GBC Falcon 160 Instruction Manual

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GBC Falcon 160

Laminator

Instruction Manual

F - 160 CE OPERATION AND

MAINTENANCE MANUAL

Do not duplicate without written permission.

GBC Films Group

4151 Anderson Road

DeForest, WI 53532

Revision : A Ph: ( 608 ) 246 - 8844

Part number : 930 - 045

Fx: ( 608 ) 246 - 8645

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The information in this publication is provided for reference and is believed to be accurate and complete. GBC Films Group 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 Films Group 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 Films Group or others. GBC Films Group assumes no liability arising from infringements of patents or any other rights of third parties.

This publication is copyrighted © 2000 by GBC Films Group. 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 Films Group.

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4151 Anderson Road

DeForest, WI 53532

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Read me fileF - 160 CE Operation and Maintenance Manual

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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 Installation ..................................................................................................1 - 7

1.8 Operations .................................................................................................1 - 10

1.9 Applications ...............................................................................................1 - 15

1.10 Troubleshooting ......................................................................................1 - 19

1.11 Maintenance ...........................................................................................1 - 20

1.12 Decal explanation ....................................................................................1 - 22

Page I

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Figure 1.12.1 Decal location - front ............................................1 - 24

Figure 1.12.2 Decal location - rear ............................................1 - 25

Section 2: Warranty

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

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

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

Page II

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

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

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

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

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

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

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

Section 5: Operations

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

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

Page IV

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

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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

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

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

Section 6: Applications

Group 1: No heat

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

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

6.3 Single sided lamination ( Sled method ) ....................................................6 - 18

6.4 Single sided lamination ( Craft paper method ) ........................................6 - 27

6.5 Decal and mount ......................................................................................6 - 37

Pass 1 Decal .........................................................................................6 - 37

Pass 2 Mount ........................................................................................6 - 46

Group 2: Top heat only

6.6 Precoating substrates ................................................................................6 - 54

Page VI

6.7 One pass mount and laminate .................................................................6 - 63

6.8 Thermal decal and mount .......................................................................6 - 72

Pass 1 Thermal decal ...........................................................................6 - 73

Pass 2 Mount ........................................................................................6 - 81

Group 3: Top and bottom heat

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6.9 Encapsulation ...........................................................................................6 - 88

6.10 Parameter charts and diagrams

Chart 6.10.1 Temperature conversion chart ...................6 - 99

Blank chart ....................................................................................................6 - 100

Blank diagram ...............................................................................................6 - 101

Chart 1 - Precoating substrates .....................................................................6 - 102

Diagram 1 - Precoating subtrates .................................................................6 - 103

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

Chart 2 - Mounting only ...............................................................................6 - 104

Diagram 2 - Mounting only .........................................................................6 - 105

Chart 3 - Single sided ( Sled ) ......................................................................6 - 106

Diagram 3 - Single sided ( Sled ) .................................................................6 - 107

Chart 4 - Single sided ( Craft paper ) ..........................................................6 - 108

Diagram 4 - Single sided ( Craft paper ) .....................................................6 - 109

Chart 5 - Decal and mount ( Decal ) ...........................................................6 - 110

Diagram 5 - Decal and mount ( Decal ) ......................................................6 - 111

Chart 6 - Decal and mount ( Mount ) .........................................................6 - 112

Diagram 6 - Decal and mount ( Mount ) ....................................................6 - 113

Chart 7 - Precoating subtrates ....................................................................6 - 114

Diagram 7 - Precoating subtrates ...............................................................6 - 115

Chart 8 - One pass mount ...........................................................................6 - 116

Diagram 8 - One pass mount ......................................................................6 - 117

Page VIII

T able of ContentsF - 160 CE Operation and Maintenance Manual

Chart 9 - Thermal decal and mount ( Decal ) ...............................................6 - 118

Diagram 9 - Thermal decal and mount ( Decal ) ..........................................6 - 119

Chart 10 - Thermal decal and mount ( Mount ) ............................................6 - 120

Diagram 10 - Thermal decal and mount ( Mount ) .......................................6 - 121

Chart 11 - Encapsulation ...............................................................................6 - 122

Diagram 11 - Encapsulation ..........................................................................6 - 123

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

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

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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

Page X

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, W arning,

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 200oF ( 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 Installation

The following symbols are positioned at various

points in Section 4 Installation.

