GBC F - 160 User Manual

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F - 160 OPERATION AND

MAINTENANCE MANUAL

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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

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The information in this publication is provided for reference and is believed to be accurate and complete. GBC Pro - Tech is not liable for errors in this publication or for incidental or consequential damage in connection with the furnishing or use of the information in this publication, including, but not limited to, any implied warranty of fitness or merchantability for any particular use.

GBC Pro - Tech reserves the right to make changes to this publication and to the products described in it without notice. All specifications and information concerning products are subject to change without notice.

Reference in this publication to information or products protected by copyright or patent does not convey any license under the rights of GBC Pro - Tech or others. GBC Pro T ech 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, in whole or in part, in any form without the prior and express written permission of GBC Pro - Tech.

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F - 160 Operation and Maintenance ManualRead me file

F - 160 Operation and Maintenance Manual Read me file

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DeForest, WI 53532

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F - 160 Operation and Maintenance ManualRead me file

F - 160 Operation and Maintenance Manual

Table of Contents

Section 1: Safety

1.1 Symbols ......................................................................................................1 - 1

1.2 Safety features ...........................................................................................1 - 1

1.3 Installation .................................................................................................1 - 4

1.4 Operations ..................................................................................................1 - 8

T able of Contents

1.5 Applications ..............................................................................................1 - 12

1.6 Troubleshooting .......................................................................................1 - 16

1.7 Maintenance .............................................................................................1 - 16

1.8 Decal Explanation ....................................................................................1 - 19

Figure 1 - 6 Decal Location .......................................................1 - 20

Section 2: Warranty

2.1 Limited warranty information ...................................................................2 - 1

2.2 Exclusions to the warranty .......................................................................2 - 1

T able of Contents

Section 3: Specifications

3.1 General .......................................................................................................3 -1

3.2 Consumables ..............................................................................................3 - 1

3.3 Function .....................................................................................................3 - 2

3.4 Electrical ...................................................................................................3 - 2

F - 160 Operation and Maintenance Manual

3.5 Dimensions ................................................................................................3 - 3

Figure 3.5.1 Dimensions ...............................................................3 - 3

Section 4: Installation

4.1 Preinstallation check list ...........................................................................4 - 1

Figure 4.1.1 Suggested floor layout .............................................4 - 3

Figure 4.1.2 Single phase ( U.S. ) ................................................4 - 4

Figure 4.1.3 Three phase ( Europe ) ...........................................4 - 4

4.2 Unpacking .................................................................................................4 - 5

F - 160 Operation and Maintenance Manual

4.3 Shrink wrapped ........................................................................................4 - 5

4.4 Crated ........................................................................................................4 - 6

4.5 Accessory pack content ............................................................................4 - 8

4.6 Leveling .....................................................................................................4 - 8

4.7 Safety check ............................................................................................4 - 11

T able of Contents

4.7.1 Front and rear infeed tables ................................................................4 - 12

4.7.2 Front and rear safety shields ...............................................................4 - 14

4.7.3 Emergency stops ..................................................................................4 - 15

4.8 Function check ........................................................................................4 - 17

4.8.1 Control panel .......................................................................................4 - 18

Figure 4.8.1 Default settings ......................................................4 - 21

4.8.2 Variable speed footswitch ....................................................................4 - 22

4.8.3 Unwind shafts and unwind brakes .......................................................4 - 22

T able of Contents

Section 5: Operations

5.1 Control panel .............................................................................................5 - 1

Figure 5.1.1 Front control panel ................................................5 - 9

5.2 Emergency ...............................................................................................5 - 10

5.3 Set up .......................................................................................................5 - 11

F - 160 Operation and Maintenance Manual

5.3.1 Power ....................................................................................................5 - 11

5.3.2 Film loading ..........................................................................................5 - 12

Figure 5.3.4 Measurement chart ................................................5 - 13

5.3.5 Heating .................................................................................................5 - 13

5.4 Job programming ...................................................................................5 - 15

Figure 5.4.1 Job save chart ......................................................5 - 17

5.5 Manual nip adjustment ...........................................................................5 - 17

5.5.1 Main roller manual nip adjustment .....................................................5 - 17

5.5.2 Pull roller manual nip adjustment ........................................................5 - 20

F - 160 Operation and Maintenance Manual

5.6 Infeed tables ............................................................................................5 - 23

5.6.1 Removing the infeed tables ..................................................................5 - 23

5.6.2 Replacing the infeed tables ..................................................................5 - 23

Section 6: Applications

T able of Contents

Group 1: No heat

6.1 Precoating substrates ...............................................................................6 - 1

6.2 Mounting only .........................................................................................6 - 10

6.3 Single sided lamination ( Sled method ) ..................................................6 - 17

6.4 Single sided lamination ( Craft paper method ) ......................................6 - 25

6.5 Decal and mount .....................................................................................6 - 34

Pass 1 Decal ........................................................................................6 - 34

Pass 2 Mount .......................................................................................6 - 43

T able of Contents

6.6 Precoating substrates ..............................................................................6 - 51

6.7 One pass mount and laminate .................................................................6 - 60

6.8 Thermal decal and mount .......................................................................6 - 69

Pass 1 Thermal decal ...........................................................................6 - 70

F - 160 Operation and Maintenance Manual

Group 2: Top heat only

Pass 2 Mount ........................................................................................6 - 78

Group 3: Top and bottom heat

6.9 Encapsulation ...........................................................................................6 - 85

6.10 Parameter charts and diagrams

Figure 6.10.1 Temperature conversion chart ...................6 - 95

Blank chart ....................................................................................................6 - 96

Blank diagram ...............................................................................................6 - 97

Chart 1 - Precoating substrates .....................................................................6 - 98

F - 160 Operation and Maintenance Manual

Diagram 1 - Precoating subtrates .................................................................6 - 99

Chart 2 - Mounting only ...............................................................................6 - 100

Diagram 2 - Mounting only .........................................................................6 - 101

Chart 3 - Single sided ( Sled ) ......................................................................6 - 102

Diagram 3 - Single sided ( Sled ) .................................................................6 - 103

T able of Contents

Chart 4 - Single sided ( Craft paper ) ..........................................................6 - 104

Diagram 4 - Single sided ( Craft paper ) .....................................................6 - 105

Chart 5 - Decal and mount ( Decal ) ...........................................................6 - 106

Diagram 5 - Decal and mount ( Decal ) ......................................................6 - 107

Chart 6 - Decal and mount ( Mount ) .........................................................6 - 108

Diagram 6 - Decal and mount ( Mount ) ....................................................6 - 109

Chart 7 - Precoating subtrates ....................................................................6 - 110

Diagram 7 - Precoating subtrates ................................................................6 - 111

Chart 8 - One pass mount ............................................................................6 - 112

T able of Contents

Diagram 8 - One pass mount .......................................................................6 - 113

Chart 9 - Thermal decal and mount ( Decal ) .............................................6 - 114

Diagram 9 - Thermal decal and mount ( Decal ) ........................................6 - 115

Chart 10 - Thermal decal and mount ( Mount ) ..........................................6 - 116

Diagram 10 - Thermal decal and mount ( Mount ) .....................................6 - 117

F - 160 Operation and Maintenance Manual

Chart 11 - Encapsulation .............................................................................6 - 118

Diagram 11 - Encapsulation ........................................................................6 - 119

Section 7: Troubleshooting

7.1 Wave problems .........................................................................................7 - 1

7.2 Film problems ...........................................................................................7 - 3

7.2.1 Thermal laminates .................................................................................7 - 3

7.2.2 Pressure senstive ....................................................................................7 - 3

7.3 Machine problems .....................................................................................7 - 4

F - 160 Operation and Maintenance Manual

7.4 Glossary ....................................................................................................7 - 5

Section 8: Maintenance

8.1 Maintenance schedule ...............................................................................8 - 1

8.2 Cleaning the rollers ..................................................................................8 - 2

8.2.1 Cabinets and covers ...............................................................................8 - 6

T able of Contents

8.2.2 Touch screen control panel ....................................................................8 - 6

T able of Contents

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F - 160 Operation and Maintenance Manual

Section 1 Safety

CAUTION

Do not attempt to operate your Falcon 160

laminator until you have read this section

carefully!

