL OL 5 SWNTO 089 1 GBC Pro Tech 1997 October Illustrated Parts List 9 10 DS 60 Heat Press Service Manual GBC Pro Tech 1997 October Illustrated Parts List DS 60 Heat Press Service Manual 9 11 EE 09 50 09 4 NIVHO q3visnrav 43101 ATIBW3SSV 8 982 E ER he te H23L ONd 289 NOISSINYId N3LLMA 350444 ANY 404 NO Q3S MO NI MO 035070618 MO 03402 LON NVHS ONY AINO NOUVWHOJNI 308 NI 030551 SI 9NIMYHO NO 03501250 105 5 101 485 3HL 01 SIHSIY Asidi SWIVID HO31 0Nd 089 1 1 mask om 1 0 GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Illustrated Parts List ON 900
14. AINO QN3 SIHL NO M33OS 135 001 610 014 TION 3 5 SOv 0 9 9 X Z 001 020 431701 ONIMV38 ON Ldvd NOULdIdIS30 SIHL S M3Y0S 135 3AOW3M 31 084 089 084 NOISSINYSd 1 35048014 404 40 303 0351 YO NI MO NI 0350702510 MO 031900 d3ondONd3M 38 LON TIVHS ONY AINO NOLWNYOINI ONIM33NION3 9 NI 03055 SI SIHL NO 0350712510 AHL OL 5 SWIVIO HO3l OBd 289 9 5 GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Illustrated Parts List Sect N Lva XX Jf 080 2 38 OL 809 X04 9 808 euoud US ODSI 11500490 U SJ PUY IG DID 5 NINQHS sv nia 03 10345 SS31Nn L 30 1 13365 5 5 3405 135 NALHOIL z OLNI 55389 1 080 017 moa 33101 0 9 9 X 310 TION 001 0c0 1
15. Assembly on page 9 6 Brake Assembly 001 396 Assembly on page 9 7 GBC Pro Tech 1997 October 9 1 Illustrated Parts List DS 60 Heat Press Service Manual Pivot Rolls Assembly 001 397 Assembly on page 9 8 Assembly on page 9 10 Adjustable Chain Idler Assembly 001 428 SA Assembly on page 9 11 Drive Rewind Assembly 001 432 6 Assembly on page 9 12 Force Sensor Assembly 001 435 Assembly on page 9 13 Magnet Force Sensor Assembly 001 437 e Assembly on page 9 14 9 2 GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Illustrated Parts List Rewind Brake 001 439 Assembly on page 9 15 Electrical Panel Assembly 001 446 Assembly on page 9 16 Core Chuck Quick Release Assembly 001 457 Assembly on page 9 18 Lockout Cable 130 001 Power Supply 245 205 Assembly on page 9 19 GBC Pro Tech 1997 October 9 3 Illustrated Parts List 9 4 DS 60 Heat Press Service Manual GBC Pro Tech 1997 October Illustrated Parts List DS 60 Heat Press Service Manual HI 5 wa 0 1077 iva 8 4410 060 X ozo XX v9 l 16 82 95 Hry 9798 972 809 809 20094 ZESES 850095 18840480 Pooy Clr NOISIA3H HSIN 39NVH3101 0340395 ISMA3HLO SS31Nn 30 13385 1816 3118 311 001
16. DS 60 Heat Press Service Manual 1997 GBC Pro Tech Do not duplicate without written permission GBC Pro Tech 4151 Anderson Road De Forest Wisconsin 53532 Tel 608 246 8844 Part Number 930 012 Fax 608 246 8645 DS 60 Heat Press Service Manual The information in this publication is provided for reference and is believed to be accurate and complete GBC Pro Tech is not liable for errors in this publication or for incidental or consequential damage in connection with the furnishing or use of the information in this publication including but not limited to any implied warranty of fitness or merchantability for any particular use GBC Pro Tech reserves the right to make changes to this publication and to the products described in it without notice All specifications and information concerning products are subject to change without notice Reference in this publication to information or products protected by copyright or patent does not convey any license under the rights of GBC Pro Tech or others GBC Pro Tech assumes no liability arising from infringements of patents or any other rights of third parties This Service Manual is Copyrighted 1997 by GBC Pro Tech All rights reserved The information contained in this manual is proprietary and may not be reproduced stored transmitted or transferred in whole or in part in any form without the prior and express written permission of GBC Pro Tech GBC Pro T
17. jv S SoS gt 2 ss 9 2 S s S 523 2 2 e 2 2 V ZR dU Y WA E S SL PEE FEE IET PETI OUTPUT TEC HNIC AL CONHGURATON 2 gt 3 S gt E rs a NS v e c8 SS E E SEV ES gt ES S 2 P3 LK NS K 37 S jv RO 2 S N 8 SS ESS ELS POY 3 SLES x S 3 N KS x2 x S xS x Ry 99 lt 22 F 22 22 qo E Yi rtric L RAE MANUAL CONTROL MODES S2 H INPUT SELECT 8 RANGING SP1 OPERATING PARAMETERS SP2 OPERATING PARAMETERS Figure 5 9 Heater Control Menu and Program Mode Guide 1 Press the up and down buttons simultaneously until LEVL appears The commands LEVL 7 and 5 flash back and fourth 2 Press the up or down button until inPt appears Press and hold the star button while pressing the up or down button until SSd appears The commands SP1 d and SSd flash back and forth The commands inPt and nonE flash back and 8 Press the up or down button until LEVL forth appears 3 Press and hold the star button while pressing the 9 Press and hold the star button and press the up or up or down button until teJ appears If you down button until 1 appears The commands accidentally pass tcJ use the up or down button LE
18. A WARNING Remove power from the heat press and make sure it won t be reapplied while you are performing this procedure You could be severely shocked electrocuted or get your fingers caught in the drive mechanisms DS 60 Heat Press Service Manual Heater Controller Tools required none To remove the heater controller A WARNING Remove power from the heat press and make sure it won t be reapplied while you are performing this procedure You could be severely shocked electrocuted or get your fingers caught in the drive mechanisms 1 Remove the control side cabinet cover see page 5 1 2 Pull back on the green tab and disconnect the connector Remove the plastic frame 4 Pull the switch through the front of the control panel To replace a control panel switch Replace the control panel switch by following the disassembly instructions in reverse order 6 10 1 Remove the control side cabinet cover see page 5 1 2 Disconnect the wires to the heater controller The terminal strip will come off the temperature controller without removing the wires Slide the green locking tab back and lift the terminal block off the temperature controller 3 Squeeze the black tabs on the retainer and pull the temperature controller out through the front of the control panel GBC Pro Tech 1997 October DS 60 Heat Press Service Manual To replace the heater controller 1 Push the heater contr
19. 0 the rolls should stop turning Run the motor in both forward and reverse Is the heater working Verify that the heater controller heats the top roll Once you have completed the startup checklist you can safely run a test sample GBC Pro Tech 1997 October 3 6 DS 60 Heat Press Service Manual Equipment Location Section 4 Equipment Location The following illustrations show the location of the main parts of the DS 60 Heat Press Upper Rewind Emergency Stop Button Upper Tie Bar Upper Main Roll Lowerr Main Roll Emergency Stop Button Lower Unwinds Main Roll Lift Crank gt Lower Unwinds Tension Adjust ea Figure 4 1 Exterior Equipment Locations Front View GBC Pro Tech 1997 October 4 1 Equipment Location Upper Rewind Hub Emergency Stop Button Reset Button Fuse Panel Lock Panel Lower Rewind Hub Lower Tie Bar DS 60 Heat Press Service Manual Upper Tie Bar Emergency Stop Button 1M 825 RUN STOP Switch Figure 4 2 Exterior Eguipment Locations Rear View 4 2 GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Equipment Location Upper Rewind Sprocket Lifter Assembly Upper Main Roll Heater and Heater Bracket Photoelectric Rewind Chain Eye Emitter Lower Main Roll Sprocket Chain Tensioner Drive Chai
