GBC F - 160 CE Laminate Trimmer User Manual

F - 160 CE OPERATION AND
MAINTENANCE MANUAL
© April 2000 GBC Films Group
Do not duplicate without written permission.
Revision :
Part number : 930 - 065
GBC Films Group
4151 Anderson Road
DeForest, WI 53532
Ph: ( 608 ) 246 - 8844
Fx: ( 608 ) 246 - 8645
F - 160 CE Operation and Maintenance Manual
Table of Contents
Table of Contents
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
1.7 Decal locations ............................................................................................1 - 7
Figure 1.7.1 Decal location - front ................................................1 - 9
Figure 1.7.2 Decal location - rear ..............................................1 - 10
Section 2: Warranty
2.1 Limited warranty information ....................................................................2 - 1
2.2 Exclusions to the warranty ........................................................................2 - 1
© GBC Films Group April 2000
Page I
Table of Contents
F - 160 CE Operation and Maintenance Manual
Section 3: Specifications
3.1 General .......................................................................................................3 -1
3.2 Consumables ...............................................................................................3 - 1
3.3 Function ......................................................................................................3 - 2
3.4 Electrical ....................................................................................................3 - 3
3.5 Dimensions ................................................................................................3 - 4
Figure 3.5.1 Dimensions ...............................................................3 - 5
Section 4: Installation
4.1 Preinstallation check list ...........................................................................4 - 1
Figure 4.1.1 Suggested floor layout .............................................4 - 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
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Table of Contents
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
4.10.1 Front feed table ...................................................................................4 - 18
4.10.2 Safety shield ..........................................................................................4 - 20
4.10.3 E-STOP ...............................................................................................4 - 21
4.10.4 E-CABLE .............................................................................................4 - 22
4.11 Function check ........................................................................................4 - 23
4.11.1 Control panel .......................................................................................4 - 23
Figure 4.11.1 Default settings ......................................................4 - 27
4.11.2 Variable speed footswitch ....................................................................4 - 27
4.11.3 Unwind shafts and unwind brakes ......................................................4 - 28
© GBC Films Group April 2000
Page III
Table of Contents
F - 160 CE Operation and Maintenance Manual
Section 5: Operations
5.1 Control panel ..............................................................................................5 - 1
Figure 5.1.1 Front control panel .................................................5 - 9
5.2 Emergency ................................................................................................5 - 10
5.2.1 In an emergency .....................................................................................5 - 10
5.2.2 Resume operation ...................................................................................5 - 11
5.3 Set up .........................................................................................................5 - 12
5.3.1 Power ......................................................................................................5 - 12
5.3.2 Film loading ..........................................................................................5 - 12
Chart 5.3.1 Measurement chart ..................................................5 - 14
5.3.5 Heating ...................................................................................................5 - 14
5.4 Job programming ....................................................................................5 - 16
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
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Table of Contents
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
Chart 6.1.1 Temperature conversion chart ...................6 - 3
Blank chart .......................................................................................................6 - 4
Blank diagram ..................................................................................................6 - 5
Chart 1 - Precoating substrates ........................................................................6 - 6
Diagram 1 - Precoating subtrates ....................................................................6 - 7
Chart 2 - Mounting only ....................................................................................6 - 8
Diagram 2 - Mounting only ..............................................................................6 - 9
Chart 3 - Single sided ( Sled ) .........................................................................6 - 10
© GBC Films Group April 2000
Page V
Table of Contents
F - 160 CE Operation and Maintenance Manual
Diagram 3 - Single sided ( Sled ) .....................................................................6 - 11
Chart 4 - Single sided ( Craft paper ) ..............................................................6 - 12
Diagram 4 - Single sided ( Craft paper ) ........................................................6 - 13
Chart 5 - Decal and mount ( Decal ) ..............................................................6 - 14
Diagram 5 - Decal and mount ( Decal ) .........................................................6 - 15
Chart 6 - Decal and mount ( Mount ) ............................................................6 - 16
Diagram 6 - Decal and mount ( Mount ) .......................................................6 - 17
Chart 7 - Precoating subtrates .......................................................................6 - 18
Diagram 7 - Precoating subtrates ...................................................................6 - 19
Chart 8 - One pass mount ...............................................................................6 - 20
Diagram 8 - One pass mount ..........................................................................6 - 21
Chart 9 - Thermal decal and mount ( Decal ) ................................................6 - 22
Diagram 9 - Thermal decal and mount ( Decal ) ...........................................6 - 23
Chart 10 - Thermal decal and mount ( Mount ) .............................................6 - 24
Diagram 10 - Thermal decal and mount ( Mount ) ........................................6 - 25
Page VI
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Table of Contents
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
7.3 Machine problems ......................................................................................7 - 4
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 - 7
8.2.2 Touch screen control panel .....................................................................8 - 7
© GBC Films Group April 2000
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F - 160 CE Operation and Maintenance Manual
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Page VIII
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Safety
Section 1 Safety
CAUTION
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.
Indicates a potentially hazardous situation
which, if not avoided, could result in minor
or moderate injury, or alerts against unsafe
practices or alerts against actions which
could damage the product.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in serious
injury.
The following symbols are used throughout this
manual to indicate Information, Caution, Warning,
Danger and Electrical Shock conditions.
DANGER
1.1 Symbols
Indicates an imminently hazardous situation
which, if not avoided, could result in death
or serious injury.
INFORMATION
Indicates helpful information that should be
considered before, during, or after an
action, step or procedure is given.
© GBC Films Group April 2000
ELECTRICAL
SHOCK
Indicates an electrical shock situation which,
if not avoided, could result in serious
paralyzation of the body or death.
Page 1 - 1
Safety
F - 160CE Operation and Maintenance Manual
1.2 Safety features
DANGER
The F-160 CE laminator has been designed
with safety as a primary consideration; however, you
must become thoroughly familiar with the controls,
proper operation, proper service procedures and safety
features of the laminator before using or servicing the
unit.
At these temperatures there is a danger of
severe burn if the rolls are touched during
setup, operation or servicing.
INFORMATION
GBC Films Group laminators are powerful
machines that are designed to mount, laminate, and
encapsulate. The forces required to accomplish these tasks
can vary from negligible to very large.
The motorized main roller lift mechanism used to
provide downward pressure on the upper main roller is
capable of producing forces greater than 400 pounds.
This force is applied to any object presented in the opening
( called the nip ) between the two rollers.
Only a qualified service technician should
perform any procedure in Part B of this
manual.
The word qualified is defined below;
Qualified ;
Use care in lowering the upper laminating roller
and know how to react quickly in an emergency. The
main laminator roll up / down control is located on the
right side of the machine within the front control panel.
The GAP up / down arrows control the motion of the
upper laminating roller. Before pressing GAP down arrow,
ensure that nothing is in the nip area.
In addition, the main laminating rollers of the F160CE can reach temperatures of over 200oF ( 100oC ).
Page 1 - 2
• Any engineer that has experience with electrical
and mechanical design of lamination equipment.The
engineers should be fully aware of all aspects of safety
with regards to lamination equipment.
• Any commissioning or service engineer must be
of competent nature, trained and qualified to GBC Films
Group standards to fulfill that job. This person will have
completed and passed the full service training course from
GBC Pro-Tech.
© GBC Films Group April 2000
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.
Figure 1.2.1 illustrates placement of the cabinets and
covers.
Safety
1.3 Safety shield
An important feature of the F-160 CE laminator
is the safety shields, when raised, the auto run is disabled
and drive control is transferred to the footswitch.Refer to
Figure 1.3.1 Safety shield raised.
WARNING
Figure 1.2.1
Cabinets and covers
Caution should always be exercised
when using the laminator with
the safety shields raised.
You can be seriously HURT or INJURED!
Cabinets
Figure 1.3.1
Safety shields raised
Covers
© GBC Films Group April 2000
Page 1 - 3
Safety
F - 160CE Operation and Maintenance Manual
1.4 Emergency stop
To engage an E-STOP, press down on any of the
four. Any E-STOP, when engaged, removes power to
the laminator. Refer to Figure 1.4.2 Engage an E-STOP.
The laminator is equipped with four emergency
stops ( E-STOP ) located at the front of the cabinets and
the rear of the cabinets. Refer to Figure 1.4.1 Emergency
stops.
Figure 1.4.2 Engage an E-STOP
Push
Figure 1.4.1
Emergency stops
INFORMATION
Front
The machine will only operate if all four
E-STOPS are in the unlatched position.
Emergency stops
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 ESTOP.
Rear
Figure 1.4.3
Emergency stops
Page 1 - 4
Reset the E-STOP
Unlatch
© GBC Films Group April 2000
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.
Safety
Figure 1.5.1 Emergency cable
Front
Figure 1.4.4 Machine rest
Emergency cable
Rear
Machine reset
Emergency cable
1.5 Emergency cable
To continue operation, press in on the cable reset
located on the right leg of the front operating position.
Refer to Figure 1.5.2 Reset the E-CABLE.
In the event an E-STOP is not reachable, use
your foot to activate an emergency cable ( E-CABLE )
located at the base of the stand from the front or rear of
the machine. Refer to Figure 1.5.1 Emergency cable.
Figure 1.5.2
Reset the E-CABLE
INFORMATION
The machine will only operate if the
E-CABLE is in the unlatched position.
© GBC Films Group April 2000
Push in
Page 1 - 5
Safety
F - 160CE Operation and Maintenance Manual
Press RESET located on the right leg at the front
of the machine. Refer to Figure 1.5.3 Machine reset.
Figure 1.6.1 Front feed table
Figure 1.5.3 Machine rest
Machine reset
To continue operation, press STOP.
5.0
SPEED
GO
STOP
FWD
REV
SAFETY
1.6 Front feed table
Then press GO.
The front feed table must be in proper position
for the laminator to operate in auto run. Refer to Figure
1.6.1 Front feed table.
5.0
SPEED
When the key is removed from the interlock, the
laminator will stop. With the table removed, the laminator
will operate using the variable speed footswitch.
Page 1 - 6
GO
STOP
FWD
REV
SAFETY
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Safety
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.
MUCHO
CUIDADO
Riesgo de
choque
electrico
No abra
Adentro, no hay
piezas
reparables
para el usuario.
Mantenimiento
solamente para
personal
calificado
!
WAARSCHUWING
Kans op
elektrische
schok.
Niet openen
Bevatgeen door
gebruik te
repareren
onderdelen.
Door bevoegd
service
personeel
laten repareren
!
WARNING
!
ACHTUNG
! MISE EN GARDE
!
MUCHO
CUIDADO
!
Risque de
secousse
electrique.
Ne pas ouvrir.
Pas de pieces
reparables par
l'utilisateur.
Entretien par
personnel
qualifie.
!
ATTENZIONE
Pericolo di
scarica
elettrica.
Nessuna parte
riparabile
dall' utente.
Chiamare un
servizio
di riparazioni
qualificato.
WARNING
Electrical shock
hazard.
Do not open.
No user
serviceable
parts inside.
Refer servicing to
qualified service
personnel.
!
WARNUNG
SpannungsfUhrend
e
Teile.
Nicht offnen.
Enthalt keine vom
Enduerbraucher zu
wartende Teile.
Fur service bitte an
qualifiziertes
Service-Personal
wenden.
Danger Voltage: High voltage wires behind this panel.
Do not remove cover. You may be shocked, electrocuted,
paralyzed or die!
Roller Pinch Point: Keep hands and fingers away.
You may be crushed and/ or burned.
Do not Lift: This point can not be used as a lifting
point. If ignored, damage will occur to the laminator.
Electrical Shock: Live voltage present. Exercise
extreme caution. You may be electrocuted!
© GBC Films Group April 2000
Page 1 - 7
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
F - 160 CE Operation and Maintenance Manual
Figure 1.7.1
!
!
Label locations - Front
!
WARNING
!
ACHTUNG
!
MISE EN GARDE
WARNING
!
ACHTUNG
!
MISE EN GARDE
MUCHO
CUIDADO
Riesgo de
choque
electrico
No abra
Adentro, no hay
piezas
reparables
para el usuario.
Mantenimiento
solamente para
personal
calificado
!
Safety
WAARSCHUWING
Kans op
elektrische
schok.
Niet openen
Bevatgeen door
gebruik te
repareren
onderdelen.
Door bevoegd
service
personeel
laten repareren
!
MUCHO
CUIDADO
!
Risque de
secousse
electrique.
Ne pas ouvrir.
Pas de pieces
reparables par
l'utilisateur.
Entretien par
personnel
qualifie.
!
ATTENZIONE
Pericolo di
scarica
elettrica.
Nessuna parte
riparabile
dall' utente.
Chiamare un
servizio
di riparazioni
qualificato.
WARNING
Electrical shock
hazard.
Do not open.
No user
serviceable
parts inside.
Refer servicing to
qualified service
personnel.
!
!
WARNUNG
SpannungsfUhrend
e
Teile.
Nicht offnen.
Enthalt keine vom
Enduerbraucher zu
wartende Teile.
Fur service bitte an
qualifiziertes
Service-Personal
wenden.
© GBC Films Group April 2000
MUCHO
CUIDADO
Riesgo de
choque
electrico
No abra
Adentro, no hay
piezas
reparables
para el usuario.
Mantenimiento
solamente para
personal
calificado
!
