GIRBAU FL Series User manual

FL SERIES
PNEUMATIC FOLDING MACHINE
GIRBAU
Crta de Manlleu, km.1
08500 VIC (Barcelona) .SPAIN
73100 Aix-Les-Bains - FRANCE
Tél : [phone]
Fax : [phone]
[email protected]
www.girbau.com
5D00001/F
FL0610A

1 FL0610A
PREAMBLE
On my own behalf and on behalf of the GIRBAU company I would like to
congratulate you for the purchase you have just made.
I hope this product, the result of several years' experience, will give you
complete satisfaction.
We are delighted to serve you, here is your list of principal contacts.
Technical assistance 33 (0)4 79 34 95 95
Hot line
Spare parts 33 (0)4 79 34 80 72
e-mail [email protected]
Sales 33 (0)4 79 34 80 80
Call them. They will be able to answer your questions.
Mr DARVE
MANAGING DIRECTOR

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2
TECHNICAL MANUAL
Part 1: General Points, Construction, Operation.
Part 2: Electrical diagrams, delivered separately.
Part 3: Automation, delivered separately.
This technical manual gives detailed of all the Series FL folding machines, all
options merged.
Translation of original notice

3 FL0610A
TABLE OF
CONTENTS
EC DECLARATION OF CONFORMITY ....................................................................................................7
1 INTRODUCTION.....................................................................................................................................9
1.1 WARNING .........................................................................................................................................9
1.2 GENERAL POINTS .........................................................................................................................10
1.3 SAFETY INDICATION .....................................................................................................................10
1.4 OPERATION PICTOGRAMS ..........................................................................................................11
1.5 TECHNICAL FEATURES ................................................................................................................13
1.6 VARIANTS AND OPTIONS .............................................................................................................16
1.6.1 PRIMARY FOLDING FOR FL-SMART-TYPE FOLDING MACHINE ........................................16
1.6.2 PRIMARY FOLDING FOR FL-KING-TYPE FOLDING MACHINE............................................16
1.6.3 CROSS FOLDING UX2P..........................................................................................................17
1.6.4 CROSS FOLDING UX3P..........................................................................................................18
1.6.5 CROSS FOLDING MX2P............................................................................................................1
1.6.6 CROSS FOLDING MX3P..........................................................................................................23
1.6.7 RECEIVER (Option)..................................................................................................................26
2 HANDLING INSTALLATION................................................................................................................27
2.1 HANDLING ......................................................................................................................................27
2.2 PUTTING THE MACHINE IN POSITION ........................................................................................28
3 SAFETY ................................................................................................................................................38
3.1 GENERAL POINTS .........................................................................................................................38
3.2 STOPPING THE MACHINE ............................................................................................................38
3.3 INTERVENTION DURING OPERATION.........................................................................................39
3.4 POSITIONING OF EMERGENCY STOPS AND SAFETY CONTACTS .........................................40
4 PRINCIPLE AND OPERATION ............................................................................................................42
4.1 PRINCIPLE......................................................................................................................................42
4.2 CROSS FOLDING UX2P.................................................................................................................42
4.3 CROSS FOLDING UX3P.................................................................................................................44
4.4 CROSS FOLDING MX2P ..................................................................................................................1
4.5 CROSS FOLDING MX3P ................................................................................................................49
4.6 OPERATION OF FL SERIES FOLDING MACHINES .....................................................................52
5 MAINTENANCE OPERATIONS ...........................................................................................................54
5.1 General maintenance ......................................................................................................................54
5.2 Air filter/regulator maintenance........................................................................................................55
5.3 Troubleshooting ...............................................................................................................................57
6 SPARE PARTS .....................................................................................................................................58
6.1 FL-SMART - FL-KING BASIC EMERGENCY KIT...........................................................................58
6.2 ROTATING CLAMP STACKER EMERGENCY KIT ........................................................................58
6.3 FL-SMART - FL-KING INDUSTRIAL MAINTENANCE KIT .............................................................59
6.4 STACKER WITH ROTATING CLAMP MAINTENANCE KIT...........................................................59
7 LIST OF STRAPS .................................................................................................................................60
8 DESCRIPTION (EXPLODED VIEWS)................................................................................................71
KIT 09-0004F SUPPLEMENTARY PRESSURE KIT.............................................................................73
KIT 09-0102F RECEIVER AND RECEIVER BYPASS KIT ..................................................................73
KIT 09-0118E FLAP INDICATOR KIT ..................................................................................................75
KIT 09-0124F BLOWING VALVE KIT - 4 LANES.................................................................................77
KIT 09-0125F BLOWING VALVE KIT FOLD 2- 4 LANES ....................................................................77
KIT 09-0126F FEEDER BYPASS KIT ..................................................................................................79
KIT 09-0127G UPPER CROSS CONVEYOR CONNECTION BYPASS KIT .......................................79
KIT 09-0134F BLOWING VALVE KIT - 2 LANES.................................................................................81
KIT 09-0135F BLOWING VALVE KIT FOLD 2- 2 LANES ....................................................................81
KIT 09-0137F RETRACTABLE STRAP LIFTING GUIDE KIT FOLD2 ..................................................83
KIT 09-0138F BLADE AND REVERSING CONVEYOR FOLDING KIT ................................................83

