Page 1 F - 160 OPERATION AND MAINTENANCE MANUAL © November 1999 GBC Pro-Tech Do not duplicate without written permission. Plane4 Plane4 Plane4 GBC Pro - Tech 4151 Anderson Road DeForest, WI 53532 Revision : B Ph: ( 608 ) 246 - 8844...
Page 2 Reference in this publication to information or products protected by copyright or patent does not convey any license under the rights of GBC Pro - Tech or others. GBC Pro - Tech assumes no liability arising from infringements of patents or any other rights of third parties.
Page 3 Read me file F - 160 Operation and Maintenance Manual This page intentionally left blank. © GBC Pro - Tech August 1999...
Page 4: Fax Correspondence
F - 160 Operation and Maintenance Manual Fax Correspondence Fax number : ( 608 ) 246 - 8645 To : Sean Flood @ GBC Pro - Tech 4151 Anderson Road DeForest, WI 53532 From : Company : Address : Phone number : ( Re : Falcon 160 Operations and Maintenance Manual ( Rev.
Page 5 Read me file F - 160 Operation and Maintenance Manual This page intentionally left blank. © GBC Pro - Tech August 1999...
Page 6: Table Of Contents
F - 160 Operation and Maintenance Manual Section 1: Safety 1.1 Symbols ...1 - 1 1.2 Safety features ...1 - 1 1.3 Installation ...1 - 4 1.4 Operations ...1 - 8 1.5 Applications ...1 - 12 1.6 Troubleshooting ...1 - 16 1.7 Maintenance ...1 - 16...
Page 7 Figure 4.1.2 Single phase ( U.S. ) ...4 - 4 Figure 4.1.3 Three phase ( Europe ) ...4 - 4 4.2 Unpacking ...4 - 5 Page II F - 160 Operation and Maintenance Manual © GBC Pro - Tech August 1999...
Page 8 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 ...4 - 8 4.7 Safety check ...4 - 11 4.7.1 Front and rear infeed tables ...4 - 12 4.7.2 Front and rear safety shields ...4 - 14...
Page 9 5.5 Manual nip adjustment ...5 - 17 5.5.1 Main roller manual nip adjustment ...5 - 17 5.5.2 Pull roller manual nip adjustment ...5 - 20 Page IV F - 160 Operation and Maintenance Manual © GBC Pro - Tech August 1999...
Page 10 F - 160 Operation and Maintenance Manual 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 6.1 Precoating substrates ...6 - 1 6.2 Mounting only ...6 - 10 6.3 Single sided lamination ( Sled method ) ...6 - 17...
Page 11 Figure 6.10.1 Temperature conversion chart ...6 - 95 Blank chart ...6 - 96 Blank diagram ...6 - 97 Chart 1 - Precoating substrates ...6 - 98 Page VI F - 160 Operation and Maintenance Manual Group 2: Top heat only © GBC Pro - Tech August 1999...
Page 12 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 ) ...6 - 102 Diagram 3 - Single sided ( Sled ) ...6 - 103...
Page 13 7.2 Film problems ...7 - 3 7.2.1 Thermal laminates ...7 - 3 7.2.2 Pressure senstive ...7 - 3 7.3 Machine problems ...7 - 4 Page VIII F - 160 Operation and Maintenance Manual © GBC Pro - Tech August 1999...
Page 14 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 ...8 - 6 8.2.2 Touch screen control panel ...8 - 6 ©...
Page 15 Table of Contents F - 160 Operation and Maintenance Manual This page is intentionally left blank Page X © GBC Pro - Tech August 1999...
Page 16: Section 1 Safety
Your safety, as well as the safety of others, is important to GBC Pro - Tech. This section contains important safety information. The following symbols are used throughout this manual to indicate Information, Caution, Warning, Danger and Electrical Shock conditions.
Page 17 • 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.
Page 18 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.
Page 19: Installation
Please see footswitch in section 3 of this manual. Figure 1.2.5 Tables and keys Page 1 - 4 F - 160 Operation and Maintenance Manual 1.3 Installation 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.
Page 20 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. 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.
Page 21 Tech bears no responsibility for personal injury or damage due to moving the laminator improperly. Page 1 - 6 F - 160 Operation and Maintenance Manual CAUTION Do not allow the top to fall into the crate. It can damage the laminator.
Page 22 F - 160 Operation and Maintenance Manual INFORMATION The side frame provides a more accurate reading than the cabinet. INFORMATION A second person can read the level while you make the appropriate adjustments. WARNING Caution should always be exercised when using the laminator with the safety shields raised.
Page 23: Operations
"beep" only once. INFORMATION When adjusting the pressure, the gap will be affected as well. Page 1 - 8 F - 160 Operation and Maintenance Manual WARNING Keep hands and fingers clear of the laminator roller nip when adjusting PRESSURE.
Page 24 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 Caution should always be exercised when using the laminator with the safety shields raised.
Page 25 Do not add PRESSURE when heating the laminating rollers, this allows the high release silicone to expand with minimum restrictions. Page 1 - 10 F - 160 Operation and Maintenance Manual INFORMATION Slow speed will assists with heat up times and distributes heat evenly. INFORMATION...
Page 26 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. INFORMATION You should store each job location with its parameters on the chart provided in Figure 5.4.1...
Page 27: Applications
If it does, you will experience complications with this application. Page 1 - 12 F - 160 Operation and Maintenance Manual CAUTION Sharp edges on a substrate should be filed smooth and GAP manually adjusted.
Page 28 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.
