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F - 160 Operation and Maintenance Manual

© GBC Pro - Tech August 1999

Page VII

Table of Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Summary of Contents for F - 160

Page 1: ...INTENANCE MANUAL November 1999 GBC Pro Tech Do not duplicate without written permission Part number 930 031 GBC Pro Tech 4151 Anderson Road DeForest WI 53532 Revision B Ph 608 246 8844 Fx 608 246 8645...

Page 2: ...Pro Tech or others GBC Pro Tech assumes no liability arising from infringements of patents or any other rights of third parties This publication is copyrighted 1999 by GBC Pro Tech All rights reserve...

Page 3: ...F 160 Operation and Maintenance Manual Read me file GBC Pro Tech August 1999 This page intentionally left blank...

Page 4: ...Fax Correspondence Fax number 608 246 8645 Date To Sean Flood GBC Pro Tech 4151 Anderson Road DeForest WI 53532 From Company Address Phone number Fax number Re Falcon 160 Operations and Maintenance M...

Page 5: ...F 160 Operation and Maintenance Manual Read me file GBC Pro Tech August 1999 This page intentionally left blank...

Page 6: ...tion 1 Safety 1 1 Symbols 1 1 1 2 Safety features 1 1 1 3 Installation 1 4 1 4 Operations 1 8 1 5 Applications 1 12 1 6 Troubleshooting 1 16 1 7 Maintenance 1 16 1 8 Decal Explanation 1 19 Figure 1 6...

Page 7: ...ions 3 1 General 3 1 3 2 Consumables 3 1 3 3 Function 3 2 3 4 Electrical 3 2 3 5 Dimensions 3 3 Figure 3 5 1 Dimensions 3 3 Section 4 Installation 4 1 Preinstallation check list 4 1 Figure 4 1 1 Sugge...

Page 8: ...cessory pack content 4 8 4 6 Leveling 4 8 4 7 Safety check 4 11 4 7 1 Front and rear infeed tables 4 12 4 7 2 Front and rear safety shields 4 14 4 7 3 Emergency stops 4 15 4 8 Function check 4 17 4 8...

Page 9: ...5 1 1 Front control panel 5 9 5 2 Emergency 5 10 5 3 Set up 5 11 5 3 1 Power 5 11 5 3 2 Film loading 5 12 Figure 5 3 4 Measurement chart 5 13 5 3 5 Heating 5 13 5 4 Job programming 5 15 Figure 5 4 1 J...

Page 10: ...emoving the infeed tables 5 23 5 6 2 Replacing the infeed tables 5 23 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 metho...

Page 11: ...trates 6 51 6 7 One pass mount and laminate 6 60 6 8 Thermal decal and mount 6 69 Pass 1 Thermal decal 6 70 Pass 2 Mount 6 78 Group 3 Top and bottom heat 6 9 Encapsulation 6 85 6 10 Parameter charts a...

Page 12: ...3 Single sided Sled 6 102 Diagram 3 Single sided Sled 6 103 Chart 4 Single sided Craft paper 6 104 Diagram 4 Single sided Craft paper 6 105 Chart 5 Decal and mount Decal 6 106 Diagram 5 Decal and mou...

Page 13: ...al 6 114 Diagram 9 Thermal decal and mount Decal 6 115 Chart 10 Thermal decal and mount Mount 6 116 Diagram 10 Thermal decal and mount Mount 6 117 Chart 11 Encapsulation 6 118 Diagram 11 Encapsulation...

Page 14: ...ance Manual GBC Pro Tech August 1999 Page IX Table of Contents 7 4 Glossary 7 5 Section 8 Maintenance 8 1 Maintenance schedule 8 1 8 2 Cleaning the rollers 8 2 8 2 1 Cabinets and covers 8 6 8 2 2 Touc...

Page 15: ...F 160 Operation and Maintenance Manual GBC Pro Tech August 1999 Page X Table of Contents This page is intentionally left blank...

Page 16: ...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 WARNING Indic...

Page 17: ...over 200o F 100o C DANGER At these temperatures there is a danger of severe burn if the rolls are touched during setup operation or servicing INFORMATION Only a qualified service technician should per...

Page 18: ...ED WARNING Figure 1 2 2 Safety shields raised Rear safety shield Front safety shield Thelaminatorisequippedwithtwo EMERGENCY STOPS located on the top of either side of the laminator To engage the EMER...

Page 19: ...ee footswitch in section 3 of this manual Figure 1 2 5 Tables and keys 1 3 Installation Thefollowingsymbolsarepositioned at various points in Section 4 Installation CAUTION Failure to follow the pre i...

Page 20: ...of this on the Bill of Lading INFORMATION Depending on the destination and customer preference the Falcon 160 may be shipped in various ways The laminator may arrive shrink wrapped or in a plywood cra...

Page 21: ...s of the machine and requires extensive realignment You can be crushed or seriously injured GBC Pro Tech s warranty does not cover malfunction of the equipment due to mishandling and or tipping GBC Pr...

Page 22: ...ller nip when changing GAP You can be CRUSHED or BURNED WARNING Do not wear ties loose fitting clothing or dangling jewelry while operating or servicing the laminator These items can get caught in the...

Page 23: ...ommand is held down the panel will beep only once INFORMATION When adjusting the pressure the gap will be affected as well WARNING Keep hands and fingers clear of the laminator roller nip when adjusti...

Page 24: ...he indicated panel speed 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...

Page 25: ...ting the laminating rollers this allows the high release silicone to expand with minimum restrictions Slow speed will assists with heat up times and distributes heat evenly INFORMATION INFORMATION Whe...

Page 26: ...ers Always use the minimum roll pressure necessary to complete the task Excessive pressure will cause the substrate to bow or flatten INFORMATION Density of the substrate will determine the amount of...

Page 27: ...t adhesive must not exceed 1 in the width of the substrate If it does you will experience complications with this application INFORMATION CAUTION Sharp edges on a substrate should be filed smooth and...

Page 28: ...t the nip in Section 5 5 1 Manually nip adjustment INFORMATION WARNING Keep hands and fingers clear of the laminator roller nip when adjusting PRESSURE You can be CRUSHED or BURNED WARNING When operat...

Page 29: ...n form flat spots on 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...

Page 30: ...ay experience difficulties with this application INFORMATION Use a slow speed If the tack point enters the rollers nip you will not be able to pull the release liner INFORMATION WARNING Keep hands and...

Page 31: ...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 CAUTION Pr...

Page 32: ...when using the laminator with the safety shields raised You can be seriously HURT or INJURED WARNING CAUTION Excessive pressure can destroy the silicone layer by pressing to hard or scrubbing too lon...

Page 33: ...rea Wear rubber gloves Use only on cool rolls CLEANING HEATED ROLLERS CAN IGNITE THE FUMES WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP You can be CRUSHED or BURN...

Page 34: ...WARNING ACHTUNG MISE EN GARDE Read Manual Read the operations manual before attemptingtooperatethismachine WARNING ACHTUNG MISE EN GARDE Roller Pinch Point Keep hands and fingers away You may be crush...

Page 35: ...abel locations WARNING ACHTUNG MISE EN GARDE WARNING ACHTUNG MISE EN GARDE Behind cabinet Behind Cover WARNING ACHTUNG MISE EN GARDE WARNING ACHTUNG MISE EN GARDE Inside cabinet WARNING ACHTUNG MISE E...

Page 36: ...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 i...

Page 37: ...efullyawareofall aspectsofsafetywithregardstolaminationequipment Anycommissioningorserviceengineermust be of competent nature trained and qualified to GBC Pro Techstandardstofulfillthatjob Thispersonw...

Page 38: ...Two unwinds 1 upper 1 lower Two rewinds 1 upper front 1 lower center Safetyshielded Infeed and oufeed tables Accelerator footswitch Job programmable Bi directionalsystem Singlesidedlamination Encapsu...

Page 39: ...0 15 ft min 0 4 6 m min 2 1 4 horse power drive motor Bi directional D C motor 68o F 290o F 20o C 143o C Front control panel Variable speed footswitch Save up to 9 job parameters Highreleasesiliconer...

Page 40: ...NipHeight SafetyShieldRaisedHeight Crated 1568 lbs 711 kg Uncrated 1200 lbs 544 kg Crated 90 in H x 46 in W x 72 in L 229 cm H x 117 cm W x 183 cm L Uncrated 54 in H x 38 in W x 82 5 in L 137 cm H x 9...

Page 41: ...Specifications F 160 Operation and Maintenance Manual GBC Pro Tech August 1999 Page 3 4 This page intentionally left blank...

Page 42: ...a must be established that allows for operation in both the front and rear of the laminator and provides space for efficient material flow Figure 4 1 1 illustrates a typical machine area layout Is the...

Page 43: ...njured or cause damage to the laminator Figure4 1 2 illustratesproperwiringforsinglephase for the U S Figure 4 1 3 illustrates proper wiring for Wye 3 phase for Europe WARNING The Falcon 160 Laminator...

Page 44: ...1999 Page 4 3 Installation Figure 4 1 1 Suggested Floor Layout 4 x 6 1 22 m x 2m Work table on wheels Table height 35 3 4 94 95m 4 x 6 1 22 m x 2m Work table on wheels Table height 35 3 4 94 95m 3 1...

Page 45: ...ual GBC Pro Tech August 1999 Page 4 4 Installation Figure 4 1 2 Single phase U S Figure 4 1 3 Wye 3 phase Europe only TB 2 L1 L2 G TB 1 Incoming line voltage TB 2 L 3 2 N 2 Correct Configuration L1 L2...

Page 46: ...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 lam...

Page 47: ...o 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 labe...

Page 48: ...surface before attempting to roll the machine off using the ramps WARNING The Falcon 160 Laminator is a large and heavy piece of equipment It is necessary to employ LICENSED RIGGERS ONLY to move the...

Page 49: ...en wrench 475 200 One Zippy knife 475 620 One Terry clothe towel 475 950 One Operators manual 930 031 One roll masking tape 475 000 Two Polyurethane O rings 480 005 One strain relief for main power 17...

Page 50: ...ollingwhileleveling Leveling a Position the level on the top of the control side frame Not on the cabinet Refer to Figure 4 6 2 The side frame provides a more accurate reading than the cabinet INFORMA...

Page 51: ...front control panel should beilluminatedatthispoint Reset Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED WARNING i Rai...

Page 52: ...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 you find a safety feature not working properly you sh...

Page 53: ...RESET The front control panel will be illuminated Reset c Press SEL The SEL key should stop flashing SEL SAV SHUT DOWN 0 JOB d Press FWD s to set a forward motor direction FWR REV STOP GO SPEED SAFETY...

Page 54: ...verts to white andGOremains flashing FWR REV STOP GO SPEED SAFETY 6 0 Flashing i PressSTOP GO stopsflashing FWR REV STOP GO SPEED SAFETY 6 0 j PressGO Thebottomrollersbeginturning FWR REV STOP GO SPEE...

Page 55: ...0 Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED WARNING b Raisethefrontsafetyshield SAFETYindicator andGObeginflashin...

Page 56: ...be seriously HURT or INJURED WARNING k Raisetherearsafetyshield SAFETY indicator andGObeginflashingandthebottomrollers stop FWR REV STOP GO SPEED SAFETY 6 0 Flashing l Lower the rear safety shield SA...

Page 57: ...tom rollers stop and the control panel is blank Push c Unlatch theE STOPas illustrated below Unlatch d Press RESET The front control panel is illuminated RESET e Press SEL SEL stops flashing SEL SAV S...

Page 58: ...elow Unlatch k Press RESET The front control panel is illuminated RESET 4 8 Function check Thefunctioncheckensuresthatthelaminator functionsproperlywhenoperating Thischeckis recommendedbeforeperformin...

Page 59: ...ngly Onceto 0 theuppermainrolleriscontactingthe lowermainroller GAP PRESSURE 1 0 d Press GAP s GAP DISPLAY increases 1 16th of an inch per press The upper main roll moves accordingly Once to 1 the upp...

Page 60: ...EL SAV SHUT DOWN 0 JOB i SEL can not be tested until you have saved parameters within a JOB location Refer to Section 5 4 Job programming for SEL and SAV SEL SAV SHUT DOWN 0 JOB Flashing INFORMATION T...

Page 61: ...turning FWR REV STOP GO SPEED SAFETY 15 n Press REV t REV is solid and FWD revertstohollow FWR REV STOP GO SPEED SAFETY 15 o Press GO The bottom rollers turn in a reverse motion at a speed of 15 ft mi...

Page 62: ...s Raise the front safety shield remove the front infeedtableandtouchthetwomainrollers Theyshouldfeelwarmtothetouch t Replace the front infeed table and lower the frontsafetyshield INFORMATION The SAFE...

Page 63: ...SHUT DOWN 0 JOB Flashing b Press FWD s for a forward motor direction FWDissolid FWR REV STOP GO SPEED SAFETY 00 0 c Press down on the variable speed footswitch GObeginsflashingandthebottomrollersare...

Page 64: ...tion Swing back and reseat the shaftinthesaddle Theswingmovementshould be smooth and easy d Ensure that the upper unwind brake adjustment knob is backed off completly The counter clockwise turn should...

Page 65: ...dbrakeadjustment knob counter clockwise i You should feel a decrease in resistance on the turningoftheupperunwindshaftasyouturnthe upper unwind brake adjustment knob counter clockwise j Lower the rear...

Page 66: ...y To wake the laminatorfromsleepmode pressanycommand TOP TEMP BOT TEMP SLEEP 32 32 1 2 TOP TEMP DISPLAY The display will show the set point temperature of the top main roller as the default display Wh...

Page 67: ...C TOP TEMP BOT TEMP SLEEP 68 68 6 7 BOT TEMP t When pressed will decrease thesetpointvalueofthebottommainrollerin increments of 2 degrees If held down it will decrease to the minimum temperature sett...

Page 68: ...ill decrease from 100 of the maximum allowed pressure to0 atwhichpointnobarswillbeilluminated GAP PRESSURE 1 4 12 WARNING Keep hands and fingers clear of the laminator roller nip when adjusting PRESSU...

Page 69: ...the stored job number selected to the correct devices Any time JOB s or JOB t is pressed SELwillflashindicatingachangeinjob number SEL SAV SHUT DOWN 5 17 JOB 18 SAVE When pressed will save the curren...

Page 70: ...WR REV STOP GO SPEED SAFETY 6 5 23 GO When pressed starts the rollers in motion GO is solid This solid indication is referred to as the panelmode Ifasafetyshieldisraisedduring panel mode GO and SAFETY...

Page 71: ...trolledthroughthecontrolpanel ATTUNG WARNING ADVERTENCIA 28 Panel to Footswitch 1 To switch from Panel mode GO is solid to Footswitch mode GO is flashing with the safety shields in the down position P...

Page 72: ...tor 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 on the variable speed footswitch approximately 1 2 the trave...

Page 73: ...tswitch speed is not indicated in the SPEED DISPLAY on the control panel To lower the safety shield Lower the safety shield INFORMATION When the safety shield is lowered speed reverts to the panel spe...

Page 74: ...Tech August 1999 Page 5 9 Operations Figure 5 1 1 Front control panel FWR REV STOP GO GAP PRESSURE SPEED TOP TEMP BOT TEMP SEL SAV SAFETY SLEEP SHUT DOWN 68 68 1 00 0 0 JOB 1 2 3 4 5 6 7 8 9 10 11 12...

Page 75: ...land know how to react quickly in an emergency The main laminator roll up down keys are located on the right sideofthemachinewithinthefrontcontrolpanel These keys control the up down gap motion of the...

Page 76: ...motion direction selected SPEED 00 0 and SLEEP flashing e Enter the desired operating parameters or select the job number prior to the emergency stopsituation f Youmaynowresumeoperatingthelaminator 5...

Page 77: ...in the saddle of the upperunwindshaft c Swingtheunwindshaftoutenoughtoslidethe roll of laminate over the core chucks and onto the unwind shaft Refer to Figure 5 3 2 INFORMATION Twisting the roll of fi...

Page 78: ...ugh f again Figure 5 3 3 Centering the roll Measure from the side frame to the edge of the roll of laminate Make sure the laminate is flush with the core h Closetherearsafetyshieldwhenfinished Figure...

Page 79: ...heat it is recommended to set both temperatures to the same set point c Press GAP t to set the gap to 0 GAP PRESSURE 0 INFORMATION Do not add PRESSURE when heating the laminating rollers this allows...

Page 80: ...programming Thejobsavefeatureisveryconvenientifthe same parameters are required to perform various applications Thisprocedurewillguideyoustepbystep throughthisfeature a Follow the prcedure in Section...

Page 81: ...ssing GAP t GAP PRESSURE 1 4 INFORMATION When storing parameters within the JOB SAVE feature of the laminator PRESSURE is not a storable setting e Enter a desired speed by pressing SPEED s FWR REV STO...

Page 82: ...bstrate thickness it is recommendedthatyouusethemanualnipsetting procedure Ifyouareperformingamountingapplication from the rear of the machine the pull rollers must be set manually Refer to Section 5...

Page 83: ...ingers clear of the laminator roller nip when changing GAP You can be CRUSHED or BURNED f At eye level with the main rollers press PRESSURE tuntil you see the upper main roller make contact with the s...

Page 84: ...or using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED h Step on the variable speed footswitch to back the leader board out Speed i...

