GBC F - 160 CE User Manual

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F - 160 CE OPERATION AND

MAINTENANCE MANUAL

Do not duplicate without written permission.

GBC Films Group

4151 Anderson Road

DeForest, WI 53532

Revision : Ph: ( 608 ) 246 - 8844

Part number : 930 - 065

Fx: ( 608 ) 246 - 8645

Section 1: Safety

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

1.2 Safety features ............................................................................................1 - 2

1.3 Safety shield ...............................................................................................1 - 3

1.4 Emergency stop ...........................................................................................1 - 4

T able of ContentsF - 160 CE Operation and Maintenance Manual

Table of Contents

1.5 Emergency cable .........................................................................................1 - 5

1.6 Front feed table ..........................................................................................1 - 6

1.7 Decal locations ............................................................................................1 - 7

Figure 1.7.1 Decal location - front ................................................1 - 9

Figure 1.7.2 Decal location - rear ..............................................1 - 10

Section 2: Warranty

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

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

Page I

T able of Contents F - 160 CE Operation and Maintenance Manual

Section 3: Specifications

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

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

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

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

3.5 Dimensions ................................................................................................3 - 4

Figure 3.5.1 Dimensions ...............................................................3 - 5

Section 4: Installation

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

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

4.2 Know your machine ...................................................................................4 - 4

4.3 Unpacking ..................................................................................................4 - 5

Page II

4.4 Shrink wrapped .........................................................................................4 - 5

4.5 Crated .........................................................................................................4 - 6

4.6 Accessory pack content ............................................................................4 - 8

T able of ContentsF - 160 CE Operation and Maintenance Manual

4.7 Installing levelers .......................................................................................4 - 9

4.8 Leveling .....................................................................................................4 - 11

4.9 Connecting power ....................................................................................4 - 15

Figure 4.9.1 Single phase ( U.S. & Canada ) ..............................4 - 17

Figure 4.9.2 Three phase ( Europe ) ...........................................4 - 17

4.10 Safety check ............................................................................................4 - 18

4.10.1 Front feed table ...................................................................................4 - 18

4.10.2 Safety shield ..........................................................................................4 - 20

4.10.3 E-STOP ...............................................................................................4 - 21

4.10.4 E-CABLE .............................................................................................4 - 22

4.11 Function check ........................................................................................4 - 23

4.11.1 Control panel .......................................................................................4 - 23

Figure 4.11.1 Default settings ......................................................4 - 27

4.11.2 Variable speed footswitch ....................................................................4 - 27

4.11.3 Unwind shafts and unwind brakes ......................................................4 - 28

Page III

T able of Contents F - 160 CE Operation and Maintenance Manual

Section 5: Operations

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

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

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

5.2.1 In an emergency .....................................................................................5 - 10

5.2.2 Resume operation ...................................................................................5 - 11

5.3 Set up .........................................................................................................5 - 12

5.3.1 Power ......................................................................................................5 - 12

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

Chart 5.3.1 Measurement chart ..................................................5 - 14

5.3.5 Heating ...................................................................................................5 - 14

5.4 Job programming ....................................................................................5 - 16

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

Page IV

5.5 Manual nip adjustment ............................................................................5 - 18

5.5.1 Main roller manual nip adjustment ......................................................5 - 18

5.5.2 Pull roller manual nip adjustment .........................................................5 - 21

5.6 Front feed table .........................................................................................5 - 24

5.6.1 Removing the table ...............................................................................5 - 24

5.6.2 Replacing the table ................................................................................5 - 24

Section 6: Applications

T able of ContentsF - 160 CE Operation and Maintenance Manual

6.1 Parameter charts and diagrams

Chart 6.1.1 Temperature conversion chart ...................6 - 3

Blank chart .......................................................................................................6 - 4

Blank diagram ..................................................................................................6 - 5

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

Diagram 1 - Precoating subtrates ....................................................................6 - 7

Chart 2 - Mounting only ....................................................................................6 - 8

Diagram 2 - Mounting only ..............................................................................6 - 9

Chart 3 - Single sided ( Sled ) .........................................................................6 - 10

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T able of Contents F - 160 CE Operation and Maintenance Manual

Diagram 3 - Single sided ( Sled ) .....................................................................6 - 11

Chart 4 - Single sided ( Craft paper ) ..............................................................6 - 12

Diagram 4 - Single sided ( Craft paper ) ........................................................6 - 13

Chart 5 - Decal and mount ( Decal ) ..............................................................6 - 14

Diagram 5 - Decal and mount ( Decal ) .........................................................6 - 15

Chart 6 - Decal and mount ( Mount ) ............................................................6 - 16

Diagram 6 - Decal and mount ( Mount ) .......................................................6 - 17

Chart 7 - Precoating subtrates .......................................................................6 - 18

Diagram 7 - Precoating subtrates ...................................................................6 - 19

Chart 8 - One pass mount ...............................................................................6 - 20

Diagram 8 - One pass mount ..........................................................................6 - 21

Chart 9 - Thermal decal and mount ( Decal ) ................................................6 - 22

Diagram 9 - Thermal decal and mount ( Decal ) ...........................................6 - 23

Page VI

Chart 10 - Thermal decal and mount ( Mount ) .............................................6 - 24

Diagram 10 - Thermal decal and mount ( Mount ) ........................................6 - 25

Chart 11 - Encapsulation ...............................................................................6 - 26

Diagram 11 - Encapsulation ..........................................................................6 - 27

Section 7: Troubleshooting

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

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

T able of ContentsF - 160 CE Operation and Maintenance Manual

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

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

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

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 - 7

8.2.2 Touch screen control panel .....................................................................8 - 7

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Page VIII

F - 160 CE Operation and Maintenance Manual

Section 1 Safety

CAUTION

Do not attempt to operate your Falcon 160

CE laminator until you have read this

section carefully!

Safety

CAUTION

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.

Your safety, as well as the safety of others, is important to GBC Films Group. This section contains important safety information.

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

Danger and Electrical Shock conditions.

1.1 Symbols

WARNING

Indicates a potentially hazardous situation

which, if not avoided, could result in serious

injury.

DANGER

Indicates an imminently hazardous situation

which, if not avoided, could result in death

or serious injury.

INFORMATION

Indicates helpful information that should be

considered before, during, or after an

action, step or procedure is given.

ELECTRICAL

SHOCK

Indicates an electrical shock situation which,

if not avoided, could result in serious

paralyzation of the body or death.

Page 1 - 1

Safety F - 160CE Operation and Maintenance Manual

1.2 Safety features

DANGER

At these temperatures there is a danger of severe burn if the rolls are touched during

The F-160 CE 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.

Only a qualified service technician should

GBC Films Group 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.

setup, operation or servicing.

INFORMATION

perform any procedure in Part B of this

manual.

The motorized main roller lift mechanism used to provide downward pressure on the upper main roller 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 rollers.

Use care in lowering the upper laminating roller 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 control the motion of the upper laminating roller. Before pressing GAP down arrow , ensure that nothing is in the nip area.

In addition, the main laminating rollers of the F160CE can reach temperatures of over 200

F ( 100oC ).

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

Page 1 - 2

F - 160 CE Operation and Maintenance Manual

Safety

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

The F-160CE laminator has cabinets and 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

1.3 Safety shield

An important feature of the F-160 CE laminator is the safety shields, when raised, the auto run is disabled and drive control is transferred to the footswitch.Refer to Figure 1.3.1 Safety shield raised.

WARNING

Caution should always be exercised

when using the laminator with

the safety shields raised.

You can be seriously HURT or INJURED!

Covers

Cabinets

Figure 1.3.1 Safety shields raised

Page 1 - 3

Safety F - 160CE Operation and Maintenance Manual

1.4 Emergency stop

The laminator is equipped with four emergency

stops ( E-STOP ) located at the front of the cabinets and the rear of the cabinets. Refer to Figure 1.4.1 Emergency

stops.

Figure 1.4.1 Emergency stops

T o engage an E-STOP, press down on any of the four . Any E-STOP, when engaged, removes power to the laminator. Refer to Figure 1.4.2 Engage an E-STOP.

Figure 1.4.2 Engage an E-STOP

Push

Emergency stops

Rear

INFORMATION

Front

The machine will only operate if all four

E-STOPS are in the unlatched position.

T o continue operation, all E-STOPs must be in the unlatched position. T o reset, twist the E-STOP 1/4 turn clockwise. Refer to Figure 1.4.3 Reset the E-

STOP.

