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GBC F - 160 CE Operation And Maintenance Manual

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

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  • Page 1 F - 160 CE OPERATION AND MAINTENANCE MANUAL © April 2000 GBC Films Group Do not duplicate without written permission. GBC Films Group 4151 Anderson Road DeForest, WI 53532 Revision : Ph: ( 608 ) 246 - 8844 Fx: ( 608 ) 246 - 8645...

  • Page 2: Table Of Contents

    F - 160 CE Operation and Maintenance Manual Section 1: Safety 1.1 Symbols ...1 - 1 1.2 Safety features ...1 - 2 1.3 Safety shield ...1 - 3 1.4 Emergency stop ...1 - 4 1.5 Emergency cable ...1 - 5 1.6 Front feed table ...1 - 6...
  • Page 3 4.2 Know your machine ...4 - 4 4.3 Unpacking ...4 - 5 4.4 Shrink wrapped ...4 - 5 4.5 Crated ...4 - 6 4.6 Accessory pack content ...4 - 8 Page II F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000...
  • Page 4 F - 160 CE Operation and Maintenance Manual 4.7 Installing levelers ...4 - 9 4.8 Leveling ...4 - 11 4.9 Connecting power ...4 - 15 Figure 4.9.1 Single phase ( U.S. & Canada ) ...4 - 17 Figure 4.9.2 Three phase ( Europe ) ...4 - 17 4.10 Safety check ...4 - 18...
  • Page 5 Chart 5.4.1 Job save chart ...5 - 17 5.5 Manual nip adjustment ...5 - 18 5.5.1 Main roller manual nip adjustment ...5 - 18 Page IV F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000...
  • Page 6 F - 160 CE Operation and Maintenance Manual 5.5.2 Pull roller manual nip adjustment ...5 - 21 5.6 Front feed table ...5 - 24 5.6.1 Removing the table ...5 - 24 5.6.2 Replacing the table ...5 - 24 Section 6: Applications 6.1 Parameter charts and diagrams...
  • Page 7 Chart 10 - Thermal decal and mount ( Mount ) ...6 - 24 Diagram 10 - Thermal decal and mount ( Mount ) ...6 - 25 Page VI F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000...
  • Page 8 F - 160 CE Operation and Maintenance Manual Chart 11 - Encapsulation ...6 - 26 Diagram 11 - Encapsulation ...6 - 27 Section 7: Troubleshooting 7.1 Wave problems ...7 - 1 7.2 Film problems ...7 - 3 7.2.1 Thermal laminates ...7 - 3 7.2.2 Pressure senstive ...7 - 3...
  • Page 9 Table of Contents F - 160 CE Operation and Maintenance Manual This page intentionally left blank. Page VIII © GBC Films Group April 2000...

  • Page 10: Section 1 Safety

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

  • Page 11: Safety Features

    • Any commissioning or service engineer must be of competent nature, trained and qualified to GBC Films Group standards to fulfill that job. This person will have completed and passed the full service training course from F ( 100 C ).

  • Page 12: Safety Shield

    F - 160 CE Operation and Maintenance Manual • Any GBC Technician, GBC Specialist, and / or GBC Films Group Technician that has been through the GBC Pro-Tech service training course. The F-160CE laminator has cabinets and panels that are bolted close to isolate the electrical and drive system components for the safety of the operator.

  • Page 13: Emergency Stop

    To continue operation, all E-STOPs must be in the unlatched position. To reset, twist the E-STOP 1/4 turn clockwise. Refer to Figure 1.4.3 Reset the E- STOP. Figure 1.4.3 P u s h INFORMATION Reset the E-STOP Unlatch © GBC Films Group April 2000...

  • Page 14: Emergency Cable

    F - 160 CE Operation and Maintenance Manual Press RESET located on the right leg at the front of the machine. Refer to Figure 1.4.4 Machine reset. Figure 1.4.4 Machine rest Machine reset 1.5 Emergency cable In the event an E-STOP is not reachable, use...