Page 29 CAUTION When manually setting the main roll nip, observe the substrate to prevent crushing. Page 1 - 14 F - 160 Operation and Maintenance Manual INFORMATION When requiring top and bottom heat, it is recommended to set both temperatures to the same set point.
Page 30 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. INFORMATION If the board is not squarely positioned, you may experience difficulties with this application.
Page 31: Troubleshooting
C L E A N I N G H E A T E D R O L L E R S C A N I G N I T E T H E F U M E S ! Page 1 - 16 F - 160 Operation and Maintenance Manual CAUTION Prolonged contact can form flat spots on the rollers.
Page 32 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. ELECTRICAL S H O C K Remove power from the laminator before servicing.
Page 33 Keep hands and fingers clear of the laminator roller nip when changing GAP. You can be CRUSHED or BURNED! Page 1 - 18 F - 160 Operation and Maintenance Manual WARNING Keep hands and fingers clear of the laminator roller nip when adjusting PRESSURE.
Page 34: Label Locations
F - 160 Operation and Maintenance Manual 1.8 Label locations Cautions / Warning 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 1.8.1 illustrates the location of each of these labels.
Page 35 WARNING ACHTUNG MISE EN GARDE Behind Cover WARNING ACHTUNG MISE EN GARDE Page 1 - 20 F - 160 Operation and Maintenance Manual WARNING ACHTUNG MISE EN GARDE Behind Cover © GBC Pro - Tech August 1999 WARNING ACHTUNG MISE EN GARDE...
Page 36: Section 2 Warranty
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.
Page 37 • 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.
Page 38: Section 3: Specifications
F - 160 Operation and Maintenance Manual Section 3.1 General Description : Features : Applications : Section 3.2 Consumables Film Types : Film Diameters : Core Size : Film Widths : Paper Widths : Mounting Thickness : © GBC Pro - Tech August 1999 •...
Page 39: Function
D/C Voltage used : A/C Voltage used: Page 3 - 2 F - 160 Operation and Maintenance Manual • 0 - 15 ft / min ( 0 - 4.6 m / min ) • 2-1/4 horse power drive motor • Bi-directional D.C. motor •...
Page 40: Figure 3.5.1 Dimensions
F - 160 Operation and Maintenance Manual Section 3.5 Dimensions Weight : Dimensions : Nip Height : Safety Shield Raised Height : Figure 3.5.1 Dimensions 54" © GBC Pro - Tech August 1999 • Crated : 1568 lbs. ( 711 kg. ) •...
Page 41 Specifications F - 160 Operation and Maintenance Manual This page intentionally left blank. Page 3 - 4 © GBC Pro - Tech August 1999...
Page 42: Section 4 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.
Page 43 Such action disturbs the exact alignment of the rolling parts of the machine and requires extensive realignment. You can be crushed or seriously injured. Page 4 - 2 F - 160 Operation and Maintenance Manual © GBC Pro - Tech August 1999...
Page 44: Figure 4.1.1 Suggested Floor Layout
F - 160 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 Pro - Tech August 1999 4' x 6' ( 1.22 m x 2m )
Page 45 Installation F - 160 Operation and Maintenance Manual Figure 4.1. 2 Single phase, U.S. TB 2 TB 1 Incoming line voltage Figure 4.1.3 Wye 3 phase, Europe only TB 2 TB 1 L 3 - 2 Incoming line voltage Correct Configuration Page 4 - 4 ©...
Page 46: Unpacking
You can cause irreparable damage to the rollers. c) With another person, carefully wheel your F - 160 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 47: Crated
Page 4 - 6 F - 160 Operation and Maintenance Manual Figure 4.4.1 Disassembling of the crate Removing the shrink wrap a) Gently unwrap the shrink wrap from around the laminator.
Page 48 F - 160 Operation and Maintenance Manual Moving the laminator 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.
Page 49: Accessory Pack Content
• One fuse, 0.5A ( 186-022 ) • Two fuses, 2.5A ( 186-220 ) Page 4 - 8 F - 160 Operation and Maintenance Manual If you are missing any of the itemslisted above, contact your local service technician or sales representative.
Page 50 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 Figure 4.6.1 Foot bolts Foot bolts Leveling pads c) Lock the castors in place to prevent the laminator from rolling while leveling.
Page 51 Press RESET. The front control panel should be illuminated at this point. Reset Page 4 - 10 F - 160 Operation and Maintenance Manual WARNING Caution should always be exercised when using the laminator with the safety shields raised.
Page 52: Safety Check
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 Figure 4.6.4 Left to right Level Plane4 l) Level the machine from left to right.
Page 53: Front And Rear Infeed Tables
Press SEL. The SEL key should stop flashing. S E L J O B S H U T D O W N Page 4 - 12 F - 160 Operation and Maintenance Manual d) Press FWD direction. 00.0 S P E E D...
Page 54 F - 160 Operation and Maintenance Manual g) Slightly lift the front infeed table. SAFETY indicator and GO begin flashing and the bottom rollers stop. S P E E D S T O P S A F E T Y = Flashing h) Lower the front infeed table.SAFETY...
Page 55: Front And Rear Safety Shields
You can be seriously HURT or INJURED! Page 4 - 14 F - 160 Operation and Maintenance Manual b) Raise the front safety shield. SAFETY indicator and GO begin flashing and the bottom rollers stop.
Page 56: Emergency Stops
F - 160 Operation and Maintenance Manual j) Press GO. The bottom rollers begin turning. S P E E D S T O P S A F E T Y WARNING Caution should always be exercised when using the laminator with the safety shields raised.