Figure 1.4.3 Reset the E-STOP

Page 1 - 4

Unlatch

Emergency stops

F - 160 CE Operation and Maintenance Manual

Safety

Press RESET located on the right leg at the front

of the machine. Refer to Figure 1.4.4 Machine reset.

Figure 1.4.4 Machine rest

Figure 1.5.1 Emergency cable

Front

Emergency cable

Rear

Machine reset

1.5 Emergency cable

In the event an E-STOP is not reachable, use

your foot to activate an emergency cable ( E-CABLE ) located at the base of the stand from the front or rear of the machine. Refer to Figure 1.5.1 Emergency cable.

Emergency cable

T o continue operation, press in on the cable reset

located on the right leg of the front operating position. Refer to Figure 1.5.2 Reset the E-CABLE.

Figure 1.5.2 Reset the E-CABLE

INFORMATION

The machine will only operate if the

E-CABLE is in the unlatched position.

Push in

Page 1 - 5

Safety F - 160CE Operation and Maintenance Manual

Press RESET located on the right leg at the front

of the machine. Refer to Figure 1.5.3 Machine reset.

Figure 1.5.3 Machine rest

Figure 1.6.1 Front feed table

Machine reset

1.6 Front feed table

The front feed table must be in proper position

for the laminator to operate in auto run. Refer to Figure

1.6.1 Front feed table.

When the key is removed from the interlock, the laminator will stop. With the table removed, the laminator will operate using the variable speed footswitch.

T o continue operation, press STOP.

5.0

SPEED

SAFETY

STOP

FWD REV

Then press GO.

5.0

SPEED

SAFETY

STOP

FWD REV

Page 1 - 6

F - 160 CE Operation and Maintenance Manual

1.7 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 1.7.1 and Figure 1.7.2 illustrates the location of each of these labels.

WARNING

ACHTUNG

MUCHO

CUIDADO

Riesgo de choque electrico No abra Adentro, no hay piezas reparables para el usuario. Mantenimiento solamente para personal calificado

WAARSCHUWING!ATTENZIONE

Kans op elektrische schok. Niet openen Bevatgeen door gebruik te repareren onderdelen. Door bevoegd service personeel laten repareren

MUCHO

CUIDADO

Risque de secousse electrique. Ne pas ouvrir. Pas de pieces reparables par l'utilisateur. Entretien par personnel qualifie.

Pericolo di scarica elettrica. Nessuna parte riparabile dall' utente. Chiamare un servizio di riparazioni qualificato.

WARNUNG

SpannungsfUhrend e

Teile. Nicht offnen. Enthalt keine vom Enduerbraucher zu wartende Teile. Fur service bitte an qualifiziertes Service-Personal wenden.

Safety

WARNING

Electrical shock hazard. Do not open. No user serviceable parts inside. Refer servicing to qualified service personnel.

MISE EN GARDE

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

Danger V oltage: High voltage wires behind this panel. Do not remove cover. You may be shocked, electrocuted, paralyzed or die!

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

Do not Lift: This point can not be used as a lifting

point. If ignored, damage will occur to the laminator .

Page 1 - 7

Safety F - 160CE Operation and Maintenance Manual

Reset: Machine reset. Press after iniating power to the

laminator or after an E-STOP or E-CABLE has been engaged then resetted.

Page 1 - 8

F - 160 CE Operation and Maintenance Manual

Figure 1.7.1 Label locations - Front

WARNING

ACHTUNG

MISE EN GARDE

WARNING

ACHTUNG

MISE EN GARDE

Safety

Riesgo de cho electrico No abra Adentro, no ha piezas reparables para el usuario. Mantenimiento solamente para personal calificado

WAARSCHUWING!ATTENZIONE!WARNUNG

Kans op elektrische schok. Niet openen Bevat

ebruik te repareren onderdelen. Door bevoe service personeel laten repareren

MUCHO

CUIDADO

een door

MUCHO

CUIDADO

Risque de secousse electri

ue. Ne pas ouvrir. Pas de pieces reparables par l'utilisateur. Entretien par personnel

ualifie.

ualificato.

SpannungsfUhrend e

Teile. Nicht offnen. Enthalt keine vom Enduerbraucher zu wartende Teile. Fur service bitte an

ualifiziertes Service-Personal wenden.

Pericolo di scarica elettrica. Nessuna parte riparabile dall' utente. Chiamare un servizio

di riparazioni

WARNING

Electrical shock hazard. Do not open. No user serviceable parts inside. Refer servicin

ualified service

personnel.

Riesgo de cho electrico No abra Adentro, no ha piezas reparables para el usuario. Mantenimiento solamente para personal calificado

WAARSCHUWING!ATTENZIONE!WARNUNG

Kans op elektrische schok. Niet openen Bevat

ebruik te repareren onderdelen. Door bevoe service personeel laten repareren

MUCHO

CUIDADO

een door

MUCHO

CUIDADO

Risque de secousse electri

ue. Ne pas ouvrir. Pas de pieces reparables par l'utilisateur. Entretien par personnel

ualifie.

ualificato.

SpannungsfUhrend e

Teile. Nicht offnen. Enthalt keine vom Enduerbraucher zu wartende Teile. Fur service bitte an

ualifiziertes Service-Personal wenden.

Pericolo di scarica elettrica. Nessuna parte riparabile dall' utente. Chiamare un servizio

di riparazioni

WARNING

Electrical shock hazard. Do not open. No user serviceable parts inside. Refer servicin

ualified service

personnel.

Page 1 - 9

Safety F - 160CE Operation and Maintenance Manual

Figure 1.7.2 Label locations - Rear

WARNING ACHTUNG

MISE EN GARDE

WARNING ACHTUNG

MISE EN GARDE

CUIDADO

Riesgo de choque electrico No abra Adentro, no hay piezas reparables para el usuario. Mantenimiento solamente para personal calificado

WAARSCHUWING!ATTENZIONE!WARNUNG

Kans op elektrische schok. Niet openen Bevatgeen door gebruik te repareren onderdelen. Door bevoegd service personeel laten repareren

MUCHO

CUIDADO

Risque de secousse electrique. Ne pas ouvrir. Pas de pieces reparables par l'utilisateur. Entretien par personnel qualifie.

Pericolo di scarica elettrica. Nessuna parte riparabile dall' utente. Chiamare un servizio di riparazioni qualificato.

SpannungsfUhrend e

Teile. Nicht offnen. Enthalt keine vom Enduerbraucher zu wartende Teile. Fur service bitte an qualifiziertes Service-Personal wenden.

WARNING

Electrical shock hazard. Do not open. No user serviceable parts inside. Refer servicing to qualified service personnel.

Page 1 - 10

WarrantyF - 160 CE Operation and Maintenance Manual

Section 2 Warranty

GBC Films Group 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 Films Group and connot be modified or amended.

GBC Films Group’s sole and exclusive liability and the customer’s sole and exclusive remedy under this warranty shall be, at GBC Films Group’s option, to repair or replace any such defective part or product. These remedies are only available if GBC Films Group’s examination of the product discloses to GBC Films Group’ 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 FILMS GROUP 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 rollers 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.

Page 2 - 1

Warranty F - 160 CE 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 Films Group T echnician that has been through the

Page 2 - 2

Section 3: Specifications

Specifications provide all of the technical data for

the Falcon 160 CE Laminator.

Section 3.1 General

SpecificationsF - 160 CE Operation and Maintenance Manual

Description:

Features:

Applications:

• Mid level, wide format color finisher for the sheet fed ink jet market. The Falcon 160 CE 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

• Four E-STOPs

• Front and rear E-Cable

• Single sided lamination

• Encapsulation

• Mounting

• Decaling

Section 3.2 Consumable

Film types:

• Pressure sensitive laminates

• Pressure sensitive adhesives

• Low melt laminates

• Thermal laminates

• Thermal adhesives

Page 3 - 1

Specifications F - 160CE Operation and Maintenance Manual

Film diameters:

Core size:

Film widths:

Paper widths:

Mounting thickness:

• 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 )

• 62” maximum paper width ( 157.8 cm )

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

Safety:

Section 3.3 Function

Speed:

Motor:

Heating capabilities:

Designed to UL / CSA / CE safety standards

• 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 )

Controls:

Page 3 - 2

• Front control panel

• V ariable speed footswitch

SpecificationsF - 160 CE Operation and Maintenance Manual

Job save:

Roll design:

Section 3.4 Electrical

United Statesand Canada:

Europe:

• Save up to 9 job parameters

• High release silicone rolls

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

• 230 - 240 VAC, Wye 3 phase, 32 amps/ phase

B.T .U. output:

Heater wattages:

Amperage draw:

D/C voltage used:

A/C voltage used:

• 31,732 B.T .U. / hour

• 5600 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

• 230 vac ( minimum )

Page 3 - 3

Specifications F - 160CE Operation and Maintenance Manual

Section 3.5 Dimensions

W eight:

Crated:

Uncrated:

Dimensions

Crated:

Uncrated

Nip Height:

• 1568 lbs. ( 711 kg. )

• 1200 lbs. ( 544 kg. )

• 90 in. (H) x 46 in. (W) x 72 in. (L) ( 229 cm (H) x 117 cm (W) x 183 cm (L) )

• 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 )

Safety Shield Raised Height:

Page 3 - 4

• 66 5/8 in. ( 169 cm)

Figure 3.5.1 Dimensions

SpecificationsF - 160 CE Operation and Maintenance Manual

53 in.

(135 cm)

76 in.

(193 cm)

82.5 in.

(210 cm)

3.63 in. (9 cm)

1.38 in.

(3.5 cm)

4.75 in. (12 cm)

28 in.

(71 cm)

4.875 in. (12 cm)

Page 3 - 5

Specifications F - 160CE Operation and Maintenance Manual

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InstallationF - 160 CE Operation and Maintenance Manual

Section 4 Installation

GBC Films Group is committed to a program of ongoing product improvement. As a result, we are providing these instructions so you can insure that your new Falcon 160 CE Laminator is properly and securely unpacked, moved, and installed.

Before a Falcon 160 CE 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.

CAUTION

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

The operating environment must be free of

dust, flammable liquids and vapors. You can

be injured by inhaling chemical vapors.

Failure to follow the pre-installation check

list can result in damage to the laminator.

4.1 Pre-installation

Are doorways and hallways wide enough for the

laminator to be moved to the installation site?

Is there ample room for the laminator?

A work area must be established that allows for

operation in both the front and rear of the

laminator and provides space for efficient material

flow. Figur e 4.1.1 illustrates a typical machine

area layout.

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 output quality.

Page 4 - 1

Installation F - 160 CE Operation and Maintenance Manual

The laminator requires 230 to 240 vac, 50/ 60 Hz, 55 amps. Or, in Europe only, 3-N phase, 240 vac, 32 amps/ phase.

WARNING

The Falcon 160 CE 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.

For instructions on how to connect power,

proceed to 4.9 Connecting power in this section.

Page 4 - 2

Figure 4.1.1 Suggested Floor Layout

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

Work table on wheels

8.4'

( 2.57 m )

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

InstallationF - 160 CE Operation and Maintenance Manual

Table height

82.5"

( 209 cm )

20'

( 6 m )

38"

( 96 cm )

8.4'

( 2.57m )

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

Work table on wheels

Table hei

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

3' ( 1 m)

13' ( 4 m)

Page 4 - 3

Installation F - 160 CE Operation and Maintenance Manual

4.2 Know your machine

Before performing any procedure within this

manual, it is recommended that you take time to know the parts of your new machine.

Figure 4.2.1 The laminator

Drive

side

Rear side

Figure 4.2.3 Front view

Upper

rewind

Front

feed

table

Lower

unwind

shaft

Castors

Main

rollers

Control

panel

Upper

unwind

brake

Lower

rewind

Pull roll

lift handle

Lower

unwind

brake

Drive

side leg

Electrical

bridge

Front side

Figure 4.2.2 Safety features

E-STOP

Rear safety shield

Control

side

Control

side leg

Figure 4.2.4 Rear view

Core

ort

Core

chuck

Power

ON/OFF

E-CABLE

Core

chuck

unwind

shaft

Pull rollers

Rear feed

table

Circuit

breaker

Front safety

shield

E-CABLE

Page 4 - 4

E-CABLE reset

Figure 4.2.5 Footswitch

E-STOP

ATTUNG

WARNING

ADVERTENCIA

Machine reset

InstallationF - 160 CE Operation and Maintenance Manual

4.3 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 .

4.4 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, your machine 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

Do not attempt to move the laminator across

The unpacking process requires at least two

people. You can be severely injured, crushed

or cause damage to the laminator.

without trained and qualified riggers. You

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 CE Laminator to the installation site.

WARNING

anything other than a flat level surface

can be crushed or seriously injured.

Page 4 - 5

Installation F - 160 CE Operation and Maintenance Manual

4.5 Crated

WARNING

The Falcon 160 CE 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.

To uncrate the laminator

a) Remove the top of the crate and then the sides

in the order shown in Figure 4.5.1

CAUTION

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

can damage the laminator.

INFORMATION

GBC Film Group's warranty does not

cover malfunction of the equipment due to

mishandling and / or tipping. GBC Films

Group bears no responsibility for personal

injury or damage due to moving the

laminator improperly.

Tools required

• # 2 Phillips head screwdriver

• 7/8” open end wrench or adjustable wrench

• Crow bar

• A second person

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 4.5.1 It can fall and

damage the laminator or cause harm to you

and others.

Page 4 - 6

InstallationF - 160 CE Operation and Maintenance Manual

Figure 4.5.1 Disassembling of the crate

P l a n e

P l a n e 4

b) Move all packing materials to a safe distance.

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 4.5.2 illustrates positioning of the ramps.

Removing the shrink wrap

a) Gently unwrap the shrink wrap from around the

laminator.

CAUTION

WARNING

Do not attempt to use the ramps if they are

not secured to the pallet. Ensure the pallet is

on a flat even surface before attempting to

roll the machine off.

Figure 4.5.2 Positioning of 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.

Page 4 - 7

Installation F - 160 CE Operation and Maintenance Manual

b) Remove any plastic strapping and/or packing

paper taped to the rollers.

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.

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.

4.6 Accessory pack

unpacked and moved into final position, open the accessory pack and verify the contents.

Once the Falcon 160 CE Laminator has been

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 ( 930-045 rev . A )

• 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 )

• Four leveling bolts ( 645-011 )

• T welve 3/4 - 10 nuts ( No P/N )

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.

Page 4 - 8

If you are missing any of the itemslisted above, contact your local service technician or sales representative.

Contacts:

GBC Parts ( 800 ) 790 - 7787

GBC Europe parts 33 - 45 - 535 - 7676

InstallationF - 160 CE Operation and Maintenance Manual

4.7 Installing levelers

Leveling of the machine is a customer option. If you choose not to level the laminator and you encounter output problems, please level the machine and try your application again before calling for technical support.

Before leveling can be performed, the castors must be replaced with leveling bolts and leveling pads.

b) Lock the castors on the drive side leg.

CAUTION

Do not lift the machine where NO LIFT

warnings are located. You can cause

damage to the electrical bridge.

c) Slide the floor jack under the control side leg.

Tools required

• T orpedo level

• ( 2 ) 3/4” open end wrenches

• Four leveling pads ( from the accessory pack )

• Four Leveling bolts ( from the accessory pack )

• T welve 3/4 - 10 nuts ( from the accessory pack )

• Floor jack ( 600 pound rating )

• Second person

Control side

a) V erify that the laminator has sufficient room

around it to load film, walk around and to be

serviced if necessary .

Center of the leg

d) Raise the control side approximately 4 in. from

the bottom of the castor to the floor. (10 cm) Must have eneough clearance to remove the castors

Page 4 - 9

Installation F - 160 CE Operation and Maintenance Manual

e) Remove the front control side castor by turning

the nut securing the castor in the leg.

Nut

Castor

f) Slide one of the leveling bolts where the castor

was removed and along with a 3/4-10 nut inside the leg.

Figure 4.7.1 Leveling pad installed

Nut

Jam nut

Leveling pad

Nut

Bolt

g) Place two more 3/4-10 nuts on the leveling bolt

under the leg. Refer to Figure 4.7.1 Leveling

pad installed.

h) Attach the leveling pad to the bottom of the

leveling bolt and secure with wrenches. Refer to

Figure 4.7.1 Leveling pad installed.

i) T ighten the jam nut against the leveling pad.

Refer to Figure 4.7.1 Leveling pad installed.

j) Perform steps e through “ i ” for the rear control

side castor and leveling pad.

Drive side

a) Perform steps “ a ” through “ j ” from the

Control side.