  • Page 15: Front Feed Table

    Page 1 - 6 F - 160CE Operation and Maintenance Manual Figure 1.6.1 Front feed table To continue operation, press STOP. STOP SPEED SAFETY Then press GO. STOP SPEED SAFETY © GBC Films Group April 2000 F W D F W D...
  • Page 16 F - 160 CE Operation and Maintenance Manual 1.7 Label locations Posted at various locations on the Falcon 160 Laminator are important safety labels. Pay careful attention to these labels at all times! Figure 1.7.1 and Figure 1.7.2 illustrates the location of each of these labels.
  • Page 17 Safety F - 160CE Operation and Maintenance Manual Reset: Machine reset. Press after iniating power to the laminator or after an E-STOP or E-CABLE has been engaged then resetted. Page 1 - 8 © GBC Films Group April 2000...
  • Page 18 F - 160 CE Operation and Maintenance Manual Figure 1.7.1 Label locations - Front WARNING ACHTUNG MISE EN GARDE M U C H O M U C H O W A R N I N G C U I D A D O...
  • Page 19 F - 160CE Operation and Maintenance Manual WARNING ACHTUNG MISE EN GARDE © GBC Films Group April 2000 M U C H O M U C H O W A R N I N G C U I D A D O...

  • Page 20: Section 2 Warranty

    ( 1 ) year parts and 90 days labor from the date of installation. This warranty is the only warranty made by GBC Films Group and connot be modified or amended. GBC Films Group’s sole and exclusive liability and the customer’s sole and exclusive...
  • Page 21 • Any commissioning or service engineer must be of competent nature, trained and qualified to GBC Films Group standards to fulfill that job. This person will have completed and passed the full service training course from GBC Pro-Tech.

  • Page 22: Section 3: Specifications

    F - 160 CE Operation and Maintenance Manual Section 3: Specifications Specifications provide all of the technical data for the Falcon 160 CE Laminator. Section 3.1 General Description: Features: Applications: Section 3.2 Consumable Film types: © GBC Films Group April 2000 •...

  • Page 23: Function

    • 0 - 15 ft / min ( 0 - 4.6 m / min ) • 2-1/4 horse power drive motor • Bi-directional D.C. motor • 68 F - 290 F ( 20 C - 143 • Front control panel • Variable speed footswitch © GBC Films Group April 2000...

  • Page 24: Electrical

    F - 160 CE Operation and Maintenance Manual Job save: Roll design: Section 3.4 Electrical United Statesand Canada: Europe: B.T.U. output: Heater wattages: Amperage draw: D/C voltage used: A/C voltage used: © GBC Films Group April 2000 • Save up to 9 job parameters •...

  • Page 25: Dimensions

    • 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 • 37 3/16 in. ( 95 cm ) • 66 5/8 in. ( 169 cm) © GBC Films Group April 2000...
  • Page 26 F - 160 CE Operation and Maintenance Manual Figure 3.5.1 Dimensions 53 in. (135 cm) 76 in. (193 cm) © GBC Films Group April 2000 82.5 in. (210 cm) Specifications 3.63 in. (9 cm) 1.38 in. (3.5 cm) 4.75 in.
  • Page 27 Specifications F - 160CE Operation and Maintenance Manual This page intentionally left blank. Page 3 - 6 © GBC Films Group April 2000...

  • Page 28: Section 4 Installation

    F - 160 CE Operation and Maintenance Manual Section 4 Installation GBC Films Group is committed to a program of ongoing product improvement. As a result, we are providing these instructions so you can insure that your new Falcon 160 CE Laminator is properly and securely unpacked, moved, and installed.
  • Page 29 You can be crushed or seriously injured. For instructions on how to connect power, proceed to 4.9 Connecting power in this section. Page 4 - 2 F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000...