20. examination of the product discloses to GBC Pro Tech s satisfaction that such defects actually exist and were not caused by misuse neglect attempt to repair unauthorized alteration or modification incorrect line voltage contaminated air supply or by fire accident flood or other hazard This warranty specifically does not cover damage to the laminating rollers caused by knives razor blades other sharp objects failure caused by adhesives or improper use of the machine Warranty repair or replacement does not extend the warranty beyond the initial ninety day period from the date of delivery A CAUTION Unauthorized customer alterations will void this warranty THE WARRANTY MADE HEREIN IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE GBC PRO TECH WILL NOT BE LIABLE FOR PROPERTY DAMAGE OR PERSONAL INJURY UNLESS PRIMARILY CAUSED BY ITS NEGLIGENCE LOSS OF PROFIT OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE THE EQUIPMENT GBC Pro Tech 1997 October Safety and Warranty Information Exclusions to the Warranty This warranty specifically does not cover 1 Damage to the main rolls caused by knives razor blades other sharp objects or failure caused by adhesives 2 Damage to the machine caused by lifting tilting and or any attempt to position the machine other than rolling on the insta
21. is level tighten down the top nuts on the cabinet nuts to lock the pads in their current position Startup The first time the heat press is started and every time it is serviced you should use the following checklist to confirm that the unit is operating properly and that all safety mechanisms are functioning DS 60 Operation and Maintenance Manual Startup Checklist Start the heat press and go through the following checklist CJ Are the emergency stop buttons working Push down on one of the emergency stop buttons The heat press should stop Pull up on the button and push the reset button on the lower back of the heat press The heat press should resume operation Always check all buttons A WARNING Never operate the heat press unless all of the emergency stop buttons are functioning properly You can be crushed or burned CJ Is the photoelectric eye system working With the heat press running place an object approximately the size of your hand just in front of the nip to confirm that the photoelectric eye system is functioning The rolls should stop Move the object away from the nip Press the Photoelectric Eye Reset button on the front control panel The heat press should resume operation A WARNING Never operate the heat press unless the photoelectric eye system is functioning properly You can be crushed or burned Is the motor functioning Test the motor at various speeds ranging from 0 18 At
22. of the way 4 Remove the top plate and hex pivot pin Remove Top Plate Bolts Remove m Top Plate 1 Hex Pivot Pin Figure 6 11 Removing the Top Plate and Hex Pivot Pin To reassemble a brake 1 Make sure that the two bushings are firmly seated in the new pivot pin 2 Grease the area around the hex pivot pin in the two areas shown in the following figure Maintenance Grease Bushings 87 Figure 6 12 Greasing the Hex Pivot Pin 3 Install the top plate and pivot pin into the bottom plate Make sure that the thrust washer is between the pin and the bottom plate Nickel plated brackets do not have thrust washers 4 Slide the assembled brake mechanism into the pivot pin The bottom unwind may require removal of the knob while installing the brake Assembled Brake Pin Mechanism Figure 6 13 Assembling the Brake 5 Secure the brake assembly to the heat press with two bolts using the 3 6 hex wrench 6 Examine the shaft for marks or scratches that could cause rapid deterioration and premature failure of the brake pads 7 Being careful not to let the top brake pad springs and piston fall from the brake loosen the knob several turns 8 Remove the shipping ring from the inside of the new brake assembly cardboard tube 9 While holding the brake assembly with the top pad slide the shaft through the bushings and the 6 12 DS 60 Heat Press Service Manual brake p
23. page 10 2 GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Section 11 Index A Adjustments 5 1 5 8 Electrical 5 6 5 8 Mechanical 5 1 5 5 B Barrier board 5 7 5 8 Brakes 6 11 C Cabinet covers 5 1 5 2 Chain Alignment 5 1 Lubrication 6 1 Tensioning 5 1 5 5 Circuit breaker 6 7 6 8 Cleaning 6 2 Clutch Common problems 8 2 Control board 6 7 Control panel 4 5 6 10 switch 6 10 D Drive chain 6 4 E Emergency stop buttons 1 1 3 6 Environment 3 1 Equipment locations 4 1 Control panel 4 5 Exterior 4 1 4 2 Footswitch 4 6 Interior 4 3 4 4 Extension cord 3 1 F Footswitch 2 1 4 6 6 1 FWD REV switch 6 2 G Grease fittings 6 1 Ground plug 3 1 GBC Pro Tech 1997 October Index H Heater 3 6 6 11 Common problems 8 2 Controller 3 6 Theory of operation 7 1 Heater control Programming 5 9 Heater controller 6 10 Horsepower resistor 5 7 Installation requirements 2 1 3 1 Isopropyl alcohol 6 2 L Laminator ORCA I Characteristics 2 1 Leveling 6 3 Lubrication 6 1 Main roll sprocket 6 6 Main rolls 2 1 5 3 6 11 6 14 Flat spots 6 3 Theory of operation 7 1 Maintenance schedule 6 1 MAX potentiometer 5 7 MIN potentiometer 5 7 Motor 3 6 5 5 5 6 6 6 6 7 Theory of operation 7 1 Motor control board 5 6 5 8 5 6 Motor controller board 5 8 6 8 6 9 Motor sprocket 6 5 6 6 N Nip 1 2 3 5 3 6 5
24. turning as you tighten the bolt into the bushing which will be forced out and separated from the sprocket Figure 6 5 Removing the Main Roll Sprocket 6 Remove the main roll sprocket To reassemble the main roll sprocket 1 Put the sprocket onto the shaft 2 Put the bushing on the shaft and use the two bolts to pull the bushing into the sprocket Be sure to tighten the bolts evenly to lock the bushing snugly into the sprocket Replace chain Measure the distance between each sprocket and the side frame of the heat press Make sure the distances are all the same Recheck these distances after all the screws are tightened to ensure proper alignment Tighten the chains using the chain tensioning instructions in this section 6 Replace the cabinet cover GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Motor Tools required 1 3 hex wrench 16 hex wrench To remove the motor A WARNING Remove power from the heat press and make sure it won t be reapplied while you are performing this procedure You could be severely shocked electrocuted or get your fingers caught in the drive mechanisms 1 Remove the drive side cabinet cover see page 5 1 2 Remove the motor sprocket See the Sprockets procedure earlier in this section 3 Disconnect the three wires green black and white from the terminal block 4 Loosen the strain relief and pull th
25. 1 5 2 5 3 6 1 Adjustment 5 1 Options 2 1 Output voltage 5 7 11 3 Index P Photoelectric eye 3 6 5 1 5 5 Adjustment 5 1 Photoelectric Eye 5 4 Potentiometers 5 6 Power cord 3 2 Power requirement 3 1 Preinstallation checklist 3 1 Pressure Sensor 5 11 R Rewind sprocket 6 5 Riggers 1 3 3 4 3 5 S Safety features 2 1 Safety information 1 1 Safety labels See Safety information Setup procedure 3 5 Specifications Dimensions 2 1 Heating 2 1 Main rolls 2 1 Material 2 1 Options 2 1 Speeds 2 1 Weight 2 1 Sprockets 6 4 6 6 11 4 DS 60 Heat Press Service Manual T Technical support 8 1 Theory of operation 7 1 Thermocouple 3 5 5 3 5 4 6 8 U Unpacking 3 4 Crate 3 4 Upper main roll 1 3 6 3 Warnings and cautions See Safety Information Warranty 1 5 GBC Pro Tech 1997 October
26. A CAUTION Do not lean the cabinet covers against the stand They can scratch the paint To replace a cabinet cover 1 Lift and place the cover into position 2 Replace each of the ten screws 5 1 Adjustments DS 60 Heat Press Service Manual Figure 5 1 Removing Frame Cabinet Covers 5 2 GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Adjusting the Main Roll Nip The gap between the two main rolls is called the nip The purpose of adjusting the nip is to ensure continuous contact between the main rolls as the media is drawn through the machine This procedure must be done regularly Tools required 16 hex wrench 34 hex wrench To adjust the main roll nip A CAUTION The main roll must be at room temperature to achieve a proper nip setting 1 Remove the left and right side cabinet covers with the 1 4 hex wrench by removing the ten screws holding each cover in place 2 Lower the upper main roll so that there is a small visible gap between it and the lower main roll 3 Loosen 34 jam nut securing the lift assembly bolt Adjust the nip by rotating the lift assembly bolt clockwise to lower the end being adjusted and counterclockwise to raise it Lift 2 Assembly Bolt Jam Nut Figure 5 2 Nip Setting Assembly GBC Pro Tech 1997 October Adjustments 4 Adjust the nip so that there is an even line of light across the width of the rolls 5 Secure the ja