Page 4 - 10

InstallationF - 160 CE Operation and Maintenance Manual

4.8 Leveling

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

a) Position the level on the top of the control side

frame. Not on the cabinet. Refer to Figure

4.8.1 Front to back control side

b) Level the control side from front to back by

holding the nut inside the leg and turning the nut below the leg with the wrench.

INFORMATION

A second person can read the level while you

make the appropriate adjustments.

- T o raise; raise the nut inside the leg and turn the nut below the leg clockwise.

Level

INFORMATION

The side frame provides a more accurate

reading than the cabinet.

Raise

Turn clockwise

- T o lower; turn the nut below the leg counter clockwise.

Lowering

limit

Turn counter

clockwise

Page 4 - 11

Installation F - 160 CE Operation and Maintenance Manual

INFORMATION

Lowering is limited to the amount of

height within the inside of the leg.

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

frame. Not on the cabinet. Refer to Figure

4.8.2 Front to back drive side

Figure 4.8.2 Front to back drive side

INFORMATION

A second person can read the level while you

make the appropriate adjustments.

- T o raise; raise the nut inside the leg and turn the nut below the leg clockwise.

Raise

Level

d) Level the control side from front to back by

holding the nut inside the leg and turning the nut below the leg with the wrench.

Turn clockwise

- T o lower; turn the nut below the leg counter clockwise.

Lowering

limit

Turn counter

clockwise

e) Confirm that power is supplied to the

laminator.

Page 4 - 12

InstallationF - 160 CE Operation and Maintenance Manual

f) Flip the circuit breaker on the laminator to the up

position.

= ON

= OFF

h) Press RESET. The front control panel should

be illuminated at this point.

Machine reset

g) Turn MAIN POWER to “ I ” position.

Power

ON/OFF

WARNING

Caution should always be exercised

when using the laminator with

the safety shields raised.

You can be seriously HURT or INJURED!

i) Raise the front safety shield. The SAFETY

indicator will begin flashing.

INFORMATION

Ensure all E-STOPS are unlatched and

the E-CABLE is reset before turning

power on to the laminator.

00.0

SPEED

SAFETY

STOP

= Flashing

FWD REV

Page 4 - 13

Installation F - 160 CE Operation and Maintenance Manual

l) Level the laminator from drive side to control

side by adjusting the two front leveling pads.

WARNING

Keep hands and fingers clear of the

laminator roller nip when changing GAP.

You can be CRUSHED or BURNED!

- T o raise; raise the nut inside the leg and turn the nut below the leg clockwise.

j) Press PRESSURE ▼ to illuminate 3 bars in

the pressure dsiplay .

GAP

PRESSURE

k) Place the level across the top of the upper main

roller in the center. Refer to Figur e 4.8.3

Drive to control side front

Raise

Turn clockwise

- T o lower; turn the nut below the leg counter clockwise.

Lowering

limit

Figure 4.8.3 Drive to control side front

Level

Page 4 - 14

n) Press GAP

GAP

Turn counter

clockwise

▲▲

▲ to 1 in. setting.

▲▲

PRESSURE

InstallationF - 160 CE Operation and Maintenance Manual

m) T urn the pull roller lift handle towards the rear

of the machine to lower the upper pull roller .

Stop after initial contact with the lower pull

roller plus 1/2 turn.

n) Raise the rear safety shield

o) Place the level across the top of the upper pull

roller in the center. Refer to Figur e 4.8.4

Drive to control side rear

Figure 4.8.4 Drive to control side rear

4.9 Connecting power

ELECTRICAL

SHOCK

Only a qualified electrician should connect

power to the laminator. You can be severely

shocked, electrocuted or cause a fire if

power is improperly applied.

a) Ensure the power at the junction box is in the OFF position.

Level

p) Verify all four leveling points. Make any

adjustments neccessary . If all four points are

leveled, secure all nuts in place.

b) Remove the drive side leg cover with a #2

phillips screw driver.

q) Lower the front and rear safety shields.

r) Turn MAIN POWER to “OFF “.

Page 4 - 15

Installation F - 160 CE Operation and Maintenance Manual

c) Feed the power cable through the power cable

strain relief located at the bottom of the drive side leg.

Strain relief

WARNING

e) Turn the junction box power to the ON

position.

f) Verify line voltage with regards to the type of

power being supplied to the laminator at the line terminal block.

Line

terminal

block

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.

d) Connect the power cord to the line terminal

block. Refer to Figure 4.9.1 Single phase or Figure 4.9.2 Wye thr ee phase.

Figure 4.9.1 Single phase illustrates proper

single phase wiring for the U.S. and Canada.

g) Once the power cord has been properly

connected, replace the drive side leg cover .

h) Proceed with 4.10 Safety check.

Figure 4.9.2 Wye thr ee phaseillustrates proper

Wye 3 phase wiring for Europe.

Page 4 - 16

Figure 4.9.1 Single phase, U.S. and Canada

InstallationF - 160 CE Operation and Maintenance Manual

Figure 4.9.2 Wye 3 phase, Europe only

Ground wire

Line 1

Line 2

L1 L2 L3 N N N PE

Ground wire

Line 1 Line 2 Line 3

Neutral

L1 L2 L3 N N N PE

Remove

Jumper

bars

Page 4 - 17

Installation F - 160 CE Operation and Maintenance Manual

4.10 Safety check

The safety check will ensure that all safety devices

and interlocks are functioning properly .

This procedure describes how to check one

E-STOP, the front E-CABLE, the front safety shield and the front feed table. Repeat the steps for the remaining three E-STOPS, the rear E-CABLE and the rear safety shield. The rear feed table is not removable. ALL

SAFETY FEA TURES MUST BE CHECKED!

WARNING

4.10.1 Front feed table

a) Turn MAIN POWER to “ON” .

Power

ON/OFF

b) Press RESET. The front control panel will be

illuminated.

Do not wear ties, loose fit 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

If a safety feature is not working

properly, contact your local service

representative immediately.

Contacts:

Machine reset

c) Press SEL. SEL stops flashing.

GBC National Service: ( 800 ) 790 - 7787

GBC Europe Service: 33 - 45 - 535 - 7676

Page 4 - 18

SAV

JOB

SE L

STANDBY

= Flashing

InstallationF - 160 CE Operation and Maintenance Manual

d) Press FWD ▲ to set a forward motor

direction.

00.0

SPEED

SAFETY

STOP

FWD REV

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

g) Slightly lift the front feed table. SAFETY

indicator and GO begin flashing and the bottom rollers stop.

6.0

SPEED

SAFETY

STOP

= Flashing

FWD REV

h) Lower the front feed table.SAFETY

indicator reverts to white and GO remains flashing.

6.0

SPEED

SAFETY

STOP

FWD REV

f) Press GO. The bottom rollers begin turning.

6.0

SPEED

SAFETY

STOP

FWD

REV

6.0

SPEED

SAFETY

i) Press STOP. GO stops flashing.

STOP

= Flashing

6.0

SPEED

SAFETY

STOP

FWD REV

Page 4 - 19

Installation F - 160 CE Operation and Maintenance Manual

4.10.2 Safety shield

a) Press GO. The bottom rollers begin turning.

6.0

SPEED

SAFETY

STOP

FWD REV

c) Lower the front safety shield. SAFETY

indicator reverts to white and GO remains flashing.

6.0

SPEED

SAFETY

STOP

= Flashing

FWD REV

WARNING

Caution should always be exercised

when using the laminator with

the safety shields raised.

You can be seriously HURT or INJURED!

b) Raise the front safety shield. SAFETY indicator

and GO begin flashing and the bottom rollers stop.

d) Press STOP .GO stops flashing.

6.0

SPEED

SAFETY

STOP

FWD REV

e) Repeat steps “ a ” through “ d ” for the rear

safety shield.

Page 4 - 20

6.0

SPEED

SAFETY

STOP

= Flashing

FWD REV

InstallationF - 160 CE Operation and Maintenance Manual

4.10.3 E-STOP

a) Press GO. The bottom rollers begin turning.

6.0

SPEED

SAFETY

b) Press PRESSURE ▼ to illuminate 3 bars in

the pressure dsiplay .

STOP

FWD

REV

d) Unlatch the E-STOP.

Unlatch

e) Press machine RESET. The front control panel is illuminated.

GAP

PRESSURE

c) Press down on the front control side E-ST OP. The E-STOP latches in the down position, bottom rollers stop, the upper main roller

raises and the control panel is blank.

