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Summary of Contents

  • Page 3

    IN G E EN M IS Part Number 930-016 © 1998 GBC Pro-Tech Do not duplicate without written permission IN G E EN M IS GBC Pro-Tech 4151 Anderson Road De Forest, Wisconsin 53532 Tel: 608-246-8844 Fax: 608-246-8645...

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    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 merchantabil- ity for any particular use.

  • Page 5: Table Of Contents

    Operator Controls ... 3-2 Front Control Panel ... 3-2 Footswitch Operation ... 3-2 Setup ... 3-3 Laminator Roll Pressure ... 3-3 Web Up Options ... 3-3 Loading the Film ... 3-3 Recommended Films ... 3-3 Positioning the Film ... 3-4 Heating ...

  • Page 6: Table Of Contents

    Adjusting the Nip ... 4-3 Chain Tensioning ... 4-4 Lubrication ... 4-5 Contacting Technical Support ... 4-5 Output Troubleshooting Guide ... 4-6 Limited Warranty ... 5-1 Exclusions to the Warranty ... 5-1 F-60 Operation and Maintenance Manual © GBC Pro-Tech 1998 July...

  • Page 7: Safety

    © GBC Pro-Tech 1998 July The F-60 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.

  • Page 8

    Do not use liquid or aerosol cleaners on the Secured in "Off" Position laminator. Do not spill liquid of any kind on the laminator. You can be severely shocked, electrocuted or cause a fire. Use only a damp Exercise care when cleaning the rolls with 80% Cleaning heated rolls can ignite the fumes.

  • Page 9

    You can be crushed or seriously injured. The F-60 Laminator is a large and heavy piece of equipment. It is necessary to employ LICENSED RIGGERS ONLY to move the machine. GBC Pro-Tech’s warranty does not cover malfunction...

  • Page 10

    M IS F-60 Operation and Maintenance Manual WARNING ACHTUNG MISE EN GARDE WARNING ACHTUNG MISE EN GARDE Figure 1-4: Locations of Safety Labels (Inside cabinet) ©1994 Hazard Communication Systems, Inc. 800-748-0241 WARNING ACHTUNG MISE EN GARDE © GBC Pro-Tech 1998 July...

  • Page 11

    F-60 Operation and Maintenance Manual The following are typical safety hazard decals used on GBC Pro-Tech machines, with a brief description (“Mean- ing” column) of each decal. Decal WARNING Moving parts can ACHTUNG crush and cut. MISE EN GARDE Do not operate with guard or door open.

  • Page 12

    Safety F-60 Operation and Maintenance Manual Blank page. © GBC Pro-Tech 1998 July...

  • Page 13: Preinstallation Checklist

    F-60 Laminator is properly and securely unpacked, moved and installed. Before a F-60 Laminator can be installed, there are a few requirements that must be met. Make certain that each of the requirements listed in the following prein- stallation checklist are met before beginning installa- tion.

  • Page 14

    78" (~2 m) Rear Front 4' x 6' (~1.22 m x 2 m) Work Table on Wheels Table Height 35-3/4" (~.94 - .95 m) 13' (~4 m) Figure 2-1: Laminator Space Requirements Wall 3' (~1 m) © GBC Pro-Tech 1998 July...

  • Page 15: Unpacking

    Bill of Lading. The F-60 Laminator is shipped in a wood crate on a skid. WARNING The unpacking process requires at least two people.

  • Page 16

    You can be crushed or seriously injured. Steps 6 through 11 should be completed by LICENSED RIGGERS ONLY. The F-60 Laminator is a large and heavy piece of equipment. It is necessary to employ LICENSED RIGGERS ONLY to move the machine.

  • Page 17: Setup, Leveling

    The shrink wrap is not recyclable, however, so it must be discarded. 14. Level the laminator using the procedure later in this section. 6HWXS Once the F-60 Laminator has been unpacked and moved into final position check each of the following items.

  • Page 18: Startup

    Installation 6WDU WXS The first time the laminator is started and every time it is serviced you should use the following checklist to confirm that the unit is operating properly and that all safety mechanisms are functioning. Startup Checklist Start the laminator and go through the following check- list.

  • Page 19

    F-60 Operation and Maintenance Manual 6HFWLRQ   2SHUDWLRQ 6DIHW\ The F-60 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.

  • Page 20: Operator Controls, Front Control Panel

    When the Controller mechanical guard is removed, use the footswitch to Upper Roll Heat feed material into the laminator at the rate you select by ON/OFF pressing the footswitch. The more pressure you apply, Lower Roll Heater Controller the faster the rolls turn.

  • Page 21: Laminator Roll Pressure, Setup

    F-60 Operation and Maintenance Manual 6HWXS Setup of the F-60 Laminator is quick and straightfor- ward when instructions are followed exactly. To adjust the nip, please see Maintenance. /DPLQDWRU 5ROO 3UHVVXUH Use only the minimum amount of roll pressure needed to accomplish the task.

  • Page 22: Heating, Process Control Charts

    Turning the knob clockwise increases tension. Turning the knob counterclockwise decreases tension. F-60 Operation and Maintenance Manual The pull rolls on the F-60 Laminator are preset for opti- mum roll pressure and requires no nip adjustment. The pull rolls can be raised for a "...

  • Page 23

    The process control charts should be kept in this man- ual or in a book close to the laminator. Use the machine to encapsulate the popular charts so they can withstand food and coffee spills and so they are always available for ready reference.

  • Page 24: Procedure

    3. Upper Laminator Roll Pressure: 10–30%. 4. Speed: 3 fpm (1 m/min). 5. Upper Laminator Roll Heat: 240°F (115 °C). 3URFHGXUH 1. Lay the print on the board. Using a tack iron, tack the leading edge of the print down onto the board so it is held in place.

  • Page 25

    Be sure there are no wrinkles in the nip area. Carefully peel off the liner as the board progresses through the laminator. 7. Trim the piece to the finished size. © GBC Pro-Tech 1998 July Operation...

  • Page 26

    Removable Idler Unwind Shaft Rewind (UM) Upper Main Roll (LM) Lower Main Roll (UP) Upper Pull Roll (LP) Lower Pull Roll F-60 Operation and Maintenance Manual FRONT CONTROL SETTINGS Reverse/Forward: Top Heater: Bottom Heater: Identification Diagram © GBC Pro-Tech 1998 July...

  • Page 27

    NOTE Guard is removed for this operation. Use automatic slow roll speed (3 ft/min). Footswitch may be used. Falcon Board © GBC Pro-Tech 1998 July Process: One Pass Mounting __________ FRONT CONTROL SETTINGS Reverse/Forward: Forward Top Heater: 240 ºF (115 ºC)

  • Page 28

    Guard is removed for this operation. Use automatic slow roll speed (3 ft/min). Footswitch may be used. Falcon Board 3-10 F-60 Operation and Maintenance Manual FRONT CONTROL SETTINGS Reverse/Forward: Forward Top Heater: 240 ºF (115 ºC) Bottom Heater: Off One Pass Mount and Laminate Printed Image Leader Board © GBC Pro-Tech 1998 July...

  • Page 29

    F-60 Operation and Maintenance Manual Product: 3 Mil Gloss/3Mil Gloss _____ Speed: 0-6 fpm (0-180 cpm) Roll Pressure: 30-60% Cooling: Optional © GBC Pro-Tech 1998 July Process: Encapsulation ______________ FRONT CONTROL SETTINGS Reverse/Forward: Forward Top Heater: 230 ºF (110 ºC) Bottom Heater: 230 ºF (110 ºC)

  • Page 30

    Roll Pressure: 30-60% Cooling: Off 3-12 F-60 Operation and Maintenance Manual FRONT CONTROL SETTINGS Reverse/Forward: Forward Top Heater: 105 ºF (40 ºC) Bottom Heater: 32 ºF (0 ºC) Cold Overlamination Release Paper Rewind Craft Paper Gloss Path © GBC Pro-Tech 1998 July...

  • Page 31

    Product:______________________ Speed: 0-6 fpm (180 cpm) Roll Pressure: 30-60% Cooling: Off Mount © GBC Pro-Tech 1998 July Process: Cold Mount & Laminate (First Pass) FRONT CONTROL SETTINGS Reverse/Forward: Forward Top Heater: 105 ºF (40 ºC) Bottom Heater: 32 ºF (0 ºC)

  • Page 32

    Release Liner (Peel prior to nip) 3-14 F-60 Operation and Maintenance Manual FRONT CONTROL SETTINGS Reverse/Forward: Forward Top Heater: 32-105 ºF (0-40 ºC) Bottom Heater: 32 ºF (0 ºC) Hold Encapsulated Image Foam Core Date: ________________ © GBC Pro-Tech 1998 July...

  • Page 33

    Process: Mount & Hot Overlaminate (First Pass) __ Speed: 0-6 fpm (0-180 cpm) Roll Pressure: 30-60% Cooling: Optional Mount and Hot Overlaminate (First Pass) © GBC Pro-Tech 1998 July FRONT CONTROL SETTINGS Reverse/Forward: Forward Top Heater: 230 ºF (110 ºC) Bottom Heater: 32 ºF (0 ºC)

  • Page 34

    F-60 Operation and Maintenance Manual Process: Mount & Hot Overlaminate (Second Pass) Date: ________________ FRONT CONTROL SETTINGS Reverse/Forward: Forward Top Heater: 32-105 ºF (0-40 ºC) Bottom Heater: 32 ºF (0 ºC) Hold Encapsulated Image Foam Core © GBC Pro-Tech 1998 July...

  • Page 35: Cleaning

    WARNING Exercise extreme caution while cleaning the laminator. You can be caught in the turning rolls and crushed or burned. While the laminator is still at normal operating temper- ature (200-250 ºF), put on the rubber gloves and, using a rubber cement eraser, remove any heat activated adhesive from the rolls.

  • Page 36

    4. With the laminator rolls no hotter than 110ºF, remove dust and dirt from the silicone laminating rolls by running an adhesive-coated board through the laminator. Be sure to set the nip for the thick- ness of the board used. 5. Allow the laminator to cool.

  • Page 37: Adjusting The Nip

    3. Loosen the ¾" jam nut securing the lift assembly bolt. Adjust the nip by rotating the lift assembly bolt clockwise to raise the end being adjusted and counterclockwise to lower it. © GBC Pro-Tech 1998 July Maintenance and Troubleshooting Lift Assembly...

  • Page 38: Chain Tensioning

    • Screwdriver To adjust the chain tension: WARNING Remove and lockout power from the laminator while you are performing this procedure. You could be severely shocked, electrocuted, or get your fingers caught in the drive mechanisms. 1. Remove the drive side cabinet cover using the hex wrench by removing the eight screws holding the cover in place.

  • Page 39: Lubrication

    High temperature grease or lithium grease • Grease gun To lubricate the laminator: WARNING Do not lubricate the laminator when it is hot. You can be burned. WARNING Remove and lockout power from the laminator while you are performing this procedure. You could be severely shocked, electrocuted, or get your fingers caught in the drive mechanisms.

  • Page 40

    Make sure main roll temperatures are the same. Adjust cooling fans. Problem: Longitudinal waves or stuttering, jerking, or excessive noise from the drive side of the laminator. Hints: • Increase chain tension, decrease unwind brake tension. © GBC Pro-Tech 1998 July...

  • Page 41

    (90) from the date of delivery to the customer. This warranty is the only warranty made by GBC Pro-Tech and cannot be modified or amended. GBC Pro-Tech’s sole and exclusive liability and the customer’s sole and exclusive remedy under this...

  • Page 42

    Warranty F-60 Operation and Maintenance Manual Blank page. © GBC Pro-Tech 1998 July...

  • Page 43

    F-60 Operation and Maintenance Manual 6HFWLRQ   6SHFLILFDWLRQV 3DUWV DQG 6FKHPDWLF Table 6-1: F-60 Laminator Specifications Characteristic Specifications Dimensions Uncrated: 80" x 33" x 57" (L x D x H) (202 x 84 x 145 cm) Crated: 90" x 44" x 68"...

  • Page 44

    Specifications F-60 Operation and Maintenance Manual Blank page. © GBC Pro-Tech 1998 July...

  • Page 45: Mounting/laminating, Setup, Procedure, Encapsulation, Setup

    Heater Controller Heaters Installing Heating 2-1, 6-1 Installation requirements Isopropyl alcohol Laminating material Laminating rolls Laminating speeds © GBC Pro-Tech 1998 July Leveling Lubrication Main rolls Maintenance schedule 2-6, 4-4 Motor Mounting Mounting/Laminating 1-2, 2-5, 4-1, 4-2, 4-3 Paper Power cord...

  • Page 46

    Index F-60 Operation and Maintenance Manual Unpacking Crate Upper main roll Warnings and cautions Warranty © GBC Pro-Tech 1998 July...

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