Safety

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.

CAUTION

Failure to follow the pre-installation check

list can result in damage to the laminator.

WARNING

The operating environment must be free of

dust, flammable liquids and vapors. You can

be injured by inhaling chemical vapors.

Be sure to follow the correct wiring diagram

ALL SHIPMENTS ARE EX-WORKS.

dock, title passes to the buyer. Please review

WARNING

when supplying power to the laminator. If

improperly connected, you can be seriously

injured or cause damage to the laminator.

INFORMATION

At our

your insurance coverage prior to shipment,

as you are responsible for all subsequent

freight charges and risks.

WARNING

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

the laminator.

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.

Page 1 - 7

Safety F - 160CE Operation and Maintenance Manual

INFORMATION

Depending on the destination and customer

preference, the Falcon 160 may be shipped in various ways. The laminator may arrive shrink wrapped or in a plywood crate on a

skid. Please follow the unpacking procedure

that pertains to your method of shipment.

WARNING

The unpacking process requires at least two

people. You can be severely injured, crushed

or cause damage to the laminator.

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

They can cause problems when trying to roll

CAUTION

can damage the laminator.

INFORMATION

Do not put packing screws on the floor.

the laminator into position or you can

become injured if stepped on.

damage the laminator or cause harm to you

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.

The Falcon 160 CE Laminator is a large and

WARNING

Do not attempt to move the laminator across

anything other than a flat level surface

without trained and qualified riggers. You

can be crushed or seriously injured.

alignment of the rolling parts of the machine and requires extensive realignment. You can

CAUTION

A second person must support the side labeled 5 in Figure 4.4.1 It can fall and

and others.

WARNING

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

be crushed or seriously injured.

Page 1 - 8

F - 160 CE Operation and Maintenance Manual

Safety

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.

CAUTION

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

can damage the laminator.

INFORMATION

Improper leveling, will result in poor

output quality.

INFORMATION

The side frame provides a more accurate

reading than the cabinet.

WARNING

Do not attempt to use the ramps if they are

not secured to the pallet. Make sure you have the pallet on a flat even surface before attempting to roll the machine off using the

ramps.

INFORMATION

About recycling: The crate components can

be reused for shipping the laminator again

or can be disassembled and the wood and

screws recycled. The shrink wrap is not

recyclable, so it must be discarded.

INFORMATION

A second person can read the level while you

make the appropriate adjustments.

WARNING

Caution should always be exercised

when using the laminator with

the safety shields raised.

You can be seriously HURT or INJURED!

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Safety F - 160CE Operation and Maintenance Manual

WARNING

Keep hands and fingers clear of the

laminator roller nip when changing GAP.

You can be CRUSHED or BURNED!

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.

INFORMATION

The SAFETY indicator should not be

flashing when the tables are properly

seated and the safety shields are in

the closed position..

INFORMATION

Notice that the footswitch speed is not

indicated in the SPEED DISPLAY on the

front control panel.

WARNING

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

service representative immediately

INFORMATION

Do not put packing screws on the floor.

They can cause problems when trying to roll

the laminator into position.

1.8 Operations

points in Section 5 Operations.

The following symbols are positioned at various

INFORMATION

Read the following warnings and cautions

before attempting to operate or service the

Falcon 160 Laminator.

Page 1 - 10

F - 160 CE Operation and Maintenance Manual

Safety

INFORMATION

When any command is pressed on the

control panel, a "beep" will sound. If the

command is held down, the panel will

"beep" only once.

INFORMATION

When adjusting the pressure, the gap

will be affected as well.

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

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!

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.

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!

Page 1 - 11

Safety F - 160CE Operation and Maintenance Manual

INFORMATION

WARNING

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.

At these temperatures there is a danger

ofsevere burn if the rolls are touched

duringsetup, operation or servicing.

INFORMATION

When the safety shield is raised, the

laminator will only run while the variable

speed footswitch is depressed.

INFORMATION

Footswitch speed is not indicated in the

SPEED DISPLAY on the control panel.

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.