Push

Machine reset

f) Repeat steps “ a ” through “ e ” for the remaining three E-STOPs.

Front

E-STOP

Rear

E-STOPs

Page 4 - 21

Installation F - 160 CE Operation and Maintenance Manual

4.10.4 E-CABLE

a) Press GO. The bottom rollers begin turning.

6.0

SPEED

SAFETY

b) Press PRESSURE ▼ to illuminate 3 bars in

the pressure dsiplay .

STOP

FWD REV

d) Latch the E-CABLE by pushing in on the E-

CABLE reset located in the front at the bottom

of the control side leg.

Push in

e) Press machine RESET. The front control panel

is illuminated.

GAP

PRESSURE

c) Press on the front E-CABLE with your foot. The bottom rollers stop, the upper main roller

raises and the control panel is blank.

Machine reset

f) Repeat steps “ a ” through “ e ” for the rear E-CABLE.

Page 4 - 22

InstallationF - 160 CE Operation and Maintenance Manual

4.11 Function check

The function check ensures that the laminator functions properly when operating. This check is recommended before performing any applications.

If a step that does not react according to the description, call your local area service representative immediately .

WARNING

b) Press BOT TEMP ▲ to a value of 120

F ( 48 oC ). BOT TEMP DISPLAY begins flashing.

TOP TEMP BOT TEMP

120 120

c) 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.

Do not wear ties, loose fit 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.

4.11.1 Control panel

a) Press TOP TEMP. ▲ to a value of 120

( 48 oC ). TOP TEMP DISPLAY begins flashing.

SAV

JOB

SE L

STANDBY

= Flashing

d) Press GAP ▼ 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.

TOP TEMP BOT TEMP

120 68

GAP

1-0

PRESSURE

Page 4 - 23

Installation F - 160 CE Operation and Maintenance Manual

e) Press GAP ▲. 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

f) Press and hold PRESSURE ▼. 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.

h) Press JOB ▲. The JOB DISPLAY increases

in increments of 1 to 9.

SEL SAV

JOB

STANDBY

i) Press JOB ▼ . The JOB DISPLAY should

decreases in increments of 1 from 9 to 0.

GAP

PRESSURE

g) Press and hold PRESSURE ▲. 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

SEL SAV

JOB

STANDBY

INFORMATION

To continue with the function checks, you

must press SEL so that it discontinues

flashing.

Page 4 - 24

InstallationF - 160 CE Operation and Maintenance Manual

j) Press SPEED ▲ once. SPEED DISPLAY

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

15.0

SPEED

SAFETY

STOP

FWD REV

k) Press FWD ▲. FWD is solid.

m) Press STOP. The bottom rollers stop turning.

15.0

SPEED

SAFETY

STOP

FWD REV

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

15.0

SPEED

SAFETY

STOP

FWD REV

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

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

15.0

SPEED

SAFETY

STOP

FWD

REV

15.0

SPEED

SAFETY

STOP

FWD REV

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

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

15.0

SPEED

SAFETY

STOP

FWD REV

Page 4 - 25

Installation F - 160 CE Operation and Maintenance Manual

p) Press STOP. The bottom rollers stop turning.

WARNING

15.0

SPEED

SAFETY

STOP

FWD REV

q) Press SPEED ▼ once. SPEED DISPLAY

decreases in increments of .5 per press down to

00.0.

00.0

SPEED

SAFETY

STOP

FWD REV

Caution should always be exercised

when using the laminator with

the safety shields raised.

You can be seriously HURT or INJURED!

s) Raise the front safety shield, remove the front

feed table.

t) T ouch the upper and lower main rollers. They

should feel warm to the touch.

r) The T OP TEMP DISPLA Y and BOT TEMP

DISPLAY are solid indicating the actual

temperature is within a +/- 6 oF of the set point temperature.

TOP TEMP BOT TEMP

120 120

Page 4 - 26

u) Replace the front feed table and lower the

front safety shield.

INFORMATION

The SAFETY indicator should not be

flashing when the tables are properly

seated and the safety shields are in

the closed position..

InstallationF - 160 CE Operation and Maintenance Manual

u) Press STANDBY. The laminator reverts to

the default settings and ST ANDBY is solid. Refer to Figure 4.1 1.1 Default settings

SEL SAV

JOB

STANDBY

Figure 4.11.1 Default settings

4.11.2 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 .

TOP TEMP BOT TEMP

68 68

PRESSURE

IIIIIII

SE L

STANDBY

1/16

JOB

GAP

00.0

SPEED

SAFETY

= Flashing

STOP

FWD REV

SAV

JOB

SE L

STANDBY

= Flashing

b) Press FWD ▲ for a forward motor direction.

FWD is solid.

00.0

SPEED

SAFETY

STOP

FWD

REV

Page 4 - 27

Installation F - 160 CE Operation and Maintenance Manual

c) Press down on the variable speed footswitch.

GO begins flashing and the bottom rollers are

turning.

ATTUNG

WARNING

ADVERTENCIA

INFORMATION

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.

WARNING

Footswitch speed is not indicated in the

SPEED DISPLAY on the control panel.

4.11.3 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.

b) Lift the clevis pin up from the saddle of the

upper unwind shaft.

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 .

Should you detect or experience complications

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

Page 4 - 28

d) Ensure that the upper unwind brake adjustment

knob is backed off completly . The counter clockwise turn should be easy .

INFORMATION

Steps " e" and " f" will be performed

simultaneously.

e) W ith one hand, slowly turn the upper unwind

shaft in either direction.

f) W ith the other hand, slowly turn the upper

unwind brake adjustment knob clockwise.

InstallationF - 160 CE Operation and Maintenance Manual

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.

Upper unwind brake

adjustment dial

k) Repeat steps “ b ” through “ h ” again for

the lower unwind shaft.

Lower unwind brake

ustment dial

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.

Page 4 - 29

Installation F - 160 CE Operation and Maintenance Manual

This page intentionally left blank.

Page 4 - 30

F - 160 CE Operation and Maintenance Manual

Operations

Section 5 Operations

The operator control panel for the Falcon 160 CE 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 +/- 6 oF range of the set point, the display will be solid. When outside of this range, the display will flash.

TOP TEMP BOT TEMP

68 68

( 3 ) TOP TEMP ▲ : 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 ).

5.1 Control Panel

( 1 ) ST ANDBY : If flashing, the machine is in standby

mode. This will occur after 3 hours of no activity . To wake the laminator from standby mode or manual engage standby mode, press STANDBY.

SEL SAV

JOB

STANDBY

TOP TEMP BOT TEMP

68 68

( 4 ) TOP TEMP ▼ : 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 ).

TOP TEMP BOT TEMP

68 68

Page 5 - 1

Operations F - 160 CE Operation and Maintenance Manual

( 5 ) BOT . TEMP . DISPLAY : The display will show

the set point temperature of the bottom main roller as the default display . When the bottom roller temperature has reached in the +/- 10oF range of the set point, the display will be solid. When outside of this range, the display will flash.

TOP TEMP BOT TEMP

68 68

( 6 ) BOT . TEMP . ▲ : 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 ) OVER/ UNDER INDICA TORS : Dislays a “+” if the temperature is above the set point. Display a “–” if the temperature is below the set point. If neither (+/ -) is displayed, the temperaure is within the +/- 6 oF range.

TOP TEMP BOT TEMP

68 68

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

TOP TEMP BOT TEMP

68 68

( 7 ) BOT . TEMP . ▼ : 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 ).

TOP TEMP BOT TEMP

68 68

GAP

PRESSURE

1/16

( 10 ) GAP ▲ : 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.

GAP

PRESSURE

1/16

Page 5 - 2

F - 160 CE Operation and Maintenance Manual

Operations

( 11 ) GAP ▼ : 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

1/16

( 12 ) 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.

( 13 ) PRESSURE ▲ : 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

WARNING

Keep hands and fingers clear of

the laminator roller nip when

adjusting PRESSURE.

You can be CRUSHED or BURNED!

GAP

PRESSURE

1/16

INFORMATION

When adjusting the pressure, the gap

will be affected as well.

( 14 ) PRESSURE ▼ : 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

Page 5 - 3

Operations F - 160 CE Operation and Maintenance Manual

( 15 ) JOB DISPLA Y : Displays the job number selected

and will set the operating parameters saved for that number once SEL has been pressed.

SEL SAV

JOB

STANDBY

INFORMATION

Job programming is explained in

Section 5.4

( 17 ) JOB ▼ : 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.

SEL SAV

JOB

STANDBY

( 18 )SEL : When pressed will send the operating parameters for the stored job number selected to the correct devices. Any time JOB ▲ or JOB ▼ is pressed,

SEL will flash indicating a change in job number.

( 16 ) JOB ▲ : 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.

SEL SAV

JOB

STANDBY

SAV

JOB

STANDBY

= Flashing

INFORMATION

If not using a JOB number, Press

SEL before changing parameters on

the control panel.

Page 5 - 4

F - 160 CE Operation and Maintenance Manual

Operations

( 19 ) SAVE : When pressed and held ( approximately 4

seconds ), will beep and save the current settings for the number showing in the JOB DISPLAY. For more information, refer to Section 5.4 Job Programming on how to save parameters.

SEL SAV

JOB

STANDBY

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

( 22 ) SPEED ▼: 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.

00.0

SPEED

SAFETY

STOP

FWD REV

( 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 )

00.0

SPEED

SAFETY

STOP

FWD

REV

( 21 ) SPEED ▲: 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.

15.0

SPEED

SAFETY

STOP

FWD

REV

00.0

SPEED

SAFETY

STOP

FWD REV

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

00.0

SPEED

SAFETY

STOP

FWD REV

Page 5 - 5

Operations F - 160 CE Operation and Maintenance Manual

( 25 ) FORWARD ▲ : When pressed, signals the

laminator to run in a forward motion and FORWARD ▲ becomes solid.

00.0

SPEED

SAFETY

STOP

FWD REV

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

( 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 but limited to the speed set in the display . If the safety shield is down, the speed is controlled through the control panel.

ATTUNG

WARNING

ADVERTENCIA

00.0

SPEED

SAFETY

STOP

FWD REV

( 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.

00.0

SPEED

SAFETY

STOP

FWD REV

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.

Page 5 - 6

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

F - 160 CE Operation and Maintenance Manual

Operations

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;

• Press and hold the variable speed footswitch down.

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!

• 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.

Page 5 - 7

Operations F - 160 CE 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!

• Raise the safety shield.

INFORMATION

Footswitch speed is not indicated in the

SPEED DISPLAY on the control panel.

To lower the safety shield

• Lower the safety shield.

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.

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.

• Adjust for desired speed using the variable speed footswitch.

Page 5 - 8

• Release GO. GO reverts to solid.

F - 160 CE Operation and Maintenance Manual

Figure 5.1.1 Front control panel

Operations

TOP TEMP BOT TEMP

5 6

68 68

GAP

1/16

PRESSURE

IIIIIII

15 17

22 27

JOB

00.0

SPEED

SAFETY

SE L

STANDBY

STOP

FWD

REV

SAV

12 19

23 24

= Flashing

Page 5 - 9

Operations F - 160 CE Operation and Maintenance Manual

5.2 Emergency

The F-160 CE 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 Films Group 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.

5.2.1 In an emergency

a) In the event of an emergency;

- Press any of the four E-STOPs, or

- Step on the front or rear E-CABLE

E-STOPs

The motorized main roller lift mechanism used to provide downward pressure on the upper main roller is capable of producing forces greater than 400 pounds.

WARNING

This force is applied to any object presented

in the opening ( called the nip ) between

the two rollers.

Use care in lowering the upper laminating roller 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 control the motion of the upper laminating roller . Before pressing GAP down arrow , ensure the nip area is clear.

E-STOPs

E-CABLE

INFORMATION

When an E-STOP or E-CABLE is engaged,

all motion stops, main rollers will gap

and power is removed.

b) Resolve the emergency situation.

E-CABLE

Page 5 - 10

F - 160 CE Operation and Maintenance Manual

Operations

5.2.2 Resume operation

a) Reset the E-STOP or the E-CABLE.

-Resetting the E-STOP

Unlatch

b) Press machine RESET. All parameters have

defaulted.

Machine reset

INFORMATION

-Resetting the E-CABLE

Push in

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

c) Enter the desired operating parameters or

select the job number prior to the emergency stop situation.

F ( 20 oC ),

The laminator will only turn on if all

E-STOPS are unlatched and

the E-CABLE is reset.

d) Y ou may now resume operating the laminator .

Page 5 - 11

Operations F - 160 CE Operation and Maintenance Manual

5.3 Set up

Initial set up of the Falcon 160 CE 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

d) Press machine RESET. The front control panel

is illuminated.

Machine reset

a) Clear the area around the laminating rollers and

pull rollers nip..

b) Ensure the laminator is plugged in.

c) Turn the MAIN POWER to the “ I ”

position.

Power

ON/OFF

5.3.2 Film loading

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.

Page 5 - 12

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

upper unwind shaft.

F - 160 CE Operation and Maintenance Manual

Operations

c) Swing the unwind shaft out enough to slide the

roll of laminate over the core chucks and onto the unwind shaft.

Brake adjust knob

Core chucks

Core support

Roll of laminate

Clevis pin

Saddle

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. For centering measurements, refer to Chart 5.3.1 Measurement chart.

Make sure

the laminate

is flush with

the core.

Measure from

the side frame

to the edge of

the roll of

laminate.

INFORMATION

Twisting the roll of film while sliding

makes loading the film onto the

unwind shaft easier.

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!

h) Close the rear safety shield.

g) For the lower unwind shaft, repeat steps “ b ”

through “ f ”.

Page 5 - 13

Operations F - 160 CE Operation and Maintenance Manual

Chart 5.3.1 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 " 60 "

15 "

13.5 "

10.5 "

9.5 "

8.5 "

6.5 " 5 " 4 "

5.3.5 Heating

Perform the following steps.if the application requires heat. Allow the rolls to heat up while rotating for even heat disbursement.

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

temperature.

TOP TEMP BOT TEMP

68 68

62 "

INFORMATION

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

the measurement.

3 "

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

lower roller temperature.

TOP TEMP BOT TEMP

68 68

Page 5 - 14

INFORMATION

When requiring top and bottom heat, it is

recommended to set both temperatures to

the same set point.

F - 160 CE Operation and Maintenance Manual

c) Press GAP ▼ to set the gap to “0”.

Operations

INFORMATION

GAP

PRESSURE

INFORMATION

Do not add PRESSURE when heating the

laminating rollers. The rollers expand.

d) Press FWD ▲ to set a forward motion

direction.

A slow speed helps distribute heat evenly.

f) Press SEL to engage the parameters.

SAV

JOB

SE L

STANDBY

g) Press GO to engage the motor drive system.

00.0

SPEED

SAFETY

STOP

FWD REV

e) Press SPEED ▲ to set a speed of 2 ft/min

( .61 m / min. ).

2.0

SPEED

SAFETY

STOP

FWD REV

2.0

SPEED

SAFETY

STOP

FWD REV

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

the temperature displays stop flashing, press

STOP and raise the gap to 1 in. by pressing GAP ▲

GAP

PRESSURE

Page 5 - 15

Operations F - 160 CE Operation and Maintenance Manual

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.

c) Press SEL.

SAV

JOB

SE L

STANDBY

d) If heat is required, press TOP TEMP . ▲ and

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

is required, leave the settings at 68

TOP TEMP BOT TEMP

225 225

F ( 20 oC ).

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

b) Press JOB ▲ to enter the desired job number

for the parameters you require to be stored.

SAV

JOB

SE L

STANDBY

WARNING

Keep hands and fingers clear of the

laminator roller nip when changing GAP.

You can be CRUSHED or BURNED!

e) Enter in the GAP setting desired by pressing

GAP ▼.

GAP

PRESSURE

Page 5 - 16

F - 160 CE Operation and Maintenance Manual

Operations

INFORMATION

When storing parameters within the JOB

SAVE feature of the laminator, PRESSURE

is not a storable setting.

f) Enter a desired speed by pressing SPEED ▲.

5.0

SPEED

SAFETY

STOP

FWD REV

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

Chart 5.4.1

g) Press and hold SAVE ( approximately 4

seconds ) until an audible beep is heard. The parameters entered have just been stored.

SEL SAV

JOB

STANDBY

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

parameters in job location numbers.

Chart 5.4.1 Job save chart

BOT. TEMP.JOB # TOP TEMP. GAP SPEED

1 2 3 4 5 6 7 8 9

Page 5 - 17

Operations F - 160 CE Operation and Maintenance Manual

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.

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.

a) T urn the MAIN POWER to the “ I ”

position.