27. N TO THESE LABELS AT ALL TIMES Figure 1 3 shows the location of each of these labels Safety and Warranty Information DS 60 Service Manual Inside cabinet IA ACHTUNG MISE EN GARDE MO A WARNING A ACHTUNG Moving parts can Crush and burn crush and cut hazard Stay clear MISE EN GARDE Do not operate with of moving rollers n Stop machine and raise roll before cleaning WARNING ACHTUNG MISE EN GARDE SAFETY INSTRUCTIONS SICHERHEITS RICHTLINIEN 2 hazard Stay clear of moving rollers CONSIGNES DE Es ston machine and SECURITE 1 Read and understand the Operation Manual and all safety labels before operating this machine 2 Only a trained person is to be permitted to operate this machine Training should include instruction in operation under normal conditions and emergency situations 3 This machine is to be serviced only by trained and authorized personnel Follow lockout procedures before A DANGER GEFAHR HAZARDOUS VOLTAGE To be serviced only by trained and authorized personnel Lockout power before servicing servicing 4 Never reach into the machine for any reason unless the machine is at a COMPLETE STOP 5 Never leave the machine stopped in such a manner that another worker start the machine while you are working or within the machine
28. TCR 6 8 Motor Controller Board de nei erret rr Eee Ee x Ee E E Ee EA ERR n a 6 9 Control Panel SWITGIeS Dd 6 10 Heater Controle i AA 6 10 PEE 6 11 Brakes tuii ADA VO SODA BV RO BO DR O DA PSN DB k 6 11 VO SAO OOP E R DV PAVO PDU 6 13 Section 7 Principle of Operation 1 nun unu EE nenne enun akama mwa 7 1 Mechanical tute CIL UI sous wee a 7 1 Mano qe 7 1 Msc 7 1 prr 7 1 Tae Dp DN 7 1 Section 8 Troubleshooting 8 1 Contacting Technical Support ite nuit o 8 1 Output Troubleshooting Guide 8 2 Section 9 Illustrated Parts 1 9 1 Section 10 iiie esecuuunuunu 10 1 Section 11 ici issus ic aan akad n 11 3 iv GBC Pro Tech 1997 October DS 60 Service Manual Section 1 Safety and Warranty Information DO NOT ATTEMPT TO OPERATE YOUR DS 60 HEAT PRESS UNTIL YOU HAVE READ THIS SECTION CAREFULLY You
29. VL 1 flash back and forth to return to it The commands inPt and tcJ flash back and forth 4 Press the up or down button until unit appears The commands unit and nonE flash back and forth 10 Press the up or down button until bAnd appears 11 Press and hold the star button and press the up or down button until 25 appears The commands bAnd and 25 flash back and forth 5 Press and hold the star button and press the up or 12 Press the up or down button until int t appears down button until F appears The commands The commands int t and 5 0 flash back and forth unit and F flash back and forth 13 Press and hold the star button and press the up or 6 Press the up or down button until SP1 d appears 5 1 4 and nonE flash back and forth down button until 20 appears The commands int t and 20 flash back and forth GBC Pro Tech 1997 October 5 9 Adjustments DS 60 Heat Press Service Manual 14 Press the up or down button until dEr t appears The commands dEr t and 25 flash back and forth 15 Press and hold the star button and press the up or down button until 70 appears The commands dEr t and 70 flash back and forth 16 Press the up or down button until LEVL appears The commands LEVL and 1 flash back and forth 17 Press and hold the star button and press the up or down button until 2 appears The commands LEVL and 2 flash back and forth 18 Press the up or down button until hi SC appear
30. WD REV switch to the REV position 3 Clean the upper main roll using a fine soft cleaning pad 4 Clean the lower main roll with either a mild dishwashing detergent or a moderate amount of 80 isopropyl alcohol on a cotton terry cloth A CAUTION Use the minimum amount of pressure necessary to clean the rolls You can destroy the silicone layer on the lower main roll by pressing too hard or scrubbing too long in one spot DS 60 Heat Press Service Manual A WARNING Exercise care when cleaning the roll with 80 isopropyl alcohol Use only in a well ventilated area Wear rubber gloves Use only on cool rolls Cleaning heated rolls can ignite the fumes A CAUTION Use only 80 isopropyl alcohol to clean lower main roll Harsh chemicals like toluene acetone or MEK destroy the silicone covering of the roll To clean the cabinet and covers A WARNING Remove power from the heat press and make sure it won t be reapplied while you are performing this procedure You could be severely shocked electrocuted or get your fingers caught in the drive mechanisms Using a damp cotton terry cloth water only clean the exterior of the heat press A WARNING Do not use liquid or aerosol cleaners on the heat press Do not spill liquid of any kind on the heat press You can be severely shocked electrocuted or cause a fire Use only a damp cloth for cleaning 6 2 GBC Pro Tech 1997 Octobe
31. a flat spot on a main roll 1 Set the top roll temperature to 255 F 124 C 2 Set the speed to the slow speed setting Motion Control FORWARD REVERSE E az EE 4 Slow Mode 1 n Control e x 2 Q Figure 6 1 Speed and Motion Controls Speed Adjustment 3 Using the main roll lift crank lower the main roll to a pressure of 0 90 4 Allow the heat press to run for 4 to 5 hours A WARNING Do not leave the heat press unattended while it is running There is a possibility of fire or overheating which can melt the silicone coating on the rolls and cause serious outgassing Maintenance Disassembly Reassembly Instructions The following procedures guide you through disassembly and reassembly of the serviceable parts of the heat press A WARNING Remove power from the heat press and make sure it won t be reapplied while you are servicing the heat press You can be severely shocked electrocuted or cause a fire MAKE SURE NO ONE CAN REAPPLY POWER TO THE HEAT PRESS WHILE YOU ARE WORKING A WARNING Do not attempt to service the heat press if it is still hot You can be severely burned Remove power and allow it to cool Drive and Rewind Chains Tools required wrench hex wrench To remove the chains A WARNING Remove power from the heat press and make sure it won t be reapplied while you are p
32. ads This may be easier with two people Insert Shaft Figure 6 14 Installing the Brake on the Shaft 10 Seat the bushing firmly against the shaft 11 Spin on the lock collar until it is snug against the bushing Tilt the shaft up and down as you are spinning it on Back off 14 turn and tighten the set screw 12 Swing the shaft into normal operating position With the adjustment knob loose the shaft should spin freely If it does not loosen the lock collar another 1 8 turn and recheck the shaft for smooth rotation Tighten Lock Collar Set 0 Screw Figure 6 15 Seating the Brake and Tightening the Set Screw GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Maintenance Main Rolls 5 Remove the upper shoulder bolt using a 16 hex wrench Secure the rod with an adjustable wrench central nut while you loosen upper shoulder bolt Repeat for the other side e wrench Remove 7 5 hex wrench Shoulder Bolt hex wrench 7 4 hex wrench hex wrench Hold With gt 9 Wrench To disassemble the main rolls A WARNING Remove power from the heat press and make Figure 6 17 Removing the Upper Shoulder Bolt sure it won t be reapplied while you are performing this procedure You could be 6 Remove the arm nut using a 716 wrench Repeat severely shocked electrocuted or get your for the other side fingers caught in the