INFORMATION

When the safety shield is lowered, speed

reverts to the panel speed setting.

Page 1 - 12

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 CE Operation and Maintenance Manual

INFORMATION

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

the measurement.

Safety

INFORMATION

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

mode.

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.

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

WARNING

Keep hands and fingers clear of the

laminator roller nip when changing GAP.

You can be CRUSHED or BURNED!

F ( 20 oC ),

INFORMATION

Slow speed will assists with heat up times

and distributes heat evenly.

INFORMATION

When storing parameters within the JOB

SAVE feature of the laminator, PRESSURE

is not a storable setting.

Page 1 - 13

Safety F - 160CE Operation and Maintenance Manual

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

Excessive pressure will cause the

substrate to bow or flatten.

INFORMATION

Density of the substrate will determine the

amount of pressure you may use.

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.

INFORMATION

If the main laminating rollers are heated,

mounting application may be run from the

rear operating position of the machine.

WARNING

Keep hands and fingers clear of the pull

roller nip when changing the gap.

You can be CRUSHED!

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F - 160 CE Operation and Maintenance Manual

Safety

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.

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.

INFORMATION

The mount adhesive must not exceed 1 in.

the width of the substrate. If it does, you

will experience complications with this

application.

CAUTION

If not installed properly, you can be injured

or cause damage to the table or laminator.

1.9 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!

Page 1 - 15

Safety F - 160CE Operation and Maintenance Manual

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!

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!

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.

Page 1 - 16

F - 160 CE Operation and Maintenance Manual

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

INFORMATION

Position the leader board squarely

onto the mount adhesive.

CAUTION

Prolonged contact can form flat spots on the

rollers.

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.

CAUTION

When manually setting the main roll nip,

observe the substrate to prevent crushing.

INFORMATION

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

the same set point.

Page 1 - 17

Safety F - 160CE Operation and Maintenance Manual

INFORMATION

If the main laminating rollers are heated,

mounting application may be run from the

rear operating position of the machine.

INFORMATION

Do not add PRESSURE when heating the

laminating rollers, this allows the high

release silicone to expand with minimum

restrictions.

INFORMATION

If the board is not squarely positioned,

you may experience difficulties with

this application.

INFORMATION

If the image is not conformed to the roller,

you may experience difficulties with

this application.

INFORMATION

Slow speed will assists with heat up times

and distributes heat evenly.

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

Use a slow speed. If the tack point enters

the rollers nip, you will not be able to

pull the release liner.

WARNING

Keep hands and fingers clear of the pull

roller nip when changing the gap.

You can be CRUSHED!

Page 1 - 18

F - 160 CE Operation and Maintenance Manual

Safety

INFORMATION

Do not lower the pull roller so that the

substrate is crushed when passing through.

This will prevent the boards from bowing.

CAUTION

Caution should always be exercised when

using a utility knife near the rollers.

You can put cuts into the rollers!

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.

INFORMATION

For optimal temperature settings of

various laminates, contact your supplier or sales representative.

INFORMATION

Stopping the rollers on the print will leave a

pressure line on the image.

1.10 Troubleshooting

The following symbols are positioned at various

points in Section 7 T roubleshooting.

CAUTION

Exercise care when cleaning the laminating

rollers with 80% isopropyl alcohol:

Use only in a well ventilated area



Wear rubber gloves



Use only on cool rolls



CLEANING HEATED ROLLERS CAN

IGNITE THE FUMES!

Page 1 - 19

Safety F - 160CE Operation and Maintenance Manual

CAUTION

Prolonged contact can form flat spots on the

rollers.

CAUTION

If silicone adhesive contacts the laminating

rollers, remove it IMMEDIATELY using

80% isopropyl alcohol. It can harden within

an hour and bond to the rollers.

schedule. Before performing any of the steps

INFORMATION

Below is a recommended maintenance

listed, read through the procedures first.

Please follow the instructions pertaining to

the step you are performing.

ELECTRICAL

SHOCK

Remove power from the laminator before

servicing. You can be severely shocked,

electrocuted or cause a fire.

1.11 Maintenance

The following symbols are positioned at various

points in Section 8 Maintenance.

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

If improperly performed, you may

encounter other problems with the output

quality.

