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Canon 6609B074 Digital Camera User Manual

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1. wI SPEED V o REV 2 0 GO SAFETY SPEED V REV STOP SAFETY t Press GAP A to the required gap setting for the substrate being used The GAP DISPLAY p Press GAP W toenter a0 in gap setting should reflect your desired setting GAP 1 PRESSURE GAP PRESSURE T i 1 4 p M 5 q Press GO INFORMATION If the thickness of the substrate is not known follow the procedure to manually set the nip in Section 5 5 1 Manual nip adjustment wI U 2 0 o GO SPEED STOP SAFETY N WARNING When operating the laminator using the variable speed footswitch keep hands and r Continue with step s when the TOP TEMP fingers away from the nip of the rollers DISPLAY stops flashing You may be CRUSHED or BURNED Page 6 54 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications u Press on the variable speed footswitch while w Press STOP guiding the leader board into the nip to confirm that the board is secure Zw wI 00 0 GO CAUTION SPEED i rev SAFETY Speed is controlled through the variable speed footswitch when the safety shield is in the raised position x Press REV V to reverse the direction of the
2. O GBC Pro Tech August 1999 Page 6 117 Applications F 160 Operation and Maintenance Manual Parameter Chart 11 Encapsulation MATERIALS UPPER UNWIND 3 mil Octiva Gloss SUBSTRATE N A LOWER UNWIND 3 mil Octiva Gloss PRINTS Any type TEMPERATURE TOP TEMP BOT TEMP 240 240 GAP amp PRESSURE MINI PRESSURE ia Footswitch PULL ROLL SETTINGS UP N A A HC 1 4 Turn PRESSURE 1 2 Turn K Q DOWN J d lt 3 4 Turn Upper and lower unwind material may be sibstituted with similar products Top and bottom temperature will be dependent on film thickness Pressure may vary acording to the output Speed will be dependent on image type Pull roll pressure will very between 1 2 turn and 3 4 turn depending on the film output quality Because the process is described from the front of the laminator motor direction is FWD Page 6 118 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications Web Diagram 11 Encapsulation g Octiva 9 Gloss Output lt e Octiva Gloss EO Finish product rewind option oy Y O GBC Pro Tech August 1999 Page 6 119
3. GAP f PRESSURE T 0 E u Press GO N M wI 2 0 GO SPEED U rev SAFETY RISE v Continue with step w when the TOP TEMP DISPLAY and BOT TEMP DISPLAY stops flashing Applications w Press STOP 20 1 rwn SPEED U nEV SAFETY Process a Raise the front safety shield and remove the front infeed table b Apply just enough brake tension to prevent the roll of thermal laminate from free spinning INFORMATION Excessive brake tension may cause the output to curl This can create complications with the second pass of this application c Pull the thermal laminate straight down toward the front infeed table so that approximately 6 in is resting on the front infeed table Refer to Figure 6 9 3 O GBC Pro Tech August 1999 Page 6 89 Applications F 160 Operation and Maintenance Manual Figure 6 9 3 Laminate e Thermal O laminate C oT ya Remove di dc ln d Apply just enough brake tension to prevent the roll of thermal laminate from free spinning INFORMATION Excessive brake tension may cause the output to curl This can create complications with the second pass of this application e Pull the thermal laminate from the bottom unwind shaft up towards
4. GAP PRESSURE 4 the laminator roller nip when adjusting PRESSURE 1 4 I DLL li You can be CRUSHED or BURNED v If the board is loose press PRESSURE V to adjust the gap between the main rollers INFORMATION If the thickness of the substrate is not known follow the procedure to manually GAP f PRESSURE 1 set the nip in Section 5 5 1 Manual nip 1 4 THO g adjustment Page 6 64 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications y Press on the variable speed footswitch to back the board out of the main rollers INFORMATION Excessive pressure will cause the substrate to bow or flatten Speed is controlled through the variable CAUTION speed footswitch when the safety shield is in the raised position w Press STOP t wri 00 0 GO Process INFORMATION If you are using precoated Hot Tissue SPEED U REV SAFETY boards proceed to step d x Press REV V to reverse the direction of the motor a Cuta sheet of Hot Tissue the same size as the image Refer to Figure 6 7 3 00 0 i bii GO SPEED U L REV STOP SAFETY b Run a thin line of glue across the leading edge of the substrate Refer to Figure 6 7 3 N WARNING INFORMATION When operating the
5. 4 Pro Mount SCS Finish product rewind option oy I O GBC Pro Tech August 1999 Page 6 115 Applications F 160 Operation and Maintenance Manual Parameter Chart 10 Thermal decal and Mount Mount MATERIALS UPPER UNWIND N A SUBSTRATE N A LOWER UNWIND N A PRINTS Decals TEMPERATURE TOP TEMP BOT TEMP 68 68 GAP amp PRESSURE PRESSURE NIN MOTOR DIRECTION amp SPEED so E Panel wb GO REV Z Footswitch J GO PULL ROLL SETTINGS UP N A AC HC 1 4 Turn PRESSURE 1 2 Turn KQ Q DOWN 4 3 4 Turn The mounting process is done from the rear position of the laminator to avoid the waiting period involved with cooling down the main rollers The rollers may be left heated or turn them down 68 F Pull roller pressure with be dependent of the substrate Apply the necessary pressure without crushing the board Page 6 116 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications Web Diagram 10 Thermal decal and mount Mount Decal C Release liner C 7 CT C Substrate LJ V E E T w
6. F 160 Operation and Maintenance Manual Installation h Press GO The bottom rollers will begin to k Press RESET The front control panel is turn illuminated RESET fr hl wri 6 0 GO SPEED nEv SAFETY i Press down on the drive side E STOP The E STOP latches in the down position bottom rollers stop and the control panel is blank 4 8 Function check Push The function check ensures that the laminator functions properly when operating This check is recommended before performing any applications If you find a step that does not react according to the description call your local area service representative immediately N WARNING Do not wear ties loose fitting clothing or dangling jewelry while operating or servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned j Unlatch the E STOP as illustrated below Unlatch O GBC Pro Tech August 1999 Page 4 17 Installation F 160 Operation and Maintenance Manual 4 8 1 Control panel a Press TOP TEMP A to a value of 120 F 48 C TOP TEMP DISPLAY begins flashing Js M BOT S 120 68 o TNCS b Press BOT TEMP A to a value of 120 F 48 C BOT TEMP DISPLAY begins flashing SLEEP TOP
7. O GBC Pro Tech August 1999 Page 4 9 Installation F 160 Operation and Maintenance Manual e Ensure that nothing is in the path of the main roll nip WARNING Caution should always be exercised when using the laminator with f Confirm that power is supplied to the laminator the safety shields raised You can be seriously HURT or INJURED g Turn the MAIN POWER to ON position i Raise the front safety shield The SAFETY indicator will begin flashing Main Power 1 FW RT 00 0 GO SPEED U Hea Mlsarety Bj Flashing AN WARNING Keep hands and fingers clear of the h Press RESET The front control panel should be illuminated at this point laminator roller nip when changing GAP You can be CRUSHED or BURNED Reset j Press GAP V to 0 GAP i PRESSURE 1 O s5 0 ALL D O GBC Pro Tech August 1999 Page4 10 F 160 Operation and Maintenance Manual Installation k Place the level across the top of the upper main roll in the center Refer to Figure 4 6 4 Figure 4 6 4 Left to right Level Saal I Level the machine from left to right m Verif
8. motor N WARNING Keep hands and fingers clear of the laminator roller nip when adjusting PRESSURE 00 0 e ms You can be CRUSHED or BURNED seen AL LL Rey SAFETY SIS v If the board is loose press PRESSURE V to adjust the gap between the main rollers N WARNING When operating the laminator through the GAP f PRESSURE f variable speed footswitch keep your hands 1 4 ILI away from the nip of the rollers You may U be crushed or burned y Press on the variable speed footswitch to back INFORMATION the board out of the main rollers Excessive pressure will cause the substrate to bow or flatten GBC Pro Tech August 1999 Page 6 55 Applications F 160 Operation and Maintenance Manual N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position Process a Pull the roll of Hot Tissue straight down toward the front infeed table so that approximately 6 in is resting on the front infeed table Refer to Figure 6 6 3 Figure 6 6 3 Leader board Hot 9 Leader Tissue C board Q L One b Position the leader board so that half is adhered to the Hot Tissue Refer to Figure 6 6 3 INFORMATION Position the leader board squarely onto the mount adhesive c Press ST
9. FWR 9 f 0 0 GO i SPEED UJ RENE p S d Raise the front and rear safety shields to the up SAFETY i position O GBC Pro Tech August 1999 Page 6 93 Applications F 160 Operation and Maintenance Manual N WARNING Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED e Raise the pull roller up by turning the crank handle counter clockwise until the pull rollers are separated f Remove the front infeed table g Cutthe web of thermal laminates at the upper and lower unwind shafts with an enclosed blade h Remove the web from the front of the laminator and the rolls of material from the upper and lower unwind shafts INFORMATION This will prevent any exposed adhesive from contacting the rollers i Clean the rollers as described in the maintenance section Section 8 2 Cleaning the rollers j Replace the front infeed table k Lower the front and rear safety shields and press SHUTDOWN if finished with the laminator SEL sav JoB End of application 6 10 Charts and Diagrams Use the parameter charts and web up diagrams can to assist you with the applications described It is recommended that you keep these parameter charts and web up diagrams in the manual for reference Make copies if you require them in other
10. 3 TOP TEMP A When pressed will increase the set point value of the top main roller in increments of 2 degrees If held down it will only increase to the maximum temperature setting of 290 F 143 C O A f BOT TEMP 32 1 7 32 n 4 TOP TEMP V When pressed will decrease the set point value of the top main roller in increments of 2 degrees If held down it will only decrease to the minimum temperature setting of 68 F 20 C SLEEP TOP TEMP BOT TEMP s gis jl O GBC Pro Tech August 1999 Page 5 1 Operations F 160 Operation and Maintenance Manual 5 BOT TEMP DISPLAY The display will show the set point temperature of the bottom main roller as the default display When the bottom roller temperature has reached in the 10 F range of the set point the display will be solid When outside of this range the display will flash SLEEP TOP TEMP A BOT TEMP 6 BOT TEMP A When pressed will increase the set point value of the bottom main roller in increments of 2 degrees If this key is held down it will only increase to the maximum temperature setting of 290 F 143 C 6 SLEEP TOP TEMP f BOT TEMP ft 68 0 68 7 BOT TEMP V When pressed will decrease the set point value of the bottom main roller in increments of 2 degrees If held down it
11. cccssssssssssssssssssssccccccccccccccscescoooooes 5 23 Section 6 Applications Group 1 No heat 6 1 Precoating substrates 5 iie eoe ietekre te epic io oae eo e ene ehiom eaa ee eoe eye eere ione i e eds 6 1 6 2 Mounting only e eani see eeceedoe nost Insee ccn ccesU UE no eke Insee cet eb eun o esde 6 10 6 3 Single sided lamination Sled method ees 6 17 6 4 Single sided lamination Craft paper method 6 25 6 5 Decal and Mount orae risen seek EVA RE SPORE ENS is e ERGERU oitenta sina steki 6 34 Pass 1 Decal assi EU x ORA okassea RYE EN sisisi 6 34 Pass 2 iT Er peer 6 43 O GBC Pro Tech August 1999 Page V Table of Contents F 160 Operation and Maintenance Manual Group 2 Top heat only 6 6 Precoating substrates secscosssscecececosooseseccecocsssssescececocsssssssseeeosssssssssee 6 51 6 7 One pass mount and laminate cccccccsssssssssssssscssssssscssssssssssssssssscssees 6 60 6 8 Thermal decal and mount eoe eer eet ouo rn en mao o Sene So ea eoa eon S ee o een ad ais 6 69 Pass basico e ER 6 70 Pass 2 MDOUPBE niensis Fo Soa AR RAE seese sotone stess sos senses ssie RES EBSASR NN PAM ARTES RUE 6 78 Group 3 Top and bottom heat 6 9 Encapsulation m 6 85 6 10 Parameter charts and diagrams Figure 6 10 1 Temperature conversion chart
12. fingers away from the nip of the rollers You may be CRUSHED or BURNED m Press on the variable speed footswitch while guiding the leader board into the nip to confirm that the board is secure N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position N WARNING Keep hands and fingers clear of the laminator roller nip when adjusting PRESSURE You can CRUSHED or BURNED n If the board is loose press PRESSURE V to adjust the gap between the main rollers a GAP f PRESSURE V4 9 MI N CAUTION Excess pressure can damage the laminating rollers Always use the minimum roll pressure necessary to complete the task INFORMATION Excessive pressure will cause the substrate to bow or flatten Page 6 20 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications 0 Press STOP Pro cess ial awe 18 a Pull the laminate to the upper rewind tube 00 0 GO Refer to Figure 6 3 3 SPEED U REV SAFETY N CAUTION Make note of the rewind tube drive p Press REV W to reverse the direction of the direction when taping the laminate motor The laminate should separate under the rewind tube REV e SPEED SIND i Figure 6 3 3 Laminate to rewind SAFETY Iii FWR
13. h Swing the upper unwind shaft out enough to slide the roll of thermal laminate over the core chucks and onto the upper unwind shaft Refer to Figure 6 7 2 INFORMATION Twisting the roll of thermal laminate while sliding makes loading the film onto the unwind shaft easier Figure 6 7 2 Unwind shaft Vana Roll of lt Thermal e Core support laminate NN mg Brake adjust knob s 4 Core chucks i Once loaded swing the upper unwind shaft back into the saddle N CAUTION Ensure the roll of laminate is loaded properly on the unwind shaft Exposed adhesive should be facing away from the rollers This will prevent hours of roll cleaning j Push the clevis pin back down to secure the unwind shaft in its saddle k Lower the rear safety shield Page 6 62 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications 0 Press SPEED A to set a motor speed of fi mint M INFORMATION haue fe D PUR If you have the parameters stored as a JOB number enter it now then press 4 SEL and skip to step p other wise continue with step wri 2 0 GO SPEED U rev STOP SAFETY I Press SEL SEL will stop flashing p Press GAP toenter aO in gap setting a NM jo
14. TIT a Slow speed will assists with heat up times and distributes heat evenly Page 5 14 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Operations f Press SEL to engage the parameters 5 4 Job programming The job save feature is very convenient if the same parameters are required to perform various JOB 0 SEL SAV applications This procedure will guide you step by step B through this feature SHUT DOWN a Follow the prcedure in Section 5 3 1 Power g Press GO to engage the motor drive system INFORMATION fu When the laminator is first turned on the FwR front control panel will go into the default 2 0 co Ms SPEED U i REV STOP SAFETY Default mode TOP TEMP 68 F 20 C BOT TEMP 68 oF 20 oC GAP 1 in PRESSURE no bars are solid JOB 0 no motion direction selected SPEED 00 0 and SLEEP flashing h When the rollers are close to it s set point value the temperature displays stop flashing pressSTOP and raise the gap to in by pressing GAP A b Press JOB A to enter the desired job number for the parameters you require to be stored GAP PRESSURE 47 SEL SAV JOB 1 VY SHUT DOWN GBC Pro Tech August 1999 Page 5 15
15. Applications F 160 Operation and Maintenance Manual This page intentionally left blank Page 6 120 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Troubleshooting Problem D waves in the image but not in the laminate Section 7 Troubleshooting N WARNING o OO Do not wear ties loose fitting clothing or dangling jewelry while operating or AOOO servicing the laminator These items can get caught in the nip and choke you or you can yo be crushed or burned As an operator you can perform some simple troubleshooting in attempt to correct your typical output type problems Use the easy to follow guide for assistance Hints Check paper tension Check relative moisture content of the paper 7 1 Wave problems Problem D Waves in the laminate The following is a list of common output wave problems you may encounter Ne a The arrow along the length of the output LEM represents the direction of feed travel COMM INFORMATION Nuls cet For optimal temperature settings of various laminates contact your supplier or sales representative Hints Check the roll pressure Check the main roll nip settings Check the pull roll nip settings O GBC Pro Tech August 1999 Page 7 1 Troubleshooting F 160 Operation and Maintenance Manual Problem Straight waves in the output Problem Angled waves in the output on both sides Hints Check for insufficient main roller
16. Page 6 108 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications Web Diagram 6 Decal and mount Mount Decal C 4 Release liner E QJ penne i Substrate Ci I5 O GBC Pro Tech August 1999 Page 6 109 Applications F 160 Operation and Maintenance Manual Parameter Chart 7 Precoating substrates Thermal MATERIALS UPPER UNWIND Hot Tissue Mount SUBSTRATE 1 4 Foam Core LOWER UNWIND N A PRINTS N A TEMPERATURE TOP TEMP BOT TEMP 140 68 GAP amp PRESSURE PRESSURE UNII MOTOR DIRECTION amp SPEED Panel GO L D Footswitch GO PULL ROLL SETTINGS T ip x N A a 1 4 Turn PRESSURE 1 2 Turn 3 4 Turn DOWN Co Upper unwind material may be sibstituted with similar product Substrate can vary Top temperature will vary slighly between 140 160 F Gap will be dependent on the substrate thickness Pressure will be determined by the operator Speed is not indicated in Footswitch mode Because the process is described from the front of the laminator motor direction is FWD and the pull rolls are not required for this application Page 6 110 GBC Pro Tech August 1999
17. Press and hold GO for 3 4 seconds before releasing the variable speed footswitch Release the variable speed footswitch Release GO GO reverts to solid Page5 8 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Operations Figure 5 1 1 Front control panel SLEEP TOP TEMP BOT TEMP 68 68 GAP PRESSURE IN EL I SAV ili c O wo M SHUT DOWN FWR 00 0 H s SPEED D GBC Pro Tech August 1999 Page 5 9 REV H Operations F 160 Operation and Maintenance Manual 5 2 Emergency The F 160 laminator 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 laminator before using or servicing the unit GBC Pro Tech laminators are powerful machines that are designed to mount laminate and encapsulate The forces required to accomplish these tasks can vary from negligible to very large The motorized main roll lift mechanism used to provide downward pressure on the top roll is capable of producing forces greater than 400 pounds This force is applied to any object presented in the opening calle
18. Set up a Turn MAIN POWER to ON Refer to Figure 6 8 1 b Press RESET Refer to Figure 6 8 1 Figure 6 8 1 MAIN POWER RESET MAIN POWER c Ensure that the rear pull rollers are in the up position d Raise the front and rear safety shields N WARNING Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED e Lift the clevis pin located in the saddle of the upper unwind shaft Saddle Ww Clevis pin lt O 9 f Swing the upper unwind shaft out enough to slide the roll of laminate over the core chucks on the upper unwind shaft Refer to Figure 6 8 2 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications INFORMATION Twisting the roll of laminate while sliding makes loading the film onto the unwind shaft easier Figure 6 8 2 Unwind shaft VA Roll of Core support X laminate NL Brake adjust bes C 37 Core chucks g Once the roll of thermal laminate is on the upper unwind shaft swing the upper unwind shaft back into the saddle N CAUTION Ensure the roll of laminate is loaded properly on the unwind shaft Exposed adhesive should be facing away from the rollers This will prevent hours of roll cleaning h Push the clevis pin back down to secure t
19. e Pull the laminate straight down toward the front BERSSDTOE infeed table so that about 6 in is resting on the front infeed table Refer to Figure 6 3 4 Zw FWR 00 0 Go U SPEED V o REY y f Position the precoated board so that about 3 in SAFETY of the board is adhered to the laminate Refer to Figure 6 3 4 h Press FWD A INFORMATION Position the leader board squarely Iii m onto the mount adhesive 00 0 GO SPEED REV J SAFETY STOP Page 6 22 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications INFORMATION yn Figure 6 3 5 Separation point Steps and j will be performed simultaneously Separation s Laminate point 7 AN WARNING Gales m oT REI T5 When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED k Once you have the brake tension set and the laminate looks smooth entering the main roller release the variable speed footswitch i Push the leader board into the main roller nip while stepping on the variable speed footswitch D Now lay the image to be laminated on the precoated board CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the r
20. N CAUTION Excess pressure can damage the laminating rollers Always use the minimum roll pressure necessary to complete the task INFORMATION INFORMATION Excessive pressure will cause the Excessive pressure will cause the substrate to bow or flatten substrate to bow or flatten GBC Pro Tech August 1999 Pagel 11 Safety F 160 Operation and Maintenance Manual N CAUTION N CAUTION If not installed properly you can be injured Sharp edges on a substrate should be filed or cause damage to the table or laminator smooth and GAP manually adjusted Sharp edges can CUT the rollers N WARNING Caution should always be exercised when using the laminator with 1 5 Applications the safety shields raised You can be seriously HURT or INJURED The following symbols are positioned at various points in Section 6 Applications A WARNING INFORMATION Do not wear ties loose fitting clothing or dangling jewelry while operating or servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned Twisting the roll of craft paper while sliding makes loading the film onto the unwind shaft easier INFORMATION N CAUTION Ensure the roll of laminate is loaded properly on the unwind shaft Exposed adhesive should be facing away from the rollers The mount adhesive must not exceed 1 in the width of the substrate If it does you will experience co
21. e 23 GO When pressed starts the rollers in motion GO is solid This solid indication is referred to as the panel mode If a safety shield is raised during panel mode GO and SAFETY referto 27 SAFETY for explanation begin flashing enabling footswitch mode refer to 28 FOOTSWITCH for explanation 6 5 4 89 SAFETY 24 STOP When pressed stops the rollers and GO becomes white m n CIS GO SPEED E Jsarerv 84 25 FORWARD A When pressed signals the laminator to run in a forward motion and FORWARD A becomes solid 6 5 Ui uM GO SPEED u LJ REV SAFETY STYR 26 REVERSE V When pressed signals the laminator to run in areverse motion and REVERSE V becomes solid L rwR 6 5 GO SPEED 44 eL _lsarety 970 O GBC Pro Tech August 1999 Page 5 5 Operations F 160 Operation and Maintenance Manual 27 SAFETY Begins flashing anytime the front or the rear safety shield is in the raised position This is an indication for the operator to be very careful when operating the laminator in the Footswitch mode LJ wel 6 5 GO SPEED STOP m SAFETY REV 28 Variable Speed Footswitch The variable speed footswitch operates the laminator in Footswitch mode Within this mode if the
22. Saddle Ww Clevis pin 9 f Swing the upper unwind shaft out enough to slide the roll of laminate over the core chucks on the upper unwind shaft Refer to Figure 6 5 2 INFORMATION Twisting the roll of laminate while sliding makes loading the film onto the unwind shaft easier O GBC Pro Tech August 1999 Page 6 35 Applications F 160 Operation and Maintenance Manual Figure 6 5 2 Unwind shaft m Roll of Core support laminate A Brake adjust koh e Core chucks O g Once the roll of laminate is on the upper unwind shaft swing the upper unwind shaft back into the saddle N CAUTION Ensure the roll of laminate is loaded properly on the unwind shaft Exposed adhesive should be facing away from the rollers This will prevent hours of roll cleaning h Push the clevis pin back down to secure the unwind shaft in its saddle i Leave the safety shield in the up position j Liftthe clevis pin located in the saddle of the lower unwind shaft Saddle Ww Clevis pin k Swing the lower unwind shaft out enough to slide the roll of mount adhesive over the core chucks on the lower unwind shaft Refer to Figure 6 5 2 INFORMATION Twisting the roll of mount adhesive while sliding makes loading the film onto the unwind shaft easier 1 Once the roll of mount adhesive
23. INFORMATION If the image is not conformed to the roller you may experience difficulties with INFORMATION Do not lower the pull roller so that the substrate is crushed when passing through This will prevent the boards from bowing N CAUTION Caution should always be exercised when using a utility knife near the rollers You can put cuts into the rollers this application INFORMATION Use a slow speed If the tack point enters the rollers nip you will not be able to pull the release liner INFORMATION Stopping the rollers on the print will leave a pressure line on the image GBC Pro Tech August 1999 Page 1 15 Safety F 160 Operation and Maintenance Manual 1 6 Troubleshooting The following symbols are positioned at various points in Section 7 Troubleshooting N WARNING Do not wear ties loose fitting clothing or dangling jewelry while operating or servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned INFORMATION For optimal temperature settings of various laminates contact your supplier or sales representative N CAUTION Exercise care when cleaning the laminating rollers with 80 isopropyl alcohol Use only in a well ventilated area Wear rubber gloves e Use only on cool rolls CLEANING HEATED ROLLERS CAN IGNITE THE FUMES N CAUTION Prolonged contact can form flat spots on