Power

ON/OFF

b) Press RESET. The front control panel will

illuminated.

5.5.1 Main roller manual

nip adjustment

INFORMATION

The laminator will only turn on if all

E-STOPS are unlatched and

the E-CABLE is reset.

Page 5 - 18

Machine reset

WARNING

Caution should always be exercised

when using the laminator with

the safety shields raised.

You can be seriously HURT or INJURED!

F - 160 CE Operation and Maintenance Manual

Operations

c) Raise the front safety shield.

d) Press SEL.

SE L

JOB

STANDBY

= Flashing

SAV

f) At eye level with the main rollers, press

PRESSURE ▼ until you see the upper main

roller make contact with the substrate.

GAP

PRESSURE

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

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.

Keep hands and fingers clear of the

laminator roller nip when changing GAP.

You can be CRUSHED or BURNED!

INFORMATION

Refer to Figure 5.5.1 for proper roller

pressure.

Page 5 - 19

Operations F - 160 CE Operation and Maintenance Manual

Figure 5.5.1 Main roller pressure

Leader board

Proper

pressure

Excessive

pressure

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!

i) Step on the variable speed footswitch to back

the leader board out.

CAUTION

g) Press REV ▼ for a reverse motor direction.

00.0

SPEED

SAFETY

STOP

FWD REV

h) Press SPEED ▲ to 5.

5.0

SPEED

SAFETY

STOP

FWD REV

Speed is controlled through the variable

speed footswitch when the safety shield

is in the raised position.

j) The main roller nip has now been manually set.

k) Press STOP.

5.0

SPEED

SAFETY

STOP

FWD REV

Page 5 - 20

F - 160 CE Operation and Maintenance Manual

Operations

l) On the control panel press FWD ▲ for a

forward motor direction. Nip is now set.

FWR

REV.

00.0

SPEED

SAFETY

STOP

5.5.2 Pull roller manual nip adjustment

b) Press RESET. The front control panel will

illuminated.

Machine reset

c) Press SEL.

INFORMATION

If the main laminating rollers are heated,

mounting application may be run from the

rear operating position of the machine.

a) T urn the MAIN POWER to the “ I ”

position.

Power

ON/OFF

SAV

JOB

SE L

STANDBY

= Flashing

d) Press FWD ▲ for a forward motor direction.

00.0

SPEED

SAFETY

STOP

FWD

REV

Page 5 - 21

Operations F - 160 CE Operation and Maintenance Manual

e) Press SPEED ▲ to 5.

CAUTION

Sharp edges on a substrate should be filed

smooth and GAP manually adjusted.

Sharp edges can CUT the rollers!

WARNING

5.0

SPEED

SAFETY

STOP

FWD REV

f) 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!

Keep hands and fingers clear of the pull

roller nip when changing the gap.

You can be CRUSHED!

i) 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.

g) Raise the rear safety shield.

h) Position the leader board in the center of the

pull rollers between the nip.

Page 5 - 22

DOWN

CAUTION

Excess pressure can damage the laminating

rollers. Always use the minimum roll

pressure necessary to complete the task.

F - 160 CE Operation and Maintenance Manual

Operations

INFORMATION

Excessive pressure will cause the

substrate to bow or flatten.

INFORMATION

Refer to Figure 5.5.2 for proper roller

pressure.

INFORMATION

Density of the substrate will determine the

amount of pressure you may use.

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!

Figure 5.5.2 Pull roller pressure

Leader board

Proper

pressure

Leader board

Excessive

pressure

j) 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.

k) The pull roller nip has now been manually set.

Page 5 - 23

Operations F - 160 CE Operation and Maintenance Manual

l) Press STOP.

5.0

SPEED

SAFETY

STOP

FWD REV

m) Press REV ▼ for a reverse motor direction. The nip is now set

5.0

SPEED

SAFETY

STOP

FWD REV

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.

5.6 Front feed table

The table is part of the Falcon 160 CE safety feature. It is neccessary to have the front feed table properly positioned before using the laminator for an application.

CAUTION

If not installed properly, you can be injured

or cause damage to the table or laminator.

INFORMATION

SAFETY flashes when a safety feature

is not in proper position.

b) W ith both hands, grip the front edge of the

infeed table and lift up and then out.

Front edge

Page 5 - 24

F - 160 CE Operation and Maintenance Manual

5.6.2 Replacing the infeed table

a) Ensure the safety shiled is in the raised

position.

b) W ith both hands, grip the front edge of the

infeed table and align the back edge with the support bolts.

Operations

INFORMATION

If the tables are not properly seated, the

laminator will not operate in

"Panel" mode.

Front

support bolt

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

Safet

roller switch

support bolt

Back

Page 5 - 25

Operations F - 160 CE Operation and Maintenance Manual

This page intentionally left blank.

Page 5 - 26

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.

ApplicationsF - 160 CE Operation and Maintenance Manual

This section contains a blank process control chart

and diagram for the Falcon 160 CE 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 fit clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

The procedures and parameters described

in this section are reference points only . Parameters will vary with regards to laminate thickness, laminate widths, laminate types, print types, ink or toner types, environment conditions, operator experience and various substrates.

Page 6 - 1

Applications

6.1 Charts and Diagrams

Use the parameter charts and web up diagrams can to assist you with the applications described. It is recommended that you keep these parameter charts and web up diagrams in the manual for reference. Make copies if you require them in other locations.

Use the blank parameter chart and blank web up diagram to record specific applications not illustrated in this section. For converting degrees Fahrenheit to degrees Celsius, refer to Chart 6.1.1

F - 160 CE Operation and Maintenance Manual

Parameters will vary with regards to laminate thickness, laminate widths, laminates types, print types, ink or toner types, enviroment conditions, operater experience, and various substrates.

Page 6 - 2

Chart 6.1.1 Temperature conversion chart

ApplicationsF - 160 CE Operation and Maintenance Manual

F 68 20 69 20.6

70 21.1

71 21.7 72 22.2 73 22.7 74 23.3 75 23.9 76 24.4 77 25 78 25.6 79 26.1

80 26.7

81 27.2 82 27.8 83 28.3 84 28.9 85 29.4 86 30 87 30.6 88 31.1 89 31.7

90 32.2

91 32.8 92 33.3 93 33.9 94 34.4 95 35 96 35.6 97 36.1 98 36.7 99 37.2

100 37.8

101 38.3 102 38.9 103 39.4 104 40 105 40.6 106 41.1 107 41.7 108 42.2 109 42.8

110 43.3

111 43.9 112 44.4

= = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = =

F 113 45 114 45.6 115 46.1 116 46.7 117 47.2 118 47.8 119 48.3

120 48.9

121 49.4 122 50 123 50.6 124 51.1 125 51.7 126 52.2 127 52.8 128 53.3 129 53.9

130 54.4

131 55 132 55.6 133 56.1 134 56.7 135 57.2 136 57.8 137 58.3 138 58.9 139 59.4

140 60

141 60.6 142 61.1 143 61.7 144 62.2 145 62.8 146 63.3 147 63.9 148 64.4 149 65

150 65.6

151 66.1 152 66.7 153 67.2 154 67.8 155 68.3 156 68.9 157 69.4

= = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = =

F 158 70 159 70.6

160 71.1

161 71.7 162 72.2 163 72.8 164 73.3 165 73.9 166 74.4 167 75 168 75.6 169 76.1

170 76.7

171 77.2 172 77.8 173 78.3 174 78.9 175 79.4 176 80 177 80.6 178 81.1 179 81.7

180 82.2

181 82.8 182 83.3 183 83.9 184 84.4 185 85 186 85.6 187 86.1 188 86.7 189 87.2

190 87.8

191 88.3 192 88.9 193 89.4 194 90 195 90.6 196 91.1 197 91.7 198 92.2 199 92.8

200 93.3

201 93.9 202 94.4

= = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = =

F 203 95 204 95.6 205 96.1 206 96.7 207 97.2 208 97.8 209 98.3

210 98.9

211 99.4 212 100 213 100.6 214 101.1 215 101.7 216 102.2 217 102.8 218 103.3 219 103.9

220 104.4

221 105 222 105.6 223 106.1 224 106.7 225 107.2 226 107.8 227 108.3 228 108.9 229 109.4

230 110

231 110.6 232 111.1 233 111.7 234 112.2 235 112.8 236 113.3 237 113.9 238 114.4 239 115

240 115.6

241 116.1 242 116.7 243 117.2 244 117.8 245 118.3 246 118.9 247 119.4

= = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = =

F 248 120 249 120.6

250 121.1

251 121.7 252 122.2 253 122.8 254 123.3 255 123.9 256 124.4 257 125 258 125.6 259 126.1

260 126.7

261 127.2 262 127.8 263 128.3 264 128.9 265 129.4 266 130 267 130.6 268 131.1 269 131.7

270 132.2

271 132.8 272 133.3 273 133.9 274 134.4 275 135 276 135.6 277 136.1 278 136.7 279 137.2

280 137.8

281 138.3 282 138.9 283 139.4 284 140 285 140.6 286 141.1 287 141.7 288 142.2 289 142.8

290 143.3

= = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = =

Page 6 - 3

Applications

F - 160 CE Operation and Maintenance Manual

Parameter Chart - Blank

MATERIALS

UPPER UNWIND : LOWER UNWIND :

TOP TEMP. BOT. TEMP.