WAARSCHUWING
Kans op
elektrische
schok.
Niet openen
Bevatgeen door
gebruik te
repareren
onderdelen.
Door bevoegd
service
personeel
laten repareren
!
MUCHO
CUIDADO
!
Risque de
secousse
electrique.
Ne pas ouvrir.
Pas de pieces
reparables par
l'utilisateur.
Entretien par
personnel
qualifie.
!
ATTENZIONE
Pericolo di
scarica
elettrica.
Nessuna parte
riparabile
dall' utente.
Chiamare un
servizio
di riparazioni
qualificato.
WARNING
Electrical shock
hazard.
Do not open.
No user
serviceable
parts inside.
Refer servicing to
qualified service
personnel.
!
WARNUNG
SpannungsfUhrend
e
Teile.
Nicht offnen.
Enthalt keine vom
Enduerbraucher zu
wartende Teile.
Fur service bitte an
qualifiziertes
Service-Personal
wenden.
Page 1 - 9
Safety
Figure 1.7.2
F - 160CE Operation and Maintenance Manual
Label locations - Rear
!
WARNING
!
ACHTUNG
!
!
WARNING
!
ACHTUNG
!
MISE EN GARDE
!
MISE EN GARDE
!
Page 1 - 10
MUCHO
CUIDADO
Riesgo de
choque
electrico
No abra
Adentro, no hay
piezas
reparables
para el usuario.
Mantenimiento
solamente para
personal
calificado
WAARSCHUWING
Kans op
elektrische
schok.
Niet openen
Bevatgeen door
gebruik te
repareren
onderdelen.
Door bevoegd
service
personeel
laten repareren
!
MUCHO
CUIDADO
!
Risque de
secousse
electrique.
Ne pas ouvrir.
Pas de pieces
reparables par
l'utilisateur.
Entretien par
personnel
qualifie.
!
ATTENZIONE
Pericolo di
scarica
elettrica.
Nessuna parte
riparabile
dall' utente.
Chiamare un
servizio
di riparazioni
qualificato.
WARNING
Electrical shock
hazard.
Do not open.
No user
serviceable
parts inside.
Refer servicing to
qualified service
personnel.
!
WARNUNG
SpannungsfUhrend
e
Teile.
Nicht offnen.
Enthalt keine vom
Enduerbraucher zu
wartende Teile.
Fur service bitte an
qualifiziertes
Service-Personal
wenden.
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Section 2 Warranty
GBC Films Group warrants the equipment sold
is free from defects in material and workmanship for a
period of one ( 1 ) year parts and 90 days labor from
the date of installation. This warranty is the only warranty
made by GBC Films Group and connot be modified or
amended.
GBC Films Group’s sole and exclusive
liability and the customer’s sole and exclusive
remedy under this warranty shall be, at GBC Films
Group’s option, to repair or replace any such
defective part or product. These remedies are only
available if GBC Films Group’s examination of the
product discloses to GBC Films Group’s satisfaction
that such defects actually exist and were not caused
by misuse, neglect, attempt to repair, unauthorized
alteration or modification, incorrect line voltage, fire,
accident, flood, or other hazard.
2.1 Limited Warranty
This warranty specifically does not cover damage
to the laminating rollers caused by knives, razor blades,
other sharp objects, failure caused by adhesives or
improper use of the machine. Warranty repair or
replacement does not extend the warranty beyond the
initial one year period from the date of delivery.
CAUTION
Unauthorized customer alterations will
void this warranty.
© GBC Films Group April 2000
Warranty
THE WARRANTY MADE HEREIN IS IN
LIEU OF ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING
ANY
WARRANTY
OR
MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE. GBC
FILMS GROUP WILL NOT BE LIABLE
FOR PROPERTY DAMAGE OR
PERSONAL INJURY ( UNLESS
PRIMARILY CAUSED BY ITS
NEGLIGENCE ), LOSS OF PROFIT OR
OTHER
INCIDENTAL
OR
CONSEQUENTIAL
DAMAGES
ARISING OUT OF THE USE OR
INABILITY TO USE THE EQUIPMENT.
2.2 Exclusions to the
Warranty
This warranty specifically does not
cover;
1. Damage to the laminating rollers caused by knives,
razor blades, other sharp objects or failure caused
by adhesives.
2. Damage to the machine caused by lifting, tilting and /
or any attempt to position the machine other than
rolling on the installed castors on even surfaces.
3. Improper use of the machine.
4. Damage due from unqualified person(s) servicing the
machine.
Page 2 - 1
Warranty
F - 160 CE Operation and Maintenance Manual
Qualified
• Any engineer that has experience with electrical
and mechanical design of lamination equipment.The
engineers should be fully aware of all aspects of safety
with regards to lamination equipment.
• Any commissioning or service engineer must be
of competent nature, trained and qualified to GBC Films
Group standards to fulfill that job. This person will have
completed and passed the full service training course from
GBC Pro-Tech.
• Any GBC Technician, GBC Specialist, and / or
GBC Films Group Technician that has been through the
Page 2 - 2
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Specifications
Section 3: Specifications
Specifications provide all of the technical data for
the Falcon 160 CE Laminator.
Section 3.1 General
Description:
• Mid level, wide format color finisher for the sheet fed
ink jet market. The Falcon 160 CE is a self standing,
bi-directional laminator..
Features:
• Two unwinds ( 1 upper, 1 lower )
• Two rewinds ( 1 upper front, 1 lower center )
• Safety shielded
• Infeed and oufeed tables
• Accelerator footswitch
• Job programmable
• Bi-directional system
• Four E-STOPs
• Front and rear E-Cable
Applications:
• Single sided lamination
• Encapsulation
• Mounting
• Decaling
Section 3.2
Consumable
Film types:
© GBC Films Group April 2000
• Pressure sensitive laminates
• Pressure sensitive adhesives
• Low melt laminates
• Thermal laminates
• Thermal adhesives
Page 3 - 1
Specifications
F - 160CE Operation and Maintenance Manual
Film diameters:
• Up to a 8” roll diameter ( 20.3 cm )
Core size:
• 3” core standard ( 7.62 cm )
• 2-1/4” optional ( must have optional core adapters )
( 5.72 cm )
Film widths:
• 64” Pressure sensitive ( 162.6 cm )
• 62” Thermal ( 157.8 cm )
Paper widths:
• 62” maximum paper width ( 157.8 cm )
Mounting thickness:
• Up to 1” inch thick ( 2.54 cm ) either direction
Safety:
Designed to UL / CSA / CE safety standards
Section 3.3
Function
Speed:
• 0 - 15 ft / min ( 0 - 4.6 m / min )
Motor:
• 2-1/4 horse power drive motor
• Bi-directional D.C. motor
Heating capabilities:
• 68oF - 290oF ( 20oC - 143oC )
Controls:
• Front control panel
• Variable speed footswitch
Page 3 - 2
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Specifications
Job save:
• Save up to 9 job parameters
Roll design:
• High release silicone rolls
Section 3.4 Electrical
United Statesand Canada:
• 230 - 240 VAC, 50/60 Hz, single phase, 55 amps.
Europe:
• 230 - 240 VAC, Wye 3 phase, 32 amps/ phase
B.T.U. output:
• 31,732 B.T.U. / hour
Heater wattages:
• 5600 watts per heater
Amperage draw:
• No heat, motor only : 1 - 3 amps
• Top heat and motor : 20 - 23 amps
• Both heat and motor : 40 - 43 amps
D/C voltage used:
• 24 vdc
• 12 vdc isolated x 2
• 24 vdc isolated
A/C voltage used:
• 230 vac ( minimum )
© GBC Films Group April 2000
Page 3 - 3
Specifications
Section 3.5
F - 160CE Operation and Maintenance Manual
Dimensions
Weight:
Crated:
• 1568 lbs. ( 711 kg. )
Uncrated:
• 1200 lbs. ( 544 kg. )
Dimensions
Crated:
Uncrated
• 90 in. (H) x 46 in. (W) x 72 in. (L)
( 229 cm (H) x 117 cm (W) x 183 cm (L) )
• 54 in. (H) x 38 in. (W) x 82.5 in. (L)
( 137 cm (H) x 96 cm (W) x 209 cm (L) )
Refer to Figure 3.5.1
Nip Height:
• 37 3/16 in. ( 95 cm )
Safety Shield Raised Height:
• 66 5/8 in. ( 169 cm)
Page 3 - 4
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Specifications
Figure 3.5.1 Dimensions
82.5 in.
(210 cm)
3.63 in.
(9 cm)
1.38 in.
(3.5 cm)
4.75 in.
(12 cm)
53 in.
(135 cm)
28 in.
(71 cm)
4.875 in.
(12 cm)
76 in.
(193 cm)
© GBC Films Group April 2000
Page 3 - 5
Specifications
F - 160CE Operation and Maintenance Manual
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Page 3 - 6
© GBC Films Group April 2000
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.
Before a Falcon 160 CE Laminator can be
installed, there are a few requirements that must be met.
Make certain that each of the requirements listed in the
following pre-installation checklist are met before beginning
installation.
Installation
Is the environment appropriate for the laminator?
The laminator requires a clean, dust and vapor
free environment to operate properly. It must not
be located where there is air blowing directly on
the machine
Have you contacted a certified electrician to both
wire the laminator and ensure that adequate power
is being supplied, having the appropriate capacity,
over current protection and safety lockouts are
available?
WARNING
CAUTION
The operating environment must be free of
dust, flammable liquids and vapors. You can
be injured by inhaling chemical vapors.
Failure to follow the pre-installation check
list can result in damage to the laminator.
WARNING
4.1 Pre-installation
Vapor build up or stored flammable
liquids can cause a fire. Excessive
dust can damage the laminator.
Are doorways and hallways wide enough for the
laminator to be moved to the installation site?
Is there ample room for the laminator?
CAUTION
A work area must be established that allows for
operation in both the front and rear of the
laminator and provides space for efficient material
flow. Figure 4.1.1 illustrates a typical machine
area layout.
© GBC Films Group April 2000
Do not locate the laminator where air is
blowing directly on the machine. The air
flow can cool the rolls unevenly and result
in poor output quality.
Page 4 - 1
Installation
F - 160 CE Operation and Maintenance Manual
The laminator requires 230 to 240 vac, 50/ 60
Hz, 55 amps. Or, in Europe only, 3-N phase,
240 vac, 32 amps/ phase.
WARNING
The Falcon 160 CE Laminator is a large and
heavy piece of equipment. It is necessary to
employ LICENSED RIGGERS ONLY to
move the laminator. The laminator is not
designed to be tipped up or sideways in any
way. Such action disturbs the exact
alignment of the rolling parts of the machine
and requires extensive realignment. 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
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Figure 4.1.1
Installation
Suggested Floor Layout
4' x 6' ( 1.22 m x 2m )
Work table on wheels
8.4'
( 2.57 m )
Table height
35-3/4" ( .94 - .95m )
82.5"
( 209 cm )
20'
( 6m)
38"
( 96 cm )
8.4'
( 2.57m )
3' ( 1 m)
4' x 6' ( 1.22 m x 2m )
Work table on wheels
Table height
35-3/4" ( .94 - .95m )
13' ( 4 m)
© GBC Films Group April 2000
Page 4 - 3
Installation
F - 160 CE Operation and Maintenance Manual
Figure 4.2.3 Front view
4.2 Know your machine
Before performing any procedure within this
manual, it is recommended that you take time to know
the parts of your new machine.
Upper
unwind
brake
Main
rollers
Upper
rewind
Front
feed
table
Lower
unwind
shaft
Pull roll
lift handle
Lower
unwind
brake
Figure 4.2.1 The laminator
Castors
Control
panel
Lower
rewind
Rear side
Drive
side
Drive
side leg
Control
side
Figure 4.2.4 Rear view
Control
side leg
Electrical
bridge
Core
support
Core
chuck
Pull rollers
Front side
Core
chuck
Rear
feed
table
Figure 4.2.2 Safety features
Power
ON/OFF
E-STOP
Rear safety shield
Circuit
breaker
E-CABLE
Upper
unwind
shaft
Figure 4.2.5 Footswitch
Front safety
shield
E-STOP
ATTUNG
E-CABLE
WARNING
ADVERTENCIA
E-CABLE reset
Page 4 - 4
Machine reset
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
4.3 Unpacking
Installation
With regards to your shipping methods, use one
of the following procedure described to safely and
properly unwrap / uncrate your laminator.
INFORMATION
A L L S H I P M E N T S A R E E X - W O R K S . At our
dock, title passes to the buyer. Please review
your insurance coverage prior to shipment,
as you are responsible for all subsequent
freight charges and risks.
INFORMATION
Before signing the Bill of Lading, you
should be sure to inspect the crate
and / or pallet for signs of damage or
missing items; if applicable, make
note of this on the Bill of Lading.
4.4 Shrink Wrapped
a) Inspect the machine for any obvious shipping
damages upon receipt.
b) Carefully unwrap the shrink wrap from around
the laminator.
CAUTION
INFORMATION
Depending on the destination and customer
preference, your machine may be shipped in
various ways. The laminator may arrive
shrink wrapped or in a plywood crate on a
skid. Please follow the unpacking procedure
that pertains to your method of shipment.