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KIT 09-0150F FRL FL-SMART 2 FOLDS WITH DOUBLE PRESSURE KIT........................................85
KIT 09-0151F KIT FRL FL-KING 3 FOLDS ..........................................................................................87
KIT 09-0152F CROSS FOLD KIT.........................................................................................................89
KIT 09-0153F ROTATING CLAMP STACKER.....................................................................................91
KIT 09-0155F MOVABLE UPTAKE KIT ...............................................................................................93
KIT 09-0156F PNEUMATIC CROSS FOLDING KIT MX2P .................................................................95
KIT 09-0158 1ST CROSS FOLD BLADE KIT......................................................................................97
4M05070 FEEDER LU 3000...............................................................................................................103
4M05071 FEEDER LU 3300...............................................................................................................103
4M05072 FEEDER LU 3500...............................................................................................................105
4M05313 FEEDER WITH BYPASS 1V2V LU3000 ............................................................................107
4M05314 FEEDER WITH BYPASS 1V2V LU3300 ............................................................................109
4M05315 FEEDER WITH BYPASS 1V2V LU3500 ............................................................................111
4M05516 FEEDER LU 3000 GIRBAU FLATWORK IRONER PC120 GAS .......................................113
4M05660 FEEDER LU 3300 GIRBAU FLATWORK IRONER PC120 GAS .......................................115
4M05661 FEEDER WITH BYPASS 1V/2V LU3000 GIRBAU FLATWORK IRONER PC120 GAS....119
4M05663 FEEDER LU 3300 GIRBAU FLATWORK IRONER PC120 GAS .......................................115
4M05659 FEEDER WITH BYPASS 1V/2V LU3300 GIRBAU FLATWORK IRONER PC120 GAS....121
4M05662 FEEDER WITH BYPASS 1V/2V LU3500 GIRBAU FLATWORK IRONER PC120 GAS....123
4M05099 FL SERIES SERVICE BRIDGE ASSEMBLY .....................................................................125
4M05291 ROLLER ASSEMBLY LG 584 Ø50 ....................................................................................127
4M05292 ROLLER ASSEMBLY LG 709 Ø50 ....................................................................................127
4M05293 ROLLER ASSEMBLY LG 684 Ø50 ....................................................................................127
4M05294 ROLLER ASSEMBLY LG 434 Ø50 ....................................................................................127
4M05769 ROLLER ASSEMBLY LG 700 Ø50 + STIRRUP ................................................................127
4M05785 BASE FL-SMART ...............................................................................................................129
4M05859 PRIMARY FOLD BASE FL-KING .......................................................................................131
4M05849 FL-SMART PRIMARY FOLD BASE WITH BYPASS..........................................................133
4M05850 FL-KING PRIMARY FOLD BASE WITH BYPASS .............................................................135
4M04233 MACHINE OPG ASSEMBLY..............................................................................................137
4M04858 LINEN OPG ASSEMBLY....................................................................................................137
4M05767 MAIN DRIVE SYSTEM .......................................................................................................139
4M05319 MOTORISATION 1.1 KW 72 TR/MN 208V-60HZ ..............................................................139
4M05320 MOTORISATION 1.1 KW 72 TR/MN 230-460V - 50-60HZ ................................................139
4M05321 MOTORISATION 1.1 KW 72 TR/MN 480V-60HZ ..............................................................139
4M04859 CROSS-ITEM MEASUREMENT CELL ASSEMBLY..........................................................141
4M04818 3-FOLD REMEASURING CELL .........................................................................................141
4M05159 1ST PRIMARY FOLD 2 LANES LU 3000...........................................................................143
4M05160 1ST PRIMARY FOLD 2 LANES LU 3300...........................................................................143
4M05161 1ST PRIMARY FOLD 2 LANES LU 3500...........................................................................143
4M05162 1ST PRIMARY FOLD 4 LANES LU 3000...........................................................................145
4M05163 1ST PRIMARY FOLD 4 LANES LU 3300...........................................................................145
4M05164 1ST PRIMARY FOLD 4 LANES LU 3500...........................................................................145
4M05186 2ND PRIMARY FOLD 2 LANES LU 3000 ..........................................................................147
4M05187 2ND PRIMARY FOLD 2 LANES LU 3300 ..........................................................................147
4M05188 2ND PRIMARY FOLD 2 LANES LU 3500 ..........................................................................147
4M05189 2ND PRIMARY FOLD 4 LANES LU 3000 ..........................................................................149
4M05190 2ND PRIMARY FOLD 4 LANES LU 3300 ..........................................................................149
4M05191 2ND PRIMARY FOLD 4 LANES LU 3500 ..........................................................................149
4M05737 2ND OR 3RD PRIMARY FOLD 2 LANES LU 3000............................................................151
4M05738 2ND OR 3RD PRIMARY FOLD 2 LANES LU 3300............................................................151
4M05739 2ND OR 3RD PRIMARY FOLD 2 LANES LU 3500............................................................151
4M05813 2ND OR 3RD PRIMARY FOLD 2 LANES LU 3000 WITH BYPASS ..................................153
4M05814 2ND OR 3RD PRIMARY FOLD 2 LANES LU 3300 WITH BYPASS ..................................153
4M05815 2ND OR 3RD PRIMARY FOLD 2 LANES LU 3500 WITH BYPASS ..................................153
4M05789 2ND OR 3RD PRIMARY FOLD 4 LANES LU 3000............................................................155
4M05790 2ND OR 3RD PRIMARY FOLD 4 LANES LU 3300............................................................155
4M05791 2ND OR 3RD PRIMARY FOLD 4 LANES LU 3500............................................................155
4M05816 2ND OR 3RD PRIMARY FOLD 4 LANES LU 3000 WITH BYPASS ..................................157
4M05817 2ND OR 3RD PRIMARY FOLD 4 LANES LU 3300 WITH BYPASS ..................................157