24. Roll of craft paper same width as the laminate Print smaller than the laminate Roll of masking tape Utility knife Cutting blade with an enclosed casing e Piece of cardboard film width x 6 in Set up a Turn MAIN POWER to ON Refer to Figure 6 4 1 O GBC Pro Tech August 1999 Page 6 25 Applications F 160 Operation and Maintenance Manual b Press RESET Refer to Figure 6 4 1 e Lift the clevis pin located in the saddle of the upper unwind shaft Saddle Figure 6 4 1 MAIN POWER RESET RS Clevis pin f Swing the upper unwind shaft out enough to slide the roll of laminate over the core chucks on the upper unwind shaft Refer to Figure 6 3 2 MAIN POWER INFORMATION Twisting the roll of laminate while sliding makes loading the film onto the unwind c Ensure that the front and rear tables are in shaft easier position and the rear pull rollers are in the up position Figure 6 3 2 Unwind shaft d Raise the rear safety shield LARA N WARNING Roll of Core support laminate Caution should always be exercised when using the laminator with the safety shields raised l You can be seriously HURT or INJURED o dd 4 Coreth eks e Page 6 26 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications g Once the roll of laminate is on the
25. a With an enclosed blade cut the finished product p Press GO from the web 9 0 a wall N CAUTION REV SPEED n U BAEETN STOP Do not use an open blade to cut the web near the rollers You can put cuts into the rollers q Feed the images through the main rollers from the front operating position of the laminator b The decals are now ready to be trimmed C If you used the lower rewind remove the rewind tube and bring it to a trimming station Replace the rewind tube when finished r After the last print has passed through the pull rollers press STOP yo UG di SPEED UJ RENE L d Raise the front and rear safety shields to the up SAFETY gt position Page 6 77 GBC Pro Tech August 1999 Applications F 160 Operation and Maintenance Manual N WARNING INFORMATION This will prevent any exposed adhesive from Caution should always be exercised when using the laminator with contacting the rollers the safety shields raised You can be seriously HURT or INJURED i Clean the rollers as described in the maintenance section Section 8 2 Cleaning the rollers e Raise the pull roller up by turning the crank handle counter clockwise until the pull rollers are separated INFORMATION If the rollers have no adhesive on them proceed to the second pass of this application
26. k Press down on the variable speed footswitch just enough to give yourself a comfortable work speed N CAUTION Speed is controlled through the variable Finishing speed footswitch when the safety shield is in the raised position a Press STOP AN WARNING 9 0 i GO fi When the laminator rollers are in s g o motion keep hands and fingers SPEED away from the nip of the rollers SAFETY You may be CRUSHED or BURNED Page 6 84 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications b Raise the pull roller up by turning the crank Group 3 e Top b ottom he at handle counter clockwise until the pull rollers are separated Group three contains applications requiring heat to activate the upper and lower materials c Clean the rollers as described in the maintenance section Section 8 2 Cleaning the rollers The procedures and its parameters described in this section are starting references only Parameters will vary with regards to laminate thickness laminate widths laminates types print d Lower the front and rear safety shields and types ink or toner types enviroment conditions press SHUTDOWN if finished with the operator experience and various substrates laminator I1 Tse C sav N WARNING JOB y A ie Do not wear ties loose fitting clothing or dangling jewelry while
27. Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED 1 rwn 6 0 GO SPEED y rev SAFETY si k Raise the rear safety shield SAFETY indicator and GO begin flashing and the bottom rollers Top 4 7 3 EMERGENCY STOPS E STOP a Press GO The bottom rollers begin turning FwR pl rev 6 0 SPEED it J liia STOP 6 0 SPEED SAFETY ll sarety F Flashing Iii wI Page 4 15 GBC Pro Tech August 1999 Installation F 160 Operation and Maintenance Manual b Press down on the control side E STOP The e Press SEL SEL stops flashing E STOP latches in the down position bottom rollers stop and the control panel is blank Push mm JoB SAV l SHUT DOWN f Press FWD A for a forward motor direction c Unlatch the E STOP as illustrated below Unlatch M 00 0 FWR GO iu SPEED V REN U STOP SAFETY d Press RESET The front control panel is illuminated g Press SPEED A toa speed of 6 ft min RESET wI 6 0 GO SPEED Q nEv STOP SAFETY Page4 16 O GBC Pro Tech August 1999
28. F 160 Operation and Maintenance Manual D Press FWD A INFORMATION If you have the parameters stored as a JOB number enter it now then press N s FWR a 000 s Ems SPEED rev STOP SAFETY j Press SEL INFORMATION Steps m and n will be performed qum Tz simultaneously SEL M SAV y JoB id SHUT DOWN m Use a piece of cardboard to push the material into the nip of the main rollers N WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP WARNING You can be CRUSHED or BURNED When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED k Press GAP V to enter a O in gap setting n Press on the variable speed footswitch to guide the cardboard mount adhesive and laminate through the main rollers GAP 1 PRESSURE f 0 h WNI GBC Pro Tech August 1999 Page 6 39 Applications F 160 Operation and Maintenance Manual N CAUTION N WARNING Speed is controlled through the variable Keep hands and fingers clear of the pull speed footswitch when the safety shield roller nip when changing the gap is in the raised position You can be CRUSHED p Once the cardboard has passed through the pull WARNING rollers lower the upper pull r
29. Mount will adhere the decal to a substrate d Trim as necessary The first part of this application Decal can only be performed from the front of the laminator using the main rollers Use Chart 9 and Diagram 9 for assistance e Clean the rollers as described in the maintenance section Section 8 2 Cleaning the rollers The second part Mount is described from the rear of the laminator since the main rollers are heated Use Chart 10 and Diagram 10 for assistance f Lower the front and rear safety shields and press SHUTDOWN if finished with the s This application can be performed in various laminator methods The process described in this manual is the most common method 3 seLL_ sav JOB y E N WARNING Do not wear ties loose fitting clothing or dangling jewelry while operating or servicing the laminator These items can get End of application caught in the nip and choke you or you can be crushed or burned O GBC Pro Tech August 1999 Page 6 69 Applications F 160 Operation and Maintenance Manual Pass 1 Decal Use Chart 9 and Diagram 9 for assistance Materials needed Roll of thermal laminate Roll of mount adhesive same width as the laminate Print smaller than the laminate Roll of masking tape Utility knife Cutting blade with an enclosed casing e Piece of cardboard film width x 6
30. Operations F 160 Operation and Maintenance Manual c If heat is required press TOP TEMP A and e Enter a desired speed by pressing SPEED A BOT TEMP A to desired settings If no heat is required leave the settings at 68 F 20 C P FW at 3 5 GO SLEEP n SPEED L rev TOP TEMP BOT TEMP SAFETY STOP 68 0 68 SZ f Press SAVE to store the parameters in the job location selected N WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP You can be CRUSHED or BURNED f T seu SAV l SHUT DOWN d Enter in the GAP setting desired by pressing GAP V h Repeat steps b through f to save other parameters in job location numbers i moe 1 4 T If you accidentally press SAVE at any time the old parameters will be replaced with the new parameters INFORMATION INFORMATION When storing parameters within the JOB You should store each job location with its SAVE feature of the laminator PRESSURE parameters on the chart provided in is not a storable setting Figure 5 4 1 Page 5 16 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Operations Pisite pr JOD CSV Eat 5 5 1 Main roller manual nip adjustment a Turn the MAIN P
31. STOP SAFETY w Press GO wri 9 0 GO Li RT SPEED STOP SAFETY AN WARNING When the laminator rollers are in motion keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED x Feed the images through the main rollers from the front operating position of the laminator Page 6 32 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications y After the last print has passed through the pull rollers press STOP 9 0 U m GO SPEED U REV SAFETY z Press GAP A toa in setting GAP PRESSURE iu Finishing a With an enclosed blade cut the finished product from the web N CAUTION Do not use an open blade to cut the web near the rollers You can put cuts into the rollers b The prints are now ready to be trimmed When trimmed the craft paper will fall away from the back of the print c If you used the lower rewind remove the rewind tube and bring it to a trimming station Replace the rewind tube when finished d Raise the front and rear safety shields to the up position N WARNING Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED e Raise the pull roller up by turning the crank h
32. UPPER UNWIND Pro Mount SUBSTRATE 1 4 Foam Core LOWER UNWIND N A PRINTS N A TEMPERATURE TOP TEMP BOT TEMP 68 68 GAP amp PRESSURE PRESSURE UNIN MOTOR DIRECTION amp SPEED Panel GO L DX Footswitch GO PULL ROLL SETTINGS z UP SI NIA HC 1 4 Turn PRESSURE Q 1 2 Turn Q DOWN 4 3 4 Turn Pro Mount can be substituted with a similar product Substrate can vary GAP will be dependent on the substrate thickness Pressure will be determined by operator Speed is not indicated in Footswitch mode Because the process is described from the front of the laminator motor direction is FWD and the pull rolls are not required for this application Page 6 98 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications Web Diagram 1 Precoating substrate E Pro Mount Substrate Ci ID O GBC Pro Tech August 1999 Page 6 99 Applications F 160 Operation and Maintenance Manual Parameter Chart 2 Mounting only MATERIALS UPPER UNWIND N A SUBSTRATE Precoated boards LOWER UNWIND N A PRINTS Inkjet prints TEMPERATURE TOP TEMP BOT TEMP 68 68 GAP amp PRESSURE PRESSURE
33. smooth and GAP manually adjusted Sharp edges can CUT the rollers INFORMATION If the thickness of the substrate is not known follow the procedure to manually set the nip in Section 5 5 2 Manually nip adjustment N CAUTION Excess pressure can damage the laminating rollers Always use the minimum roll pressure necessary to complete the task INFORMATION Excessive pressure will cause the substrate to bow or flatten O GBC Pro Tech August 1999 Page 6 79 Applications F 160 Operation and Maintenance Manual d Press FWD A T C A 00 0 GO SPEED LU REV J C SAFETY STOF N WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED e Press on the variable speed footswitch to back the leader board out N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position f Press STOP 00 0 Sd wi SPEED V o rev SAFETY g Press REV V to reverse the direction of the motor o 00 0 H a SPEED lt REV STOP SAFETY Process a Align the leading edge of the image with the leading edge of the board and one
34. INFORMATION Stopping the rollers on the print will leave a pressure line on the image INFORMATION This will prevent any exposed adhesive from contacting the rollers Page 6 24 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications d Press STOP 00 0 i Q SPEED U E rev SAFETY e Clean the rollers as described in the maintenance section Section 8 2 Cleaning the rollers f Remove the roll of laminate from the upper unwind shaft and remove the release liner from the rewind tube g Lower the front and rear safety shields and press SHUTDOWN if finished with the laminator z N Fa seLl L_Jsav JOB 0 i4 E End of application 6 4 Single sided lamination Craft paper method This application may be performed from the front of the laminator using the main rollers or from the rear of the laminator using the pull rollers in the event the main rollers are heated This application is explained in detail using the main rollers from the front ofthe laminator Use Chart 4 and Diagram 4 for assistance N WARNING Do not wear ties loose fitting clothing or dangling jewelry while operating or servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned Materials needed Roll of pressure sensitive over laminate
35. directional laminator Features wo unwinds 1 upper 1 lower Two rewinds 1 upper front 1 lower center e Safety shielded nfeed and oufeed tables Accelerator footswitch Job programmable Bi directional system Applica ons 9 Single sided lamination Encapsulation Mounting Decaling Section 3 2 Consumables Film Types Pressure sensitive laminates e Pressure sensitive adhesives e Low melt laminates e Thermal laminates e Thermal adhesives Film Diameters 8 Uptoa8 roll diameter 20 3 cm Core Size 3 core standard 7 62 cm e 2 1 4 optional must have optional core adapters 5 72 cm HilmWidths 64 Pressure sensitive 162 6 cm 62 Thermal 157 8 cm Paper Widths 9 62 maximum paper width 157 8 cm Mounting Thickness Upto D inch thick 2 54 cm either direction O GBC Pro Tech August 1999 Page3 1 Specifications F 160 Operation and Maintenance Manual Section 3 3 Function Speed Motor Heating Capabilities Controls Job Save Roll Design Section 3 4 United States Europe B T U output Heater Wattages Amperage Draw D C Voltage used A C Voltage used 0 15ft min 0 4 6m mi
36. in whole or in part in any form without the prior and express written permission of GBC Pro Tech In the electronic version of this publication the hand will change to a pointer finger identifying hyperlinked When moving from page to page use I4 to return to the first PAGE use to advance to the last PAGE use 4 to go back one PAGE and use gt to advance one PAGE When moving from view to view use 4 to return to a previous VIEW and use gt gt to advance to the next VIEW Should you find an error within this publication or would like to make a suggestion please utilize the fax correspondence sheet following this read me file and fax it to the number provided Your comments and help will ensure up to date information Thank you O GBC Pro Tech August 1999 Read me file F 160 Operation and Maintenance Manual This page intentionally left blank GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Read me file Fax Correspondence Fax number 608 246 8645 Date To Sean Flood GBC Pro Tech 4151 Anderson Road DeForest WI 53532 From Company Address Phone number Fax number Re Falcon 160 Operations and Maintenance Manual Rev A What section J A WhatPage What needs correcting Additional comments O GBC Pro Tech August 1999 R
37. 00 0 GO J AN vs 36 P S A 9 Rewind When operating the laminator using the Laminate tube variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED C Co ie Te 2 i Press on the variable speed footswitch to back the leader board out of the main rollers b Use a piece of masking tape to adhere the leading edge of the laminate to the upper rewind tube CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position c Wrap one full turn of laminate onto the upper rewind tube GBC Pro Tech August 1999 Page 6 21 Applications F 160 Operation and Maintenance Manual Figure 6 3 4 Laminate separation INFORMATION Do not cut too deeply into the laminate Ren you can cut into the release liner Precoated Laminate O A 1 d With the utility knife make an incision across CHET O Ci J the width of the laminate J N CAUTION N CAUTION Caution should always be exercised If the board is not squarely positioned when using a knife you may experience difficulties with Sharp knife can cut you this application
38. 125 51 7 170 76 7 215 101 7 260 126 7 81 27 2 126 52 2 171 77 2 216 102 2 261 127 2 82 27 8 127 52 8 172 77 8 217 102 8 262 127 8 83 28 3 128 53 3 173 78 3 218 103 3 263 128 3 84 28 9 129 53 9 174 78 9 219 103 9 264 128 9 85 29 4 130 54 4 175 79 4 220 104 4 265 129 4 86 30 131 55 176 80 221 105 266 130 87 30 6 132 55 6 177 80 6 222 105 6 267 130 6 88 31 1 133 56 1 178 81 1 223 106 1 268 131 1 89 31 7 134 56 7 179 81 7 224 106 7 269 131 7 90 32 2 135 57 2 180 82 2 225 107 2 270 132 2 91 32 8 136 57 8 181 82 8 226 107 8 271 132 8 92 33 3 137 58 3 182 83 3 227 108 3 272 133 3 93 33 9 138 58 9 183 83 9 228 108 9 273 133 9 94 34 4 139 59 4 184 84 4 229 109 4 274 134 4 95 J 35 140 60 185 85 230 110 275 135 96 35 6 141 60 6 186 85 6 231 110 6 276 135 6 97 36 1 142 61 1 187 86 1 232 111 1 277 136 1 98 36 7 143 61 7 188 86 7 233 111 7 278 136 7 99 37 2 144 62 2 189 87 2 234 112 2 279 137 2 100 37 8 145 62 8 190 87 8 235 112 8 280 137 8 101 38 3 146 63 3 191 88 3 236 113 3 281 138 3 102 38 9 147 63 9 192 88 9 237 113 9 282 138 9 103 39 4 148 64 4 193 89 4 238 114 4 283 139 4 104 40 149 65 194 90 239 115 284 140 105 40 6 150 65 6 195 90 6 240 115 6 285 140 6 106 4
39. 6 95 Plata CHAE eI TM 6 96 Blank diagram et eceacasssecceces axes osccccuscaaee scents cccaesuctessacezesaGesevees 6 97 Chart 1 Pr coating substrates eto croceo ie eere ee tenere ee eere erani 6 98 Page VI O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Table of Contents Diagram 1 Precoating subtrates cccccccsssssscssssccccccccccccecccccsccssscsssssees 6 99 Chart 2 Mounting only ii eee ice eei tees ene eee t eto nu ete e oae abet eeu ka une une 6 100 Diagram 2 Mounting only ecce ceee coro e epe rero o cte o recu o DuroRs 6 101 Chart 3 Single sided Sled iuueni tene eene ene svo side 6 102 Diagram 3 Single sided Sled iier etie tiet tech enecc eoe caesis nuce 6 103 Chart 4 Single sided Craft paper ee eeees eee eere eere 6 104 Diagram 4 Single sided Craft paper e eeeeeeeee eere 6 105 Chart 5 Decal and mount Decal eee eee eee eee eee eee eene nn ette 6 106 Diagram 5 Decal and mount Decal c eeee eee eee eee eren eee nne 6 107 Chart 6 Decal and mount Mount ce eeeee eee ee eee eee eee eene esee tette eeeae 6 108 Diagram 6 Decal and mount Mount cereus scere nete ee eee eee tnauue 6 109 Chart 7 Precoating subtrates cerei ce eee
40. F 160 Operation and Maintenance Manual Applications Web Diagram 7 Precoating substrate Thermal Hot Tissue Leader Substrate oy v O GBC Pro Tech August 1999 Page 6 111 Applications F 160 Operation and Maintenance Manual Parameter Chart 8 One pass mount and laminate MATERIALS UPPER UNWIND 3 mil Octiva Gloss SUBSTRATE 1 4 Foam Core LOWER UNWIND N A PRINTS Electrostatic images TEMPERATURE TOP TEMP BOT TEMP 240 68 GAP amp PRESSURE PRESSURE NIN MOTOR DIRECTION amp SPEED Panel GO D a Footswitch GO PULL ROLL SETTINGS T gt is lt I N A gt 1 4 Turn PRESSURE 1 2 Turn 3 4 Turn DOWN GC Upper unwind material may be sibstituted with similar product Substrate can vary Top temperature will vary slighly between 240 260 F depending on laminate thickness Gap will be dependent on the substrate thickness Pressure will be determined by the operator Speed is not indicated in Footswitch mode Because the process is described from the front of the laminator motor direction is FWD and the pull rolls are not required for this application Page 6 112 GBC Pro Tech August 1999 F 160 Operati
41. FWD A j Apply the minimum amount of brake tension on the roll of thermal laminate to prevent it from free spinning 00 0 GO web U me o INFORMATION _ SAFETY did Excessive tension will cause the substrate to bow INFORMATION Steps i and j will be performed k Once tentioned let off the variable speed simultaneously footswitch N WARNING I Position the board with the glued sheet of Hot Tissue and image against the leader board A WARNING When operating the laminator using the i Push the leader board into the main roller nip variable speed footswitch keep hands and while stepping on the variable speed footswitch fingers away from the nip of the rollers You may be CRUSHED or BURNED N CAUTION m using a slow speed press on the variable speed Speed is controlled through the variable footswitch while guiding the board into the main speed footswitch when the safety shield roller nip is in the raised position When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED O GBC Pro Tech August 1999 Page 6 67 Applications F 160 Operation and Maintenance Manual INFORMATION INFORMATION Stopping the rollers on the print will leave a pressure line on the image The heat must penetrate through the thermal laminate image Hot Tissue a
42. Ii P 00 0 GO SPEED LU REV STOP C SAFETY GBC Pro Tech August 1999 Page 5 19 Operations F 160 Operation and Maintenance Manual k You may now begin mounting from the front operating position 5 5 2 Pull roller manual nip adjustment INFORMATION If the main laminating rollers are heated mounting application may be run from the rear operating position of the machine a Turn the MAIN POWER to the ON position Power b Press RESET The front control panel will illuminated Reset c Press SEL jos 0 Tas SAV lU SHUT DOWN E Flashing d Press FWD A for a forward motor direction 00 0 GO SPEED U REV STOP SAFETY e Bring the footswitch around to the rear of the laminator N WARNING Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED Page 5 20 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Operations N CAUTION Excess pressure can damage the laminating f Raise the rear safety shield g Position the leader board in the center of the rollers Always use the minimum roll pull rollers between the nip pressure necessary to complete the task N CAUTION Sharp edges on a substrate should be filed INFORMATI
43. Operation and Maintenance Manual i Press on the variable speed footswitch to back the leader board out of the main rollers N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position Process a Align the leading edge of the image with the leading edge of the board and one other side Refer to Figure 6 5 7 Figure 6 5 7 Align edges 4 Align two sides Leading edge Substrate INFORMATION The leading edge is the first part of the board or image that enters the nip of the rollers b Is the decal compatible with the substrate If the substrate is larger than the decal you can position the image any where on the board Figure 6 5 8 Figure 6 5 8 Setting the decal You must trim the decal so that no more than 1 in exceeds the size of the substrate Refer to Figure 6 5 9 Figure 6 5 9 Trim the decal Image _ No more than 1 in over hang Page 6 46 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications c Peel back about 1 in of the release liner from the decal and fold back Refer to Figure 6 5 10 INFORMATION Avoid tacking at the ends first and pressing towards the center you may create a tunnel once you have reached the center This will Figure 6 5 10 Peel back release liner make for a difficult mounting application Leading edge Rele
44. SHUT DOWN Page 4 12 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Installation g Slightly lift the front infeed table SAFETY j Press GO The bottom rollers begin turning indicator and GO begin flashing and the bottom rollers stop lt gt hl wri 6 0 E cwn fl 6 0 GO GO SPEED X rev SPEED l rev STOP W sarery 77 dic jl Flashing k Slighly lift the rear infeed table SAFETY h Lower the front infeed table SAFETY indicator and GO begin flashing and the bottom indicator reverts to white and GO remains rollers stop flashing 6 0 1 E w GO 6 0 in E rwr I SPEED UCI REV In m aev I SAFETY STOP SAREN F Flashing F Flashing 1 Lower the rear infeed table SAFETY indicator reverts to white and GO remains flashing i Press STOP GO stops flashing ie wI 6 0 x wall 6 0 Go PEU SPEED l REV SPEED UJ REV STOP eee SAFETY F Flashing GBC Pro Tech August 1999 Page 4 13 Installation F 160 Operation and Maintenance Manual m Press S
45. UNIN MOTOR DIRECTION amp SPEED Panel GO U DX Footswitch GO PULL ROLL SETTINGS T gt ji DX N A gt 1 4 Turn PRESSURE q 1 2 Turn DOWN RC 3 4 Turn Substrate will vary Print can be of any type GAP will be dependent on the substrate thickness Pressure will be determined by operator Speed is not indicated in Footswitch mode Because the process is described from the front of the laminator motor direction is FWD and the pull rolls are not required for this application Page 6 100 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications Web Diagram 2 Mounting only Print 4 Release liner i F Precoated board Ci w GBC Pro Tech August 1999 Page 6 101 Applications F 160 Operation and Maintenance Manual Parameter Chart 3 Single sided Sled MATERIALS UPPER UNWIND Pro Gloss SUBSTRATE 1 4 Foam Core LOWER UNWIND N A PRINTS Inkjet prints TEMPERATURE TOP TEMP BOT TEMP 68 68 GAP amp PRESSURE PRESSURE UNIN MOTOR DIRECTION amp SPEED Panel GO L DX Footswitch GO PULL ROLL SETTINGS To ji DX N A gt 1 4 T
46. Use only on cool rolls CLEANING HEATED ROLLERS CAN IGNITE THE FUMES N WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP You can be CRUSHED or BURNED Page 1 18 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Safety 1 8 Label locations Cautions Warning Label Locations Posted at various locations on the Falcon 160 Laminator are important safety labels Pay careful attention to these labels at all times Figure 1 8 1 illustrates the location of each of these labels Chain Pinch Point Exercise extreme caution when working around this area Moving chains and sprockets are present Read Manual Read the operations manual before attempting to operate this machine Electrical Shock Live voltage present Exercise extreme caution You may be electrocuted Danger Voltage High voltage wires You may be Roller Pinch Point Keep hands and fingers away shocked electrocuted paralyzed or die You may be crushed and or burned GBC Pro Tech August 1999 Page 1 19 Safety F 160 Operation and Maintenance Manual Figure 1 8 1 Label locations ir Av Inside cabinet Rear location Page 1 20 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Warranty Section 2 Warranty GBC Pro Tech warrants the equipment sold is free from defects in materi
47. d Wrap one full turn of laminate onto the upper rewind tube N CAUTION Do not cut too deeply into the laminate you can cut into the release liner O GBC Pro Tech August 1999 Page 6 37 Applications F 160 Operation and Maintenance Manual e With the utility knife make an incision across the width of the laminate N CAUTION Caution should always be exercised when using a knife Sharp knife can cut you f Remove the front infeed table g Pull the laminate straight down toward the front ofthe lower main roller Refer to Figure 6 5 4 Figure 6 5 4 Laminate separation CF Laminate o CIO Remove ur T h Apply just enough brake tension to prevent the roll of mount adhesive from free spinning INFORMATION Excessive brake tension may cause the output to curl This can create complications with the second pass of this application i Pull the mount adhesive up towards the upper main roller and tack it the laminate resting on the upper main roller Refer to Figure 6 5 5 ineonmarion The mount adhesive will adhere to the exposed adhesive from the laminate Figure 6 5 5 Mount adhesive Laminate 2 Q C C c Mount adhesive Page 6 38 O GBC Pro Tech August 1999 Applications
48. eee eee eeeeee eee 4 22 O GBC Pro Tech August 1999 Page III Table of Contents F 160 Operation and Maintenance Manual Section 5 Operations 5 1 Control partiel cii tete eiecti eines 5 1 Figure 5 1 1 Front control panel eeeeeeeeeeeeee 5 9 5 2 Emergenty t ta ossai 5 10 5 3 Set UP aue dcr eiae ceci dia cunteecuaateuet vadvectccuet eesiuatevetoeswecedancawecucete 5 11 M POWER ee 5 11 5 3 2 Film LO AGUS T c osiossa 5 12 Figure 5 3 4 Measurement chart e eeeeeeeeeeeee 5 13 5 95 5 HedlIDg 1er o cece sate ener Hd cie asinna sasos Mende ie siiani eU E paene A e LeE 5 13 5 4 Job programming 2n ete E Oe eames eee 5 15 Figure 5 4 1 Job save chart eere eterne eser rero etes 5 17 5 5 Manual nip adjustment coi ree ee eret e Ine see t e eene paseo en ee aenea nv y E Y Va nne aa nun 5 17 5 5 1 Main roller manual nip adjustment ssscccccccccsssssssssssssrcccsssssssees 5 17 5 5 2 Pull roller manual nip adjustment ecce e eese eene eene eren 5 20 Page IV O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Table of Contents 5 0 Inf ed tables disse e 5 23 5 6 1 Removing the infeed tables ssc c scis scsesssscaccsessasvssensesvasasecnseenccceewesecceswess 5 23 5 6 2 Replacing the infeed tables
49. eoi Duro eee eere ree eene s 6 110 Diagram 7 Precoating subtrates eee eee eee eee eee eere eene eee esee eee eee 6 111 Chart One pass Mount 55 eee erre ere ree Ea ru eoe Ee epa eee Ra Pao eoe esae eaa ESI Ce n UeUE Ud 6 112 O GBC Pro Tech August 1999 Page VII Table of Contents F 160 Operation and Maintenance Manual Diagram One pass mount c ococci iocos eeee reete eee te ese ree oe paa enne esa rena RE ERR UE 6 113 Chart 9 Thermal decal and mount Decal eere creen 6 114 Diagram 9 Thermal decal and mount Decal 6 115 Chart 10 Thermal decal and mount Mount e eere 6 116 Diagram 10 Thermal decal and mount Mount eese 6 117 Chart 11 Encapsulation repere set koe etpac eno uico Coppe pace eoe eR e ka rea sp QUE EeEE 6 118 Diagram 11 Encapsulation ecce ee eere eee eee eee ettet tette oett tete 6 119 Section 7 Troubleshooting 731 Wave problems err cco irent n eate qu e ussai etes exe ue e Ope oUdU Oeo E NE ee d UR U Ee ritto 7 1 yPoulgoussiitec E 7 3 7 2 1 Thermal laminafes uei eerte bios S etur Ree o eon po eo D ne Vue o eon Sue o na PES Va eso ed UR En ES 7 3 752 2 PreSSUEC SEDSUVE uoi euer too S SEE INE TRIER assests ionos asua o RIA LES 7 3 7 3 Machine problems 4e oret terri dece potete nier o Sc
50. is on the lower unwind shaft swing the lower unwind shaft back into the saddle N CAUTION Ensure the roll of mount adhesive is loaded properly on the unwind shaft Exposed adhesive should be facing away from the rollers This will prevent hours of roll cleaning Page 6 36 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications m Push the clevis pin back down to secure the unwind shaft in its saddle n Center the upper roll and the lower roll of material on the unwind shafts You may refer to your measurement chart in Section 5 3 2 Loading film Figure 5 3 4 INFORMATION For the lower unwind shaft add 1 4 in to the measurement Process a Apply just enough brake tension to prevent the roll of laminate from free spinning INFORMATION Excessive brake tension may cause the output to curl This can create complications with the second pass of this application b Pull the laminate to the upper rewind tube Refer to Figure 6 5 3 N CAUTION Make note of the rewind tube drive direction when taping the laminate The laminate should separate under the rewind tube Figure 6 5 3 Laminate to rewind P S A 9 Rewind Laminate tube Q O C S Ne OT A c Use a piece of masking tape to adhere the leading edge of the laminate to the upper rewind tube
51. laminator through the variable speed footswitch keep your hands The leading edge is the first part of the away from the nip of the rollers You may board or image that enters the nip be crushed or burned of the rollers O GBC Pro Tech August 1999 Page 6 65 Applications F 160 Operation and Maintenance Manual c Lay the sheet of Hot Tissue on the board so the two leading edges are aligned Refer to Figure 6 7 3 INFORMATION The thin line of glue will assist with holding the layers to the board d Runa thin line of glue across the leading edge of Hot Tissue just placed on the board Figure 6 7 3 Print Hot Tissue Substrate Thin line of glue e Pull the thermal laminate straight down toward the front infeed table so that approximately 6 in is resting on the front infeed table Refer to Figure 6 7 4 Figure 6 7 4 Leader board Thermal gt 9 laminate Leader C board ox f Position the leader board so that half is pressed against the thermal laminate resting on the front table Refer to Figure 6 7 4 INFORMATION Position the leader board squarely onto the thermal laminate g Press STOP 20 m rwn SPEED U D rev SAFETY Page 6 66 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications h Press
52. locations Use the blank parameter chart and blank web up diagram to record specific applications not illustrated in this section For converting degrees Fahrenheit to degrees Celsius refer to Figure 6 10 1 Parameters will vary with regards to laminate thickness laminate widths laminates types print types ink or toner types enviroment conditions operater experience and various substrates Page 6 94 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications Figure 6 10 1 Temperature conversion chart oF oC oF oC o F ut SF C oF C 68 20 113 45 158 70 203 95 248 120 69 20 6 114 45 6 159 70 6 204 95 6 249 120 6 70 f 21 1 115 46 1 160 71 1 205 96 1 250 121 1 71 21 7 116 46 7 161 71 7 206 96 7 251 121 7 72 22 2 117 47 2 162 72 2 207 97 2 252 122 2 73 22 7 118 47 8 163 72 8 208 97 8 253 122 8 74 23 3 119 48 3 164 73 3 209 98 3 254 123 3 75 23 9 120 48 9 165 73 9 210 98 9 255 123 9 76 244 121 49 4 166 74 4 211 99 4 256 124 4 77 25 122 50 167 75 212 100 257 125 78 25 6 123 50 6 168 75 6 213 100 6 258 125 6 79 26 1 124 51 1 169 76 1 214 101 1 259 126 1 80 26 7
53. n Press on the variable speed footswitch to guide the cardboard craft paper and laminate through the main rollers N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position N WARNING Keep hands and fingers clear of the laminator roller nip when adjusting PRESSURE You can be CRUSHED or BURNED 0 When the cardboard has travel pass the main rollers press PRESSURE V to set a pressure of 60 8096 GAP iii PRESSURE 1 o 5 Il b N CAUTION Excess pressure can damage the laminating rollers Always use the minimum roll pressure necessary to complete the task O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications N WARNING Keep hands and fingers clear of the pull roller nip when changing the gap You can be CRUSHED INFORMATION If you choose to use the lower rewind tube make note of the direction of travel p Once the cardboard has passed through the pull rollers lower the upper pull roller onto the web Turn the pull roll crank handle 3 4 turn clockwise after you feel the initial contact Refer to Figure 6 4 6 INFORMATION PRESSURE will vary with the thickness and width of the laminate you are using Adjust as necessary q Cut the cardboard from the webbed material Refer to Figure 6 4 6 N CAUTION Do not use an open blade to c
54. on a substrate should be filed smooth and GAP manually adjusted Sharp edges can CUT the rollers INFORMATION Density of the substrate will determine the amount of pressure you may use WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP You can be CRUSHED or BURNED INFORMATION Refer to Figure 5 5 1 for proper roller pressure Page 5 18 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Operations Figure 5 5 1 Main roller pressure Leader board Proper Cas pressure Leader board Excessive 9 ail pressure g Press REV WV for a reverse motor direction 00 0 eL SPEED B REV STOP SAFETY AN WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED h Step on the variable speed footswitch to back the leader board out N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position i The main roller nip has now been manually set j Press STOP 0 00 U D GO SPEED U rev SAFETY k On the control panel press FWD A for a forward motor direction
55. operating or servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned End of application 6 9 Encapsulation This application can only be performed from the front of the laminator using the main rollers This application is explained in detail using the main rollers at the front operating position ofthe laminator Use Chart 11 and Diagram 11 for assistance O GBC Pro Tech August 1999 Page 6 85 Applications F 160 Operation and Maintenance Manual Materials needed Two rolls of thermal laminate Both rolls should be of equal widths Prints smaller than the laminate Roll of masking tape Utility knife Cutting blade with an enclosed casing e Piece of cardboard film width x 6 Set up a Turn MAIN POWER to ON Refer to Figure 6 9 1 b Press RESET Refer to Figure 6 9 1 Figure 6 9 1 MAIN POWER RESET MAIN POWER c Ensure that the rear pull rollers are in the up position d Raise the front and rear safety shields N WARNING Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED e Lift the clevis pin located in the saddle of the upper unwind shaft Saddle Clevis pin f Swing the upper unwind shaft out enough to slide the roll of laminate over the core chucks on the upper unwind shaft Refer
56. other side Refer to Figure 6 8 6 Figure 6 8 6 Align edges d Align two sides Leading edge Substrate INFORMATION The leading edge is the first part of the board or image that enters the nip of the rollers Page 6 80 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications b Is the decal compatible with the substrate c Peel back about 1 in of the release liner from the decal and fold back Refer to Figure 6 8 9 If the substrate is larger than the decal you can position the image any where on the board Refer to Figure 6 8 7 Figure 6 8 9 Peel back release liner Leading edge Figure 6 8 7 Setting the decal Release liner Back of Image T 28 d Place a padded paper weight or similar object in the center This will help hold the image in place You must trim the decal so that no more than 1 in exceeds the size of the substrate Refer to Figure 6 8 8 e From the center use one finger to tack down the leading edge ofthe decal to the leading edge of the substrate Refer to Figure 6 8 10 Figure 6 8 8 Trim the decal Figure 6 8 10 Tack leading edge No more than 1 in over hang O GBC Pro Tech August 1999 Page 6 81 Applications F 160 Operation and Maintenance Manual INFORMATION INFORMATION Avoid tacking at the ends first and pressing towards the center you may create a tunnel Use a slow speed If the tack
57. point enters the rollers nip you will not be able to once you have reached the center This will pull the release liner make for a difficult mounting application f Set the substrate and decal in the center of the N CAUTION rear infeed table Speed is controlled through the variable speed footswitch when the safety shield is in the raised position INFORMATION Steps g and h will be performed simultaneously If the tack point enters the rollers nip perform the following steps g Push the leading edge of the substrate with the 1 Press STOP decal up to the nip of the pull rollers 2 Press FWD A 3 Press the variable speed footswitch to back the tack point out of the rollers nip WARNING 4 Press STOP When operating the laminator using the variable speed footswitch keep hands and 5 Press REV V fingers away from the nip of the rollers You may be CRUSHED or BURNED 6 Continue from step i h Using the variable speed footswitch slowly work the substrate into the nip of the rollers and stop just before the end of the tacked down section of the image enters the nip i Drape the loose part of the decal over the upper main roller Refer to Figure 6 8 11 Page 6 82 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications N WARNING When operating the laminator using the variable speed footswitch keep hands and Figure 6 8 11 Draping the deca
58. pressure Check for insufficient pull roller pressure Check the main roller nip settings Check the pull roller nip settings Hints Check operational settings for materials being used problenm Waves omon yoe tHe OPUICOUTUT Problem Indent waves in output after the pull rollers Hints Check the nip setting of main rolls Hints Insufficient cooling time Check the nip setting of pull rolls Allow output to cool before handling Check for even paper tension Check operating temperatures of material Page 7 2 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Troubleshooting 7 2 Film problems The following is alist of common film problems you may encounter For definitions of terminologies please refer to 7 4 Glossary of terminology 7 2 4 Thermal laminates Problem Blistering within the image Hints Increase the speed Decrease the operating temperature e Allow a longer drying time for the image Problem Coiling or curling of encapsulated images Hints Balance the upper and the lower brake tension Make sure set point temperatures are the same Change the chill idler configuration if applicable Problem Silvering in the laminate Hints Decrease the speed ncrease the operating temperature Problem Delamination Hints Check operating temperatures Check operating speed Laminate compatibility with ink nk compatibility with paper 7 2 2
59. roll of material from the upper Finishing unwind shaft a Cut the web of mount adhesive at the upper unwind shaft with an enclosed blade e Press STOP N CAUTION zs FWR Do not use an open blade to cut 00 0 GO t the web near the rollers SPEED U av You can put cuts into the rollers SAFETY aj b Pull the pr ecoated board and trailer board out f Clean the rollers as described in the maintenance from the laminator section Section 8 2 Cleaning the rollers INFORMATION g Lower the front and rear safety shields and press SHUTDOWN if finished with the This will prevent any exposed adhesive from laminator contacting the rollers UE 0 Br __ sav c Raise the main rollers to a 1 in gap by pressing b SHU a N GAP A End of application GAP PRESSURE f O GBC Pro Tech August 1999 Page 6 9 Applications F 160 Operation and Maintenance Manual 6 2 Mounting only This application may be performed from the front of the laminator using the main rollers or from the rear of the laminator using the pull rollers in the event the main rollers are heated This application is explained in detail using the main rollers from the front of the laminator Use Chart 2 and Diagram 2 for assistance N WARNING Do not wear ties loose fitting clothing or dangling jewelry while o
60. safety shield is up speed is determined by the variable speed footswitch If the safety shield is down the speed is controlled through the control panel Panel to Footswitch 1 To switch from Panel mode GO is solid to Footswitch mode GO is flashing with the safety shields in the down position Perform the following steps Press on the variable speed footswitch GO begins flashing identifying Footswitch mode Once the variable speed footswitch is released the rollers will stop To make the rollers turn simply press on the variable speed footswitch INFORMATION When the safety shield is in the lowered position and Footswitch mode is engaged speed is controlled through the control panel Footswitch to Panel 2 To switch from Footswitch mode GO is flashing to Panel mode GO is solid with the safety shields in the down position Perform the following Steps Page5 6 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Operations Press and hold the variable speed footswitch down Press and hold GO for 3 4 seconds before releasing the variable speed footswitch Release the variable speed footswitch Release GO GO should be solid 3 In the event that the safety shield must be raised while the laminator is running Perform the following steps INFORMATION If the variable speed footswitc
61. the raised position adhesive coated boards Method 2 1 4 g iin i a Allow the laminator to cool slightly to no higher than 110 F 43 C N WARNING SLEEP TOP TEMP BOT TEMP Keep hands and fingers clear of i the laminator roller nip when lt 110 lt 110 g adjusting PRESSURE We You can be CRUSHED or BURNED b Set the motion direction toREV V c Using the variable speed footswitch run the adhesive coated boards through the rolls fl FWR 00 0 GO U SPEED REV SAFETY ibo d Do this as many times as needed to clean the laminator rolls O GBC Pro Tech August 1999 Page 8 5 Maintenance F 160 Operation and Maintenance Manual 8 2 1 Clean the cabinets and 8 2 2 Cleaning the touch covers A ELECTRICAL SHOCK Remove power from the laminator before cleaning You can be severely shocked electrocuted or cause a fire a Use a damp cotton terry cloth water only clean the exterior of the laminator b If water is not strong enough you may use a mild dishwashing detergent with water and a cotton terry cloth A ELECTRICAL SHOCK Do not use liquid or aerosol cleaners on the laminator Do not spill liquid of any kind on the laminator You can be severely shocked electrocuted or cause a fire Use only a damp cloth for cleanin
62. the upper main roller and tack it the laminate resting on the upper main roller Refer to Figure 6 9 4 INFORMATION The mount adhesive will adhere to the activated adhesive from the laminate Figure 6 9 4 Lower laminate Thermal laminate Q C E Thermal laminate f Use a piece of cardboard to push the material into the nip of the main rollers N WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED g Press on the variable speed footswitch to guide the cardboard and thermal laminate through the main rollers Page 6 90 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications N CAUTION N WARNING Speed is controlled through the variable Keep hands and fingers clear of the pull speed footswitch when the safety shield roller nip when changing the gap is in the raised position You can be CRUSHED i Once the cardboard has passed through the pull WARNING rollers lower the upper pull roller onto the web Turn the pull roll crank handle 3 4 turn Keep hands and fingers clear of clockwise after you feel the initial contact Refer the laminator roller nip when to Figure 6 9 5 adjusting PRESSURE You can be CRUSHED or BURNED INFORMATION h When the cardboard has traveled pass the main PRESSURE will va
63. to separate the boards GBC Pro Tech August 1999 Page 6 7 Applications F 160 Operation and Maintenance Manual Figure 6 1 5 Trailer board N CAUTION Caution should always be exercised when using a knife Sharp knife can cut you Precoated 9 C Trailer board board o N CAUTION E d dud oe Caution should always be exercised when using a utility knife near the rollers You can put cuts into the rollers m Stop the laminator when the trailer board is in the main roller nip Refer to Figure 6 1 5 k Inform the second person of the last board to be precoated before feeding the trailer board INFORMATION into the main roller nip Refer to Figure 6 1 5 Do not stop in the middle of a board an impression of the roller footprint will be evident on the board This can cause a tunnel effect in the mounting process INFORMATION Before stopping the rollers position the pull rollers up This will prevent an impression n Trim any excess mount adhesive from the in the last pre coated board boards N CAUTION D The second person will raise the rear pull roller b necem ndi wow Caution should always be exercised suman d andie counterclockwise when using a knife Ga a Sharp knife can cut you Page 6 8 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications 321 d Remove the
64. upper unwind shaft swing the upper unwind shaft back into deci iem INFORMATION Twisting the roll of craft paper while sliding makes loading the film onto the unwind shaft easier N CAUTION Ensure the roll of laminate is loaded M ide M ea Vara d D Once the roll of craft paper is on the lower p 5 unwind shaft swing the lower unwind shaft away from the rollers This will prevent hours of roll cleaning Poek miothesaddig h Push the clevis pin back down to secure the INFORMATION unwind shaft in its saddle The roll of craft paper has no preference to side since both sides are the same i Leave the safety shield in the up position m Push the clevis pin back down to secure the unwind shaft in its saddle j Lift the clevis pin located in the saddle of the lower unwind shaft n Center the upper roll and the lower roll of Saddle 7 mE material on the unwind shafts You may refer to S Clevis pin your measurement chart in Section 5 3 2 o 2 Loading film Figure 5 3 4 INFORMATION k Swing the lower unwind shaft out enough to tior the loweramvintehaticada 1 4 Ai slide the roll of craft paper over the core chucks ih maasme e t on the lower unwind shaft Refer to Figure 6 4 2 O GBC Pro Tech August 1999 Page 6 27 Applications F 160 Operation and Maintenance Manual Process a Apply just enough brake tension to prevent the roll of laminate from free spinning INF
65. 1 1 151 66 1 196 91 1 241 116 1 286 141 1 107 41 7 152 66 7 197 91 7 242 116 7 287 141 7 108 42 2 153 67 2 198 92 2 243 117 2 288 142 2 109 42 8 154 67 8 199 92 8 244 117 8 289 142 8 110 43 3 155 68 3 200 93 3 245 118 3 290 143 3 111 43 9 156 68 9 201 93 9 246 118 9 112 44 4 157 69 4 202 94 4 247 119 4 GBC Pro Tech August 1999 Page 6 95 Applications F 160 Operation and Maintenance Manual Parameter Chart Blank MATERIALS UPPER UNWIND SUBSTRATE LOWER UNWIND PRINTS TEMPERATURE TOP TEMP BOT TEMP GAP amp PRESSURE PRESSURE AM MOTOR DIRECTION amp SPEED Somme Panel GO Z Footswitch GO PULL ROLL SETTINGS N A ae UP HC 1 4 Turn PRESSURE Z 1 2 Turn pown 3 4 Turn Page 6 96 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications Web Diagram Blank E f L U E E J T wy v O GBC Pro Tech August 1999 Page 6 97 Applications F 160 Operation and Maintenance Manual Parameter Chart 1 Precoating substrates MATERIALS
66. ETY D Press on the variable speed footswitch to back the board out of the main rollers N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position Process a Align the leading edge of the image with the leading edge of the precoated board and one other side Refer to Figure 6 2 2 Figure 6 2 2 Align edges lt 4 Align two sides Leading edge Pre coated board Page 6 12 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications INFORMATION The leading edge is the first part of the board or image that enters the nip of the rollers b Place a padded paper weight or similar object in the center of the image to help hold the image in place If the pre coated board is larger than the image you must trim the board or make an incision in the release liner so that only the desired amount of release liner is removed Refer to Figure 6 2 3 N CAUTION Caution should always be exercised when using a knife Sharp knife can cut you Figure 6 2 3 Trim the release liner Make a shallow cut into B the release liner F B c Ifthe image is larger you must trim the image so that no more than 1 in exceeds the precoated board all the way around Refer to Figure 6 2 4 Figure 6 2 4 Trim the image Pre coated Boar
67. Electrical Shock conditions A ELECTRICAL SHOCK Indicates an electrical shock situation which 1 1 Symbols INFORMATION Indicates helpful information that should be if not avoided could result in serious paralyzation of the body or death considered before during or after an action step or procedure is given 1 2 Safety features N CAUTION The F 160 laminator 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 laminator before using or servicing the unit 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 O GBC Pro Tech August 1999 Page1 1 Safety F 160 Operation and Maintenance Manual GBC Pro Tech laminators are powerful machines that are designed to mount laminate and encapsulate The forces required to accomplish these tasks can vary from negligible to very large The motorized main roll lift mechanism used to provide downward pressure on the top roll is capable of producing forces greater than 400 pounds This force is applied to any object presented in the opening called the nip between the two rolls Use care in lowering the top laminating roll and know how to react quickly in an emer
68. F 160 OPERATION AND MAINTENANCE MANUAL O November 1999 GBC Pro Tech Do not duplicate without written permission GBC Pro Tech 4151 Anderson Road DeForest WI 53532 Revision B Ph 608 246 8844 Part number 930 031 Fx 608 246 8645 F 160 Operation and Maintenance Manual Read me file Read Me File 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 merchant ability for any particular use GBC Pro Tech reserves the right to make changes to this publication and to the prod ucts 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 publication is copyrighted 1999 by GBC Pro Tech All rights reserved The information contained in this publication is proprietary and may not be reproduced stored transmitted or transferred
