F - 160 OPERATION AND MAINTENANCE MANUAL © November 1999 GBC Pro-Tech Do not duplicate without written permission.
F - 160 Operation and Maintenance Manual Read me file Read Me File . . . . . . . . . The information in this publication is provided for reference and is believed to be accurate and complete. GBC Pro - Tech is not liable for errors in this publication or for incidental or consequential damage in connection with the furnishing or use of the information in this publication, including, but not limited to, any implied warranty of fitness or merchantability for any particular use.
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F - 160 Operation and Maintenance Manual Read me file 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 Manual ( Rev.
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F - 160 Operation and Maintenance Manual Table of Contents Table of Contents Section 1: Safety 1.1 Symbols ......................................................................................................1 - 1 1.2 Safety features ...........................................................................................1 - 1 1.3 Installation .................................................................................................1 - 4 1.4 Operations ........................................
Table of Contents F - 160 Operation and Maintenance Manual Section 3: Specifications 3.1 General .......................................................................................................3 -1 3.2 Consumables ..............................................................................................3 - 1 3.3 Function .....................................................................................................3 - 2 3.4 Electrical ...................................................
F - 160 Operation and Maintenance Manual Table of Contents 4.3 Shrink wrapped ........................................................................................4 - 5 4.4 Crated ........................................................................................................4 - 6 4.5 Accessory pack content ............................................................................4 - 8 4.6 Leveling ............................................................................................
Table of Contents F - 160 Operation and Maintenance Manual Section 5: Operations 5.1 Control panel .............................................................................................5 - 1 Figure 5.1.1 Front control panel ................................................5 - 9 5.2 Emergency ...............................................................................................5 - 10 5.3 Set up ...............................................................................................
F - 160 Operation and Maintenance Manual Table of Contents 5.6 Infeed tables ............................................................................................5 - 23 5.6.1 Removing 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 ...................................................
Table of Contents F - 160 Operation and Maintenance Manual Group 2: Top heat only 6.6 Precoating substrates ..............................................................................6 - 51 6.7 One pass mount and laminate .................................................................6 - 60 6.8 Thermal decal and mount .......................................................................6 - 69 Pass 1 Thermal decal ...........................................................................
F - 160 Operation and Maintenance Manual Table of Contents Diagram 1 - Precoating subtrates .................................................................6 - 99 Chart 2 - Mounting only ...............................................................................6 - 100 Diagram 2 - Mounting only .........................................................................6 - 101 Chart 3 - Single sided ( Sled ) ......................................................................
Table of Contents F - 160 Operation and Maintenance Manual Diagram 8 - One pass mount .......................................................................6 - 113 Chart 9 - Thermal decal and mount ( Decal ) .............................................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 ) ........
F - 160 Operation and Maintenance Manual 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 .........................................................
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F - 160 Operation and Maintenance Manual Safety Section 1 Safety WARNING CAUTION Indicates a potentially hazardous situation which, if not avoided, could result in serious injury. Do not attempt to operate your Falcon 160 laminator until you have read this section carefully! Your safety, as well as the safety of others, is important to GBC Pro - Tech. This section contains important safety information.
Safety F - 160 Operation and Maintenance Manual GBC Pro - Tech laminators are powerful machines that are designed to mount, laminate, and encapsulate. The forces required to accomplish these tasks can vary from negligible to very large. The motorized main roll lift mechanism used to provide downward pressure on the top roll is capable of producing forces greater than 400 pounds. This force is applied to any object presented in the opening ( called the nip ) between the two rolls.
F - 160 Operation and Maintenance Manual An important feature of the F-160 laminator are the safety shields, when raised, the auto run is disabled and drive control is transferred to the footswitch. Figure 1.2.2 illustrates the safety shields in the up position. Safety Figure 1.2.3 Emergency stops Plane4 Em erg e bu ncy s tto ns top Plane4 WARNING Plane4 Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! Figure 1.2.
Safety F - 160 Operation and Maintenance Manual Press RESET located on the left leg at the rear of the machine. 1.3 Installation Reset The following symbols are positioned at various points in Section 4 Installation. CAUTION Failure to follow the pre-installation check list can result in damage to the laminator. The front and rear tables must be in proper position for the laminator to operate under normal condition. Figure 1.2.5 illustrates the tables and keys.
F - 160 Operation and Maintenance Manual WARNING Be sure to follow the correct wiring diagram when supplying power to the laminator. If improperly connected, you can be seriously injured or cause damage to the laminator. Safety WARNING The unpacking process requires at least two people. You can be severely injured, crushed or cause damage to the laminator. INFORMATION CAUTION A L L S H I P M E N T S A R E E X - W O R K S . At our dock, title passes to the buyer.
Safety F - 160 Operation and Maintenance Manual INFORMATION Do 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 labeled 5 in Figure 4.4.1 It can fall and damage the laminator or cause harm to you and others. CAUTION Do not allow the top to fall into the crate. It can damage the laminator.
F - 160 Operation and Maintenance Manual INFORMATION The side frame provides a more accurate reading than the cabinet. Safety 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. INFORMATION A second person can read the level while you make the appropriate adjustments.
Safety F - 160 Operation and Maintenance Manual INFORMATION Notice that the footswitch speed is not indicated in the SPEED DISPLAY on the front control panel. WARNING Keep hands and fingers clear of the laminator roller nip when adjusting PRESSURE. You can be CRUSHED or BURNED! 1.4 Operations INFORMATION The following symbols are positioned at various points in Section 5 Operations.
F - 160 Operation and Maintenance Manual CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. Safety INFORMATION Footswitch speed is not indicated in the SPEED DISPLAY on the control panel. INFORMATION WARNING When the safety shield is lowered, speed reverts to the panel speed setting. Caution should always be exercised when using the laminator with the safety shields raised.
Safety F - 160 Operation and Maintenance Manual CAUTION Ensure the roll of laminate is loaded properly on the unwind shaft. Exposed adhesive should be facing away from the rollers. This will prevent hours of roll cleaning! INFORMATION Slow speed will assists with heat up times and distributes heat evenly. INFORMATION INFORMATION For the lower unwind shaft, add 1/4 in. to the measurement. When the laminator is first turned on, the front control panel will go into the default mode.
F - 160 Operation and Maintenance Manual CAUTION If you accidentally press SAVE at any time, the old parameters will be replaced with the new parameters. Safety INFORMATION Density of the substrate will determine the amount of pressure you may use. INFORMATION INFORMATION You should store each job location with its parameters on the chart provided in Figure 5.4.1 CAUTION Sharp edges on a substrate should be filed smooth and GAP manually adjusted.
Safety F - 160 Operation and Maintenance Manual CAUTION If not installed properly, you can be injured or cause damage to the table or laminator. CAUTION Sharp edges on a substrate should be filed smooth and GAP manually adjusted. Sharp edges can CUT the rollers! WARNING 1.5 Applications The following symbols are positioned at various points in Section 6 Applications. WARNING Do not wear ties, loose fitting clothing or dangling jewelry while operating or servicing the laminator.
F - 160 Operation and Maintenance Manual CAUTION Ensure the roll of mount adhesive is loaded properly on the unwind shaft. Exposed adhesive should be facing away from the rollers. This will prevent hours of roll cleaning! WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP. You can be CRUSHED or BURNED! INFORMATION If the thickness of the substrate is not known, follow the procedure to manually set the nip in Section 5.5.1 Manually nip adjustment.
Safety F - 160 Operation and Maintenance Manual INFORMATION PRESSURE will vary with the thickness and width of the laminate you are using. Adjust as necessary. INFORMATION When requiring top and bottom heat, it is recommended to set both temperatures to the same set point. INFORMATION INFORMATION The leading edge is the first part of the board or image that enters the nip of the rollers.
F - 160 Operation and Maintenance Manual INFORMATION Avoid tacking at the ends first and pressing towards the center, you may create a tunnel once you have reached the center. This will make for a difficult mounting application. Safety WARNING Keep hands and fingers clear of the pull roller nip when changing the gap. You can be CRUSHED! INFORMATION INFORMATION If the board is not squarely positioned, you may experience difficulties with this application.
Safety F - 160 Operation and Maintenance Manual 1.6 Troubleshooting CAUTION The following symbols are positioned at various points in Section 7 Troubleshooting. Prolonged contact can form flat spots on the rollers. 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.
F - 160 Operation and Maintenance Manual INFORMATION Below is a recommended maintenance schedule. Before performing any of the steps listed, read through the procedures first. Please follow the instructions pertaining to the step you are performing. Safety CAUTION Excessive pressure can destroy the silicone layer by pressing to hard or scrubbing too long in one spot. CAUTION ELECTRICAL SHOCK Remove power from the laminator before servicing. You can be severely shocked, electrocuted or cause a fire.
Safety F - 160 Operation and Maintenance Manual CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. WARNING Keep hands and fingers clear of the laminator roller nip when adjusting PRESSURE. You can be CRUSHED or BURNED! 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.
F - 160 Operation and Maintenance Manual Safety 1.8 Label locations Cautions / Warning Label Locations ! WARNING ! ACHTUNG ! MISE EN GARDE Posted at various locations on the Falcon 160 Laminator are important safety labels. Pay careful attention to these labels at all times! Figure 1.8.1 illustrates the location of each of these labels. ! WARNING ! ACHTUNG Chain Pinch Point: Exercise extreme caution when working around this area. Moving chains and sprockets are present.
Safety F - 160 Operation and Maintenance Manual Figure 1.8.
F - 160 Operation and Maintenance Manual Section 2 Warranty GBC Pro-Tech 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 Pro-Tech and connot be modified or amended.
Warranty F - 160 Operation and Maintenance Manual 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 be of competent nature, trained and qualified to GBC Pro-Tech standards to fulfill that job. This person will have completed and passed the full service training course from GBC Pro-Tech.
Specifications F - 160 Operation and Maintenance Manual Section 3.1 General Description : • Mid level, wide format color finisher for the sheet fed ink jet market. The Falcon 160 is a self standing, bi directional laminator..
Specifications Section 3.3 F - 160 Operation and Maintenance Manual Function Speed : • 0 - 15 ft / min ( 0 - 4.6 m / min ) Motor : • 2-1/4 horse power drive motor • Bi-directional D.C. motor Heating Capabilities : • 68oF - 290oF ( 20oC - 143oC ) Controls : • Front control panel • Variable speed footswitch Job Save : • Save up to 9 job parameters Roll Design : • High release silicone rolls Section 3.4 Electrical Requirements United States : • 230 - 240 VAC, 50/60 Hz, single phase, 55 amps.
Specifications F - 160 Operation and Maintenance Manual Section 3.5 Dimensions Weight : • Crated : 1568 lbs. ( 711 kg. ) • Uncrated : 1200 lbs. ( 544 kg. ) Dimensions : • 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 96 cm (W) x 209 cm (L) ) Refer to Figure 3.5.1 Nip Height : • 37 3/16 in. ( 95 cm ) Safety Shield Raised Height : • 66 5/8 in. ( 169 cm) Figure 3.5.1 Dimensions 82.
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Installation F - 160 Operation and Maintenance Manual Section 4 Installation GBC Pro-Tech is committed to a program of ongoing product improvement. As a result, we are providing these instructions so that you can insure that your new Falcon 160 Laminator is properly and securely unpacked, moved, and installed. Before a Falcon 160 Laminator can be installed, there are a few requirements that must be met.
F - 160 Operation and Maintenance Manual Installation The laminator requires 230 to 240 vac, 50/60 Hz, 55 amps. Or, in Europe only, 3-N phase, 220 vac, 32 amps per phase. WARNING Be sure to follow the correct wiring diagram when supplying power to the laminator. If improperly connected, you can be seriously injured or cause damage to the laminator. Figure 4.1.2 illustrates proper wiring for single phase for the U.S.. Figure 4.1.3 illustrates proper wiring for Wye 3 phase for Europe.
F - 160 Operation and Maintenance Manual Figure 4.1.1 Installation Suggested Floor Layout 4' x 6' ( 1.22 m x 2m ) Work table on wheels 8.4' ( 2.57 m ) Table height 35-3/4" ( .94 - .95m ) 82.5" ( 209 cm ) 20' ( 6m) 38" ( 96 cm ) 8.4' ( 2.57m ) 3' ( 1 m) 4' x 6' ( 1.22 m x 2m ) Work table on wheels Table height 35-3/4" ( .94 - .
F - 160 Operation and Maintenance Manual Installation Figure 4.1. 2 Single phase, U.S. TB 2 L2 L1 G TB 1 Incoming line voltage Figure 4.1.
Installation F - 160 Operation and Maintenance Manual 4.2 Unpacking With regards to your shipping methods, use one of the following procedure described to safely and properly unwrap / uncrate your laminator. INFORMATION A L L S H I P M E N T S A R E E X - W O R K S . 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.
F - 160 Operation and Maintenance Manual Installation Figure 4.4.1 4.4 Crated Disassembling of the crate Tools required • # 2 Phillips head screwdriver • 7/8” open end wrench or adjustable wrench • Crow bar • A second person 1 3 5 Pl a n e 4 P al n e 4 Pl a n e 4 To uncrate the laminator 4 2 a) Remove the top of the crate and then the sides in the order shown in Figure 4.4.1 CAUTION Do not allow the top to fall into the crate. It can damage the laminator.
Installation F - 160 Operation and Maintenance Manual Moving the laminator WARNING a) Have the laminator rolled off the skid and placed on the floor by licensed riggers. The ramps included with the laminator can be secured utilizing screws removed from the disassembled crate. Figure 4.4.2 illustrates positioning of the ramps. The Falcon 160 Laminator is a large and heavy piece of equipment. It is necessary to employ LICENSED RIGGERS ONLY to move the laminator.
F - 160 Operation and Maintenance Manual Installation c) Remove all packing materials to a safe distance from the laminator and dispose of properly. If you are missing any of the itemslisted above, contact your local service technician or sales representative. d) Use two people to carefully roll the laminator to the desired location. 4.6 Leveling INFORMATION About recycling: The crate components can be reused for shipping the laminator again or can be disassembled and the wood and screws recycled.
Installation F - 160 Operation and Maintenance Manual b) Attach one leveling pad to each one of the four foot bolts near the castors. Refer to Figure 4.6.1 b) Level the control side from front to back. INFORMATION Figure 4.6.1 Foot bolts A second person can read the level while you make the appropriate adjustments. c) Position the level on the top of the drive side frame. Not on the cabinet. Foot bolts d) Level the drive side from front to back. Leveling pads s t Figure 4.6.
F - 160 Operation and Maintenance Manual Installation e) Ensure that nothing is in the path of the main roll nip. WARNING f) Confirm that power is supplied to the laminator. g) Turn the MAIN POWER to “ON” position. Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! i) Raise the front safety shield. The SAFETY indicator will begin flashing. Main Power 00.0 FWR GO REV.
Installation F - 160 Operation and Maintenance Manual k) Place the level across the top of the upper main roll in the center. Refer to Figure 4.6.4 o) Remove the level. p) Lower the front safety shield. Figure 4.6.4 Left to right q) Turn MAIN POWER to “OFF “. Level Plane4 Plane4 4.7 Safety check The safety check will ensure that all safety devices and interlock switches are functioning properly. l) Level the machine from left to right. WARNING m) Verify your adjustments when finished.
F - 160 Operation and Maintenance Manual Installation 4.7.1 Front and rear infeed tables d) Press FWD s to set a forward motor direction. a) Turn MAIN POWER to “ON” . 00.0 FWR GO REV. SPEED Main power SAFETY STOP e) Press SPEED s to set a speed of 6 ft/min. b) Press RESET. The front control panel will be illuminated. Reset 6.0 FWR GO REV. SPEED SAFETY STOP f) Press GO. The bottom rollers will begin to turn. c) Press SEL. The SEL key should stop flashing. 6.0 JOB 0 SEL SAV FWR GO REV.
Installation F - 160 Operation and Maintenance Manual g) Slightly lift the front infeed table. SAFETY indicator and GO begin flashing and the bottom rollers stop. 6.0 FWR GO REV. SPEED SAFETY j) Press GO. The bottom rollers begin turning. 6.0 REV. SPEED SAFETY STOP FWR GO STOP = Flashing h) Lower the front infeed table.SAFETY indicator reverts to white and GO remains flashing. k) Slighly lift the rear infeed table. SAFETY indicator and GO begin flashing and the bottom rollers stop. 6.0 6.
F - 160 Operation and Maintenance Manual Installation m) Press STOP. GO stops flashing. 6.0 FWR GO REV. SPEED SAFETY b) Raise the front safety shield. SAFETY indicator and GO begin flashing and the bottom rollers stop. STOP 6.0 FWR GO REV. SPEED SAFETY STOP = Flashing 4.7.2 Front and rear safety shields h) Lower the front safety shield. SAFETY indicator reverts to white and GO remains flashing. a) Press GO. The bottom rollers begin turning. 6.0 FWR GO REV. SPEED SAFETY 6.
Installation F - 160 Operation and Maintenance Manual j) Press GO. The bottom rollers begin turning. 6.0 SAFETY FWR 6.0 REV. SPEED GO SPEED l) Lower the rear safety shield. SAFETY indicator reverts to white and GO remains flashing. STOP SAFETY FWR GO REV. STOP = Flashing WARNING Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! m) Press STOP. GO stops flashing. 6.0 FWR GO REV.
F - 160 Operation and Maintenance Manual Installation b) Press down on the control side E-STOP. The E-STOP latches in the down position, bottom rollers stop, and the control panel is blank e) Press SEL. SEL stops flashing. Push JOB 0 SAV SEL SHUT DOWN f) Press FWD s for a forward motor direction. c) Unlatch the E-STOP as illustrated below. Unlatch 00.0 FWR GO REV. SPEED SAFETY d) Press RESET. The front control panel is illuminated. STOP g) Press SPEED s to a speed of 6 ft/min. RESET 6.
Installation F - 160 Operation and Maintenance Manual h) Press GO. The bottom rollers will begin to turn. k) Press RESET. The front control panel is illuminated. RESET FWR 6.0 GO REV. SPEED SAFETY STOP i) Press down on the drive side E-STOP. The ESTOP latches in the down position, bottom rollers stop, and the control panel is blank. 4.8 Function check Push The function check ensures that the laminator functions properly when operating. This check is recommended before performing any applications.
F - 160 Operation and Maintenance Manual Installation 4.8.1 Control panel a) Press TOP TEMP. s to a value of 120oF ( 48 oC ). TOP TEMP DISPLAY begins flashing. d) Press GAP s. GAP DISPLAY increases 1/16th of an inch per press. The upper main roll moves accordingly. Once to “1”, the upper main roller stops. GAP SLEEP TOP TEMP. 120 0-1 BOT. TEMP 68 b) Press BOT TEMP s to a value of 120oF ( 48 oC ). BOT TEMP DISPLAY begins flashing. SLEEP TOP TEMP. 120 1-0 e) Press and hold PRESSURE t.
Installation F - 160 Operation and Maintenance Manual g) Press JOB s. The JOB DISPLAY should increases in increments of 1 to 9. INFORMATION To continue with the function checks, you must press SEL so that it discontinues flashing. JOB 9 SEL SAV SHUT DOWN j) Press SPEED s once. SPEED DISPLAY increases in increments of .5 per press up to 15. h) Press JOB t . The JOB DISPLAY should decreases in increments of 1 from 9 to 0. 15 FWR GO REV.
F - 160 Operation and Maintenance Manual Installation l) Press GO. The bottom rollers turn in a forward motion at a speed of 15 ft./min. ( 4.57 m / min. ). 15 FWR GO REV. SPEED SAFETY o) Press GO. The bottom rollers turn in a reverse motion at a speed of 15 ft./min. ( 4.57 m / min. ). 15 FWR GO REV. SPEED STOP SAFETY STOP p) Press STOP. The bottom rollers stop turning. m) Press STOP. The bottom rollers stop turning. 15 FWR GO SAFETY STOP n) Press REV t .
Installation F - 160 Operation and Maintenance Manual r) The TOP TEMP DISPLAY and BOT TEMP DISPLAY are solid indicating the actual temperature is within a +/- 10oF of the set point temperature. SLEEP TOP TEMP. 120 u) Press SHUTDOWN. The laminator reverts to the default settings and SLEEP is solid. Refer to Figure 4.8.1 JOB BOT. TEMP SAV SEL 0 SHUT DOWN 120 Figure 4.8.1 Default settings WARNING Caution should always be exercised when using the laminator with the safety shields raised.
F - 160 Operation and Maintenance Manual Installation c) Press down on the variable speed footswitch. GO begins flashing and the bottom rollers are turning. 4.8.2 Variable speed footswitch This check is to ensure that the footswitch works. For complete instructions on the footswitch and its relation to “Footswitch” mode to “ Panel” mode, refer to Section 5.1 Controls / ( 28 ) Footswitch. ATTUNG WARNING ADVERTENCIA a) Press SEL on the front control panel to “wake” the laminator from SLEEP mode.
Installation F - 160 Operation and Maintenance Manual INFORMATION WARNING Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! Steps " e" and " f" will be performed simultaneously. e) With one hand, slowly turn the upper unwind shaft in either direction. a) Raise the rear safety shield. b) Lift the clevis pin up from the saddle of the upper unwind shaft.
F - 160 Operation and Maintenance Manual Installation h) Slowly turn the upper unwind brake adjustment knob counter clockwise. i) You should feel a decrease in resistance on the turning of the upper unwind shaft as you turn the upper unwind brake adjustment knob counter clockwise. j) Lower the rear safety shield. k) Now perform steps “b” through “h” again for the lower unwind shaft.
Operations F - 160 Operation and Maintenance Manual Section 5 Operations The operator control panel for the Falcon 160 Laminator is located on the front of the machine, to the right of the front operating position. ( 2 ) TOP TEMP DISPLAY : The display will show the set point temperature of the top main roller as the default display. When the top roller temperature has reached in the +/- 10oF range of the set point, the display will be solid. When outside of this range, the display will flash.
Operations F - 160 Operation and Maintenance Manual ( 5 ) BOT. TEMP. DISPLAY : 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 +/- 10oF range of the set point, the display will be solid. When outside of this range, the display will flash. ( 8 ) GAP DISPLAY : Displays the current main roller nip opening. The nip has a range of 0 to 1” gap. GAP PRESSURE 1/4 SLEEP TOP TEMP. 8 BOT.
Operations F - 160 Operation and Maintenance Manual ( 11 ) PRESSURE DISPLAY : Displays the amount of pressure being used. Each bar represents 10% of the maximum allowable pressure. All ten bars illuminated equals 100% of the maximum allowable pressure. GAP ( 13 ) PRESSURE t : When pressed once, will increase the pressure by 5%. If held down, it will increase from 0% of the minimum allowed pressure to 100% at which point all bars will be illuminated.
Operations F - 160 Operation and Maintenance Manual ( 15 ) JOB s : When pressed once will increase the job number in JOB DISPLAY by increments of 1. If pressed and held, the JOB DISPLAY will increase to 9 at which point it will stop. ( 18 ) SAVE : When pressed, will save the current settings for the number showing in the JOB DISPLAY. For more information, refer to Section 5.4 Job Programming on how to save parameters.
F - 160 Operation and Maintenance Manual Operations ( 21 ) SPEED s: When pressed, increases the speed of the laminator in increments of 0.5 ft/min. When pressed and held, speed will automatically increase by 0.5 ft/min increments until it has reached the maximum allowed speed of 15 ft/min. ( 24 ) STOP : When pressed, stops the rollers and GO becomes white. FWR 21 6.5 GO REV. SPEED FWR 6.5 STOP SAFETY GO REV.
Operations F - 160 Operation and Maintenance Manual ( 27 ) SAFETY : Begins flashing anytime the front or the rear safety shield is in the raised position. This is an indication for the operator to be very careful when operating the laminator in the “Footswitch” mode. FWR 6.5 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. Perform the following steps; GO REV.
Operations F - 160 Operation and Maintenance Manual • Press and hold the variable speed footswitch down. • Press and hold GO for 3 -4 seconds before releasing the variable speed footswitch. • Release the variable speed footswitch. • Press and hold on the variable speed footswitch. ( approximately 1/2 the travel distance of the variable speed footswitch ) CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. • Release GO. GO should be solid.
Operations F - 160 Operation and Maintenance Manual • Adjust for desired speed using the variable speed footswitch. INFORMATION Footswitch 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 speed setting. • Press and hold GO for 3 -4 seconds before releasing the variable speed footswitch. • Release the variable speed footswitch. • Release GO.
Operations F - 160 Operation and Maintenance Manual Figure 5.1.1 Front control panel 3 1 4 5 11 SLEEP TOP TEMP. BOT. TEMP 68 68 GAP PRESSURE 2 9 8 6 7 12 13 1 17 10 14 JOB 16 SAV SEL 0 19 SHUT DOWN 21 20 18 FWR 00.0 15 25 GO REV.
Operations F - 160 Operation and Maintenance Manual 5.2 Emergency The F-160 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 or servicing the unit. GBC Pro - Tech laminators are powerful machines that are designed to mount, laminate, and encapsulate.
Operations F - 160 Operation and Maintenance Manual d) Press RESET at the rear of the machine on the drive side Please refer to Figure 5.2.2 Figure 5.2.2 RESET Reset 5.3 Set up Initial set up of the Falcon 160 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 understanding of this section will enable you to follow the procedures descibed in Section 6.
Operations F - 160 Operation and Maintenance Manual d) Press RESET. The front control panel will illuminated. c) Swing the unwind shaft out enough to slide the roll of laminate over the core chucks and onto the unwind shaft. Refer to Figure 5.3.2 Reset INFORMATION Twisting the roll of film while sliding makes loading the film onto the unwind shaft easier. Figure 5.3.2 Unwind shaft Brake adjust knob Saddle Core support 5.3.
Operations F - 160 Operation and Maintenance Manual e) Push the clevis pin back down to secure the unwind shaft its saddle. f) Now you must center the roll of laminate on the unwind shaft. Refer to Figure 5.3.3 for measurements. For centering measurements, refer to Figure 5.5.4. g) For the lower unwind shaft, repeat steps “b” through “f” again. Figure 5.3.3 Centering the roll Figure 5.3.4 Measurement chart Common film widths Film width Measurement 12 " 24 " 28 " 22 " 31 " 18.5 " 37 " 38 " 15.
Operations F - 160 Operation and Maintenance Manual a) Press TOP TEMP. s to set your upper roller temperature. SLEEP TOP TEMP. BOT. TEMP INFORMATION Do not add PRESSURE when heating the laminating rollers, this allows the high release silicone to expand with minimum restrictions. 68 68 b) If required, press BOT. TEMP. s to set your lower roller temperature. d) Press FWD s to set a forward motion direction. FWR 0 SLEEP TOP TEMP. 68 GO REV. SPEED BOT.
Operations F - 160 Operation and Maintenance Manual f) Press SEL to engage the parameters. JOB 0 SAV SEL 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. SHUT DOWN a) Follow the prcedure in Section 5.3.1 Power. g) Press GO to engage the motor drive system. INFORMATION 2.0 FWR GO REV.
Operations F - 160 Operation and Maintenance Manual c) If heat is required, press TOP TEMP. s and BOT. TEMP. s to desired settings. If no heat is required, leave the settings at 68 oF ( 20 oC ). e) Enter a desired speed by pressing SPEED s. FWR 3.5 SLEEP TOP TEMP. 68 GO REV. SPEED BOT. TEMP SAFETY STOP 68 f) Press SAVE to store the parameters in the job location selected. WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP.
Operations F - 160 Operation and Maintenance Manual Figure 5.4.1 Job save chart JOB # TOP TEMP. BOT. TEMP. GAP 5.5.1 Main roller manual nip adjustment SPEED 1 2 a) Turn the MAIN POWER to the “ON” position. 3 Power 4 5 6 7 8 9 b) Press RESET. The front control panel will illuminated. 5.5 Manual nip adjustment Reset If the substrate does not fall with in the preset GAP settings available, a manual nip setting must be performed.
Operations F - 160 Operation and Maintenance Manual c) Raise the front safety shield. f) At eye level with the main rollers, press PRESSURE t until you see the upper main roller make contact with the substrate. d) Press SEL. GAP PRESSURE 0 JOB 0 SAV SEL SHUT DOWN = Flashing CAUTION Excess pressure can damage the laminating rollers. Always use the minimum roll pressure necessary to complete the task. e) Position the leader board in the center of the main rollers between the nip.
Operations F - 160 Operation and Maintenance Manual Figure 5.5.1 Main roller pressure h) Step on the variable speed footswitch to back the leader board out. Leader board Proper pressure CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. i) The main roller nip has now been manually set. Leader board Excessive pressure j) Press STOP. 0.00 FWR GO REV. SPEED g) Press REV t for a reverse motor direction. 00.0 FWR GO REV.
Operations F - 160 Operation and Maintenance Manual k) You may now begin mounting from the front operating position. 5.5.2 Pull roller manual nip adjustment c) Press SEL. JOB 0 SAV SEL SHUT DOWN = Flashing INFORMATION If the main laminating rollers are heated, mounting application may be run from the rear operating position of the machine. a) Turn the MAIN POWER to the “ON” position. d) Press FWD s for a forward motor direction. 00.0 FWR GO REV.
Operations F - 160 Operation and Maintenance Manual f) Raise the rear safety shield. CAUTION g) Position the leader board in the center of the pull rollers between the nip. Excess pressure can damage the laminating rollers. Always use the minimum roll pressure necessary to complete the task. CAUTION Sharp edges on a substrate should be filed smooth and GAP manually adjusted. Sharp edges can CUT the rollers! INFORMATION Excessive pressure will cause the substrate to bow or flatten.
Operations F - 160 Operation and Maintenance Manual Figure 5.5.2 Pull roller pressure CAUTION Leader board Proper pressure Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. h) The pull roller nip has now been manually set. i) Press STOP. Leader board Excessive pressure 0.00 FWR GO REV. SPEED SAFETY STOP j) Press REV t for a reverse motor direction.
Operations F - 160 Operation and Maintenance Manual 5.6 Infeed tables These tables are part of the Falcon 160 safety features. It is neccessary to have the two infeed tables properly positioned before running the laminator. Figure 5.6.1 Front edge Front edge CAUTION If not installed properly, you can be injured or cause damage to the table or laminator. 5.6.1 Removing the table WARNING Caution should always be exercised when using the laminator with the safety shields raised.
Operations F - 160 Operation and Maintenance Manual c) Now lower the front edge while ensuring that the pin aligns with the safety roller switch and the back support bolt. Refer to Figure 5.6.3 INFORMATION If the tables are not properly seated, the laminator will not operate in "Panel" mode. Figure 5.6.
Applications F - 160 Operation and Maintenance Manual Section 6 Applications 6.1 Precoating substrates To 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 control settings for each application with regards to your products.
F - 160 Operation and Maintenance Manual Applications Figure 6.1.1 MAIN POWER / RESET CAUTION Sharp edges on a substrate should be filed smooth and GAP manually adjusted. Sharp edges can CUT the rollers! RESET b) Place these two pieces by the laminator for future use. the of r a Re tor na i lam MAIN POWER INFORMATION The two pieces cut in step "a" will be used as the leader board and trailer board. These two pieces can be saved and reused for other applications.
Applications F - 160 Operation and Maintenance Manual Figure 6.1.2 Unwind shaft WARNING Saddle Clevis pin Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! Roll of adhesive Core support INFORMATION Brake adjust knob Core chucks If you have the parameters stored as a JOB number enter it now then press SEL and skip to step " o ", other wise continue with step " l".
F - 160 Operation and Maintenance Manual Applications WARNING CAUTION Sharp edges on a substrate should be filed smooth and GAP manually adjusted. Sharp edges can CUT the rollers! m) Press GAP t to the required gap setting for the substrate being used. The GAP DISPLAY should reflect your desired setting. When operating the laminator using the variable speed footswitch, keep hands and fingers away from the nip of the rollers.
Applications F - 160 Operation and Maintenance Manual INFORMATION Excessive pressure will cause the substrate to bow or flatten. CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. q) Press STOP. Process 00.0 FWR GO REV. SPEED SAFETY STOP r) Press REV t to reverse the direction of the motor. 00.0 FWR GO Figure 6.1.3 Leader board Mount adhesive Leader board REV.
F - 160 Operation and Maintenance Manual Applications c) Press STOP. e) Push the leader board into the main roller nip while stepping on the variable speed footswitch. FWR 00.0 GO REV. SPEED SAFETY STOP CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. d) Press FWD s. f) Apply the minimum amount of brake tension on the roll of mount adhesive to prevent it from free spinning. FWR 00.0 GO REV.
Applications F - 160 Operation and Maintenance Manual 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! h) With the stack of substrates within reach of the first person, step on the variable speed footswitch while sliding one board in after the leader board with a 1/2 in. gap between the two. Refer to Figure 6.1.4 The 1/2 in.
F - 160 Operation and Maintenance Manual Applications Figure 6.1.5 Trailer board CAUTION Caution should always be exercised when using a knife . Sharp knife can cut you! Precoated board Trailer board CAUTION Caution should always be exercised when using a utility knife near the rollers. You can put cuts into the rollers! m) Stop the laminator when the trailer board is in the main roller nip. Refer to Figure 6.1.
Applications F - 160 Operation and Maintenance Manual Finishing d) Remove the roll of material from the upper unwind shaft. a) Cut the web of mount adhesive at the upper unwind shaft with an enclosed blade. e) Press STOP. CAUTION Do not use an open blade to cut the web near the rollers. You can put cuts into the rollers! b) Pull the precoated board and trailer board out from the laminator. INFORMATION This will prevent any exposed adhesive from contacting the rollers. 00.0 REV.
F - 160 Operation and Maintenance Manual Applications Figure 6.2.1 MAIN POWER / RESET 6.2 Mounting only RESET This application may be performed from the front of the laminator using the main rollers or from the rear of the laminator using the pull rollers in the event the main rollers are heated. This application is explained in detail using the main rollers from the front of the laminator. Use Chart 2 and Diagram 2 for assistance.
Applications F - 160 Operation and Maintenance Manual e) Press SEL. SEL will stop flashing. WARNING JOB 0 SAV SEL 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! SHUT DOWN WARNING h) Press on the variable speed footswitch while guiding the leader board into the nip to confirm that the board is secure. Keep hands and fingers clear of the laminator roller nip when changing GAP.
F - 160 Operation and Maintenance Manual Applications WARNING CAUTION Excess pressure can damage the laminating rollers. Always use the minimum roll pressure necessary to complete the task. INFORMATION 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) Press on the variable speed footswitch to back the board out of the main rollers. Excessive pressure will cause the substrate to bow or flatten.
Applications F - 160 Operation and Maintenance Manual INFORMATION The leading edge is the first part of the board or image that enters the nip of the rollers. - If the image is larger , you must trim the image so that no more than 1 in. exceeds the precoated board all the way around. Refer to Figure 6.2.4 Figure 6.2.4 Trim the image Cut b) Place a padded paper weight or similar object in the center of the image to help hold the image in place.
F - 160 Operation and Maintenance Manual Applications d) From the center, use one finger to tack down the leading edge of the image to the leading edge of the precoated board. Refer to Figure 6.2.6 f) Press STOP. 00.0 FWR GO REV. SPEED SAFETY STOP INFORMATION The leading edge is the first part of the board or image that enters the nip of the rollers. g) Press FWD s. Figure 6.2.6 Tack leading edge 00.0 FWR GO REV.
Applications F - 160 Operation and Maintenance Manual Figure 6.2.7 Draping the image INFORMATION Use a slow speed. If the tack point enters the rollers nip, you will not be able to pull the release liner. Upper Main Roll Image Release liner Pre-coated board - If the tack point enters the rollers nip perform the following steps then continue with this procedure. k) Make sure the image is conformed to the upper main roller. Refer to Figure 6.2.
F - 160 Operation and Maintenance Manual Applications - If it is not, slowly move the board into the nip until the image is conformed. Refer to Figure 6.2.9 l) Press down on the variable speed footswitch just enough to give yourself a comfortable work speed. CAUTION CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. Figure 6.2.
Applications F - 160 Operation and Maintenance Manual Finishing a) Raise the main rollers to a 1 in. gap by pressing GAP s. GAP 6.3 Single sided lamination ( Sled method ) This application may be performed from the front of the laminator using the main rollers or from the rear of the laminator using the pull rollers in the event the main rollers are heated. This application is explained in detail using the main rollers from the front of the laminator. Use Chart 3 and Diagram 3 for assistance.
F - 160 Operation and Maintenance Manual Applications b) Press RESET. Refer to Figure 6.3.1 Figure 6.3.1 MAIN POWER / RESET e) Lift the clevis pin located in the saddle of the upper unwind shaft. Saddle Clevis pin RESET R r ea th of el a na mi f) Swing the upper unwind shaft out enough to slide the roll of laminate over the core chucks on the upper unwind shaft. Refer to Figure 6.3.
Applications F - 160 Operation and Maintenance Manual g) Once loaded, swing the upper unwind shaft back into the saddle. WARNING CAUTION Ensure the roll of laminate is loaded properly on the unwind shaft. Exposed adhesive should be facing away from the rollers. This will prevent hours of roll cleaning! h) Push the clevis pin back down to secure the unwind shaft in its saddle. Keep hands and fingers clear of the laminator roller nip when changing GAP.
F - 160 Operation and Maintenance Manual Applications k) Press SEL. WARNING JOB 0 SAV SEL SHUT DOWN Keep hands and fingers clear of the laminator roller nip when adjusting PRESSURE. You can CRUSHED or BURNED! l) Press FWD s. n) If the board is loose, press PRESSURE t to adjust the gap between the main rollers. 00.0 FWR GO REV. SPEED SAFETY STOP GAP PRESSURE 1/4 WARNING When operating the laminator using the variable speed footswitch, keep hands and fingers away from the nip of the rollers.
Applications F - 160 Operation and Maintenance Manual o) Press STOP. 00.0 Process FWR GO REV. SPEED SAFETY a) Pull the laminate to the upper rewind tube. Refer to Figure 6.3.3 STOP CAUTION p) Press REV t to reverse the direction of the motor. 00.0 FWR GO REV. SPEED SAFETY Make note of the rewind tube drive direction when taping the laminate. The laminate should separate under the rewind tube. STOP Figure 6.3.
F - 160 Operation and Maintenance Manual Applications Figure 6.3.4 Laminate separation INFORMATION Release liner Do not cut too deeply into the laminate, you can cut into the release liner. Precoated board Laminate d) With the utility knife, make an incision across the width of the laminate. CAUTION CAUTION Caution should always be exercised when using a knife . Sharp knife can cut you! e) Pull the laminate straight down toward the front infeed table so that about 6 in.
Applications F - 160 Operation and Maintenance Manual Figure 6.3.5 Separation point INFORMATION Steps " i" and " j" will be performed simultaneously. Laminate Separation point 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! k) Once you have the brake tension set and the laminate looks smooth entering the main roller, release the variable speed footswitch.
F - 160 Operation and Maintenance Manual Applications m) Press on the variable speed footswitch. Finishing a) Cut the web of laminate at the upper unwind shaft with an enclosed blade. CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. CAUTION Do not use an open blade to cut the web near the rollers. You can put irreparable cuts into the rollers.
Applications F - 160 Operation and Maintenance Manual d) Press STOP. 6.4 Single sided lamination ( Craft paper method ) 00.0 FWR GO REV. SPEED SAFETY STOP This application may be performed from the front of the laminator using the main rollers or from the rear of the laminator using the pull rollers in the event the main rollers are heated. This application is explained in detail using the main rollers from the front of the laminator. Use Chart 4 and Diagram 4 for assistance.
F - 160 Operation and Maintenance Manual Applications b) Press RESET. Refer to Figure 6.4.1 e) Lift the clevis pin located in the saddle of the upper unwind shaft. Saddle Figure 6.4.1 MAIN POWER / RESET Clevis pin RESET the of r a Re f) Swing the upper unwind shaft out enough to slide the roll of laminate over the core chucks on the upper unwind shaft. Refer to Figure 6.3.
Applications F - 160 Operation and Maintenance Manual g) Once the roll of laminate is on the upper unwind shaft, swing the upper unwind shaft back into the saddle. INFORMATION Twisting the roll of craft paper while sliding makes loading the film onto the unwind shaft easier. CAUTION Ensure the roll of laminate is loaded properly on the unwind shaft. Exposed adhesive should be facing away from the rollers.
F - 160 Operation and Maintenance Manual Applications c) Use a piece of masking tape, to adhere the leading edge of the laminate to the upper rewind tube. Process a) Apply just enough brake tension to prevent the roll of laminate from free spinning. d) Wrap one full turn of laminate onto the upper rewind tube. INFORMATION Excessive brake tension may cause the image to curl when separated from the craft paper. CAUTION Do not cut too deeply into the laminate, you can cut into the release liner.
Applications F - 160 Operation and Maintenance Manual Figure 6.4.4 Laminate separation Laminate Figure 6.4.5 Craft paper Laminate Craft paper Remove h) Apply just enough brake tension to prevent the roll of craft paper from free spinning. INFORMATION 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 Excessive brake tension may cause the image to curl when separated from the craft paper.
F - 160 Operation and Maintenance Manual Applications k) Press GAP t to enter a 0 in. gap setting. n) Press on the variable speed footswitch to guide the cardboard, craft paper and laminate through the main rollers. PRESSURE GAP 0 CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. l) Press FWD s WARNING FWR 00.0 GO REV. SPEED SAFETY STOP INFORMATION Steps " m " and " n " will be performed simultaneously.
Applications F - 160 Operation and Maintenance Manual INFORMATION WARNING Keep hands and fingers clear of the pull roller nip when changing the gap. You can be CRUSHED! p) Once the cardboard has passed through the pull rollers, lower the upper pull roller onto the web. Turn the pull roll crank handle 3/4 turn clockwise after you feel the initial contact. Refer to Figure 6.4.6 If you choose to use the lower rewind tube, make note of the direction of travel. Figure 6.4.
F - 160 Operation and Maintenance Manual Applications CAUTION v) Press SPEED s to a speed you feel comfortable working with. It is recommended that SPEED not exceed 9 ft./ min. ( 2.74 m/ min. ) . Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. 9.0 s) Replace the front infeed table. Ensure that the table is seated properly. t) Close the front and rear safety shields. INFORMATION FWR GO REV. SPEED SAFETY STOP w) Press GO. 9.
Applications F - 160 Operation and Maintenance Manual y) After the last print has passed through the pull rollers, press STOP. 9.0 FWR GO REV. SPEED SAFETY STOP z) Press GAP s to a 1 in. setting. GAP c) If you used the lower rewind, remove the rewind tube and bring it to a trimming station. Replace the rewind tube when finished. PRESSURE d) Raise the front and rear safety shields to the up position.
F - 160 Operation and Maintenance Manual Applications h) Remove the web from the front of the laminator and the rolls of material from the upper and lower unwind shafts. INFORMATION This will prevent any exposed adhesive from contacting the rollers. i) Clean the rollers as described in the maintenance section. ( Section 8.2 Cleaning the rollers ) j) Replace the front infeed table. k) Lower the front and rear safety shields and press SHUTDOWN if finished with the laminator. 6.
Applications F - 160 Operation and Maintenance Manual Materials needed • Roll of pressure sensitive over laminate • Roll of mount adhesive ( same width as the laminate ) • Print ( smaller than the laminate ) • Roll of masking tape • Utility knife • Cutting blade with an enclosed casing. • Piece of cardboard ( film width x 6” ) Set up d) Raise the front and rear safety shields. WARNING Caution should always be exercised when using the laminator with the safety shields raised.
F - 160 Operation and Maintenance Manual Applications j) Lift the clevis pin located in the saddle of the lower unwind shaft. Figure 6.5.2 Unwind shaft Saddle Clevis pin Saddle Clevis pin Core support Roll of laminate Brake adjust knob Core chucks g) Once the roll of laminate is on the upper unwind shaft, swing the upper unwind shaft back into the saddle. k) Swing the lower unwind shaft out enough to slide the roll of mount adhesive over the core chucks on the lower unwind shaft.
Applications F - 160 Operation and Maintenance Manual m) Push the clevis pin back down to secure the unwind shaft in its saddle. CAUTION n) Center the upper roll and the lower roll of material on the unwind shafts. You may refer to your measurement chart in Section 5.3.2 Loading film ( Figure 5.3.4 ) Make note of the rewind tube drive direction when taping the laminate. The laminate should separate under the rewind tube. Figure 6.5.
F - 160 Operation and Maintenance Manual Applications e) With the utility knife, make an incision across the width of the laminate. INFORMATION Excessive brake tension may cause the output to curl. This can create complications with the second pass of this application. CAUTION Caution should always be exercised when using a knife . Sharp knife can cut you! i) Pull the mount adhesive up towards the upper main roller and tack it the laminate resting on the upper main roller. Refer to Figure 6.5.
Applications F - 160 Operation and Maintenance Manual l) Press FWD s INFORMATION 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". FWR 00.0 GO REV. SPEED SAFETY STOP j) Press SEL. INFORMATION JOB 0 SAV SEL Steps " m " and " n " will be performed simultaneously. SHUT DOWN m) Use a piece of cardboard to push the material into the nip of the main rollers.
F - 160 Operation and Maintenance Manual Applications CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. WARNING Keep hands and fingers clear of the laminator roller nip when adjusting PRESSURE. You can be CRUSHED or BURNED! WARNING Keep hands and fingers clear of the pull roller nip when changing the gap. You can be CRUSHED! p) Once the cardboard has passed through the pull rollers, lower the upper pull roller onto the web.
Applications F - 160 Operation and Maintenance Manual r) Tape the web to the lower rewind tube or let the web run out to a work table. Refer to Figure 6.5.6 - Press on the variable speed footswitch to lengthen the web enough to get one full wrap around the lower rewind tube. CAUTION INFORMATION If you choose to use the lower rewind tube, make note of the direction of travel. Figure 6.5.
F - 160 Operation and Maintenance Manual Applications v) Press SPEED s to a speed you feel comfortable working with. It is recommended that SPEED not exceed 9 ft./ min. ( 2.74 m/ min. ) . z) Press GAP s to a 1 in. setting. GAP PRESSURE 1 9.0 FWR GO REV. SPEED SAFETY STOP Finishing a) With an enclosed blade, cut the finished product from the web. w) Press GO. 9.0 FWR GO SPEED SAFETY STOP REV . x) Feed the images through the main rollers from the front operating position of the laminator.
Applications F - 160 Operation and Maintenance Manual WARNING Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! INFORMATION This will prevent any exposed adhesive from contacting the rollers. i) Clean the rollers as described in the maintenance section. ( Section 8.2 Cleaning the rollers ) e) Raise the pull roller up by turning the crank handle counter clockwise until the pull rollers are separated.
F - 160 Operation and Maintenance Manual Applications Materials needed CAUTION • Prints ( Decals ) • Substrates • Utility knife • Leader board ( substrate width x 6” ) Sharp edges on a substrate should be filed smooth and GAP manually adjusted. Sharp edges can CUT the rollers! INFORMATION Set up If the thickness of the substrate is not known, follow the procedure to manually set the nip in Section 5.5.1 Manually nip adjustment. a) Replace the front infeed table.
Applications F - 160 Operation and Maintenance Manual e) Press on the variable speed footswitch while guiding the leader board into the nip to confirm that the board is secure. INFORMATION Excessive pressure will cause the substrate to bow or flatten. CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. g) Press STOP. 00.0 WARNING FWR GO REV.
F - 160 Operation and Maintenance Manual Applications i) Press on the variable speed footswitch to back the leader board out of the main rollers. b) Is the decal compatible with the substrate? - If the substrate is larger than the decal, you can position the image any where on the board. Figure 6.5.8 CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. Figure 6.5.
Applications F - 160 Operation and Maintenance Manual c) Peel back about 1 in. of the release liner from the decal and fold back. Refer to Figure 6.5.10 Figure 6.5.10 Peel back release liner INFORMATION Avoid tacking at the ends first and pressing towards the center, you may create a tunnel once you have reached the center. This will make for a difficult mounting application. Leading edge Release liner f) Set the substrate and decal in the center of the front infeed table.
F - 160 Operation and Maintenance Manual Applications INFORMATION Steps " j" and " k " will be performed simultaneously. j) Push the leading edge of the substrate with the decal up to the nip of the main rollers. CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. - If the tack point enters the rollers nip perform the following steps.
Applications F - 160 Operation and Maintenance Manual m) Make sure the image is conformed to the upper main roller. Refer to Figure 6.5.13 CAUTION INFORMATION If the image is not conformed to the roller, you may experience difficulties with this application. Figure 6.5.13 Conformed print Upper Main Roll Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. Figure 6.5.
F - 160 Operation and Maintenance Manual Applications Finishing CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. a) Press STOP. 9.0 FWR GO REV. SPEED SAFETY STOP WARNING When the laminator rollers are in motion, keep hands and fingers away from the nip of the rollers. You may be CRUSHED or BURNED! b) Press GAP s to a 1 in. setting.
Applications F - 160 Operation and Maintenance Manual Group 2 : Top heat only Top heat only applications are very similar to the applications described in Group 1: No heat. Thermal type ( heat activated ) laminating film will replace the pressure sensitive type laminating film used in Group 1: No heat. The procedures and parameters described in this section are starting references only.
F - 160 Operation and Maintenance Manual Applications Figure 6.6.1 MAIN POWER / RESET INFORMATION The two pieces cut in step "a" will be used as the leader board and trailer board. These two pieces can be saved and reused for other applications. RESET the of r a Re c) Turn MAIN POWER to “ON”. Refer to Figure 6.6.1 tor na i lam MAIN POWER g) Lift the clevis pin located in the saddle of the upper unwind shaft. d) Press RESET. Refer to Figure 6.6.
Applications F - 160 Operation and Maintenance Manual Figure 6.6.2 Unwind shaft INFORMATION Saddle Clevis pin Core support Roll of Hot Tissue 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". l) Press SEL. SEL will stop flashing. Brake adjust knob Core chucks JOB 0 SAV SEL SHUT DOWN i) Once loaded, swing the upper unwind shaft back into the saddle.
F - 160 Operation and Maintenance Manual Applications o) Press SPEED s to set a motor speed of 2 ft. / min. ( .6 m / min. ) s) Press STOP. FWR 2.0 2.0 FWR GO SAFETY STOP STOP p) Press GAP t to enter a 0 in. gap setting. GAP REV. SPEED REV. SPEED SAFETY GO PRESSURE t) Press GAP s to the required gap setting for the substrate being used. The GAP DISPLAY should reflect your desired setting. GAP PRESSURE 1/4 0 q) Press GO.
Applications F - 160 Operation and Maintenance Manual u) Press on the variable speed footswitch while guiding the leader board into the nip to confirm that the board is secure. w) Press STOP. 00.0 CAUTION FWR GO REV. SPEED SAFETY STOP Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. x) Press REV t to reverse the direction of the motor. WARNING Keep hands and fingers clear of the laminator roller nip when adjusting PRESSURE.
F - 160 Operation and Maintenance Manual Applications INFORMATION CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. Position the leader board squarely onto the mount adhesive. c) Press STOP. Process a) Pull the roll of Hot Tissue straight down toward the front infeed table so that approximately 6 in. is resting on the front infeed table. Refer to Figure 6.6.3 GO REV. SPEED SAFETY STOP d) Press FWD s. Figure 6.6.
Applications F - 160 Operation and Maintenance Manual 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! INFORMATION Steps " h " and " i" will be performed simultaneously. WARNING e) Push the leader board into the main roller nip while stepping on the variable speed footswitch.
F - 160 Operation and Maintenance Manual Applications Figure 6.6.4 ( 1/2” ) Gap CAUTION Caution should always be exercised when using a knife . Sharp knife can cut you! Substrate 1/2" Gap Precoated board CAUTION Caution should always be exercised when using a utility knife near the rollers. You can put cuts into the rollers! WARNING Keep hands and fingers clear of the pull roller nip when changing the gap.
Applications F - 160 Operation and Maintenance Manual m) Stop the laminator when the trailer board is in the main roller nip. Refer to Figure 6.6.5 Finishing a) Cut the web of Hot Tissue at the upper unwind shaft with an enclosed blade. Figure 6.6.5 Trailer board CAUTION Precoated board Trailer board Do not use an open blade to cut the web near the rollers. You can put cuts into the rollers! b) Pull the precoated board and trailer board out from the front of laminator.
F - 160 Operation and Maintenance Manual Applications e) Lower the front and rear safety shields and press SHUTDOWN if finished with the laminator. JOB 0 6.7 One pass mount and laminate SAV SEL SHUT DOWN f) Trim any excess Hot Tissue from the boards. CAUTION Caution should always be exercised when using a knife . Sharp knife can cut you! This application can only be performed from the front of the laminator using the main rollers. Use Chart 8 and Diagram 8 for assistance.
Applications F - 160 Operation and Maintenance Manual • Leader and trailer board • Roll of thermal laminate • Glue stick • Prints ( print that are not heat sensitive ) • Utility knife • Cutting blade with an enclosed casing. INFORMATION The two pieces cut in step "a" will be used as the leader board and trailer board. These two pieces can be saved and reused for other applications. INFORMATION The laminate must not exceed 1 in. the width of the substrate.
F - 160 Operation and Maintenance Manual Applications Figure 6.7.1 MAIN POWER / RESET Figure 6.7.2 Unwind shaft Saddle Clevis pin RESET the of r a Re tor na i lam Roll of Thermal laminate Core support MAIN POWER Brake adjust knob Core chucks g) Lift the clevis pin located in the saddle of the upper unwind shaft. i) Once loaded, swing the upper unwind shaft back into the saddle.
Applications F - 160 Operation and Maintenance Manual o) Press SPEED s to set a motor speed of 2 ft. / min. ( .6 m / min. ) INFORMATION 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". 2.0 FWR GO REV. SPEED SAFETY STOP l) Press SEL. SEL will stop flashing. p) Press GAP t to enter a 0 in. gap setting. JOB 0 SAV SEL SHUT DOWN GAP m) Press TOP TEMP s to set a temperature of 240-260 oF ( 115-126 oC ).
F - 160 Operation and Maintenance Manual Applications r) Continue with step s) when the TOP TEMP DISPLAY stops flashing. 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! s) Press STOP. FWR 2.0 GO REV. SPEED SAFETY u) Press on the variable speed footswitch while guiding the leader board into the nip to confirm that the board is secure.
Applications F - 160 Operation and Maintenance Manual y) Press on the variable speed footswitch to back the board out of the main rollers. INFORMATION Excessive pressure will cause the substrate to bow or flatten. CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. w) Press STOP. 00.0 FWR GO SAFETY Process REV. SPEED STOP INFORMATION x) Press REV t to reverse the direction of the motor.
F - 160 Operation and Maintenance Manual Applications c) Lay the sheet of Hot Tissue on the board so the two leading edges are aligned. Refer to Figure 6.7.3 Figure 6.7.4 Leader board Thermal laminate Leader board INFORMATION The thin line of glue will assist with holding the layers to the board. d) Run a thin line of glue across the leading edge of Hot Tissue just placed on the board. f) Position the leader board so that half is pressed against the thermal laminate resting on the front table.
Applications F - 160 Operation and Maintenance Manual h) Press FWD s. j) Apply the minimum amount of brake tension on the roll of thermal laminate to prevent it from free spinning. FWR 00.0 GO REV. SPEED SAFETY STOP INFORMATION Excessive tension will cause the substrate to bow. INFORMATION Steps " i" and " j" will be performed simultaneously.
F - 160 Operation and Maintenance Manual Applications INFORMATION INFORMATION The heat must penetrate through the thermal laminate, image, Hot Tissue and to the board. Dwell time is crucial for the success of this application. Stopping the rollers on the print will leave a pressure line on the image. o) Raise the main rollers to a 1 in. gap by pressing GAP s. WARNING When the laminator rollers are in motion, keep hands and fingers away from the nip of the rollers.
Applications F - 160 Operation and Maintenance Manual INFORMATION This will prevent any activated adhesive from contacting the rollers. c) Remove the roll of material from the upper unwind shaft. 6.8 Thermal decal and mount This is a two pass mount and laminate process. Two pass meaning that the print will pass through the laminator twice. The first pass ( Decal ) will apply a mount adhesive to the back of the print while applying a laminate to the front of the print.
F - 160 Operation and Maintenance Manual Applications c) Ensure that the rear pull rollers are in the up position.. Pass 1: Decal Use Chart 9 and Diagram 9 for assistance. Materials needed • Roll of thermal laminate • Roll of mount adhesive ( same width as the laminate ) • Print ( smaller than the laminate ) • Roll of masking tape • Utility knife • Cutting blade with an enclosed casing. • Piece of cardboard ( film width x 6” ) d) Raise the front and rear safety shields.
Applications F - 160 Operation and Maintenance Manual h) Push the clevis pin back down to secure the unwind shaft in its saddle. INFORMATION Twisting the roll of laminate while sliding makes loading the film onto the unwind shaft easier. i) Lift the clevis pin located in the saddle of the lower unwind shaft. Figure 6.8.
F - 160 Operation and Maintenance Manual Applications o) Press SEL. SEL will stop flashing. CAUTION Ensure the roll of mount adhesive is loaded properly on the unwind shaft. Exposed adhesive should be facing away from the rollers. This will prevent hours of roll cleaning! JOB 0 SAV SEL SHUT DOWN l) Push the clevis pin back down to secure the unwind shaft in its saddle. p) Press TOP TEMP s to set a temperature of 220-230 oF ( 104-110 oC ).
Applications F - 160 Operation and Maintenance Manual r) Press SPEED s to set a motor speed of 2 ft. / min. ( .6 m / min. ) 2.0 FWR GO SAFETY FWR 2.0 GO REV. SPEED REV. SPEED v) Press STOP. SAFETY STOP STOP s) Press GAP t to enter a 0 in. gap setting. Process a) Raise the front safety shield and remove the front infeed table. GAP PRESSURE 0 b) Apply just enough brake tension to prevent the roll of thermal laminate from free spinning. t) Press GO. INFORMATION 2.0 FWR GO REV.
F - 160 Operation and Maintenance Manual Applications Figure 6.8.3 Laminate Figure 6.8.4 Mount adhesive Thermal laminate Thermal laminate Remove Mount adhesive d) Apply just enough brake tension to prevent the roll of mount adhesive from free spinning. f) Use a piece of cardboard to push the material into the nip of the main rollers. INFORMATION Excessive brake tension may cause the output to curl. This can create complications with the second pass of this application.
Applications F - 160 Operation and Maintenance Manual CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. WARNING Keep hands and fingers clear of the laminator roller nip when adjusting PRESSURE. You can be CRUSHED or BURNED! WARNING Keep hands and fingers clear of the pull roller nip when changing the gap. You can be CRUSHED! i) Once the cardboard has passed through the pull rollers, lower the upper pull roller onto the web.
F - 160 Operation and Maintenance Manual Applications k) Tape the web to the lower rewind tube or let the web run out to a work table. Refer to Figure 6.8.5 - Press on the variable speed footswitch to lengthen the web enough to get one full wrap around the lower rewind tube. CAUTION INFORMATION If you choose to use the lower rewind tube, make note of the direction of travel. Figure 6.8.
Applications F - 160 Operation and Maintenance Manual o) Press SPEED s to a speed you feel comfortable working with. It is recommended that SPEED not exceed 5 ft./ min. ( 1.52 m/ min. ) . s) Press GAP s to a 1 in. setting. GAP PRESSURE 1 9.0 FWR GO REV. SPEED SAFETY STOP Finishing a) With an enclosed blade, cut the finished product from the web. p) Press GO. 9.0 FWR GO SPEED SAFETY STOP REV . q) Feed the images through the main rollers from the front operating position of the laminator.
F - 160 Operation and Maintenance Manual Applications WARNING Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! INFORMATION This will prevent any exposed adhesive from contacting the rollers. i) Clean the rollers as described in the maintenance section. ( Section 8.2 Cleaning the rollers ) e) Raise the pull roller up by turning the crank handle counter clockwise until the pull rollers are separated.
Applications F - 160 Operation and Maintenance Manual Materials needed c) While observing the leader board at eye level, lower the upper pull roller by turning the pull roll crank handle clockwise until contact with the leader board has been made. • Prints ( Decals ) • Substrates • Utility knife • Leader board ( substrate width x 6” ) CAUTION Sharp edges on a substrate should be filed smooth and GAP manually adjusted. Sharp edges can CUT the rollers! Set up a) Replace the front infeed table.
F - 160 Operation and Maintenance Manual Applications d) Press FWD s. 00.0 g) Press REV t to reverse the direction of the motor. FWR GO SAFETY FWR 00.0 REV. SPEED STOP GO REV. SPEED SAFETY STOP 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! e) Press on the variable speed footswitch to back the leader board out.
Applications F - 160 Operation and Maintenance Manual b) Is the decal compatible with the substrate? - If the substrate is larger than the decal, you can position the image any where on the board. Refer to Figure 6.8.7 c) Peel back about 1 in. of the release liner from the decal and fold back. Refer to Figure 6.8.9 Figure 6.8.9 Peel back release liner Leading edge Figure 6.8.7 Setting the decal Release liner Back of Image d) Place a padded paper weight or similar object in the center.
F - 160 Operation and Maintenance Manual Applications INFORMATION Avoid tacking at the ends first and pressing towards the center, you may create a tunnel once you have reached the center. This will make for a difficult mounting application. f) Set the substrate and decal in the center of the rear infeed table. INFORMATION Use a slow speed. If the tack point enters the rollers nip, you will not be able to pull the release liner.
Applications F - 160 Operation and Maintenance Manual Figure 6.8.11 Draping the decal WARNING Decal Upper pull roll Release liner 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! Substrate - If its not, slowly move the substrate into the nip until the decal is conformed. Refer to Figure 6.8.13 j) Make sure the image is conformed to the upper main roller. Refer to Figure 6.8.
F - 160 Operation and Maintenance Manual Applications INFORMATION l) Use one hand to pull the release liner off as the substrate moves towards the nip and the other hand to apply slight back tension to the decal. Steps " n " and " o " will be performed simultaneously. m) Once the substrate and the decal are completely through the pull rollers, you can let off the variable speed footswitch.
Applications F - 160 Operation and Maintenance Manual b) Raise the pull roller up by turning the crank handle counter clockwise until the pull rollers are separated. Group 3 : Top / bottom heat Group three contains applications requiring heat to activate the upper and lower materials. c) Clean the rollers as described in the maintenance section. ( Section 8.2 Cleaning the rollers ) d) Lower the front and rear safety shields and press SHUTDOWN if finished with the laminator.
F - 160 Operation and Maintenance Manual Applications Materials needed • Two rolls of thermal laminate ( Both rolls should be of equal widths ) • Prints ( smaller than the laminate ) • Roll of masking tape • Utility knife • Cutting blade with an enclosed casing. • Piece of cardboard ( film width x 6” ) d) Raise the front and rear safety shields. WARNING Caution should always be exercised when using the laminator with the safety shields raised.
Applications F - 160 Operation and Maintenance Manual i) Lift the clevis pin located in the saddle of the lower unwind shaft. Figure 6.9.2 Unwind shaft Saddle Clevis pin Saddle Clevis pin Core support Roll of laminate Brake adjust knob Core chucks j) Swing the lower unwind shaft out enough to slide the roll of thermal laminate over the core chucks on the lower unwind shaft. Refer to Figure 6.9.
F - 160 Operation and Maintenance Manual Applications m) Center the upper roll and the lower roll of material on the unwind shafts. You may refer to your measurement chart in Section 5.3.2 Loading film ( Figure 5.3.4 ) p) Press TOP TEMP s to set a temperature of 220-230 oF ( 104-110 oC ). SLEEP INFORMATION For the lower unwind shaft, add 1/4 in. to the measurement. TOP TEMP BOT TEMP 140 68 q) Press BOT TEMP s to set a temperature of 220-230 oF ( 104-110 oC ). n) Lower the safety shields.
Applications F - 160 Operation and Maintenance Manual s) Press SPEED s to set a motor speed of 2 ft. / min. ( .6 m / min. ) 2.0 FWR GO SAFETY FWR 2.0 GO REV. SPEED REV. SPEED w) Press STOP. SAFETY STOP STOP t) Press GAP t to enter a 0 in. gap setting. Process a) Raise the front safety shield and remove the front infeed table. GAP PRESSURE 0 b) Apply just enough brake tension to prevent the roll of thermal laminate from free spinning. u) Press GO. INFORMATION 2.0 FWR GO REV.
F - 160 Operation and Maintenance Manual Applications Figure 6.9.3 Laminate Figure 6.9.4 Lower laminate Thermal laminate Thermal laminate Remove Thermal laminate d) Apply just enough brake tension to prevent the roll of thermal laminate from free spinning. f) Use a piece of cardboard to push the material into the nip of the main rollers. INFORMATION Excessive brake tension may cause the output to curl. This can create complications with the second pass of this application.
Applications F - 160 Operation and Maintenance Manual CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. WARNING Keep hands and fingers clear of the laminator roller nip when adjusting PRESSURE. You can be CRUSHED or BURNED! WARNING Keep hands and fingers clear of the pull roller nip when changing the gap. You can be CRUSHED! i) Once the cardboard has passed through the pull rollers, lower the upper pull roller onto the web.
F - 160 Operation and Maintenance Manual Applications k) Tape the web to the lower rewind tube or let the web run out to a work table. Refer to Figure 6.9.5 - Press on the variable speed footswitch to lengthen the web enough to get one full wrap around the lower rewind tube. CAUTION INFORMATION If you choose to use the lower rewind tube, make note of the direction of travel. Figure 6.9.
Applications F - 160 Operation and Maintenance Manual o) Press SPEED s to a speed you feel comfortable working with. It is recommended that SPEED not exceed 5 ft./ min. ( 1.52 m/ min. ) . s) Press GAP s to a 1 in. setting. GAP PRESSURE 1 9.0 FWR GO REV. SPEED SAFETY STOP Finishing p) Press GO. a) With an enclosed blade, cut the finished product from the web. 9.0 FWR GO SPEED SAFETY STOP REV . CAUTION Do not use an open blade to cut the web near the rollers.
F - 160 Operation and Maintenance Manual Applications j) Replace the front infeed table. WARNING Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! k) Lower the front and rear safety shields and press SHUTDOWN if finished with the laminator. JOB e) Raise the pull roller up by turning the crank handle counter clockwise until the pull rollers are separated.
Applications F - 160 Operation and Maintenance Manual Figure 6.10.1 o F 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 o = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = C 20 20.6 21.1 21.7 22.2 22.7 23.3 23.9 24.4 25 25.6 26.1 26.7 27.2 27.8 28.3 28.9 29.4 30 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35 35.6 36.1 36.7 37.2 37.8 38.3 38.9 39.4 40 40.6 41.1 41.
F - 160 Operation and Maintenance Manual Applications Parameter Chart - Blank MATERIALS UPPER UNWIND : SUBSTRATE : LOWER UNWIND : PRINTS : TEMPERATURE TOP TEMP. BOT. TEMP. GAP & PRESSURE PRESSURE GAP MOTOR DIRECTION & SPEED SOLID = Panel GO SPEED F L A S HING = Footswitch FWR REV.
F - 160 Operation and Maintenance Manual Applications Web Diagram - Blank © GBC Pro - Tech August 1999 Page 6 - 97
F - 160 Operation and Maintenance Manual Applications Parameter Chart 1 - Precoating substrates MATERIALS U P P E R U N W I N D : Pro Mount S U B S T R A T E : 1/4" Foam Core LOWER UNWIND : N / A PRINTS : N/A TEMPERATURE TOP TEMP. BOT. TEMP. 68 68 GAP & PRESSURE PRESSURE GAP 1/4" MOTOR DIRECTION & SPEED SOLID = Panel GO 00.0 SPEED FLASHING = Footswitch FWD REV.
F - 160 Operation and Maintenance Manual Applications Web Diagram 1 - Precoating substrate Pro Mount Substrate Leader board © GBC Pro - Tech August 1999 Page 6 - 99
F - 160 Operation and Maintenance Manual Applications Parameter Chart 2 - Mounting only MATERIALS UPPER UNWIND : N / A S U B S T R A T E : Precoated boards LOWER UNWIND : N / A PRINTS : Inkjet prints TEMPERATURE TOP TEMP. BOT. TEMP. 68 68 GAP & PRESSURE PRESSURE GAP 1/4 MOTOR DIRECTION & SPEED SOLID = Panel GO 00.0 SPEED FLAS HING = Footswitch FWD REV. GO PULL ROLL SETTINGS N/A UP 1/4 Turn PRESSURE 1/2 Turn DOWN 3/4 Turn NOTES Substrate will vary. Print can be of any type.
Applications F - 160 Operation and Maintenance Manual Web Diagram 2 - Mounting only Print Release liner Precoated board © GBC Pro - Tech August 1999 Page 6 - 101
F - 160 Operation and Maintenance Manual Applications Parameter Chart 3 - Single sided ( Sled ) MATERIALS U P P E R U N W I N D : Pro Gloss S U B S T R A T E : 1/4" Foam Core LOWER UNWIND : N / A PRINTS : Inkjet prints TEMPERATURE TOP TEMP. BOT. TEMP. 68 68 GAP & PRESSURE PRESSURE GAP 1/4 MOTOR DIRECTION & SPEED SOLID = Panel GO 00.0 SPEED F L A SH I N G = Footswitch FWD REV. GO PULL ROLL SETTINGS N/A UP 1/4 Turn PRESSURE 1/2 Turn DOWN 3/4 Turn NOTES Substrate will vary.
F - 160 Operation and Maintenance Manual Applications Web Diagram 3 - Single sided ( Sled ) P.S.A.
F - 160 Operation and Maintenance Manual Applications Parameter Chart 4 - Single sided ( Craft paper ) MATERIALS U P P E R U N W I N D : Pro Gloss SUBSTRATE : N / A L O W E R U N W I N D : Craft Paper PRINTS : Inkjet prints TEMPERATURE TOP TEMP. BOT. TEMP. 68 68 GAP & PRESSURE PRESSURE GAP 0 MOTOR DIRECTION & SPEED SOLID = Panel GO 3-6 SPEED F L A SH I N G = Footswitch FWD REV.
Applications F - 160 Operation and Maintenance Manual Web Diagram 4 - Single sided ( Craft paper ) P.S.A.
F - 160 Operation and Maintenance Manual Applications Parameter Chart 5 - Decal and mount ( Decal ) MATERIALS U P P E R U N W I N D : Pro Gloss SUBSTRATE : N / A L O W E R U N W I N D : Pro Mount PRINTS : Inkjet prints TEMPERATURE TOP TEMP. BOT. TEMP. 68 68 GAP & PRESSURE PRESSURE GAP 0 MOTOR DIRECTION & SPEED SOLID = Panel GO 3-6 SPEED F L A SH I N G = Footswitch FWD REV.
Applications F - 160 Operation and Maintenance Manual Web Diagram 5 - Decal and mount ( Decal ) P.S.A.
F - 160 Operation and Maintenance Manual Applications Parameter Chart 6 - Decal and mount ( Mount ) MATERIALS UPPER UNWIND : N / A S U B S T R A T E : 1/4" Foam Core LOWER UNWIND : N / A PRINTS : Decals TEMPERATURE TOP TEMP. BOT. TEMP. 68 68 GAP & PRESSURE PRESSURE GAP 1/4 MOTOR DIRECTION & SPEED SOLID = Panel GO 00.0 SPEED F L A SH I N G = Footswitch FWD REV.
Applications F - 160 Operation and Maintenance Manual Web Diagram 6 - Decal and mount ( Mount ) Decal Release liner Substrate © GBC Pro - Tech August 1999 Page 6 - 109
F - 160 Operation and Maintenance Manual Applications Parameter Chart 7 - Precoating substrates ( Thermal ) MATERIALS U P P E R U N W I N D : Hot Tissue Mount S U B S T R A T E : 1/4" Foam Core LOWER UNWIND : N / A PRINTS : N/A TEMPERATURE TOP TEMP. BOT. TEMP. 140 68 GAP & PRESSURE PRESSURE GAP 1/4 MOTOR DIRECTION & SPEED SOLID = Panel GO 00.0 SPEED F L A SH I N G = Footswitch FWD REV.
Applications F - 160 Operation and Maintenance Manual Web Diagram 7 - Precoating substrate ( Thermal ) Hot Tissue Substrate Leader board 140 160 © GBC Pro - Tech August 1999 Page 6 - 111
F - 160 Operation and Maintenance Manual Applications Parameter Chart 8 - One pass mount and laminate MATERIALS U P P E R U N W I N D : 3 mil Octiva Gloss S U B S T R A T E : 1/4" Foam Core LOWER UNWIND : N / A PRINTS : Electrostatic images TEMPERATURE TOP TEMP. BOT. TEMP. 240 68 GAP & PRESSURE PRESSURE GAP 1/4 MOTOR DIRECTION & SPEED SOLID = Panel GO 00.0 SPEED F L A SH I N G = Footswitch FWD REV.
Applications F - 160 Operation and Maintenance Manual Web Diagram 8 - One pass mount and laminate Octiva Gloss Hot Tissue Leader board Image 240 - 260 Substrate © GBC Pro - Tech August 1999 Page 6 - 113
F - 160 Operation and Maintenance Manual Applications Parameter Chart 9 - Thermal decal and Mount ( Decal ) MATERIALS U P P E R U N W I N D : 3 mil Octiva Gloss SUBSTRATE : N / A L O W E R U N W I N D : Pro Mount PRINTS : Any type TEMPERATURE TOP TEMP. BOT. TEMP. 230 68 GAP & PRESSURE PRESSURE GAP 0 MOTOR DIRECTION & SPEED SOLID = Panel GO 3-6 SPEED F L A SH I N G = Footswitch FWD REV.
Applications F - 160 Operation and Maintenance Manual Web Diagram 9 - Thermal decal and mount ( Decal ) Octiva Gloss Output Print 230 Pro Mount Finish product rewind option © GBC Pro - Tech August 1999 Page 6 - 115
F - 160 Operation and Maintenance Manual Applications Parameter Chart 10 - Thermal decal and Mount ( Mount ) MATERIALS UPPER UNWIND : N / A SUBSTRATE : N / A LOWER UNWIND : N / A PRINTS : Decals TEMPERATURE TOP TEMP. BOT. TEMP. 68 68 GAP & PRESSURE PRESSURE GAP 1 MOTOR DIRECTION & SPEED SOLID = Panel FWD GO 0.00 SPEED F L A SH I N G = Footswitch REV.
F - 160 Operation and Maintenance Manual Applications Web Diagram 10 - Thermal decal and mount ( Mount ) Decal Release liner Substrate © GBC Pro - Tech August 1999 Page 6 - 117
F - 160 Operation and Maintenance Manual Applications Parameter Chart 11 - Encapsulation MATERIALS U P P E R U N W I N D : 3 mil Octiva Gloss SUBSTRATE : N / A L O W E R U N W I N D : 3 mil Octiva Gloss PRINTS : Any type TEMPERATURE TOP TEMP. BOT. TEMP. 240 240 GAP & PRESSURE PRESSURE GAP 0 MOTOR DIRECTION & SPEED SOLID = Panel GO 0-7 SPEED F L A SH I N G = Footswitch FWD REV.
Applications F - 160 Operation and Maintenance Manual Web Diagram 11 - Encapsulation Octiva Gloss Output Print 230 230 Octiva Gloss Finish product rewind option © GBC Pro - Tech August 1999 Page 6 - 119
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Troubleshooting F - 160 Operation and Maintenance Manual Section 7 Troubleshooting Problem: D waves in the image but not in the laminate 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 can perform some simple troubleshooting in attempt to correct your typical output type problems. Use the easy to follow guide for assistance.
Troubleshooting Problem: Straight waves in the output Hints: • Check operational settings for materials being used.
Troubleshooting F - 160 Operation and Maintenance Manual 7.2 Film problems Problem: Delamination The following is a list of common film problems you may encounter. Hints: • Check operating temperatures • Check operating speed • Laminate compatibility with ink • Ink compatibility with paper For definitions of terminologies, please refer to 7.4 Glossary of terminology. 7.2.2 Pressure sensitive 7.2.
Troubleshooting F - 160 Operation and Maintenance Manual Problem: Delamination WARNING 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 call must be placed for a qualified service personnel to fix the problem. You may do this by dialing 1 ( 800 ) 790 7787. This will connect you with GBC National Service dispatch .
Troubleshooting F - 160 Operation and Maintenance Manual Problem : I press GO, and the rolls will not turn. CAUTION 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 the laminator. Hints : • Check for excessive brake tension • Confirm that the rolls of laminate are on correctly. • Place a service call.
Troubleshooting F - 160 Operation and Maintenance Manual Clutch tension Encapsulation 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 applied to the pull rolls. This tension is important for maintaining a smooth flat finished image. When an image is completely encased in laminating film, it is encapsulated.
Troubleshooting F - 160 Operation and Maintenance Manual Main rollers Pull 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. These rolls provide for tension of the laminated media. Tensioning of the laminated media helps to make it flat and smooth. In most laminators they may also be used for cold mounting and laminating applications.
Troubleshooting F - 160 Operation and Maintenance Manual 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 sensitive film, which will disappear once the adhesive is fully activated. This activation process can be sped up if a small amount of heat is applied during the application.
Maintenance F - 160 Operation and Maintenance Manual Section 8 Maintenance GBC Pro-Tech 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 this section. Daily • Clean the rolls ( See cleaning in this section ) • Inspect the electrical cord for damage.
Maintenance F - 160 Operation and Maintenance Manual 8.2 Cleaning the rollers b) Press RESET. The front control panel will illuminated.
Maintenance F - 160 Operation and Maintenance Manual Removing adhesive build up INFORMATION a) For pressure sensitive adhesives: put on the rubber gloves and use isopropyl alcohol and a terry cloth towel. 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.
Maintenance F - 160 Operation and Maintenance Manual Cleaning the beads of adhesives, dust and dirt from the rolls 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. This can be done one of two different methods. Both are acceptable forms of cleaning the beads of adhesives, dust, and dirt from the rolls.
Maintenance F - 160 Operation and Maintenance Manual d) Since the safety shields are raised and the tables removed, you must use the footswitch to rotate the bottom rollers after cleaning a section. WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP. You can be CRUSHED or BURNED! CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position.
Maintenance F - 160 Operation and Maintenance Manual 8.2.1 Clean the cabinets and 8.2.2 Cleaning the touch covers screen 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 water is not strong enough, you may use a mild dishwashing detergent with water and a cotton terry cloth.