33. akes contact with the upper main roll See Maintenance for the procedure A WARNING ALWAYS CHECK THE POSITION AND CONDITION OF THE THERMOCOUPLE PRIOR TO OPERATION The thermal junction of the thermocouple MUST make contact with the upper main roll to maintain proper roll operating temperatures The thermocouple must also be free of adhesive and dirt The roll can overheat and cause a fire or seriously damage the heat press 6 Replace both cabinet covers 3 5 Installation Leveling Tools required e Adjustable wrench Carpenter s level To level the heat press 1 Raise each end remove the castors and install a leveling pad and stud onto each of the cabinet nuts at the four bottom corners of the heat press Thread third nut on stud above cabinet 2 Thread studs into 4 leveling pads Lock down with nut Thread second nut onto stud 3 Place a carpenter s level front to rear across the two lower tie bars at one end of the machine 4 Level this end of the machine front to rear raising or lowering the leveling pads by adjusting the middle nuts on the foot bolts 5 Move the level to the other end of the machine and level front to rear 6 Place the level directly on one of the tie bars and level the machine side to side 7 Recheck the front to rear level condition to insure that it has not changed If it has repeat the leveling procedure 8 When all the measurements indicate that the machine
34. arings A CAUTION When you remove both bearings the table bracket is released and will pivot down 6 14 DS 60 Heat Press Service Manual 15 Remove the side roll end covers 16 Lift the lower main roll out the front side of the heat press To reassemble the main rolls Reinstall the main rolls by following the disassembly instructions in reverse order Be sure to put a light coat of grease on the shoulder bolt and the ways before replacing the lifter assembly GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Section 7 Principle of Operation Mechanical The DS 60 Heat Press is equipped with two main rolls Main Rolls The lower main roll is silicone coated The upper roll is raised and lowered via mechanical crank This roll is free rolling and is not connected to the drive system The lower main roll is fixed and cannot be moved or adjusted It is connected to a sprocket that is driven by the motor via a chain Electrical Motor The heat press motor controls are located on the control panel on the front of the machine Main power to the heat press is controlled by the circuit breaker on the back of the machine When power is supplied to the motor it is activated when the AUTO STOP switch is set to AUTO or when it is set to STOP and the footswitch is pressed The motor direction is controlled by the FWD REV switch The SPEED ADJUST switch controls the speed of the motor The motor stops runn
35. cabinet cover and reapply power to the heat press 5 6 DS 60 Heat Press Service Manual Electrical Adjustments Electrical adjustments for the DS 60 Heat Press consist of programming the heater control setting the motor control board potentiometers and adjusting the pressure sensor The heater control sets the temperature of the upper main roll the potentiometers control the speed settings for the heat press and the pressure sensor monitors the roll pressure between the main rolls Motor Control Board Potentiometers Tools required Small screwdriver potentiometer adjusting size e Tachometer optional e Volt meter To set the motor control potentiometers 1 Apply power to the heat press 2 Remove the control side cabinet cover see page 5 1 AN oman EXERCISE EXTREME CAUTION WHEN REMOVING THE RIGHT CABINET COVER WHILE THE HEAT PRESS IS OPERATIONAL You can be severely shocked or electrocuted 3 Set the FWD REV switch to the FWD position and the RUN STOP switch to STOP 4 Turn the SPEED ADJUST knob on the control panel to the full clockwise position maximum speed GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Motion Control FORWARD REVERSE 48 408 E 4 Slow Mode 1 4 Control e x 2 Q Figure 5 7 Motor Controls Spee Adjustment 42 Locate the barrier board You can set the potent
36. drive mechanisms 1 Remove the drive and control side cabinet covers see page 5 1 2 Remove the heater and heater brackets see the procedure earlier in this section 3 Place foam between the main rolls and lower the upper main roll 4 Using the hex wrench loosen the black lock collar and move it down to relieve pressure on the spring Repeat for the other side Figure 6 18 Removing the Arm Nut Loosen Set Screw 7 Remove the bolts securing the ways to the side of the heat press Repeat for the other side R Figure 6 16 Loosening the Set Screw on the Lock Collar GBC Pro Tech 1997 October 6 13 Maintenance Release Ways Figure 6 19 Releasing the Ways 8 Slide the lifter assembly out keeping the assembly together Repeat for the other side 9 Remove the side roll end covers 10 Lift the upper main roll out of the front of the heat press Note If you are replacing only the top roll go to the reassembly procedure If you are replacing both rolls continue with this procedure 11 Remove the drive chain see the procedure earlier in this section 12 Remove the main roll sprocket see the procedure earlier in this section Repeat for the other side 13 Remove the two 7 3 set screws that hold the bearing to the journal Repeat for the other side 14 Unbolt both flanged bearings using hex wrench and remove Figure 6 20 Removing the Flanged Be
37. e wires through it 5 Support the motor as you remove the four bolts holding the motor to the frame using the hex wrench Motor These Nuts Will Fall 4 Total Only Three Shown Here Figure 6 6 Removing the Motor 6 There are four nuts on the motor that will fall as you lift it away from the frame GBC Pro Tech 1997 October Maintenance To replace the motor Reinstall the motor by following the disassembly instructions in reverse order Control Board Tools required 3 5 hex wrench To remove the control board 1 Remove the control side cabinet cover see page 5 1 2 Unplug the connector at the bottom of the board 3 Remove the four 2 3 bolts holding the control board to the side of the heat press Connector Figure 6 7 Removing the Control Board Circuit Breaker Tools required e hex wrench e Straight slot screwdriver To remove a circuit breaker A WARNING Remove power from the heat press and make sure it won t be reapplied while you are performing this procedure You could be severely shocked electrocuted or get your fingers caught in the drive mechanisms 1 Remove the control side cabinet cover see page 5 1 6 7 Maintenance 2 Remove the linking shaft from the circuit breaker switch handles by removing the clip at one end of the shaft and sliding the shaft out Be sure to catch the white plastic spacers 2 as the shaft is removed
38. ease or lithium grease e Grease gun To lubricate the heat press A WARNING Do not lubricate the heat press when it is hot You can be burned A WARNING Remove power from the heat press and make sure it won t be reapplied while you are performing this procedure You could be severely shocked electrocuted or get your fingers caught in the drive mechanisms 1 Remove the drive and control side cabinet covers using the g hex wrench by removing the ten screws holding each cover in place 2 Using the grease gun lubricate each grease fitting with one squirt of high temperature grease 3 Apply a small amount of high temperature grease to the worm gear 4 Lubricate the chain using a soft cloth and automotive oil 5 Replace the cabinet covers and reapply power to the heat press Maintenance Cleaning Tools required 80 isopropyl alcohol or dishwashing detergent e Several 100 cotton terry cloths Protective rubber gloves Soft cleaning pad To clean dust and dirt from the rolls The silicone lower main roll can be cleaned of dust and dirt by passing an adhesive coated board through the nip Be sure to set the nip for the thickness of the board used A WARNING Exercise extreme caution while cleaning the heat press You can be caught in the turning rolls and crushed or burned To clean beads of adhesive from the rolls 1 Allow the heat press to cool completely 2 Set the F