Safety

WARNING

Indicates a potentially hazardous situation

which, if not avoided, could result in serious

injury.

Y our safety , as well as the safety of others, is important to GBC Pro - T ech. This section contains important safety information.

The following symbols are used throughout this manual to indicate Information, Caution, W arning,

Danger and Electrical Shock conditions.

1.1 Symbols

INFORMATION

DANGER

Indicates an imminently hazardous situation

which, if not avoided, could result in death

or serious injury.

ELECTRICAL

SHOCK

Indicates an electrical shock situation which,

if not avoided, could result in serious

paralyzation of the body or death.

Indicates helpful information that should be

considered before, during, or after an

action, step or procedure is given.

1.2 Safety features

CAUTION

The F-160 laminator has been designed with

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.

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.

Safety F - 160 Operation and Maintenance Manual

Cabi

GBC Pro - T ech 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 emergency . 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.

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-T ech standards to fulfill that job. This person will have completed and passed the full service training course from GBC Pro-T ech.

• Any GBC T echnician, GBC Specialist, and / or GBC Pro-T ech Technician that has been through the GBC Pro-T ech service training course.

In addition, the main laminating rolls of the F160 can reach temperatures of over 200oF ( 100oC ).

DANGER

At these temperatures there is a danger of

severe burn if the rolls are touched during

setup, operation or servicing.

INFORMATION

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 cabinets and covers.

Figure 1.2.1 Cabinets and covers

nets

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Only a qualified service technician should

perform any procedure in Part B of this

manual.

Covers

F - 160 Operation and Maintenance Manual

Safety

An important feature of the F-160 laminator are 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.

WARNING

Caution should always be exercised

when using the laminator with

the safety shields raised.

You can be seriously HURT or INJURED!

Figure 1.2.3 Emergency stops

Emergency stop

buttons

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Figure 1.2.2 Safety shields raised

Rear safety

shield

Front safety

shield

T o continue operation, both EMERGENCY

STOPS ( E-STOPS ) must be in the up position. T o

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

Unlatch

The laminator is equipped with two EMERGENCY STOPS located on the top of either side of the laminator. T o 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.

Safety F - 160 Operation and Maintenance Manual

Press 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.

1.3 Installation

The following symbols are positioned at

various points in Section 4 Installation.

CAUTION

Failure to follow the pre-installation check

list can result in damage to the laminator.

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

WARNING

The operating environment must be free of

dust, flammable liquids and vapors. You can

be injured by inhaling chemical vapors.

WARNING

Vapor build up or stored flammable liquids can cause a fire. Excessive dust can damage

the laminator.

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.

F - 160 Operation and Maintenance Manual

Safety

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.

INFORMATION

ALL SHIPMENTS ARE EX-WORKS.

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.

At our

people. You can be severely injured, crushed

WARNING

The unpacking process requires at least two

or cause damage to the laminator.

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.

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.

Do not attempt to move the laminator across

Do not allow the top to fall into the crate. It

WARNING

anything other than a flat level surface

without trained and qualified riggers. You

can be crushed or seriously injured.

CAUTION

can damage the laminator.

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 or you can

become injured if stepped on.

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.

CAUTION

Do not allow the top to fall into the crate. It

can damage the laminator.

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.

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.

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.

F - 160 Operation and Maintenance Manual

Safety

INFORMATION

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

INFORMATION

A second person can read the level while you

make the appropriate adjustments.

WARNING

Do not wear ties, loose fitting clothing or

dangling jewelry while operating or

be crushed or burned.

WARNING

If you find a safety feature not working properly, you should contact your local

service representative immediately

WARNING

Caution should always be exercised

when using the laminator with

the safety shields raised.

You can be seriously HURT or INJURED!

WARNING

Keep hands and fingers clear of the

laminator roller nip when changing GAP.

You can be CRUSHED or BURNED!

INFORMATION

Do not put packing screws on the floor.

They can cause problems when trying to roll

the laminator into position.

INFORMATION

The SAFETY indicator should not be

flashing when the tables are properly

seated and the safety shields are in

the closed position..

Safety F - 160 Operation and Maintenance Manual

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.

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

Read the following warnings and cautions

before attempting to operate 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

If the variable speed footswitch is not

close to the speed of the control panel,

output quality may be affected by the

speed difference.

WARNING

INFORMATION

When adjusting the pressure, the gap

will be affected as well.

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!

F - 160 Operation and Maintenance Manual

Safety

CAUTION

Speed is controlled through the variable

speed footswitch when the safety shield

is in the raised position.

WARNING

Caution should always be exercised

when using the laminator with

the safety shields raised.

You can be seriously HURT or INJURED!

INFORMATION

Footswitch speed is not indicated in the

SPEED DISPLAY on the control panel.

INFORMATION

When the safety shield is lowered, speed

reverts to the panel speed setting.

WARNING

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.

At these temperatures there is a danger

ofsevere burn if the rolls are touched

duringsetup, operation or servicing.

INFORMATION

When an EMERGENCY STOP is engaged,

all motion stops. The nip will not change

from the operating setting.

INFORMATION

Twisting the roll of film while sliding

makes loading the film onto the

unwind shaft easier.

Safety F - 160 Operation and Maintenance Manual

INFORMATION

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!

INFORMATION

For the lower unwind shaft, add 1/4 in. to

the measurement.

Slow speed will assists with heat up times

and distributes heat evenly.

INFORMATION

When the laminator is first turned on, the front control panel will go into the default

mode.

Default mode; TOP TEMP. = 68

F ( 20 oC ), 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

INFORMATION

When requiring top and bottom heat, it is

recommended to set both temperatures to

the same set point.

INFORMATION

Do not add PRESSURE when heating the

laminating rollers, this allows the high

release silicone to expand with minimum

restrictions.

WARNING

Keep hands and fingers clear of the

laminator roller nip when changing GAP.

You can be CRUSHED or BURNED!

INFORMATION

When storing parameters within the JOB

SAVE feature of the laminator, PRESSURE

is not a storable setting.

F - 160 Operation and Maintenance Manual

Safety

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

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.

CAUTION

Sharp edges on a substrate should be filed

smooth and GAP manually adjusted.

Sharp edges can CUT the rollers!

CAUTION

Excess pressure can damage the laminating

rollers. Always use the minimum roll

pressure necessary to complete the task.

WARNING

Keep hands and fingers clear of the pull

roller nip when changing the gap.

You can be CRUSHED!

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.

Excessive pressure will cause the

substrate to bow or flatten.

INFORMATION

Safety F - 160 Operation and Maintenance Manual

CAUTION

If not installed properly, you can be injured

or cause damage to the table or laminator.

1.5 Applications

The following symbols are positioned at

various points in Section 6 Applications.

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!

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

The mount adhesive must not exceed 1 in.

the width of the substrate. If it does, you

will experience complications with this

application.

INFORMATION

Twisting the roll of craft paper while

sliding makes loading the film onto

the unwind shaft easier.

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!

F - 160 Operation and Maintenance Manual

Safety

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!

WARNING

Keep hands and fingers clear of the

laminator roller nip when changing GAP.

You can be CRUSHED or BURNED!

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!

CAUTION

Speed is controlled through the variable

speed footswitch when the safety shield

is in the raised position.

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.

WARNING

Keep hands and fingers clear of

the laminator roller nip when

adjusting PRESSURE.