69. G The operating environment must be free of dust flammable liquids and vapors You can be injured by inhaling chemical vapors N WARNING Vapor build up or stored flammable liquids can cause a fire Excessive dust can damage the laminator N CAUTION Do not locate the laminator where air is blowing directly on the machine The air flow can cool the rolls unevenly and result in poor quality output O GBC Pro Tech August 1999 Page 4 1 Installation F 160 Operation and Maintenance Manual L The laminator requires 230 to 240 vac 50 60 Hz 55 amps Or in Europe only 3 N phase 220 vac 32 amps per phase N WARNING Be sure to follow the correct wiring diagram when supplying power to the laminator If improperly connected you can be seriously injured or cause damage to the laminator Figure 4 1 2 illustrates proper wiring for single phase for the U S Figure 4 1 3 illustrates proper wiring for Wye 3 phase for Europe N WARNING The Falcon 160 Laminator is a large and heavy piece of equipment It is necessary to employ LICENSED RIGGERS ONLY to move the laminator The laminator 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 You can be crushed or seriously injured Page4 2 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Installa
70. ION When requiring top and bottom heat it is recommended to set both temperatures to the same set point WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP You can be CRUSHED or BURNED INFORMATION Do not add PRESSURE when heating the laminating rollers this allows the high release silicone to expand with minimum INFORMATION restrictions When storing parameters within the JOB SAVE feature of the laminator PRESSURE is not a storable setting Page 1 10 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual N CAUTION If you accidentally press SAVE at any time the old parameters will be replaced with the new parameters INFORMATION You should store each job location with its parameters on the chart provided in Figure 5 4 1 N CAUTION Sharp edges on a substrate should be filed smooth and GAP manually adjusted Sharp edges can CUT the rollers N CAUTION Excess pressure can damage the laminating rollers Always use the minimum roll pressure necessary to complete the task Safety INFORMATION Density of the substrate will determine the amount of pressure you may use INFORMATION If the main laminating rollers are heated mounting application may be run from the rear operating position of the machine N WARNING Keep hands and fingers clear of the pull roller nip when changing the gap You can be CRUSHED
71. L SEL will stop flashing N CAUTION Ensure the roll of laminate is loaded properly on the unwind shaft Ps Exposed adhesive should be facing 108 Q SEE ud away from the rollers This will prevent hours of roll cleaning gt lt SHUT DOWN j Push the clevis pin back down to secure the N unwind shaft in its saddle WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP You can CRUSHED or BURNED k Raise the front safety shield O GBC Pro Tech August 1999 Page 6 3 Applications F 160 Operation and Maintenance Manual N CAUTION Sharp edges on a substrate should be filed smooth and GAP manually adjusted Sharp edges can CUT the rollers N WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED m Press GAP to the required gap setting for the substrate being used The GAP DISPLAY should reflect your desired setting GAP 1 PRESSURE 1 1 4 p INFORMATION If the thickness of the substrate is not known follow the procedure to manually set the nip in Section 5 5 1 Manual nip adjustment n Press FWD A ZR T c FWR 00 0 GO SPEED V Top REV __ SAFETY 0 Press on t
72. L DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE THE EQUIPMENT 2 2 Exclusions to the Warranty This warranty specifically does not cover 1 Damage to the laminating 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 installed castors on even surfaces 3 Improper use of the machine 4 Damage due from unqualified person s servicing the machine O GBC Pro Tech August 1999 Page2 1 Warranty F 160 Operation and Maintenance Manual Qualified Any engineer that has experience with electrical and mechanical design of lamination equipment The engineers should be fully aware of all aspects of safety with regards to lamination equipment Any commissioning or service engineer must be of competent nature trained and qualified to GBC Pro Tech standards to fulfill that job This person will have completed and passed the full service training course from GBC Pro Tech Any GBC Technician GBC Specialist and or GBC Pro Tech Technician that has been through the GBC Pro Tech service training course Page 2 2 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Specifications Section 3 1 General Description ee Midlevel wide format color finisher for the sheet fed ink jet market The Falcon 160 is a self standing bi
73. ON smooth and GAP manually adjusted Sharp edges can CUT the rollers Excessive pressure will cause the substrate to bow or flatten N WARNING Keep hands and fingers clear of the pull roller nip when changing the gap INFORMATION You can be CRUSHED Density of the substrate will determine the amount of pressure you may use g Ateye level with the pull rollers turn the pull roll crank handle clockwise until you see the upper pull roller make contact with the substrate INFORMATION Refer to Figure 5 5 2 for proper roller pressure e DOWN KG GBC Pro Tech August 1999 Page 5 21 Operations F 160 Operation and Maintenance Manual Figure 5 5 2 Pull roller pressure Leader board Proper X pressure EST Leader board Excessive P aii pressure N WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED g Step on the variable speed footswitch to back the leader board out N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position h The pull roller nip has now been manually set i Press STOP 0 00 SPEED SAFETY a p GO ev e Fwr j Press
74. OP GO 20 if FWR SPEED U in rev SAFETY d Press FWD A Ii Ps 00 0 GO SPEED U REV STOP SAFETY INFORMATION Steps e and f will be performed simultaneously Page 6 56 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual N WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED e Push the leader board into the main roller nip while stepping on the variable speed footswitch N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position f Apply the minimum amount of brake tension on the roll of Hot Tissue to prevent it from free spinning INFORMATION Excessive tension will cause the substrate to bow g Have the second person stand at the rear of the laminator O GBC Pro Tech August 1999 Applications INFORMATION Steps h and i will be performed simultaneously N WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED h With the stack of substrates within reach of the first person step on the variable speed footswitch while sliding one b
75. ORMATION Excessive brake tension may cause the image to curl when separated from the craft paper b Pull the laminate to the upper rewind tube Refer to Figure 6 4 3 N CAUTION Make note of the rewind tube drive direction when taping the laminate The laminate should separate under the rewind tube Figure 6 4 3 Laminate to rewind P S A 19 Rewind Laminate tube i s T S c Use a piece of masking tape to adhere the leading edge of the laminate to the upper rewind tube d Wrap one full turn of laminate onto the upper rewind tube N CAUTION Do not cut too deeply into the laminate you can cut into the release liner e With the utility knife make an incision across the width of the laminate N CAUTION Caution should always be exercised when using a knife Sharp knife can cut you f Remove the front infeed table g Pull the laminate straight down toward the front ofthe lower main roller Refer to Figure 6 4 4 Page 6 28 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications Figure 6 4 4 Laminate separation Figure 6 4 5 Craft paper Laminate Laminate CTY Craft paper Remove gt gt mes O INFORMATION h A
76. OWER to the ON position Power b Press RESET The front control panel will illuminated 5 5 Manual nip adjustment Reset If the substrate does not fall with in the preset GAP settings available a manual nip setting must be performed If you are unsure of a substrate thickness it is recommended that you use the manual nip setting procedure N WARNING Caution should always be exercised when using the laminator with If you are performing a mounting application from the rear of the machine the pull rollers must be set manually Refer to Section 5 5 2 Pull roller nip the safety shields raised adjustment procedure You can be seriously HURT or INJURED O GBC Pro Tech August 1999 Page 5 17 Operations F 160 Operation and Maintenance Manual c Raise the front safety shield f At eye level with the main rollers press PRESSURE V until you see the upper main roller make contact with the substrate d Press SEL GAP i PRESSURE o g M Gl JoB Q SHUT DOWN _ Flashing N CAUTION Excess pressure can damage the laminating rollers Always use the minimum roll pressure necessary to complete the task e Position the leader board in the center of the main rollers between the nip INFORMATION N CAUTION Excessive pressure will cause the substrate to bow or flatten Sharp edges
77. Pressure sensitive Problem Silvering in the laminate Hints Add 100 120 F 37 49 C to the temperature Increase pressure to laminating rolls Problem Tunneling Hints Print should be wound image side out Do not roll tightly Do not roll at all Problem Image creases when mounting Hints Press down on leading edge from center outwards Be sure image is conformed to the roll Use a speed you are comfortable with Besure even tension is supplied to the image O GBC Pro Tech August 1999 Page 7 3 Troubleshooting F 160 Operation and Maintenance Manual Problem Delamination Hints Check operating pressures Check operating speed Laminate compatibility with ink Ink compatibility with paper 7 3 Machine problems Once the Hints are all checked and your problem still exists a service call must be placed for a qualified service personnel to fix the problem You may do this by dialing 1 800 790 7787 This will connect you with GBC National Service dispatch You will be required to give the serial number of your machine when placing a service call A space below has been provided to keep this number readily available if and when needed My Falcon 160 Laminator serial number is At no time does GBC Pro Tech suggest or recommend that you attempt to fix the machine by removing the cabinets or leg covers of yourself N WARNING Do not wear ties loose fitting
78. RESET located on the left leg at the rear of the machine Reset The front and rear tables must be in proper position for the laminator to operate under normal condition Figure 1 2 5 illustrates the tables and keys If these tables are removed you may operate the laminator using the variable speed footswitch The speed is controlled through a accelerator pedal style footswitch Please see footswitch in section 3 of this manual Figure 1 2 5 Tables and keys 1 3 Installation The following symbols are positioned at various points in Section 4 Installation N CAUTION Failure to follow the pre installation check list can result in damage to the laminator N WARNING The operating environment must be free of dust flammable liquids and vapors You can be injured by inhaling chemical vapors N WARNING Vapor build up or stored flammable liquids can cause a fire Excessive dust can damage the laminator N CAUTION Do not locate the laminator where air is blowing directly on the machine The air flow can cool the rolls unevenly and result in poor quality output O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual N WARNING Be sure to follow the correct wiring diagram when supplying power to the laminator If improperly connected you can be seriously Safety N WARNING The unpacking process requires at least two people You can be seve
79. REV WY for a reverse motor direction 00 0 SPEED SAFETY U STOP k You may now begin mounting from the rear operating position Page 5 22 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Operations 5 6 Infeed tables Figure 5 6 1 Front edge These tables are part of the Falcon 160 safety Front edge features It is neccessary to have the two infeed tables properly positioned before running the laminator c 5 25 25 r C i N CAUTION If not installed properly you can be injured or cause damage to the table or laminator 5 6 2 Replacing the infeed table a Ensure the safety shiled is in the raised 5 6 1 Removing the table position b With both hands grip the front edge of the A WARNING infeed table and align the back edge with the Caution should always be exercised supportbolis Referte Mere 3 0 4 when using the laminator with the safety shields raised You can be seriously HURT or INJURED Figure 5 6 2 Back edge a Raise the safety shield Front support bolt b With both hands grip the front edge of the infeed table and lift up and then out Refer to Figure 5 6 1 GBC Pro Tech August 1999 Page 5 23 Operations F 160 Operation and Maintenance Manual c Now lower the front edge while ensuring that the pin aligns with the safety roller switch an
80. SHED or BURNED N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position N WARNING SAR TIERE Keep hands and fingers clear of 1 4 TUI I the laminator roller nip when f Press GAP to the required gap setting for the substrate being used The GAP DISPLAY should reflect your desired setting adjusting PRESSURE You can be CRUSHED or BURNED i If the board is loose press PRESSURE V to eee adjust the gap between the main rollers 00 0 co GAP f1 PRESSURE f1 SPEED UJ aa REV 1 4 l TRI SAFETY O GBC Pro Tech August 1999 Page 6 11 Applications F 160 Operation and Maintenance Manual N CAUTION Excess pressure can damage the laminating rollers Always use the minimum roll pressure necessary to complete the task N WARNING When operating the laminator through the variable speed footswitch keep your hands away from the nip of the rollers You may be crushed or burned INFORMATION Excessive pressure will cause the substrate to bow or flatten j Press STOP 00 0 1 wi SPEED U D REV SAFETY k Press REV WV to reverse the direction of the motor FWR 00 0 Go SPEED REV STOP SAF
81. STOP The bottom rollers stop turning 19 SPEED SAFETY he Fwr rev D q Press SPEED V once SPEED DISPLAY decreases in increments of 5 per press down to 00 0 FWR 00 0 GO i SPEED rev SAFETY wr Page 4 20 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Installation r The TOP TEMP DISPLAY and BOT TEMP u Press SHUTDOWN The laminator reverts to DISPLAY are solid indicating the actual the default settings and SLEEP is solid Refer temperature is within a 10 F of the set point to Figure 4 8 1 temperature t SLEEP Jon 0 SEL SAV TOP TEMP 4 BOT TEMP f1 120 p 120 E J U Figure 4 8 1 Default settings WARNING Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED P SLEEP TOP TEMP z BOTTEMP id v s Raise the front safety shield remove the front GAP lt PRESSURE 7 infeed table and touch the two main rollers They should feel warm to the touch 1 AI M ur 0
82. TEMP BOT TEMP 120 120 5 c Press GAP V once GAP DISPLAY decreases 1 16th of an inch per press The upper main roller moves accordingly Once to 0 the upper main roller is contacting the lower main roller GAP 1 PRESSURE 1 d Press GAP A GAP DISPLAY increases 1 16th of an inch per press The upper main roll moves accordingly Once to 1 the upper main roller stops GAP PRESSURE ial e Press and hold PRESSURE WV The upper main roller travels in a constant downward motion Once making contact with the lower main roller the bars turn solid one at a time until all 10 bars are solid EE a f Press and hold PRESSURE s The upper main roller travels in a constant upward motion The pressure bars turn hollow one at a time until no bars are solid and GAP DISPLAY changes to 1 then stops vus E Page 4 18 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Installation g Press JOB A The JOB DISPLAY should increases in increments of 1 to 9 INFORMATION To continue with the function checks you must press SEL so that it discontinues ia flashing SEL SAV JoB Q Vv SHUT DOWN j Press SPEED A once SPEED DISPLAY increases in increme
83. TOP GO stops flashing 6 0 fT rwn SPEED U nEv SAFETY 4 7 23 Front and rear safety shields a Press GO The bottom rollers begin turning 6 0 0 GO SPEED l SAFETY N WARNING Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED b Raise the front safety shield SAFETY indicator and GO begin flashing and the bottom rollers stop 6 0 SPEED ane Wi SAFETY GO ii wi V Bj Flashing h Lower the front safety shield SAFETY indicator reverts to white and GO remains flashing Bj Flashing i Press STOP GO stops flashing 6 0 UG mt GO SPEED U REV SAFETY Page 4 14 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Installation j Press GO The bottom rollers begin turning I Lower the rear safety shield SAFETY indicator reverts to white and GO remains flashing Iii wri ND run fl 6 0 GO 6 0 GO SPEED y nEv SPEED y nEv STOP AIR SAFETY SAFETY Bj Flashing m Press STOP GO stops flashing WARNING
84. Tech August 1999 Page 6 15 Applications If itis not slowly move the board into the nip until the image is conformed Refer to Figure 6 2 9 N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position Figure 6 2 9 Non conformed print F 160 Operation and Maintenance Manual D Press down on the variable speed footswitch just enough to give yourself a comfortable work speed N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position N WARNING When the laminator rollers are in motion keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED INFORMATION Steps and m will be performed simultaneously N WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED Page 6 16 m Use one hand to pull the release liner off as the substrate moves towards the nip and the other hand to apply slight back tension to the decal n Once the board and the image are completely through the main rolls let off the variable speed footswitch 0 The mounted image can now be removed from the rear of the laminator O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications UH 6 3 Single sided lam
85. aised position INFORMATION The laminate will not adhere to the release liner of the precoated board which makes the board reusable j Apply the minimum amount of brake tension on the roll of laminate to prevent it from free spinning Refer to Figure 6 3 5 N WARNING INFORMATION When operating the laminator using the variable speed footswitch keep hands and Excessive brake tension may cause the fingers away from the nip of the rollers image to curl when separated from the You may be CRUSHED or BURNED precoated board O GBC Pro Tech August 1999 Page 6 23 Applications F 160 Operation and Maintenance Manual m Press on the variable speed footswitch Finishing a Cut the web of laminate at the upper unwind shaft with an enclosed blade CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position CAUTION Do not use an open blade to cut the web near the rollers You can put irreparable cuts into the rollers AN WARNING When the laminator rollers are in motion keep hands and fingers b Raise the main rolls to a 1 in gap by pressing away from the nip of the rollers GAP A You may be CRUSHED or BURNED GAP 4 PRESSURE 17 n Once the image passes through the main rollers itis safe to release the variable speed footswitch c Pull the material out the front of the laminator
86. al and workmanship for a period of one 1 year parts and 90 days labor from the date of installation This warranty is the only warranty made by GBC Pro Tech and connot 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 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 fire accident flood or other hazard 2 1 Limited Warranty 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 one year period from the date of delivery N 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 CONSEQUENTIA
87. and Maintenance Manual Safety INFORMATION N WARNING Do not wear ties loose fitting clothing or dangling jewelry while operating or The side frame provides a more accurate reading than the cabinet servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned INFORMATION A second person can read the level while you N WARNING make the appropriate adjustments If you find a safety feature not working properly you should contact your local service representative immediately N WARNING Caution should always be exercised INFORMATION when using the laminator with the safety shields raised You can be seriously HURT or INJURED Do not put packing screws on the floor They can cause problems when trying to roll the laminator into position N WARNING Keep hands and fingers clear of the INFORMATION laminator roller nip when changing GAP You can be CRUSHED or BURNED The SAFETY indicator should not be flashing when the tables are properly seated and the safety shields are in the closed position O GBC Pro Tech August 1999 Page1 7 Safety INFORMATION Notice that the footswitch speed is not indicated in the SPEED DISPLAY on the front control panel 1 4 Operations The following symbols are positioned at various points in Section 5 Operations INFORMATION Read the following warnings and cautions before attempting to op
88. andle counter clockwise until the pull rollers are separated f Remove the front infeed table g Cut the web of laminate and craft paper at the upper and lower unwind shafts with an enclosed blade N CAUTION Do not use an open blade to cut the web near the rollers You can put cuts into the rollers O GBC Pro Tech August 1999 Page 6 33 Applications F 160 Operation and Maintenance Manual h Remove the web from the front of the laminator and the rolls of material from the upper and 6 5 Decal and mount lower unwind shafts This application may be performed from the INFORMATION front of the laminator using the main rollers or from the rear of the laminator using the pull rollers in the event This will prevent any exposed adhesive from the main rollers are heated This application is explained contacting the rollers in detail using the main rollers from the front of the laminator This is a two pass mount and laminate process Two pass meaning that the print will pass through the laminator twice The first pass Decal will apply a mount adhesive to the back of the print while applying a laminate to the front of the print Use Chart 5 and Diagram 5 for assistance The second pass Mount will adhere the decal to a substrate Use Chart 6 and Diagram 6 for assistance i Clean the rollers as described in the maintenance section Section 8 2 Cleaning the rollers j Replace the front infeed
89. ase liner f Set the substrate and decalin the center of the front infeed table Back of Image g Press STOP d Place a padded paper weight or similar object inthe center This will help hold the image in place 9 0 GO ewe SPEED l D rev SAFETY e From the center use one finger to tack down the leading edge of the decal to the leading edge of the substrate Refer to Figure 6 5 11 h Press FWD A Figure 6 5 11 Tack leading edge 9 0 GO bi SPEED 44 REVI STOP SAFETY O GBC Pro Tech August 1999 Page 6 47 Applications F 160 Operation and Maintenance Manual INFORMATION Steps j and k will be performed simultaneously j Push the leading edge of the substrate with the decal up to the nip of the main rollers N WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED k Using the variable speed footswitch slowly work the substrate into the nip of the rollers and stop just before the end of the tacked down section of the image enters the nip INFORMATION Use a slow speed If the tack point enters the rollers nip you will not be able to pull the release liner N CAUTION Speed is controlled through the variable speed footswitch whe
90. can be seriously HURT or INJURED N WARNING At these temperatures there is a danger ofsevere burn if the rolls are touched duringsetup operation or servicing INFORMATION When a safety shield is raised while pressing on the variable speed footswitch the speed may be faster or slower than the indicated panel speed INFORMATION When an EMERGENCY STOP is engaged all motion stops The nip will not change from the operating setting INFORMATION When the safety shield is raised the laminator will only run while the variable INFORMATION speed footswitch is depressed Twisting the roll of film while sliding makes loading the film onto the unwind shaft easier O GBC Pro Tech August 1999 Page1 9 Safety F 160 Operation and Maintenance Manual INFORMATION N CAUTION Sonet voll ot lamiiateie waded Slow speed will assists with heat up times properly on the unwind shaft and distributes heat evenly Exposed adhesive should be facing away from the rollers This will prevent hours of roll cleaning INFORMATION When the laminator is first turned on the front control panel will go into the default INFORMATION mode For the lower unwind shaft add 1 4 in to the measurement Default mode TOP TEMP 68 F 20 C BOT TEMP 68 oF 20 oC GAP 1 in PRESSURE no bars are solid JOB 0 no motion direction selected SPEED 00 0 and SLEEP flashing INFORMAT
91. ceecesesessssssso 3 3 Section 4 Installation 4 1 Preinstallation check list oeooosssoeseoessssssoessosssssossesssssssoossosssssossossssssssse 4 1 Figure 4 1 1 Suggested floor layout ssssssssossooooccocsoooeseeeeeesese 4 3 Figure 4 1 2 Single phase U S essessccsssssssssooccccccceccesssesoooosee 4 4 Figure 4 1 3 Three phase Europe sssecssecscssssssssoccooeeceseseoososeee 4 4 LRPANUDEIdsu peer 4 5 Page II O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Table of Contents zs edid dr 4 5 LE EB RT M M 4 6 4 5 Accessory pack content iiec eec treten eee ee ee ce ee tomo ee nuoto sua ace ce euo o uen ns 4 8 4 6 Develme 4 5 ni rps en orn tte SUIS cedens eue susp eS en 4 8 4 7 Safety check 5 2 e trie qu oho SEE RE oe 9 SEGUE F3 034208 Seg e c ee ten eerie lacia geeke Eee 4 11 4 7 1 Front and rear infeed tables cs sccssscsscasecssssssscessssecedacssesesseacsosscsnasscteoosens 4 12 4 7 2 Front and rear safety shields esesssessssscossssssscccccsssssossssssssssssssessse 4 14 4 7 3 Emergenty Stops ct m 4 15 o guinis M 4 17 4 8 1 Control panel p 4 18 Figure 4 8 1 Default settings ccccssssssssssssscccccccscscsecoeooes 4 21 4 8 2 Variable speed footswitch ccsscsssssscccccccccccccesscssssssssssssssssccsceees 4 22 4 8 3 Unwind shafts and unwind brakes