Page 57 Press RESET. The front control panel is illuminated. R E S E T Page 4 - 16 F - 160 Operation and Maintenance Manual e) Press SEL. SEL stops flashing. S E L J O B S H U T D O W N f) Press FWD for a forward motor direction.
Page 58: Function Check
F - 160 Operation and Maintenance Manual h) Press GO. The bottom rollers will begin to turn. S P E E D S T O P S A F E T Y i) Press down on the drive side E-STOP. The E- STOP latches in the down position, bottom rollers stop, and the control panel is blank.
Page 59: Control Panel
G A P P R E S S U R E 1 - 0 Page 4 - 18 F - 160 Operation and Maintenance Manual d) Press GAP . GAP DISPLAY increases 1/16th of an inch per press. The upper main roll moves accordingly.
Page 60 F - 160 Operation and Maintenance Manual g) Press JOB . The JOB DISPLAY should increases in increments of 1 to 9. S E L J O B S H U T D O W N h) Press JOB . The JOB DISPLAY should decreases in increments of 1 from 9 to 0.
Page 61 S T O P S A F E T Y Page 4 - 20 F - 160 Operation and Maintenance Manual o) Press GO. The bottom rollers turn in a reverse motion at a speed of 15 ft./min. ( 4.57 m / min. ).
Page 62: Figure 4.8.1 Default Settings
F - 160 Operation and Maintenance Manual r) The TOP TEMP DISPLAY and BOT TEMP DISPLAY are solid indicating the actual temperature is within a +/- 10 temperature. S L E E P T O P T E M P .
Page 63: Variable Speed Footswitch
S P E E D S T O P S A F E T Y Page 4 - 22 F - 160 Operation and Maintenance Manual c) Press down on the variable speed footswitch. GO begins flashing and the bottom rollers are turning.
Page 64: Clevis Pin
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! a) Raise the rear safety shield. b) Lift the clevis pin up from the saddle of the upper unwind shaft.
Page 65 Lower the rear safety shield. k) Now perform steps “b” through “h” again for the lower unwind shaft. Lower unwind brake adjustment dial Page 4 - 24 F - 160 Operation and Maintenance Manual © GBC Pro - Tech August 1999...
Page 66: Section 5 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. For an illustration of the complete front control panel, please refer to Figure 5.1.1.
Page 67 B O T . T E M P Page 5 - 2 F - 160 Operation and Maintenance Manual ( 8 ) GAP DISPLAY : Displays the current main roller nip opening. The nip has a range of 0 to 1” gap.
Page 68 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.
Page 69 J O B S H U T D O W N Page 5 - 4 F - 160 Operation and Maintenance Manual ( 18 ) SAVE : When pressed, will save the current settings for the number showing in the JOB DISPLAY.
Page 70 F - 160 Operation and Maintenance Manual ( 21 ) SPEED : 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.
Page 71 ATTUNG WARNING ADVERTENCIA Page 5 - 6 F - 160 Operation and Maintenance Manual 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;...
Page 72 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. • Release GO. GO should be solid.
Page 73 • Press and hold GO for 3 -4 seconds before releasing the variable speed footswitch. • Release the variable speed footswitch. • Release GO. GO reverts to solid. Page 5 - 8 F - 160 Operation and Maintenance Manual © GBC Pro - Tech August 1999...
Page 74: Figure 5.1.1 Front Control Panel
F - 160 Operation and Maintenance Manual Figure 5.1.1 Front control panel S L E E P T O P T E M P . G A P J O B 00.0 S P E E D S A F E T Y ©...
Page 75: Emergency
Page 5 - 10 F - 160 Operation and Maintenance Manual Reacting to an emergency a) In the event of an emergency, press one of the two E-STOP located on the top of the drive side and control side cabinets.
Page 76: Set Up
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 INFORMATION Once RESET has been engaged, power will be restored, Laminating rollers will reset to 1 in.
Page 77: Film Loading
Lift the clevis pin located in the saddle of the upper unwind shaft. Page 5 - 12 F - 160 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.
Page 78: Figure 5.3.4 Measurement Chart
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.
Page 79 P R E S S U R E G A P Page 5 - 14 F - 160 Operation and Maintenance Manual Do not add PRESSURE when heating the laminating rollers, this allows the high release silicone to expand with minimum d) Press FWD direction.
Page 80: Job Programming
F - 160 Operation and Maintenance Manual f) Press SEL to engage the parameters. S E L J O B S H U T D O W N g) Press GO to engage the motor drive system. S P E E D...
Page 81 When storing parameters within the JOB SAVE feature of the laminator, PRESSURE is not a storable setting. Page 5 - 16 F - 160 Operation and Maintenance Manual e) Enter a desired speed by pressing SPEED F ( 20 C ).
Page 82: Figure 5.4.1 Job Save Chart
F - 160 Operation and Maintenance Manual Figure 5.4.1 Job save chart JOB # TOP TEMP. BOT. TEMP. 5.5 Manual nip adjustment If the substrate does not fall with in the preset GAP settings available, a manual nip setting must be performed.
Page 83 Keep hands and fingers clear of the laminator roller nip when changing GAP. You can be CRUSHED or BURNED! Page 5 - 18 F - 160 Operation and Maintenance Manual f) At eye level with the main rollers, press PRESSURE roller make contact with the substrate.
Page 84 F - 160 Operation and Maintenance Manual Figure 5.5.1 Main roller pressure Leader board Leader board g) Press REV for a reverse motor direction. 00.0 S P E E D S T O P S A F E T Y...