Do not use a knife or other sharp object to
remove the shrink wrap from around the
laminator. You can cause irreparable
damage to the rollers.
c) With another person, carefully wheel your
F - 160 CE Laminator to the installation site.
WARNING
WARNING
The unpacking process requires at least two
people. You can be severely injured, crushed
or cause damage to the laminator.
© GBC Films Group April 2000
Do not attempt to move the laminator across
anything other than a flat level surface
without trained and qualified riggers. You
can be crushed or seriously injured.
Page 4 - 5
Installation
F - 160 CE Operation and Maintenance Manual
4.5 Crated
To uncrate the laminator
WARNING
The Falcon 160 CE Laminator is a large and
heavy piece of equipment. It is necessary to
employ LICENSED RIGGERS ONLY to
move the laminator. The laminator is not
designed to be tipped up or sideways in any
way. Such action disturbs the exact
alignment of the rolling parts of the machine
and requires extensive realignment. You can
be crushed or seriously injured.
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. It
can damage the laminator.
INFORMATION
GBC Film Group's warranty does not
cover malfunction of the equipment due to
mishandling and / or tipping. GBC Films
Group bears no responsibility for personal
injury or damage due to moving the
laminator improperly.
INFORMATION
Do not put packing screws on the floor.
They can cause problems when trying to roll
the laminator into position or you can
become injured if stepped on.
Tools required
CAUTION
• # 2 Phillips head screwdriver
• 7/8” open end wrench or adjustable wrench
• Crow bar
• A second person
Page 4 - 6
A second person must support the side
labeled 5 in Figure 4.5.1 It can fall and
damage the laminator or cause harm to you
and others.
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Figure 4.5.1
Disassembling of the crate
Installation
b) Move all packing materials to a safe distance.
Moving the laminator
1
3
5
Pl
a
n
e
4
P
al
n
e
4
Pl
a
n
e
4
4
2
a) Have the laminator rolled off the skid and
placed on the floor by licensed riggers. The ramps
included with the laminator can be secured utilizing
screws removed from the disassembled crate.
Figure 4.5.2 illustrates positioning of the ramps.
WARNING
Removing the shrink wrap
Do not attempt to use the ramps if they are
not secured to the pallet. Ensure the pallet is
on a flat even surface before attempting to
roll the machine off.
a) Gently unwrap the shrink wrap from around the
laminator.
Figure 4.5.2 Positioning of the ramps
CAUTION
Do not use a knife or other sharp object to
remove the shrink wrap from around the
laminator. You can cause irreparable
damage to the rollers.
© GBC Films Group April 2000
Page 4 - 7
Installation
F - 160 CE Operation and Maintenance Manual
b) Remove any plastic strapping and/or packing
paper taped to the rollers.
CAUTION
Do not use a knife or other sharp object to
remove the shrink wrap from around the
laminator. You can cause irreparable
damage to the rollers.
c) Remove all packing materials to a safe distance
from the laminator and dispose of properly.
d) Use two people to carefully roll the laminator to
the desired location.
INFORMATION
About recycling: The crate components can
be reused for shipping the laminator again
or can be disassembled and the wood and
screws recycled. The shrink wrap is not
recyclable, so it must be discarded.
4.6 Accessory pack
Once the Falcon 160 CE Laminator has been
unpacked and moved into final position, open the accessory
pack and verify the contents.
Accessory Pack contents
• One T-handle allen wrench ( 475-200 )
• One Zippy knife ( 475-620 )
• One Terry clothe towel ( 475-950 )
• One Operators manual ( 930-045 rev. A )
• One roll masking tape ( 475-000 )
• Two Polyurethane O-rings ( 480-005 )
• One strain relief for main power ( 175-201 )
• One rubber cement pad ( 930320 )
• One crankhandle ( 629-018 )
• One fuse, 0.5A ( 186-022 )
• Two fuses, 2.5A ( 186-220 )
• Four leveling bolts ( 645-011 )
• Twelve 3/4 - 10 nuts ( No P/N )
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
Page 4 - 8
© GBC Films Group April 2000
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.
Installation
b) Lock the castors on the drive side leg.
CAUTION
Do not lift the machine where NO LIFT
warnings are located. You can cause
damage to the electrical bridge.
Before leveling can be performed, the castors
must be replaced with leveling bolts and leveling pads.
c) Slide the floor jack under the control side leg.
Tools required
• Torpedo level
• ( 2 ) 3/4” open end wrenches
• Four leveling pads
( from the accessory pack )
• Four Leveling bolts
( from the accessory pack )
• Twelve 3/4 - 10 nuts
( from the accessory pack )
• Floor jack
( 600 pound rating )
• Second person
Center of the leg
Control side
a) Verify that the laminator has sufficient room
around it to load film, walk around and to be
serviced if necessary.
© GBC Films Group April 2000
d) Raise the control side approximately 4 in. from
the bottom of the castor to the floor. (10 cm)
Must have eneough clearance to remove the
castors
Page 4 - 9
Installation
F - 160 CE Operation and Maintenance Manual
e) Remove the front control side castor by turning
the nut securing the castor in the leg.
Figure 4.7.1 Leveling pad installed
Nut
Nut
Nut
Castor
f) Slide one of the leveling bolts where the castor
was removed and along with a 3/4-10 nut
inside the leg.
Jam nut
Leveling pad
i) Tighten the jam nut against the leveling pad.
Refer to Figure 4.7.1 Leveling pad installed.
Nut
Bolt
j) Perform steps e through “ i ” for the rear control
side castor and leveling pad.
g) Place two more 3/4-10 nuts on the leveling bolt
under the leg. Refer to Figure 4.7.1 Leveling
pad installed.
h) 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
Drive side
a) Perform steps “ a ” through “ j ” from the
Control side.
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
4.8 Leveling
Installation
b) Level the control side from front to back by
holding the nut inside the leg and turning the nut
below the leg with the wrench.
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.
INFORMATION
A second person can read the level while you
make the appropriate adjustments.
a) Position the level on the top of the control side
frame. Not on the cabinet. Refer to Figure
4.8.1 Front to back control side
- To raise; raise the nut inside the leg and turn
the nut below the leg clockwise.
4.8.1 Front to back control side
Level
Raise
Turn clockwise
- To lower; turn the nut below the leg counter
clockwise.
INFORMATION
The side frame provides a more accurate
reading than the cabinet.
© GBC Films Group April 2000
Lowering
limit
Turn counter
clockwise
Page 4 - 11
Installation
F - 160 CE Operation and Maintenance Manual
INFORMATION
INFORMATION
Lowering is limited to the amount of
height within the inside of the leg.
c) Position the level on the top of the drive side
frame. Not on the cabinet. Refer to Figure
4.8.2 Front to back drive side
Figure 4.8.2 Front to back drive side
A second person can read the level while you
make the appropriate adjustments.
- To raise; raise the nut inside the leg and turn
the nut below the leg clockwise.
Raise
Turn clockwise
Level
- To lower; turn the nut below the leg counter
clockwise.
Lowering
limit
Turn counter
clockwise
d) Level the control side from front to back by
holding the nut inside the leg and turning the nut
below the leg with the wrench.
e) Confirm that power is supplied to the
laminator.
Page 4 - 12
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
f) Flip the circuit breaker on the laminator to the up
position.
Installation
h) Press RESET. The front control panel should
be illuminated at this point.
= ON
= OFF
Machine reset
g) Turn MAIN POWER to “ I ” position.
WARNING
Caution should always be exercised
when using the laminator with
the safety shields raised.
You can be seriously HURT or INJURED!
Power
ON/OFF
i) Raise the front safety shield. The SAFETY
indicator will begin flashing.
INFORMATION
Ensure all E-STOPS are unlatched and
the E-CABLE is reset before turning
power on to the laminator.
00.0
SPEED
GO
STOP
FWD
REV
SAFETY
= Flashing
© GBC Films Group April 2000
Page 4 - 13
Installation
F - 160 CE Operation and Maintenance Manual
l) Level the laminator from drive side to control
side by adjusting the two front leveling pads.
WARNING
Keep hands and fingers clear of the
laminator roller nip when changing GAP.
You can be CRUSHED or BURNED!
j) Press PRESSURE ▼ to illuminate 3 bars in
the pressure dsiplay.
- To raise; raise the nut inside the leg and turn
the nut below the leg clockwise.
Raise
Turn clockwise
PRESSURE
GAP
0
- To lower; turn the nut below the leg counter
clockwise.
k) Place the level across the top of the upper main
roller in the center. Refer to Figure 4.8.3
Drive to control side front
Lowering
limit
Figure 4.8.3 Drive to control side front
Turn counter
clockwise
Level
n) Press GAP ▲ to 1 in. setting.
GAP
PRESSURE
1
Page 4 - 14
© GBC Films Group April 2000
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. Refer to Figure 4.8.4
Drive to control side rear
Figure 4.8.4 Drive to control side rear
Installation
4.9 Connecting power
ELECTRICAL
SHOCK
Only a qualified electrician should connect
power to the laminator. You can be severely
shocked, electrocuted or cause a fire if
power is improperly applied.
a) Ensure the power at the junction box is in the
OFF position.
Level
b) Remove the drive side leg cover with a #2
phillips screw driver.
p) Verify all four leveling points. Make any
adjustments neccessary. If all four points are
leveled, secure all nuts in place.
q) Lower the front and rear safety shields.
r) Turn MAIN POWER to “OFF “.
© GBC Films Group April 2000
Page 4 - 15
Installation
F - 160 CE Operation and Maintenance Manual
c) Feed the power cable through the power cable
strain relief located at the bottom of the drive
side leg.
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.
Strain relief
WARNING
Line
terminal
block
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.
d) Connect the power cord to the line terminal
block. Refer to Figure 4.9.1 Single phase or
Figure 4.9.2 Wye three phase.
Figure 4.9.1 Single phase illustrates proper
single phase wiring for the U.S. and Canada.
g) Once the power cord has been properly
connected, replace the drive side leg cover.
h) Proceed with 4.10 Safety check.
Figure 4.9.2 Wye three phaseillustrates proper
Wye 3 phase wiring for Europe.
Page 4 - 16
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Installation
Ground wire
N
Figure 4.9.1 Single phase, U.S. and Canada
L1
L2
Line 1
L3
N
N
Line 2
N
PE
L2
L3
wire
1
2
3
L1
Ground
Line
Line
Line
N
Figure 4.9.2 Wye 3 phase, Europe only
N
N
Neutral
N
Remove
Jumper
bars
PE
© GBC Films Group April 2000
Page 4 - 17
Installation
F - 160 CE Operation and Maintenance Manual
4.10 Safety check
The safety check will ensure that all safety devices
and interlocks are functioning properly.
4.10.1 Front feed table
a) Turn MAIN POWER to “ON” .
This procedure describes how to check one
E-STOP, the front E-CABLE, the front safety shield
and the front feed table. Repeat the steps for the remaining
three E-STOPS, the rear E-CABLE and the rear safety
shield. The rear feed table is not removable. ALL
SAFETY FEATURES MUST BE CHECKED!
WARNING
Power
ON/OFF
b) Press RESET. The front control panel will be
illuminated.
Do not wear ties, loose fit 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.
WARNING
Machine reset
If a safety feature is not working
properly, contact your local service
representative immediately.
c) Press SEL. SEL stops flashing.
Contacts:
SE L
GBC National Service: ( 800 ) 790 - 7787
GBC Europe Service: 33 - 45 - 535 - 7676
Page 4 - 18
JOB
0
SAV
STANDBY
= Flashing
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
d) Press FWD ▲ to set a forward motor
direction.
00.0
SPEED
GO
STOP
Installation
g) Slightly lift the front feed table. SAFETY
indicator and GO begin flashing and the
bottom rollers stop.
FWD
REV
6.0
SPEED
G O
STOP
FWD
REV
SAFETY
SAFETY
= Flashing
e) Press SPEED ▲ to set a speed of 6 ft/min.
h) Lower the front feed table.SAFETY
indicator reverts to white and GO remains
flashing.
6.0
SPEED
GO
STOP
FWD
REV
6.0
SAFETY
SPEED
G O
STOP
FWD
REV
SAFETY
= Flashing
f) Press GO. The bottom rollers begin turning.
i) Press STOP. GO stops flashing.
6.0
SPEED
GO
STOP
FWD
REV
6.0
SPEED
GO
STOP
FWD
REV
SAFETY
SAFETY
© GBC Films Group April 2000
Page 4 - 19
Installation
F - 160 CE Operation and Maintenance Manual
4.10.2 Safety shield
c) Lower the front safety shield. SAFETY
indicator reverts to white and GO remains
flashing.
a) Press GO. The bottom rollers begin turning.
6.0
SPEED
G O
STOP
FWD
REV
SAFETY
6.0
SPEED
GO
FWD
= Flashing
STOP
REV
SAFETY
d) Press STOP .GO stops flashing.
WARNING
Caution should always be exercised
when using the laminator with
the safety shields raised.
You can be seriously HURT or INJURED!
6.0
SPEED
GO
STOP
FWD
REV
SAFETY
b) Raise the front safety shield. SAFETY indicator
and GO begin flashing and the bottom rollers
stop.
e) Repeat steps “ a ” through “ d ” for the rear
safety shield.
6.0
SPEED
G O
STOP
FWD
REV
SAFETY
= Flashing
Page 4 - 20
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Installation
d) Unlatch the E-STOP.