92. ch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED Page 6 44 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications e Press on the variable speed footswitch while guiding the leader board into the nip to confirm that the board is secure INFORMATION Excessive pressure will cause the substrate to bow or flatten N CAUTION Speed is controlled through the variable speed footswitch when the safety shield g Press STOP is in the raised position Z wi 00 0 GO WARNING ere A rev SAFETY j Keep hands and fingers clear of the laminator roller nip when adjusting PRESSURE You can be CRUSHED or BURNED h Press REV V to reverse the direction of the motor f If the board is loose press PRESSURE V to adjust the gap between the main rollers GO rwn 00 0 SPEED GAP f1 PRESSURE f1 SAFETY STOP lh V4 9 MI N WARNING N CAUTION When operating the laminator using the variable speed footswitch keep hands and Excess pressure can damage the laminating fingers away from the nip of the rollers rollers Always use the minimum roll You may be CRUSHED or BURNED pressure necessary to complete the task O GBC Pro Tech August 1999 Page 6 45 Applications F 160
93. cking procedure that pertains to your method of shipment c With another person carefully wheel your F 160 Laminator to the installation site N WARNING N WARNING Do not attempt to move the laminator across anything other than a flat level surface without trained and qualified riggers You can be crushed or seriously injured The unpacking process requires at least two people You can be severely injured crushed or cause damage to the laminator O GBC Pro Tech August 1999 Page4 5 Installation F 160 Operation and Maintenance Manual 4 4 Crated Figure 4 4 1 Disassembling of the crate Tools required e 2 Phillips head screwdriver 7 8 open end wrench or adjustable wrench Crow bar second person To uncrate the laminator a Remove the top of the crate and then the sides in the order shown in Figure 4 4 1 N CAUTION Do not allow the top to fall into the crate It can damage the laminator Removing the shrink wrap INFORMATION a Gently unwrap the shrink wrap from around the laminator N CAUTION Do not use a knife or other sharp object to CAUTION remove the shrink wrap from around the laminator You can cause irreparable Ca MS Do not put packing screws on the floor They can cause problems when trying to roll the laminator into position or you can become injured if stepped on A second person must support the side damage to the rollers labeled 5 i
94. cleaning the beads of adhesives dust and dirt from the rolls c With the rubber gloves on clean the rolls using a moderate amount of 8096 isopropyl Mi et h od I alcohol on a cotton terry cloth a Allow the laminator to cool slightly to no higher than 110 F 43 C CAUTION Exercise care when cleaning the laminating rollers with 80 isopropyl alcohol SLEEP TOP TEMP z BOT TEMP A e Use only in a well ventilated area Wear rubber gloves 110 110 i e Use only on cool rolls Bn A CLEANING HEATED ROLLERS CAN IGNITE THE FUMES b Set the motion direction to REV V jl Fwr A EARNING 00 0 Go SPEED li REV When operating the laminator using the SAFET STOP a variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED Page 8 4 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Maintenance d Since the safety shields are raised and the tables removed you must use the footswitch to rotate the bottom rollers after cleaning a WARNING section Keep hands and fingers clear of the laminator roller nip when changing GAP You can be CRUSHED or BURNED N CAUTION Speed is controlled through the variable speed footswitch when the safety shield b Setthe nip of the rollers to the thickness of the is in
95. clothing or dangling jewelry while operating or servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned Problem No illumination to the control panel Hints Ensure an E stop has not been pushed down Press RESET Confirm that the MAIN POWER is to the on position Besure power is supplied to the laminator Problem I can only operate in Footswitch mode Hints Be surethe tables are properly seated in the table brackets Be sure the safety shields are in the down position e Ifthe SAFETY indicator is flashing place a service call Problem I press GO it will always be flashing Hints Be surethe tables are properly seated in the table brackets Be sure the safety shields are completely in the down position Page 7 4 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Troubleshooting Problem I press GO and the rolls will not turn Hints Be sure a speed has been entered Make sure a motion direction has been selected Make sure GO or SEL is not flashing Problem Jerking stuttering or excessive noise from the laminator Hints Check for excessive brake tension Confirm that the rolls of laminate are on correctly Place a service call Rolls in the up position Problem The control panel is locked up Hints Push the blue reset button Press an E stop then unlatch the E sto
96. ction 8 2 Cleaning the rollers O GBC Pro Tech August 1999 Page 6 59 Applications F 160 Operation and Maintenance Manual e Lower the front and rear safety shields and press SHUTDOWN if finished with the laminator SEL SAV JOB M vie f Trim any excess Hot Tissue from the boards N CAUTION Caution should always be exercised when using a knife Sharp knife can cut you End of application 6 7 One pass mount and laminate This application can only be performed from the front ofthe laminator using the main rollers Use Chart 8 and Diagram 8 for assistance This application can save time but is limited to the type of prints you can use This process requires more heat and a longer dwell time in the nip Heat sensitive images should not be used for this process Heat sensitive images would be of ink jet types and medias that have plastic characteristics to them For these type of images use GBC Low Melt film or comparable laminate N WARNING Do not wear ties loose fitting clothing or dangling jewelry while operating or servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned Materials needed Sheet of Hot Tissue Mount adhesive or comparable material e Substrates Must have a porous surface Page 6 60 O GBC Pro Tech August 1999 F 160 Operation an
97. d No more than 1 in over hang c Peel back about 1 in of the release liner from the precoated board and fold back Refer to Figure 6 2 5 Figure 6 2 5 Peel back release liner Leading edge Release liner LANG Pre coated board O GBC Pro Tech August 1999 Page 6 13 Applications F 160 Operation and Maintenance Manual d From the center use one finger to tack down f Press STOP the leading edge of the image to the leading edge of the precoated board Refer to Figure 6 2 6 00 0 i wal SPEED U i REV SAFETY INFORMATION The leading edge is the first part of the board or image that enters the nip of the rollers g Press FWD A igure 6 2 6 Tack leading edge P 00 0 GO SPEED V rev STOP SAFETY h Push the leading edge of the precoated board up to the nip of the main rolls INFORMATION AN WARNING When operating the laminator using the Avoid tacking at the ends first and pressing Gartable speed tootswitch keep hands and towards the center you may create a tunnel fingers away from the nip of the rollers You may be CRUSHED or BURNED once you have reached the center This will make for a difficult mounting application i Using the variable speed footswitch slowly e Set the precoated board with the image tacked wore rocoto post into iHe nipoith
98. d the back support bolt Refer to Figure 5 6 3 INFORMATION If the tables are not properly seated the laminator will not operate in Panel mode Figure 5 6 3 Safety roller switch Safety roller switch Back support bolt Page 5 24 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications Section 6 Applications To assist you with a variety of web ups please refer to the process control charts and diagrams Process control charts allow you to record the way you thread film through the machine s rollers called webbing and the control settings for each application with regards to your products This section contains a blank process control chart and diagram for the Falcon 160 as well as completed charts and diagrams for the basic operations of the laminator It is recommended that you make copies of the blanks and fill them in as needed N WARNING Do not wear ties loose fitting clothing or dangling jewelry while operating or servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned The procedures and parameters described in this section are reference points only Parameters will vary with regards to laminate thickness laminate widths laminate types print types ink or toner types environment conditions operator experience and various substrates Group 1 No heat No heat applications do not re
99. d Maintenance Manual Installation Section 4 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 Falcon 160 Laminator is properly and securely unpacked moved and installed Before a Falcon 160 Laminator can be installed there are a few requirements that must be met Make certain that each of the requirements listed in the following pre installation checklist are met before beginning installation N CAUTION Failure to follow the pre installation check list can result in damage to the laminator 4 1 Pre installation L Are doorways and hallways wide eneough for the laminator to be moved to the installation site Is there ample room for the laminator A work area must be established that allows for operation in both the front and rear of the laminator and provides space for efficient material flow Figure 4 1 1 illustrates a typical machine area layout Is the environment appropriate for the laminator The laminator 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 L Have you contacted a certified electrician to both wire the laminator and ensure that adequate power is being supplied having the appropriate capacity over current protection and safety lockouts are available N WARNIN
100. d Maintenance Manual Applications Leader and trailer board Roll of thermal laminate e Glue stick INFORMATION Prints print that are not heat sensitive The two pieces cut in step a will be e Utility knife used as the leader board and trailer Cutting blade with an enclosed casing board These two pieces can be saved and reused for other applications INFORMATION c Turn MAIN POWER to ON Refer to The laminate must not exceed 1 in the Figure 6 7 1 width of the substrate If it does you will experience complications with this application d Press RESET Refer to Figure 6 7 1 Set up e Be sure the front and rear tables are in position and the pull rollers are in the up position a Cut two leader boards 6 inch in length of the material you are about to precoat f Raise the rear safety shield N CAUTION Sharp edges on a substrate should be filed smooth and GAP manually adjusted Sharp edges can CUT the rollers WARNING Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED b Place these two pieces by the laminator for future use GBC Pro Tech August 1999 Page 6 61 Applications F 160 Operation and Maintenance Manual Figure 6 7 1 MAIN POWER RESET MAIN POWER g Lift the clevis pin located in the saddle of the upper unwind shaft Saddle Ww Clevis pin
101. d the nip between the two rolls Use care in lowering the top laminating roll and know how to react quickly in an emergency The main laminator roll up down keys are located on the right side of the machine within the front control panel These keys control the up down gap motion of the top main laminating roller Before pressing the down arrow key ensure that nothing is in the nip area In addition the main laminating rolls of the F 160 can reach temperatures over 200 F 939C N WARNING At these temperatures there is a danger ofsevere burn if the rolls are touched duringsetup operation or servicing Page 5 10 Reacting to an emergency situation a In the event of an emergency press one of the two E STOP located on the top of the drive side and control side cabinets The control panel display will go blank INFORMATION When an EMERGENCY STOP is engaged all motion stops The nip will not change from the operating setting b Resolve the emergency situation c Reset the E STOP by rotating 1 4 turn counter clockwise The E STOP will unlatch Refer to Figure 5 2 1 Figure 5 2 1 Emergency stop O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Operations d Press RESET at the rear of the machine on the drive side Please refer to Figure 5 2 2 5 3 Set up Figure 5 2 2 RESET l Initial setup of the Falcon 160 laminator is easily attained when instructions are foll
102. ddle of the upper unwind shaft c Swing the unwind shaft out enough to slide the roll of laminate over the core chucks and onto the unwind shaft Refer to Figure 5 3 2 INFORMATION Twisting the roll of film while sliding makes loading the film onto the unwind shaft easier Figure 5 3 2 Unwind shaft Brake adjust knob Saddle Core support jo 5 f Roll of laminate O krs Core chucks Aca Clevis pin d Onceloaded swing the unwind shaft back into the saddle N CAUTION Ensure the roll of laminate is loaded properly on the unwind shaft Exposed adhesive should be facing away from the rollers This will prevent hours of roll cleaning Page 5 12 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Operations e Push the clevis pin back down to secure the Figure 5 3 4 Measurement chart unwind shaft its saddle f Now you must center the roll of laminate on the Common film widths unwind shaft Refer to Figure 5 3 3 for measurements For centering measurements refer to Figure 5 5 4 g For the lower unwind shaft repeat steps b through f again Figure 5 3 3 Centering the roll Y PN e I yununu TRA INFORMATION Make sure Measure from the laminate the side frame is flush with to the edge of Fo
103. e 4 6 Leveling Leveling of the laminator is very important in the way the machine performs Leveling is crucial to the tram tracking of the materials through the machine INFORMATION Improper leveling will result in poor output quality Tools required Torpedo level 2 3 4 open end wrenches Four leveling pads from the accessory pack Second person Preparation a Verify that the laminator has sufficient room around it to load film walk around and serviced if necessary Page4 8 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Installation b Attach one leveling pad to each one of the four b Level the control side from front to back foot bolts near the castors Refer to Figure 4 6 1 Figure 4 6 1 Foot bolts INFORMATION A second person can read the level while you make the appropriate adjustments Position the level on the top of the drive side frame Not on the cabinet A T Foot bolts T d Level the drive side from front to back ae Y Leveling pads 7 Figure 4 6 2 Front to back Lock the castors in place to prevent the laminator from rolling while leveling Leveling a Position the level on the top of the control side frame Not on the cabinet Refer to Figure 4 6 2 INFORMATION The side frame provides a more accurate reading than the cabinet
104. e laminator ibe 0 set __ sav y EE End of application O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications Group 2 Top heat only Top heat only applications are very similar to the applications described in Group 1 No heat Thermal type heat activated laminating film will replace the pressure sensitive type laminating film used in Group 1 No heat The procedures and parameters described in this section are starting references only Parameters will vary with regards to laminate thickness laminate widths laminate types print types ink or toner types environment conditions operator experience and various substrates N WARNING Do not wear ties loose fitting clothing or dangling jewelry while operating or servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned 6 6 Precoating substrates This application can only be performed from the front ofthe laminator using the main rollers Use Chart 7 and Diagram 7 for assistance Materials needed Roll of Hot Tissue Mount adhesive or comparable material e Substrates to precoat Must have a porous surface Leader board Trailer board Second person Utility knife Cutting blade with an enclosed casing INFORMATION The Hot Tissue must not exceed 1 in the width of the substrate If it does you wil
105. e uM rollers Stop just before the end of the tacked to itin the center of the front infeed table l down section of the image enters the nip Page 6 14 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications INFORMATION Use a slow speed If the tack point enters the rollers nip you will not be able to pull the release liner If the tack point enters the rollers nip perform the following steps then continue with this procedure 1 Press STOP 2 Press REV V 3 Press on the variable speed footswitch to back the tack point out of the rollers nip 4 Press STOP 5 Press FWD A 6 Continue from step i N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position j Drape the loose part of the image over the upper main roller Refer to Figure 6 2 7 Figure 6 2 7 Draping the image Image ae Release liner Pre coated board ua k Make sure the image is conformed to the upper main roller Refer to Figure 6 2 8 INFORMATION If the image is not conformed to the roller you may experience difficulties with this application Figure 6 2 8 Conformed print Conformed AN WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED GBC Pro
106. e 4 1 3 Wye 3 phase Europe only TB 2 D TBA D l Ove Ol E nee Il Cole co P OR Eldo De C J eoo leis N2 Cole Co O00 OPO 4l uw clle co f iia r ese Galo Incoming line voltage L3 2 C 6 cJ o Correct Configuration Page4 4 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Installation 4 2 Unp acking With regards to your shipping methods use one of the following procedure described to safely and INFORMATION properly unwrap uncrate your laminator ALL SHIPMENTS ARE EX WORKS At our 4 3 Shrink Wrapped 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 a Inspect the machine for any obvious shipping damages upon receipt INFORMATION 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 note of this on the Bill of Lading CAUTION b Carefully unwrap the shrink wrap from around the laminator Do not use a knife or other sharp object to remove the shrink wrap from around the laminator You can cause irreparable INFORMATION damage to the rollers Depending on the destination and customer preference the Falcon 160 may be shipped in various ways The laminator may arrive shrink wrapped or in a plywood crate on a skid Please follow the unpa
107. e 6 8 5 around the lower rewind tube INFORMATION N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position If you choose to use the lower rewind tube make note of the direction of travel Figure 6 8 5 Finish product rewind D Replace the front infeed table Ensure that the table is seated properly m Close the front and rear safety shields INFORMATION The SAFETY indicator should not be flashing when the tables are properly Finished product seated and the safety shields are in rewind the closed position Cut the piece of cardboard off n Press STOP N WARNING When operating the laminator using the A wri variable speed footswitch keep hands and 00 0 GO fingers away from the nip of the rollers SPEED l REV You may be CRUSHED or BURNED SAFETY si Page 6 76 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications 0 Press SPEED A to a speed you feel s Press GAP A toa 1 in setting comfortable working with It is recommended that SPEED not exceed 5 ft min 1 52 m min GAP M PRESSURE 17 id MOI 9 0 um wI SPEED lt gt REV SAFETY TIEN Finishing
108. e 8 1 Maintenance F 160 Operation and Maintenance Manual 8 2 Cleaning the rollers Tools required Adhesive coated boards picks up dust and particles off of the rolls Protective rubber gloves This will protect your hands from the isopropyl alcohol e 80 isopropyl alcohol amild dishwashing detergent and water may be used instead Rubber cement eraser a belt sander dressing block may be used instead e Several 100 cotton terry cloths best for lint free cleaning Preparation of the laminator a Turn the MAIN POWER to the ON position Power b Press RESET The front control panel will illuminated Reset c Press SEL iili p deg 0 SEL SAV M SHUT DOWN _ Flashing N WARNING Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED d Open the front and rear safety shields e Remove the front and rear tables Page 8 2 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Maintenance INFORMATION Removing adhesive build up When cleaning the bottom main roller switch the motion direction to reverse When cleaning the bottom pull roller a For pressure sensitive adhesives put on the rubber gloves and use isopropyl alcohol and a terry cloth towel switch the motion direction to forward This wil
109. e bot ebat un eee deee 7 4 Page VIII GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Table of Contents We B EISA a qe 7 5 Section 8 Maintenance 8 1 Maintenance schedule sesecsecssssseststssssaccasessssessscovasensannstesnessaceseveneesenesssaresss 8 1 8 2 Cleaning the rollers o ceeeera e e eot aor iore Eve oe ee Due piu ae e es ee aa eens 8 2 8 2 1 Cabinets and COVEES 5i esit pie EY II A RNV d nup P PIDE EIS 8 6 8 2 2 Touch screen control panel creer eee eI ree see een ee coser eere e ne rrec 8 6 O GBC Pro Tech August 1999 Page IX Table of Contents F 160 Operation and Maintenance Manual This page is intentionally left blank Page X GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Safety Section 1 Safety AN anna Indicates a potentially hazardous situation CAUTION which if not avoided could result in serious injury Do not attempt to operate your Falcon 160 laminator until you have read this section carefully Your safety as well as the safety of others is A DANGER important to GBC Pro Tech This section contains i Indicates an imminently hazardous situation important safety information y which if not avoided could result in death or serious injury The following symbols are used throughout this manual to indicate Information Caution Warning Danger and
110. e laminator b The decals are now ready to be trimmed y After the last print has passed through the pull c If you used the lower rewind remove the rollers press STOP rewind tube and bring it to a trimming station Replace the rewind tube when finished FWR 9 0 i GO t SPEED UJ REV l d Raise the front and rear safety shields to the up SAFETY sls position Page 6 42 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications A WARNING Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED e Raise the pull roller up by turning the crank handle counter clockwise until the pull rollers are separated f Remove the front infeed table g Cut the web of laminate and craft paper at the upper and lower unwind shafts with an enclosed blade N CAUTION Do not use an open blade to cut the web near the rollers You can put cuts into the rollers h Remove the web from the front of the laminator and the rolls of material from the upper and lower unwind shafts INFORMATION This will prevent any exposed adhesive from contacting the rollers i Clean the rollers as described in the maintenance section Section 8 2 Cleaning the rollers INFORMATION If the rollers have no adhesive on them proceed to the second pass of this applicatio
111. e rollers You may be CRUSHED or BURNED If its not slowly move the substrate into the nip until the decal is conformed Refer to Figure 6 5 14 n Press down on the variable speed footswitch just enough to give yourself a comfortable work speed O GBC Pro Tech August 1999 Page 6 49 Applications F 160 Operation and Maintenance Manual N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position N WARNING When the laminator rollers are in motion keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED 0 Use one hand to pull the release liner off as the substrate moves towards the nip and the other hand to apply slight back tension to the decal p Once the substrate and the decal are completely through the main rolls you can let off the variable speed footswitch q The mounted image can now be removed from the rear of the laminator r Trim the mounted piece as necessary Page 6 50 Finishing a Press STOP T wri 9 0 GO SPEED gi REv SAFETY b Press GAP A toa 1 in setting GAP PRESSURE f c Clean the rollers as described in the maintenance section Section 8 2 Cleaning the rollers d Lower the front and rear safety shields and press SHUTDOWN if finished with th
112. e thickness When requiring top and bottom heat it is and width of the laminate you are using recommended to set both temperatures to Adjust as necessary the same set point INFORMATION INFORMATION The leading edge is the first part of the board or image that enters the nip of the rollers If the main laminating rollers are heated mounting application may be run from the rear operating position of the machine INFORMATION Position the leader board squarely onto the mount adhesive INFORMATION Do not add PRESSURE when heating the laminating rollers this allows the high release silicone to expand with minimum restrictions N CAUTION Prolonged contact can form flat spots on the rollers INFORMATION Slow speed will assists with heat up times and distributes heat evenly N CAUTION mee big When manually setting the main roll nip observe the substrate to prevent crushing Page 1 14 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual INFORMATION Avoid tacking at the ends first and pressing towards the center you may create a tunnel once you have reached the center This will Safety AN WARNING Keep hands and fingers clear of the pull roller nip when changing the gap You can be CRUSHED make for a difficult mounting application INFORMATION If the board is not squarely positioned you may experience difficulties with this application
113. ead me file F 160 Operation and Maintenance Manual This page intentionally left blank GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Table of Contents Table of Contents Section 1 Safety 1 1 Symbolsc22 5n ertet IE I IE ieu niet i 1 1 1 2 Safety features oin Ie rer uten ne eee tone obras qekoot nesnese sitsen ow e tasse nueces 1 1 Muir M 1 4 1 4 Operations vices E ee eta eae 1 8 1 5 Apple at lonis cerno eei due eee ere eio ede keen 2e e coe ceux cc cn UE He ehe va save esde 1 12 1 6 nnb dini TS 1 16 1 7 Ni aIMCCN ANCE M 1 16 1 8 Decal Explanation 2 oce tectis eere eo etre one ea Date ee eats 1 19 Figure 1 6 Decal Location ccccsssssssssssssssccccsssssssssees 1 20 Section 2 Warranty 2 1 Limited warranty information eee e eee ee eee eee ettet tete esee eeeesoooo 2 1 2 2 Exclusions to the warranty eie eee eere teen e rennen tana n eura vana una e ausu eeu u 2 1 O GBC Pro Tech August 1999 Page I Table of Contents F 160 Operation and Maintenance Manual Section 3 Specifications Do Meme al EE A A E E R R ET 3 1 3 2 C ONSUMADIES e eesin erissa aiaia 3 1 RRS DIRILAN E 3 2 Doh A D LEN a L 1 EEE E E A EET 3 2 3 5 Dimensi ns asiss cdccsssesznvsacctsecasaessnccecsesscesnasssasecoavsedscesuasoadosdsnssaeseesadccsuacsasts 3 3 Figure 3 5 1 Dimensions ssssooosssssssecccecocceeoooooossessse
