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GBC F - 160 CE manual

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Table of contents for the manual

  • Page 1

    GBC Films Group 4151 Anderson Road DeForest, WI 53532 Revision : Ph: ( 608 ) 246 - 8844 Fx: ( 608 ) 246 - 8645 F - 160 CE OPERA TION AND MAINTENANCE MANUAL © April 2000 GBC Films Group Do not duplicate without written permission. Part number : 930 - 065[...]

  • Page 2

    Page I T able of Contents F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 T able of Contents Section 1: Safety 1.1 Symbols .......................................................................................................1 - 1 1.2 Safety features ........................................................................[...]

  • Page 3

    Page II T able of Contents F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Section 3: Specifications 3.1 General .......................................................................................................3 -1 3.2 Consumables .......................................................................................[...]

  • Page 4

    Page III T able of Contents F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 4.7 Installing levelers .......................................................................................4 - 9 4.8 Leveling .....................................................................................................4 - 1 1 4.9 Conne[...]

  • Page 5

    Page IV T able of Contents F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Section 5: Operations 5.1 Control panel ..............................................................................................5 - 1 Figure 5.1.1 Front control panel .................................................5 - 9 5.2 Emergency .......[...]

  • Page 6

    Page V T able of Contents F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 5.5.2 Pull roller manual nip adjustment .........................................................5 - 21 5.6 Front feed table .........................................................................................5 - 24 5.6.1 Removing the table ....[...]

  • Page 7

    Page VI T able of Contents F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Diagram 3 - Single sided ( Sled ) .....................................................................6 - 1 1 Chart 4 - Single sided ( Craft paper ) ..............................................................6 - 12 Diagram 4 - Single sided ( Cra[...]

  • Page 8

    Page VII T able of Contents F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Chart 1 1 - Encapsulation ...............................................................................6 - 26 Diagram 1 1 - Encapsulation ..........................................................................6 - 27 Section 7: T r oubleshootin[...]

  • Page 9

    Page VIII T able of Contents F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 This page intentionally left blank.[...]

  • Page 10

    Safety Page 1 - 1 F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Section 1 Safety CAUTION Do not attempt to operate your Falcon 160 CE laminator until you have read this section carefully! Y our safety , as well as the safety of others, is important to GBC Films Group. This section contains important safety information. T[...]

  • Page 11

    Page 1 - 2 Safety F - 160CE Operation and Maintenance Manual © GBC Films Group April 2000 1.2 Safety features The F-160 CE laminator has been designed with safety as a primary consideration; however , you must become thoroughly familiar with the controls, proper operation, proper service procedures and safety features of the laminator before using[...]

  • Page 12

    Safety Page 1 - 3 F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 • Any GBC T echnician, GBC Specialist, and / or GBC Films Group T echnician that has been through the GBC Pro-T ech service training course. The F-160CE laminator has cabinets and panels that are bolted close to isolate the electrical and drive system comp[...]

  • Page 13

    Page 1 - 4 Safety F - 160CE Operation and Maintenance Manual © GBC Films Group April 2000 1.4 Emergency stop The laminator is equipped with four emergency stops ( E-STOP ) located at the front of the cabinets and the rear of the cabinets. Refer to Figure 1.4.1 Emergency stops. Figure 1.4.1 Emergency stops Front Rear Emergency stops Emergency stops[...]

  • Page 14

    Safety Page 1 - 5 F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Press RESET located on the right leg at the front of the machine. Refer to Figure 1.4.4 Machine reset . Figure 1.4.4 Machine rest Machine reset 1.5 Emergency cable In the event an E-STOP is not reachable, use your foot to activate an emergency cable ( E-CABL[...]

  • Page 15

    Page 1 - 6 Safety F - 160CE Operation and Maintenance Manual © GBC Films Group April 2000 Press RESET located on the right leg at the front of the machine. Refer to Figure 1.5.3 Machine reset . Figure 1.5.3 Machine rest Machine reset 1.6 Front feed table The front feed table must be in proper position for the laminator to operate in auto run. Refe[...]

  • Page 16

    Safety Page 1 - 7 F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 WAARSCHUWING ! ATTENZIONE ! WARNUNG ! Kans op elektrische schok. Niet openen Bevatgeen door gebruik te repareren onderdelen. Door bevoegd service personeel laten repareren Pericolo di scarica elettrica. Nessuna parte riparabile dall' utente. Chiamare un[...]

  • Page 17

    Page 1 - 8 Safety F - 160CE Operation and Maintenance Manual © GBC Films Group April 2000 Reset: Machine reset. Press after iniating power to the laminator or after an E-STOP or E-CABLE has been engaged then resetted.[...]

  • Page 18

    Safety Page 1 - 9 F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Figure 1.7.1 Label locations - Front WAARSCHUWING ! ATTENZIONE ! WARNUNG ! Kans op elektrische schok. Niet openen Bevat g een door g ebruik te repareren onderdelen. Door bevoe g d service personeel laten repareren Pericolo di scarica elettrica. Nessuna parte[...]

  • Page 19

    Page 1 - 10 Safety F - 160CE Operation and Maintenance Manual © GBC Films Group April 2000 Figure 1.7.2 Label locations - Rear WAARSCHUWING ! ATTENZIONE ! WARNUNG ! Kans op elektrische schok. Niet openen Bevatgeen door gebruik te repareren onderdelen. Door bevoegd service personeel laten repareren Pericolo di scarica elettrica. Nessuna parte ripar[...]

  • Page 20

    Page 2 - 1 Warranty F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Section 2 W arranty GBC Films Group warrants the equipment sold is free from defects in material and workmanship for a period of one ( 1 ) year parts and 90 days labor from the date of installation. This warranty is the only warranty made by GBC Films Grou[...]

  • Page 21

    Page 2 - 2 W arranty F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Qualified • Any engineer that has experience with electrical and mechanical design of lamination equipment.The engineers should be fully aware of all aspects of safety with regards to lamination equipment. • Any commissioning or service engineer must [...]

  • Page 22

    Page 3 - 1 Specifications F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Section 3: Specifications Specifications provide all of the technical data for the Falcon 160 CE Laminator . Section 3.1 General Description: Features: Applications: Section 3.2 Consumable Film types: • Mid level, wide format color finisher for the[...]

  • Page 23

    Page 3 - 2 Specifications F - 160CE Operation and Maintenance Manual © GBC Films Group April 2000 Film diameters: Core size: Film widths: Paper widths: Mounting thickness: Safety: Section 3.3 Function Speed: Motor: Heating capabilities: Controls: • Up to a 8” roll diameter ( 20.3 cm ) • 3” core standard ( 7.62 cm ) • 2-1/4” optional ( [...]

  • Page 24

    Page 3 - 3 Specifications F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Job save: Roll design: Section 3.4 Electrical United Statesand Canada: Europe: B.T .U. output: Heater wattages: Amperage draw: D/C voltage used: A/C voltage used: • Save up to 9 job parameters • High release silicone rolls • 230 - 240 V AC, 50/[...]

  • Page 25

    Page 3 - 4 Specifications F - 160CE Operation and Maintenance Manual © GBC Films Group April 2000 Section 3.5 Dimensions W eight: Crated: Uncrated: Dimensions Crated: Uncrated Nip Height: Safety Shield Raised Height: • 1568 lbs. ( 71 1 kg. ) • 1200 lbs. ( 544 kg. ) • 90 in. (H) x 46 in. (W) x 72 in. (L) ( 229 cm (H) x 1 17 cm (W) x 183 cm (L[...]

  • Page 26

    Page 3 - 5 Specifications F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Figure 3.5.1 Dimensions 76 in. (193 cm) 28 in. (71 cm) 4.875 in. (12 cm) 4.75 in. (12 cm) 53 in. (135 cm) 82.5 in. (210 cm) 3.63 in. (9 cm) 1.38 in. (3.5 cm)[...]

  • Page 27

    Page 3 - 6 Specifications F - 160CE Operation and Maintenance Manual © GBC Films Group April 2000 This page intentionally left blank.[...]

  • Page 28

    Page 4 - 1 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Section 4 Installation GBC Films Group is committed to a program of ongoing product improvement. As a result, we are providing these instructions so you can insure that your new Falcon 160 CE Laminator is properly and securely unpacked, moved, and inst[...]

  • Page 29

    Page 4 - 2 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 The laminator requires 230 to 240 vac, 50/ 60 Hz, 55 amps. Or , in Europe only , 3-N phase, 240 vac, 32 amps/ phase. WARNING The Falcon 160 CE Laminator is a large and heavy piece of equipment. It is necessary to employ LICENSED RIGGERS ONLY to move th[...]

  • Page 30

    Page 4 - 3 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Figure 4.1.1 Suggested Floor Layout 4' x 6' ( 1.22 m x 2m ) Work table on wheels Table hei g ht 35-3/4" ( .94 - .95m ) 4' x 6' ( 1.22 m x 2m ) Work table on wheels Table hei g ht 35-3/4" ( .94 - .95m ) 3' ( 1 m) 13&ap[...]

  • Page 31

    Page 4 - 4 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 4.2 Know your machine Before performing any procedure within this manual, it is recommended that you take time to know the parts of your new machine. Figure 4.2.1 The laminator Rear side Electrical bridge Drive side Control side Control side leg Drive [...]

  • Page 32

    Page 4 - 5 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 4.3 Unpacking INFORMATION ALL SHIPMENTS ARE EX-WORKS. At our dock, title passes to the buyer. Please review your insurance coverage prior to shipment, as you are responsible for all subsequent freight charges and risks. INFORMATION Before signing the B[...]

  • Page 33

    Page 4 - 6 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 4.5 Crated WARNING The Falcon 160 CE Laminator is a large and heavy piece of equipment. It is necessary to employ LICENSED RIGGERS ONLY to move the laminator. The laminator is not designed to be tipped up or sideways in any way. Such action disturbs th[...]

  • Page 34

    Page 4 - 7 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Figure 4.5.1 Disassembling of the crate P l a n e 4 P l a n e 4 P l a n e 4 1 2 3 4 5 Removing the shrink wrap a) Gently unwrap the shrink wrap from around the laminator . CAUTION Do not use a knife or other sharp object to remove the shrink wrap from [...]

  • Page 35

    Page 4 - 8 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 4.6 Accessory pack Once the Falcon 160 CE Laminator has been unpacked and moved into final position, open the accessory pack and verify the contents. Accessory Pack contents • One T-handle allen wrench ( 475-200 ) • One Zippy knife ( 475-620 ) • [...]

  • Page 36

    Page 4 - 9 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 4.7 Installing levelers Leveling of the machine is a customer option. If you choose not to level the laminator and you encounter output problems, please level the machine and try your application again before calling for technical support. Before level[...]

  • Page 37

    Page 4 - 10 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Figure 4.7.1 Leveling pad installed Leveling pad Jam nut Nut Nut i) Tighten the jam nut against the leveling pad. Refer to Figure 4.7.1 Leveling pad installed. j) Perform steps e through “ i ” for the rear control side castor and leveling pad. Dri[...]

  • Page 38

    Page 4 - 11 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 4.8 Leveling Leveling of the laminator is very important in the way the machine performs. Leveling is crucial to the tram ( tracking ) of the materials through the machine. a) Position the level on the top of the control side frame. Not on the cabinet[...]

  • Page 39

    Page 4 - 12 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Lowering is limited to the amount of height within the inside of the leg. INFORMATION c) Position the level on the top of the drive side frame. Not on the cabinet. Refer to Figure 4.8.2 Front to back drive side Figure 4.8.2 Front to back drive side Le[...]

  • Page 40

    Page 4 - 13 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 f) Flip the circuit breaker on the laminator to the up position. = ON = OFF g) T urn MAIN POWER to “ I ” position. Power ON/OFF Ensure all E-STOPS are unlatched and the E-CABLE is reset before turning power on to the laminator. INFORMATION h) Pres[...]

  • Page 41

    Page 4 - 14 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP. You can be CRUSHED or BURNED! j) Press PRESSURE ▼ to illuminate 3 bars in the pressure dsiplay . 0 GAP PRESSURE k) Place the level across the top of the upper main r[...]

  • Page 42

    Page 4 - 15 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 m) T urn the pull roller lift handle towards the rear of the machine to lower the upper pull roller . Stop after initial contact with the lower pull roller plus 1/2 turn. n) Raise the rear safety shield o) Place the level across the top of the upper p[...]

  • Page 43

    Page 4 - 16 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 c) Feed the power cable through the power cable strain relief located at the bottom of the drive side leg. Strain relief WARNING Follow the correct wiring diagram when supplying power to the laminator. If improperly connected, you can be seriously inj[...]

  • Page 44

    Page 4 - 17 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Figure 4.9.1 Single phase, U.S. and Canada Figure 4.9.2 W ye 3 phase, Europe only N L1 L2 L3 N N N PE Ground wire Line 2 Line 1 N L1 L2 L3 N N N PE Ground wire Line 2 Line 1 Remove Jumper bars Line 3 Neutral[...]

  • Page 45

    Page 4 - 18 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 4.10 Safety check The safety check will ensure that all safety devices and interlocks are functioning properly . This procedure describes how to check one E-STOP , the front E-CABLE , the front safety shield and the front feed table. Repeat the steps [...]

  • Page 46

    Page 4 - 19 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 d) Press FWD ▲ to set a forward motor direction. SPEED SAFETY FWD REV 00.0 GO STOP e) Press SPEED ▲ to set a speed of 6 ft/min. SPEED SAFETY FWD REV 6.0 GO STOP f) Press GO . The bottom rollers begin turning. SPEED SAFETY FWD REV 6.0 GO STOP g) Sl[...]

  • Page 47

    Page 4 - 20 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 4.10.2 Safety shield a) Press GO . The bottom rollers begin turning. SPEED SAFETY FWD REV 6.0 GO STOP Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! WARNING b) Raise th[...]

  • Page 48

    Page 4 - 21 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 4.10.3 E-STOP a) Press GO . The bottom rollers begin turning. SPEED SAFETY FWD REV 6.0 GO STOP b) Press PRESSURE ▼ to illuminate 3 bars in the pressure dsiplay . 0 GAP PRESSURE c) Press down on the front control side E-STOP . The E-STOP latches in t[...]

  • Page 49

    Page 4 - 22 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 4.10.4 E-CABLE a) Press GO . The bottom rollers begin turning. SPEED SAFETY FWD REV 6.0 GO STOP b) Press PRESSURE ▼ to illuminate 3 bars in the pressure dsiplay . 0 GAP PRESSURE c) Press on the front E-CABLE with your foot. The bottom rollers stop, [...]

  • Page 50

    Page 4 - 23 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 4.1 1 Function check The function check ensures that the laminator functions properly when operating. This check is recommended before performing any applications. If a step that does not react according to the description, call your local area servic[...]

  • Page 51

    Page 4 - 24 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 e) Press GAP ▲ . GAP DISPLA Y increases 1/16th of an inch per press. The upper main roll moves accordingly . Once to “1”, the upper main roller stops. 0-1 GAP PRESSURE f) Press and hold PRESSURE ▼ . The upper main roller travels in a constant [...]

  • Page 52

    Page 4 - 25 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 j) Press SPEED ▲ once. SPEED DISPLA Y increases in increments of .5 per press up to 15. SPEED SAFETY FWD REV 15.0 GO STOP k) Press FWD ▲ . FWD is solid. SPEED SAFETY FWD REV 15.0 GO STOP l) Press GO . The bottom rollers turn in a forward motion at[...]

  • Page 53

    Page 4 - 26 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 p) Press STOP . The bottom rollers stop turning. SPEED SAFETY FWD REV 15.0 GO STOP q) Press SPEED ▼ once. SPEED DISPLA Y decreases in increments of .5 per press down to 00.0. SPEED SAFETY FWD REV 00.0 GO STOP r) The TOP TEMP DISPLA Y and BOT TEMP DI[...]

  • Page 54

    Page 4 - 27 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 u) Press ST ANDBY . The laminator reverts to the default settings and ST ANDBY is solid. Refer to Figure 4.1 1.1 Default settings JOB STANDBY SEL SAV 0 Figure 4.1 1.1 Default settings 68 68 TOP TEMP BOT TEMP 1/16 GAP PRESSURE IIIIIII 0 JOB STANDBY SAV[...]

  • Page 55

    Page 4 - 28 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 c) Press down on the variable speed footswitch. GO begins flashing and the bottom rollers are turning. ATTUNG WARNING ADVERTENCIA INFORMATION Footswitch speed is not indicated in the SPEED DISPLAY on the control panel. 4.1 1.3 Unwind shafts and unwind[...]

  • Page 56

    Page 4 - 29 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 INFORMATION Steps " e " and " f " will be performed simultaneously. e) With one hand, slowly turn the upper unwind shaft in either direction. f) With the other hand, slowly turn the upper unwind brake adjustment knob clockwise. Upp[...]

  • Page 57

    Page 4 - 30 Installation F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 This page intentionally left blank.[...]

  • Page 58

    Page 5 - 1 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Section 5 Operations The operator control panel for the Falcon 160 CE Laminator is located on the front of the machine, to the right of the front operating position. For an illustration of the complete front control panel, please refer to Figure 5.1.1. T[...]

  • Page 59

    Page 5 - 2 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 ( 5 ) BOT . TEMP . DISPLA Y : The display will show the set point temperature of the bottom main roller as the default display . When the bottom roller temperature has reached in the +/- 10 o F range of the set point, the display will be solid. When outs[...]

  • Page 60

    Page 5 - 3 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 ( 1 1 ) GAP ▼ : When pressed, will decrease the gap by 1/16 in. increments. If held down, it will automatically decrease the gap by 1/16 in. increments until it has reached a minimum opening of 0 in. on the GAP DISPLA Y . 1/16 GAP PRESSURE 11 ( 12 ) PR[...]

  • Page 61

    Page 5 - 4 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 ( 15 ) JOB DISPLA Y : Displays the job number selected and will set the operating parameters saved for that number once SEL has been pressed. JOB STANDBY SEL SAV 0 15 INFORMATION Job programming is explained in Section 5.4 ( 16 ) JOB ▲ : When pressed o[...]

  • Page 62

    Page 5 - 5 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 ( 19 ) SA VE : When pressed and held ( approximately 4 seconds ), will beep and save the current settings for the number showing in the JOB DISPLA Y . For more information, refer to Section 5.4 Job Programming on how to save parameters. JOB STANDBY SEL S[...]

  • Page 63

    Page 5 - 6 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 ( 25 ) FOR W ARD ▲ : When pressed, signals the laminator to run in a forward motion and FOR W ARD ▲ becomes solid. SPEED SAFETY FWD REV 00.0 STOP GO 25 ( 26 ) REVERSE ▼ : When pressed, signals the laminator to run in a reverse motion and REVERSE ?[...]

  • Page 64

    Page 5 - 7 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 INFORMATION When the safety shield is in the lowered position and "Footswitch" mode is engaged, speed is controlled through the control panel Footswitch to Panel 2. T o switch from “Footswitch” mode ( GO is flashing ) to “Panel” mode ( [...]

  • Page 65

    Page 5 - 8 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! WARNING • Raise the safety shield. INFORMATION When a safety shield is raised while pressing on the variable speed footswi[...]

  • Page 66

    Page 5 - 9 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Figure 5.1.1 Front control panel = Flashing 1 68 68 TOP TEMP BOT TEMP + - 1/16 GAP PRESSURE IIIIIII 0 JOB STANDBY SAV SPEED SAFETY GO STOP FWD REV 00.0 SE L 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 25 26 23 24[...]

  • Page 67

    Page 5 - 10 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 5.2 Emergency The F-160 CE laminator has been designed with safety as a primary consideration; however , you must become thoroughly familiar with the controls, proper operation, proper service procedures, and safety features of the laminator before usin[...]

  • Page 68

    Page 5 - 11 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 5.2.2 Resume operation a) Reset the E-STOP or the E-CABLE . -Resetting the E-STOP Unlatch -Resetting the E-CABLE Push in The laminator will only turn on if all E-STOPS are unlatched and the E-CABLE is reset. INFORMATION b) Press machine RESET . All para[...]

  • Page 69

    Page 5 - 12 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 5.3 Set up Initial set up of the Falcon 160 CE laminator is easily attained when instructions are followed exactly . It is suggested and helpful if you take the time to read this section thoroughly before attempting to do any of the steps. A complete un[...]

  • Page 70

    Page 5 - 13 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 c) Swing the unwind shaft out enough to slide the roll of laminate over the core chucks and onto the unwind shaft. Core chucks Core support Clevis pin Brake adjust knob Roll of laminate Saddle INFORMATION Twisting the roll of film while sliding makes lo[...]

  • Page 71

    Page 5 - 14 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Chart 5.3.1 Measurement chart Common film widths 12 " 28 " 24 " 22 " 31 " 18.5 " 37 " 15.5 " 41 " 15 " 47 " 13.5 " 49 " 10.5 " 51 " 9.5 " 55 " 8.5 " 58 " 6.5 [...]

  • Page 72

    Page 5 - 15 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 c) Press GAP ▼ to set the gap to “ 0 ”. 0 GAP PRESSURE INFORMATION Do not add PRESSURE when heating the laminating rollers. The rollers expand. d) Press FWD ▲ to set a forward motion direction. SPEED SAFETY FWD REV 00.0 GO STOP e) Press SPEED ?[...]

  • Page 73

    Page 5 - 16 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 5.4 Job programming The job save feature is very convenient if the same parameters are required to perform various applications. This procedure will guide you step by step through this feature. a) Follow the prcedure in Section 5.3.1 Power . INFORMATION[...]

  • Page 74

    Page 5 - 17 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 INFORMATION When storing parameters within the JOB SAVE feature of the laminator, PRESSURE is not a storable setting. f) Enter a desired speed by pressing SPEED ▲ . SPEED SAFETY FWD REV 5.0 GO STOP g) Press and hold SA VE ( approximately 4 seconds ) u[...]

  • Page 75

    Page 5 - 18 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 5.5 Manual nip adjustment If the substrate does not fall with in the preset GAP settings available, a manual nip setting must be performed. If you are unsure of a substrate thickness, it is recommended that you use the manual nip setting procedure. If y[...]

  • Page 76

    Page 5 - 19 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 c) Raise the front safety shield. d) Press SEL. JOB STANDBY SAV 0 SE L = Flashing e) Position the leader board in the center of the main rollers between the nip. CAUTION Sharp edges on a substrate should be filed smooth and GAP manually adjusted. Sharp [...]

  • Page 77

    Page 5 - 20 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Figure 5.5.1 Main roller pressure Leader board Proper pressure Leader board Excessive pressure g) Press REV ▼ for a reverse motor direction. SPEED SAFETY FWD REV 00.0 GO STOP h) Press SPEED ▲ to 5. SPEED SAFETY FWD REV 5.0 GO STOP WARNING When opera[...]

  • Page 78

    Page 5 - 21 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 l) On the control panel press FWD ▲ for a forward motor direction. Nip is now set. FWR REV. STOP GO SPEED SAFETY 00.0 5.5.2 Pull roller manual nip adjustment If the main laminating rollers are heated, mounting application may be run from the rear oper[...]

  • Page 79

    Page 5 - 22 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 e) Press SPEED ▲ to 5. SPEED SAFETY FWD REV 5.0 GO STOP f) Bring the footswitch around to the rear of the laminator . Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! WAR[...]

  • Page 80

    Page 5 - 23 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Excessive pressure will cause the substrate to bow or flatten. INFORMATION Refer to Figure 5.5.2 for proper roller pressure. INFORMATION Figure 5.5.2 Pull roller pressure Leader board Proper pressure Leader board Excessive pressure Density of the substr[...]

  • Page 81

    Page 5 - 24 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 l) Press STOP . SPEED SAFETY FWD REV 5.0 GO STOP m) Press REV ▼ for a reverse motor direction. The nip is now set SPEED SAFETY FWD REV 5.0 GO STOP 5.6 Front feed table The table is part of the Falcon 160 CE safety feature. It is neccessary to have the[...]

  • Page 82

    Page 5 - 25 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 5.6.2 Replacing the infeed table a) Ensure the safety shiled is in the raised position. b) W ith both hands, grip the front edge of the infeed table and align the back edge with the support bolts. Front support bolt c) Now lower the front edge while ens[...]

  • Page 83

    Page 5 - 26 Operations F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 This page intentionally left blank.[...]

  • Page 84

    Page 6 - 1 Applications F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Section 6 Applications T o assist you with a variety of web ups, please refer to the process control charts and diagrams. Process control charts allow you to record the way you thread film through the machine’ s rollers ( called webbing ) and the con[...]

  • Page 85

    Page 6 - 2 Applications © GBC Films Group April 2000 F - 160 CE Operation and Maintenance Manual 6.1 Charts and Diagrams Use the parameter charts and web up diagrams can to assist you with the applications described. It is recommended that you keep these parameter charts and web up diagrams in the manual for reference. Make copies if you require t[...]

  • Page 86

    Page 6 - 3 Applications F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 o F o C 68 20 = 69 20.6 = 70 21.1 = 71 21.7 = 72 22.2 = 73 22.7 = 74 23.3 = 75 23.9 = 76 24.4 = 77 25 = 78 25.6 = 79 26.1 = 80 26.7 = 81 27.2 = 82 27.8 = 83 28.3 = 84 28.9 = 85 29.4 = 86 30 = 87 30.6 = 88 31.1 = 89 31.7 = 90 32.2 = 91 32.8 = 92 33.3 = [...]

  • Page 87

    Page 6 - 4 Applications © GBC Films Group April 2000 F - 160 CE Operation and Maintenance Manual Parameter Chart - Blank TEMPERATURE GAP & PRESSURE MOTOR DIRECTION & SPEED TOP TEMP. BOT. TEMP. PRESSURE GAP SPEED FWR REV. GO GO = Panel SOLID FLAS HING = Footswitch PULL ROLL SETTINGS NOTES N / A 1/4 Turn 1/2 Turn 3/4 Turn PRESSURE MATERIALS [...]

  • Page 88

    Page 6 - 5 Applications F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 W eb Diagram - Blank[...]

  • Page 89

    Page 6 - 6 Applications © GBC Films Group April 2000 F - 160 CE Operation and Maintenance Manual Parameter Chart 1 - Precoating substrates TEMPERATURE GAP & PRESSURE MOTOR DIRECTION & SPEED TOP TEMP. BOT. TEMP. PRESSURE GAP SPEED FWD REV. GO GO = Panel SOLID FLAS HING = Footswitch PULL ROLL SETTINGS NOTES N / A 1/4 Turn 1/2 Turn 3/4 Turn P[...]

  • Page 90

    Page 6 - 7 Applications F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 W eb Diagram 1 - Precoating substrate Pro Mount Leader board Substrate[...]

  • Page 91

    Page 6 - 8 Applications © GBC Films Group April 2000 F - 160 CE Operation and Maintenance Manual Parameter Chart 2 - Mounting only TEMPERATURE GAP & PRESSURE MOTOR DIRECTION & SPEED TOP TEMP. BOT. TEMP. PRESSURE GAP SPEED FWD REV. GO GO = Panel SOLID FLAS HING = Footswitch PULL ROLL SETTINGS NOTES N / A 1/4 Turn 1/2 Turn 3/4 Turn PRESSURE [...]

  • Page 92

    Page 6 - 9 Applications F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 W eb Diagram 2 - Mounting only Precoated board Release liner Print[...]

  • Page 93

    Page 6 - 10 Applications © GBC Films Group April 2000 F - 160 CE Operation and Maintenance Manual Parameter Chart 3 - Single sided ( Sled ) TEMPERATURE GAP & PRESSURE MOTOR DIRECTION & SPEED TOP TEMP. BOT. TEMP. PRESSURE GAP SPEED FWD REV. GO GO = Panel SOLID FLAS HING = Footswitch PULL ROLL SETTINGS NOTES N / A 1/4 Turn 1/2 Turn 3/4 Turn [...]

  • Page 94

    Page 6 - 11 Applications F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 W eb Diagram 3 - Single sided ( Sled ) Sled Print P.S.A. Laminate Release liner[...]

  • Page 95

    Page 6 - 12 Applications © GBC Films Group April 2000 F - 160 CE Operation and Maintenance Manual Parameter Chart 4 - Single sided ( Craft paper ) TEMPERATURE GAP & PRESSURE MOTOR DIRECTION & SPEED TOP TEMP. BOT. TEMP. PRESSURE GAP SPEED FWD REV. GO GO = Panel SOLID FLAS HING = Footswitch PULL ROLL SETTINGS NOTES N / A 1/4 Turn 1/2 Turn 3/[...]

  • Page 96

    Page 6 - 13 Applications F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 W eb Diagram 4 - Single sided ( Craft paper ) C r a ft P a p e r Pr i nt P. S. A. Lam i nat e R el ease l i ner Fi ni sh product r ew i nd opt i on O ut put[...]

  • Page 97

    Page 6 - 14 Applications © GBC Films Group April 2000 F - 160 CE Operation and Maintenance Manual Parameter Chart 5 - Decal and mount ( Decal ) TEMPERATURE GAP & PRESSURE MOTOR DIRECTION & SPEED TOP TEMP. BOT. TEMP. PRESSURE GAP SPEED FWD REV. GO GO = Panel SOLID FLAS HING = Footswitch PULL ROLL SETTINGS NOTES N / A 1/4 Turn 1/2 Turn 3/4 T[...]

  • Page 98

    Page 6 - 15 Applications F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 W eb Diagram 5 - Decal and mount ( Decal ) Pro Mount Print P.S.A. Laminate Release liner Finish product rewind option Output[...]

  • Page 99

    Page 6 - 16 Applications © GBC Films Group April 2000 F - 160 CE Operation and Maintenance Manual Parameter Chart 6 - Decal and mount ( Mount ) TEMPERATURE GAP & PRESSURE MOTOR DIRECTION & SPEED TOP TEMP. BOT. TEMP. PRESSURE GAP SPEED FWD REV. GO GO = Panel SOLID FLAS HING = Footswitch PULL ROLL SETTINGS NOTES N / A 1/4 Turn 1/2 Turn 3/4 T[...]

  • Page 100

    Page 6 - 17 Applications F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 W eb Diagram 6 - Decal and mount ( Mount ) Substrate Release liner Decal[...]

  • Page 101

    Page 6 - 18 Applications © GBC Films Group April 2000 F - 160 CE Operation and Maintenance Manual Parameter Chart 7 - Precoating substrates ( Thermal ) TEMPERATURE GAP & PRESSURE MOTOR DIRECTION & SPEED TOP TEMP. BOT. TEMP. PRESSURE GAP SPEED FWD REV. GO GO = Panel SOLID FLAS HING = Footswitch PULL ROLL SETTINGS NOTES N / A 1/4 Turn 1/2 Tu[...]

  • Page 102

    Page 6 - 19 Applications F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 W eb Diagram 7 - Precoating substrate ( Thermal ) Hot Tissue Leader board Substrate 140 - 160[...]

  • Page 103

    Page 6 - 20 Applications © GBC Films Group April 2000 F - 160 CE Operation and Maintenance Manual Parameter Chart 8 - One pass mount and laminate TEMPERATURE GAP & PRESSURE MOTOR DIRECTION & SPEED TOP TEMP. BOT. TEMP. PRESSURE GAP SPEED FWD REV. GO GO = Panel SOLID FLAS HING = Footswitch PULL ROLL SETTINGS NOTES N / A 1/4 Turn 1/2 Turn 3/4[...]

  • Page 104

    Page 6 - 21 Applications F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 W eb Diagram 8 - One pass mount and laminate Octiva Gloss Leader board Substrate 240 - 260 Hot Tissue Image[...]

  • Page 105

    Page 6 - 22 Applications © GBC Films Group April 2000 F - 160 CE Operation and Maintenance Manual Parameter Chart 9 - Thermal decal and Mount ( Decal ) TEMPERATURE GAP & PRESSURE MOTOR DIRECTION & SPEED TOP TEMP. BOT. TEMP. PRESSURE GAP SPEED FWD REV. GO GO = Panel SOLID FLAS HING = Footswitch PULL ROLL SETTINGS NOTES N / A 1/4 Turn 1/2 Tu[...]

  • Page 106

    Page 6 - 23 Applications F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 W eb Diagram 9 - Thermal decal and mount ( Decal ) Pro Mount Print Octiva Gloss Finish product rewind option Output 230[...]

  • Page 107

    Page 6 - 24 Applications © GBC Films Group April 2000 F - 160 CE Operation and Maintenance Manual Parameter Chart 10 - Thermal decal and Mount ( Mount ) TEMPERATURE GAP & PRESSURE MOTOR DIRECTION & SPEED TOP TEMP. BOT. TEMP. PRESSURE GAP SPEED FWD REV. GO GO = Panel SOLID FLAS HING = Footswitch PULL ROLL SETTINGS NOTES N / A 1/4 Turn 1/2 T[...]

  • Page 108

    Page 6 - 25 Applications F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 W eb Diagram 10 - Thermal decal and mount ( Mount ) Substrate Release liner Decal[...]

  • Page 109

    Page 6 - 26 Applications © GBC Films Group April 2000 F - 160 CE Operation and Maintenance Manual Parameter Chart 1 1 - Encapsulation TEMPERATURE GAP & PRESSURE MOTOR DIRECTION & SPEED TOP TEMP. BOT. TEMP. PRESSURE GAP SPEED FWD REV. GO GO = Panel SOLID FLAS HING = Footswitch PULL ROLL SETTINGS NOTES N / A 1/4 Turn 1/2 Turn 3/4 Turn PRESSU[...]

  • Page 110

    Page 6 - 27 Applications F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 W eb Diagram 1 1 - Encapsulation Octiva Gloss Print Octiva Gloss Finish product rewind option Output 230 230[...]

  • Page 111

    Page 6 - 28 Applications © GBC Films Group April 2000 F - 160 CE Operation and Maintenance Manual This page intentionally left blank.[...]

  • Page 112

    Page 7 - 1 T roubleshooting F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Section 7 T r oubleshooting WARNING Do not wear ties, loose fitting clothing or dangling jewelry while operating or servicing the laminator. These items can get caught in the nip and choke you or you can be crushed or burned. As an operator , you c[...]

  • Page 113

    Page 7 - 2 T roubleshooting F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Problem: Straight waves in the output Hints: • Check operational settings for materials being used. Problem: W aves on only one side of the output Hints: • Check the nip setting of main rolls • Check the nip setting of pull rolls • Check fo[...]

  • Page 114

    Page 7 - 3 T roubleshooting F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 7.2 Film problems The following is a list of common film problems you may encounter . For definitions of terminologies, please refer to 7.4 Glossary of terminology . 7.2.1 Thermal laminates Problem: Blistering within the image Hints: • Increase t[...]

  • Page 115

    Page 7 - 4 T roubleshooting F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Problem: Delamination Hints: • Check operating pressures • Check operating speed • Laminate compatibility with ink • Ink compatibility with paper 7.3 Machine problems Once the Hints are all checked, and your problem still exists, a service [...]

  • Page 116

    Page 7 - 5 T roubleshooting F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Problem : I press GO , and the rolls will not turn. Hints : • Be sure a speed has been entered. • Make sure a motion direction has been selected. • Make sure GO or SEL is not flashing. Problem : Jerking, stuttering, or excessive noise from th[...]

  • Page 117

    Page 7 - 6 T roubleshooting F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Clutch tension The tension that is applied to the laminated material between the main and pull rolls. This tension is applied by having the pull rolls turn faster than the main rolls, and then having some form of clutching or torque limiting applie[...]

  • Page 118

    Page 7 - 7 T roubleshooting F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Main rollers These are the rolls that perform the actual lamination. They are rolls capable of being heated in thermal roll laminators and are usually larger in diameter than the pull rolls. Media T erm used to describe the materials used to print [...]

  • Page 119

    Page 7 - 8 T roubleshooting F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Silvering A term used to describe one of two occurrences; 1) air bubbles trapped between the product and a thermal laminate, generally caused by insufficient heat being applied to the laminator or 2) the adhesive not fully activated in a pressure s[...]

  • Page 120

    Page 8 - 1 Maintenance F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Section 8 Maintenance GBC Films Group laminators require minimal maintenance. However , regular maintenance is essential to keep any piece of precision machinery at peak performance. A maintenance schedule and a section of procedures are included in thi[...]

  • Page 121

    Page 8 - 2 Maintenance F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 Semi-Annual • Lubricate the grease fittings, chain, and gears. ( performed by service technician ) • Check wire termination tightness. ( performed by service technician ) ELECTRICAL SHOCK Remove power from the laminator before servicing. You can be [...]

  • Page 122

    Page 8 - 3 Maintenance F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 c) Press SEL. JOB STANDBY SAV 0 SE L = Flashing Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! WARNING d) Open the front and rear safety shields. e) Remove the front feed[...]

  • Page 123

    Page 8 - 4 Maintenance F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 When cleaning the bottom main roller, switch the motion direction to reverse. When cleaning the bottom pull roller, switch the motion direction to forward. This will prevent anything from being pulled into the nip. INFORMATION WARNING When operating the[...]

  • Page 124

    Page 8 - 5 Maintenance F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 c) Press SPEED ▲ to enter a speed of 3. SPEED SAFETY FWD REV 3.0 GO STOP 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. d) [...]

  • Page 125

    Page 8 - 6 Maintenance F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 b) Set the motion direction to REV ▼ . SPEED SAFETY FWD REV 00.0 GO STOP c) Press SPEED ▲ to enter a speed of 3. SPEED SAFETY FWD REV 3.0 GO STOP WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP. You can be CRUSHED [...]

  • Page 126

    Page 8 - 7 Maintenance F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 8.2.1 Clean the cabinets and covers ELECTRICAL SHOCK Remove power from the laminator before cleaning. You can be severely shocked, electrocuted or cause a fire. a) Use a damp cotton terry cloth ( water only ), clean the exterior of the laminator . b) If[...]

  • Page 127

    Page 8 - 8 Maintenance F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000 This page intentionally left blank.[...]