5 FL0610A
4M05818 2ND OR 3RD PRIMARY FOLD 4 LANES LU 3500............................................................157
4M03246 GENERAL BYPASS MOTORISATION IN 200V/50HZ.......................................................159
4M03248 GENERAL BYPASS MOTORISATION IN 208V/60HZ.......................................................159
4M03249 GENERAL BYPASS MOTORISATION IN 220-480V/50-60HZ ..........................................159
4M05316 UPPER CROSS CONVEYOR LINKING BYPASS LU 3000-3500 .....................................161
4M05764 1ST CROSS FOLD BLADE ................................................................................................163
4M05147 METAL SHEET UNDER UPPER CONVEYOR STRAPS CROSS 1 LANE .......................165
4M05148 METAL SHEET UNDER UPPER CONVEYOR STRAPS CROSS 1V2V LU3000 .............167
4M05149 METAL SHEET UNDER UPPER CONVEYOR STRAPS CROSS 1V2V LU3300 .............167
4M05150 METAL SHEET UNDER UPPER CONVEYOR STRAPS CROSS 1V2V LU3500 .............167
4M05151 UPPER CROSS CONVEYOR CLUTCH ROLLER 1 LANE................................................169
4M05153 UPPER CROSS CONVEYOR CLUTCH ROLLER 1V2V LU 3000-3500 ...........................171
4M05152 UPPER CROSS CONVEYOR ROLLER AND BRAKE 1 LANE .........................................173
4M05154 UPPER CROSS CONVEYOR ROLLER AND BRAKE 1V2V LU 3000-3500 .....................175
4M04860 ARTICLE SIZE OR CROSS STOP DETECTION CELL.....................................................177
4M04723 UPPER CROSS CONVEYOR DRIVE SYSTEM 2V...........................................................179
4M05760 LOWER FRAME .................................................................................................................181
4M05143 UPTAKE WITH MOVABLE PILOT CONVEYOR 970MM LONG........................................183
4M05145 REVERSING AND BLADE FOLDING 970 MM WIDTH .....................................................185
4M05441 THIRD CROSS FOLD BASE 970 MM................................................................................187
4M05568 OSCILLATING CONVEYOR LA1000 .................................................................................189
4M05544 REVERSING FOLD CELL ASSEMBLY..............................................................................191
4M05545 THIRD CROSS FOLD CELL ASSEMBLY .........................................................................191
4M05146 LOWER CROSS CONVEYOR TIGHTENER .....................................................................193
4M05241 METAL SHEET UNDER CROSS STRAPS C2100 ...........................................................195
4M05553 METAL SHEET UNDER CROSS STRAPS C3100 LU3000-3500 .....................................195
4M05243 METAL SHEET UNDER CROSS STRAPS C2112 LU3300...............................................197
4M05442 METAL SHEET UNDER CROSS STRAPS C3122 LU3300...............................................197
4M05589 UPTAKE DRIVE SYSTEM V65M/MN 208V-60HZ .............................................................199
4M05590 UPTAKE DRIVE SYSTEM V65M/MN 220V-400V-50HZ....................................................199
4M05591 UPTAKE DRIVE SYSTEM V65M/MN 230-480V-60HZ ......................................................199
4M05219 LOWER CONVEYOR DRIVE SYSTEM V65M/MN 208V-60HZ..........................................201
4M05220 LOWER CONVEYOR DRIVE SYSTEM V65M/MN 220-400V-50HZ..................................201
4M05221 LOWER CONVEYOR DRIVE SYSTEM V65M/MN 230-480V-60HZ..................................201
4M05595 REVERSING CONVEYOR DRIVE SYSTEM V65M/MN 208V-60HZ.................................203
4M05596 REVERSING CONVEYOR DRIVE SYSTEM V65M/MN 220-400V-50 HZ.........................203
4M05597 REVERSING CONVEYOR DRIVE SYSTEM V65M/MN 230-480V-60HZ..........................203
4M05446 OSCILLATING CONVEYOR DRIVE SYSTEM V65/MN 220-480V-50HZ ..........................205
4M05447 OSCILLATING CONVEYOR DRIVE SYSTEM V65/MN 220-480V-60HZ ...........................205
4M05549 LOWER CONVEYOR DRIVE SYSTEM C3100-C3122 V65M 208V-60HZ ........................207
4M05550 LOWER CONVEYOR DRIVE SYSTEM C3100-C3122 V65M 230V/400V-50HZ...............207
4M05551 LOWER CONVEYOR DRIVE SYSTEM C3100-C3122 V65M 230/480V-60HZ .................207
4M05166 SIMPLE TABLE LG 3550 ...................................................................................................209
4M05200 TABLE WITH D/T SELECTION 1 LANE.............................................................................211
4M05192 TABLE WITH D/T SELECTION 1V 2V ...............................................................................213
4M05201 2 DEFECT RECOVERY TROUGH.....................................................................................215
4M05155 LOWER TABLE SCREEN ..................................................................................................217
4M05180 UPPER TABLE COVER .....................................................................................................219
4M05196 SERIES FL BACK COVER WITHOUT RECEIVER............................................................221
4M05761 DISCHARGE TABLE UX3P................................................................................................223
4M05866 RECEIVING BASE WITH NAPKIN.....................................................................................223
4M05265 OSCILLATING ARM LANE OF 825....................................................................................227
4M05266 OSCILLATING ARM LANE OF 750....................................................................................227
4M05267 OSCILLATING ARM LANE OF 875....................................................................................227
4M05401 GIRBAU LEFT COVER ASSEMBLY PS AND PSN8030.8033.8035 .................................229
4M05402 GIRBAU RIGHT COVER ASSEMBLY PS AND PSN8030.8033.8035...............................229
4M05309 LAPAUW RIGHT COVER ASSEMBLY ..............................................................................231
4M05310 LAPAUW LEFT COVER ASSEMBLY.................................................................................231
4M05414 RIGHT COVER ASSEMBLY CEFLEX 900 GAS................................................................231
4M05415 LEFT COVER ASSEMBLY CEFLEX 900 GAS ..................................................................231