114. eces can be saved upper unwind s and reused for other applications Saddle c Turn MAIN POWER to ON Refer to N Clevis pin Figure 6 1 1 O C d Press RESET Refer to Figure 6 1 1 o e Be sure the front and rear tables are in position and the pull rollers are in the up position h Swing the upper unwind shaft out enough to slide the roll of mount adhesive over the core chucks and onto the upper unwind shaft Refer f Raise the rear safety shield to Figure 6 1 2 N WARNING INFORMATION Caution should always be exercised Twisting the roll of laminate while sliding when using the laminator with makes loading the film onto the unwind the safety shields raised shaft easier You can be seriously HURT or INJURED Page 6 2 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications N WARNING Caution should always be exercised Figure 6 1 2 Unwind shaft rl when using the laminator with the safety shields raised A LA You can be seriously HURT or INJURED lt Roll of adhesive NT M INFORMATION Brake adjust z knob 17 Core chucks Core support If you have the parameters stored as a 0 JOB number enter it now then press SEL and skip to step o other wise continue with step i Once loaded swing the upper unwind shaft back into the saddle D Press SE
115. ech August 1999 F 160 Operation and Maintenance Manual Figure 6 6 2 Unwind shaft e A LA Roll of Core support Hot Tissue I NA is e 4 Core chucks m i Once loaded swing the upper unwind shaft back into the saddle INFORMATION The roll of Hot Tissue has no preference to side since both sides are the same j Push the clevis pin back down to secure the unwind shaft in its saddle k Lower the rear safety shield O GBC Pro Tech August 1999 Applications INFORMATION If you have the parameters stored as a JOB number enter it now then press SEL and skip to step p other wise continue with step I Press SEL SEL will stop flashing JOB 0 ise Sav SHUT DOWN m Press TOP TEMP A to set a temperature of 140 160 F 60 71 C SLEEP TOP TEMP E BOT TEMP 4 NZ 68 in d n PressFWD A 00 0 SPEED SAFETY NT Go STOP FWR REV Page 6 53 Applications F 160 Operation and Maintenance Manual 0 Press SPEED A to set a motor speed of s Press STOP 2 ft min 6 m min 2 0 UG eL
116. ed table Ensure that the table is seated properly t Close the front and rear safety shields INFORMATION The SAFETY indicator should not be flashing when the tables are properly Finished product seated and the safety shields are in rewind the closed position Cut the piece of cardboard off u Press STOP AN WARNING When operating the laminator using the N wi variable speed footswitch keep hands and 00 0 GO fingers away from the nip of the rollers SPEED Jb rev You may be CRUSHED or BURNED SAFETY i O GBC Pro Tech August 1999 Page 6 41 Applications F 160 Operation and Maintenance Manual v Press SPEED A to a speed you feel Zz Press GAP A toa in setting comfortable working with It is recommended that SPEED not exceed 9 ft min 2 74 m min FWR 9 0 GO L SPEED lt gt REV STOP SAFETY Finishing w Press GO a With an enclosed blade cut the finished product from the web 9 0 8D wall N CAUTION li REI ad STOP Do not use an open blade to cut REBR the web near the rollers You can put cuts into the rollers x Feed the images through the main rollers from the front operating position of th
117. edia Inkjet A term used to describe a type of printing where an ink is projected topically onto a paper or paper like media This is a noncontact form of printing Craft paper A strong brown paper commonly used for single sided applications Laminate A two part material consisting an adhesive layer anda substrate The adhesive and the substrate may or may not be clear This is the material used for lamination Page 7 6 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Troubleshooting Main rollers These are the rolls that perform the actual lamination They are rolls capable of being heated in thermal roll laminators and are usually larger in diameter than the pull rolls Media Term used to describe the materials used to print an image 1 e the papers inks toners etc Mount adhesive A term used to describe a two sided pressure sensitive adhesive used in mounting images to various substrates This material can come with one or two release liners and may be optically clear for face mounting applications Mount tissue A thermally activated mount adhesive used in either a vacuum or roll type laminator Primarily used for mounting bond type papers to porous substrates Nip The interrelationship of any two rolls The distance between the closest points of the two rolls is referred to as the nip of the rolls Outgassing The term that describes the phenomenon where the
118. efer to u Continue with step v when the TOP TEMP Figure 6 8 3 DISPLAY stops flashing O GBC Pro Tech August 1999 Page 6 73 Applications F 160 Operation and Maintenance Manual Figure 6 8 3 Laminate e Thermal O laminate Q eT Remove di qc d Apply just enough brake tension to prevent the roll of mount adhesive from free spinning INFORMATION Excessive brake tension may cause the output to curl This can create complications with the second pass of this application e Pull the mount adhesive up towards the upper main roller and tack it the laminate resting on the upper main roller Refer to Figure 6 8 4 INFORMATION The mount adhesive will adhere to the activated adhesive from the laminate Figure 6 8 4 Mount adhesive Thermal laminate C2 ES Mount adhesive f Usea piece of cardboard to push the material into the nip of the main rollers N WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED g Press on the variable speed footswitch to guide the cardboard mount adhesive and laminate through the main rollers Page 6 74 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applicati
119. el a decrease in resistance on the turning of the upper unwind shaft as you turn the upper unwind brake adjustment knob counter clockwise j Lower the rear safety shield k Now perform steps b through h again for the lower unwind shaft Lower unwind brake adjustment dial Page 4 24 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Operations Section 5 Operations The operator control panel for the Falcon 160 Laminator is located on the front of the machine to the right of the front operating position For an illustration of the complete front control panel please refer to Figure 5 1 1 The names and functions of these controls are as follows INFORMATION When any command is pressed on the control panel a beep will sound If the command is held down the panel will beep only once 5 1 Control Panel 1 SLEEP If flashing the machine is in sleep mode This will occur after 3 hours of no activity To wake the laminator from sleep mode press any command SLEEP TOP TEMP BOT TEMP 32 132 2 TOP TEMP DISPLAY The display will show the set point temperature of the top main roller as the default display When the top roller temperature has reached in the 10 F range of the set point the display will be solid When outside of this range the display will flash SLEEP TOP TEMP lt BOT TEMP gt aa 32
120. erate or service the Falcon 160 Laminator INFORMATION When any command is pressed on the control panel a beep will sound If the command is held down the panel will beep only once INFORMATION When adjusting the pressure the gap will be affected as well Page1 8 F 160 Operation and Maintenance Manual A WARNING Keep hands and fingers clear of the laminator roller nip when adjusting PRESSURE You can be CRUSHED or BURNED INFORMATION When the safety shield is in the lowered position and Footswitch mode is engaged speed is controlled through the control panel INFORMATION If the variable speed footswitch is not close to the speed of the control panel output quality may be affected by the speed difference N WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Safety N CAUTION INFORMATION Footswitch speed is not indicated in the Speed is controlled through the variable SPEED DISPLAY on the control panel speed footswitch when the safety shield is in the raised position INFORMATION N WARNING When the safety shield is lowered speed reverts to the panel speed setting Caution should always be exercised when using the laminator with the safety shields raised You
121. f Remove the front infeed table g Cut the web of thermal laminate and mount adhesive at the upper and lower unwind shafts with an enclosed blade P ass two M ount Use Chart 10 and Diagram 10 for assistance N CAUTION Do not use an open blade to cut the web near the rollers You can put cuts into the rollers WARNING Do not wear ties loose fitting clothing or dangling jewelry while operating or servicing the laminator These items can get h Remove the web from the front of the laminator caught in the nip and choke you or you can and the rolls of material from the upper and be crushed or burned lower unwind shafts Page 6 78 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications Materials needed Prints Decals e Substrates Utility knife Leader board substrate width x 6 Set up a Replace the front infeed table N WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP You can be CRUSHED or BURNED b Position the leader board between the pull rollers N WARNING Keep hands and fingers clear of the pull roller nip when changing the gap You can be CRUSHED c While observing the leader board at eye level lowerthe upper pull roller by turning the pull roll crank handle clockwise until contact with the leader board has been made N CAUTION Sharp edges on a substrate should be filed
122. g a change in job number m SEL sav ie SHUT DOWN 18 SAVE When pressed will save the current settings for the number showing in the JOB DISPLAY For more information refer to Section 5 4 Job Programming on how to save parameters 6 5 n oT sav SHUT DOWN 19 SHUTDOWN When pressed automatically raises the main roller gap setting to 1 in turns the top and bottom temperature controller units off and stops the drive motor The LCD on the control panel remains illuminated and the SLEEP indicator will be solid F ser l JOB 5 H SAV pe SHUT DOWN 20 SPEED DISPLAY Displays the current speed setting of the laminator SPEED SAFETY Page 5 4 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Operations 21 SPEED A When pressed increases the speed of the laminator in increments of 0 5 ft min When pressed and held speed will automatically increase by 0 5 ft min increments until it has reached the maximum allowed speed of 15 ft min 6 5 rwr GO SPEED 4 REV C sarery STOP 22 SPEED V When pressed decreases the speed of the laminator in increments of 0 5 ft min When pressed and held speed will automatically decrease by 0 5 ft min increments until it has reached 0 ft min 6 5 QE rwa GO SPEED nev aren
123. g pulled into the nip If improperly performed you may encounter other problems with the output quality N WARNING N WARNING Caution should always be exercised When operating the laminator using the when using the laminator with variable speed footswitch keep hands and the safety shields raised fingers away from the nip of the rollers You can be seriously HURT or INJURED You may be CRUSHED or BURNED O GBC Pro Tech August 1999 Page1 17 Safety F 160 Operation and Maintenance Manual N CAUTION A WARNING Speed is controlled through the variable Keep hands and fingers clear of speed footswitch when the safety shield the laminator roller nip when is in the raised position adjusting PRESSURE You can be CRUSHED or BURNED N CAUTION ELECTRICAL Use only isopropyl alcohol or rubber cement SHOCK eraser to clean the rollers Harsh chemicals like toluene acetone or MEK can destroy Remove power from the laminator before the silicone covering of the rolls cleaning You can be severely shocked electrocuted or cause a fire N CAUTION A ELECTRICAL pt SHOCK Exercise care when cleaning the laminating Do not use liquid or aerosol cleaners on the laminator Do not spill liquid of any kind on the laminator You can be severely shocked electrocuted or cause a fire Use only a damp cloth for cleaning unless other wise specified e Use only in a well ventilated area Wear rubber gloves e
124. g unless other wise specified screen A ELECTRICAL SHOCK Remove power from the laminator before cleaning You can be severely shocked electrocuted or cause a fire a Use only a slightly damp water only non abrasive cloth b The same type of cloth used to clean eye glasses may be used instead A ELECTRICAL SHOCK Do not use liquid or aerosol cleaners on the laminator Do not spill liquid of any kind on the laminator You can be severely shocked electrocuted or cause a fire Use only a damp cloth for cleaning unless other wise specified Page 8 6 GBC Pro Tech August 1999
125. gency The main laminator roll up down control is located on the right side of the machine within the front control panel The GAP up down arrows controls the motion of the top main laminating roll Before pressing the GAP down arrow ensure that nothing is in the nip area In addition the main laminating rolls of the F 160 can reach temperatures of over 200 F 100 C A DANGER At these temperatures there is a danger of severe burn if the rolls are touched during setup operation or servicing INFORMATION Only a qualified service technician should perform any procedure in Part B of this manual The word qualified is defined below Qualified Any engineer that has experience with electrical and mechanical design of lamination equipment The engineers should be fully aware of all aspects of safety with regards to lamination equipment Any commissioning or service engineer must be of competent nature trained and qualified to GBC Pro Tech standards to fulfill that job This person will have completed and passed the full service training course from GBC Pro Tech Any GBC Technician GBC Specialist and or GBC Pro Tech Technician that has been through the GBC Pro Tech service training course The F 160 laminator has steel cabinets and leg panels that are bolted close to isolate the electrical and drive system components for the safety of the operator Figure 1 2 1 illustrates placement of the cabine
126. h is not close to the speed of the control panel output quality may be affected by the speed difference To raise the safety shield A WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED GBC Pro Tech August 1999 Press and hold on the variable speed footswitch approximately 1 2 the travel distance of the variable speed footswitch N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position N WARNING Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED Raise the safety shield INFORMATION When a safety shield is raised while pressing on the variable speed footswitch the speed may be faster or slower than the indicated panel speed INFORMATION When the safety shield is raised the laminator will only run while the variable speed footswitch is depressed Page 5 7 Operations F 160 Operation and Maintenance Manual Adjust for desired speed using the variable speed footswitch INFORMATION Footswitch speed is not indicated in the SPEED DISPLAY on the control panel To lower the safety shield Lower the safety shield INFORMATION When the safety shield is lowered speed reverts to the panel speed setting
127. he unwind shaft in its saddle i Lift the clevis pin located in the saddle of the lower unwind shaft Saddle Ww Clevis pin V Oo 9 J Swing the lower unwind shaft out enough to slide the roll of mount adhesive over the core chucks on the lower unwind shaft Refer to Figure 6 8 2 INFORMATION Twisting the roll of mount adhesive while sliding makes loading the film onto the unwind shaft easier k Once the roll of mount adhesive 1s on the lower unwind shaft swing the lower unwind shaft back into the saddle O GBC Pro Tech August 1999 Page 6 71 Applications N CAUTION Ensure the roll of mount adhesive is loaded properly on the unwind shaft Exposed adhesive should be F 160 Operation and Maintenance Manual 0 Press SEL SEL will stop flashing facing away from the rollers This will prevent hours of roll cleaning JOB 0 os SEL SAV MA SHUT DOWN D Push the clevis pin back down to secure the unwind shaft in its saddle p Press TOP TEMP A to set a temperature of 220 230 F 104 110 C m Center the upper roll and the lower roll of material on the unwind shafts You may refer to your measurement chart in Section 5 3 2 Loading film Figure 5 3 4 SLEEP lul TOP TEMP BOT TEMP 4 INFORMATION 140 i 68 i For the lo
128. he variable speed footswitch while guiding the leader board into the nip to confirm that the board is secure N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position N WARNING Keep hands and fingers clear of the laminator roller nip when adjusting PRESSURE You can be CRUSHED or BURNED p If the board is loose press PRESSURE V to adjust the gap between the main rollers GAP i PRESSURE 1 1 4 5 IN Page 6 4 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications INFORMATION N A Pxcegsive pnessurewHE Cause Me Speed is controlled through the variable substrate to how or flatten speed footswitch when the safety shield is in the raised position q Press STOP Process N wi 00 0 GO SPEED Hew V a Pull the roll of mount adhesive straight down SAFETY toward the front infeed table so that approximately 6 in is resting on the front infeed table Refer to Figure 6 1 3 r Press REV W to reverse the direction of the Figure 6 1 3 Leader board motor Leader board f BE FWR Mount 00 0 GO adhesive U SPEED m h STOP SAFETY N WARNING When operating the laminator through the b Position the leader board so that half is adhered variable speed footswitch keep your hands to the
129. heat from the laminating process turns components of the printed media into a gas This is seen as a cloudy or murky finished image It can also be caused by a chemical incompatibility between the overlaminate s adhesive and the printed media Pull rollers These rolls provide for tension of the laminated media Tensioning of the laminated media helps to make it flat and smooth In most laminators they may also be used for cold mounting and laminating applications Usually these rolls are of smaller diameter than the main rolls PS A Stands for Pressure Sensitive Adhesive An adhesive that requires no heat to activate only pressure Itis employed by removing a protective release liner and then pressed onto the material to be laminated This type of film is commonly used on materials that are temperature sensitive Release liner A coated paper or other media used to protect the adhesive side of a pressure sensitive material Rewind A system that rolls up media The rewind tubes used on the Falcon 160 laminator is a prime example Scarring The visual effect of folding papers or laminates and breaking the surface When done to a printed material it will be seen as a white crack in the image Second surface A term to denote the back side of a substrate Commonly referenced when discussing front mounted images to a clear substrate with an optically clear mount adhesive O GBC Pro Tech August 1999 Page 7 7 T
130. igure 6 3 1 O GBC Pro Tech August 1999 Page 6 17 Applications F 160 Operation and Maintenance Manual b Press RESET Refer to Figure 6 3 1 Figure 6 3 1 MAIN POWER RESET MAIN POWER c Ensure that the front and rear tables are in position and the rear pull rollers are in the up position d Raise the rear safety shield A WARNING Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED e Lift the clevis pin located in the saddle of the upper unwind shaft Saddle N Clevis pin MV f O 7A NC 2A N DN A ON O SS f Swing the upper unwind shaft out enough to slide the roll of laminate over the core chucks on the upper unwind shaft Refer to Figure 6 3 2 INFORMATION Twisting the roll of laminate while sliding makes loading the film onto the unwind shaft easier Figure 6 3 2 Unwind shaft T Roll of Core support laminate RLJ Brake adjust pice e 1 Core chucks O Page 6 18 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications g Once loaded swing the upper unwind shaft back into the saddle WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP CAUTION You can CRUSHED or BURNED Ensure the roll of
131. ination a Raise the main rollers to a 1 in gap by pressing Sled method GAP A lul This application may be performed from the GAP PRESSURE front ofthe laminator using the main rollers or from the 1 rear of the laminator using the pull rollers in the event u u the main rollers are heated This application is explained in detail using the main rollers from the front of the laminator Use Chart 3 and Diagram 3 for assistance b Press STOP N WARNING Do not wear ties loose fitting clothing or wi dangling jewel hil i 00 0 z angling jewelry while operating or ll Lxx REV l servicing the laminator These items can get SPPED S caught in the nip and choke you or you can SAFETY be crushed or burned c Clean the rollers as described in the Mater ials nee d d maintenance section Section 8 2 Cleaning the rollers Roll of pressure sensitive over laminate Precoated board same width as laminate Print smaller than the precoated board d Lower the front and rear safety shields and Roll of masking tape press SHUTDOWN if finished with the Utility knife laminator Cutting blade with an enclosed casing Leader board same material as the precoated board BE SAV i o y T Set up a Turn MAIN POWER to ON Refer to End of application F
132. ions SPE D u REV with the unwind shaft movement or the unwind brake saRETY STOP tension call you local area service representative Page 4 22 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Installation N WARNING Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED a Raise the rear safety shield b Liftthe clevis pin up from the saddle of the upper unwind shaft Saddle OM Clevis pin O 9 c Swing the upper unwind shaft to its fully extended position Swing back and reseat the shaft in the saddle The swing movement should be smooth and easy d Ensure that the upper unwind brake adjustment knob is backed off completly The counter clockwise turn should be easy INFORMATION Steps e and f will be performed simultaneously e With one hand slowly turn the upper unwind shaft in either direction f With the other hand slowly turn the upper unwind brake adjustment knob clockwise Upper unwind brake g You should feel an increase in resistance on the turning of the upper unwind shaft as you turn the upper unwind brake adjustment knob clockwise O GBC Pro Tech August 1999 Page 4 23 Installation F 160 Operation and Maintenance Manual h Slowly turn the upper unwind brake adjustment knob counter clockwise i You should fe
133. l Decal _ fingers away from the nip of the rollers You may be CRUSHED or BURNED Release liner RO ae UN Substrate If its not slowly move the substrate into the nip until the decal is conformed Refer to Figure 6 8 13 j Make sure the image is conformed to the upper main roller Refer to Figure 6 8 12 N CAUTION INFORMATION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position If the image is not conformed to the roller you may experience difficulties with this application Figure 6 8 13 Non conformed decal Figure 6 8 12 Conformed print Not conformed W Conformed O GBC Pro Tech August 1999 Page 6 83 Applications F 160 Operation and Maintenance Manual D Use one hand to pull the release liner off as the substrate moves towards the nip and the other INEDITA hand to apply slight back tension to the decal Steps n and o will be performed simultaneously m Once the substrate and the decal are completely through the pull rollers you can let off the variable speed footswitch A WARNING When operating the laminator using the n The mounted image can now be removed from variable speed footswitch keep hands and the front of the laminator fingers away from the nip of the rollers You may be CRUSHED or BURNED 0 Trim the mounted piece as necessary
134. l experience complications with this application Set up a Cut two leader boards 6 inch in length of the material you are about to precoat N CAUTION Sharp edges on a substrate should be filed smooth and GAP manually adjusted Sharp edges can CUT the rollers b Place these two pieces by the laminator for future use O GBC Pro Tech August 1999 Page 6 51 Applications F 160 Operation and Maintenance Manual INFORMATION The two pieces cut in step a will be used as the leader board and trailer Figure 6 6 1 MAIN POWER RESET board These two pieces can be saved and reused for other applications MAIN POWER c Turn MAIN POWER to ON Refer to Figure 6 6 1 g Lift the clevis pin located in the saddle of the upper unwind shaft d Press RESET Refer to Figure 6 6 1 Saddle Ww Clevis pin e Be sure the front and rear tables are in position O 9 and the pull rollers are in the up position C f Raise the rear safety shield h Swing the upper unwind shaft out enough to slide the roll of Hot Tissue over the core chucks and onto the upper unwind shaft Refer to Figure 6 6 2 N WARNING Caution should always be exercised when using the laminator with INFORMATION the safety shields raised You can be seriously HURT or INJURED Twisting the roll of Hot Tissue while sliding makes loading the film onto the unwind shaft easier Page 6 52 O GBC Pro T
135. l prevent anything from being pulled into the nip b For thermal adhesives while the laminator is at normal operating temperature put on the rubber gloves and use the rubber cement eraser This allows the eraser to bead up the adhesive N WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers CAUTION You may be CRUSHED or BURNED Excessive pressure can destroy the silicone layer by pressing to hard or scrubbing too long in one spot d Since the safety shields are raised and the tables removed you must use the footswitch to rotate the bottom rollers after cleaning a c Wipe away the beads with isopropyl section alcohol and a cotton terry cloth N HR N CAUTION Do NOT pick or pull heat activated adhesive off the rolls when they are cold You can Speed is controlled through the variable speed footswitch when the safety shield is in the raised position cause irreparable damage to the laminating rolls O GBC Pro Tech August 1999 Page 8 3 Maintenance F 160 Operation and Maintenance Manual Cleaning the beads of adhesives dust and dirt from N CAUTION the rolls Use only isopropyl alcohol or rubber cement eraser to clean the rollers Harsh chemicals like toluene acetone or MEK can destroy the silicone covering of the rolls This can be done one of two different methods Both are acceptable forms of
