Castle Edgebanding Machine Equalizer Operator Manual Castle, Inc. Petaluma, CA 800-282-8338 U.S. Patent No.
Table of Contents Safety Notification Page 1 Machine Inventory Page 2 Machine Requirements Page 2 Setting Up Page 3 Operating Instruction Page 9 Understanding the LOGO! PLC Page 11 Machine Adjustments Page 15 Definition and Description of Parts Page 19 Maintenance Page 21 Troubleshooting Page 22 Warranty Information Page 26
DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE READ THIS MANUAL. Safety Notification WARNING: The Castle Equalizer edge banding machine was designed with operator safety as a priority. This machine was carefully prepared for shipment at our factory. Upon receipt of the machine, inspect for shipping damage. Report any damage IMMEDIATELY to the freight company, your Castle dealer and to Castle, Inc. DO NOT attempt to operate the machine if you observe any physical damage. Contact Castle, Inc.
Inventory You should have received the following with your Castle Equalizer: Warranty Card (Please fill out & mail to Castle, Inc. to activate warranty) Equalizer Operator Manual Band Reel Three (3) Glue Hopper Extensions One (1) 2 ½ lb bag Glue Pellets – CANPLAST Brand **The Equalizer is sent out with CanPlast brand pellets.
Setting Up Your Equalizer Begin unpacking your machine by removing and discarding the cardboard and wood skid materials. Loosen the leg locknut and then the set screw on one side of the machine and raise the Equalizer to the working height of your choice. It may be easier to do this incrementally, first one side then the other. There is a retaining bolt inside the legs so that they will not fall out during this adjustment.
Mount the Wheel Cage on the Outriggers. They should be mirror images of each other, left and right. Remove the Band Reel from the shipping position. Use the Allen wrench provided to remove the collar from the shaft. Put the long end of the shaft into the cutout location in the front bottom center of the machine. It should go all the way through to the rear cutout. Place the collar on the shaft protruding through the back of the machine and tighten.
Remove your Glue Pot by first loosening the Start Knob directly beneath the Glue Pot on the under side of the machine. With the Glue Pot out of the machine, add Glue Pellets directly to the pot until the Transfer Wheel Axle is covered. **The Equalizer is sent out with CanPlast brand pellets. If you would like to use a different brand, DO NOT fill the Glue Pot with the pellets supplied! This addition of Glue Pellets outside the machine is only done when starting with a completely emptied Pot.
The Stock Guide goes on top of the Glue Pot Shield and is held in place by the two Tri-Arm Knobs. The Stock Guide should be mounted so that the Laminate faces IN, towards the machine. The Stock Guide and Glue Pot Shield come from the factory already assembled. To install the banding onto the Band Reel begin by removing the outer cover. Place the roll of banding over the Expansion Fingers so that the tape hangs down, ready to travel in a CLOCKWISE direction.
Push the tape into the Band Guide until you have more than a couple of inches exposed above the Glue Pot. The Band Guide is located just left of the Glue Pot. The banding travels up through the Band Guide from front to back. The width can be adjusted with the panhead screw on the front of the Mechanical Channel. Tighten lightly until you feel a slight increase in drag on the tape. At this point the screw should be backed off one quarter of a turn.
Adjusting the machine for different thicknesses of tape can be done with the screw directly behind the tape and above the work surface. Loosen the screw and slide the plate right or left to adjust the amount of drag, so the tape stays in position without falling. Plug in the machine. To test, begin by making sure the machine is warmed up and in Run Mode (see page 10 for Mode definitions). The light should be on solid. Expose the tape to the point where it is JUST at the bottom of the Guide Rail.
Operating Instructions IMPORTANT NOTE: Do not mix glue pellet brands! Most do not mix well with others! **The Equalizer is sent out with CanPlast brand pellets. If you would like to use a different brand, DO NOT fill the Glue Pot with the pellets supplied! Before running the machine: Begin by dumping a small amount of glue pellets into Glue Magazine. Do not fill the Magazine past halfway full.
When running boards be sure that: The board is sitting flat on the Roller Wheels with the backside flush against the Guide Rails. While pushing down with enough pressure to push the Glue Pot down, run the board through the machine right to left. The pressure required will be met by the weight of a larger board, but a smaller board may require additional downward pressure. To ensure a complete application of glue to the board make sure to run the board out to the end of the machine.
Understanding the LOGO! PLC Warm-Up Mode Definition: The Warm-up Cycle runs for approximately 18 minutes. It is signaled by a 1 second interval blinking strobe and a non-functional Guillotine. Once the Warm-up Cycle is complete the Strobe will go solid and the Guillotine will become operational. HOW TO start Warm-Up Mode: Make sure the Glue Pot is installed and filled. Plug in the Equalizer and turn it on. The Warm-Up screen displays on the LOGO! module.