4.10.3 E-STOP
Unlatch
a) Press GO. The bottom rollers begin turning.
6.0
SPEED
GO
FWD
REV
STOP
e) Press machine RESET. The front control panel
is illuminated.
SAFETY
b) Press PRESSURE ▼ to illuminate 3 bars in
the pressure dsiplay.
GAP
PRESSURE
Machine reset
0
f) Repeat steps “ a ” through “ e ” for the
remaining three E-STOPs.
Front
c) Press down on the front control side E-STOP.
The E-STOP latches in the down position,
bottom rollers stop, the upper main roller
raises and the control panel is blank.
E-STOP
Rear
Push
E-STOPs
© GBC Films Group April 2000
Page 4 - 21
Installation
F - 160 CE Operation and Maintenance Manual
d) Latch the E-CABLE by pushing in on the ECABLE reset located in the front at the bottom
of the control side leg.
4.10.4 E-CABLE
a) Press GO. The bottom rollers begin turning.
6.0
SPEED
GO
STOP
FWD
REV
Push in
SAFETY
b) Press PRESSURE ▼ to illuminate 3 bars in
the pressure dsiplay.
GAP
e) Press machine RESET. The front control panel
is illuminated.
PRESSURE
0
c) Press on the front E-CABLE with your foot.
The bottom rollers stop, the upper main roller
raises and the control panel is blank.
Machine reset
f) Repeat steps “ a ” through “ e ” for the
rear E-CABLE.
Page 4 - 22
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
4.11 Function check
Installation
b) Press BOT TEMP ▲ to a value of 120oF
( 48 oC ). BOT TEMP DISPLAY begins
flashing.
The function check ensures that the laminator
functions properly when operating. This check is
recommended before performing any applications.
TOP TEMP
120
If a step that does not react according to the
description, call your local area service representative
immediately.
WARNING
BOT TEMP
-
120
-
c) SEL can not be tested until you have saved
parameters within a JOB location. Refer to
Section 5.4 Job programming for SEL and
SAV.
Do not wear ties, loose fit 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.
SE L
JOB
0
SAV
STANDBY
= Flashing
4.11.1
Control panel
a) Press TOP TEMP. ▲ to a value of 120oF
( 48 oC ). TOP TEMP DISPLAY begins
flashing.
d) Press GAP ▼ once. GAP DISPLAY
decreases 1/16th of an inch per press. The
upper main roller moves accordingly. Once to
“0”, the upper main roller is contacting the
lower main roller.
GAP
TOP TEMP
120
BOT TEMP
-
PRESSURE
1-0
68
© GBC Films Group April 2000
Page 4 - 23
Installation
F - 160 CE Operation and Maintenance Manual
e) Press GAP ▲. GAP DISPLAY increases
1/16th of an inch per press. The upper main roll
moves accordingly. Once to “1”, the upper
main roller stops.
GAP
PRESSURE
0-1
SEL
JOB
f) Press and hold PRESSURE ▼. The upper
main roller travels in a constant downward
motion. Once making contact with the lower
main roller, the bars turn solid one at a time until
all 10 bars are solid.
GAP
h) Press JOB ▲. The JOB DISPLAY increases
in increments of 1 to 9.
9
SEL
JOB
g) Press and hold PRESSURE ▲. The upper
main roller travels in a constant upward motion.
The pressure bars turn hollow one at a time until
no bars are solid and GAP DISPLAY changes
to “ 1 ” then stops.
STANDBY
i) Press JOB ▼ . The JOB DISPLAY should
decreases in increments of 1 from 9 to 0.
PRESSURE
0
SAV
0
SAV
STANDBY
INFORMATION
To continue with the function checks, you
must press SEL so that it discontinues
flashing.
GAP
PRESSURE
1
Page 4 - 24
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
j) Press SPEED ▲ once. SPEED DISPLAY
increases in increments of .5 per press up to 15.
Installation
m) Press STOP. The bottom rollers stop turning.
15.0
15.0
SPEED
GO
STOP
FWD
REV
SPEED
GO
STOP
FWD
REV
SAFETY
SAFETY
k) Press FWD ▲. FWD is solid.
15.0
SPEED
GO
STOP
FWD
15.0
REV
SPEED
l) Press GO. The bottom rollers turn in a forward
motion at a speed of 15 ft./min.
( 4.57 m / min. ).
SPEED
GO
STOP
FWD
REV
SAFETY
SAFETY
15.0
n) Press REV ▼ . REV is solid and FWD
reverts to hollow.
GO
STOP
FWD
REV
SAFETY
© GBC Films Group April 2000
o) Press GO. The bottom rollers turn in a reverse
motion at a speed of 15 ft./min.
( 4.57 m / min. ).
15.0
SPEED
GO
STOP
FWD
REV
SAFETY
Page 4 - 25
Installation
F - 160 CE Operation and Maintenance Manual
p) Press STOP. The bottom rollers stop turning.
WARNING
15.0
SPEED
GO
STOP
FWD
REV
SAFETY
q) Press SPEED ▼ once. SPEED DISPLAY
decreases in increments of .5 per press down to
00.0.
00.0
SPEED
GO
STOP
FWD
Caution should always be exercised
when using the laminator with
the safety shields raised.
You can be seriously HURT or INJURED!
s) Raise the front safety shield, remove the front
feed table.
t) Touch the upper and lower main rollers. They
should feel warm to the touch.
REV
SAFETY
u) Replace the front feed table and lower the
front safety shield.
r) The TOP TEMP DISPLAY and BOT TEMP
DISPLAY are solid indicating the actual
temperature is within a +/- 6 oF of the set point
temperature.
INFORMATION
TOP TEMP
BOT TEMP
120
120
Page 4 - 26
The SAFETY indicator should not be
flashing when the tables are properly
seated and the safety shields are in
the closed position..
© GBC Films Group April 2000
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
SEL
0
JOB
Figure 4.11.1
Installation
4.11.2 Variable speed
footswitch
SAV
This check is to ensure that the footswitch works.
For complete instructions on the footswitch and its relation
to “Footswitch” mode to “ Panel” mode, refer to Section
5.1 Controls / ( 28 ) Footswitch.
STANDBY
Default settings
a) Press SEL on the front control panel to “wake”
the laminator from SLEEP mode. SLEEP
indicator reverts to hollow.
TOP TEMP
BOT TEMP
68
68
SAV
SE L
JOB
GAP
PRESSURE
1/16
IIIIIII
0
SAV
STANDBY
GO
00.0
STOP
SPEED
SAFETY
STANDBY
= Flashing
SE L
JOB
0
b) Press FWD ▲ for a forward motor direction.
FWD is solid.
FWD
REV
00.0
SPEED
= Flashing
© GBC Films Group April 2000
GO
STOP
FWD
REV
SAFETY
Page 4 - 27
Installation
F - 160 CE Operation and Maintenance Manual
c) Press down on the variable speed footswitch.
GO begins flashing and the bottom rollers are
turning.
WARNING
Caution should always be exercised
when using the laminator with
the safety shields raised.
You can be seriously HURT or INJURED!
ATTUNG
WARNING
ADVERTENCIA
a) Raise the rear safety shield.
INFORMATION
Footswitch speed is not indicated in the
SPEED DISPLAY on the control panel.
b) Lift the clevis pin up from the saddle of the
upper unwind shaft.
Saddle
Clevis pin
4.11.3 Unwind shafts and
unwind brakes
The unwind shafts swing out and the unwind
brakes tension the turning of the shaft from no tension to
complete stop tension.
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
c) Swing the upper unwind shaft to its fully
extended position. Swing back and reseat the
shaft in the saddle. The swing movement should
be smooth and easy.
d) Ensure that the upper unwind brake adjustment
knob is backed off completly. The counter
clockwise turn should be easy.
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
INFORMATION
Installation
h) Slowly turn the upper unwind brake adjustment
knob counter clockwise.
Steps " e" and " f" will be performed
simultaneously.
i) You should feel a decrease in resistance on the
turning of the upper unwind shaft as you turn the
upper unwind brake adjustment knob counter
clockwise.
e) With one hand, slowly turn the upper unwind
shaft in either direction.
j) Lower the rear safety shield.
f) With the other hand, slowly turn the upper
unwind brake adjustment knob clockwise.
Upper unwind brake
adjustment dial
k) Repeat steps “ b ” through “ h ” again for
the lower unwind shaft.
Lower unwind brake
adjustment dial
g) You should feel an increase in resistance on the
turning of the upper unwind shaft as you turn the
upper unwind brake adjustment knob
clockwise.
© GBC Films Group April 2000
Page 4 - 29
Installation
F - 160 CE Operation and Maintenance Manual
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Page 4 - 30
© GBC Films Group April 2000
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.
( 2 ) TOP TEMP DISPLAY : The display will show the
set point temperature of the top main roller as the default
display. When the top roller temperature has reached in
the +/- 6 oF range of the set point, the display will be
solid. When outside of this range, the display will flash.
TOP TEMP
BOT TEMP
68
68
For an illustration of the complete front control
panel, please refer to Figure 5.1.1. The names and
functions of these controls are as follows:
INFORMATION
When any command is pressed on the
control panel, a "beep" will sound. If the
command is held down, the panel will
"beep" only once.
5.1 Control Panel
( 1 ) STANDBY: If flashing, the machine is in standby
mode. This will occur after 3 hours of no activity. To wake
the laminator from standby mode or manual engage standby
mode, press STANDBY.
SEL
JOB
0
STANDBY
1
© GBC Films Group April 2000
SAV
2
( 3 ) TOP TEMP ▲ : When pressed, will increase the
set point value of the top main roller in increments of 2
degrees. If held down, it will only increase to the maximum
temperature setting of 290oF ( 143oC ).
3
TOP TEMP
BOT TEMP
68
68
( 4 ) TOP TEMP ▼ : When pressed, will decrease the
set point value of the top main roller in increments of 2
degrees. If held down, it will only decrease to the minimum
temperature setting of 68oF ( 20oC ).
TOP TEMP
BOT TEMP
68
68
4
Page 5 - 1
Operations
F - 160 CE Operation and Maintenance Manual
( 5 ) BOT. TEMP. DISPLAY : The display will show
the set point temperature of the bottom main roller as the
default display. When the bottom roller temperature has
reached in the +/- 10oF range of the set point, the display
will be solid. When outside of this range, the display will
flash.
( 8 ) 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
displayed, the temperaure is within the +/- 6 oF range.
TOP TEMP
TOP TEMP
68
68
BOT TEMP
68
BOT TEMP
+
68
-
8
5
( 6 ) BOT. TEMP. ▲ : When pressed, will increase the
set point value of the bottom main roller in increments of
2 degrees. If this key is held down, it will only increase to
the maximum temperature setting of 290oF ( 143oC ).
( 9 ) GAP DISPLAY : Displays the current main roller
nip opening. The nip has a range of 0 to 1” gap.
GAP
6
TOP TEMP
BOT TEMP
68
68
( 7 ) BOT. TEMP. ▼ : When pressed, will decrease the
set point value of the bottom main roller in increments of
2 degrees. If held down, it will decrease to the minimum
temperature setting of 68oF ( 20oC ).
PRESSURE
1/16
9
( 10 ) GAP ▲ : When pressed, will increase the gap by
1/16 in. increments. If held down, it will automatically
increase the gap by 1/16 in. increments until it has reached
a maximum opening of 1 in. on the GAP DISPLAY.
10
TOP TEMP
BOT TEMP
68
68
GAP
PRESSURE
1/16
7
Page 5 - 2
© GBC Films Group April 2000
Operations
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. on the GAP DISPLAY.
( 13 ) PRESSURE ▲ : When pressed once, will
decrease the pressure by 5%. If held down, it will decrease
from 100% of the maximum allowed pressure to 0% at
which point no bars will be illuminated.
13
GAP
PRESSURE
GAP
1/16
PRESSURE
1
11
( 12 ) PRESSURE DISPLAY : Displays the amount of
pressure being used. Each bar represents 10% of the
maximum allowable pressure. All ten bars illuminated
equals 100% of the maximum allowable pressure.
GAP
WARNING
Keep hands and fingers clear of
the laminator roller nip when
adjusting PRESSURE.
You can be CRUSHED or BURNED!
PRESSURE
1/16
12
( 14 ) PRESSURE ▼ : When pressed once, will increase
the pressure by 5%. If held down, it will increase from
0% of the minimum allowed pressure to 100% at which
point all bars will be illuminated.
INFORMATION
GAP
When adjusting the pressure, the gap
will be affected as well.
PRESSURE
0
14
© GBC Films Group April 2000
Page 5 - 3
Operations
F - 160 CE Operation and Maintenance Manual
( 15 ) JOB DISPLAY : Displays the job number selected
and will set the operating parameters saved for that number
once SEL has been pressed.
SEL
JOB
0
( 17 ) JOB ▼ : When pressed once will decrease the 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.
SAV
SEL
STANDBY
JOB
0
SAV
STANDBY
15
17
INFORMATION
Job programming is explained in
Section 5.4
( 18 )SEL : When pressed will send the operating
parameters for the stored job number selected to the
correct devices. Any time JOB ▲ or JOB ▼ is pressed,
SEL will flash indicating a change in job number.