136. laminate is loaded properly on the unwind shaft Exposed adhesive should be facing MEL from the rollers j Press GAP to the required gap setting for This will prevent hours of roll cleaning the substrate being used The GAP DISPLAY should reflect your desired setting h Push the clevis pin back down to secure the unwind shaft in its saddle S GAP fi PR 1 4 i il 2 iN p i Raise the front safety shield N CAUTION N WARNING Sharp edges on a substrate should be filed Caution should always be exercised when using the laminator with smooth and GAP manually adjusted Sharp edges can CUT the rollers the safety shields raised You can be seriously HURT or INJURED INFORMATION INFORMATION If the thickness of the substrate is not If you have the parameters stored as a known follow the procedure to manually JOB number enter it now then press set the nip in Section 5 5 1 Manual nip SEL and skip to step m other wise adjustment continue with step j O GBC Pro Tech August 1999 Page 6 19 F 160 Operation and Maintenance Manual Applications k Press SEL JoB Fse Ci sav U SHUT DOWN l Press FWD A z L FWR 00 0 80 SPEED 4 REV SAFETY N WARNING When operating the laminator using the variable speed footswitch keep hands and
137. ller nip Refer to Figure 6 6 5 INFORMATION Before stopping the rollers position the pull rollers up This will prevent an impression in the last pre coated board D The second person will raise the rear pull roller by turning the crank handle counterclockwise until separated Page 6 58 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications m Stop the laminator when the trailer board is in the main roller nip Refer to Figure 6 6 5 Figure 6 6 5 Trailer board Precoated board CL 3 MED Trailer board INFORMATION Do not stop in the middle of a board an impression of the roller footprint will be evident on the board This can cause a Finishing a Cut the web of Hot Tissue at the upper unwind shaft with an enclosed blade N CAUTION Do not use an open blade to cut the web near the rollers You can put cuts into the rollers b Pull the precoated board and trailer board out from the front of laminator INFORMATION This will prevent any activated adhesive from contacting the rollers tunnel effect in the mounting process n Raise the main rollers to a 1 in gap by pressing GAP A GAP i PRESSURE f c Remove the roll of material from the upper unwind shaft d Clean the rollers as described in the maintenance section Se
138. mance A maintenance schedule and a section of procedures are included in this section N WARNING Do not wear ties loose fitting clothing or dangling jewelry while operating or servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned INFORMATION Improper maintenance can result in poor output quality 8 1 Maintenance Schedule INFORMATION Below is a recommended maintenance schedule Before performing any of the steps listed read through the procedures first Please follow the instructions pertaining to the step you are performing O GBC Pro Tech August 1999 Daily Clean the rolls See cleaning in this section nspect the electrical cord for damage If damaged you should replace or repair it immediately nspect the footswitch cord for damage If damaged you should replace or repair it immediately Monthly Adjust the nip if needed See calibrations in this section Check the chain tension See calibrations in this section nspect the area around the laminator for possible hazards dust buildup combustible items stored too close etc Semi Annual Lubricate the grease fittings chain and gears See Lubrication in this section Check wire termination tightness A ELECTRICAL SHOCK Remove power from the laminator before servicing You can be severely shocked electrocuted or cause a fire Pag
139. mount adhesive Referto Figure 6 1 3 INFORMATION S Press on the variable speed footswitch to back Position the leader board squarely the board out of the main rollers onto the mount adhesive O GBC Pro Tech August 1999 Page 6 5 CT ye away from the nip of the rollers You may be crushed or burned Applications F 160 Operation and Maintenance Manual c Press STOP e Push the leader board into the main roller nip while stepping on the variable speed footswitch 00 0 GO SPEED E REV CAUTION SAFETY Speed is controlled through the variable speed footswitch when the safety shield is in the raised position d Press FWD A f Apply the minimum amount of brake tension on the roll of mount adhesive to prevent it from free spinning Os PM FWR 00 0 GO SPEED lt REVI STOP SAFETY INFORMATION Excessive tension will cause the substrate to bow INFORMATION Steps e and f will be performed simultaneously g Have the second person stand at the rear of the laminator WARNING A INFORMATION When operating the laminator using the S h and i will b f d variable speed footswitch keep hands and teps an jt e E peores fingers a
140. mplications with this application This will prevent hours of roll cleaning Page 1 12 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Safety N CAUTION Ensure the roll of mount adhesive is loaded properly on the unwind shaft Exposed adhesive should be facing away from the rollers This will prevent hours of roll cleaning AN WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP You can be CRUSHED or BURNED INFORMATION If the thickness of the substrate is not known follow the procedure to manually set the nip in Section 5 5 1 Manually nip adjustment N WARNING Keep hands and fingers clear of the laminator roller nip when adjusting PRESSURE You can be CRUSHED or BURNED GBC Pro Tech August 1999 N WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position INFORMATION Excessive pressure will cause the substrate to bow or flatten N CAUTION Excess pressure can damage the laminating rollers Always use the minimum roll pressure necessary to complete the task Page 1 13 Safety F 160 Operation and Maintenance Manual INFORMATION INFORMATION PRESSURE will vary with th
141. n Pass two Mount Use Chart 6 and Diagram 6 for assistance N WARNING Do not wear ties loose fitting clothing or dangling jewelry while operating or servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned O GBC Pro Tech August 1999 Page 6 43 Applications F 160 Operation and Maintenance Manual Materials needed Prints Decals e Substrates Utility knife Leader board substrate width x 6 Set up a Replace the front infeed table N WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP You can be CRUSHED or BURNED b Press GAP to the required gap setting for the substrate being used The GAP DISPLAY should reflect your desired setting GAP 1 4 TY gt N CAUTION Sharp edges on a substrate should be filed smooth and GAP manually adjusted Sharp edges can CUT the rollers INFORMATION If the thickness of the substrate is not known follow the procedure to manually set the nip in Section 5 5 1 Manually nip adjustment c Position the leader board in the middle between the upper and lower main rollers d Press FWD A Iii a 00 0 GO SPEED U REV STOP SAFETY N WARNING When operating the laminator using the variable speed footswit
142. n 2 1 4 horse power drive motor Bi directional D C motor e 68 F 290 F 20 C 143 C Front control panel Variable speed footswitch e Save up to 9 job parameters High release silicone rolls Electrical Requirements e 230 240 VAC 50 60 Hz single phase 55 amps e 230 240 VAC Wye 3 phase 32 amps phase e 31 732 B T U hour 4650 watts per heater No heat motor only 1 3 amps Top heat and motor 20 23 amps Both heat and motor 40 43 amps 24 vdc 12 vdc isolated x 2 24 vdc isolated 230 vac minimum Page 3 2 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Specifications Section 3 5 Dimensions Weight Crated 1568 Ibs 711 kg Uncrated 1200 Ibs 544 kg Dimensions 1 A Crate 90 in H x 46 in W x 72 in L 229 cm H x 117 cm W x 183 cm L Uncrated 54 in H x 38 in W x 82 5 in L 137 cm H x 96 cm W x 209 cm L Refer to Figure 3 5 1 Nip Height 9 37 3 16 in 95 em Safety Shield Raised Height 66 5 8in 169 cm Figure 3 5 1 Dimensions GBC Pro Tech August 1999 Page 3 3 Specifications F 160 Operation and Maintenance Manual This page intentionally left blank Page 3 4 GBC Pro Tech August 1999 F 160 Operation an
143. n Figure 4 4 1 It can fall and damage the laminator or cause harm to you and others Page4 6 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Installation Moving the laminator a Have the laminator rolled off the skid and placed on the floor by licensed riggers The ramps included with the laminator can be secured utilizing screws removed from the disassembled crate Figure 4 4 2 illustrates positioning of the ramps N WARNING Do not attempt to move the laminator across anything other than a flat level surface without trained and qualified riggers You can be crushed or seriously injured Figure 4 4 2 Positioning of the ramps N WARNING Do not attempt to use the ramps if they are not secured to the pallet Make sure you have the pallet on a flat even surface before attempting to roll the machine off using the ramps O GBC Pro Tech August 1999 N WARNING The Falcon 160 Laminator is a large and heavy piece of equipment It is necessary to employ LICENSED RIGGERS ONLY to move the laminator The laminator 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 You can be crushed or seriously injured INFORMATION GBC Pro Tech s warranty does not cover malfunction of the equipment due to mishandling and or tipping GBC Pro Tech bears no responsibility f
144. n the safety shield is in the raised position If the tack point enters the rollers nip perform the following steps 1 Press STOP 2 Press REV VW 3 Press the variable speed footswitch to back the tack point out of the rollers nip 4 Press STOP 5 Press FWD A 6 Continue from step i D Drape the loose part of the decal over the upper main roller Refer to Figure 6 5 12 Figure 6 512 Draping the decal Decal ap Release liner a Substrate Page 6 48 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications m Make sure the image is conformed to the upper main roller Refer to Figure 6 5 13 CAUTION Speed is controlled through the variable speed footswitch when the safety shield INFORMATION is in the raised position If the image is not conformed to the roller you may experience difficulties with this application Figure 6 5 14 Non conformed decal Figure 6 5 13 Conformed print Not conformed lt lt Y Conformed INFORMATION Steps n and o will be performed simultaneously N WARNING When operating the laminator using the variable speed footswitch keep hands and WARNING fingers away from the nip of the rollers You may be CRUSHED or BURNED When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of th
145. nd Cut the piece of cardboard off n Press STOP N WARNING When operating the laminator using the 00 0 ew GO variable speed footswitch keep hands and li REV yi fingers away from the nip of the rollers SPEED S l You may be CRUSHED or BURNED SAFELY Page 6 92 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications 0 Press SPEED A to a speed you feel s Press GAP A toa 1 in setting comfortable working with It is recommended that SPEED not exceed 5 ft min 1 52 m min GAP hd PRESSURE 17 id 1 MONI 9 0 rwr ol SPEED L REV SAFETY TIEN Finishing p Press GO a With an enclosed blade cut the finished product from the web 9 0 U 1 j REV ve DC N am REOS i U CAUTION Do not use an open blade to cut the web near the rollers You can put cuts into the rollers q Feed the images through the main rollers from the front operating position of the laminator b The prints are now ready to be trimmed r After the last print has passed through the pull rollers press STOP c If you used the lower rewind remove the rewind tube and bring it to a trimming station Replace the rewind tube when finished
146. nd to the board Dwell time is crucial for the success of this application 0 Raise the main rollers to a 1 in gap by pressing GAP A N WARNING When the laminator rollers are in motion keep hands and fingers Eus SHEEBUHE 3 away from the nip of the rollers You may be CRUSHED or BURNED 1 A g n Stop the laminator when the trailer board is in the main roller nip Refer to Figure 6 7 5 Finishing a Cut the web of thermal laminate at the upper Figure 6 7 5 Trailer board unwind shaft with an enclosed blade N N CAUTION y Ne Do not use an open blade to cut S the web near the rollers Mounted C Trailer image board You can put cuts into the rollers irs it S N b Pull the leader board mounted image and trailer board out from the front of laminator Page 6 68 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications INFORMATION 6 8 Thermal decal and This will prevent any activated adhesive mount from contacting the rollers SC G56 A oOUEMV This is a two pass mount and laminate process Two pass meaning that the print will pass through the laminator twice The first pass Decal will apply a c Remove the roll of material from the upper ae mount adhesive to the back of the print while applying a laminate to the front of the print The second pass
147. nts of 5 per press up to 15 h Press JOB VW The JOB DISPLAY should decreases in increments of 1 from 9 to 0 FWR 15 GO SPEED U REV L STOP SAFETY 0 SEL SAV JOB k Press FWD A FWD is solid i SEL can not be tested until you have saved parameters within a JOB location Refer to Section 5 4 Job programming for SEL and SAV P2 ee FWR SPEED V Top REV __ SAFETY 2 108 0 SEL L_ sav J SHUT DOWN Flashing GBC Pro Tech August 1999 Page 4 19 Installation F 160 Operation and Maintenance Manual 1 Press GO The bottom rollers turn in a forward motion at a speed of 15 ft min 4 57 m min d FWR 15 GO 1 SPEED U REV SAFETY STOR m Press STOP The bottom rollers stop turning 15 SPEED SAFETY rwn E n Press REV V REV is solid and FWD reverts to hollow os 1 FWR 15 GO SPEED UC REV SAFETY 0 Press GO The bottom rollers turn in a reverse motion at a speed of 15 ft min 4 57 m min 15 SPEED _ SAFETY p Press
148. oard in after the leader board with a 1 2 inch gap between the two Refer to Figure 6 6 4 N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position INFORMATION The 1 2 in gap between boards will allow for easier separation of the boards by the second person Page 6 57 Applications F 160 Operation and Maintenance Manual Figure 6 6 4 1 2 Gap Substrate 1 2 Gap C CSNY sy NS J Precoated board N WARNING Keep hands and fingers clear of the pull roller nip when changing the gap You can be CRUSHED i The person at the rear of the laminator will guide and lower the upper pull roller onto the leader board as it passes through the nip opening INFORMATION Do not lower the pull roller so that the substrate is crushed when passing through This will prevent the boards from bowing J As the boards come through the person at the rear of the machine will use the utility knife to separate the boards N CAUTION Caution should always be exercised when using a knife Sharp knife can cut you N CAUTION Caution should always be exercised when using a utility knife near the rollers You can put cuts into the rollers k Inform the second person of the last board to be precoated before feeding the trailer board into the main ro
149. oller onto the web Turn the pull roll crank handle 3 4 turn Keep hands and fingers clear of clockwise after you feel the initial contact Refer the laminator roller nip when to Figure 6 5 6 adjusting PRESSURE You can be CRUSHED or BURNED INFORMATION 0 When the cardboard has travel pass the main PRESSURE will vary with the thickness rollers press PRESSURE V to set a pressure of 60 8096 and width of the laminate you are using Adjust as necessary GAP f PRESSURE f 0 TTL q Cut the cardboard from the webbed material t I Refer to figure 6 5 6 Do not use an open blade to cut the web near the rollers You can put cuts into the rollers Excess pressure can damage the laminating rollers Always use the minimum roll pressure necessary to complete the task Page 6 40 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications r Tape the web to the lower rewind tube or let the Press on the variable speed footswitch to web run out to a work table Refer to Figure lengthen the web enough to get one full wrap 6 5 6 around the lower rewind tube INFORMATION N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position If you choose to use the lower rewind tube make note of the direction of travel Figure 6 5 6 Finish product rewind s Replace the front infe
150. on and Maintenance Manual Applications Web Diagram 8 One pass mount and laminate Octiva Gloss C Hot Tissue Leader Substrate oy v O GBC Pro Tech August 1999 Page 6 113 Applications F 160 Operation and Maintenance Manual Parameter Chart 9 Thermal decal and Mount Decal MATERIALS UPPER UNWIND 3 mil Octiva Gloss SUBSTRATE N A LOWER UNWIND Pro Mount PRINTS Any type TEMPERATURE TOP TEMP BOT TEMP 230 68 GAP amp PRESSURE DUUM PRESSURE 1 MOTOR DIRECTION amp SPEED 1 M lt E Panel GO Footswitch PULL ROLL SETTINGS UP N A 7 HC 1 4 Turn PRESSURE 1 2 T G 2 Turn DOWN D lt 3 4 Turn Upper and lower unwind material can be of similar product Print can be of any type Pressure will will vary slightly with regards to quality of the output Speed will be determined by the operator Pull roll pressure may vary between 1 2 turn and 3 4 turn Because the process is described from the front of the laminator motor direction is FWD Page 6 114 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications Web Diagram 9 Thermal decal and mount Decal
151. ons N CAUTION N WARNING Speed is controlled through the variable Keep hands and fingers clear of the pull speed footswitch when the safety shield roller nip when changing the gap is in the raised position You can be CRUSHED i Once the cardboard has passed through the pull WARNING rollers lower the upper pull roller onto the web Turn the pull roll crank handle 3 4 turn Keep hands and fingers clear of clockwise after you feel the initial contact Refer the laminator roller nip when to Figure 6 8 6 adjusting PRESSURE You can be CRUSHED or BURNED INFORMATION h When the cardboard has traveled pass the main PRESSURE will vary with the thickness rollers press PRESSURE V to set a pressure of 60 80 and width of the laminate you are using Adjust as necessary GAP f PRESSURE Refer to figure 6 8 5 0 g IIll j Cut the cardboard from the webbed material N CAUTION N CAUTION Excess pressure can damage the laminating Do not use an open blade to cut rollers Always use the minimum roll the web near the rollers i pressure necessary to complete the task You can put cuts into the rollers GBC Pro Tech August 1999 Page 6 75 Applications F 160 Operation and Maintenance Manual k Tape the web to the lower rewind tube or let Press on the variable speed footswitch to the web run out to a work table Refer to lengthen the web enough to get one full wrap Figur
152. or personal injury or damage due to moving the laminator improperly b Remove any plastic strapping and or packing paper taped to the rolls N CAUTION Do not use a knife or other sharp object to remove the shrink wrap from around the laminator You can cause irreparable damage to the rollers Page4 7 Installation F 160 Operation and Maintenance Manual c Remove all packing materials to a safe distance from the laminator and dispose of properly d Use two people to carefully roll the laminator to the desired location INFORMATION About recycling The crate components can be reused for shipping the laminator again or can be disassembled and the wood and screws recycled The shrink wrap is not recyclable so it must be discarded 4 5 Accessory pack Once the Falcon 160 Laminator has been unpacked and moved into final position open the accessory pack and verify the contents Accessory Pack contents One T handle allen wrench 475 200 One Zippy knife 475 620 e One Terry clothe towel 475 950 One Operators manual 930 031 One roll masking tape 475 000 Two Polyurethane O rings 480 005 One strain relief for main power 175 201 One rubber cement pad 930320 One crankhandle 629 018 One fuse 0 5A 186 022 Two fuses 2 5A 186 220 If you are missing any of the itemslisted above contact your local service technician or sales representativ
153. or you can become injured if stepped on N CAUTION Do not allow the top to fall into the crate It can damage the laminator N CAUTION A second person must support the side labeled 5 in Figure 4 4 1 It can fall and damage the laminator or cause harm to you and others N WARNING The Falcon 160 Laminator is a large and heavy piece of equipment It is necessary to employ LICENSED RIGGERS ONLY to move the laminator The laminator 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 You can be crushed or seriously injured INFORMATION 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 laminator improperly Page1 6 N WARNING Do not attempt to use the ramps if they are not secured to the pallet Make sure you have the pallet on a flat even surface before attempting to roll the machine off using the ramps INFORMATION About recycling The crate components can be reused for shipping the laminator again or can be disassembled and the wood and screws recycled The shrink wrap is not recyclable so it must be discarded INFORMATION Improper leveling will result in poor output quality O GBC Pro Tech August 1999 F 160 Operation
154. owed exactly It is suggested and helpful if you take the time to read this section thoroughly before attempting to do any of the steps A complete understanding of this section will enable you to follow the procedures descibed in Section 6 1 Application 5 3 1 Power a Clear the area around the laminating rollers and pull rollers nip INFORMATION Once RESET has been engaged power will b Make sure the laminator is plugged in be restored Laminating rollers will reset to 1 in GAP and the display will return to it s default settings c Turn the MAIN POWER to the ON position Default mode TOP TEMP 68 F 20 C BOT TEMP 68 oF 20 oC GAP 1 in PRESSURE no bars are solid JOB 0 no motion direction selected SPEED 00 0 and Power SLEEP flashing e Enter the desired operating parameters or select the job number prior to the emergency stop situation f You may now resume operating the laminator GBC Pro Tech August 1999 Page 5 11 Operations F 160 Operation and Maintenance Manual d Press RESET The front control panel will illuminated Reset a 5 3 2 Film loading N WARNING Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED a Raise the rear safety shield if placing a roll of laminate onto the upper unwind shaft b Lift the clevis pin located in the sa
155. p and push RESET Place a service call Rollers in the down position Problem The control panel is locked up Hints Press RESET Press an E stop then unlatch the E stop and push RESET Disconnect power and then reconnect power Placea service call immediately and remove all power to the laminator N CAUTION Prolonged contact can form flat spots on the rollers 7 4 Glossary The glossary can help you in understanding some of the terminology used when referring to the laminator applications or troubleshooting aspects of the machine Blistering A condition where the paper coating is bubbled up from the image paper causing a blister It is created by using excessive heat during the lamination process Blistering is most commonly found with photographic and ink jet media Bond strength Refers to one of three conditions 1 the anchor strength of adhesive to laminate substrate 2 the anchor strength of the laminating film to the product that has been laminated or 3 when two layers of film are laminated together the strength of the adhesive to adhesive bond Center mount A mounting technique where an image is mounted centrally on a substrate to provide a decorative border O GBC Pro Tech August 1999 Page 7 5 Troubleshooting F 160 Operation and Maintenance Manual Clutch tension The tension that is applied to the laminated material between the main and pull rolls Thi
156. perating or servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned Materials needed Prints e P S A mount boards Utility knife Leader board Set up a Turn MAIN POWER to ON Refer to Figure 6 2 1 b Press RESET Refer to Figure 6 2 1 Figure 6 2 1 MAIN POWER RESET MAIN POWER c Be sure the front and rear tables are in position and the rear pull rollers are in the up position d Raise the front and rear safety shields N WARNING Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED INFORMATION If you have the parameters stored as a JOB number enter it now then press SEL and skip to step h other wise continue with step e Page 6 10 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications AN WARNING e Press SEL SEL will stop flashing When operating the laminator using the P variable speed footswitch keep hands and JOB 0 n SAV fingers away from the nip of the rollers ea You may be CRUSHED or BURNED SHUT DOWN h Press on the variable speed footswitch while N WARNING guiding the leader board into the nip to confirm that the board is secure Keep hands and fingers clear of the laminator roller nip when changing GAP You can be CRU
157. pply just enough brake tension to prevent the loton papet iames gpinning If you have the parameters stored as a JOB number enter it now then press SEL and skip to step m other wise continue with step j INFORMATION Excessive brake tension may cause the image to curl when separated from j Press SEL the craft paper Tse M sav i Pull the craft paper up towards the upper JOB main roller and tack it the laminate Refer to LU SHUT DOWN Figure 6 4 5 N WARNING 0 INFORMATION Keep hands and fingers clear of the The craft paper will adhere to the exposed laminator roller nip when changing GAP adhesive from the laminate You can be CRUSHED or BURNED GBC Pro Tech August 1999 Page 6 29 Applications F 160 Operation and Maintenance Manual k Press GAP V to enter a 0 in gap setting GAP f PRESSURE N D Press FWD A Gl FWR 00 0 Go SPEED 4 REVI STOP SAFETY INFORMATION Steps m and n will be performed simultaneously m Use a piece of cardboard to push the material into the nip of the main rollers N WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED Page 6 30
