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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., tefnikova 1347/III, 293 01 Mlad Boleslav
Company ID (IO) 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., tefnikova 1347/III, 293 01 Mlad 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:
SN EN 292-1:1994, SN EN 292-2:1994/A1: 2000, SN EN 294:1993, SN EN 953:1998,
SN EN 954-1:1998, SN EN 1050:1998, SN ISO 7000:1996,
SN EN 60335-1:1997, SN EN 61000-3-2+A12:1997, SN EN 61000-3-3:1995+A1: 2001
SN EN 33 0120:2001, SN 1037:1997, SN EN 60073:1997, SN EN 50081-1:1994,
SN EN 55014-1:1995, SN 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 TV, s.r.o, Modansk 98, 147 00 Prague 4,
Company ID (IO) 63987 121- Inspection body no. 4002
Certificate (number, date, validity):



2004-05-03 Ing. Ladislav Moc - General Manager ---------------
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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 operators 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 720

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.

SN EN 292-1:1994 (EN 292-1:1991)
Machinery safety. Basic terms, general design principles,
Part 1: Basic terminology, methodology.
SN 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.
SN EN 294:1993 (EN 294:1992)
Machinery safety. Safe distances to avoid touching dangerous points with arms.
SN EN 953:1998 (EN 953:1997)
Machinery safety. General requirements for the design and construction of protective guards (fixed,
movable).
SN EN 954-1:1998 (EN 954-1:1996)
Machinery safety. Safety parts of control systems. Part 1: General construction principles.
SN EN 1050:1998 (EN 1050:1996)
Machinery safety. Principles for risk degree determination.
SN 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.
SN 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.

SN EN 60335-1:1997 (EN 60335-1:1994)
Safety of electrical appliances designed for household and similar purposes. Part1: General
requirements.
SN 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)
SN 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
SN 33 0120:2001 (IEC 38:1983)
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Electrotechnical regulations. IEC Standardized voltage.
SN EN 1037:1997 (EN 1037:1995)
Machinery safety Prevention of spontaneous start.
SN EN 60073:1997 (EN 60073:1996)
Electrotechnical regulations. Coding of communicators and controllers by means of colours and
additional means..
SN EN 50081-1:1994 (EN 55081:1992)
Electromagnetic compatibility. General standard dealing with radiation. Part one: Residential,
business, and light-industrial buildings.
SN 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.
SN 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.




1.
3. 2.
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N L
L
N
T 6,3 A
T 315 mA
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10
11
2
1
4
5
6
8
7
3
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 machines 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.










A
B
C
4
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2.2 Storing the machine

The machine must be placed on a firm and flat surface *
Storage temperatures: -10C up to 60 C (-10F up to 140F)
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
4
4
2
1
8
7
5
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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 40C (41F up to 104F);
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 operators 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









18 17
15
19
16
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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.
















13
10
14
11
9
12
X Q Y
1
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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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20
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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 doesnt 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.