Page 85: Pull Roller Manual Nip Adjustment
Power b) Press RESET. The front control panel will illuminated. Reset Page 5 - 20 F - 160 Operation and Maintenance Manual c) Press SEL. S E L J O B S H U T D O W N Flashing d) Press FWD for a forward motor direction.
Page 86 F - 160 Operation and Maintenance Manual f) Raise the rear safety shield. g) Position the leader board in the center of the pull rollers between the nip. CAUTION Sharp edges on a substrate should be filed smooth and GAP manually adjusted.
Page 87 Y o u m a y b e C R U S H E D o r B U R N E D ! g) Step on the variable speed footswitch to back the leader board out. Page 5 - 22 F - 160 Operation and Maintenance Manual Speed is controlled through the variable speed footswitch when the safety shield Proper pressure h) The pull roller nip has now been manually set.
Page 88: Infeed Tables
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. CAUTION If not installed properly, you can be injured or cause damage to the table or laminator.
Page 89 If the tables are not properly seated, the laminator will not operate in "Panel" mode. Figure 5.6.3 Safety roller switch Safety roller switch Page 5 - 24 F - 160 Operation and Maintenance Manual Back support bolt © GBC Pro - Tech August 1999...
Page 90: Section 6 Applications
F - 160 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 91: Clevis Pin
You can be seriously HURT or INJURED! Page 6 - 2 F - 160 Operation and Maintenance Manual Figure 6.1.1 MAIN POWER / RESET g) Lift the clevis pin located in the saddle of the upper unwind shaft.
Page 92 F - 160 Operation and Maintenance Manual Figure 6.1.2 Unwind shaft Saddle Core support Brake adjust knob i) Once loaded, swing the upper unwind shaft back into the saddle. CAUTION Ensure the roll of laminate is loaded properly on the unwind shaft.
Page 93 S T O P S A F E T Y Page 6 - 4 F - 160 Operation and Maintenance Manual When operating the laminator using the variable speed footswitch, keep hands and fingers away from the nip of the rollers.
Page 94 F - 160 Operation and Maintenance Manual INFORMATION Excessive pressure will cause the substrate to bow or flatten. q) Press STOP. 00.0 S P E E D S T O P S A F E T Y r) Press REV to reverse the direction of the motor.
Page 95 Y o u m a y b e C R U S H E D o r B U R N E D ! Page 6 - 6 F - 160 Operation and Maintenance Manual e) Push the leader board into the main roller nip while stepping on the variable speed footswitch.
Page 96 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. Y o u m a y b e C R U S H E D o r B U R N E D !
Page 97 The second person will raise the rear pull roller by turning the crank handle counterclockwise until separated. Page 6 - 8 F - 160 Operation and Maintenance Manual Figure 6.1.5 Trailer board Precoated board m) Stop the laminator when the trailer board is in the main roller nip.
Page 98 F - 160 Operation and Maintenance Manual Finishing a) Cut the web of mount adhesive at the upper unwind shaft with an enclosed blade. 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.
Page 99: Mounting Only
Figure 6.2.1 b) Press RESET. Refer to Figure 6.2.1 Page 6 - 10 F - 160 Operation and Maintenance Manual Figure 6.2.1 MAIN POWER / RESET c) Be sure the front and rear tables are in position and the rear pull rollers are in the up position.
Page 100 F - 160 Operation and Maintenance Manual e) Press SEL. SEL will stop flashing. S E L J O B S H U T D O W N WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP.
Page 101 S T O P S A F E T Y Page 6 - 12 F - 160 Operation and Maintenance Manual When operating the laminator through the variable speed footswitch, keep your hands away from the nip of the rollers. You may l) Press on the variable speed footswitch to back the board out of the main rollers.
Page 102 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. b) Place a padded paper weight or similar object in the center of the image to help hold the image in place.
Page 103 Set the precoated board with the image tacked to it in the center of the front infeed table. Page 6 - 14 F - 160 Operation and Maintenance Manual f) Press STOP. 00.0 S P E E D...
Page 104 F - 160 Operation and Maintenance Manual INFORMATION Use a slow speed. If the tack point enters the rollers nip, you will not be able to pull the release liner. - If the tack point enters the rollers nip perform the following steps then continue with this procedure.
Page 105 Y o u m a y b e C R U S H E D o r B U R N E D ! Page 6 - 16 F - 160 Operation and Maintenance Manual l) Press down on the variable speed footswitch just enough to give yourself a comfortable work speed.
Page 106: Single Sided Lamination ( Sled Method )
F - 160 Operation and Maintenance Manual Finishing a) Raise the main rollers to a 1 in. gap by pressing G A P P R E S S U R E b) Press STOP. 00.0 S P E E D...
Page 107 You can be seriously HURT or INJURED! Page 6 - 18 F - 160 Operation and Maintenance Manual e) Lift the clevis pin located in the saddle of the upper unwind shaft. Saddle...
Page 108 F - 160 Operation and Maintenance Manual g) Once loaded, swing the upper unwind shaft back into the saddle. CAUTION Ensure the roll of laminate is loaded properly on the unwind shaft. Exposed adhesive should be facing away from the rollers.
Page 109 Page 6 - 20 F - 160 Operation and Maintenance Manual Keep hands and fingers clear of S A V Y o u c a n C R U S H E D o r B U R N E D ! n) If the board is loose, press PRESSURE adjust the gap between the main rollers.
Page 110 F - 160 Operation and Maintenance Manual o) Press STOP. 00.0 S P E E D S T O P S A F E T Y p) Press REV to reverse the direction of the motor. 00.0 S P E E D...
