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Troubleshooting

F 60 H Operation and Maintenance Manual

© April 2001 General Binding Corporation

7.4 Glossary

The glossary can help you in understanding some

of the terminology used when referring to the laminator,
applications, or troubleshooting aspects of the machine.

Blistering

A condition where the paper coating is bubbled

up from the image paper causing a “blister”. It is created
by using excessive heat during the lamination process.
Blistering is most commonly found with photographic and
ink jet media.

Bond strength

Refers to one of three conditions; 1) the anchor

strength of adhesive to laminate substrate, 2) the anchor
strength of the laminating film to the product that has been
laminated, or 3) when two layers of film are laminated
together, the strength of the adhesive to adhesive bond.

Center mount

A mounting technique where an image is mounted

centrally on a substrate to provide a decorative 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
application process.

Cold laminate

Film that does not require heat to activate the

adhesive. Please see P.S.A. for more information.

Craft paper

A strong brown paper commonly used for single

sided applications.

D waves

A term used to describe a wave pattern caused,

generally, by incorrect paper tension.

Delamination

Refers to either one of two conditions; 1) the

adhesive separating from the laminate substrate, or 2) the
laminate separating from the product being laminated.

Edgewrap

A mounting technique where the image wraps

around the edges of the mounting substrate so as to provide
a finished edge.

Encapsulation

When an image is completely encased in laminating

film, it is encapsulated. A border of laminate on laminate
exists around the perimeter of the product.

Film

A two part material consisting an adhesive layer

and a substrate. The adhesive and the substrate may or
may not be clear. This is the material used for lamination.
Please refer to laminate.

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Содержание F-60H

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

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

Страница 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...

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

Страница 70: ...Page 6 8 April 2001 General Binding Corporation Applications F 60 H Operation and Maintenance Manual This page intentionally left blank...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 78: ...Page 6 16 April 2001 General Binding Corporation Applications F 60 H Operation and Maintenance Manual This page intentionally left blank...

Страница 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...

Страница 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...

Страница 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...

Страница 82: ...Page 6 20 April 2001 General Binding Corporation Applications F 60 H Operation and Maintenance Manual This page intentionally left blank...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 90: ...Page 6 28 April 2001 General Binding Corporation Applications F 60 H Operation and Maintenance Manual This page intentionally left blank...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 96: ...Page 6 34 April 2001 General Binding Corporation Applications F 60 H Operation and Maintenance Manual This page intentionally left blank...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 104: ...Page 7 8 Troubleshooting F 60 H Operation and Maintenance Manual April 2001 General Binding Corporation This page intentionally left blank...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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