39. eat press and make sure it won t be reapplied while you are performing this procedure You could be severely shocked electrocuted or get your fingers caught in the drive mechanisms 1 Remove the drive side cabinet cover see page 5 1 2 Loosen the drive chain by loosening the four bolts holding the motor to the frame using the vh hex wrench 3 Therewind sprockets are bolted directly to the heat press To remove the a rewind sprocket remove the bolt holding the sprocket on Remove S Bolt N 2 v Figure 6 3 Removing a Rewind Sprocket 4 Remove the rewind sprocket GBC Pro Tech 1997 October Maintenance To reassemble a rewind sprocket 1 Reassemble by following the disassembly instructions in reverse 2 Replace the cabinet cover To disassemble the motor sprocket A WARNING Remove power from the heat press and make sure it won t be reapplied while you are performing this procedure You could be severely shocked electrocuted or get your fingers caught in the drive mechanisms Tools required y hex wrench 16 hex wrench 1 Remove the drive side cabinet cover see page 5 1 2 Loosen the chain tensioner in the rewind chain loop to loosen the chain 3 Loosen the drive chain by loosening the four bolts holding the motor to the frame using the p 16 hex wrench Raise the motor to loosen the chain 4 Loosen the two set screws on the motor spr
40. ech 1997 October DS 60 Heat Press Service Manual Table of Contents Section 1 Safety and Warranty Information e 1 1 Warning kabel Locations odis a ed oo in EE Les o tel a pei to 1 3 ESS Warranty cetus 1 5 EXGCIUSIONS to the Wartranly iii oec eod inch kd 1 5 Section 2 2 1 52181516 16 21 N 2 1 Section 3 Installation 3 1 Preinstallation e lie rh ele de do 3 1 ced si cuoc ced 444822 54425442 date 3 4 p mM 3 5 Eje RE 3 6 SA CL C 3 6 Section 4 Equipment Location 4 1 Section 5 Adjustments 5 1 Mechanical AdJUustiigfle o ri zoki ua E Up eui oyun cy 5 1 Removing Drive and Control Side Cabinet Covers
41. erforming this procedure You could be severely shocked electrocuted or get your fingers caught in the drive mechanisms 6 4 DS 60 Heat Press Service Manual 1 Remove the drive side cabinet cover see page 5 1 2 Back the automatic tensioner off rewind chain Loosen the four bolts that hold the motor to the frame using the 3 16 hex wrench lift the motor and tighten the bolts This loosens the chain 4 Locate and remove the master links and release the chains 5 Remove the chains Remove Replace Master Link Automatic Chain Tensioner Loosen Motor Mount Bolts Figure 6 2 Removing Replacing the Chains To reinstall the chains 1 Thread each chain around the sprockets 2 Replace the master link 3 Adjust the chain tension using the procedure in Section 5 This may need to be done regularly for the first month 4 Replace the cabinet cover GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Sprockets There are five types of sprockets on the DS 60 Heat Press e Rewind sprocket 2 Motor sprocket 1 roll sprocket 1 e Automatic chain tensioner 1 The assembly illustrations show how each type of sprocket is constructed Instructions for assembling and disassembling the automatic chain tensioner are not included here Tools required wrench 3 7 8 hex wrench To disassemble a rewind sprocket A WARNING Remove power from the h
42. ess It has emergency stop buttons and photoelectric eye protection to prevent objects from entering the nip The heat press is equipped with four emergency stop buttons located on the top front and back of either side of the heat press Any of these if engaged stops the heat press To continue operation all emergency stop buttons must be in the up position and you must press the reset button above the fuse panel on the back of the heat press Twist button to resume operation Push any button to stop the laminator the button pops up Figure 1 1 Using the Emergency Stop Buttons Safety and Warranty Information Reset Button 9 9 Figure 1 2 Resetting the Heat Press Despite the safety features built into the DS 60 Heat Press extreme caution must be used when operating or servicing the unit READ THE FOLLOWING WARNINGS AND CAUTIONS BEFORE ATTEMPTING TO OPERATE OR SERVICE THE DS 60 HEAT PRESS A WARNING Never place fingers or arms between the rolls when they are turning or when the rolls are in the closed position You can be crushed or burned A WARNING Do not wear ties loose fitting clothing or dangling jewelry while operating or servicing the heat press These items can get caught in the nip and choke you or you can be crushed or burned DS 60 Service Manual A WARNING Do not operate the heat press near water You can be severely shocked electrocuted or cause a fire 2
43. g the 3 hex wrench If the magnet requires replacement you can remove the entire magnet bracket and replace it now 3 Move the bracket until the bottom of the top tooth aligns with the bottom of the sensor plug as shown in Figure 5 9 There should be gap between the tooth and the sensor plug 1 8 Gap Line Up Bottoms Figure 5 10 Aligning the Pressure Sensor 4 Tighten the magnet bracket 5 Replace the cabinet cover GBC Pro Tech 1997 October Adjustments 5 11 Adjustments DS 60 Heat Press Service Manual Blank page 5 12 GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Section 6 Maintenance Performing regular maintenance on the DS 60 Heat Press is critical to the proper operation of the machine A maintenance schedule and a section of procedures for disassembling and reassembling the serviceable areas of the heat press are included in this section Table 6 1 Maintenance Schedule Clean the rolls Adjust the thermocouple Inspect the electrical cord for damage Inspect the footswitch cord for damage Adjust the nip Check the chain tension Inspect the area around the heat press for possible hazards dust buildup combustible items stored too close etc Lubricate the grease fittings and chain Check wire termination tightness GBC Pro Tech 1997 October Maintenance Lubrication Tools required hex wrench e High temperature gr
44. he rolls A WARNING Do not operate the heat press if the power cord is damaged or frayed You can be severely shocked electrocuted or cause a fire Contact a qualified electrician to replace the cord GBC Pro Tech 1997 October Safety and Warranty Information A WARNING Do not attempt to move the heat press across anything other than a flat level surface without trained and qualified riggers You can be crushed or seriously injured The DS 60 Heat Press is a large and heavy piece of equipment It is necessary to employ LICENSED RIGGERS ONLY to move the machine The heat press is not designed to be tipped up or sideways in any way Such action disturbs the exact alignment of the rolling parts of the machine and requires extensive realignment GBC Pro Tech s warranty does not cover malfunction of the equipment due to mishandling and or tipping GBC Pro Tech bears no responsibility for personal injury or damage due to moving the heat press improperly A WARNING Do not allow anything to rest on the power cord Do not locate the cord where people can walk on it You or others can be severely shocked electrocuted or cause a fire ALWAYS USE GOOD SAFETY PRACTICES WHEN OPERATING OR SERVICING THE HEAT PRESS AND KNOW HOW TO REACT QUICKLY IN AN EMERGENCY Caution Warning Label Locations Posted at various locations on your DS 60 Heat Press are important safety labels PAY CAREFUL ATTENTIO
45. hotoelectric eye Remove the control side cabinet cover using the hex wrench by removing the ten screws holding each cover in place 2 Using the small screwdriver remove the guard from the photoelectric eye receiver control side 3 Turn the white plastic screw to set the photoelectric eye to the light setting This means that the photoelectric eye reacts when the beam is interrupted You may need to try each extreme to determine which is the light setting 4 Turn the main roll lift crank in a clockwise direction to lower the upper main roll 5 Turn the SPEED adjustment knob to the full counter clockwise position to stop roll movement Block the photoelectric eye at the frame Confirm that the photoelectric activation lamp red LED lights A WARNING When making this adjustment use extreme caution Your fingers and hands could be crushed 8 Ifthe lamp does not light first check the dark setting then turn the adjusting screw to adjust the sensitivity Be sure to check at different locations across the whole width of the table 9 Raise the upper main roll until the rolls are not touching 10 Replace the photoelectric eye guard and cabinet cover GBC Pro Tech 1997 October Adjustments Chain Tensioning Smaller chain tensioning adjustments on the DS 60 Heat Press are handled by a secondary chain tensioner however when installing a new chain or when the chain tension is more ser