WARNING

Caution should always be exercised

when using the laminator with

the safety shields raised.

You can be seriously HURT or INJURED!

Page 1 - 20

F - 160 CE Operation and Maintenance Manual

Safety

CAUTION

Excessive pressure can destroy the silicone

layer by pressing to hard or scrubbing

too long in one spot.

CAUTION

Do NOT pick or pull heat activated adhesive

off the rolls when they are cold. You can

cause irreparable damage to the

laminating rolls.

Use only isopropyl alcohol or rubber cement

CAUTION

Speed is controlled through the variable

speed footswitch when the safety shield

is in the raised position.

CAUTION

eraser to clean the rollers. Harsh chemicals

like toluene, acetone, or MEK can destroy

the silicone covering of the rolls.

INFORMATION

When cleaning the bottom main roller,

switch the motion direction to reverse.

When cleaning the bottom pull roller,

switch the motion direction to forward.

This will prevent anything from

being pulled into the nip.

WARNING

When operating the laminator using the

variable speed footswitch, keep hands and

fingers away from the nip of the rollers.

You may be CRUSHED or BURNED!

CAUTION

Exercise care when cleaning the laminating

rollers with 80% isopropyl alcohol:



Use only in a well ventilated area



Wear rubber gloves



Use only on cool rolls

CLEANING HEATED ROLLERS CAN

IGNITE THE FUMES!

Page 1 - 21

Safety F - 160CE Operation and Maintenance Manual

1.12 Label locations

WARNING

Keep hands and fingers clear of the

laminator roller nip when changing GAP.

You can be CRUSHED or BURNED!

WARNING

Keep hands and fingers clear of

the laminator roller nip when

adjusting PRESSURE.

You can be CRUSHED or BURNED!

Laminator are important safety labels. Pay careful attention to these labels at all times! Figure 1.12.1

and Figure 1.12.2 illustrates the location of each of these labels.

Posted at various locations on the Falcon 160

WARNING

ACHTUNG

MISE EN GARDE

ELECTRICAL

SHOCK

Remove power from the laminator before

cleaning. You can be severely shocked,

electrocuted or cause a fire.

ELECTRICAL

SHOCK

Do not use liquid or aerosol cleaners on the

laminator. Do not spill liquid of any kind on

the laminator. You can be severely shocked,

electrocuted or cause a fire. Use only a damp

cloth for cleaning unless other wise

specified.

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

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

Page 1 - 22

F - 160 CE Operation and Maintenance Manual

Safety

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.

WARNING

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

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

Reset: Machine reset. Press after iniating power to the laminator or after an E-STOP or E-CABLE has been engaged then resetted.

Do not Lift: This point can not be used as a lifting point. If ignored, damage will occur to the laminator.

Page 1 - 23

Safety F - 160CE Operation and Maintenance Manual

Figure 1.12.1 Label locations - Front

WARNING

ACHTUNG

MISE EN GARDE

WARNING

ACHTUNG

MISE EN GARDE

Riesgo de choque 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

Page 1 - 24

MUCHO

CUIDADO

een door

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 servicin qualified service personnel.

Riesgo de choque 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 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 servicin qualified service personnel.

F - 160 CE Operation and Maintenance Manual

Figure 1.12.2 Label locations - Rear

WARNING ACHTUNG

MISE EN GARDE

WARNING ACHTUNG

MISE EN GARDE

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

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.

Safety

WARNING

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

Page 1 - 25

Safety F - 160CE Operation and Maintenance Manual

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Page 1 - 26

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 VAC, 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

Weight:

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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Page 3 - 6

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 . Figure 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

support

Core

chuck

Power

ON/OFF

E-CABLE

Core

chuck

Pull rollers

Rear

feed

table

Circuit

breaker

Upper

unwind

shaft

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) Turn 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) V erify 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) V erify 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

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 DISPLA Y 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 TOP TEMP DISPLA Y and BOT TEMP

DISPLA Y 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

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.

INFORMATION

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) With 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 ST ANDBY.

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

SAV

FWD REV

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 oF ( 20 oC ).

TOP TEMP BOT TEMP

225 225

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

GBC Falcon 160 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual