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F - 160 Operation and Maintenance Manual

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© GBC Pro - Tech August 1999

Fax Correspondence

Fax number : ( 608 ) 246 - 8645 Date :

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Sean Flood @ GBC Pro - Tech
4151 Anderson Road
DeForest, WI 53532

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Re : Falcon 160 Operations and Maintenance Manual ( Rev. A )

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Содержание F - 160

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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