18
SE L
JOB
( 16 ) JOB ▲ : When pressed once will increase the job
number in JOB DISPLAY by increments of 1. If pressed
and held, the JOB DISPLAY will increase to 9 at which
point it will stop.
0
SAV
STANDBY
= Flashing
16
INFORMATION
SEL
JOB
Page 5 - 4
9
STANDBY
SAV
If not using a JOB number, Press
SEL before changing parameters on
the control panel.
© GBC Films Group April 2000
Operations
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.
19
( 22 ) SPEED ▼: When pressed, decreases the speed
of the laminator in increments of 0.5 ft/min. When pressed
and held, speed will automatically decrease by 0.5 ft/min
increments until it has reached 0 ft/min.
00.0
SPEED
SEL
JOB
9
SAV
GO
FWD
REV
STOP
SAFETY
STANDBY
22
( 20 ) SPEED DISPLAY : Displays the current speed
setting of the laminator.
20
00.0
SPEED
GO
( 23 ) GO: When pressed, starts the rollers in motion.
GO is solid. This solid indication is referred to as the “panel
mode”. If a safety shield is raised during “panel mode”,
GO and SAFETY ( refer to ( 27 ) SAFETY for
explanation ) begin flashing enabling “footswitch” mode.
( refer to ( 28 ) FOOTSWITCH for explanation )
FWD
23
REV
STOP
SAFETY
00.0
SPEED
GO
STOP
FWD
REV
SAFETY
( 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.
( 24 ) STOP : When pressed, stops the rollers and GO
becomes white.
21
00.0
15.0
SPEED
GO
STOP
FWD
REV
SPEED
GO
STOP
FWD
REV
SAFETY
SAFETY
24
© GBC Films Group April 2000
Page 5 - 5
Operations
F - 160 CE Operation and Maintenance Manual
( 25 ) FORWARD ▲ : When pressed, signals the
laminator to run in a forward motion and FORWARD ▲
becomes solid.
25
GO
00.0
STOP
SPEED
( 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. If the safety shield is down,
the speed is controlled through the control panel.
FWD
28
REV
SAFETY
ATTUNG
WARNING
ADVERTENCIA
( 26 ) REVERSE ▼ : When pressed, signals the
laminator to run in a reverse motion and REVERSE ▼
becomes solid.
Panel to Footswitch
GO
00.0
STOP
SPEED
FWD
REV
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;
SAFETY
26
( 27 ) SAFETY : Begins flashing anytime the front or the
rear safety shield is in the raised position. This is an
indication for the operator to be very careful when
operating the laminator in the “Footswitch” mode.
GO
00.0
STOP
SPEED
• Press on the variable speed footswitch. GO
begins flashing identifying “Footswitch” mode.
• Once the variable speed footswitch is released,
the rollers will stop.
FWD
REV
SAFETY
27
Page 5 - 6
• To make the rollers turn, simply press on the
variable speed footswitch.
© GBC Films Group April 2000
Operations
F - 160 CE Operation and Maintenance Manual
INFORMATION
INFORMATION
When the safety shield is in the lowered
position and "Footswitch" mode is
engaged, speed is controlled through
the control panel
If the variable speed footswitch is not
close to the speed of the control panel,
output quality may be affected by the
speed difference.
Footswitch to Panel
To raise the safety shield
2. To switch from “Footswitch” mode ( GO is flashing )
to “Panel” mode ( GO is solid ) with the safety
shields in the down position. Perform the following
steps;
• Press and hold the variable speed footswitch
down.
• Press and hold GO for 3 -4 seconds before
releasing the variable speed footswitch.
WARNING
When operating the laminator using the
variable speed footswitch, keep hands and
fingers away from the nip of the rollers.
You may be CRUSHED or BURNED!
• Press and hold on the variable speed footswitch.
( approximately 1/2 the travel distance of the
variable speed footswitch )
• Release the variable speed footswitch.
• Release GO. GO should be solid.
CAUTION
Speed is controlled through the variable
speed footswitch when the safety shield
is in the raised position.
3. In the event that the safety shield must be raised
while the laminator is running, Perform the following
steps;
© GBC Films Group April 2000
Page 5 - 7
Operations
F - 160 CE Operation and Maintenance Manual
WARNING
Caution should always be exercised
when using the laminator with
the safety shields raised.
You can be seriously HURT or INJURED!
INFORMATION
Footswitch speed is not indicated in the
SPEED DISPLAY on the control panel.
To lower the safety shield
• Raise the safety shield.
• Lower the safety shield.
INFORMATION
When a safety shield is raised while pressing
on the variable speed footswitch, the speed
may be faster or slower than the indicated
panel speed.
INFORMATION
When the safety shield is raised, the
laminator will only run while the variable
speed footswitch is depressed.
INFORMATION
When the safety shield is lowered, speed
reverts to the panel speed setting.
• Press and hold GO for 3 -4 seconds before
releasing the variable speed footswitch.
• Release the variable speed footswitch.
• Adjust for desired speed using the variable
speed footswitch.
Page 5 - 8
• Release GO. GO reverts to solid.
© GBC Films Group April 2000
Operations
F - 160 CE Operation and Maintenance Manual
Figure 5.1.1 Front control panel
2
3
TOP TEMP
68
5
6
BOT TEMP
+
68
4
7
8
10
GAP
PRESSURE
13
9
1/16
IIIIIII
14
11
12
16
15
SAV
SE L
JOB
0
STANDBY
17
22
27
1
18
21
20
19
00.0
SPEED
GO
STOP
FWD
25
REV
26
23
SAFETY
24
= Flashing
© GBC Films Group April 2000
Page 5 - 9
Operations
F - 160 CE Operation and Maintenance Manual
5.2 Emergency
The F-160 CE laminator has been designed with
safety as a primary consideration; however, you must
become thoroughly familiar with the controls, proper
operation, proper service procedures, and safety features
of the laminator before using or servicing the unit.
5.2.1 In an emergency
a) In the event of an emergency;
- Press any of the four E-STOPs, or
- Step on the front or rear E-CABLE
GBC Films Group laminators are powerful
machines that are designed to mount, laminate, and
encapsulate. The forces required to accomplish these tasks
can vary from negligible to very large.
The motorized main roller lift mechanism used to
provide downward pressure on the upper main roller is
capable of producing forces greater than 400 pounds.
E-STOPs
E-STOPs
E-CABLE
E-CABLE
WARNING
This force is applied to any object presented
in the opening ( called the nip ) between
the two rollers.
INFORMATION
When an E-STOP or E-CABLE is engaged,
all motion stops, main rollers will gap
and power is removed.
Use care in lowering the upper laminating roller
and know how to react quickly in an emergency. The
main laminator roll up / down control is located on the
right side of the machine within the front control panel.
The GAP up / down arrows control the motion of the
upper laminating roller. Before pressing GAP down
arrow, ensure the nip area is clear.
Page 5 - 10
b) Resolve the emergency situation.
© GBC Films Group April 2000
Operations
F - 160 CE Operation and Maintenance Manual
5.2.2 Resume operation
b) Press machine RESET. All parameters have
defaulted.
a) Reset the E-STOP or the E-CABLE.
-Resetting the E-STOP
Machine reset
Unlatch
INFORMATION
-Resetting the E-CABLE
Once RESET has been engaged, power will
be restored, Laminating rollers will reset to
1 in. GAP and the display will return to it's
default settings.
Default mode; TOP TEMP. = 68 o F ( 20 o C ),
BOT. TEMP. = 68 oF ( 20 oC ), GAP = 1 in.,
PRESSURE = no bars are solid, JOB = 0, no
motion direction selected, SPEED = 00.0 and
SLEEP = flashing
Push in
c) Enter the desired operating parameters or
select the job number prior to the emergency
stop situation.
INFORMATION
The laminator will only turn on if all
E-STOPS are unlatched and
the E-CABLE is reset.
© GBC Films Group April 2000
d) You may now resume operating the laminator.
Page 5 - 11
Operations
5.3 Set up
F - 160 CE Operation and Maintenance Manual
d) Press machine RESET. The front control panel
is illuminated.
Initial set up of the Falcon 160 CE laminator is
easily attained when instructions are followed exactly. It
is suggested and helpful if you take the time to read this
section thoroughly before attempting to do any of the steps.
A complete understanding of this section will enable you
to follow the procedures descibed in Section 6.1
Application.
Machine reset
5.3.1 Power
a) Clear the area around the laminating rollers and
pull rollers nip..
5.3.2 Film loading
b) Ensure the laminator is plugged in.
WARNING
c) Turn the MAIN POWER to the “ I ”
position.
Power
ON/OFF
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 if placing a roll of
laminate onto the upper unwind shaft.
b) Lift the clevis pin located in the saddle of the
upper unwind shaft.
Page 5 - 12
© GBC Films Group April 2000
Operations
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
Saddle
Core support
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. For centering measurements,
refer to Chart 5.3.1 Measurement chart.
Roll of laminate
Core chucks
Clevis pin
Make sure
the laminate
is flush with
the core.
Measure from
the side frame
to the edge of
the roll of
laminate.
INFORMATION
Twisting the roll of film while sliding
makes loading the film onto the
unwind shaft easier.
d) Onceloaded, swing the unwind shaft back into
the saddle.
h) Close the rear safety shield.
CAUTION
Ensure the roll of laminate is loaded
properly on the unwind shaft.
Exposed adhesive should be facing
away from the rollers.
This will prevent hours of roll cleaning!
© GBC Films Group April 2000
g) For the lower unwind shaft, repeat steps “ b ”
through “ f ”.
Page 5 - 13
Operations
F - 160 CE Operation and Maintenance Manual
Chart 5.3.1 Measurement chart
Common film widths
Film width
Measurement
12 "
24 "
28 "
22 "
31 "
18.5 "
37 "
38 "
15.5 "
15 "
41 "
47 "
13.5 "
10.5 "
49 "
9.5 "
51 "
55 "
8.5 "
6.5 "
58 "
60 "
5"
4"
3"
62 "
5.3.5 Heating
Perform the following steps.if the application
requires heat. Allow the rolls to heat up while rotating for
even heat disbursement.
a) Press TOP TEMP. ▲ to set your upper roller
temperature.
TOP TEMP
BOT TEMP
68
68
b) If required, press BOT. TEMP. ▲ to set your
lower roller temperature.
INFORMATION
For the lower unwind shaft, add 1/4 in. to
the measurement.
TOP TEMP
BOT TEMP
68
68
INFORMATION
When requiring top and bottom heat, it is
recommended to set both temperatures to
the same set point.
Page 5 - 14
© GBC Films Group April 2000
Operations
F - 160 CE Operation and Maintenance Manual
c) Press GAP ▼ to set the gap to “0”.
INFORMATION
PRESSURE
GAP
A slow speed helps distribute heat evenly.
0
f) Press SEL to engage the parameters.
INFORMATION
SAV
SE L
Do not add PRESSURE when heating the
laminating rollers. The rollers expand.
d) Press FWD ▲ to set a forward motion
direction.
00.0
SPEED
GO
STOP
JOB
0
STANDBY
g) Press GO to engage the motor drive system.
2.0
FWD
SPEED
REV
GO
STOP
FWD
REV
SAFETY
SAFETY
e) Press SPEED ▲ to set a speed of 2 ft/min
( .61 m / min. ).
2.0
SPEED
GO
STOP
h) When the rollers are close to it’s set point value,
the temperature displays stop flashing, press
STOP and raise the gap to 1 in. by pressing
GAP ▲
FWD
GAP
REV
1
PRESSURE
SAFETY
© GBC Films Group April 2000
Page 5 - 15
Operations
F - 160 CE Operation and Maintenance Manual
5.4 Job programming
c) Press SEL.
SAV
SE L
The job save feature is very convenient if the same
parameters are required to perform various applications.
This procedure will guide you step by step through this
feature.
a) Follow the prcedure in Section 5.3.1 Power.
JOB
1
d) If heat is required, press TOP TEMP. ▲ and
BOT. TEMP. ▲ to desired settings. If no heat
is required, leave the settings at 68 oF ( 20 oC ).
TOP TEMP
INFORMATION
225
When the laminator is first turned on, the
front control panel will go into the default
mode.
Default mode; TOP TEMP. = 68 o F ( 20 o C ),
BOT. TEMP. = 68 oF ( 20 oC ), GAP = 1 in.,
PRESSURE = no bars are solid, JOB = 0, no
motion direction selected, SPEED = 00.0 and
SLEEP = flashing
b) Press JOB ▲ to enter the desired job number
for the parameters you require to be stored.
JOB
Page 5 - 16
1
SAV
BOT TEMP
-
225
-
WARNING
Keep hands and fingers clear of the
laminator roller nip when changing GAP.
You can be CRUSHED or BURNED!
e) Enter in the GAP setting desired by pressing
GAP ▼.
GAP
SE L
STANDBY
PRESSURE
0
STANDBY
© GBC Films Group April 2000
Operations
F - 160 CE Operation and Maintenance Manual
INFORMATION
CAUTION
When storing parameters within the JOB
SAVE feature of the laminator, PRESSURE
is not a storable setting.
If you accidentally press SAVE at any time,
the old parameters will be replaced with the
new parameters.
f) Enter a desired speed by pressing SPEED ▲.