Rest Mode Definition: The Equalizer will enter Rest Mode if it remains un-cycled for more than 18 minutes when it is in Run Mode. While the Equalizer is in Rest Mode, the glue will be maintained at a slightly lower temperature then when in Run Mode and the light will blink a ½ second on and a ½ second off. HOW TO start Rest Mode: Rest Mode will be automatically engaged only after the Equalizer remains un-cycled for more than 18 minutes when in Run Mode.
Temperature Setting Definition: The Equalizer has 10 temperature settings, 10 being the hottest and 1 the coldest. The machine is factory set for a temperature level of 5. HOW TO change the Temperature: Turn on the machine and allow it to go into Run Mode. During the Warm-Up Mode, the Screen will display the countdown timer. Once the Running Temperature has been reached the Run Screen will appear.
Guillotine Lock-out Definition The Guillotine can be set to NOT automatically cut the banding. This setting is built in to allow the use of Vertical Grade Laminate. HOW TO Lock-out the Guillotine: From the Run Screen press ESC + RIGHT arrow and hold for 2 seconds Guidelines: The Guillotine Lock-out can be toggled On and Off as need by following the above instructions.
Machine Adjustments Remove or Replace the Glue Pot Release the tension on the Glue Pot Clamp by loosening the Star Knob found under the Glue Pot.
With the Clamp released, use a pair of pliers to grab the lip of the Glue Pot. Pull it out and place it on the Galvanized Shelf. Reverse this procedure to install the Glue Pot, making sure it is installed all the way back onto the rear of the Hot Plate. Fill the empty Glue Pot with glue pellets to the top of the Transfer Wheel Axle prior to installation.
Changing the Hopper Extension To change the Hopper Extension, remove the Glue Pot (following the above instructions) and place it on the Galvanized Shelf. Loosen the lower Philips head screws in the Hopper and slide the old Hopper Extension off. Put a new Hopper Extension on so that the Castle logo is visible from the front of the machine. Place the Glue Pot back into position, align the Hopper Extension with the hole in the top of the Glue Pot, and retighten the screw.
Adjust for the width of the tape with the screw on the front of the Mechanical Channel. It has a spring under its head. This should also be adjusted until the tape has a slight drag. The spring keeps the adjustment from changing with use. Leveling the Outrigger Wheels Each Outrigger Wheel can be independently leveled.
Description of Parts Glue Pot: Found in the middle of the yellow Mechanical Channel. The main part is the Glue Transfer Wheel located in the top of the Glue Pot. It applies glue as the board is pushed through the machine. Guillotine: Cuts the banding after a board is passed through and glued. Pushing the white Delrin plate above the Guillotine will also activate it. Glue Magazine: Where the glue pellets are loaded and stored for transfer into the Glue Pot.
Band Guide: These stainless steel guides ensure that the tape stays centered on the board. They are adjustable for both thickness and width. The thickness is adjusted with the Philips head bolt to the left of the Transfer Wheel as it goes through the main Front Panel. The width is adjusted with the Phillips head screw pictured. Outriggers: Should be used when longer panels are being banded. They are simply inserted until they run into the stop bolts inside the Mechanical Channel.
Maintenance WARNING! Electrical Hazard: Do not attempt to service any Control Box components. Contact a Castle, Inc. service technician for proper service information. Machine The amount of use on the Glue Pot will determine how often it needs to be cleaned out. A considerable amount of burned glue in the Pot is a good sign that your Pot requires cleaning. Contact your Castle dealer or Castle, Inc to find Pot Cleaner.
Troubleshooting Band dispenser is too stiff The screws may have become too tight. The lock washers should be slightly compressed, but not fully flattened. Locate and adjust as appropriate. The Finger Slides may have become dry. Try lubing them with silicone grease or dry white graphite. Do not use liquid oil as it may drip onto the tape.
Glue pot is overfilling Check for leaks in the Control Hoses. Check the small black and white Control Tubes for kinks and blockages. Do not attempt to service the controls without guidance. Contact Castle, Inc. before undertaking any troubleshooting of the Control Box. Attempting to service controls without authorization will void your warranty. The Sensor may have failed. Check the wires to the Temperature Sensor, being careful to notice any broken wires.
transfer wheel has a dry line The Glue Pot may have become contaminated. While the Glue Pot is hot, remove the top, dump the liquid glue, and scrape out any foreign matter along the bottom of the Pot. The Glue Pot may need to be cleaned. Tape edges not centered enough on board edge The machine is factory set to place the tape closest to the edge of the board that is facing IN from the machine when running the board.
The Band Guide may not be set properly for the width of tape you are attempting to use. Check and reset the Band Guide. Check the Glue Pot to make sure that it is squarely set into machine. Check Stock Guide to ensure that it is aligned properly. When running the board, make sure it is fully flush against the Guide Rails and that pressure is being applied constantly while running the board.
Warranty Information Castle, Inc. uses only the highest quality materials available for the construction of our machines. Your Equalizer edgebanding machine is warranted for one full year from the date of purchase against workmanship or material defects under normal use and service. We are not responsible for negligence, misuse or accidents. We suggest that any and all machine maintenance or repair be discussed with an authorized Castle Representative prior to any disassembly.