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6
4M05416 RIGHT COVER ASSEMBLY CEFLEX 1200 GAS..............................................................233
4M05417 LEFT COVER ASSEMBLY CEFLEX 1200 GAS ................................................................233
4M05419 LEFT COVER ASSEMBLY DUBIX CEFLEX 900 - 1200....................................................235
4M05704 ROTATING CLAMP STACKER..........................................................................................237
4M05558 CLAMP ...............................................................................................................................239
4M05474 PILROT DISCHARGE CONVEYOR (380-480V-50-60HZ).................................................241
4M05835 PILROT DISCHARGE CONVEYOR (200-208V-50-60HZ).................................................241
4M05836 PILROT DISCHARGE CONVEYOR (220-230V-50-60HZ).................................................241
4M05705 ROTATING CLAMP STACKER BACK COVER .................................................................243
4E00478 ELECTRICAL BASE............................................................................................................245
4E00437 UPTAKE ELECTRICAL BASE, 1-LANE, 2-LANE ...............................................................245
4E00483 ELECTRICAL BASE M340 RECEIVER (NEXT) .................................................................247
4E00479 ELECTRICAL BASE M340 STACKER (NEXT)....................................................................247
4E00436 1-LANE/2-LANE AUTOMATIC BASE ..................................................................................249
9 CHECK-LIST.......................................................................................................................................250
10 ELECTRICAL DIAGRAMS................................................................................................................251
11 AUTOMATION BOOKLET ................................................................................................................251