GAP

SUBSTRATE : PRINTS :

TEMPERATURE

GAP & PRESSURE

PRESSURE

MOTOR DIRECTION & SPEED

DOWN

SPEED

SOLID

= Panel

FLASHING

= Footswitch

PULL ROLL SETTINGS

PRESSURE

NOTES

FWR

REV.

N / A 1/4 Turn 1/2 Turn

3/4 Turn

Page 6 - 4

Web Diagram - Blank

ApplicationsF - 160 CE Operation and Maintenance Manual

Page 6 - 5

Applications

F - 160 CE Operation and Maintenance Manual

Parameter Chart 1 - Precoating substrates

MATERIALS

UPPER UNWIND : LOWER UNWIND :

TOP TEMP. BOT. TEMP.

Pro Mount

N / A

68 68

GAP

1/4"

SUBSTRATE : PRINTS :

TEMPERATURE

GAP & PRESSURE

1/4" Foam Core

N / A

PRESSURE

DOWN

00.0

SPEED

MOTOR DIRECTION & SPEED

SOLID

FLASHING

PULL ROLL SETTINGS

NOTES

= Panel

= Footswitch

PRESSURE

FWD

REV.

N / A 1/4 Turn 1/2 Turn

3/4 Turn

Pro Mount can be substituted with a similar product. Substrate can vary. GAP will be dependent on the substrate thickness. Pressure will be determined by operator. Speed is not indicated in Footswitch mode. Because the process is described from the front of the laminator, motor direction is FWD and the pull rolls are not required for this application.

Page 6 - 6

Pro

Mount

Leader

board

ApplicationsF - 160 CE Operation and Maintenance Manual

Web Diagram 1 - Precoating substrate

Substrate

Page 6 - 7

Applications

F - 160 CE Operation and Maintenance Manual

Parameter Chart 2 - Mounting only

MATERIALS

UPPER UNWIND : LOWER UNWIND :

TOP TEMP. BOT. TEMP.

N / A

68 68

GAP

1/4

SUBSTRATE : PRINTS :

TEMPERATURE

GAP & PRESSURE

Precoated boards

Inkjet prints

PRESSURE

DOWN

00.0

SPEED

MOTOR DIRECTION & SPEED

SOLID

FLASHING

PULL ROLL SETTINGS

NOTES

= Panel

= Footswitch

PRESSURE

FWD

REV.

N / A 1/4 Turn 1/2 Turn

3/4 Turn

Substrate will vary. Print can be of any type. GAP will be dependent on the substrate thickness. Pressure will be determined by operator. Speed is not indicated in Footswitch mode. Because the process is described from the front of the laminator, motor direction is FWD and the pull rolls are not required for this application.

Page 6 - 8

Web Diagram 2 - Mounting only

ApplicationsF - 160 CE Operation and Maintenance Manual

Release liner

Precoated

board

Page 6 - 9

Applications

F - 160 CE Operation and Maintenance Manual

Parameter Chart 3 - Single sided ( Sled )

MATERIALS

UPPER UNWIND : LOWER UNWIND :

TOP TEMP. BOT. TEMP.

Pro Gloss

N / A

68 68

GAP

1/4

SUBSTRATE : PRINTS :

TEMPERATURE

GAP & PRESSURE

1/4" Foam Core

Inkjet prints

PRESSURE

DOWN

00.0

SPEED

MOTOR DIRECTION & SPEED

SOLID

FLASHING

PULL ROLL SETTINGS

NOTES

= Panel

= Footswitch

PRESSURE

FWD

REV.

N / A 1/4 Turn 1/2 Turn

3/4 Turn

Page 6 - 10

Web Diagram 3 - Single sided ( Sled )

ApplicationsF - 160 CE Operation and Maintenance Manual

P.S.A.

Laminate

Release liner

Sled

Page 6 - 11

Applications

F - 160 CE Operation and Maintenance Manual

Parameter Chart 4 - Single sided ( Craft paper )

MATERIALS

UPPER UNWIND : LOWER UNWIND :

TOP TEMP. BOT. TEMP.

Pro Gloss Craft Paper

68 68

GAP

SUBSTRATE : PRINTS :

TEMPERATURE

GAP & PRESSURE

N / A

Inkjet prints

PRESSURE

DOWN

3 - 6

SPEED

MOTOR DIRECTION & SPEED

SOLID

FLASHING

PULL ROLL SETTINGS

NOTES

= Panel

= Footswitch

PRESSURE

FWD

REV.

N / A 1/4 Turn 1/2 Turn

3/4 Turn

Upper unwind material can be of similar product. Print can be of any type. Pressure will will vary slightly with regards to quality of the output. Speed will be determined by the operator. Pull roll pressure may vary between 1/2 turn and 3/4 turn. Because the process is described from the front of the laminator, motor direction is FWD.

Page 6 - 12

Web Diagram 4 - Single sided ( Craft paper )

ApplicationsF - 160 CE Operation and Maintenance Manual

Laminate

Output

P.S.A.

Release liner

C ra ft P a p e r

Finish product

rewind option

Page 6 - 13

Applications

F - 160 CE Operation and Maintenance Manual

Parameter Chart 5 - Decal and mount ( Decal )

MATERIALS

UPPER UNWIND : LOWER UNWIND :

TOP TEMP. BOT. TEMP.

Pro Gloss Pro Mount

68 68

GAP

SUBSTRATE : PRINTS :

TEMPERATURE

GAP & PRESSURE

N / A

Inkjet prints

PRESSURE

DOWN

3 - 6

SPEED

MOTOR DIRECTION & SPEED

SOLID

FLASHING

PULL ROLL SETTINGS

NOTES

= Panel

= Footswitch

PRESSURE

FWD

REV.

N / A 1/4 Turn 1/2 Turn

3/4 Turn

Upper and lower unwind material can be of similar product. Print can be of any type. Pressure will will vary slightly with regards to quality of the output. Speed will be determined by the operator. Pull roll pressure may vary between 1/2 turn and 3/4 turn. Because the process is described from the front of the laminator, motor direction is FWD.

Page 6 - 14

Web Diagram 5 - Decal and mount ( Decal )

ApplicationsF - 160 CE Operation and Maintenance Manual

P.S.A.

Laminate

Output

Release liner

Pro Mount

Finish product

rewind option

Page 6 - 15

Applications

F - 160 CE Operation and Maintenance Manual

Parameter Chart 6 - Decal and mount ( Mount )

MATERIALS

UPPER UNWIND : LOWER UNWIND :

TOP TEMP. BOT. TEMP.

N / A

68 68

GAP

1/4

SUBSTRATE : PRINTS :

TEMPERATURE

GAP & PRESSURE

1/4" Foam Core

Decals

PRESSURE

DOWN

00.0

SPEED

MOTOR DIRECTION & SPEED

SOLID

FLASHING

PULL ROLL SETTINGS

NOTES

= Panel

= Footswitch

PRESSURE

FWD

REV.

N / A 1/4 Turn 1/2 Turn

3/4 Turn

Decal will come from the previous chart and diagram application. Substrate can vary. GAP will be dependent on the substrate thickness. Pressure will be determined by operator. Speed is not indicated in Footswitch mode. Because the process is described from the front of the laminator, motor direction is FWD and the pull rolls are not required for this application.

Page 6 - 16

Web Diagram 6 - Decal and mount ( Mount )

Decal

ApplicationsF - 160 CE Operation and Maintenance Manual

Release liner

Substrate

Page 6 - 17

GBC F - 160 CE User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual