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Troubleshooting

F 60 H Operation and Maintenance Manual

© April 2001 General Binding Corporation

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Summary of Contents for F-60H

Page 1: ...Provided By http www MyBinding com http www MyBindingBlog com GBC F 60H Roll Laminator Instruction Manual...

Page 2: ...Tech 4151 Anderson Road DeForest WI 53532 Revision A Ph 608 246 8844 Fx 608 246 8645 FALCON 60 H OPERATION MAINTENANCE MANUAL APRIL 2001 GENERAL BINDING CORPORATION ALL RIGHTS RESERVED Do not duplicat...

Page 3: ...inding Corporation assumes no liability arising from infringements of patents or any other rights of third parties This publication is copyrighted 2001 by General Binding Corporation All rights re ser...

Page 4: ...Read me file F 60 H Operation and Maintenance Manual April 2001 General Binding Corporation This page intentionally left blank...

Page 5: ...Corporation Fax Correspondence Fax number 608 246 8645 Date To Technical Coordinator at GBC Protech 4151 Anderson Road DeForest WI 53532 From Company Address Phone number Fax number Re F 60 H Operatio...

Page 6: ...Read me file F 60 H Operation and Maintenance Manual April 2001 General Binding Corporation This page intentionally left blank...

Page 7: ...ty 1 1 Symbols 1 1 1 2 Safety precautions 1 2 1 3 Safety features 1 3 1 4 Installation 1 4 1 5 Operations 1 7 1 6 Applications 1 9 1 7 Troubleshooting 1 10 1 8 Maintenance 1 10 1 9 Decal explanation 1...

Page 8: ...3 1 General 3 1 3 2 Consumables 3 2 3 3 Function 3 3 3 4 Electrical 3 4 3 5 Dimensions 3 5 Figure 3 5 1 Dimensions 3 6 4 0 Installation 4 1 Pre installation check list 4 1 Figure 4 1 1 Suggested floor...

Page 9: ...velers 4 9 4 8 Leveling 4 9 4 9 Connecting power 4 11 4 10 Safety check 4 13 5 0 Operations 5 1 Power ON OFF 5 2 5 2 Control panel 5 3 Figure 5 2 1 Front control panel 5 4 5 3 Set temperature 5 5 5 4...

Page 10: ...chart 6 3 6 3 Charts and diagrams 6 5 Blank chart 6 6 Blank diagram 6 7 Blank diagram w roll to roll option 6 9 Chart Pre coating substrates 6 10 Diagram Pre coating substrates 6 11 Chart Mounting an...

Page 11: ...ided lamination sled 6 24 Diagram PSA single sided lamination sled 6 25 Chart PSA single sided lamination craft paper 6 26 Diagram PSA single sided lamination craft paper 6 27 Diagram PSA single sided...

Page 12: ...ding Corporation 7 0 Troubleshooting 7 1 Wave problems 7 1 7 2 Film problems 7 3 7 3 Machine problems 7 4 7 4 Glossary 7 5 8 0 Maintenance 8 1 Maintenance schedule 8 1 8 2 Cleaning the rollers 8 2 8 3...

Page 13: ...FORMATION Indicates helpful information that should be considered before during or after an action step or procedure is given CAUTION Indicates a potentially hazardous situation which if not avoided c...

Page 14: ...ront Beforeturning thecrankhandletosettheGAPdown ensurethatnothing is in the nip area W ARNING Keep hands and fingers clear of the laminator roller nip when adjusting nip You can be CRUSHED or BURNED...

Page 15: ...l four E STOPS are in the unlatched position To continue operation all E STOPs mustbein the unlatched position To reset twist the E STOP 1 4 turncounterclockwise 1 4 tu r n PressRESETlocatedonthecontr...

Page 16: ...ning 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 WARNING The unpacking process r...

Page 17: ...ed riggers You can be crushed or seriously injured 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 p...

Page 18: ...d electrician should connect power to the laminator You can be severely shocked electrocuted or cause a fire if power is improperly applied WARNING Follow the correct wiring diagram when supplying pow...

Page 19: ...hands and fingers clear of the laminator roller nip when changing GAP You can be CRUSHED or BURNED W ARNING When the laminator rollers are in motion keep hands and fingers away from the nip of the ro...

Page 20: ...amount of brake for the job INFO RM ATIO N If more brake is needed add an O ring to the brake side of the rewind INFO RM ATIO N CAUTIO N Excess pressure can damage the laminating rollers Always use t...

Page 21: ...ect the bond strength of Lo Melt adhesives INFO RM ATIO N The mount adhesive must not exceed 1 in the width of the substrate If it does you will experience complications with this application INFO RM...

Page 22: ...esentative 1 8 Maintenance Thefollowingsymbolsarepositioned atvarious points in Section 8 Maintenance WARNING Do not wear ties loose fit clothing or dangling jewelry while operating or servicing the l...

Page 23: ...tch keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED ELECTRICAL SHOCK Remove power from the laminator before cleaning You can be severely shocked electrocuted or ca...

Page 24: ...cabinets This machine is to be serviced only by trained and authorized personnel W ARNING ACHT UNG M ISE EN G ARDE Crush and burn hazard Stay clear of m oving rollers Stop m achine and raise roll befo...

Page 25: ...extreme caution You may be electrocuted Lift Here This point may be used as a lifting point If ignored damagewilloccurtothelaminator Reset Machine reset Press after initiating power to the laminator o...

Page 26: ...clear of moving rollers Stop machine and raise roll before cleaning WARNING ACHTUNG MISE EN GARDE Carefully read operator s Manual before handling this machine Observe instructions and safety rules wh...

Page 27: ...ecificallydoesnotcoverdamage 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...

Page 28: ...uld be fully aware of all aspects of safety withregardstolaminationequipment Anycommissioningorserviceengineermustbe ofcompetentnature trainedandqualifiedtoGBCFilms Group standards to fulfill that job...

Page 29: ...ostefficient wideformatcolorfinisherforthesheet fed ink jet market The Falcon 60 H is a self standing bi directionalcoldmounterandlaminatorwiththeabilty to run Lo Melt overlaminate Two unwinds 1 upper...

Page 30: ...ting thickness Safety Pressuresensitivelaminates Pressuresensitiveadhesives Lowmeltlaminates Up to a 8 in roll diameter 20 3 cm 3 in core standard 7 62 cm 2 1 4 in optional must have optional core ada...

Page 31: ...ril 2001 General Binding Corporation 3 3 Function Speed Motor Heating capabilities Controls Roll design 0 16 ft min 0 4 6 m min 2 1 4 horse power drive motor Bi directional D C motor 68o F 200o F 20o...

Page 32: ...ration 3 4 Electrical United Statesand Canada B T U output Heater wattages Amperagedraw D C voltage used A C voltage used 230 240 VAC 50 60 Hz single phase 40 amps 18 520 B T U hour 5429 watts per hea...

Page 33: ...ng Corporation 3 5 Dimensions Weight Uncrated Crated Dimensions Uncrated Crated Nip Height 1350 lbs 612 kg 1625 lbs 737 kg 80 in L x 38 5 in W x 57 in H 203 cm H x 98 cm W x 145 cm L Refer to Figure 3...

Page 34: ...3 6 Specifications F 60 H Operation and Maintenance Manual April 2001 General Binding Corporation Figure 3 5 1 Dimensions WARNING ACHTU NG M S N AR PRO TECH F 60 H 57 in 145 cm 80 in 203 cm 38 5 in 9...

Page 35: ...ir flow can cool the rolls unevenly and result in poor output quality 4 0 Installation GBC Films Group is committed to a program of ongoing product improvement As a result we are providing these instr...

Page 36: ...60 H 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 a...

Page 37: ...re 4 1 1 Suggested Floor Layout 4 ft x 6 ft 1 22 m x 2 m W ork table on w heels Table height 37 3 4 in 95 96 m 4 ft x 6 ft 1 22 m x 2 m W ork table on w heels Table height 37 3 4 in 95 96 m 3 ft 1 m 1...

Page 38: ...side Right Drive side Left PRO TECH F 60 H Figure 4 2 2 Safety and controls PRO TECH F 60 H Control panel Foot switch Main roller lift Upper unwind brake Lower unwind brake Core grip E stop Core supp...

Page 39: ...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 With r...

Page 40: ...to mishandling and or tipping GBC Films Group bears no responsibility for personal injury or damage due to moving the laminator improperly INFORMATION Tools required 2 Phillips head screwdriver 7 8 op...

Page 41: ...o the rollers 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 includedwiththelaminat...

Page 42: ...5 210 One roll of masking tape 475 000 One crank handle One BHCS floor stock item If you are missing any of the items listed above contact your local service technician or sales representative Contact...

Page 43: ...o load film walk around and to be servicedifnecessary b Place one leveling pad on each of the four levelingboltsonthelaminator Leveling pads Jam nuts c Use a 3 4 in open end wrench to secure the jamnu...

Page 44: ...g Position the level center of the upper tie bar PRO TECH F 60 H h Levelthelaminatorfromdrivesidetocontrol sidebyturningthelevelingnutclockwiseto raise or counter clockwise to lower b Loosen the nut...

Page 45: ...You will need the control side cabinet cover off to connect the electrical power INFO RM ATIO N 4 9 Connecting power ELECTRICAL SHOCK Only a qualified electrician should connect power to the laminato...

Page 46: ...operly connected you can be seriously injured or cause damage to the laminator d Secure the main power strain relief to the cabinet e Turn the junction box power to the ON position f Verifylinevoltage...

Page 47: ...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 saf...

Page 48: ...E STOPs h Thebottommainrollerstopsturning thepower indicatorlightgoesout thedisplayonthe temperaturecontrollerunitgoesout i Turn the E STOP 1 4 turn counter clockwise to unlatch 1 4 tu r n j Repeatst...

Page 49: ...motor direction to FWD reverse forward e Lower the main roller to initial contact one bar onthepressuredisplayisilluminated f Pressthemotorengage disengageto ENGAGE disengage engage g Slide the finger...

Page 50: ...ardbackawayfromtherollers nip Press the motor engage disengage to ENGAGE disengage engage n If the finger board comes in contact with the rollerswhiletheyareturning contactyour service representative...

Page 51: ...These items can get caught in the nip and choke you or you can be crushed or burned INFO RM ATIO N The machine will only operate if all four emergency stops are unlatched and RESET has been pressed It...

Page 52: ...Psareintheunlatchedposition 1 4 tu r n b Turn the MAIN POWER to the up position POW ER On Off c Press RESET located above the main power on off POW ER Reset d Power indicator on the control panel shou...

Page 53: ...MOTOR ENGAGE DISENGAGE When pressed to the right power to the motor is supplied and the rollers will begin to turn When pressed to the left powertothemotorisremovedandtherollersstopturning disengage...

Page 54: ...control the operating temperature of the upper roller To set temperature refer to Section 5 3 CAL 3200 Figure 5 2 1 Front control panel 7 POWER INDICATOR When illuminated represents power to the lamin...

Page 55: ...roller unit press and hold the star key locatedjusttotheleftjustbelowthetemperaturedisplay When the star key is released the temperature display reverts to the current temperature of the upper roller...

Page 56: ...ilm Lo M elt Poly in Craft paper Lo Melt film Thefilmsupplyshafts commonlyknownasunwind shafts pivotoutforeaseofloadingandunloadingoffilm Always pay particular attention to which side is the adhesive...

Page 57: ...d support saddle c Swingtheunwindshaftoutfarenoughtoslidethe rolloffilmcompletelyon Never leave the unwind shaft out of the unwind support saddle unless loading or unloading film W ARNING d Swingtheun...

Page 58: ...Never use an open blade near the laminating rollers You may cut the rollers or your self CAUTIO N b Liftupontheclevispintotheunwindshaftlocated in the unwind support saddle Clevis pin Unw ind support...

Page 59: ...e b Turn the upper black brake knob shown above or the lower gray brake disc not shown counter clockwise to decrease unwind brake tension 5 6 Rewind brake tension The rewind brake controls the tension...

Page 60: ...p hands and fingers clear of the laminator roller nip when adjusting nip You can be CRUSHED or BURNED CAUTIO N Excess pressure can damage the laminating rollers Always use the minimum roll pressure ne...

Page 61: ...ler until it makes contact with the substrate Lower enough to applysufficientpressurewithoutcrushingthe substrate Excessive pressure will cause the substrate to bow or flatten INFO RM ATIO N Sufficien...

Page 62: ...ess the motor direction to FWD reverse forward b Set your speed dial to a comfortable operating speed 1 2 3 4 5 6 7 8 9 10 W ARNING The variable speed footswitch over rides the PHOTO EYE safety circui...

Page 63: ...ou or you can be crushed or burned Theprocesscontrolchartsandwebdiagrams illustrated in this section are reference points only Parameters will vary with regards to laminate thickness laminate widths l...

Page 64: ...s pressure as little as 50 on theroller Whenitcomestomounting theonegeneral rule istonotcrushthesubstrate Mostsubstratesonlyrequire about 20 50 of pressure but variables can effect how much pressure i...

Page 65: ...105 40 6 106 41 1 107 41 7 108 42 2 109 42 8 110 43 3 111 43 9 113 45 114 45 6 115 46 1 116 46 7 117 47 2 118 47 8 119 48 3 120 48 9 121 49 4 122 50 123 50 6 124 51 1 125 51 7 126 52 2 127 52 8 128 53...

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Page 67: ...ontrolchart and diagram for the Falcon 60 H as well as completed charts for the basic operations of the laminator The pro cess control charts should be kept in this manual or in a book close to the la...

Page 68: ...tions F 60 H Operation and Maintenance Manual PROCESS CONTROL CHART Materials Top material Bottom material Other material s CAL3200 CAL3200 Motor Direction Motor Speed 1 2 3 4 5 6 7 8 9 10 Roller Pres...

Page 69: ...Page 6 7 Applications F 60 H Operation and Maintenance Manual April 2001 General Binding Corporation Diagram Blank...

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Page 71: ...Page 6 9 Applications F 60 H Operation and Maintenance Manual April 2001 General Binding Corporation Diagram Blank w roll to roll options...

Page 72: ...3 4 5 6 7 8 9 10 range Roller Pressure Upper Roller Temperature Heater RANGE Notes The roll of mount adhesive should not exceed the substrate by more than 1 in 2 5 cm Speed will be determined by what...

Page 73: ...Page 6 11 Applications F 60 H Operation and Maintenance Manual April 2001 General Binding Corporation Diagram Pre coating substrates Roll of mount adhesive Leader board Substrate...

Page 74: ...ater RANGE Notes The image shoud not exceed the pre coated board by more than 1 in 2 5 cm If the image is smaller than the precoated board trim the board or pre trim the release liner around the image...

Page 75: ...Page 6 13 Applications F 60 H Operation and Maintenance Manual April 2001 General Binding Corporation Diagram Mounting an image Pre coated board Liner Image Hold image here...

Page 76: ...essure sensitive mount adhesive Other material s prints Motor Direction Motor Speed 1 2 3 4 5 6 7 8 9 10 range Roller Pressure Upper Roller Temperature Heater RANGE Notes Speed should be comfortable f...

Page 77: ...Page 6 15 Applications F 60 H Operation and Maintenance Manual April 2001 General Binding Corporation Diagram PSA decaling Image Decal Roll of PSA film Roll of mount adhesive Release liner...

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Page 79: ...ations F 60 H Operation and Maintenance Manual April 2001 General Binding Corporation Roll of PSA film Roll of mount adhesive Release liner Roll of prints Rewind of decals Diagram PSA decaling w roll...

Page 80: ...terial s prints CAL 3200 CAL 3200 Motor Direction Motor Speed 1 2 3 4 5 6 7 8 9 10 r a n g e Roller Pressure Upper Roller Temperature Heater RANGE Notes Speed will be dependent on the activation of th...

Page 81: ...Page 6 19 Applications F 60 H Operation and Maintenance Manual April 2001 General Binding Corporation Diagram Lo Melt decaling Image Decal Roll of Lo Melt film Roll of mount adhesive...

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Page 83: ...lications F 60 H Operation and Maintenance Manual April 2001 General Binding Corporation Diagram Lo Melt decaling w roll to roll options Roll of Lo Melt film Roll of mount adhesive Roll of prints Rewi...

Page 84: ...AL3200 CAL3200 Motor Direction Motor Speed Roller Pressure Upper Roller Temperature Heater RANGE Notes Speed for mounting should be comfortable for the operator Use the footswitch for this application...

Page 85: ...Page 6 23 Applications F 60 H Operation and Maintenance Manual April 2001 General Binding Corporation Diagram Mounting a decal Substrate Liner Decal Hold decal here...

Page 86: ...e Upper Roller Temperature Heater RANGE Notes The leader board and trailer board should be the same width as the pre coated board The laminate should not exceed the pre coated board by more than 1 in...

Page 87: ...5 Applications F 60 H Operation and Maintenance Manual April 2001 General Binding Corporation Pre coated board Roll of PSA film Release liner Leader board Image Diagram PSA single sided lamination sle...

Page 88: ...ints CAL3200 CAL3200 Motor Direction Motor Speed 1 2 3 4 5 6 7 8 9 10 range Roller Pressure Upper Roller Temperature Heater RANGE Notes Top and bottom material should be of the same width Do not use e...

Page 89: ...cations F 60 H Operation and Maintenance Manual April 2001 General Binding Corporation Diagram PSA single sided lamination craft paper method Image Finished product Roll of PSA film Roll of craft pape...

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Page 91: ...ion and Maintenance Manual April 2001 General Binding Corporation Diagram PSA single sided lamination craft paper method w roll to roll option Roll of PSA film Roll of craft paper Release liner Roll o...

Page 92: ...ction Motor Speed 1 2 3 4 5 6 7 8 9 10 range Roller Pressure Upper Roller Temperature Heater RANGE Notes The laminate should not exceed the pre mounted image by more than 3 in 7 6 cm Speed will be det...

Page 93: ...e 6 31 Applications F 60 H Operation and Maintenance Manual April 2001 General Binding Corporation Diagram PSA over lamination of a mounted image Mounted image Roll of PSA film Release liner Leader bo...

Page 94: ...ed 1 2 3 4 5 6 7 8 9 10 r a n g e Roller Pressure Upper Roller Temperature Heater RANGE Notes The laminate should not exceed the pre mounted image by more than 3 in 7 6 cm Speed will be determined by...

Page 95: ...Page 6 33 Applications F 60 H Operation and Maintenance Manual April 2001 General Binding Corporation Diagram Lo Melt over lamination of a mounted image Mounted image Roll of Lo Melt film Leader board...

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Page 97: ...eshooting in attempt to correct your typical output typeproblems Usetheeasytofollowguideforassistance 7 1 Wave problems Thefollowingisalistofcommonoutputwave problemsyoumayencounter Thearrowalongthele...

Page 98: ...Problem Waves on only one side of the output Hints Check the nip setting of main rolls Check for even paper tension Problem Angled waves in the output on both sides Hints Checkforinsufficientmainroll...

Page 99: ...on Hints Check operating pressures Check operating speed Laminatecompatibilitywithink Inkcompatibilitywithpaper Lo Melt laminates Problem Blisteringwithintheimage Hints Increase the speed Decrease the...

Page 100: ...ARNING 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 Proble...

Page 101: ...ative border Coiling A term used to describe an image rolling up on itself This is caused by differences in the brake tension used between the upper and lower laminates during and applicationprocess C...

Page 102: ...rindiameter thanthepullrolls Media Termusedtodescribethematerialsusedtoprint an image i e the papers inks toners etc Mount adhesive A term used to describe a two sided pressure sensitive adhesive used...

Page 103: ...hesivenotfullyactivatedina pressure sensitive film which will disappear once the adhesiveisfullyactivated Thisactivationprocesscanbe sped up if a small amount of heat is applied during the application...

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Page 105: ...SHOCK Remove power from the laminator before servicing You can be severely shocked electrocuted or cause a fire 8 1 Maintenance Schedule Below is a recommended maintenance schedule Before performing a...

Page 106: ...he laminator before servicing You can be severely shocked electrocuted or cause a fire 8 2 Cleaning the rollers Tools required Protective rubber gloves Thiswillprotectyourhandsfromtheisopropyl alcohol...

Page 107: ...ubber cement eraser This allows the eraser to bead up the adhesive f Wipe away the beads with isopropyl alcohol and a cotton terry cloth CAUTION Exercise care when cleaning the laminating rollers with...

Page 108: ...inator 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 4 Clean the control pa...

Page 109: ...e nip and choke you or you can be crushed or burned Remove ALL power to the laminator before removing any cabinet covers You may be shocked or electrocuted W ARNING W ARNING Always practice lock out t...

Page 110: ...tensioning loosenthefour motor mount bolts with a 7 16 in wrench Four bolts INFO RM ATIO N The motor controls the tension of the both chains If one is chain is still too loose a half link may be remov...

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