INFORMATION
You should store each job location with its
parameters on the chart provided in
Chart 5.4.1
5.0
SPEED
GO
STOP
FWD
REV
SAFETY
Chart 5.4.1 Job save chart
g) Press and hold SAVE ( approximately 4
seconds ) until an audible beep is heard. The
parameters entered have just been stored.
JOB #
TOP TEMP.
BOT. TEMP.
GAP
SPEED
1
2
3
SEL
JOB
1
SAV
STANDBY
4
5
6
7
8
h) Repeat steps “b” through “f” to save other
parameters in job location numbers.
© GBC Films Group April 2000
9
Page 5 - 17
Operations
F - 160 CE Operation and Maintenance Manual
5.5 Manual nip adjustment
a) Turn the MAIN POWER to the “ I ”
position.
If the substrate does not fall with in the preset
GAP settings available, a manual nip setting must be
performed.
Power
ON/OFF
If you are unsure of a substrate thickness, it is
recommended that you use the manual nip setting
procedure.
If you are performing a mounting application from
the rear of the machine, the pull rollers must be set manually.
Refer to Section 5.5.2 Pull roller nip adjustment
procedure.
5.5.1 Main roller manual
nip adjustment
INFORMATION
The laminator will only turn on if all
E-STOPS are unlatched and
the E-CABLE is reset.
Page 5 - 18
b) Press RESET. The front control panel will
illuminated.
Machine reset
WARNING
Caution should always be exercised
when using the laminator with
the safety shields raised.
You can be seriously HURT or INJURED!
© GBC Films Group April 2000
Operations
F - 160 CE Operation and Maintenance Manual
c) Raise the front safety shield.
f) At eye level with the main rollers, press
PRESSURE ▼ until you see the upper main
roller make contact with the substrate.
d) Press SEL.
GAP
PRESSURE
0
SE L
JOB
0
SAV
STANDBY
= Flashing
CAUTION
Excess pressure can damage the laminating
rollers. Always use the minimum roll
pressure necessary to complete the task.
e) Position the leader board in the center of the
main rollers between the nip.
INFORMATION
Excessive pressure will cause the
substrate to bow or flatten.
CAUTION
Sharp edges on a substrate should be filed
smooth and GAP manually adjusted.
Sharp edges can CUT the rollers!
INFORMATION
Density of the substrate will determine the
amount of pressure you may use.
WARNING
Keep hands and fingers clear of the
laminator roller nip when changing GAP.
You can be CRUSHED or BURNED!
INFORMATION
Refer to Figure 5.5.1 for proper roller
pressure.
© GBC Films Group April 2000
Page 5 - 19
Operations
F - 160 CE Operation and Maintenance Manual
Figure 5.5.1 Main roller pressure
WARNING
Leader board
Proper
pressure
Leader board
Excessive
pressure
When operating the laminator using the
variable speed footswitch, keep hands and
fingers away from the nip of the rollers.
You may be CRUSHED or BURNED!
i) Step on the variable speed footswitch to back
the leader board out.
CAUTION
Speed is controlled through the variable
speed footswitch when the safety shield
is in the raised position.
g) Press REV ▼ for a reverse motor direction.
00.0
SPEED
GO
STOP
j) The main roller nip has now been manually set.
FWD
REV
SAFETY
k) Press STOP.
h) Press SPEED ▲ to 5.
5.0
SPEED
5.0
SPEED
GO
STOP
FWD
GO
STOP
FWD
REV
SAFETY
REV
SAFETY
Page 5 - 20
© GBC Films Group April 2000
Operations
F - 160 CE Operation and Maintenance Manual
l) On the control panel press FWD ▲ for a
forward motor direction. Nip is now set.
b) Press RESET. The front control panel will
illuminated.
FWR
00.0
GO
REV.
SPEED
SAFETY
STOP
Machine reset
5.5.2 Pull roller manual nip
adjustment
c) Press SEL.
INFORMATION
If the main laminating rollers are heated,
mounting application may be run from the
rear operating position of the machine.
SAV
SE L
JOB
0
STANDBY
= Flashing
a) Turn the MAIN POWER to the “ I ”
position.
d) Press FWD ▲ for a forward motor direction.
Power
ON/OFF
00.0
SPEED
GO
STOP
FWD
REV
SAFETY
© GBC Films Group April 2000
Page 5 - 21
Operations
F - 160 CE Operation and Maintenance Manual
e) Press SPEED ▲ to 5.
CAUTION
5.0
SPEED
GO
STOP
FWD
Sharp edges on a substrate should be filed
smooth and GAP manually adjusted.
Sharp edges can CUT the rollers!
REV
SAFETY
WARNING
f) Bring the footswitch around to the rear of the
laminator.
WARNING
Caution should always be exercised
when using the laminator with
the safety shields raised.
You can be seriously HURT or INJURED!
g) Raise the rear safety shield.
h) Position the leader board in the center of the
pull rollers between the nip.
Keep hands and fingers clear of the pull
roller nip when changing the gap.
You can be CRUSHED!
i) At eye level with the pull rollers, turn the pull
roll crank handle clockwise until you see the
upper pull roller make contact with the
substrate.
DOWN
CAUTION
Excess pressure can damage the laminating
rollers. Always use the minimum roll
pressure necessary to complete the task.
Page 5 - 22
© GBC Films Group April 2000
Operations
F - 160 CE Operation and Maintenance Manual
INFORMATION
Excessive pressure will cause the
substrate to bow or flatten.
INFORMATION
Density of the substrate will determine the
amount of pressure you may use.
INFORMATION
WARNING
Refer to Figure 5.5.2 for proper roller
pressure.
When operating the laminator using the
variable speed footswitch, keep hands and
fingers away from the nip of the rollers.
You may be CRUSHED or BURNED!
Figure 5.5.2 Pull roller pressure
j) Step on the variable speed footswitch to back
the leader board out.
Leader board
Proper
pressure
CAUTION
Speed is controlled through the variable
speed footswitch when the safety shield
is in the raised position.
Leader board
Excessive
pressure
k) The pull roller nip has now been manually set.
© GBC Films Group April 2000
Page 5 - 23
Operations
F - 160 CE Operation and Maintenance Manual
l) Press STOP.
5.0
SPEED
5.6.1 Removing the table
GO
STOP
FWD
REV
SAFETY
WARNING
m) Press REV ▼ for a reverse motor direction.
The nip is now set
5.0
SPEED
GO
STOP
Caution should always be exercised
when using the laminator with
the safety shields raised.
You can be seriously HURT or INJURED!
FWD
REV
a) Raise the safety shield.
SAFETY
INFORMATION
5.6 Front feed table
The table is part of the Falcon 160 CE safety
feature. It is neccessary to have the front feed table properly
positioned before using the laminator for an application.
SAFETY flashes when a safety feature
is not in proper position.
b) With both hands, grip the front edge of the
infeed table and lift up and then out.
Front edge
CAUTION
If not installed properly, you can be injured
or cause damage to the table or laminator.
Page 5 - 24
© GBC Films Group April 2000
Operations
F - 160 CE Operation and Maintenance Manual
5.6.2 Replacing the infeed
table
INFORMATION
If the tables are not properly seated, the
laminator will not operate in
"Panel" mode.
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.
Front
support bolt
c) Now lower the front edge while ensuring that
the pin aligns with the safety roller switch and
the back support bolt. Refer to Figure 5.6.3
Safety
roller switch
Back
support bolt
© GBC Films Group April 2000
Page 5 - 25
Operations
F - 160 CE Operation and Maintenance Manual
This page intentionally left blank.
Page 5 - 26
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Applications
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.
This section contains a blank process control chart
and diagram for the Falcon 160 CE as well as completed
charts and diagrams for the basic operations of the
laminator. It is recommended that you make copies of the
blanks and fill them in as needed.
WARNING
Do not wear ties, loose fit 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.
The procedures and parameters described
in this section are reference points only. Parameters
will vary with regards to laminate thickness, laminate
widths, laminate types, print types, ink or toner types,
environment conditions, operator experience and
various substrates.
© GBC Films Group April 2000
Page 6 - 1
Applications
F - 160 CE Operation and Maintenance Manual
6.1 Charts and Diagrams
Use the parameter charts and web up diagrams
can to assist you with the applications described. It is
recommended that you keep these parameter charts and
web up diagrams in the manual for reference. Make copies
if you require them in other locations.
Use the blank parameter chart and blank web up
diagram to record specific applications not illustrated in
this section. For converting degrees Fahrenheit to degrees
Celsius, refer to Chart 6.1.1
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
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Applications
Chart 6.1.1 Temperature conversion chart
o
F
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
o
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
C
20
20.6
21.1
21.7
22.2
22.7
23.3
23.9
24.4
25
25.6
26.1
26.7
27.2
27.8
28.3
28.9
29.4
30
30.6
31.1
31.7
32.2
32.8
33.3
33.9
34.4
35
35.6
36.1
36.7
37.2
37.8
38.3
38.9
39.4
40
40.6
41.1
41.7
42.2
42.8
43.3
43.9
44.4
o
F
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
o
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
C
45
45.6
46.1
46.7
47.2
47.8
48.3
48.9
49.4
50
50.6
51.1
51.7
52.2
52.8
53.3
53.9
54.4
55
55.6
56.1
56.7
57.2
57.8
58.3
58.9
59.4
60
60.6
61.1
61.7
62.2
62.8
63.3
63.9
64.4
65
65.6
66.1
66.7
67.2
67.8
68.3
68.9
69.4
© GBC Films Group April 2000
o
F
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
o
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
C
70
70.6
71.1
71.7
72.2
72.8
73.3
73.9
74.4
75
75.6
76.1
76.7
77.2
77.8
78.3
78.9
79.4
80
80.6
81.1
81.7
82.2
82.8
83.3
83.9
84.4
85
85.6
86.1
86.7
87.2
87.8
88.3
88.9
89.4
90
90.6
91.1
91.7
92.2
92.8
93.3
93.9
94.4
o
F
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
o
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
C
95
95.6
96.1
96.7
97.2
97.8
98.3
98.9
99.4
100
100.6
101.1
101.7
102.2
102.8
103.3
103.9
104.4
105
105.6
106.1
106.7
107.2
107.8
108.3
108.9
109.4
110
110.6
111.1
111.7
112.2
112.8
113.3
113.9
114.4
115
115.6
116.1
116.7
117.2
117.8
118.3
118.9
119.4
o
F
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
o
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
C
120
120.6
121.1
121.7
122.2
122.8
123.3
123.9
124.4
125
125.6
126.1
126.7
127.2
127.8
128.3
128.9
129.4
130
130.6
131.1
131.7
132.2
132.8
133.3
133.9
134.4
135
135.6
136.1
136.7
137.2
137.8
138.3
138.9
139.4
140
140.6
141.1
141.7
142.2
142.8
143.3
=
=
Page 6 - 3
Applications
F - 160 CE Operation and Maintenance Manual
Parameter Chart - Blank
MATERIALS
UPPER UNWIND :
SUBSTRATE :
LOWER UNWIND :
PRINTS :
TEMPERATURE
TOP TEMP.
BOT. TEMP.
GAP & PRESSURE
PRESSURE
GAP
MOTOR DIRECTION & SPEED
SOLID
= Panel
FWR
GO
SPEED
F L A S HING
= Footswitch
REV.
GO
PULL ROLL SETTINGS
N/A
UP
1/4 Turn
PRESSURE
1/2 Turn
DOWN
3/4 Turn
NOTES
Page 6 - 4
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Applications
Web Diagram - Blank
© GBC Films Group April 2000
Page 6 - 5
Applications
F - 160 CE Operation and Maintenance Manual
Parameter Chart 1 - Precoating substrates
MATERIALS
U P P E R U N W I N D : Pro Mount
S U B S T R A T E : 1/4" Foam Core
LOWER UNWIND : N / A
PRINTS :
N/A
TEMPERATURE
TOP TEMP.
BOT. TEMP.
68
68
GAP & PRESSURE
PRESSURE
GAP
1/4"
MOTOR DIRECTION & SPEED
SOLID
= Panel
FWD
GO
00.0
SPEED
FLASHING
= Footswitch
REV.
GO
PULL ROLL SETTINGS
N/A
UP
1/4 Turn
PRESSURE
1/2 Turn
DOWN
3/4 Turn
NOTES
Pro Mount can be substituted with a similar product. Substrate can vary. GAP will be dependent on the
substrate thickness. 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 6 - 6
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Applications
Web Diagram 1 - Precoating substrate
Pro
Mount
Substrate
Leader
board
© GBC Films Group April 2000
Page 6 - 7
Applications
F - 160 CE Operation and Maintenance Manual
Parameter Chart 2 - Mounting only
MATERIALS
UPPER UNWIND : N / A
S U B S T R A T E : Precoated boards
LOWER UNWIND : N / A
PRINTS :
Inkjet prints
TEMPERATURE
TOP TEMP.
BOT. TEMP.
68
68
GAP & PRESSURE
PRESSURE
GAP
1/4
MOTOR DIRECTION & SPEED
SOLID
= Panel
FWD
GO
00.0
SPEED
FLAS HING
= Footswitch
REV.
GO
PULL ROLL SETTINGS
N/A
UP
1/4 Turn
PRESSURE
1/2 Turn
DOWN
3/4 Turn
NOTES
Substrate will vary. Print can be of any type. GAP will be dependent on the substrate thickness. 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 6 - 8
© GBC Films Group April 2000
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
Applications
F - 160 CE Operation and Maintenance Manual
Parameter Chart 3 - Single sided ( Sled )
MATERIALS
U P P E R U N W I N D : Pro Gloss
S U B S T R A T E : 1/4" Foam Core
LOWER UNWIND : N / A
PRINTS :
Inkjet prints
TEMPERATURE
TOP TEMP.
BOT. TEMP.
68
68
GAP & PRESSURE
PRESSURE
GAP
1/4
MOTOR DIRECTION & SPEED
SOLID
= Panel
FWD
GO
00.0
SPEED
F L A SH I N G
= Footswitch
REV.
GO
PULL ROLL SETTINGS
N/A
UP
1/4 Turn
PRESSURE
1/2 Turn
DOWN
3/4 Turn
NOTES
Substrate will vary. Print can be of any type. GAP will be dependent on the substrate thickness. 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 6 - 10
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Applications
Web Diagram 3 - Single sided ( Sled )
P.S.A.
Laminate
Release liner
Print
Sled
© GBC Films Group April 2000
Page 6 - 11
Applications
F - 160 CE Operation and Maintenance Manual
Parameter Chart 4 - Single sided ( Craft paper )
MATERIALS
U P P E R U N W I N D : Pro Gloss
SUBSTRATE : N / A
L O W E R U N W I N D : Craft Paper
PRINTS :
Inkjet prints
TEMPERATURE
TOP TEMP.
BOT. TEMP.
68
68
GAP & PRESSURE
PRESSURE
GAP
0
MOTOR DIRECTION & SPEED
SOLID
= Panel
FWD
GO
3-6
SPEED
F L A SH I N G
= Footswitch
REV.
GO
PULL ROLL SETTINGS
N/A
UP
1/4 Turn
PRESSURE
1/2 Turn
DOWN
3/4 Turn
NOTES
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 6 - 12
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Applications
Web Diagram 4 - Single sided ( Craft paper )
P .S .A.
L a m in a te
R e le a s e lin e r
O u tp u t
P rin t
C ra ft P a p e r
F in is h p ro d u c t
re w in d o p tio n
© GBC Films Group April 2000
Page 6 - 13
Applications
F - 160 CE Operation and Maintenance Manual
Parameter Chart 5 - Decal and mount ( Decal )
MATERIALS
U P P E R U N W I N D : Pro Gloss
SUBSTRATE : N / A
L O W E R U N W I N D : Pro Mount
PRINTS :
Inkjet prints
TEMPERATURE
TOP TEMP.
BOT. TEMP.
68
68
GAP & PRESSURE
PRESSURE
GAP
0
MOTOR DIRECTION & SPEED
SOLID
= Panel
FWD
GO
3-6
SPEED
F L A SH I N G
= Footswitch
REV.
GO
PULL ROLL SETTINGS
N/A
UP
1/4 Turn
PRESSURE
1/2 Turn
DOWN
3/4 Turn
NOTES
Upper and lower 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 6 - 14
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Applications
Web Diagram 5 - Decal and mount ( Decal )
P.S.A.
Laminate
Release liner
Output
Print
Pro Mount
Finish product
rewind option
© GBC Films Group April 2000
Page 6 - 15
Applications
F - 160 CE Operation and Maintenance Manual
Parameter Chart 6 - Decal and mount ( Mount )
MATERIALS
UPPER UNWIND : N / A
S U B S T R A T E : 1/4" Foam Core
LOWER UNWIND : N / A
PRINTS :
Decals
TEMPERATURE
TOP TEMP.
BOT. TEMP.
68
68
GAP & PRESSURE
PRESSURE
GAP
1/4
MOTOR DIRECTION & SPEED
SOLID
= Panel
FWD
GO
00.0
SPEED
F L A SH I N G
= Footswitch
REV.
GO
PULL ROLL SETTINGS
N/A
UP
1/4 Turn
PRESSURE
1/2 Turn
DOWN
3/4 Turn
NOTES
Decal will come from the previous chart and diagram application. Substrate can vary. GAP will be dependent
on the substrate thickness. 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 6 - 16
© GBC Films Group April 2000
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
Applications
F - 160 CE Operation and Maintenance Manual
Parameter Chart 7 - Precoating substrates ( Thermal )
MATERIALS
U P P E R U N W I N D : Hot Tissue Mount
S U B S T R A T E : 1/4" Foam Core
LOWER UNWIND : N / A
PRINTS :
N/A
TEMPERATURE
TOP TEMP.
BOT. TEMP.
140
68
GAP & PRESSURE
PRESSURE
GAP
1/4
MOTOR DIRECTION & SPEED
SOLID
= Panel
FWD
GO
00.0
SPEED
F L A SH I N G
= Footswitch
REV.
GO
PULL ROLL SETTINGS
N/A
UP
1/4 Turn
PRESSURE
1/2 Turn
DOWN
3/4 Turn
NOTES
Upper unwind material may be sibstituted with similar product. Substrate can vary. Top temperature will vary
slighly between 140 - 160 o F. Gap will be dependent on the substrate thickness. 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 6 - 18
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Applications
Web Diagram 7 - Precoating substrate ( Thermal )
Hot
Tissue
Substrate
Leader
board
140 160
© GBC Films Group April 2000
Page 6 - 19
Applications
F - 160 CE Operation and Maintenance Manual
Parameter Chart 8 - One pass mount and laminate
MATERIALS
U P P E R U N W I N D : 3 mil Octiva Gloss
S U B S T R A T E : 1/4" Foam Core
LOWER UNWIND : N / A
PRINTS :
Electrostatic images
TEMPERATURE
TOP TEMP.
BOT. TEMP.
240
68
GAP & PRESSURE
PRESSURE
GAP
1/4
MOTOR DIRECTION & SPEED
SOLID
= Panel
FWD
GO
00.0
SPEED
F L A SH I N G
= Footswitch
REV.
GO
PULL ROLL SETTINGS
N/A
UP
1/4 Turn
PRESSURE
1/2 Turn
DOWN
3/4 Turn
NOTES
Upper unwind material may be sibstituted with similar product. Substrate can vary. Top temperature will vary
slighly between 240 - 260 o F depending on laminate thickness. Gap will be dependent on the substrate
thickness. 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 6 - 20
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Applications
Web Diagram 8 - One pass mount and laminate
Octiva
Gloss
Hot Tissue
Leader
board
Image
240 - 260
Substrate
© GBC Films Group April 2000
Page 6 - 21
Applications
F - 160 CE Operation and Maintenance Manual
Parameter Chart 9 - Thermal decal and Mount ( Decal )
MATERIALS
U P P E R U N W I N D : 3 mil Octiva Gloss
SUBSTRATE : N / A
L O W E R U N W I N D : Pro Mount
PRINTS :
Any type
TEMPERATURE
TOP TEMP.
BOT. TEMP.
230
68
GAP & PRESSURE
PRESSURE
GAP
0
MOTOR DIRECTION & SPEED
SOLID
= Panel
FWD
GO
3-6
SPEED
F L A SH I N G
= Footswitch
REV.
GO
PULL ROLL SETTINGS
N/A
UP
1/4 Turn
PRESSURE
1/2 Turn
DOWN
3/4 Turn
NOTES
Upper and lower 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 6 - 22
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Applications
Web Diagram 9 - Thermal decal and mount ( Decal )
Octiva
Gloss
Output
Print
230
Pro Mount
Finish product
rewind option
© GBC Films Group April 2000
Page 6 - 23
Applications
F - 160 CE Operation and Maintenance Manual
Parameter Chart 10 - Thermal decal and Mount ( Mount )
MATERIALS
UPPER UNWIND : N / A
SUBSTRATE : N / A
LOWER UNWIND : N / A
PRINTS :
Decals
TEMPERATURE
TOP TEMP.
BOT. TEMP.
68
68
GAP & PRESSURE
PRESSURE
GAP
1
MOTOR DIRECTION & SPEED
SOLID
= Panel
FWD
GO
0.00
SPEED
F L A SH I N G
= Footswitch
REV.
GO
PULL ROLL SETTINGS
N/A
UP
1/4 Turn
PRESSURE
1/2 Turn
DOWN
3/4 Turn
NOTES
The mounting process is done from the rear position of the laminator to avoid the waiting period involved with
o
cooling down the main rollers. The rollers may be left heated or turn them down 68
F. Pull roller pressure
with be dependent of the substrate. Apply the necessary pressure without crushing the board.
Page 6 - 24
© GBC Films Group April 2000
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
Applications
F - 160 CE Operation and Maintenance Manual
Parameter Chart 11 - Encapsulation
MATERIALS
U P P E R U N W I N D : 3 mil Octiva Gloss
SUBSTRATE : N / A
L O W E R U N W I N D : 3 mil Octiva Gloss
PRINTS :
Any type
TEMPERATURE
TOP TEMP.
BOT. TEMP.
240
240
GAP & PRESSURE
PRESSURE
GAP
0
MOTOR DIRECTION & SPEED
SOLID
= Panel
FWD
GO
0-7
SPEED
F L A SH I N G
= Footswitch
REV.
GO
PULL ROLL SETTINGS
N/A
UP
1/4 Turn
PRESSURE
1/2 Turn
DOWN
3/4 Turn
NOTES
Upper and lower unwind material may be sibstituted with similar products. Top and bottom temperature will
be dependent on film thickness . 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 - 26
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Applications
Web Diagram 11 - Encapsulation
Octiva
Gloss
Output
Print
230
230
Octiva
Gloss
Finish product
rewind option
© GBC Films Group April 2000
Page 6 - 27
Applications
F - 160 CE Operation and Maintenance Manual
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© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Section 7 Troubleshooting
Troubleshooting
Problem: D waves in the image but not in the laminate
WARNING
Do not wear ties, loose fitting clothing or
dangling jewelry while operating or
servicing the laminator. These items can get
caught in the nip and choke you or you can
be crushed or burned.
As an operator, you can perform some simple
troubleshooting in attempt to correct your typical output
type problems. Use the easy to follow guide for assistance.
Hints: • Check paper tension
• Check relative moisture content of the paper
7.1 Wave problems
Problem: D Waves in the laminate
The following is a list of common output wave
problems you may encounter.
The arrow along the length of the output
represents the direction of feed ( travel ).
INFORMATION
For optimal temperature settings of
various laminates, contact your
supplier or sales representative.
© GBC Films Group April 2000
Hints: • Check the roll pressure
• Check the main roll nip settings
• Check the pull roll nip settings
Page 7 - 1
Troubleshooting
Problem: Straight waves in the output
Hints: • Check operational settings for materials
being used.
Problem: Waves on only one side of the output
Hints: • Check the nip setting of main rolls
• 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
• Check for insufficient pull roller pressure
• Check the main roller nip settings
• Check the pull roller nip settings
Problem: Indent waves in output after the pull rollers
Hints: • Insufficient cooling time
• Allow output to cool before handling
• Check operating temperatures of material
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Troubleshooting
7.2 Film problems
Problem: Delamination
The following is a list of common film problems
you may encounter.
Hints: • Check operating temperatures
• Check operating speed
• Laminate compatibility with ink
• Ink compatibility with paper
For definitions of terminologies, please refer to
7.4 Glossary of terminology.
7.2.2 Pressure sensitive
7.2.1 Thermal laminates
Problem : Silvering in the laminate
Problem: Blistering within the image
Hints: • Increase the speed
• Decrease the operating temperature
• Allow a longer drying time for the image
Hints : • Add 100 - 120oF ( 37 - 49oC ) to the
temperature
• Increase pressure to laminating rolls
Problem : Tunneling
Problem: Coiling or curling of encapsulated images
Hints: • Balance the upper and the lower brake
tension
• Make sure set point temperatures are the
same
• Change the chill idler configuration
( if applicable )
Hints : • Print should be wound image side out.
• Do not roll tightly
• Do not roll at all.
Problem : Image creases when mounting
Problem: Silvering in the laminate
Hints: • Decrease the speed
• Increase the operating temperature
© GBC Films Group April 2000
Hints : • Press down on leading edge from center
outwards.
• Be sure image is conformed to the roll
• Use a speed you are comfortable with
• Be sure even tension is supplied to the image
Page 7 - 3
Troubleshooting
F - 160 CE Operation and Maintenance Manual
Problem: Delamination
Hints: • Check operating pressures
• Check operating speed
• Laminate compatibility with ink
• Ink compatibility with paper
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.
7.3 Machine problems
Problem : No illumination to the control panel
Once the Hints are all checked, and your problem
still exists, a service call must be placed for a qualified
service personnel to fix the problem.
Hints : • Ensure an E-stop has not been pushed
down
• Press RESET.
• Confirm that the MAIN POWER is to the
on position.
• Be sure power is supplied to the laminator
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.
Problem : I can only operate in “Footswitch” mode.
A space below has been provided to keep this
number readily available if and when needed.
My Falcon 160 CE Laminator serial # is :
Hints : • Be sure the tables are properly seated in the
table brackets.
• Be sure the safety shields are in the down
position.
• If the SAFETY indicator is flashing, place a
service call.
Problem : I press GO, it will always be flashing.
At no time does GBC Films Group suggest or
recommend that you attempt to fix the machine by
removing the cabinets or leg covers yourself.