46. ier Board Tools required 1 hex wrench e hex wrench To remove the motor controller board A WARNING Remove power from the heat press and make sure it won t be reapplied while you are P3 P2 P1 H F F L1 L2 A A P N 9884 Remove Bolt performing this procedure You could be severely shocked electrocuted or get your fingers caught in the drive mechanisms 1 Remove the control side cabinet cover see page 5 1 2 Loosen and pull the barrier board out of the way It is not necessary to disconnect the terminations to the board 3 Remove the two bolts holding motor controller board to the frame using the 5 5 hex wrench and remove the motor controller board and the mounting frame Remove Bolt Figure 6 9 Barrier Board and Motor Controller Board 4 Resetthe motor control potentiometers see the Motor Controller Board procedure in Section 5 Adjustments 5 If new motor controller board did not come with a horsepower resistor remove the horsepower resistor from the old controller and install it in the new one To replace the motor controller board Reinstall the motor controller board by following the disassembly instructions in reverse order GBC Pro Tech 1997 October 6 9 Maintenance Control Panel Switches Tools required e wrench To remove a control panel switch
47. ing when the AUTO STOP switch is set to STOP and the footswitch is not being pressed In an emergency the motor can immediately be stopped by either emergency stop button located on either side of the top of the heat press The motor also stops when the photoelectric eye is blocked GBC Pro Tech 1997 October Principle of Operation Heater The top roll heater is regulated by the heater controller on the control panel of the heat press When the heat press is on the heater controller can be turned to activate the heater The temperature of the rolls is sensed by the thermocouple When the roll reaches the proper operating temperature as determined by the heater controller the heater cycles off and on to maintain operating temperature 7 1 Principle of Operation Blank page T 2 DS 60 Heat Press Service Manual GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Section 8 Troubleshooting Contacting Technical Support For machine parts and technical service in North America please call 1 800 790 7787 Please provide serial number when calling for service In Europe please call 444 0 1844 202 440 or fax 44 0 1844 202 441 For film and application questions in North America please call 1 800 236 8843 In Europe please call 44 0 1844 202 440 or fax 44 0 1844 202 441 Troubleshooting GBC Pro Tech 1997 October 8 1 Troubleshooting Output Troubleshooting Guide 2
48. iometers on the board through the openings on the barrier board See Figure 5 8 Check the output voltage to the motor from terminals A and A on the barrier The output voltage DC should be between 80 and 90V If it is too low or too high adjust the MAX potentiometer accordingly NOTE Note the location of the horsepower resistor in Figure 5 6 It should be a 0 12 resistor A CAUTION Do not operate the heat press without the correct horsepower resistor in place An improper resistor damages the circuit board Turn the SPEED ADJUST on the control panel to the full counter clockwise position Press the footswitch and monitor the output voltage to the motor from terminals A and A Adjust the MIN potentiometer until the roll begins to turn Turn the MIN potentiometer back to the point where there is no output voltage going to the motor There should be no voltage going to the motor when the SPEED ADJUST is set to the full counterclockwise position minimum speed Check the MAX setting again to see if it is within tolerance If not repeat this procedure until MIN and MAX settings are within tolerance Adjustments 10 The IR CL and ACC potentiometers are factory set See Figure 5 8 for typical settings 11 Replace the cabinet cover GBC Pro Tech 1997 October 5 7 Adjustments DS 60 Heat Press Service Manual Barrier Board
49. iously out of adjustment use the following procedure to adjust the chain tension Tools required hex wrench 16 hex wrench e Screwdriver To adjust the chain tension A WARNING Remove power from the heat press and make sure it won t be reapplied while you are performing this procedure You could be severely shocked electrocuted or get your fingers caught in the drive mechanisms 1 Remove the drive side cabinet cover using the 1 4 hex wrench by removing the 10 screws holding the cover in place 2 Loosen the secondary chain tensioner on the secondary drive chain The tensioner should at this point not be engaging its respective chain 3 Loosen all four motor mount bolts using the 3 16 hex wrench as shown in the figure below The motor should just move freely within the slots Adjustments 1 4 to 1 2 Play Downward Force Tightens Chain Secondary AS 3 Chain S6 Tensioner pos Loosen Motor Mount Bolts Figure 5 6 Adjusting the Chain Tension 4 Using screwdriver apply a small amount of downward pressure on the motor by prying against the inside of the side frame until there is no play in the chain 5 Tighten the mounting bolts while maintaining the downward pressure on the motor 6 Engage the secondary chain tensioner and apply pressure until its chain exhibits similar tension to the primary chain tension then tighten the tensioner 7 Replace the
50. led 5 in Figure 2 2 It can fall and damage the heat press 3 4 DS 60 Operation and Maintenance Manual Figure 3 2 Removing the Crate 2 Gently unwrap the shrink wrap from around the heat press A CAUTION Do not use a knife or other sharp instrument during installation or while servicing the heat press You can cause irreparable damage to the rolls 3 Carefully remove any accessories packed with the heat press The accessory pack should contain 1 Set hex wrenches 1 Slitting knife 1 Manual 1 Set spare fuses 1 Tape measure 1 Roll of masking tape 1 100 cotton terry cloth 4 Leveling studs 4 Leveling pads 4 Have the heat press rolled off the skid and placed on the floor by licensed riggers The ramps included with the heat press can be secured to the edge of the crate bottom using the screws left over from the crate disassembly see Figure 2 2 GBC Pro Tech 1997 October DS 60 Operation and Maintenance Manual A WARNING Do not attempt to move the heat press across anything other than a flat level surface without trained and qualified riggers You can be crushed or seriously injured The DS 60 Heat Press is a large and heavy piece of equipment It is necessary to employ LICENSED RIGGERS ONLY to move the machine The heat press is not designed to be tipped up or sideways in any way Such action disturbs the exact alignment of the rolling parts of the
51. lled casters on even surfaces 3 Improper use of the machine Safety and Warranty Information DS 60 Service Manual Blank page 1 6 GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Section 2 Characteristics Specifications Table 2 1 DS 60 Heat Press Specifications Dimensions 80 x 33 x 57 Lx Dx H 203 x 84 x 145 cm Weight Uncrated 1000 Ibs 453 kg Crated 1350 lbs 612 kg Main Rolls 64 163 cm roll face with a chrome plated steel top roll and a high heat high release silicone rubber coated lower roll Material Uses image material and fabrics up to 62 inches 157 com wide on a 3 inch 7 6 com inside diameter core maximum roll diameter of 10 inches 25 4 cm Speeds 0 to 18 fmp 0 to 5 5 mpm with variable speed reversible action start and stop controlled either through the instrument panel or with the footswitch Heating Capable of operating temperatures of up to 475 F 235 C on the upper chrome roll High output heater to fully replace heat as it is used in the transfer process Safety Features Double redundant circuit protected safety shielding e Photoelectric eye protection on the infeed side of the nipping rolls Four emergency stop buttons e Front hinged guard Heated upper main roll Installation 220 VAC 50 to 60 Hz single Requirement phase 30A GBC Pro Tech 1997 October Characteristics 2 1 Characteristics DS 60 Heat Press Service Man