7 FL0610A
CE DECLARATION OF CONFORMITY

FL0610
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8

9 FL0610
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1INTRODUCTION
1.1 WARNING
Usage conditions:
It is IMPERATIVE that all staff who have to work on this machine or maintain it
(commissioning, maintenance, dismantling...) read and follow all the instructions
contained in this notice, as well as those concerning control (electrical and pneumatic
diagrams).
Appropriate technical training and qualifications are essential for those
responsible for maintenance.
The machines are designed following safety standards. It is forbidden to attempt
any manoeuvre or action not established as part of the normal usage of the machine:
going inside the machine without making sure it has completely stopped (see Chapter
3 Safety) or altering a cycle or a cover.
The supply networks for the machines must meet the applicable standards and
be kept in good condition.
Note: the machine's identification plate is on the bottom of the electrical box.

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10
1.2 GENERAL POINTS
The FL SERIES of folding machines has been specially designed for the fast, accurate
folding of articles such as:
Small items: cloths, pillowcases, mats.
Large items: sheets, mattress covers, tablecloths, surgical sheets, fitted sheets.
The machine integrates the latest technological advances in programmable, pneumatic
and mechanical automatons.
Simple, compact FL folding machines require minimal adjustment and maintenance
operations.
Their programmable automatons make it possible to select or create a folding program
and to display the origin of a problem encountered.
This machine is intended to fold only pieces of linen material in good condition.
- FL-SMART capacity 500 to 3600mm.
- FL-KING capacity 500 to 4000mm.
Any other use is strongly discouraged and will under no circumstances be considered
normal usage of the machine.
The manufacturer accepts no responsibility for injury or damage resulting from use
other than the normal use for which the machine is intended or under conditions that do
not follow all technical instructions.
1.3 SAFETY INDICATION
The meanings of the stickers that may appear on the machine are given below:
Prohibition pictograms (red and white circles):
Do not enter (do not set foot inside)
Do not lift
Do not remain under load
Unauthorised persons must not enter

11 FL0610
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DANGER pictograms (yellow and black triangles):
General danger
Electrical danger
Mechanical danger
Danger of falling
Mechanical maintenance
DANGER area (yellow and black strip)
1.4 OPERATION PICTOGRAMS
Emergency stop
Use the touch screen
Start
Stop
Reset

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12
Grease using a pump
Set the selector to Start
Set the selector to Stop and padlock it (padlock not provided)
Open the air intake valve
Shut the air intake valve and padlock it (padlock not
provided)