Page 85: ...operating position of the machine INFORMATION a Turn the MAIN POWER to the ON position Power b PressRESET Thefrontcontrolpanelwill illuminated Reset c Press SEL SEL SAV SHUT DOWN 0 JOB Flashing d Pre...

Page 86: ...f the pull roller nip when changing the gap You can be CRUSHED g Ateyelevelwiththepullrollers turnthepull rollcrankhandleclockwiseuntilyouseethe upperpullrollermakecontactwiththe substrate D O W N CAU...

Page 87: ...ngers away from the nip of the rollers You may be CRUSHED or BURNED g Step on the variable speed footswitch to back the leader board out Speed is controlled through the variable speed footswitch when...

Page 88: ...e table Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED WARNING a Raisethesafetyshield b With both hands grip the front...

Page 89: ...ower the front edge while ensuring that thepinalignswiththesafetyrollerswitchand the back support bolt Refer to Figure 5 6 3 If the tables are not properly seated the laminator will not operate in Pan...

Page 90: ...ection are reference points only Parameters will vary with regards to laminate thickness laminate widths laminate types print types ink or toner types environment conditions operator experience and va...

Page 91: ...Figure 6 1 1 e Be sure the front and rear tables are in position and the pull rollers are in the up position f Raise the rear safety shield Caution should always be exercised when using the laminator...

Page 92: ...ll prevent hours of roll cleaning CAUTION j Push the clevis pin back down to secure the unwindshaftinitssaddle k Raisethefrontsafetyshield Caution should always be exercised when using the laminator w...

Page 93: ...NFORMATION n Press FWD s s s s s FWR REV STOP GO SPEED SAFETY 00 0 WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You...

Page 94: ...rollers You may be crushed or burned s Press on the variable speed footswitch to back the board out of the main rollers Speed is controlled through the variable speed footswitch when the safety shiel...

Page 95: ...rs away from the nip of the rollers You may be CRUSHED or BURNED e Push the leader board into the main roller nip whilesteppingonthevariablespeedfootswitch Speed is controlled through the variable spe...

Page 96: ...afety shield is in the raised position CAUTION Figure 6 1 4 1 2 in Gap Substrate 1 2 Gap Precoated board The 1 2 in gap between boards will allow for easier separation of the boards by the second pers...

Page 97: ...rs position the pull rollers up This will prevent an impression in the last pre coated board INFORMATION l The second person will raise the rear pull roller byturningthecrankhandlecounterclockwise unt...

Page 98: ...board out fromthelaminator This will prevent any exposed adhesive from contacting the rollers INFORMATION c Raise the main rollers to a 1 in gap by pressing GAP s s s s s GAP PRESSURE 1 d Removethero...

Page 99: ...et caught in the nip and choke you or you can be crushed or burned Materials needed Prints P S A mount boards Utilityknife Leader board Set up a Turn MAIN POWER to ON Refer to Figure 6 2 1 b Press RES...

Page 100: ...P GO SPEED SAFETY 00 0 WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED h Press on the vari...

Page 101: ...motor FWR REV STOP GO SPEED SAFETY 00 0 WARNING When operating the laminator through the variable speed footswitch keep your hands away from the nip of the rollers You may be crushed or burned l Pres...

Page 102: ...d amount of release liner is removed Refer to Figure 6 2 3 CAUTION Caution should always be exercised when using a knife Sharp knife can cut you Figure 6 2 3 Trim the release liner Make a shallow cut...

Page 103: ...center This will make for a difficult mounting application INFORMATION e Set the precoated board with the image tacked to it in the center of the front infeed table f Press STOP FWR REV STOP GO SPEED...

Page 104: ...d is controlled through the variable speed footswitch when the safety shield is in the raised position CAUTION j Drape the loose part of the image over the upper main roller Refer to Figure 6 2 7 Figu...

Page 105: ...away from the nip of the rollers You may be CRUSHED or BURNED l Press down on the variable speed footswitch justenoughtogiveyourselfacomfortablework speed Speed is controlled through the variable spee...

Page 106: ...elaminatorusingthemainrollersorfromthe rearofthelaminatorusingthepullrollersintheevent themainrollersareheated Thisapplicationisexplained indetailusingthemainrollersfromthefrontofthe laminator Use Cha...

Page 107: ...ys be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED WARNING e Lift the clevis pin located in the saddle of the upperunwindshaft Clevis pin Sadd...

Page 108: ...ised You can be seriously HURT or INJURED WARNING If you have the parameters stored as a JOB number enter it now then press SEL and skip to step m other wise continue with step j INFORMATION WARNING K...

Page 109: ...leaderboardintotheniptoconfirm that the board is secure Speed is controlled through the variable speed footswitch when the safety shield is in the raised position CAUTION WARNING Keep hands and finger...

Page 110: ...able speed footswitch to back the leader board out of the main rollers Speed is controlled through the variable speed footswitch when the safety shield is in the raised position CAUTION Process a Pull...

Page 111: ...dthefront infeed table so that about 6 in is resting on the front infeed table Refer to Figure 6 3 4 f Position the precoated board so that about 3 in of the board is adhered to the laminate Refer to...

Page 112: ...heminimumamountofbraketensionon therolloflaminatetopreventitfromfree spinning Refer to Figure 6 3 5 Excessive brake tension may cause the image to curl when separated from the precoated board INFORMAT...

Page 113: ...Once the image passes through the main rollers it is safe to release the variable speed footswitch Stopping the rollers on the print will leave a pressure line on the image INFORMATION Finishing a Cut...

Page 114: ...he frontofthelaminatorusingthemainrollersorfromthe rearofthelaminatorusingthepullrollersintheevent themainrollersareheated Thisapplicationisexplained indetailusingthemainrollersfromthefrontofthe lamin...

Page 115: ...ys be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED WARNING e Lift the clevis pin located in the saddle of the upperunwindshaft Clevis pin Sadd...

Page 116: ...n Saddle k Swingthelowerunwindshaftoutenoughto slide the roll of craft paper over the core chucks on the lower unwind shaft Refer to Figure 6 4 2 INFORMATION Twisting the roll of craft paper while sli...

Page 117: ...he laminate should separate under the rewind tube Figure 6 4 3 Laminate to rewind Rewind tube P S A Laminate c Use a piece of masking tape to adhere the leading edge of the laminate to the upper rewin...

Page 118: ...ON i Pull the craft paper up towards the upper mainrollerandtackitthelaminate Referto Figure 6 4 5 The craft paper will adhere to the exposed adhesive from the laminate INFORMATION Figure 6 4 5 Craft...

Page 119: ...from the nip of the rollers You may be CRUSHED or BURNED n Press on the variable speed footswitch to guide the cardboard craft paper and laminate through themainrollers Speed is controlled through th...

Page 120: ...rdboard from the webbed material Refer to Figure 6 4 6 CAUTION Do not use an open blade to cut the web near the rollers You can put cuts into the rollers r Tape the web to the lower rewind tube or let...

Page 121: ...be flashing when the tables are properly seated and the safety shields are in the closed position u PressSTOP FWR REV STOP GO SPEED SAFETY 00 0 v Press SPEED s s s s s to a speed you feel comfortable...

Page 122: ...perwillfallaway from the back of the print c If you used the lower rewind remove the rewindtubeandbringittoatrimmingstation Replacetherewindtubewhenfinished d Raise the front and rear safety shields t...

Page 123: ...thepullrollersintheevent themainrollersareheated Thisapplicationisexplained indetailusingthemainrollersfromthefrontofthe laminator This is a two pass mount and laminate process Twopassmeaningthatthepr...

Page 124: ...1 MAIN POWER RESET Rear of the laminator MAIN POWER RESET c Ensure that the rear pull rollers are in the up position d Raise the front and rear safety shields Caution should always be exercised when u...

Page 125: ...secure the unwindshaftinitssaddle i Leavethesafetyshieldintheupposition j Lift the clevis pin located in the saddle of the lowerunwindshaft Clevis pin Saddle k Swingthelowerunwindshaftoutenoughto sli...

Page 126: ...fromfreespinning Excessive brake tension may cause the output to curl This can create complications with the second pass of this application INFORMATION b Pull the laminate to the upper rewind tube Re...

Page 127: ...igure 6 5 4 Figure 6 5 4 Laminate separation Laminate Remove h Apply just enough brake tension to prevent the rollofmountadhesivefromfreespinning Excessive brake tension may cause the output to curl T...

Page 128: ...can be CRUSHED or BURNED k Press GAP t t t t t to enter a 0 in gap setting GAP PRESSURE 0 l Press FWD s s s s s FWR REV STOP GO SPEED SAFETY 00 0 INFORMATION Steps m and n will be performed simultane...

Page 129: ...damage the laminating rollers Always use the minimum roll pressure necessary to complete the task WARNING Keep hands and fingers clear of the pull roller nip when changing the gap You can be CRUSHED...

Page 130: ...eed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED Press on the variable speed footswitch to lengthenthewebenoughtogetonefullwrap around the lower rewi...

Page 131: ...thelaminator y After the last print has passed through the pull rollers pressSTOP FWR REV STOP GO SPEED SAFETY 9 0 z Press GAP s s s s s to a 1 in setting GAP PRESSURE 1 Finishing a With an enclosed b...

Page 132: ...ut the web near the rollers You can put cuts into the rollers h Removethewebfromthefrontofthelaminator and the rolls of material from the upper and lowerunwindshafts This will prevent any exposed adhe...

Page 133: ...DISPLAY shouldreflectyourdesiredsetting GAP PRESSURE 1 4 CAUTION Sharp edges on a substrate should be filed smooth and GAP manually adjusted Sharp edges can CUT the rollers If the thickness of the sub...

Page 134: ...D or BURNED f If the board is loose press PRESSURE t t t t t to adjust the gap between the main rollers GAP PRESSURE 1 4 CAUTION Excess pressure can damage the laminating rollers Always use the minimu...

Page 135: ...nd one other side Refer to Figure 6 5 7 Figure 6 5 7 Align edges Substrate Align two sides Leading edge The leading edge is the first part of the board or image that enters the nip of the rollers INFO...

Page 136: ...heimagein place e From the center use one finger to tack down the leading edge of the decal to the leading edge of the substrate Refer to Figure 6 5 11 Figure 6 5 11 Tack leading edge Avoid tacking at...

Page 137: ...the end of the tacked down section of the image enters the nip Use a slow speed If the tack point enters the rollers nip you will not be able to pull the release liner INFORMATION Speed is controlled...

Page 138: ...om the nip of the rollers You may be CRUSHED or BURNED If its not slowly move the substrate into the nipuntilthedecalisconformed Referto Figure 6 5 14 Speed is controlled through the variable speed fo...

Page 139: ...e nip and the other hand to apply slight back tension to the decal p Once the substrate and the decal are completely throughthemainrolls youcanletoffthe variablespeedfootswitch q The mounted image can...

Page 140: ...ervicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned 6 6 Precoating substrates Thisapplicationcanonlybeperformedfromthe frontofthelaminatorusingth...

Page 141: ...are in the up position f Raise the rear safety shield Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED WARNING Figure 6...

Page 142: ...rence to side since both sides are the same j Push the clevis pin back down to secure the unwindshaftinitssaddle k Lower the rear safety shield If you have the parameters stored as a JOB number enter...

Page 143: ...he TOP TEMP DISPLAYstopsflashing s Press STOP FWR REV STOP GO SPEED SAFETY 2 0 t Press GAP s s s s s to the required gap setting for the substrate being used The GAP DISPLAY shouldreflectyourdesiredse...

Page 144: ...RESSURE You can be CRUSHED or BURNED v If the board is loose press PRESSURE t t t t t to adjust the gap between the main rollers GAP PRESSURE 1 4 Excessive pressure will cause the substrate to bow or...

Page 145: ...ntinfeedtablesothatapproximately6in is resting on the front infeed table Refer to Figure 6 6 3 Figure 6 6 3 Leader board Leader board Hot Tissue b Position the leader board so that half is adhered to...

Page 146: ...tension will cause the substrate to bow INFORMATION g Have the second person stand at the rear of the laminator INFORMATION Steps h and i will be performed simultaneously WARNING When operating the la...

Page 147: ...NFORMATION j As the boards come through the person at the rear of the machine will use the utility knife to separate the boards CAUTION Caution should always be exercised when using a knife Sharp knif...

Page 148: ...process INFORMATION n Raise the main rollers to a 1 in gap by pressing GAP s s s s s GAP PRESSURE 1 Finishing a Cut the web of Hot Tissue at the upper unwind shaft with an enclosed blade CAUTION Do n...

Page 149: ...r assistance Thisapplicationcansavetimebutislimitedto the type of prints you can use This process requires more heat and a longer dwell time in the nip Heat sensitive images should not be used for thi...

Page 150: ...TION Sharp edges on a substrate should be filed smooth and GAP manually adjusted Sharp edges can CUT the rollers b Place these two pieces by the laminator for futureuse The two pieces cut in step a wi...

Page 151: ...ure 6 7 2 INFORMATION Twisting the roll of thermal laminate while sliding makes loading the film onto the unwind shaft easier Figure 6 7 2 Unwind shaft Core chucks Core support Clevis pin Brake adjust...

Page 152: ...l Press SEL SEL will stop flashing SEL SAV SHUT DOWN 0 JOB m Press TOP TEMP s s s s s to set a temperature of 240 260 o F 115 126 o C TOP TEMP BOT TEMP SLEEP 68 140 n Press FWD s s s s s FWR REV STOP...

Page 153: ...1 Manual nip adjustment INFORMATION 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 u Pres...

Page 154: ...from the nip of the rollers You may be crushed or burned y Press on the variable speed footswitch to back the board out of the main rollers Speed is controlled through the variable speed footswitch wh...

Page 155: ...just placed on the board Figure 6 7 3 Print Hot Tissue Substrate Thin line of glue e Pullthethermallaminatestraightdowntoward thefrontinfeedtablesothatapproximately6in is resting on the front infeed...

Page 156: ...trolled through the variable speed footswitch when the safety shield is in the raised position CAUTION j Applytheminimumamountofbraketensionon therollofthermallaminatetopreventitfrom freespinning Exce...

Page 157: ...Stop the laminator when the trailer board is in the main roller nip Refer to Figure 6 7 5 Figure 6 7 5 Trailer board Trailer board Mounted image Stopping the rollers on the print will leave a pressur...

Page 158: ...laminator twice The first pass Decal will apply a mountadhesivetothebackoftheprintwhileapplyinga laminate to the front of the print The second pass Mount will adhere the decal to a substrate The firs...

Page 159: ...o ON Refer to Figure 6 8 1 b Press RESET Refer to Figure 6 8 1 Figure 6 8 1 MAIN POWER RESET Rear of the laminator MAIN POWER RESET c Ensure that the rear pull rollers are in the up position d Raise t...

Page 160: ...operly on the unwind shaft Exposed adhesive should be facing away from the rollers This will prevent hours of roll cleaning CAUTION h Push the clevis pin back down to secure the unwindshaftinitssaddle...

Page 161: ...r roll of materialontheunwindshafts Youmayreferto your measurement chart in Section 5 3 2 Loading film Figure 5 3 4 INFORMATION For the lower unwind shaft add 1 4 in to the measurement n Lowerthesafet...

Page 162: ...n the TOP TEMP DISPLAYstopsflashing v Press STOP FWR REV STOP GO SPEED SAFETY 2 0 Process a Raise the front safety shield and remove the frontinfeedtable b Apply just enough brake tension to prevent t...

Page 163: ...rds the upper mainrollerandtackitthelaminaterestingon the upper main roller Refer to Figure 6 8 4 The mount adhesive will adhere to the activated adhesive from the laminate INFORMATION Figure 6 8 4 Mo...

Page 164: ...n damage the laminating rollers Always use the minimum roll pressure necessary to complete the task WARNING Keep hands and fingers clear of the pull roller nip when changing the gap You can be CRUSHED...

Page 165: ...peed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED Press on the variable speed footswitch to lengthenthewebenoughtogetonefullwrap around the lower rew...

Page 166: ...thelaminator r After the last print has passed through the pull rollers pressSTOP FWR REV STOP GO SPEED SAFETY 9 0 s Press GAP s s s s s to a 1 in setting GAP PRESSURE 1 Finishing a With an enclosed b...

Page 167: ...to cut the web near the rollers You can put cuts into the rollers h Removethewebfromthefrontofthelaminator and the rolls of material from the upper and lowerunwindshafts This will prevent any exposed...

Page 168: ...ing the gap You can be CRUSHED c While observing the leader board at eye level lowertheupperpullrollerbyturningthepullroll crankhandleclockwiseuntilcontactwiththe leader board has been made CAUTION Sh...

Page 169: ...leader board out Speed is controlled through the variable speed footswitch when the safety shield is in the raised position CAUTION f Press STOP FWR REV STOP GO SPEED SAFETY 00 0 g Press REV t t t t t...

Page 170: ...of the substrate Refer to Figure 6 8 8 Figure 6 8 8 Trim the decal Board No more than 1 in over hang Image Cut c Peel back about 1 in of the release liner from the decal and fold back Refer to Figure...

Page 171: ...from the nip of the rollers You may be CRUSHED or BURNED h Usingthevariablespeedfootswitch slowly work the substrate into the nip of the rollers and stop just before the end of the tacked down sectio...

Page 172: ...with this application INFORMATION Figure 6 8 12 Conformed print Upper pull roll Conformed WARNING When operating the laminator using the variable speed footswitch keep hands and fingers away from the...

Page 173: ...riable speed footswitch when the safety shield is in the raised position CAUTION WARNING When the laminator rollers are in motion keep hands and fingers away from the nip of the rollers You may be CRU...

Page 174: ...rials The procedures and its parameters described in this section are starting references only Parameters will vary with regards to laminate thickness laminate widths laminates types print types ink o...

Page 175: ...WER RESET Rear of the laminator MAIN POWER RESET c Ensure that the rear pull rollers are in the up position d Raise the front and rear safety shields Caution should always be exercised when using the...

Page 176: ...will prevent hours of roll cleaning CAUTION h Push the clevis pin back down to secure the unwindshaftinitssaddle i Lift the clevis pin located in the saddle of the lowerunwindshaft Clevis pin Saddle j...

Page 177: ...surement n Lowerthesafetyshields If you have the parameters stored as a JOB number enter it now then press SEL and skip to step p other wise continue with step l INFORMATION o PressSEL SEL will stop f...

Page 178: ...EMP DISPLAY and BOT TEMP DISPLAY stops flashing w PressSTOP FWR REV STOP GO SPEED SAFETY 2 0 Process a Raise the front safety shield and remove the frontinfeedtable b Apply just enough brake tension t...

Page 179: ...unwindshaftuptowardstheuppermain rollerandtackitthelaminaterestingonthe upper main roller Refer to Figure 6 9 4 The mount adhesive will adhere to the activated adhesive from the laminate INFORMATION F...

Page 180: ...n damage the laminating rollers Always use the minimum roll pressure necessary to complete the task WARNING Keep hands and fingers clear of the pull roller nip when changing the gap You can be CRUSHED...

Page 181: ...peed footswitch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED Press on the variable speed footswitch to lengthenthewebenoughtogetonefullwrap around the lower rew...

Page 182: ...thelaminator r After the last print has passed through the pull rollers pressSTOP FWR REV STOP GO SPEED SAFETY 9 0 s Press GAP s s s s s to a 1 in setting GAP PRESSURE 1 Finishing a With an enclosed b...

Page 183: ...enviroment conditions operater experience and various substrates Caution should always be exercised when using the laminator with the safety shields raised You can be seriously HURT or INJURED WARNING...

Page 184: ...8 9 175 79 4 176 80 177 80 6 178 81 1 179 81 7 180 82 2 181 82 8 182 83 3 183 83 9 184 84 4 185 85 186 85 6 187 86 1 188 86 7 189 87 2 190 87 8 191 88 3 192 88 9 193 89 4 194 90 195 90 6 196 91 1 197...

Page 185: ...ions Parameter Chart Blank TEMPERATURE GAP PRESSURE MOTOR DIRECTION SPEED TOP TEMP BOT TEMP PRESSURE GAP SPEED FWR REV GO GO Panel SOLID FLASHING Footswitch PULL ROLL SETTINGS NOTES N A 1 4 Turn 1 2 T...

Page 186: ...F 160 Operation and Maintenance Manual GBC Pro Tech August 1999 Page 6 97 Applications Web Diagram Blank...

Page 187: ...4 Turn 1 2 Turn 3 4 Turn PRESSURE MATERIALS UPPER UNWIND LOWER UNWIND SUBSTRATE PRINTS Pro Mount N A 1 4 Foam Core N A 68 68 1 4 00 0 Pro Mount can be substituted with a similar product Substrate can...

Page 188: ...F 160 Operation and Maintenance Manual GBC Pro Tech August 1999 Page 6 99 Applications Web Diagram 1 Precoating substrate Pro Mount Leader board Substrate...

Page 189: ...N A 1 4 Turn 1 2 Turn 3 4 Turn PRESSURE MATERIALS UPPER UNWIND LOWER UNWIND SUBSTRATE PRINTS N A N A Precoated boards Inkjet prints 68 68 1 4 00 0 Substrate will vary Print can be of any type GAP will...

Page 190: ...F 160 Operation and Maintenance Manual GBC Pro Tech August 1999 Page 6 101 Applications Web Diagram 2 Mounting only Precoated board Release liner Print...

Page 191: ...N A 1 4 Turn 1 2 Turn 3 4 Turn PRESSURE MATERIALS UPPER UNWIND LOWER UNWIND SUBSTRATE PRINTS Pro Gloss N A 1 4 Foam Core Inkjet prints 68 68 1 4 00 0 Substrate will vary Print can be of any type GAP w...

Page 192: ...F 160 Operation and Maintenance Manual GBC Pro Tech August 1999 Page 6 103 Applications Web Diagram 3 Single sided Sled Sled Print P S A Laminate Release liner...

Page 193: ...N A 1 4 Turn 1 2 Turn 3 4 Turn PRESSURE MATERIALS UPPER UNWIND LOWER UNWIND SUBSTRATE PRINTS Pro Gloss Craft Paper N A Inkjet prints 68 68 0 3 6 Upper unwind material can be of similar product Print...

Page 194: ...Operation and Maintenance Manual GBC Pro Tech August 1999 Page 6 105 Applications Web Diagram 4 Single sided Craft paper Craft Paper Print P S A Laminate Release liner Finish product rewind option Ou...

Page 195: ...1 4 Turn 1 2 Turn 3 4 Turn PRESSURE MATERIALS UPPER UNWIND LOWER UNWIND SUBSTRATE PRINTS Pro Gloss Pro Mount N A Inkjet prints 68 68 0 3 6 Upper and lower unwind material can be of similar product Pri...

Page 196: ...160 Operation and Maintenance Manual GBC Pro Tech August 1999 Page 6 107 Applications Web Diagram 5 Decal and mount Decal Pro Mount Print P S A Laminate Release liner Finish product rewind option Outp...

Page 197: ...rn 1 2 Turn 3 4 Turn PRESSURE MATERIALS UPPER UNWIND LOWER UNWIND SUBSTRATE PRINTS N A N A 1 4 Foam Core Decals 68 68 1 4 00 0 Decal will come from the previous chart and diagram application Substrate...

Page 198: ...F 160 Operation and Maintenance Manual GBC Pro Tech August 1999 Page 6 109 Applications Web Diagram 6 Decal and mount Mount Substrate Release liner Decal...

Page 199: ...MATERIALS UPPER UNWIND LOWER UNWIND SUBSTRATE PRINTS Hot Tissue Mount N A 1 4 Foam Core N A 140 68 1 4 00 0 Upper unwind material may be sibstituted with similar product Substrate can vary Top tempera...

Page 200: ...F 160 Operation and Maintenance Manual GBC Pro Tech August 1999 Page 6 111 Applications Web Diagram 7 Precoating substrate Thermal Hot Tissue Leader board Substrate 140 160...

Page 201: ...ER UNWIND SUBSTRATE PRINTS 3 mil Octiva Gloss N A 1 4 Foam Core Electrostatic images 240 68 1 4 00 0 Upper unwind material may be sibstituted with similar product Substrate can vary Top temperature wi...

Page 202: ...F 160 Operation and Maintenance Manual GBC Pro Tech August 1999 Page 6 113 Applications Web Diagram 8 One pass mount and laminate Octiva Gloss Leader board Substrate 240 260 Hot Tissue Image...

Page 203: ...1 4 Turn 1 2 Turn 3 4 Turn PRESSURE MATERIALS UPPER UNWIND LOWER UNWIND SUBSTRATE PRINTS 3 mil Octiva Gloss Pro Mount N A Any type 230 68 0 3 6 Upper and lower unwind material can be of similar produ...

Page 204: ...F 160 Operation and Maintenance Manual GBC Pro Tech August 1999 Page 6 115 Applications Web Diagram 9 Thermal decal and mount Decal Pro Mount Print Octiva Gloss Finish product rewind option Output 230...

Page 205: ...PULL ROLL SETTINGS NOTES N A 1 4 Turn 1 2 Turn 3 4 Turn PRESSURE MATERIALS UPPER UNWIND LOWER UNWIND SUBSTRATE PRINTS N A N A Decals 68 68 1 0 00 The mounting process is done from the rear position of...

Page 206: ...F 160 Operation and Maintenance Manual GBC Pro Tech August 1999 Page 6 117 Applications Web Diagram 10 Thermal decal and mount Mount Substrate Release liner Decal...

Page 207: ...RIALS UPPER UNWIND LOWER UNWIND SUBSTRATE PRINTS 3 mil Octiva Gloss N A Any type 240 240 0 0 7 Upper and lower unwind material may be sibstituted with similar products Top and bottom temperature will...

Page 208: ...F 160 Operation and Maintenance Manual GBC Pro Tech August 1999 Page 6 119 Applications Web Diagram 11 Encapsulation Octiva Gloss Print Octiva Gloss Finish product rewind option Output 230 230...

Page 209: ...GBC Pro Tech August 1999 Page 6 120 F 160 Operation and Maintenance Manual Applications This page intentionally left blank...

Page 210: ...ocorrectyourtypicaloutput type problems Use the easy to follow guide for assistance 7 1 Wave problems Thefollowingisalistofcommonoutputwave problemsyoumayencounter Thearrowalongthelengthoftheoutput re...

Page 211: ...ck the nip setting of main rolls Checkthenipsettingofpullrolls Check for even paper tension Problem Angled waves in the output on both sides Hints Checkforinsufficientmainrollerpressure Checkforinsuff...

Page 212: ...e same Changethechillidlerconfiguration if applicable Problem Silveringinthelaminate Hints Decrease the speed Increase the operating temperature Problem Delamination Hints Check operating temperatures...

Page 213: ...GBC Pro Tech suggest or recommendthatyouattempttofixthemachineby removingthecabinetsorlegcoversofyourself WARNING Do not wear ties loose fitting clothing or dangling jewelry while operating or servici...

Page 214: ...push RESET Disconnect power and then reconnect power Placeaservicecallimmediatelyandremove all power to the laminator CAUTION Prolonged contact can form flat spots on the rollers 7 4 Glossary Theglos...

Page 215: ...natesubstrate or2 thelaminateseparatingfromtheproductbeing laminated Edgewrap Amountingtechniquewheretheimagewraps around the edges of the mounting substrate so as to provideafinishededge Encapsulatio...

Page 216: ...gas This is seen as a cloudy or murky finished image It can also be caused by a chemicalincompatibilitybetweentheoverlaminate s adhesiveandtheprintedmedia Pull rollers Theserollsprovidefortensionofth...

Page 217: ...pliedduringtheapplication Substrate The material to which an adhesive is to be bonded In film the substrate is the polyester and in mounting thesubstrateisthematerialbeingmountedto Tunneling Whenalami...

Page 218: ...re performing any of the steps listed read through the procedures first Please follow the instructions pertaining to the step you are performing INFORMATION Daily Clean the rolls See cleaning in this...

Page 219: ...used instead Rubber cement eraser a belt sander dressing block may be used instead Several 100 cotton terry cloths bestforlintfreecleaning Preparation of the laminator a Turn the MAIN POWER to the ON...

Page 220: ...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 When cleaning the bottom main roller switch the motion dir...

Page 221: ...0 CAUTION Use only isopropyl alcohol or rubber cement eraser to clean the rollers Harsh chemicals like toluene acetone or MEK can destroy the silicone covering of the rolls c With the rubber gloves on...

Page 222: ...er than 110o F 43o C TOP TEMP BOT TEMP SLEEP 110 110 b Set the motion direction to REV t FWR REV STOP GO SPEED SAFETY 00 0 WARNING Keep hands and fingers clear of the laminator roller nip when changin...

Page 223: ...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 8 2 2 Cleaning the touch scree...

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