52. m nut on the lift assembly bolt Properly Set Nip Distance Between Rolls is Equal Figure 5 3 Properly Set Nip 6 Replace both cabinet covers Thermocouple Positioning and Cleaning One of the most crucial adjustments to the DS 60 Heat Press is positioning the thermocouple and making sure it is clean If the thermocouple loses contact with the roll the roll can overheat and be seriously damaged or can even start a fire Therefore it is absolutely critical that the thermocouple be clean and positioned properly before operating the heat press and it should become second nature to check its condition prior to applying power to the heat press Tools required 1 3 hex wrench 80 isopropyl alcohol 100 cotton terry cloth A CAUTION ALWAYS CHECK THE POSITION AND CONDITION OF THE THERMOCOUPLE PRIOR TO OPERATION The thermal junction of the thermocouple MUST make contact with the main rolls to maintain proper roll operating temperatures The thermocouple must also be free of adhesive and dirt The roll can overheat and cause a fire or seriously damage the heat press 5 3 Adjustments A WARNING Do not attempt to adjust the position of the thermocouple if the roll is hot You can be seriously burned To adjust a thermocouple 1 Locate the thermocouple on the rod behind the upper main roll on the rear of the heat press 2 Remove the two screws securing the thermocouple to the heat
53. machine and requires extensive realignment GBC Pro Tech s warranty does not cover malfunction of the equipment due to mishandling and or tipping GBC Pro Tech bears no responsibility for personal injury or damage due to moving the heat press improperly 5 Remove any plastic strapping and packing paper taped to the rolls A CAUTION Do not use a knife or other sharp instrument during installation or while servicing the heat press You can cause irreparable damage to the rolls 6 Remove all packing materials to a safe distance from the heat press ANOTE ABOUT RECYCLING The crate components can be reused for shipping the machine again or can be disassembled and the wood and screws recycled The shrink wrap is not recyclable however so it must be discarded 7 Level the heat press using the procedure later in this section GBC Pro Tech 1997 October Installation Setup Once the DS 60 Heat Press has been unpacked and moved into final position check each of the following items Tools required YA hez wrench Adjustable wrench Setup Procedure 1 Inspect the heat press for any obvious shipping damage 2 Remove the left and right side cabinet covers with the 1 4 hex wrench by removing the ten screws holding each cover in place 3 Inspect all the bolts and tighten any that were loosened during shipping 4 Setthe nip See Maintenance for the procedure Verify that thermocouple m
54. n Lower Rewind Sprocket Motor Sprocket Figure 4 3 Drive Side Equipment Locations GBC Pro Tech 1997 October 4 3 Equipment Location DS 60 Heat Press Service Manual s GM 0 Lifter Assembly Pressure Sensor V S T S T Upper Main Roll Heater and Thermocouple Bracket Under Cover Cnn O Photoelectric Eye Receiver Lower Main Roll Bearing gt Worm Gear 2222 ZA A Wire Duct Safety Circuit Motor Control Unwind Brake Filter Relay Control Board Power Transformer Unwind Brake Figure 4 4 Control Side Equipment Locations Mo GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Equipment Location ES Upper Roll Heater Controller Upper Roll Heat ON OFF Tachometer Counter Display Roll Pressure Display 0000 i Motion Control imis 4 e FORWARD REVERSE Ma Slow Mode Ls n Control Z 7 Ej Photoelectric Eye P Reset Figure 4 5 Front Control Panel GBC Pro Tech 1997 October 4 5 Equipment Location DS 60 Heat Press Service Manual Figure 4 6 Footswitch A WARNING Use extreme caution when operating the heat press with the footswitch The photoelectric eye system is overridden and your fingers can get caught in the nip You can be crushed or burned
55. ocket Loosen 2 Set Screws Figure 6 4 Removing the Motor Sprocket Maintenance 5 Pull the sprocket off the motor taking care not to lose the key stock To reassemble the motor sprocket 1 Reassemble the motor sprocket by following the disassembly instructions in reverse order Ensure that the sprocket alignment is correct before tightening set screws 2 Replace the cabinet cover To disassemble the main roll sprocket A WARNING Remove power from the heat press and make sure it won t be reapplied while you are performing this procedure You could be severely shocked electrocuted or get your fingers caught in the drive mechanisms Tools required hex wrench y hex wrench e open end wrench e Screwdriver 1 Remove the drive side cabinet cover see page 5 1 2 Loosen the chain tensioner in the rewind chain loop to loosen the chain 3 Loosen the drive chain by loosening the four bolts holding the motor to the frame using the 3 16 hex wrench Raise the motor to loosen the chain 4 Disconnect the heater wire and remove the heater bracket See the procedure for removing the main rolls later in this section if you are unsure how to do this 5 Remove the main drive sprocket by removing the two bolts that secure it and inserting one of them into the threaded hole in the bushing Use the screwdriver as a lever to keep the assembly from DS 60 Heat Press Service Manual
56. oller through the front of the control panel Attach and secure retainer 2 Reconnect the wires using the old controller as a guide Heater Tools required hex wrench 3 hex wrench To remove a heater A WARNING Remove power from the heat press and make sure it won t be reapplied while you are performing this procedure You could be severely shocked electrocuted or get your fingers caught in the drive mechanisms 1 Remove the control and drive side cabinet covers see page 5 1 2 Remove the barrier tubing from both heater ends and disconnect the wires 3 Remove the heater wires using the 32 hex wrench 4 Loosen the set screw on either side of the heat press using the hex wrench 5 Slide the heater out of the control side of the heat press GBC Pro Tech 1997 October Maintenance Brakes Tools required 16 hex wrench hex wrench To disassemble a brake 1 Loosen the top locking stud 2 Loosen the lock collar set screw using the Y 16 hex wrench and remove the lock collar LoosenTop Locking Stud Loosen Lock Collar Set Screw Figure 6 10 Loosening the Top Locking Stud and Removing the Lock Collar 3 Remove the two bolts from the top plate using the hex wrench The bottom unwind requires the removal of the electrical panel mounting bolts Note where the ground wire is attached to the panel and then swing it out
57. press using the hex wrench and take the thermocouple out 3 Inspect the thermocouple If there is any adhesive or dirt on the thermocouple gently clean it off with 80 isopropyl alcohol and a cotton terry cloth 4 Grasp the aluminum base of the thermocouple on either side of the rivets to provide support as shown in Figure 4 1 Using your fingers gently bend the thermocouple where the guitar pick sensor meets the aluminum base Use Your Other Hand to Provide Gently Bend Support At Rivets Figure 5 4 Adjusting the Thermocouple Once installed the critical point of the thermocouple MUST make direct contact with the roll as shown in Figure 5 5 5 4 DS 60 Heat Press Service Manual Upper Main _ 4 Roll Tube to Frame Thermocouple Thermal Junction Figure 5 5 Correct Thermocouple Contact A CAUTION Firmly hold the thermocouple where the guitar pick sensor is riveted to the aluminum base while bending You can break the sensor off the base if you do not provide this added support 5 Replace the thermocouple and tighten the screws Photoelectric Eye Adjustment nnm EXERCISE EXTREME CAUTION WHEN REMOVING THE CABINET COVERS WHILE THE HEAT PRESS IS OPERATIONAL You can be severely shocked or electrocuted Tools required hex wrench e Small screwdriver GBC Pro Tech 1997 October DS 60 Heat Press Service Manual To adjust the p