158. quire heat to activate the adhesive 6 1 Precoating substrates This application may be performed from the front of the laminator using the main rollers or from the rear of the laminator using the pull rollers in the event the main rollers are heated This application is explained in detail using the main rollers at the front operating position of the laminator Use Chart 1 and Diagram 1 for assistance Materials needed Roll of Pro Mount or Premium Mount adhesive or comparable material e Substrates to precoat Foamcore Gator Board etc Leader board e Trailer board Second person Utility knife Cutting blade with an enclosed casing INFORMATION The mount adhesive must not exceed 1 in the width of the substrate If it does you may experience complications with this application Set up a Cut two leader boards 6 inch in length of the material you are about to precoat O GBC Pro Tech August 1999 Page 6 1 Applications F 160 Operation and Maintenance Manual N CAUTION Sharp edges on a substrate should be filed Figure 6 1 1 MAIN POWER RESET smooth and GAP manually adjusted Sharp edges can CUT the rollers b Place these two pieces by the laminator for future use MAIN POWER INFORMATION The two pieces cut in step a will be used as the leader board and trailer g Lift the clevis pin located in the saddle of the ind shaft board These two pi
159. r the lower unwind shaft add 1 4 in to the core the roll of the measurement laminate O 5 3 5 Heating Perform the following steps if the application requires heat Allow the rolls to heat up while rotating h Close the rear safety shield when finished for even heat disbursement O GBC Pro Tech August 1999 Page 5 13 Operations F 160 Operation and Maintenance Manual a Press TOP TEMP A to set your upper roller temperature INFORMATION Do not add PRESSURE when heating the laminating rollers this allows the high siEEP release silicone to expand with minimum TOP TEMP BOT TEMP gt restrictions y U d Press FWD A to set a forward motion direction b If required press BOT TEMP A to set your lower roller temperature fT FWR 0 GO SLEEP SPEED T REV TOP TEMP lt BOT TEMP SAFETY V n e Press SPEED A to set a speed of 2 ft min 61 m min INFORMATION When requiring top and bottom heat it is recommended to set both temperatures to lul the same set point 20 FWRI SPEED lt gt rev STOP SAFETY c Press GAP V to set the gap to 0 PRESSURE f1 INFORMATION ll GAP
160. rely injured crushed or cause damage to the laminator injured or cause damage to the laminator INFORMATION 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 INFORMATION 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 note of this on the Bill of Lading INFORMATION Depending on the destination and customer preference the Falcon 160 may be shipped in various ways The laminator may arrive shrink wrapped or in a plywood crate on a skid Please follow the unpacking procedure that pertains to your method of shipment GBC Pro Tech August 1999 N CAUTION Do not use a knife or other sharp object to remove the shrink wrap from around the laminator You can cause irreparable damage to the rollers N WARNING Do not attempt to move the laminator across anything other than a flat level surface without trained and qualified riggers You can be crushed or seriously injured N CAUTION Do not allow the top to fall into the crate It can damage the laminator Page1 5 Safety F 160 Operation and Maintenance Manual INFORMATION Do not put packing screws on the floor They can cause problems when trying to roll the laminator into position
161. ro Tech August 1999 Page 6 87 Applications F 160 Operation and Maintenance Manual m Center the upper roll and the lower roll of p Press TOP TEMP A to set a temperature of material on the unwind shafts You may refer to 220 230 F 104 110 C your measurement chart in Section 5 3 2 Loading film Figure 5 3 4 SLEEP INFORMATION TOP TEMP BOT TEMP f For the lower unwind shaft add 1 4 in to 140 U 68 l the measurement q Press BOT TEMP A to set a temperature of n Lower the safety shields 220 230 F 104 110 C TOP TEMP INFORMATION SEEE 4 BOT TEMP If you have the parameters stored as a JOB number enter it now then press 120 120 SEL and skip to step p other wise Sus Nt continue with step r Press FWD A 0 Press SEL SEL will stop flashing m 00 0 zu SEL SAV SPEED REV JOB 0 STOP SAFETY CU v SHUT DOWN Page 6 88 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual s Press SPEED A to set a motor speed of 2 ft min 6 m min 2 0 GO SPEED 4 Rev STOP SAFETY t Press GAP VW toenter aO in gap setting
162. roubleshooting F 160 Operation and Maintenance Manual Silvering A term used to describe one of two occurrences 1 air bubbles trapped between the product and a thermal laminate generally caused by insufficient heat being applied to the laminator or 2 the adhesive not fully activated in a pressure sensitive film which will disappear once the adhesive is fully activated This activation process can be sped up if a small amount of heat is applied during the application Substrate The material to which an adhesive is to be bonded In film the substrate is the polyester and in mounting the substrate is the material being mounted to Tunneling When a laminated image is rolled up for any period of time and the laminate separates from the image Generally in a pattern that follows the direction the laminated image was rolled up in This is very common with pressure sensitive laminates and finished products that have been wound tightly Unwind A system that unwinds media Unwinds are used on all laminators to dispense laminate for lamination Web The path that rolled media unwinding from a supply roll takes through a machine or array of rollers Page7 8 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Maintenance Section 8 Maintenance GBC Pro Tech laminators require minimal maintenance However regular maintenance is essential to keep any piece of precision machinery at peak perfor
163. ry with the thickness rollers press PRESSURE V to set a pressure of 60 80 and width of the laminate you are using Adjust as necessary GAP f PRESSURE Refer to figure 6 9 5 0 g IIll j Cut the cardboard from the webbed material N CAUTION N CAUTION Excess pressure can damage the laminating Do not use an open blade to cut rollers Always use the minimum roll the web near the rollers i pressure necessary to complete the task You can put cuts into the rollers GBC Pro Tech August 1999 Page 6 91 Applications F 160 Operation and Maintenance Manual k Tape the web to the lower rewind tube or let Press on the variable speed footswitch to the web run out to a work table Refer to lengthen the web enough to get one full wrap Figure 6 9 5 around the lower rewind tube INFORMATION N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position If you choose to use the lower rewind tube make note of the direction of travel Figure 6 9 5 Finish product rewind D Replace the front infeed table Ensure that the table is seated properly m Close the front and rear safety shields INFORMATION The SAFETY indicator should not be flashing when the tables are properly Finished seated and the safety shields are in product the closed position rewi
164. s Q SEL SAV SHUT DOWN GAP f PRESSURE 1 0 N m Press TOP TEMP A to set a temperature of V 240 260 F 115 126 C SLEEP TOP TEMP BOT TEMP 4 140 68 q Press GO 2 0 SPEED Rev a E SAFETY gt OP 00 0 GO SPEED REVI STOP SAFETY n Press FWD A 1 wi V O GBC Pro Tech August 1999 Page 6 63 Applications F 160 Operation and Maintenance Manual r Continue with step s when the TOP TEMP DISPLAY stops flashing WARNING When operating the laminator using the variable speed footswitch keep hands and s Press STOP fingers away from the nip of the rollers You may be CRUSHED or BURNED f 1 u Press on the variable speed footswitch while 2 0 GO id guiding the leader board into the nip to confirm sep tl l REV that the board is secure N CAUTION Speed is controlled through the variable SAFETY speed footswitch when the safety shield is in the raised position N WARNING Keep hands and fingers clear of t Press GAP A to the required gap setting for the substrate being used The GAP DISPLAY should reflect your desired setting
165. s tension is applied by having the pull rolls turn faster than the main rolls and then having some form of clutching or torque limiting applied to the pull rolls This tension is important for maintaining a smooth flat finished image Coiling A term used to describe an image rolling up on itself This is caused by differences in the brake tension used between the upper and lower laminates during and application process Cold laminate Film that does not require heat to activate the adhesive Please see P S A for more information D waves A term used to describe a wave pattern caused generally by incorrect paper tension Delamination Refers to either one of two conditions 1 the adhesive separating from the laminate substrate or 2 the laminate separating from the product being laminated Edgewrap A mounting technique where the image wraps around the edges of the mounting substrate so as to provide a finished edge Encapsulation When an image is completely encased in laminating film itis encapsulated A border of laminate on laminate exists around the perimeter of the product Film A two part material consisting an adhesive layer and a substrate The adhesive and the substrate may or may not be clear This is the material used for lamination Please refer to laminate Foamboard A material commonly used as a mounting substrate It is made up of foam sandwiched between two layers of paper or paper like m
166. se the process is described from the front of the laminator motor direction is FWD Page 6 106 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications Web Diagram 5 Decal and mount Decal P S A Release liner Laminate Output 4 Pro Mount Finish product rewind option oy Io O GBC Pro Tech August 1999 Page 6 107 Applications F 160 Operation and Maintenance Manual Parameter Chart 6 Decal and mount Mount MATERIALS UPPER UNWIND N A SUBSTRATE 1 4 Foam Core LOWER UNWIND N A PRINTS Decals TEMPERATURE TOP TEMP BOT TEMP 68 68 GAP amp PRESSURE PRESSURE UNII MOTOR DIRECTION amp SPEED Panel GO L D Footswitch GO PULL ROLL SETTINGS T x N A HC 1 4 Turn PRESSURE Z 1 2 Turn DOWN RC 3 4 Turn Decal will come from the previous chart and diagram application Substrate can vary GAP will be dependent on the substrate thickness Pressure will be determined by operator Speed is not indicated in Footswitch mode Because the process is described from the front of the laminator motor direction is FWD and the pull rolls are not required for this application
167. set SAV t Replace the front infeed table and lower the M SHUT DOWN front safety shield z p FWD 00 0 GO SPEED ian Y STOP id i INFORMATION SAFETY The SAFETY indicator should not be flashing when the tables are properly LL Flashi ng seated and the safety shields are in the closed position GBC Pro Tech August 1999 Page 4 21 Installation F 160 Operation and Maintenance Manual 1 Press down on the variable speed footswitch 4 8 2 Variable speed GO begins flashing and the bottom rollers are footswitch tuming This check is to ensure that the footswitch works For complete instructions on the footswitch and its relation to Footswitch mode to Panel mode refer to Section 5 1 Controls 28 Footswitch i I I Cii a Press SEL on the front control panel to wake the laminator from SLEEP mode SLEEP indicator reverts to hollow INFORMATION Notice that the footswitch speed is not indicated in the SPEED DISPLAY on the front control panel ia I SEL SAV L ww SHUT DOWN B ashing 4 8 3 Unwind shafts and unwind brakes JoB Q b Press FWD A for a forward motor direction The unwind shafts swing out and the unwind EWID SONIS brakes tension the turning of the shaft from no tension to complete stop tension 00 0 U GO dd P Should you detect or experience complicat
168. t Speed will be determined by the operator Pull roll pressure may vary between 1 2 turn and 3 4 turn Because the process is described from the front of the laminator motor direction is FWD Page 6 104 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications Web Diagram 4 Single sided Craft paper P S A Release liner Laminate Output 4 Craft Paper Finish product rewind option oy Io O GBC Pro Tech August 1999 Page 6 105 Applications F 160 Operation and Maintenance Manual Parameter Chart 5 Decal and mount Decal MATERIALS UPPER UNWIND Pro Gloss SUBSTRATE N A LOWER UNWIND Pro Mount PRINTS Inkjet prints TEMPERATURE TOP TEMP BOT TEMP 68 68 GAP amp PRESSURE PRESSURE MI MOTOR DIRECTION amp SPEED M lt Panel GO i Footswitch GO PULL ROLL SETTINGS i UP N A a lt a 1 4 Turn PRESSURE G 1 2 Turn DOWN D 3 4 Turn Upper and lower unwind material can be of similar product Print can be of any type Pressure will will vary slightly with regards to quality of the output Speed will be determined by the operator Pull roll pressure may vary between 1 2 turn and 3 4 turn Becau
169. t which point no bars will be illuminated GAP r PRESSURE 14 N WARNING Keep hands and fingers clear of the laminator roller nip when adjusting PRESSURE MANIN U You can be CRUSHED or BURNED 13 PRESSURE V When pressed once will increase the pressure by 596 If held down it will increase from 0 of the minimum allowed pressure to 100 at which point all bars will be illuminated GAP r PRESSURE 17 1 4 li DIU 14 JOB DISPLAY Displays the job number selected and will set the operating parameters saved for that number once SEL has been pressed SHUT DOWN INFORMATION Job programming is explained in Section 5 4 O GBC Pro Tech August 1999 Page 5 3 Operations F 160 Operation and Maintenance Manual 15 JOB A When pressed once will increase the job number in JOB DISPLAY by increments of 1 If pressed and held the JOB DISPLAY will increase to 9 at which point it will stop SHUT DOWN 16 JOB V When pressed once will decrease the job number in JOB DISPLAY by increments of 1 If pressed and held the JOB DISPLAY will decrease to O at which point it will stop fse I sav JOB A 1 SHUT DOWN 6 17 SEL When pressed will send the operating parameters for the stored job number selected to the correct devices Any time JOB A or JOB V is pressed SEL will flash indicatin
170. table This application can be performed in various methods The process described in this manual is the most common method N WARNING JoB 0 Do not wear ties loose fitting clothing or v sp dangling jewelry while operating or k Lower the front and rear safety shields and press SHUTDOWN if finished with the laminator servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned End of application Pass 1 Decal Use Chart 5 and Diagram 5 for assistance Page 6 34 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications Materials needed Roll of pressure sensitive over laminate Roll of mount adhesive same width as the laminate Print smaller than the laminate Roll of masking tape Utility knife Cutting blade with an enclosed casing e Piece of cardboard film width x 6 Set up a Turn MAIN POWER to ON Refer to Figure 6 5 1 b Press RESET Refer to Figure 6 5 1 Figure 6 5 1 MAIN POWER RESET MAIN POWER c Ensure that the rear pull rollers are in the up position d Raise the front and rear safety shields N WARNING Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED e Lift the clevis pin located in the saddle of the upper unwind shaft
171. the rollers N CAUTION If silicone adhesive contacts the laminating rollers remove it IMMEDIATELY using 80 isopropyl alcohol It can harden within an hour and bond to the rollers 1 7 Maintenance The following symbols are positioned at various points in Section 7 Troubleshooting N WARNING Do not wear ties loose fitting clothing or dangling jewelry while operating or servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned Page 1 16 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Safety INFORMATION N CAUTION Below is a recommended maintenance Excessive pressure can destroy the silicone schedule Before performing any of the steps layer by pressing to hard or scrubbing listed read through the procedures first too long in one spot Please follow the instructions pertaining to the step you are performing N CAUTION ELECTRICAL f i SHOCK Do NOT pick or pull heat activated adhesive off the rolls when they are cold You can cause irreparable damage to the laminating rolls Remove power from the laminator before servicing You can be severely shocked electrocuted or cause a fire INFORMATION INFORMATION When cleaning the bottom main roller switch the motion direction to reverse When cleaning the bottom pull roller switch the motion direction to forward This will prevent anything from bein
172. tion Figure 4 1 1 Suggested Floor Layout 20 d 6m 96 cm A A 4 x 6 1 22 m x 2m Work table on wheels 8 4 2 57 m Table height 35 3 4 94 95m 82 5 Y 209 cm E um 3 1 m 4 x6 1 22mx 2m Work table on wheels 8 4 2 57m Table height 35 3 4 94 95m J t 13 4m GBC Pro Tech August 1999 Page 4 3 Installation F 160 Operation and Maintenance Manual Figure 4 1 2 Single phase U S TB 2 TB 1 2 D Ill eres CJ e OOO e Ill C 9 gode e elele S O CES Q DOO CD lel lc GOO CO Cp IBI Cp CO ER eel Oe Incoming line voltage d CJ Figur
173. to Figure 6 9 2 INFORMATION Twisting the roll of laminate while sliding makes loading the film onto the unwind shaft easier Page 6 86 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications Figure 6 9 2 Unwind shaft i Lift the clevis pin located in the saddle of the lower unwind shaft Saddle ALA S Clevis pin O 9 Roll of C iy 9 laminate Core support Brake adjust knob e Core chucks O J Swing the lower unwind shaft out enough to slide the roll of thermal laminate over the core chucks on the lower unwind shaft Refer to Figure 6 9 2 g Once the roll of thermal laminate is on the upper unwind shaft swing the upper unwind shaft back into the saddle INFORMATION Twisting the roll of thermal laminate N CAUTION while sliding makes loading the film onto the unwind shaft easier Ensure the roll of laminate is loaded properly on the unwind shaft Exposed adhesive should be facing away from the rollers This will prevent hours of roll cleaning k Once the roll of thermal laminate is on the lower unwind shaft swing the lower unwind shaft back into the saddle h Push the clevis pin back down to secure the unwind shaft in its saddle D Push the clevis pin back down to secure the unwind shaft in its saddle O GBC P
174. ts and covers Figure 1 2 1 Cabinets and covers Cabinets Covers Page 1 2 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Safety An important feature of the F 160 laminator are Figure 1 2 3 Emergency stops the safety shields when raised the auto run is disabled and drive control is transferred to the footswitch Figure 1 2 2 illustrates the safety shields in the up position N WARNING Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED Figure 1 2 2 Safety shields raised To continue operation both EMERGENCY STOPS E STOPS must be in the up position To reset the E STOP twist the button 1 4 turn clockwise Refer to Figure 1 2 4 for illustration Figure 1 2 4 Reset E Stop buttons Rear safety Front safety shield T shield The laminator is equipped with two EMERGENCY STOPS located on the top of either side of the laminator To engage the EMERGENCY STOP feature press down on either one Either of these when engaged stops the laminator Refer to Figure 1 2 3 for illustration GBC Pro Tech August 1999 Page 1 3 Safety F 160 Operation and Maintenance Manual Press
175. urn PRESSURE q 1 2 Turn DOWN RC 3 4 Turn Substrate will vary Print can be of any type GAP will be dependent on the substrate thickness Pressure will be determined by operator Speed is not indicated in Footswitch mode Because the process is described from the front of the laminator motor direction is FWD and the pull rolls are not required for this application Page 6 102 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications Web Diagram 3 Single sided Sled P S A Release liner Laminate Print yy Y O GBC Pro Tech August 1999 Page 6 103 Applications F 160 Operation and Maintenance Manual Parameter Chart 4 Single sided Craft paper MATERIALS UPPER UNWIND Pro Gloss SUBSTRATE N A LOWER UNWIND Craft Paper PRINTS Inkjet prints TEMPERATURE TOP TEMP BOT TEMP 68 68 GAP amp PRESSURE PRESSURE MIM MOTOR DIRECTION amp SPEED 1 xq Panel GO Nu Footswitch GO PULL ROLL SETTINGS UP N A AP MC 1 4 Turn PRESSURE Qe 1 2 Turn DOWN D 3 4 Turn Upper unwind material can be of similar product Print can be of any type Pressure will will vary slightly with regards to quality of the outpu
176. ut the web near the rollers You can put cuts into the rollers r Tape the web to the lower rewind tube or let the web run out to a work table Refer to Figure 6 4 6 Figure 6 4 6 Finish product rewind Finished product rewind Cut the piece of cardboard off N WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED Presson the variable speed footswitch to lengthen the web enough to get one full wrap around the lower rewind tube O GBC Pro Tech August 1999 Page 6 31 Applications F 160 Operation and Maintenance Manual N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position s Replace the front infeed table Ensure that the table is seated properly t Close the front and rear safety shields INFORMATION The SAFETY indicator should not be flashing when the tables are properly seated and the safety shields are in the closed position u Press STOP 00 0 i maf GO SPEED l nEV SAFETY v Press SPEED A to a speed you feel comfortable working with It is recommended that SPEED not exceed 9 ft min 2 74 m min 9 0 GO SPEED U rev
177. way from the nip of the rollers SORORIS OU E You may be CRUSHED or BURNED Page 6 6 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications N WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED h With the stack of substrates within reach of the first person step on the variable speed footswitch while sliding one board in after the leader board with a 1 2 in gap between the two Refer to Figure 6 1 4 N CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position Figure 6 1 4 1 2 in Gap Substrate 1 2 Gap Precoated board INFORMATION The 1 2 in gap between boards will allow for easier separation of the boards by the second person AN WARNING Keep hands and fingers clear of the pull roller nip when changing the gap You can be CRUSHED i The person at the rear of the laminator will guide and lower the upper pull roller onto the leader board as it passes through the nip opening INFORMATION Do not lower the pull roller so that the substrate is crushed when passing through This will prevent the boards from bowing J As the boards come through the person at the rear of the machine will use the utility knife
178. wer unwind shaft add 1 4 in to the measurement q Press FWD A n Lower the safety shields FWR rev INFORMATION 00 0 If you have the parameters stored as a SPEED JOB number enter it now then press SAFETY GO CU STOP SEL and skip to step p other wise continue with step Page 6 72 O GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Applications r Press SPEED A to set a motor speed of v Press STOP 2 ft min 6 m min 1 rwn i wri 2 0 ao 2 0 GO SPEED U Rev SPEED nEV SAFETY 8 SAFETY s Press GAP to enter aO in gap setting Proce SS a Raise the front safety shield and remove the front infeed table GAP f PRESSURE fT o c LI Mo b Apply just enough brake tension to prevent the roll of thermal laminate from free spinning t Press GO INFORMATION Excessive brake tension may cause the with the second pass of this application output to curl This can create complications wei 2 0 ra aEv SPEED SAFETY c Pull the thermal laminate straight down toward the front infeed table so that approximately 6 in is resting on the front infeed table R
179. will decrease to the minimum temperature setting of 68 F 20 C SLEEP TOP TEMP i BOT TEMP A 8 88 ig 8 GAP DISPLAY Displays the current main roller nip opening The nip has a range of 0 to 1 gap SS M R D GAP T PR 9 GAP A When pressed will increase the gap by 1 16 in increments If held down it will automatically increase the gap by 1 16 in increments until it has reached a maximum opening of 1 in on the GAP DISPLAY GAP PRESSURE fi V4 p MM p 10 GAP V When pressed will decrease the gap by 1 16 in increments If held down it will automatically decrease the gap by 1 16 in increments until it has reached a minimum opening of 0 in on the GAP DISPLAY GAP 7 PRESSURE f M Page 5 2 GBC Pro Tech August 1999 F 160 Operation and Maintenance Manual Operations 11 PRESSURE DISPLAY Displays the amount of pressure being used Each bar represents 10 of the maximum allowable pressure All ten bars illuminated equals 100 of the maximum allowable pressure GAP i PRESSURE a4 I INFORMATION When adjusting the pressure the gap will be affected as well 12 PRESSURE A When pressed once will decrease the pressure by 5 If held down it will decrease from 10046 of the maximum allowed pressure to 096 a
180. y your adjustments when finished n Press GAP A to 1 in setting GAP PRESSURE f 0 Remove the level p Lower the front safety shield q Turn MAIN POWER to OFF 4 7 Safety check The safety check will ensure that all safety devices and interlock switches are functioning properly N WARNING Do not wear ties loose fitting clothing or dangling jewelry while operating or servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned N WARNING If you find a safety feature not working properly you should contact your local service representative immediately O GBC Pro Tech August 1999 Page 4 11 F 160 Operation and Maintenance Manual Installation 4 7 1 Front and rear infeed d Press FWD A to set a forward motor tables direction a Turn MAIN POWER to ON 00 0 c s 7 Main power L serv l Rd e Press SPEED A to seta speed of 6 ft min b Press RESET The front control panel will be illuminated wi Reset 6 0 GO SPEED lt gt nEv STOP SAFETY f Press GO The bottom rollers will begin to turn c Press SEL The SEL key should stop flashing i rwr 6 0 60 N SPEED 44 REV SEL SAV STOP JoB 7 SAFETY MV

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