You can be CRUSHED or BURNED!

INFORMATION

Excessive pressure will cause the

substrate to bow or flatten.

CAUTION

Excess pressure can damage the laminating

rollers. Always use the minimum roll

pressure necessary to complete the task.

Safety F - 160 Operation and Maintenance Manual

INFORMATION

PRESSURE will vary with the thickness and width of the laminate you are using.

Adjust as necessary.

INFORMATION

The leading edge is the first part of the

board or image that enters the nip

of the rollers.

INFORMATION

When requiring top and bottom heat, it is recommended to set both temperatures to

the same set point.

INFORMATION

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.

CAUTION

Prolonged contact can form flat spots on the

rollers.

CAUTION

INFORMATION

Do not add PRESSURE when heating the

laminating rollers, this allows the high

release silicone to expand with minimum

restrictions.

INFORMATION

Slow speed will assists with heat up times

and distributes heat evenly.

When manually setting the main roll nip,

observe the substrate to prevent crushing.

F - 160 Operation and Maintenance Manual

Safety

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

make for a difficult mounting application.

INFORMATION

If the board is not squarely positioned,

you may experience difficulties with

this application.

WARNING

Keep hands and fingers clear of the pull

roller nip when changing the gap.

You can be CRUSHED!

INFORMATION

Do not lower the pull roller so that the

substrate is crushed when passing through.

This will prevent the boards from bowing.

INFORMATION

If the image is not conformed to the roller,

you may experience difficulties with

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.

CAUTION

Caution should always be exercised when

using a utility knife near the rollers.

You can put cuts into the rollers!

INFORMATION

Stopping the rollers on the print will leave a

pressure line on the image.

Safety F - 160 Operation and Maintenance Manual

1.6 Troubleshooting

CAUTION

The following symbols are positioned at

various points in Section 7 Troubleshooting.

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

Prolonged contact can form flat spots on the

rollers.

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.

For optimal temperature settings of

various laminates, contact your supplier or sales representative.

1.7 Maintenance

various points in Section 7 Troubleshooting.

CAUTION

Exercise care when cleaning the laminating

rollers with 80% isopropyl alcohol:

Use only in a well ventilated area



Wear rubber gloves



Use only on cool rolls



CLEANING HEATED ROLLERS CAN

IGNITE THE FUMES!

The following symbols are positioned at

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.

F - 160 Operation and Maintenance Manual

Safety

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.

ELECTRICAL

SHOCK

Remove power from the laminator before

servicing. You can be severely shocked,

electrocuted or cause a fire.

Do NOT pick or pull heat activated adhesive

CAUTION

Excessive pressure can destroy the silicone

layer by pressing to hard or scrubbing

too long in one spot.

CAUTION

off the rolls when they are cold. You can

cause irreparable damage to the

laminating rolls.

INFORMATION

If improperly performed, you may

encounter other problems with the output

quality.

WARNING

Caution should always be exercised

when using the laminator with

the safety shields raised.

You can be seriously HURT or INJURED!

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

being pulled into the nip.

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!

Safety F - 160 Operation and Maintenance Manual

CAUTION

Speed is controlled through the variable

speed footswitch when the safety shield

is in the raised position.

CAUTION

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.

WARNING

Keep hands and fingers clear of

the laminator roller nip when

adjusting PRESSURE.

You can be CRUSHED or BURNED!

ELECTRICAL

SHOCK

Remove power from the laminator before

cleaning. You can be severely shocked,

electrocuted or cause a fire.

CAUTION

Exercise care when cleaning the laminating

rollers with 80% isopropyl alcohol:



Use only in a well ventilated area



Wear rubber gloves



Use only on cool rolls

CLEANING HEATED ROLLERS CAN

IGNITE THE FUMES!

WARNING

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.

Keep hands and fingers clear of the

laminator roller nip when changing GAP.

You can be CRUSHED or BURNED!

F - 160 Operation and Maintenance Manual

1.8 Label locations

WARNING ACHTUNG

Safety

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.

WARNING ACHTUNG

MISE EN GARDE

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.

WARNING

ACHTUNG

MISE EN GARDE

Roller Pinch Point: Keep hands and fingers away. Y ou may be crushed and/ or burned.

Electrical Shock: Live voltage present. Exercise extreme caution. Y ou may be electrocuted!

Danger V oltage: High voltage wires. Y ou may be shocked, electrocuted, paralyzed or die!

Safety F - 160 Operation and Maintenance Manual

Figure 1.8.1 Label locations

WARNING ACHTUNG

MISE EN GARDE

WARNING ACHTUNG

MISE EN GARDE

Inside cabinet

WARNING ACHTUNG

MISE EN GARDE

Behind Cover

WARNING

ACHTUNG

MISE EN GARDE

WARNING ACHTUNG

MISE EN GARDE

Behind cabinet

WARNING ACHTUNG

MISE EN GARDE

WARNING ACHTUNG

MISE EN GARDE

Rear location

WarrantyF - 160 Operation and Maintenance Manual

Section 2 Warranty

GBC Pro-T ech warrants the equipment sold is

free from defects in material 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-T ech and connot be modified or amended.

GBC Pro-T ech’ s sole and exclusive liability and the customer’s sole and exclusive remedy under this warranty shall be, at GBC Pro-T ech’ s option, to repair or replace any such defective part or product. These remedies are only available if GBC Pro-T ech’ s examination of the product discloses to GBC Pro-T ech’ 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.

THE WARRANTY MADE HEREIN IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. GBC PRO-TECH WILL NOT BE LIABLE FOR PROPERTY DAMAGE OR PERSONAL INJURY ( UNLESS PRIMARILY CAUSED BY ITS NEGLIGENCE ), LOSS OF PROFIT OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE THE EQUIPMENT.

2.2 Exclusions to the

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 .

CAUTION

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.

Unauthorized customer alterations will

void this warranty.

4. Damage due from unqualified person(s) servicing the

machine.

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 GBC T echnician, GBC Specialist, and / or GBC Pro-T ech Technician that has been through the GBC Pro-T ech service training course.

F - 160 Operation and Maintenance Manual

Section 3.1 General

Specifications

Description :

Features :

Applications :

• Mid level, wide format color finisher for the sheet fed ink jet market. The Falcon 160 is a self standing, bi directional laminator..

• T wo unwinds ( 1 upper, 1 lower )

• T wo rewinds ( 1 upper front, 1 lower center )

• Safety shielded

• Infeed and oufeed tables

• Accelerator footswitch

• Job programmable

• Bi-directional system

• Single sided lamination

• Encapsulation

• Mounting

• Decaling

Section 3.2 Consumables

Film T ypes :

Film Diameters :

Core Size :

Film Widths :

• Pressure sensitive laminates

• Pressure sensitive adhesives

• Low melt laminates

• Thermal laminates

• Thermal adhesives

• Up to a 8” roll diameter ( 20.3 cm )

• 3” core standard ( 7.62 cm )

• 2-1/4” optional ( must have optional core adapters ) ( 5.72 cm )

• 64” Pressure sensitive ( 162.6 cm )

• 62” Thermal ( 157.8 cm )

Paper Widths :

Mounting Thickness :

• 62” maximum paper width ( 157.8 cm )

• Up to 1” inch thick ( 2.54 cm ) either direction

Specifications F - 160 Operation and Maintenance Manual

Section 3.3 Function

Speed :

Motor :

Heating Capabilities :

Controls :

Job Save :

Roll Design :

• 0 - 15 ft / min ( 0 - 4.6 m / min )

• 2-1/4 horse power drive motor

• Bi-directional D.C. motor

• 68oF - 290oF ( 20oC - 143oC )

• Front control panel

• V ariable speed footswitch

• Save up to 9 job parameters

• High release silicone rolls

Section 3.4 Electrical

United States :

Europe :

B.T .U. output :

Heater W attages :

Amperage Draw :

D/C V oltage used :

Requirements

• 230 - 240 VAC, 50/60 Hz, single phase, 55 amps.

• 230 - 240 VAC, W ye 3 phase, 32 amps/ phase

• 31,732 B.T .U. / hour

• 4650 watts per heater

• No heat, motor only : 1 - 3 amps

• T op heat and motor : 20 - 23 amps

• Both heat and motor : 40 - 43 amps

• 24 vdc

• 12 vdc isolated x 2

• 24 vdc isolated

A/C V oltage used:

• 230 vac ( minimum )

F - 160 Operation and Maintenance Manual

Section 3.5 Dimensions

Specifications

W eight :

Dimensions :

Nip Height :

Safety Shield Raised Height :

Figure 3.5.1 Dimensions

• Crated : 1568 lbs. ( 711 kg. )

• Uncrated : 1200 lbs. ( 544 kg. )

• Crated : 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

• 37 3/16 in. ( 95 cm )

• 66 5/8 in. ( 169 cm)

54"

82.5"

Plane4

38"

Specifications F - 160 Operation and Maintenance Manual

This page intentionally left blank.

F - 160 Operation and Maintenance Manual

Installation

Section 4 Installation

GBC Pro-T ech 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.

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.

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.

WARNING

CAUTION

Failure to follow the pre-installation check

list can result in damage to the laminator.

4.1 Pre-installation

Are doorways and hallways wide eneough for the laminator to be moved to the installation site?

Is there ample room for the laminator?

The operating environment must be free of

dust, flammable liquids and vapors. You can

be injured by inhaling chemical vapors.

WARNING

Vapor build up or stored flammable liquids can cause a fire. Excessive dust can damage

the laminator.

CAUTION

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. machine area layout.

Figure 4.1.1

illustrates a typical

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.

Installation

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.

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.

F - 160 Operation and Maintenance Manual

Figure 4.1.2 illustrates proper wiring for single phase

for the U.S..

Figure 4.1.3 illustrates proper wiring for W ye 3 phase for Europe.

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.

F - 160 Operation and Maintenance Manual

Figure 4.1.1 Suggested Floor Layout

4' x 6' ( 1.22 m x 2m )

Work table on wheels

8.4'

( 2.57 m )

Table height

35-3/4" ( .94 - .95m )

Installation

82.5"

( 209 cm )

20'

( 6 m )

38"

( 96 cm )

8.4'

( 2.57m )

3' ( 1 m)

4' x 6' ( 1.22 m x 2m )

Work table on wheels

Table height

35-3/4" ( .94 - .95m )

13' ( 4 m)

Installation

Figure 4.1. 2 Single phase, U.S.

TB 1

F - 160 Operation and Maintenance Manual

TB 2

Incoming line voltage

Figure 4.1.3 Wye 3 phase, Europe only

TB 1

TB 2

Incoming line voltage

N 2

L 3 - 2

Correct Configuration

F - 160 Operation and Maintenance Manual

Installation

4.2 Unpacking

INFORMATION

ALL SHIPMENTS ARE EX-WORKS.

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.

At our

With regards to your shipping methods, use one of the following procedure described to safely and properly unwrap / uncrate your laminator .

4.3 Shrink Wrapped

a) Inspect the machine for any obvious shipping

damages upon receipt.

b) Carefully unwrap the shrink wrap from around

the laminator .

CAUTION

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.

WARNING

The unpacking process requires at least two

people. You can be severely injured, crushed

or cause damage to the laminator.

Do not attempt to move the laminator across

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.

c) With another person, carefully wheel your

F - 160 Laminator to the installation site.

WARNING

anything other than a flat level surface

without trained and qualified riggers. You

can be crushed or seriously injured.

Installation

F - 160 Operation and Maintenance Manual

4.4 Crated

Tools required

• # 2 Phillips head screwdriver

• 7/8” open end wrench or adjustable wrench

• Crow bar

• A 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

Figure 4.4.1 Disassembling of the crate

P l a n e

P l a n e 4

CAUTION

Do not allow the top to fall into the crate. It

can damage the laminator.

Removing the shrink wrap

INFORMATION

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.

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.

a) Gently unwrap the shrink wrap from around the

laminator.

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.

F - 160 Operation and Maintenance Manual

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.

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.

Installation

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

Figure 4.4.2 Positioning of the ramps

WARNING

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.

b) Remove any plastic strapping and/or packing

paper taped to the rolls.

CAUTION

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.

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.

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.

contact your local service technician or sales representative.

4.6 Leveling

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.

way the machine performs. Leveling is crucial to the tram ( tracking ) of the materials through the machine.

If you are missing any of the itemslisted above,

Leveling of the laminator is very important in the

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 )

• One T erry clothe towel ( 475-950 )

• One Operators manual ( 930-031 )

• One roll masking tape ( 475-000 )

• T wo 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 )

• T wo fuses, 2.5A ( 186-220 )

INFORMATION

Improper leveling, will result in poor

output quality.

Tools required

• T orpedo level

• ( 2 ) 3/4” open end wrenches

• Four leveling pads ( from the accessory pack )

• Second person

Preparation

a) V erify that the laminator has sufficient room

around it to load film, walk around and serviced if necessary .

F - 160 Operation and Maintenance Manual

Installation

b) Attach one leveling pad to each one of the four

foot bolts near the castors. Refer to Figure

4.6.1

Figure 4.6.1 Foot bolts

Foot bolts

b) Level the control side from front to back.

INFORMATION

A second person can read the level while you

make the appropriate adjustments.

c) Position the level on the top of the drive side

frame. Not on the cabinet.

d) Level the drive side from front to back.

Levelin

pads

c) 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

Figure 4.6.2 Front to back

Level

INFORMATION

The side frame provides a more accurate

reading than the cabinet.

Installation

e) Ensure that nothing is in the path of the main roll

nip.

f) Confirm that power is supplied to the laminator.

F - 160 Operation and Maintenance Manual

WARNING

Caution should always be exercised

when using the laminator with

the safety shields raised.

You can be seriously HURT or INJURED!

g) Turn the MAIN POWER to “ON” position.

Main Power

h) Press RESET. The front control panel should

be illuminated at this point.

i) Raise the front safety shield. The SAFETY

indicator will begin flashing.

FWR

REV.

00.0

SPEED

SAFETY

STOP

= Flashing

WARNING

Keep hands and fingers clear of the

laminator roller nip when changing GAP.

You can be CRUSHED or BURNED!

Reset

j) Press GAP t to “0”.

GAP PRESSURE

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

Plane4

o) Remove the level.

p) Lower the front safety shield.

q) Turn MAIN POWER to “OFF “.

Plane4

4.7 Safety check

l) Level the machine from left to right.

m) V erify your adjustments when finished.

n) Press GAP

s to 1 in. setting.

The safety check will ensure that all safety

devices and interlock switches are functioning properly .

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.

WARNING

GAP

PRESSURE

properly, you should contact your local

service representative immediately

If you find a safety feature not working

Installation

F - 160 Operation and Maintenance Manual

4.7.1 Front and rear infeed

tables

a) Turn MAIN POWER to “ON” .

Main power

d) Press FWD s to set a forward motor

direction.

FWR

REV.

00.0

SPEED

SAFETY

STOP

e) Press SPEED s to set a speed of 6 ft/min.

b) Press RESET. The front control panel will be

illuminated.

Reset

c) Press SEL. The SEL key should stop flashing.

FWR

REV.

6.0

SPEED

SAFETY

STOP

f) Press GO. The bottom rollers will begin to turn.

JOB

SEL

SHUT DOWN

SAV

6.0

SPEED

SAFETY

FWR

REV.