58. r DS 60 Heat Press Service Manual Leveling Tools required e Adjustable wrench Carpenter s level To level the heat press 1 Raise each end remove the castors and install a leveling pad and stud onto each of the cabinet nuts at the four bottom corners of the heat press Thread third nut on stud above cabinet 2 Thread studs into 4 leveling pads and lock down with nut Thread second nut onto stud 3 Place a carpenter s level front to rear across the two lower tie bars at one end of the machine 4 Level this end of the machine front to rear raising or lowering the leveling pads by adjusting the middle nuts on the foot bolts 5 Move the level to the other end of the machine and level front to rear 6 Place the level directly on one of the tie bars and level the machine side to side 7 Recheck the front to rear level condition to insure that it has not changed If it has repeat the leveling procedure 8 When all the measurements indicate that the machine is level tighten down the top nuts on the cabinet nuts to lock the pads in their current position GBC Pro Tech 1997 October Maintenance Removing Flat Spots on the Main Rolls Main rolls will develop a flat spot if the operator forgets to raise the upper main roll when the heat press is not in operation A CAUTION Raise the upper main roll when the heat press is not in operation Prolonged contact can damage the rolls To remove
59. r safety as well as the safety of others is important to GBC Pro Tech This section contains important safety information The following symbols are used throughout this manual to indicate warnings and cautions Indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION Indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury or alerts against unsafe practices or alerts against actions which could damage the product The DS 60 Heat Press has been designed with safety as a primary consideration However you must become thoroughly familiar with the controls proper operation proper service procedures and safety features of the Heat Press before using or servicing the unit GBC Pro Tech 1997 October Safety and Warranty Information GBC Pro Tech DS 60 Heat Press is a powerful machine that is designed to perform dye sublimation The forces required to accomplish these tasks can vary from negligible to very large In addition the main roll of the DS 60 can reach temperatures of 475 F 235 C At these temperatures there is a danger of a severe burn if the roll is touched during set up operation or servicing Safety is an important feature of the DS 60 Heat Pr
60. s The commands hi SC and 1472 flash back and forth 19 Press and hold the star button and press the up or down button until 270 appears The commands hi SC and 270 flash back and forth 20 Press the up or down button until LEVL appears The commands LEVL and 2 flash back and forth 21 Press and hold the star button and press the up or down button until 3 appears The commands LEVL and 3 flash back and forth 22 Press the up or down button until VER appears The commands VER and 2 flash back and forth 23 While VER is displayed press both the up and down button at the same time make sure you press them when the panel displays VER and not 2 Hold the buttons down until LOCK appears about 10 seconds The commands LOCK and nonE flash back and forth 24 Press and hold the star button and press the up or down button until ALL appears The commands LOCK and ALL flash back and forth 25 Press the up or down button until PARK appears 26 Press and hold the star button and press up or down button until a number appears That number is the temperature of the roll 5 10 GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Pressure Sensor Adjustment The pressure sensor on the DS 60 Heat Press monitors the pressure between the two main rolls Tools required 5 7 hex wrench To align the pressure sensor Remove the control side cabinet cover See page 5 1 2 Loosen the magnet bracket usin
61. ual Blank page 2 2 GBC Pro Tech 1997 October DS 60 Operation and Maintenance Manual Section 3 Installation GBC Pro Tech is committed to a program of ongoing product improvement As a result we are providing these instructions so that you can insure that your new DS 60 Heat Press is properly and securely unpacked moved and installed Before a DS 60 Heat Press can be installed there are a few requirements that must be met Make certain that each of the requirements listed in the following preinstallation checklist are met before beginning installation A CAUTION Failure to follow the preinstallation checklist can result in damage to the heat press Preinstallation Checklist Are doorways and hallways wide enough for the heat press to be moved to the installation site Is there ample room for the heat press A work area must be established that allows for operation in both the front and the rear of the machine and provides space for efficient material flow Figure 3 1 shows a typical machine area layout Is the environment appropriate for the heat press The heat press requires a clean dust and vapor free environment to operate properly It must not be located where there is air blowing directly on the machine A WARNING The operating environment must be free of dust flammable liquids and vapors You can be injured by inhaling chemical vapors Vapor build up or stored flammable liquids can ca
62. use a fire Excessive dust can damage the heat press GBC Pro Tech 1997 October Installation A CAUTION Do not locate the heat press where air is blowing directly on the machine The air flow can cool the rolls unevenly and result in poor quality output Is there an appropriate power outlet available or has a certified electrician been contacted to wire the heat press directly The heat press requires 30A single phase service and a power receptacle that accepts a 30A 250V NEMA L6 30P plug A WARNING Do not attempt to defeat the grounding feature of the ground plug on the heat press You can be severely shocked electrocuted or cause a fire The three prong plug fits only into a grounding type power outlet If you are unable to insert the plug into the existing outlet contact a qualified electrician to replace the obsolete outlet A WARNING Do not use an extension cord on this heat press You can be severely shocked electrocuted or cause a fire If you need a longer cable contact a qualified electrician A WARNING Do not operate the heat press if the power cord is damaged or frayed You can be severely shocked electrocuted or cause a fire Contact a qualified electrician to replace the cord Installation A WARNING Do not allow anything to rest on the power cord Do not locate the cord where people can walk on it You or others can be severely shocked electrocuted or cause a fire
63. x 306 SIH O84 55444 0 Sr 220 080 8 9 X 91 8 c SSvHB M3H9S 135 334 01 960 X 8 1 134OG NId 920 m LOS LOMA MD018 HJAL 08d 289 VCO 0 e 4 00 5 M 2 M04 0351 NI HO 310HM 03501050 MO 03403 ra 38 LON TIVHS ANO NOIIVWHOJNI ONIM33NION3 404 NI 031551 51 ONIMwHO SIHL NO 0350710510 AHL OL 5 SWIVID AWVv L3lddOsd GBC Pro Tech 1997 October Illustrated Parts List 9 18 DS 60 Heat Press Service Manual GBC Pro Tech 1997 October Illustrated Parts List DS 60 Heat Press Service Manual ON NOILdI80S30 INAJVAINOJ YO V vCBH ON dNO MN3MOd 9 19 GBC Pro Tech 1997 October Illustrated Parts List DS 60 Heat Press Service Manual Blank page 9 20 GBC Pro Tech 1997 October DS 60 Heat Press Service Manual Section 10 Addenda GBC Pro Tech 1997 October Addenda Addenda DS 60 Heat Press Service Manual Blank
Download Pdf Manuals
Related Search