13 FL0610
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1.5 TECHNICAL FEATURES
The technical features of the FL SERIES vary depending on the options ordered.
Several folds can be made, depending on the model:
1, 2, or 3 primary folds in 1, 2 or 4 lanes using an air jet (the item comes out with
the corners inside),
1, 2, or 3 primary folds in 1 to 2 lanes using mechanical blade (the item comes out with
the corners inside).
The items are measured on the folding machine feeder conveyor:
- A roller in contact with the linen turns and drives an optical pulse generator (OPG),
- A cell triggers the start and end of impulse counting.
This makes this measurement regardless of the speed of the ironer, allowing very accurate
folding
TECHNICAL FL-SMART
FEATURES FL-KING
ELECTRICAL
Power installed 3 to 4,5 KVA
Power cable section 3x2.5²
Basic voltage and frequency 380-400 Volts/50 Hertz
COMPRESSED AIR
Maximum supply pressure 10 bars
Power cable section Ø15 x 21
Maximum supply pressure 6 bars with temporary pressure drop
de 0,5 bars maximum
Power consumption
for 100 items
5 Nm³/100p
835l/100p at 6 bars
Air pressure safety switch Set to 4.8 bars
OTHERS
Noise level 76 dbA
Height 1840 + 80 lifting rings
Mass 1 800 to 2 300 kg
Weight/Foot (Pressure on the ground) 57 to 73 N/cm²/ 4 feed
Useful Width (Lu)
Lu = 3000 4010 mm
Lu = 3300 4010 mm
Lu = 3500 4010 mm
Operating temperature
5°C to 40°C
Humidity 95% at 25°C without condensation
Conveyor speed
Primary 10 to 50m/min
Cross 65m/min
Options:
- Feeder with by-pass 1V2V
- Antistatic double bar
- Front end remote control
- Small linen receiver
- Dirty/Torn selection using flap or bell and warning light

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- Specific voltages and frequencies:
- 208 Volts / 60 Hertz
- 220-230 Volts / 50 Hertz
- 220-230 Volts / 60 Hertz
- 380-400 Volts / 60 Hertz
- 440 Volts / 60 Hertz
- 460 Volts / 60 Hertz
- 480Volts / 60Hertz

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16
1.6 VARIANTS AND OPTIONS
1.6.1 PRIMARY FOLDING FOR FL-SMART-TYPE FOLDING MACHINE
B-P: Feeder with by-pass (option)
1: Fold 1 blade position 1 air jet 1V, 2V, 4V
2: Fold 2 blade position 4 air jet 1V, 2V, 4V
1.6.2 PRIMARY FOLDING FOR FL-KING-TYPE FOLDING MACHINE
B-P: Feeder with by-pass (option)
1: Fold 1 blade position 1 air jet 1V, 2V, 4V
2: Fold 2 blade position 2 air jet 1V, 2V, 4V
3: Fold 3 blade position 4 air jet 1V, 2V, 4V
2 folds
2nd fold
1st fold
Bypas
Bypass
3 folds
Bypass
B
yp
ass
2nd fold1st fold 3
r
d
fold

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1.6.3 CROSS FOLDING UX2P
DISCHARGE ON TO SIDE TABLE
1: 1st fold by mechanical blade
2: 2nd fold by mechanical blade and
reversing conveyor
The operator picks up the cross-folded items on the discharge side table
DISCHARGE WITH SINGLE ROTATING CLAMP STACKER
1: 1st fold by mechanical blade
2: 2nd fold by mechanical blade and
reversing conveyor
3: 3rd fold (in the stacker) by
mechanical blade and rotating
clamp
The operator picks up the cross-folded and stacked items at the stacker discharge.
Side
table
2nd fold1st fold
2nd fold1st fold 3
r
dfold

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DISCHARGE WITH DOUBLE ROTATING CLAMP STACKER
1: 1st fold by mechanical blade
2: 2nd fold by mechanical blade and
reversing conveyor
3: 3rd fold (in the stacker) by
mechanical blade and rotating clamp
The operator picks up the cross-folded and stacked items at the stacker discharge.
1.6.4 CROSS FOLDING UX3P
DISCHARGE ON TO TABLE
1: 1st fold by mechanical blade
2: 2nd fold by mechanical blade and
reversing conveyor
3: 3rd cross fold by mechanical blade
The operator picks up the cross-folded items on the discharge side table
2nd fold
1st fold 3
r
dfold
Side
table
If 2n
d
fold
done with 3rd
1st fold 3
r
dfold