Page 111 Figure 6.3.4 INFORMATION Position the leader board squarely onto the mount adhesive. Page 6 - 22 F - 160 Operation and Maintenance Manual Figure 6.3.4 Laminate separation Laminate CAUTION If the board is not squarely positioned, you may experience difficulties with this application.
Page 112 F - 160 Operation and Maintenance Manual INFORMATION Steps " i" and " j" will be performed simultaneously. WARNING When operating the laminator using the variable speed footswitch, keep hands and fingers away from the nip of the rollers. Y o u m a y b e C R U S H E D o r B U R N E D ! i) Push the leader board into the main roller nip while stepping on the variable speed footswitch.
Page 113 Stopping the rollers on the print will leave a pressure line on the image. Page 6 - 24 F - 160 Operation and Maintenance Manual Finishing a) Cut the web of laminate at the upper unwind shaft with an enclosed blade.
Page 114: Single Sided Lamination ( Craft Paper Method )
F - 160 Operation and Maintenance Manual d) Press STOP. 00.0 S P E E D S T O P S A F E T Y e) Clean the rollers as described in the maintenance section. ( Section 8.2 Cleaning...
Page 115 You can be seriously HURT or INJURED! Page 6 - 26 F - 160 Operation and Maintenance Manual e) Lift the clevis pin located in the saddle of the upper unwind shaft. S a d d l e...
Page 116 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. CAUTION Ensure the roll of laminate is loaded properly on the unwind shaft.
Page 117 Figure 6.4.3 Laminate to rewind P.S.A. Laminate Page 6 - 28 F - 160 Operation and Maintenance Manual c) Use a piece of masking tape, to adhere the leading edge of the laminate to the upper rewind tube. d) Wrap one full turn of laminate onto the upper rewind tube.
Page 118 F - 160 Operation and Maintenance Manual Figure 6.4.4 Laminate separation Remove h) Apply just enough brake tension to prevent the roll of craft paper from free spinning. INFORMATION Excessive brake tension may cause the image to curl when separated from the craft paper.
Page 119 Y o u m a y b e C R U S H E D o r B U R N E D ! Page 6 - 30 F - 160 Operation and Maintenance Manual n) Press on the variable speed footswitch to guide the cardboard, craft paper and laminate through the main rollers.
Page 120 F - 160 Operation and Maintenance Manual 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.
Page 121 S P E E D S T O P S A F E T Y Page 6 - 32 F - 160 Operation and Maintenance Manual v) Press SPEED comfortable working with. It is recommended that SPEED not exceed 9 ft./ min.
Page 122 F - 160 Operation and Maintenance Manual y) After the last print has passed through the pull rollers, press STOP. S P E E D S T O P S A F E T Y z) Press GAP to a 1 in. setting.
Page 123: Decal And Mount
S H U T D O W N End of application Page 6 - 34 F - 160 Operation and Maintenance Manual 6.5 Decal and mount 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.
Page 124: Clevis Pin
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 •...
Page 125 Leave the safety shield in the up position. Page 6 - 36 F - 160 Operation and Maintenance Manual j) Lift the clevis pin located in the saddle of the lower unwind shaft. Clevis pin...
Page 126 F - 160 Operation and Maintenance Manual m) Push the clevis pin back down to secure the unwind shaft in its saddle. 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...
Page 127 Apply just enough brake tension to prevent the roll of mount adhesive from free spinning. Page 6 - 38 F - 160 Operation and Maintenance Manual Excessive brake tension may cause the output to curl. This can create complications with the second pass of this application.
Page 128 F - 160 Operation and Maintenance Manual 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". j) Press SEL.
Page 129 Always use the minimum roll pressure necessary to complete the task. Page 6 - 40 F - 160 Operation and Maintenance Manual Keep hands and fingers clear of the pull roller nip when changing the gap. p) Once the cardboard has passed through the pull rollers, lower the upper pull roller onto the web.
Page 130 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 INFORMATION If you choose to use the lower rewind tube, make note of the direction of travel.
Page 131 S P E E D S T O P S A F E T Y Page 6 - 42 F - 160 Operation and Maintenance Manual z) Press GAP F W R R E V . a) With an enclosed blade, cut the finished product from the web.
Page 132 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! e) Raise the pull roller up by turning the crank handle counter clockwise until the pull rollers are separated.
Page 133 G A P P R E S S U R E Page 6 - 44 F - 160 Operation and Maintenance Manual CAUTION Sharp edges on a substrate should be filed smooth and GAP manually adjusted.
Page 134 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. CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position.
Page 135 Page 6 - 46 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.
Page 136 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 Leading edge Release liner d) Place a padded paper weight or similar object in the center.
Page 137 Use a slow speed. If the tack point enters the rollers nip, you will not be able to pull the release liner. Page 6 - 48 F - 160 Operation and Maintenance Manual CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position.
Page 138 F - 160 Operation and Maintenance Manual m) Make sure the image is conformed to the upper main roller. Refer to Figure 6.5.13 INFORMATION If the image is not conformed to the roller, you may experience difficulties with this application.
Page 139 The mounted image can now be removed from the rear of the laminator. r) Trim the mounted piece as necessary. Page 6 - 50 F - 160 Operation and Maintenance Manual Finishing a) Press STOP. S P E E D...
Page 140: Precoating Substrates
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.
Page 141: Clevis Pin
You can be seriously HURT or INJURED! Page 6 - 52 F - 160 Operation and Maintenance Manual Figure 6.6.1 MAIN POWER / RESET g) Lift the clevis pin located in the saddle of the upper unwind shaft.
Page 142 F - 160 Operation and Maintenance Manual Figure 6.6.2 Unwind shaft Saddle Core support Brake adjust knob i) Once loaded, swing the upper unwind shaft back into the saddle. INFORMATION The roll of Hot Tissue has no preference to side since both sides are the same.
Page 143 S A F E T Y r) Continue with step s) when the TOP TEMP DISPLAY stops flashing. Page 6 - 54 F - 160 Operation and Maintenance Manual s) Press STOP. F W R R E V . t) Press GAP the substrate being used.
Page 144 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. CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position.
Page 145 Position the leader board so that half is adhered to the Hot Tissue. Refer to Figure 6.6.3 Page 6 - 56 F - 160 Operation and Maintenance Manual Position the leader board squarely onto the mount adhesive. c) Press STOP.
Page 146 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. Y o u m a y b e C R U S H E D o r B U R N E D ! e) Push the leader board into the main roller nip while stepping on the variable speed footswitch.
Page 147 As the boards come through, the person at the rear of the machine will use the utility knife to separate the boards. Page 6 - 58 F - 160 Operation and Maintenance Manual Caution should always be exercised when using a knife . Sharp knife can cut you!
Page 148 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 Figure 6.6.5 Trailer board Precoated board INFORMATION Do not stop in the middle of a board, an impression of the roller footprint will be evident on the board.
Page 149: One Pass Mount And Laminate
Heat sensitive images would be of ink jet types, and medias that have plastic characteristics to them. For these type of images, use GBC Low Melt film or comparable laminate. Do not wear ties, loose fitting clothing or dangling jewelry while operating or servicing the laminator.
Page 150 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.
Page 151 Twisting the roll of thermal laminate while sliding makes loading the film onto the unwind shaft easier. Page 6 - 62 F - 160 Operation and Maintenance Manual Figure 6.7.2 Unwind shaft Saddle R E S E T Core support...
Page 152 F - 160 Operation and Maintenance Manual 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". l) Press SEL. SEL will stop flashing.
Page 153 Section 5.5.1 Manual nip adjustment. Page 6 - 64 F - 160 Operation and Maintenance Manual When operating the laminator using the variable speed footswitch, keep hands and fingers away from the nip of the rollers.
Page 154 F - 160 Operation and Maintenance Manual INFORMATION Excessive pressure will cause the substrate to bow or flatten. w) Press STOP. 00.0 S P E E D S T O P S A F E T Y x) Press REV to reverse the direction of the motor.
Page 155 6 in. is resting on the front infeed table. Refer to Figure 6.7.4 Page 6 - 66 F - 160 Operation and Maintenance Manual Figure 6.7.4 Leader board Thermal laminate f) Position the leader board so that half is pressed against the thermal laminate resting on the front table.
Page 156 F - 160 Operation and Maintenance Manual h) Press FWD 00.0 S P E E D S T O P S A F E T Y INFORMATION Steps " i" and " j" will be performed simultaneously. WARNING When operating the laminator using the variable speed footswitch, keep hands and fingers away from the nip of the rollers.
Page 157 M o u n t e d i m a g e Page 6 - 68 F - 160 Operation and Maintenance Manual 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...
Page 158: Thermal Decal And Mount
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. d) Trim as necessary. e) Clean the rollers as described in the maintenance section.
Page 159 Press RESET. Refer to Figure 6.8.1 Figure 6.8.1 MAIN POWER / RESET Page 6 - 70 F - 160 Operation and Maintenance Manual c) Ensure that the rear pull rollers are in the up position.. d) Raise the front and rear safety shields.
Page 160 F - 160 Operation and Maintenance Manual INFORMATION Twisting the roll of laminate while sliding makes loading the film onto the unwind shaft easier. Figure 6.8.2 Unwind shaft Saddle Core support Brake adjust knob g) Once the roll of thermal laminate is on the upper unwind shaft, swing the upper unwind shaft back into the saddle.
Page 161 JOB number enter it now then press SEL and skip to step " p ", other wise continue with step " l". Page 6 - 72 F - 160 Operation and Maintenance Manual o) Press SEL. SEL will stop flashing. S E L J O B...
Page 162 F - 160 Operation and Maintenance Manual r) Press SPEED to set a motor speed of 2 ft. / min. ( .6 m / min. ) S P E E D S T O P S A F E T Y s) Press GAP to enter a 0 in.
Page 163 Refer to Figure 6.8.4 INFORMATION The mount adhesive will adhere to the activated adhesive from the laminate. Page 6 - 74 F - 160 Operation and Maintenance Manual Figure 6.8.4 Mount adhesive Thermal laminate Thermal laminate f) Use a piece of cardboard to push the material into the nip of the main rollers.
Page 164 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!
Page 165 Y o u m a y b e C R U S H E D o r B U R N E D ! Page 6 - 76 F - 160 Operation and Maintenance Manual - Press on the variable speed footswitch to lengthen the web enough to get one full wrap around the lower rewind tube.
Page 166 F - 160 Operation and Maintenance Manual o) Press SPEED to a speed you feel comfortable working with. It is recommended that SPEED not exceed 5 ft./ min. ( 1.52 m/ min. ) . S P E E D S T O P S A F E T Y p) Press GO.
Page 167 Remove the web from the front of the laminator and the rolls of material from the upper and lower unwind shafts. Page 6 - 78 F - 160 Operation and Maintenance Manual INFORMATION This will prevent any exposed adhesive from contacting the rollers.
Page 168 F - 160 Operation and Maintenance Manual Materials needed • Prints ( Decals ) • Substrates • Utility knife • Leader board ( substrate width x 6” ) Set up a) Replace the front infeed table. WARNING Keep hands and fingers clear of the laminator roller nip when changing GAP.
Page 169 00.0 S P E E D S T O P S A F E T Y Page 6 - 80 F - 160 Operation and Maintenance Manual g) Press REV motor. F W R REV. a) Align the leading edge of the image with the leading edge of the board and one other side.
Page 170 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 Figure 6.8.7 Setting the decal - You must trim the decal so that no more than 1 in.
Page 171 Page 6 - 82 F - 160 Operation and Maintenance Manual INFORMATION Use a slow speed. If the tack point enters the rollers nip, you will not be able to pull the release liner.
Page 172 F - 160 Operation and Maintenance Manual Figure 6.8.11 Draping the decal Decal Release liner Substrate j) Make sure the image is conformed to the upper main roller. Refer to Figure 6.8.12 INFORMATION If the image is not conformed to the roller, you may experience difficulties with this application.
Page 173 Y o u m a y b e C R U S H E D o r B U R N E D ! Page 6 - 84 F - 160 Operation and Maintenance Manual 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.
Page 174: Encapsulation
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. c) Clean the rollers as described in the maintenance section. ( Section 8.2 Cleaning...
Page 175: Clevis Pin
Ensure that the rear pull rollers are in the up position.. Page 6 - 86 F - 160 Operation and Maintenance Manual d) Raise the front and rear safety shields. Caution should always be exercised when using the laminator with the safety shields raised.
Page 176 F - 160 Operation and Maintenance Manual Figure 6.9.2 Unwind shaft Saddle Core support Brake adjust knob g) Once the roll of thermal laminate is on the upper unwind shaft, swing the upper unwind shaft back into the saddle. CAUTION Ensure the roll of laminate is loaded properly on the unwind shaft.
Page 177 S E L J O B S H U T D O W N Page 6 - 88 F - 160 Operation and Maintenance Manual p) Press TOP TEMP 220-230 S L E E P T O P T E M P...
Page 178 F - 160 Operation and Maintenance Manual s) Press SPEED to set a motor speed of 2 ft. / min. ( .6 m / min. ) S P E E D S T O P S A F E T Y t) Press GAP to enter a 0 in.
Page 179 Refer to Figure 6.9.4 INFORMATION The mount adhesive will adhere to the activated adhesive from the laminate. Page 6 - 90 F - 160 Operation and Maintenance Manual Figure 6.9.4 Lower laminate Thermal laminate Thermal laminate f) Use a piece of cardboard to push the material into the nip of the main rollers.
Page 180 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!
Page 181 Y o u m a y b e C R U S H E D o r B U R N E D ! Page 6 - 92 F - 160 Operation and Maintenance Manual - Press on the variable speed footswitch to lengthen the web enough to get one full wrap around the lower rewind tube.
Page 182 F - 160 Operation and Maintenance Manual o) Press SPEED to a speed you feel comfortable working with. It is recommended that SPEED not exceed 5 ft./ min. ( 1.52 m/ min. ) . S P E E D S T O P S A F E T Y p) Press GO.
Page 183: Charts And Diagrams
( Section 8.2 Cleaning the rollers ) Page 6 - 94 F - 160 Operation and Maintenance Manual j) Replace the front infeed table. k) Lower the front and rear safety shields and press SHUTDOWN if finished with the laminator.
Page 184: Figure 6.10.1 Temperature Conversion Chart
F - 160 Operation and Maintenance Manual Figure 6.10.1 Temperature conversion chart 1 1 3 20.6 1 1 4 1 1 5 21.1 1 1 6 21.7 1 1 7 22.2 22.7 1 1 8 23.3 1 1 9 23.9 1 2 0 24.4...
Page 185 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 - 96 F - 160 Operation and Maintenance Manual Parameter Chart - Blank MATERIALS SUBSTRATE : PRINTS : TEMPERATURE GAP &...
Page 186 F - 160 Operation and Maintenance Manual Applications Web Diagram - Blank © GBC Pro - Tech August 1999 Page 6 - 97...
Page 187: Chart 1 - Precoating Substrates
Pressure will be determined by operator. Speed is not indicated in Footswitch mode. 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 188 F - 160 Operation and Maintenance Manual Applications Web Diagram 1 - Precoating substrate Mount Substrate Leader board © GBC Pro - Tech August 1999 Page 6 - 99...
Page 189: Chart 2 - Mounting Only
Speed is not indicated in Footswitch mode. 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 - 100...
Page 190: Diagram 2 - Mounting Only
F - 160 Operation and Maintenance Manual Applications Web Diagram 2 - Mounting only Print Release liner Precoated board © GBC Pro - Tech August 1999 Page 6 - 101...
Page 191: Chart 3 - Single Sided ( Sled )
Speed is not indicated in Footswitch mode. 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 - 102...
Page 192: Diagram 3 - Single Sided ( Sled )
F - 160 Operation and Maintenance Manual Applications Web Diagram 3 - Single sided ( Sled ) P.S.A. Release liner Laminate Print Sled © GBC Pro - Tech August 1999 Page 6 - 103...
Page 193: Chart 4 - Single Sided ( Craft Paper )
Upper unwind material can be of similar product. Print can be of any type. Pressure will will vary slightly with regards to quality of the output. Speed will be determined by the operator. Pull roll pressure may vary between 1/2 turn and 3/4 turn. Because the process is described from the front of the laminator, motor direction is FWD.
Page 194: Diagram 4 - Single Sided ( Craft Paper )
F - 160 Operation and Maintenance Manual Applications Web Diagram 4 - Single sided ( Craft paper ) P.S.A. Release liner Laminate Output Print Craft Paper Finish product rewind option © GBC Pro - Tech August 1999 Page 6 - 105...
Page 195: Chart 5 - Decal And Mount ( Decal )
Speed will be determined by the operator. Pull roll pressure may vary between 1/2 turn and 3/4 turn. Because the process is described from the front of the laminator, motor direction is FWD.
Page 196: Diagram 5 - Decal And Mount ( Decal )
F - 160 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 Pro - Tech August 1999 Page 6 - 107...
Page 197: Chart 6 - Decal And Mount ( Mount )
Pressure will be determined by operator. Speed is not indicated in Footswitch mode. 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 198: Diagram 6 - Decal And Mount ( Mount )
F - 160 Operation and Maintenance Manual Applications Web Diagram 6 - Decal and mount ( Mount ) Decal Release liner Substrate © GBC Pro - Tech August 1999 Page 6 - 109...
Page 199 140 - 160 by the operator. Speed is not indicated in Footswitch mode. 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 - 110...
Page 200 F - 160 Operation and Maintenance Manual Applications Web Diagram 7 - Precoating substrate ( Thermal ) Tissue Substrate Leader board 140 - © GBC Pro - Tech August 1999 Page 6 - 111...
Page 201: Chart 8 - One Pass Mount
Pressure will be determined by the operator. Speed is not indicated in Footswitch mode. 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 202: Diagram 8 - One Pass Mount
F - 160 Operation and Maintenance Manual Applications Web Diagram 8 - One pass mount and laminate Octiva Hot Tissue Gloss Leader Image board 240 - 260 Substrate © GBC Pro - Tech August 1999 Page 6 - 113...
Page 203: Chart 9 - Thermal Decal And Mount ( Decal )
Speed will be determined by the operator. Pull roll pressure may vary between 1/2 turn and 3/4 turn. Because the process is described from the front of the laminator, motor direction is FWD.
Page 204: Diagram 9 - Thermal Decal And Mount ( Decal )
F - 160 Operation and Maintenance Manual Applications Web Diagram 9 - Thermal decal and mount ( Decal ) Octiva Gloss Output Print Pro Mount Finish product rewind option © GBC Pro - Tech August 1999 Page 6 - 115...
Page 205: Chart 10 - Thermal Decal And Mount ( Mount )
S P E E D D O W N The mounting process is done from the rear position of the laminator to avoid the waiting period involved with cooling down the main rollers. The rollers may be left heated or turn them down 68 with be dependent of the substrate.
Page 206: Diagram 10 - Thermal Decal And Mount ( Mount )
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...
Page 207: Chart 11 - Encapsulation
. Pressure may vary acording to the output. Speed will be dependent on image type. 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 - 118...
Page 208: Diagram 11 - Encapsulation
F - 160 Operation and Maintenance Manual Applications Web Diagram 11 - Encapsulation Octiva Gloss Output Print Octiva Gloss Finish product rewind option © GBC Pro - Tech August 1999 Page 6 - 119...
Page 209 Applications F - 160 Operation and Maintenance Manual This page intentionally left blank. Page 6 - 120 © GBC Pro - Tech August 1999...
Page 210: Wave Problems
F - 160 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 211 • Check the nip setting of pull rolls • Check for even paper tension Page 7 - 2 F - 160 Operation and Maintenance Manual Problem: Angled waves in the output on both sides Hints: • Check for insufficient main roller pressure •...
Page 212: Thermal Laminates
F - 160 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 213: 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 214: Glossary
F - 160 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 215 Page 7 - 6 F - 160 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 216 F - 160 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. Media Term used to describe the materials used to print an image, i.e.
Page 217 The path that rolled media unwinding from a supply roll takes through a machine or array of rollers. Page 7 - 8 F - 160 Operation and Maintenance Manual © GBC Pro - Tech August 1999...
Page 218: Maintenance Schedule
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.
Page 219: Cleaning The Rollers
Preparation of the laminator a) Turn the MAIN POWER to the “ON” position. P o w e r Page 8 - 2 F - 160 Operation and Maintenance Manual b) Press RESET. The front control panel will illuminated. Reset c) Press SEL.
Page 220 F - 160 Operation and Maintenance Manual Removing adhesive build up a) For pressure sensitive adhesives: put on the rubber gloves and use isopropyl alcohol and a terry cloth towel. b) For thermal adhesives: while the laminator is at normal operating temperature, put on the rubber gloves and use the rubber cement eraser.
Page 221 S T O P S A F E T Y Page 8 - 4 F - 160 Operation and Maintenance Manual 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 222 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. CAUTION Speed is controlled through the variable speed footswitch when the safety shield is in the raised position.
Page 223: Cabinets And Covers
You can be severely shocked, electrocuted or cause a fire. Use only a damp cloth for cleaning unless other wise specified. Page 8 - 6 F - 160 Operation and Maintenance Manual 8.2.2 Cleaning the touch screen ELECTRICAL S H O C K Remove power from the laminator before cleaning.

GBC F - 160 Operation And Maintenance Manual

Section 1 Safety

Section 2 Warranty

Section 3: Specifications

Section 4 Installation

Section 5 Operations

Section 6 Applications

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