STOP

F - 160 Operation and Maintenance Manual

Installation

g) Slightly lift the front infeed table. SAFETY

indicator and GO begin flashing and the bottom rollers stop.

FWR

REV.

6.0

SPEED

SAFETY

STOP

= Flashing

h) Lower the front infeed table.SAFETY

indicator reverts to white and GO remains flashing.

j) Press GO. The bottom rollers begin turning.

FWR

REV.

6.0

SPEED

SAFETY

STOP

k) Slighly lift the rear infeed table. SAFETY

indicator and GO begin flashing and the bottom rollers stop.

FWR

REV.

6.0

SPEED

SAFETY

STOP

= Flashing

i) Press STOP. GO stops flashing.

FWR

REV.

6.0

SPEED

SAFETY

STOP

FWR

REV.

6.0

SPEED

SAFETY

STOP

= Flashing

l) Lower the rear infeed table. SAFETY indicator

reverts to white and GO remains flashing.

FWR

REV.

6.0

SPEED

SAFETY

STOP

= Flashing

Installation

F - 160 Operation and Maintenance Manual

m) Press STOP. GO stops flashing.

FWR

REV.

6.0

SPEED

SAFETY

STOP

4.7.2 Front and rear safety

shields

b) Raise the front safety shield. SAFETY indicator

and GO begin flashing and the bottom rollers stop.

FWR

REV.

6.0

SPEED

SAFETY

STOP

= Flashing

h) Lower the front safety shield. SAFETY

indicator reverts to white and GO remains flashing.

a) Press GO. The bottom rollers begin turning.

FWR

REV.

6.0

SPEED

SAFETY

STOP

WARNING

Caution should always be exercised

when using the laminator with

the safety shields raised.

You can be seriously HURT or INJURED!

FWR

REV.

6.0

SPEED

SAFETY

STOP

= Flashing

i) Press STOP .GO stops flashing.

FWR

REV.

6.0

SPEED

SAFETY

STOP

F - 160 Operation and Maintenance Manual

Installation

j) Press GO. The bottom rollers begin turning.

FWR

REV.

6.0

SPEED

SAFETY

STOP

WARNING

Caution should always be exercised

when using the laminator with

the safety shields raised.

You can be seriously HURT or INJURED!

l) Lower the rear safety shield. SAFETY indicator

reverts to white and GO remains flashing.

FWR

REV.

6.0

SPEED

SAFETY

STOP

= Flashing

m) Press STOP. GO stops flashing.

FWR

REV.

6.0

SPEED

SAFETY

STOP

k) Raise the rear safety shield. SAFETY indicator

and GO begin flashing and the bottom rollers stop.

FWR

REV.

6.0

SPEED

SAFETY

STOP

= Flashing

4.7.3 EMERGENCY STOPS ( E-STOP )

a) Press GO. The bottom rollers begin turning.

FWR

REV.

6.0

SPEED

SAFETY

STOP

Installation

Push

Unl

F - 160 Operation and Maintenance Manual

b) Press down on the control side E-STOP. The

E-STOP latches in the down position, bottom

rollers stop, and the control panel is blank

c) Unlatch the E-STOP as illustrated below .

e) Press SEL. SEL stops flashing.

JOB

SEL

SHUT DOWN

SAV

f) Press FWD s for a forward motor direction.

atc

d) Press RESET. The front control panel is

illuminated.

RESET

FWR

REV.

00.0

SPEED

SAFETY

STOP

g) Press SPEED s to a speed of 6 ft/min.

FWR

REV.

6.0

SPEED

SAFETY

STOP

F - 160 Operation and Maintenance Manual

Push

Unl

Installation

h) Press GO. The bottom rollers will begin to

turn.

6.0

SPEED

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.

STOP

FWR

REV.

k) Press RESET. The front control panel is

illuminated.

RESET

4.8 Function check

j) Unlatch the E-STOP as illustrated below .

atc

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 .

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.

Installation

F - 160 Operation and Maintenance Manual

4.8.1 Control panel

a) Press TOP TEMP . s to a value of 120oF

( 48 oC ). TOP TEMP DISPLAY begins flashing.

SLEEP

TOP TEMP.

120

b) Press BOT TEMP s to a value of 120oF

( 48 oC ). BOT TEMP DISPLAY begins flashing.

BOT. TEMP

d) Press GAP s. 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

0 - 1

e) Press and hold PRESSURE t. 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.

SLEEP

TOP TEMP.

120

c) Press GAP t 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 PRESSURE

BOT. TEMP

120

1 - 0

GAP PRESSURE

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.

GAP PRESSURE

F - 160 Operation and Maintenance Manual

g) Press JOB s. The JOB DISPLAY should

increases in increments of 1 to 9.

Installation

INFORMATION

To continue with the function checks, you

must press SEL so that it discontinues

flashing.

JOB

SEL

SHUT DOWN

SAV

h) Press JOB t . The JOB DISPLAY should

decreases in increments of 1 from 9 to 0.

JOB

SEL

SHUT DOWN

SAV

j) Press SPEED s once. SPEED DISPLAY

increases in increments of .5 per press up to 15.

FWR

REV.

SPEED

SAFETY

STOP

k) Press FWD s. 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.

FWR

REV.

JOB

SEL

SHUT DOWN

= Flashing

SAV

SPEED

SAFETY

STOP

Installation

F - 160 Operation and Maintenance Manual

l) Press GO. The bottom rollers turn in a forward

motion at a speed of 15 ft./min. ( 4.57 m / min. ).

FWR

REV.

SPEED

SAFETY

STOP

m) Press STOP. The bottom rollers stop turning.

o) Press GO. The bottom rollers turn in a reverse

motion at a speed of 15 ft./min. ( 4.57 m / min. ).

FWR

REV.

SPEED

SAFETY

STOP

p) Press STOP. The bottom rollers stop turning.

FWR

REV.

SPEED

SAFETY

STOP

n) Press REV t . REV is solid and FWD reverts to hollow .

FWR

REV.

SPEED

SAFETY

STOP

FWR

REV.

SPEED

SAFETY

STOP

q) Press SPEED t once. SPEED DISPLAY

decreases in increments of .5 per press down to

00.0.

FWR

REV.

00.0

SPEED

SAFETY

STOP

F - 160 Operation and Maintenance Manual

Installation

r) The TOP TEMP DISPLA Y and BOT TEMP

DISPLA Y are solid indicating the actual

temperature is within a +/- 10oF of the set point temperature.

SLEEP

TOP TEMP.

120

BOT. TEMP

120

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!

u) Press SHUTDOWN. The laminator reverts to

the default settings and SLEEP is solid. Refer to Figure 4.8.1

JOB

SLEEP

SEL

SHUT DOWN

SAV

s) Raise the front safety shield, remove the front

infeed table and touch the two main rollers. They should feel warm to the touch.

t) Replace the front infeed table and lower the

front safety shield.

INFORMATION

TOP TEMP

GAP

00.0

SPEED

SAFETY

BOT TEMP

PRESSURE

SEL

SHUT DOWN

FWD

REV

STOP

SAV

The SAFETY indicator should not be

flashing when the tables are properly

seated and the safety shields are in

the closed position..

= Flashing

Installation

F - 160 Operation and Maintenance Manual

4.8.2 Variable speed footswitch

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.

a) Press SEL on the front control panel to “wake”

the laminator from SLEEP mode. SLEEP indicator reverts to hollow .

c) Press down on the variable speed footswitch.

GO begins flashing and the bottom rollers are

turning.

ATTUNG

WARNING

ADVERTENCIA

INFORMATION

Notice that the footswitch speed is not

indicated in the SPEED DISPLAY on the

front control panel.

JOB

SEL

SHUT DOWN

Flashin

SAV

b) Press FWD s for a forward motor direction.

FWD is solid.

FWR

REV.

00.0

SPEED

SAFETY

STOP

4.8.3 Unwind shafts and unwind brakes

The unwind shafts swing out and the unwind

brakes tension the turning of the shaft from no tension to complete stop tension.

Should you detect or experience complications

with the unwind shaft movement or the unwind brake tension, call you local area service representative.

F - 160 Operation and Maintenance Manual

Installation

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) Lift the clevis pin up from the saddle of the

upper unwind shaft.

INFORMATION

Steps " e" and " f" will be performed

simultaneously.

e) W ith 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.

Saddle

Clevis pin

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 .

Upper unwind brake

adjustment knob

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.

Installation

h) Slowly turn the upper unwind brake adjustment

knob counter clockwise.

i) Y ou should feel 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.

F - 160 Operation and Maintenance Manual

k) Now perform steps “b” through “h” again for

the lower unwind shaft.

Lower unwind

brake adjustment dial

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.

( 2 ) TOP TEMP DISPLA Y : 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 +/- 10oF range of the set point, the display will be solid. When outside of this range, the display will flash.

SLEEP

TOP TEMP.

( 3 ) TOP TEMP s : 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 290oF ( 143oC ).

BOT. TEMP

5.1 Control Panel

( 1 ) SLEEP: If flashing, the machine is in sleep mode.

This will occur after 3 hours of no activity . T o wake the laminator from sleep mode, press any command.

SLEEP

TOP TEMP.

BOT. TEMP

SLEEP

TOP TEMP.

( 4 ) TOP TEMP t : 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 68oF ( 20oC ).

SLEEP

TOP TEMP.

BOT. TEMP

Operations

F - 160 Operation and Maintenance Manual

( 5 ) BOT . TEMP . DISPLA Y : 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 +/- 10oF range of the set point, the display will be solid. When outside of this range, the display will flash.

SLEEP

TOP TEMP.

BOT. TEMP

( 6 ) BOT . TEMP . s : 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 290oF ( 143oC ).

( 8 ) GAP DISPLA Y : Displays the current main roller nip opening. The nip has a range of 0 to 1” gap.

GAP

PRESSURE

1/4

( 9 ) GAP s : 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 DISPLA Y.

SLEEP

TOP TEMP.

BOT. TEMP

( 7 ) BOT . TEMP . t : When pressed, will decrease the set point value of the bottom main roller in increments of 2 degrees. If held down, it will decrease to the minimum temperature setting of 68oF ( 20oC ).

SLEEP

TOP TEMP.

BOT. TEMP

GAP

PRESSURE

1/4

( 10 ) GAP t : 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 DISPLA Y.

GAP

PRESSURE

1/4

F - 160 Operation and Maintenance Manual

Operations

( 1 1 ) PRESSURE DISPLA Y : 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 PRESSURE

1/4

INFORMATION

When adjusting the pressure, the gap

will be affected as well.

( 13 ) PRESSURE t : When pressed once, will increase the pressure by 5%. If held down, it will increase from 0% of the minimum allowed pressure to 100% at which point all bars will be illuminated.

GAP PRESSURE

1/4

( 14 ) JOB DISPLA Y : Displays the job number selected and will set the operating parameters saved for that number once SEL has been pressed.

( 12 ) PRESSURE s : When pressed once, will decrease the pressure by 5%. If held down, it will decrease from 100% of the maximum allowed pressure to 0% at which point no bars will be illuminated.

GAP

PRESSURE

1/4

WARNING

Keep hands and fingers clear of

the laminator roller nip when

adjusting PRESSURE.

You can be CRUSHED or BURNED!

JOB

SEL

SHUT DOWN

SAV

INFORMATION

Job programming is explained in

Section 5.4

Operations

F - 160 Operation and Maintenance Manual

( 15 ) JOB s : When pressed once will increase the

job number in JOB DISPLA Y by increments of 1. If pressed and held, the JOB DISPLA Y will increase to 9 at which point it will stop.

JOB

SEL

SHUT DOWN

SAV

( 16 ) JOB t : When pressed once will decrease the job number in JOB DISPLA Y by increments of 1. If pressed and held, the JOB DISPLA Y will decrease to 0 at which point it will stop.

( 18 ) SAVE : When pressed, will save the current settings for the number showing in the JOB DISPLA Y. For more information, refer to Section 5.4 Job Programming on how to save parameters.

JOB

SEL

SHUT DOWN

SAV

( 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.

JOB

SEL

SHUT DOWN

SAV

( 17 )SEL : When pressed will send the operating parameters for the stored job number selected to the correct devices. Any time JOB s or JOB t is pressed, SEL will flash indicating a change in job number .

JOB

SEL

SHUT DOWN

SAV

JOB

SEL

SHUT DOWN

SAV

( 20 ) SPEED DISPLA Y : Displays the current speed setting of the laminator .

FWR

REV.

6.5

SPEED

SAFETY

STOP

F - 160 Operation and Maintenance Manual

Operations

( 21 ) SPEED s: 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.

FWR

REV.

6.5

SPEED

SAFETY

STOP

( 22 ) SPEED t: 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.

( 24 ) STOP : When pressed, stops the rollers and GO becomes white.

FWR

REV.

6.5

SPEED

SAFETY

STOP

( 25 ) FORWARD s : When pressed, signals the laminator to run in a forward motion and FORW ARD s becomes solid.

FWR

REV.

6.5

SPEED

SAFETY

STOP

( 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 ( refer to ( 27 ) SAFETY for explanation ) begin flashing enabling “footswitch” mode. ( refer to ( 28 ) FOOTSWITCH for explanation )

FWR

REV.

6.5

SPEED

SAFETY

STOP

FWR

REV.

6.5

SPEED

SAFETY

STOP

( 26 ) REVERSE t : When pressed, signals the laminator to run in a reverse motion and REVERSE t becomes solid.

FWR

REV.

6.5

SPEED

SAFETY

STOP

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.

FWR

REV.

6.5

SPEED

SAFETY

STOP

( 28 ) V ariable Speed Footswitch : The variable speed footswitch, operates the laminator in “Footswitch” mode. Within this mode, if the 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. T o 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.

• T o make the rollers turn, simply press on the variable speed footswitch.

ATTUNG

WARNING

ADVERTENCIA

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. T o 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;

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;

• Press and hold on the variable speed footswitch. ( approximately 1/2 the travel distance of the variable speed footswitch )

CAUTION

Speed is controlled through the variable

speed footswitch when the safety shield

is in the raised position.

WARNING

Caution should always be exercised

when using the laminator with

the safety shields raised.

You can be seriously HURT or INJURED!

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.

To raise the safety shield

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!

• 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.

Operations

• 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

F - 160 Operation and Maintenance Manual

• Lower the safety shield.

INFORMATION

When the safety shield is lowered, speed

reverts to the panel speed setting.

• 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.

F - 160 Operation and Maintenance Manual

Figure 5.1.1 Front control panel

Operations

3 4

SLEEP

TOP TEMP.

GAP

BOT. TEMP

PRESSURE

6 7

14 16

21 20

JOB

00.0

SPEED

SAFETY

SEL

STOP

SAV

SHUT DOWN

FWR

REV.

2324

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 - T ech 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.

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.

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 F160 can reach temperatures over 200oF ( 93oC ).

WARNING

At these temperatures there is a danger

ofsevere burn if the rolls are touched

duringsetup, operation or servicing.

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

Unlatch

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

Figure 5.2.2 RESET

Reset

Rear of the laminator

5.3 Set up

Initial set up of the Falcon 160 laminator is easily attained when instructions are followed 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

INFORMATION

Once RESET has been engaged, power will be restored, Laminating rollers will reset to

1 in. GAP and the display will return to it's

default settings.

