GBC F - 160 User Manual

F - 160 OPERATION AND

MAINTENANCE MANUAL

Do not duplicate without written permission.

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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.

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