  • Page 30: Figure 4.1.1 Suggested Floor Layout

    F - 160 CE Operation and Maintenance Manual Figure 4.1.1 Suggested Floor Layout 8.4' ( 2.57 m ) 38" ( 96 cm ) ( 6 m ) 8.4' ( 2.57m ) © GBC Films Group April 2000 4' x 6' ( 1.22 m x 2m )

  • Page 31: Know Your Machine

    Front side Figure 4.2.2 Safety features Rear safety shield E-STOP Front safety shield E-CABLE E-CABLE reset Page 4 - 4 F - 160 CE Operation and Maintenance Manual Figure 4.2.3 Front view Upper rewind Front feed table Lower unwind shaft...

  • Page 32: Unpacking

    You can cause irreparable damage to the rollers. c) With another person, carefully wheel your F - 160 CE Laminator to the installation site. WARNING Do not attempt to move the laminator across anything other than a flat level surface without trained and qualified riggers.

  • Page 33: Crated

    • Crow bar • A second person Page 4 - 6 F - 160 CE Operation and Maintenance Manual To uncrate the laminator a) Remove the top of the crate and then the sides in the order shown in Figure 4.5.1 CAUTION Do not allow the top to fall into the crate.
  • Page 34 F - 160 CE Operation and Maintenance Manual Figure 4.5.1 Disassembling of the crate Removing the shrink wrap a) Gently unwrap the shrink wrap from around the laminator. CAUTION Do not use a knife or other sharp object to remove the shrink wrap from around the laminator.
  • Page 35 If you are missing any of the itemslisted above, contact your local service technician or sales representative. Contacts: GBC Parts ( 800 ) 790 - 7787 GBC Europe parts 33 - 45 - 535 - 7676 © GBC Films Group April 2000...

  • Page 36: Installing Levelers

    F - 160 CE Operation and Maintenance Manual 4.7 Installing levelers Leveling of the machine is a customer option. If you choose not to level the laminator and you encounter output problems, please level the machine and try your application again before calling for technical support.
  • Page 37 Attach the leveling pad to the bottom of the leveling bolt and secure with wrenches. Refer to Figure 4.7.1 Leveling pad installed. Page 4 - 10 F - 160 CE Operation and Maintenance Manual Figure 4.7.1 Leveling pad installed Jam nut Leveling pad i) Tighten the jam nut against the leveling pad.

  • Page 38: Leveling

    F - 160 CE Operation and Maintenance Manual 4.8 Leveling Leveling of the laminator is very important in the way the machine performs. Leveling is crucial to the tram ( tracking ) of the materials through the machine. a) Position the level on the top of the control side frame.
  • Page 39 Page 4 - 12 F - 160 CE Operation and Maintenance Manual INFORMATION A second person can read the level while you make the appropriate adjustments.
  • Page 40 F - 160 CE Operation and Maintenance Manual f) Flip the circuit breaker on the laminator to the up position. = ON = OFF g) Turn MAIN POWER to “ I ” position. Power ON/OFF INFORMATION Ensure all E-STOPS are unlatched and the E-CABLE is reset before turning power on to the laminator.
  • Page 41 Figure 4.8.3 Drive to control side front Level Page 4 - 14 F - 160 CE Operation and Maintenance Manual l) Level the laminator from drive side to control side by adjusting the two front leveling pads. - To raise; raise the nut inside the leg and turn the nut below the leg clockwise.

  • Page 42: Connecting Power

    F - 160 CE Operation and Maintenance Manual m) Turn the pull roller lift handle towards the rear of the machine to lower the upper pull roller. Stop after initial contact with the lower pull roller plus 1/2 turn. n) Raise the rear safety shield o) Place the level across the top of the upper pull roller in the center.
  • Page 43 Figure 4.9.2 Wye three phaseillustrates proper Wye 3 phase wiring for Europe. Page 4 - 16 F - 160 CE Operation and Maintenance Manual e) Turn the junction box power to the ON position. f) Verify line voltage with regards to the type of power being supplied to the laminator at the line terminal block.
  • Page 44 F - 160 CE Operation and Maintenance Manual Figure 4.9.1 Single phase, U.S. and Canada Figure 4.9.2 Wye 3 phase, Europe only © GBC Films Group April 2000 Installation Ground wire Line 1 Line 2 Ground wire Line 1 Line 2...

  • Page 45: Safety Check

    Contacts: GBC National Service: ( 800 ) 790 - 7787 GBC Europe Service: 33 - 45 - 535 - 7676 Page 4 - 18 F - 160 CE Operation and Maintenance Manual 4.10.1 Front feed table a) Turn MAIN POWER to “ON”...
  • Page 46 F - 160 CE Operation and Maintenance Manual d) Press FWD to set a forward motor direction. 00.0 STOP SPEED SAFETY e) Press SPEED to set a speed of 6 ft/min. STOP SPEED SAFETY f) Press GO. The bottom rollers begin turning.

  • Page 47: Safety Shield

    STOP SPEED SAFETY = Flashing Page 4 - 20 F - 160 CE Operation and Maintenance Manual c) Lower the front safety shield. SAFETY indicator reverts to white and GO remains flashing. F W D d) Press STOP .GO stops flashing.

  • Page 48: E-Stop

    F - 160 CE Operation and Maintenance Manual 4.10.3 E-STOP a) Press GO. The bottom rollers begin turning. STOP SPEED SAFETY b) Press PRESSURE to illuminate 3 bars in the pressure dsiplay. PRESSURE c) Press down on the front control side E-STOP.

  • Page 49: E-Cable

    The bottom rollers stop, the upper main roller raises and the control panel is blank. Page 4 - 22 F - 160 CE Operation and Maintenance Manual d) Latch the E-CABLE by pushing in on the E- CABLE reset located in the front at the bottom of the control side leg.

  • Page 50: Function Check

    F - 160 CE Operation and Maintenance Manual 4.11 Function check The function check ensures that the laminator functions properly when operating. This check is recommended before performing any applications. If a step that does not react according to the description, call your local area service representative immediately.
  • Page 51 GAP DISPLAY changes to “ 1 ” then stops. PRESSURE Page 4 - 24 F - 160 CE Operation and Maintenance Manual h) Press JOB in increments of 1 to 9. . The upper i) Press JOB decreases in increments of 1 from 9 to 0.
  • Page 52 F - 160 CE Operation and Maintenance Manual j) Press SPEED once. SPEED DISPLAY increases in increments of .5 per press up to 15. 15.0 STOP SPEED SAFETY k) Press FWD . FWD is solid. 15.0 STOP SPEED SAFETY l) Press GO. The bottom rollers turn in a forward motion at a speed of 15 ft./min.
  • Page 53 +/- 6 temperature. TOP TEMP BOT TEMP Page 4 - 26 F - 160 CE Operation and Maintenance Manual Caution should always be exercised when using the laminator with F W D You can be seriously HURT or INJURED! s) Raise the front safety shield, remove the front feed table.

  • Page 54: Figure 4.11.1 Default Settings

    F - 160 CE Operation and Maintenance Manual u) Press STANDBY. The laminator reverts to the default settings and STANDBY is solid. Refer to Figure 4.11.1 Default settings STANDBY Figure 4.11.1 Default settings TOP TEMP BOT TEMP PRESSURE 1/16 IIIIIII STANDBY 00.0...

  • Page 55: Unwind Shafts And Unwind Brakes

    Should you detect or experience complications with the unwind shaft movement or the unwind brake tension, call you local area service representative. Page 4 - 28 F - 160 CE Operation and Maintenance Manual WARNING Caution should always be exercised when using the laminator with the safety shields raised.
  • Page 56 F - 160 CE Operation and Maintenance Manual INFORMATION Steps " e" and " f" will be performed simultaneously. e) With one hand, slowly turn the upper unwind shaft in either direction. f) With the other hand, slowly turn the upper unwind brake adjustment knob clockwise.
  • Page 57 Installation F - 160 CE Operation and Maintenance Manual This page intentionally left blank. Page 4 - 30 © GBC Films Group April 2000...

  • Page 58: Section 5 Operations

    F - 160 CE Operation and Maintenance Manual Section 5 Operations The operator control panel for the Falcon 160 CE Laminator is located on the front of the machine, to the right of the front operating position. For an illustration of the complete front control panel, please refer to Figure 5.1.1.
  • Page 59 TOP TEMP BOT TEMP Page 5 - 2 F - 160 CE Operation and Maintenance Manual ( 8 ) OVER/ UNDER INDICATORS : Dislays a “+” if the temperature is above the set point. Display a “–” if the temperature is below the set point. If neither (+/ -) is...
  • Page 60 F - 160 CE Operation and Maintenance Manual ( 11 ) GAP : When pressed, will decrease the gap by 1/16 in. increments. If held down, it will automatically decrease the gap by 1/16 in. increments until it has reached a minimum opening of 0 in.
  • Page 61 STANDBY Page 5 - 4 F - 160 CE Operation and Maintenance Manual ( 17 ) JOB number in JOB DISPLAY by increments of 1. If pressed and held, the JOB DISPLAY will decrease to 0 at which point it will stop.
  • Page 62 F - 160 CE Operation and Maintenance Manual ( 19 ) SAVE : When pressed and held ( approximately 4 seconds ), will beep and 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.
  • Page 63 SPEED SAFETY Page 5 - 6 F - 160 CE Operation and Maintenance Manual ( 28 ) Variable Speed Footswitch : The variable speed footswitch, operates the laminator in “Footswitch” mode. Within this mode, if the safety shield is up, speed is determined by the variable speed footswitch but limited to the speed set in the display.
  • Page 64 F - 160 CE Operation and Maintenance Manual INFORMATION When the safety shield is in the lowered position and "Footswitch" mode is engaged, speed is controlled through the control panel Footswitch to Panel 2. To switch from “Footswitch” mode ( GO is flashing ) to “Panel”...
  • Page 65 • Adjust for desired speed using the variable speed footswitch. Page 5 - 8 F - 160 CE Operation and Maintenance Manual INFORMATION Footswitch speed is not indicated in the SPEED DISPLAY on the control panel.

  • Page 66: Figure 5.1.1 Front Control Panel

    F - 160 CE Operation and Maintenance Manual Figure 5.1.1 Front control panel TOP TEMP 1/16 00.0 SPEED © GBC Films Group April 2000 BOT TEMP PRESSURE IIIIIII STANDBY STOP SAFETY = Flashing Operations F W D Page 5 - 9...

  • Page 67: Emergency

    Before pressing GAP down arrow, ensure the nip area is clear. Page 5 - 10 F - 160 CE Operation and Maintenance Manual 5.2.1 In an emergency a) In the event of an emergency; - Press any of the four E-STOPs, or...

  • Page 68: Resume Operation

    F - 160 CE Operation and Maintenance Manual 5.2.2 Resume operation a) Reset the E-STOP or the E-CABLE. -Resetting the E-STOP Unlatch -Resetting the E-CABLE Push in INFORMATION The laminator will only turn on if all E-STOPS are unlatched and the E-CABLE is reset.

  • Page 69: Set Up

    Turn the MAIN POWER to the “ I ” position. Power ON/OFF Page 5 - 12 F - 160 CE Operation and Maintenance Manual d) Press machine RESET. The front control panel is illuminated. Machine reset 5.3.2 Film loading...
  • Page 70 F - 160 CE Operation and Maintenance Manual c) Swing the unwind shaft out enough to slide the roll of laminate over the core chucks and onto the unwind shaft. Brake adjust knob Core support Roll of laminate Core chucks...

  • Page 71: Chart 5.3.1 Measurement Chart

    For the lower unwind shaft, add 1/4 in. to the measurement. Page 5 - 14 F - 160 CE Operation and Maintenance Manual 5.3.5 Heating Perform the following steps.if the application requires heat. Allow the rolls to heat up while rotating for 28 "...
  • Page 72 F - 160 CE Operation and Maintenance Manual c) Press GAP to set the gap to “0”. PRESSURE INFORMATION Do not add PRESSURE when heating the laminating rollers. The rollers expand. d) Press FWD to set a forward motion direction.

  • Page 73: Job Programming

    STANDBY Page 5 - 16 F - 160 CE Operation and Maintenance Manual c) Press SEL. d) If heat is required, press TOP TEMP. BOT. TEMP.

  • Page 74: Chart 5.4.1 Job Save Chart

    F - 160 CE Operation and Maintenance Manual INFORMATION When storing parameters within the JOB SAVE feature of the laminator, PRESSURE is not a storable setting. f) Enter a desired speed by pressing SPEED STOP SPEED SAFETY g) Press and hold SAVE ( approximately 4 seconds ) until an audible beep is heard.

  • Page 75: Manual Nip Adjustment

    The laminator will only turn on if all E-STOPS are unlatched and the E-CABLE is reset. Page 5 - 18 F - 160 CE Operation and Maintenance Manual a) Turn the MAIN POWER to the “ I ” position. Power ON/OFF b) Press RESET.
  • Page 76 F - 160 CE Operation and Maintenance Manual c) Raise the front safety shield. d) Press SEL. STANDBY = Flashing e) Position the leader board in the center of the main rollers between the nip. CAUTION Sharp edges on a substrate should be filed smooth and GAP manually adjusted.
  • Page 77 Press SPEED to 5. STOP SPEED SAFETY Page 5 - 20 F - 160 CE Operation and Maintenance Manual Proper When operating the laminator using the pressure variable speed footswitch, keep hands and fingers away from the nip of the rollers.

  • Page 78: Pull Roller Manual Nip Adjustment

    F - 160 CE Operation and Maintenance Manual l) On the control panel press FWD forward motor direction. Nip is now set. 00.0 S P E E D S T O P S A F E T Y 5.5.2 Pull roller manual nip...
  • Page 79 Position the leader board in the center of the pull rollers between the nip. Page 5 - 22 F - 160 CE Operation and Maintenance Manual Sharp edges on a substrate should be filed smooth and GAP manually adjusted.
  • Page 80 F - 160 CE Operation and Maintenance Manual INFORMATION Excessive pressure will cause the substrate to bow or flatten. INFORMATION Refer to Figure 5.5.2 for proper roller pressure. Figure 5.5.2 Pull roller pressure Leader board Leader board © GBC Films Group April 2000 Density of the substrate will determine the amount of pressure you may use.

  • Page 81: Front Feed Table

    If not installed properly, you can be injured or cause damage to the table or laminator. Page 5 - 24 F - 160 CE Operation and Maintenance Manual 5.6.1 Removing the table F W D Caution should always be exercised...
  • Page 82 F - 160 CE Operation and Maintenance Manual 5.6.2 Replacing the infeed table a) Ensure the safety shiled is in the raised position. b) With both hands, grip the front edge of the infeed table and align the back edge with the support bolts.
  • Page 83 Operations F - 160 CE Operation and Maintenance Manual This page intentionally left blank. Page 5 - 26 © GBC Films Group April 2000...

  • Page 84: Section 6 Applications

    F - 160 CE Operation and Maintenance Manual Section 6 Applications 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.
  • Page 85 Parameters will vary with regards to laminate thickness, laminate widths, laminates types, print types, ink or toner types, enviroment conditions, operater experience, and various substrates. Page 6 - 2 F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000...

  • Page 86: Chart 6.1.1 Temperature Conversion Chart

    F - 160 CE Operation and Maintenance Manual Chart 6.1.1 Temperature conversion chart 1 1 3 20.6 1 1 4 1 1 5 21.1 1 1 6 21.7 22.2 1 1 7 22.7 1 1 8 23.3 1 1 9 23.9...
  • Page 87 L O W E R U N W I N D : TOP TEMP. G A P S P E E D D O W N Page 6 - 4 F - 160 CE Operation and Maintenance Manual Parameter Chart - Blank MATERIALS SUBSTRATE : PRINTS : TEMPERATURE GAP &...
  • Page 88 F - 160 CE Operation and Maintenance Manual Applications Web Diagram - Blank © GBC Films Group April 2000 Page 6 - 5...

  • Page 89: Chart 1 - Precoating Substrates

    Because the process is described from the front of the laminator, motor direction is FWD and the pull rolls are not required for this application. Page 6 - 6 F - 160 CE Operation and Maintenance Manual MATERIALS S U B S T R A T E :...
  • Page 90 F - 160 CE Operation and Maintenance Manual Applications Web Diagram 1 - Precoating substrate Mount Substrate Leader board © GBC Films Group April 2000 Page 6 - 7...

  • Page 91: Chart 2 - Mounting Only

    FWD and the pull rolls are not required for this application. Page 6 - 8 F - 160 CE Operation and Maintenance Manual MATERIALS S U B S T R A T E :...

  • Page 92: Diagram 2 - Mounting Only

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

  • Page 93: Chart 3 - Single Sided ( Sled )

    FWD and the pull rolls are not required for this application. Page 6 - 10 F - 160 CE Operation and Maintenance Manual MATERIALS S U B S T R A T E :...

  • Page 94: Diagram 3 - Single Sided ( Sled )

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

  • Page 95: Chart 4 - Single Sided ( Craft Paper )

    1/2 turn and 3/4 turn. Because the process is described from the front of the laminator, motor direction is FWD. Page 6 - 12 F - 160 CE Operation and Maintenance Manual MATERIALS S U B S T R A T E :...

  • Page 96: Diagram 4 - Single Sided ( Craft Paper )

    F - 160 CE Operation and Maintenance Manual Applications Web Diagram 4 - Single sided ( Craft paper ) P .S .A. R e le a s e lin e r L a m in a te O u tp u t...

  • Page 97: Chart 5 - Decal And Mount ( Decal )

    1/2 turn and 3/4 turn. Because the process is described from the front of the laminator, motor direction is FWD. Page 6 - 14 F - 160 CE Operation and Maintenance Manual MATERIALS S U B S T R A T E :...

  • Page 98: Diagram 5 - Decal And Mount ( Decal )

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

  • Page 99: Chart 6 - Decal And Mount ( Mount )

    Because the process is described from the front of the laminator, motor direction is FWD and the pull rolls are not required for this application. Page 6 - 16 F - 160 CE Operation and Maintenance Manual MATERIALS S U B S T R A T E :...

  • Page 100: Diagram 6 - Decal And Mount ( Mount )

    F - 160 CE Operation and Maintenance Manual Applications Web Diagram 6 - Decal and mount ( Mount ) Decal Release liner Substrate © GBC Films Group April 2000 Page 6 - 17...
  • Page 101 FWD and the pull rolls are not required for this application. Page 6 - 18 F - 160 CE Operation and Maintenance Manual MATERIALS S U B S T R A T E :...
  • Page 102 F - 160 CE Operation and Maintenance Manual Applications Web Diagram 7 - Precoating substrate ( Thermal ) Tissue Substrate Leader board 140 - © GBC Films Group April 2000 Page 6 - 19...

  • Page 103: Chart 8 - One Pass Mount

    FWD and the pull rolls are not required for this application. Page 6 - 20 F - 160 CE Operation and Maintenance Manual MATERIALS S U B S T R A T E :...

  • Page 104: Diagram 8 - One Pass Mount

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

  • Page 105: Chart 9 - Thermal Decal And Mount ( Decal )

    1/2 turn and 3/4 turn. Because the process is described from the front of the laminator, motor direction is FWD. Page 6 - 22 F - 160 CE Operation and Maintenance Manual MATERIALS S U B S T R A T E :...

  • Page 106: Diagram 9 - Thermal Decal And Mount ( Decal )

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

  • Page 107: Chart 10 - Thermal Decal And Mount ( Mount )

    The rollers may be left heated or turn them down 68 with be dependent of the substrate. Apply the necessary pressure without crushing the board. Page 6 - 24 F - 160 CE Operation and Maintenance Manual MATERIALS S U B S T R A T E :...

  • Page 108: Diagram 10 - Thermal Decal And Mount ( Mount )

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

  • Page 109: Chart 11 - Encapsulation

    Pull roll pressure will very between 1/2 turn and 3/4 turn, depending on the film output quality. Because the process is described from the front of the laminator, motor direction is FWD. Page 6 - 26 F - 160 CE Operation and Maintenance Manual MATERIALS S U B S T R A T E :...

  • Page 110: Diagram 11 - Encapsulation

    F - 160 CE Operation and Maintenance Manual Applications Web Diagram 11 - Encapsulation Octiva Gloss Output Print Octiva Gloss Finish product rewind option © GBC Films Group April 2000 Page 6 - 27...
  • Page 111 Applications F - 160 CE Operation and Maintenance Manual This page intentionally left blank. Page 6 - 28 © GBC Films Group April 2000...

  • Page 112: Wave Problems

    F - 160 CE Operation and Maintenance Manual Section 7 Troubleshooting 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.
  • Page 113 • Check the nip setting of pull rolls • Check for even paper tension Page 7 - 2 F - 160 CE Operation and Maintenance Manual Problem: Angled waves in the output on both sides Hints: • Check for insufficient main roller pressure •...

  • Page 114: Film Problems

    F - 160 CE Operation and Maintenance Manual 7.2 Film problems The following is a list of common film problems you may encounter. For definitions of terminologies, please refer to 7.4 Glossary of terminology. 7.2.1 Thermal laminates Problem: Blistering within the image Hints: •...

  • Page 115: Machine Problems

    You may do this by dialing 1 ( 800 ) 790 - 7787. This will connect you with GBC National Service dispatch . You will be required to give the serial number of your machine when placing a service call.

  • Page 116: Glossary

    F - 160 CE Operation and Maintenance Manual Problem : I press GO, and the rolls will not turn. Hints : • Be sure a speed has been entered. • Make sure a motion direction has been selected. • Make sure GO or SEL is not flashing.
  • Page 117 Page 7 - 6 F - 160 CE Operation and Maintenance Manual Encapsulation When an image is completely encased in laminating film, it is encapsulated. A border of laminate on laminate exists around the perimeter of the product.
  • Page 118 F - 160 CE Operation and Maintenance Manual Main rollers These are the rolls that perform the actual lamination. They are rolls capable of being heated in thermal roll laminators and are usually larger in diameter than the pull rolls.
  • Page 119 A system that unwinds media. Unwinds are used on all laminators to dispense laminate for lamination. The path that rolled media unwinding from a supply Page 7 - 8 F - 160 CE Operation and Maintenance Manual © GBC Films Group April 2000...

  • Page 120: Maintenance Schedule

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

  • Page 121: Cleaning The Rollers

    • Several 100% cotton terry cloths ( best for lint free cleaning ) Page 8 - 2 F - 160 CE Operation and Maintenance Manual Preparation of the laminator a) Turn the MAIN POWER to the “ I ” position.
  • Page 122 F - 160 CE Operation and Maintenance Manual c) Press SEL. STANDBY = Flashing WARNING Caution should always be exercised when using the laminator with the safety shields raised. You can be seriously HURT or INJURED! d) Open the front and rear safety shields.
  • Page 123 Speed is controlled through the variable speed footswitch when the safety shield is in the raised position. Page 8 - 4 F - 160 CE Operation and Maintenance Manual Cleaning the beads of adhesives, dust and dirt from the rolls This can be done one of two different methods.
  • Page 124 F - 160 CE Operation and Maintenance Manual c) Press SPEED to enter a speed of 3. STOP SPEED SAFETY 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.
  • Page 125 Position the center of the board between the rollers. Page 8 - 6 F - 160 CE Operation and Maintenance Manual e) Set the nip of the rollers to the thickness of the adhesive coated boards. F W D...

  • Page 126: Cabinets And Covers

    F - 160 CE Operation and Maintenance Manual 8.2.1 Clean the cabinets and covers ELECTRICAL S H O C K 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.
  • Page 127 Maintenance F - 160 CE Operation and Maintenance Manual This page intentionally left blank. Page 8 - 8 © GBC Films Group April 2000...

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