Default mode; TOP TEMP. = 68

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

F ( 20 oC ),

a) Clear the area around the laminating rollers and

pull rollers nip..

b) Make sure the laminator is plugged in.

c) Turn the MAIN POWER to the “ON”

position.

Power

e) Enter the desired operating parameters or

select the job number prior to the emergency stop situation.

f) Y ou may now resume operating the laminator .

Operations

F - 160 Operation and Maintenance Manual

d) Press RESET. The front control panel will

illuminated.

Reset

5.3.2 Film loading

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

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 saddle of the

upper unwind shaft.

Roll of laminate

Core chucks

d) Onceloaded, swing the unwind shaft back into

the saddle.

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!

Clevis pin

F - 160 Operation and Maintenance Manual

Operations

e) Push the clevis pin back down to secure the

unwind shaft its saddle.

f) Now you must center the roll of laminate on the

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

Figure 5.3.4 Measurement chart

Common film widths

Film width Measurement

12 " 28 " 24 " 22 " 31 " 18.5 " 37 " 15.5 " 38 " 41 " 47 " 49 " 51 " 55 " 58 "

15 "

13.5 "

10.5 "

9.5 "

8.5 "

6.5 " 5 "

Make sure

the laminate

is flush with

the core.

Measure from

the side frame

to the edge of

the roll of

laminate.

60 " 62 "

4 " 3 "

INFORMATION

For the lower unwind shaft, add 1/4 in. to

the measurement.

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.

Operations

a) Press TOP TEMP . s to set your upper roller

temperature.

SLEEP

TOP TEMP.

BOT. TEMP

F - 160 Operation and Maintenance Manual

INFORMATION

Do not add PRESSURE when heating the

laminating rollers, this allows the high

release silicone to expand with minimum

restrictions.

b) If required, press BOT . TEMP . s to set your

lower roller temperature.

SLEEP

TOP TEMP.

BOT. TEMP

d) Press FWD s to set a forward motion

direction.

FWR

REV.

SPEED

SAFETY

STOP

e) Press SPEED s 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

the same set point.

c) Press GAP t to set the gap to “0”.

GAP

PRESSURE

FWR

REV.

2.0

SPEED

SAFETY

STOP

INFORMATION

Slow speed will assists with heat up times

and distributes heat evenly.

F - 160 Operation and Maintenance Manual

Operations

f) Press SEL to engage the parameters.

JOB

SEL

SHUT DOWN

SAV

g) Press GO to engage the motor drive system.

FWR

REV.

2.0

SPEED

SAFETY

STOP

h) When the rollers are close to it’s set point value,

the temperature displays stop flashing, pressSTOP and raise the gap to 1 in. by pressing GAP s

5.4 Job programming

The job save feature is very convenient if the same parameters are required to perform various applications. This procedure will guide you step by step through this feature.

a) Follow the prcedure in Section 5.3.1 Power.

INFORMATION

When the laminator is first turned on, the front control panel will go into the default

mode.

Default mode; TOP TEMP. = 68 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

F ( 20 oC ),

b) Press JOB s to enter the desired job number

for the parameters you require to be stored.

GAP

PRESSURE

JOB

SEL

SHUT DOWN

SAV

Operations

F - 160 Operation and Maintenance Manual

c) If heat is required, press T OP TEMP . s and

BOT . TEMP . s to desired settings. If no heat

is required, leave the settings at 68 oF ( 20 oC ).

SLEEP

TOP TEMP.

BOT. TEMP

WARNING

Keep hands and fingers clear of the

laminator roller nip when changing GAP.

You can be CRUSHED or BURNED!

e) Enter a desired speed by pressing SPEED s.

FWR

REV.

3.5

SPEED

SAFETY

STOP

f) Press SAVE to store the parameters in the job

location selected.

SEL

SAV

SHUT DOWN

d) Enter in the GAP setting desired by pressing

GAP t.

GAP

PRESSURE

1/4

INFORMATION

When storing parameters within the JOB

SAVE feature of the laminator, PRESSURE

is not a storable setting.

h) Repeat steps “b” through “f” to save other

parameters in job location numbers.

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

F - 160 Operation and Maintenance Manual

Operations

Figure 5.4.1 Job save chart

BOT. TEMP.JOB # TOP TEMP. GAP SPEED

1 2 3 4 5 6 7 8 9

5.5.1 Main roller manual

nip adjustment

a) Turn the MAIN POWER to the “ON”

position.

Power

5.5 Manual nip adjustment

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.

b) Press RESET. The front control panel will

illuminated.

Reset

WARNING

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 adjustment procedure.

Caution should always be exercised

when using the laminator with

the safety shields raised.

You can be seriously HURT or INJURED!

Operations

F - 160 Operation and Maintenance Manual

c) Raise the front safety shield.

d) Press SEL.

JOB

SEL

SHUT DOWN

Flashin

f) At eye level with the main rollers, press

PRESSURE t until you see the upper main

roller make contact with the substrate.

GAP PRESSURE

SAV

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.

CAUTION

Sharp edges on a substrate should be filed

smooth and GAP manually adjusted.

Sharp edges can CUT the rollers!

WARNING

Keep hands and fingers clear of the

laminator roller nip when changing GAP.

You can be CRUSHED or BURNED!

INFORMATION

Excessive pressure will cause the

substrate to bow or flatten.

INFORMATION

Density of the substrate will determine the

amount of pressure you may use.

INFORMATION

Refer to Figure 5.5.1 for proper roller

pressure.

F - 160 Operation and Maintenance Manual

Operations

Figure 5.5.1 Main roller pressure

Leader board

Proper

pressure

Leader board

Excessive

pressure

h) Step on the variable speed footswitch to back

the leader board out.

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 .

g) Press REV t for a reverse motor direction.

FWR

REV.

00.0

SPEED

SAFETY

STOP

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!

FWR

REV.

0.00

SPEED

SAFETY

STOP

k) On the control panel press FWD s for a

forward motor direction.

FWR

REV.

00.0

SPEED

SAFETY

STOP

Operations

F - 160 Operation and Maintenance Manual

k) Y ou 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.

c) Press SEL.

JOB

SEL

SHUT DOWN

Flashin

SAV

d) Press FWD s for a forward motor direction.

a) T urn the MAIN POWER to the “ON”

position.

Power

b) Press RESET. The front control panel will

illuminated.

Reset

FWR

REV.

00.0

SPEED

SAFETY

STOP

e) Bring the footswitch around to the rear of the

laminator.

WARNING

Caution should always be exercised

when using the laminator with

the safety shields raised.

You can be seriously HURT or INJURED!

F - 160 Operation and Maintenance Manual

f) Raise the rear safety shield.

g) Position the leader board in the center of the

pull rollers between the nip.

CAUTION

Operations

CAUTION

Excess pressure can damage the laminating

rollers. Always use the minimum roll

pressure necessary to complete the task.

Sharp edges on a substrate should be filed

smooth and GAP manually adjusted.

Sharp edges can CUT the rollers!

WARNING

Keep hands and fingers clear of the pull

roller nip when changing the gap.

You can be CRUSHED!

g) At eye 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

Excessive pressure will cause the

substrate to bow or flatten.

INFORMATION

Density of the substrate will determine the

amount of pressure you may use.

INFORMATION

Refer to Figure 5.5.2 for proper roller

pressure.

DOWN

Operations

Figure 5.5.2 Pull roller pressure

F - 160 Operation and Maintenance Manual

CAUTION

Leader board

Proper

pressure

Excessive

pressure

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 .

FWR

REV.

0.00

SPEED

SAFETY

STOP

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.

j) Press REV t for a reverse motor direction.

FWR

REV.

00.0

SPEED

SAFETY

STOP

k) Y ou may now begin mounting from the rear

operating position.