Page 7 - 4
Hints : • Be sure the tables are properly seated in the
table brackets.
• Be sure the safety shields are completely in
the down position.
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Troubleshooting
Problem : I press GO, and the rolls will not turn.
CAUTION
Hints : • Be sure a speed has been entered.
• Make sure a motion direction has been
selected.
• Make sure GO or SEL is not flashing.
Prolonged contact can form flat spots on the
rollers.
Problem : Jerking, stuttering, or excessive noise from
the laminator.
7.4 Glossary
Hints : • Check for excessive brake tension
• Confirm that the rolls of laminate are on
correctly.
• Place a service call.
Rolls in the up position
Problem : The control panel is locked up
Hints : • Push the blue reset button.
• Press an E-stop, then unlatch the E-stop and
push RESET.
• Place a service call.
The glossary can help you in understanding some
of the terminology used when referring to the laminator,
applications, or troubleshooting aspects of the machine.
Blistering
A condition where the paper coating is bubbled
up from the image paper causing a “blister”. It is created
by using excessive heat during the lamination process.
Blistering is most commonly found with photographic and
ink jet media.
Bond strength
Rollers in the down position
Problem : The control panel is locked up
Hints : • Press RESET.
• Press an E-stop, then unlatch the E-stop and
push RESET.
• Disconnect power and then reconnect power.
• Place a service call immediately and remove
all power to the laminator.
© GBC Films Group April 2000
Refers to one of three conditions; 1) the anchor
strength of adhesive to laminate substrate, 2) the anchor
strength of the laminating film to the product that has been
laminated, or 3) when two layers of film are laminated
together, the strength of the adhesive to adhesive bond.
Center mount
A mounting technique where an image is mounted
centrally on a substrate to provide a decorative border.
Page 7 - 5
Troubleshooting
F - 160 CE Operation and Maintenance Manual
Clutch tension
Encapsulation
The tension that is applied to the laminated material
between the main and pull rolls. This tension is applied by
having the pull rolls turn faster than the main rolls, and
then having some form of clutching or torque limiting
applied to the pull rolls. This tension is important for
maintaining a smooth flat finished image.
When an image is completely encased in laminating
film, it is encapsulated. A border of laminate on laminate
exists around the perimeter of the product.
Film
Coiling
A term used to describe an image rolling up on
itself. This is caused by differences in the brake tension
used between the upper and lower laminates during and
application process.
A two part material consisting an adhesive
layer and a substrate. The adhesive and the substrate may
or may not be clear. This is the material used for lamination.
Please refer to laminate.
Foamboard
Cold laminate
A material commonly used as a mounting
substrate. It is made up of foam sandwiched between
two layers of paper, or paper like media.
Film that does not require heat to activate the
adhesive. Please see P.S.A. for more information.
Inkjet
D waves
A term used to describe a wave pattern caused,
generally, by incorrect paper tension.
A term used to describe a type of printing where
an ink is projected topically onto a paper or paper like
media. This is a noncontact form of printing.
Craft paper
Delamination
Refers to either one of two conditions; 1) the
adhesive separating from the laminate substrate, or 2) the
laminate separating from the product being laminated.
A strong brown paper commonly used for single
sided applications.
Laminate
Edgewrap
A mounting technique where the image wraps
around the edges of the mounting substrate so as to provide
a finished edge.
Page 7 - 6
A two part material consisting an adhesive layer
and a substrate. The adhesive and the substrate may or
may not be clear. This is the material used for lamination.
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Troubleshooting
Main rollers
Pull rollers
These are the rolls that perform the actual
lamination. They are rolls capable of being heated in
thermal roll laminators and are usually larger in diameter
than the pull rolls.
These rolls provide for tension of the laminated
media. Tensioning of the laminated media helps to make it
flat and smooth. In most laminators they may also be used
for cold mounting and laminating applications. Usually
these rolls are of smaller diameter than the main rolls.
Media
Term used to describe the materials used to print
an image, i.e. the papers, inks, toners, etc.
Mount adhesive
A term used to describe a two sided pressure
sensitive adhesive used in mounting images to various
substrates. This material can come with one or two release
liners and may be optically clear for face mounting
applications.
P.S.A.
Stands for Pressure Sensitive Adhesive. An
adhesive that requires no heat to activate, only pressure.
It is employed by removing a protective release liner and
then pressed onto the material to be laminated. This type
of film is commonly used on materials that are temperature
sensitive.
Release liner
A coated paper or other media used to protect
the adhesive side of a pressure sensitive material.
Mount tissue
A thermally activated mount adhesive used in
either a vacuum or roll type laminator. Primarily used for
mounting bond type papers to porous substrates.
Rewind
A system that rolls up media. The rewind tubes
used on the Falcon 160 laminator is a prime example.
Nip
Scarring
The interrelationship of any two rolls. The distance
between the closest points of the two rolls is referred to
as the nip of the rolls.
The visual effect of folding papers or laminates
and breaking the surface. When done to a printed material
it will be seen as a white crack in the image.
Outgassing
Second surface
The term that describes the phenomenon where
the heat from the laminating process turns components of
the printed media into a gas. This is seen as a cloudy or
murky finished image. It can also be caused by a chemical
incompatibility between the overlaminate’s adhesive and
the printed media.
© GBC Films Group April 2000
A term to denote the back side of a substrate.
Commonly referenced when discussing front mounted
images to a clear substrate with an optically clear mount
adhesive.
Page 7 - 7
Troubleshooting
F - 160 CE Operation and Maintenance Manual
Silvering
A term used to describe one of two occurrences;
1) air bubbles trapped between the product and a thermal
laminate, generally caused by insufficient heat being applied
to the laminator or 2) the adhesive not fully activated in a
pressure sensitive film, which will disappear once the
adhesive is fully activated. This activation process can be
sped up if a small amount of heat is applied during the
application.
Substrate
The material to which an adhesive is to be bonded.
In film, the substrate is the polyester and in mounting, the
substrate is the material being mounted to.
Tunneling
When a laminated image is rolled up for any period
of time and the laminate separates from the image.
Generally in a pattern that follows the direction the
laminated image was rolled up in. This is very common
with pressure sensitive laminates and finished products
that have been wound tightly.
Unwind
A system that unwinds media. Unwinds are used
on all laminators to dispense laminate for lamination.
Web
The path that rolled media unwinding from a supply
Page 7 - 8
© GBC Films Group April 2000
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.
Maintenance
8.1 Maintenance Schedule
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.
WARNING
Do not wear ties, loose fit 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.
Daily
• Clean the rollers
( See cleaning in this section )
• Inspect the electrical cord for damage.
( If damaged, you should replace or repair it
immediately )
• Inspect the footswitch cord for damage.
( If damaged, you should replace or repair it
immediately )
INFORMATION
Improper maintenance, can
result in poor output quality.
ELECTRICAL
SHOCK
Remove power from the laminator before
servicing. You can be severely shocked,
electrocuted or cause a fire.
© GBC Films Group April 2000
Monthly
• Adjust the nip if needed.
( performed by service technician )
• Check the chain tension.
( performed by service technician )
• Inspect the area around the laminator for
possible hazards
( dust buildup, combustible items stored too
close, etc. )
Page 8 - 1
Maintenance
F - 160 CE Operation and Maintenance Manual
Semi-Annual
• Lubricate the grease fittings, chain, and gears.
( performed by service technician )
• Check wire termination tightness.
( performed by service technician )
Preparation of the laminator
a) Turn the MAIN POWER to the “ I ”
position.
ELECTRICAL
SHOCK
Remove power from the laminator before
servicing. You can be severely shocked,
electrocuted or cause a fire.
Power
ON/OFF
8.2 Cleaning the rollers
b) Press machine RESET.
Tools required
• Adhesive coated boards
( picks up dust and particles off of the rolls )
• Protective rubber gloves
( This will protect your hands from the isopropyl
alcohol )
• 80% isopropyl alcohol
( a mild dishwashing detergent and water may
be used instead )
• Rubber cement eraser
( a belt sander dressing block may be used
instead )
• Several 100% cotton terry cloths
( best for lint free cleaning )
Page 8 - 2
Machine reset
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Removing adhesive build up
c) Press SEL.
SE L
JOB
0
Maintenance
SAV
a) For pressure sensitive adhesives: put on the
rubber gloves and use isopropyl alcohol and a
terry cloth towel.
STANDBY
= Flashing
b) For thermal adhesives: while the laminator is at
normal operating temperature, put on the rubber
gloves and use the rubber cement eraser. This
allows the eraser to bead up the adhesive.
WARNING
Caution should always be exercised
when using the laminator with
the safety shields raised.
You can be seriously HURT or INJURED!
CAUTION
Excessive pressure can destroy the silicone
layer by pressing to hard or scrubbing
too long in one spot.
d) Open the front and rear safety shields.
c) Wipe away the beads with isopropyl alcohol
and a cotton terry cloth.
e) Remove the front feed table.
CAUTION
Do NOT pick or pull heat activated adhesive
off the rolls when they are cold. You can
cause irreparable damage to the
laminating rolls.
© GBC Films Group April 2000
Page 8 - 3
Maintenance
F - 160 CE Operation and Maintenance Manual
INFORMATION
When cleaning the bottom main roller,
switch the motion direction to reverse.
When cleaning the bottom pull roller,
switch the motion direction to forward.
This will prevent anything from
being pulled into the nip.
WARNING
When operating the laminator using the
variable speed footswitch, keep hands and
fingers away from the nip of the rollers.
You may be CRUSHED or BURNED!
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.
Cleaning the beads of
adhesives, dust and dirt from
the rolls
This can be done one of two different methods.
Both are acceptable forms of cleaning the beads of
adhesives, dust, and dirt from the rolls.
Method 1
a) Allow the laminator to cool slightly to no
higher than 110oF ( 43oC ).
TOP TEMP
<110
BOT TEMP
-
<110
-
b) Set the motion direction to REV ▼.
CAUTION
Speed is controlled through the variable
speed footswitch when the safety shield
is in the raised position.
00.0
SPEED
GO
STOP
FWD
REV
SAFETY
Page 8 - 4
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Maintenance
c) Press SPEED ▲ to enter a speed of 3.
WARNING
3.0
SPEED
GO
STOP
FWD
REV
When operating the laminator using the
variable speed footswitch, keep hands and
fingers away from the nip of the rollers.
You may be CRUSHED or BURNED!
SAFETY
CAUTION
e) Since the safety shields are raised and the table
removed, you must use the footswitch to rotate
the bottom rollers after cleaning a section.
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.
CAUTION
d) With the rubber gloves on, clean the rolls
using a moderate amount of 80% isopropyl
alcohol on a cotton terry cloth.
Speed is controlled through the variable
speed footswitch when the safety shield
is in the raised position.
Method 2
CAUTION
Exercise care when cleaning the laminating
rollers with 80% isopropyl alcohol:
Ÿ
a) Allow the laminator to cool slightly to no
higher than 110oF ( 43oC ).
Use only in a well ventilated area
Ÿ Wear rubber gloves
Ÿ Use only on cool rolls
TOP TEMP
CLEANING HEATED ROLLERS CAN
IGNITE THE FUMES!
© GBC Films Group April 2000
<110
BOT TEMP
-
<110
-
Page 8 - 5
Maintenance
F - 160 CE Operation and Maintenance Manual
b) Set the motion direction to REV ▼.
00.0
SPEED
GO
STOP
e) Set the nip of the rollers to the thickness of the
adhesive coated boards.
FWD
REV
GAP
PRESSURE
1/4
SAFETY
c) Press SPEED ▲ to enter a speed of 3.
WARNING
3.0
SPEED
GO
STOP
FWD
REV
Keep hands and fingers clear of
the laminator roller nip when
adjusting PRESSURE.
You can be CRUSHED or BURNED!
SAFETY
WARNING
f) Using the variable speed footswitch, run
the adhesive coated boards through the rolls.
Keep hands and fingers clear of the
laminator roller nip when changing GAP.
You can be CRUSHED or BURNED!
g) Do this as many times as needed to clean the
laminator rolls.
d) Position the center of the board between the
rollers.
Page 8 - 6
© GBC Films Group April 2000
F - 160 CE Operation and Maintenance Manual
Maintenance
8.2.1 Clean the cabinets and 8.2.2 Cleaning the touch
covers
screen
ELECTRICAL
SHOCK
Remove power from the laminator before
cleaning. You can be severely shocked,
electrocuted or cause a fire.
a) Use a damp cotton terry cloth ( water only ),
clean the exterior of the laminator.
b) If water is not strong enough, you may use a
mild dishwashing detergent with water and a
cotton terry cloth.
ELECTRICAL
SHOCK
Remove power from the laminator before
cleaning. You can be severely shocked,
electrocuted or cause a fire.
a) Use only a slightly damp ( water only ) non
abrasive cloth.
b) The same type of cloth used to clean eye
glasses may be used instead.
ELECTRICAL
SHOCK
ELECTRICAL
SHOCK
Do not use liquid or aerosol cleaners on the
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
cloth for cleaning unless other wise
specified.
© GBC Films Group April 2000
Do not use liquid or aerosol cleaners on the
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
cloth for cleaning unless other wise
specified.
Page 8 - 7
Maintenance
F - 160 CE Operation and Maintenance Manual
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© GBC Films Group April 2000