F - 160 Operation and Maintenance Manual

Operations

5.6 Infeed tables

These tables are part of the Falcon 160 safety features. It is neccessary to have the two infeed tables properly positioned before running the laminator.

CAUTION

If not installed properly, you can be injured

or cause damage to the table or laminator.

Figure 5.6.1 Front edge

Front edge

5.6.2 Replacing the infeed table

5.6.1 Removing the table

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 safety shield.

a) Ensure the safety shiled is in the raised

position.

b) With both hands, grip the front edge of the

infeed table and align the back edge with the support bolts. Refer to Figure 5.6.2

Figure 5.6.2 Back edge

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

Operations

c) Now lower the front edge while ensuring that

the pin aligns with the safety roller switch and 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

F - 160 Operation and Maintenance Manual

Safety

roller switch

Back

support bolt

F - 160 Operation and Maintenance Manual

Section 6 Applications

T o 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.

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.

Applications

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 )

• Substrates to precoat

( Foamcore, Gator Board, etc....)

• Leader board

• Trailer board

• Second person

• Utility knife

• Cutting blade with an enclosed casing.

INFORMATION

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.

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

Group 1 : No heat

a) Cut two leader boards 6 inch in length of the

No heat applications do not require heat to activate the adhesive.

material you are about to precoat.

Applications

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.

INFORMATION

F - 160 Operation and Maintenance Manual

Figure 6.1.1 MAIN POWER / RESET

RESET

MAIN POWER

Rear of the laminator

The two pieces cut in step "a" will be

used as the leader board and trailer

board. These two pieces can be saved

and reused for other applications.

c) Turn MAIN POWER to “ON”. Refer to

Figure 6.1.1

d) Press RESET. Refer to Figure 6.1.1

e) Be sure the front and rear tables are in position

and the pull rollers are in the up position.

f) Raise the rear safety shield.

g) Lift the clevis pin located in the saddle of the

upper unwind shaft.

Saddle

Clevis pin

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 to Figure 6.1.2.

WARNING

Caution should always be exercised

when using the laminator with

the safety shields raised.

You can be seriously HURT or INJURED!

INFORMATION

Twisting the roll of laminate while sliding

makes loading the film onto the unwind

shaft easier.

F - 160 Operation and Maintenance Manual

Figure 6.1.2 Unwind shaft

Applications

WARNING

Saddle

Core support

Brake adjust

knob

Clevis pin

Roll of

adhesive

Core chucks

i) Once loaded, swing the upper unwind shaft back

into the saddle.

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 " o", other wise

continue with step " l".

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.

l) Press SEL. SEL will stop flashing.

JOB

SEL

SHUT DOWN

SAV

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.

Applications

F - 160 Operation and Maintenance Manual

CAUTION

Sharp edges on a substrate should be filed

smooth and GAP manually adjusted.

Sharp edges can CUT the rollers!

m) Press GAP

t to the required gap setting for

the substrate being used. The GAP DISPLA Y should reflect your desired setting.

GAP

PRESSURE

1/4

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) Press on the variable speed footswitch while

guiding the leader board into the nip to confirm that the board is secure.

CAUTION

Speed is controlled through the variable

speed footswitch when the safety shield

is in the raised position.

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

00.0

SPEED

SAFETY

FWR

REV.

STOP

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

t to

adjust the gap between the main rollers.

GAP

PRESSURE

1/4

F - 160 Operation and Maintenance Manual

Applications

INFORMATION

Excessive pressure will cause the

substrate to bow or flatten.

q) Press STOP.

FWR

REV.

00.0

SPEED

SAFETY

STOP

CAUTION

Speed is controlled through the variable

speed footswitch when the safety shield

is in the raised position.

Process

a) Pull the roll of mount adhesive straight down

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

t to reverse the direction of the

Figure 6.1.3 Leader board

motor.

FWR

REV.

00.0

SPEED

SAFETY

STOP

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.

Mount

adhesive

Leader

board

b) Position the leader board so that half is adhered

to the mount adhesive. Refer to Figure 6.1.3

INFORMATION

s) Press on the variable speed footswitch to back

the board out of the main rollers.

Position the leader board squarely

onto the mount adhesive.

Applications

F - 160 Operation and Maintenance Manual

c) Press ST OP.

00.0

SPEED

SAFETY

d) Press FWD

STOP

FWR

REV.

e) Push the leader board into the main roller nip

while stepping on the variable speed footswitch.

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 mount adhesive to prevent it from free spinning.

FWR

REV.

00.0

SPEED

SAFETY

STOP

INFORMATION

Steps " e" and " f" will be performed

simultaneously.

INFORMATION

Excessive tension will cause the

substrate to bow.

g) Have the second person stand at the rear of the

laminator.

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!

INFORMATION

Steps " h" and "i" will be performed

simultaneously.

F - 160 Operation and Maintenance Manual

Applications

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) W ith 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

INFORMATION

The 1/2 in. gap between boards will allow

for easier separation of the boards by

the second person.

WARNING

Keep hands and fingers clear of the pull

roller nip when changing the gap.

You can be CRUSHED!

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

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

Precoated board

separate the boards.

Applications

Caution should always be exercised

F - 160 Operation and Maintenance Manual

Figure 6.1.5 Trailer board

CAUTION

when using a knife .

Sharp knife can cut you!

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 roller nip. Refer to Figure 6.1.5

Precoated

board

Trailer

board

m) Stop the laminator when the trailer board is in

the main roller nip. Refer to Figure 6.1.5

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

tunnel effect in the mounting process.

INFORMATION

Before stopping the rollers, position the pull

rollers up. This will prevent an impression

in the last pre-coated board.

l) The second person will raise the rear pull roller

by turning the crank handle counterclockwise until separated.

n) Trim any excess mount adhesive from the

boards.

CAUTION

Caution should always be exercised

when using a knife .

Sharp knife can cut you!

F - 160 Operation and Maintenance Manual

Applications

Finishing

a) Cut the web of mount adhesive at the upper

unwind shaft with an enclosed blade.

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 laminator.

d) Remove the roll of material from the upper

unwind shaft.

e) Press STOP.

FWR

REV.

00.0

SPEED

SAFETY

STOP

f) Clean the rollers as described in the maintenance

section. ( Section 8.2 Cleaning the rollers )

INFORMATION

This will prevent any exposed adhesive from

contacting the rollers.

c) Raise the main rollers to a 1 in. gap by pressing

GAP

PRESSURE

g) Lower the front and rear safety shields and

press SHUTDOWN if finished with the laminator.

JOB

SEL

SHUT DOWN

SAV

End of application

Applications

6.2 Mounting only

F - 160 Operation and Maintenance Manual

Figure 6.2.1 MAIN POWER / RESET

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.

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.

RESET

MAIN POWER

Rear of the laminator

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.

Materials needed

• Prints

• 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

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".

F - 160 Operation and Maintenance Manual

e) Press SEL. SEL will stop flashing.

JOB

SEL

SHUT DOWN

WARNING

Keep hands and fingers clear of the

laminator roller nip when changing GAP.

You can be CRUSHED or BURNED!

SAV

Applications

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) Press on the variable speed footswitch while

guiding the leader board into the nip to confirm that the board is secure.

f) Press GAP

t to the required gap setting for

the substrate being used. The GAP DISPLA Y should reflect your desired setting.

GAP

PRESSURE

1/4

g) Press FWD

CAUTION

Speed is controlled through the variable

speed footswitch when the safety shield

is in the raised position.

WARNING

Keep hands and fingers clear of

the laminator roller nip when

adjusting PRESSURE.

You can be CRUSHED or BURNED!

i) If the board is loose, press PRESSURE

t to

adjust the gap between the main rollers.

00.0

SPEED

SAFETY

STOP

FWR

REV.

GAP

1/4

PRESSURE

GBC F - 160 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual