GBC F - 160 CE User manual

GBCFilmsGroup
4151Anderson Road
DeForest, WI 53532
Revision : Ph: ( 608 ) 246 - 8844
Fx: ( 608 ) 246 - 8645
F - 160 CE OPERATION AND
MAINTENANCE MANUAL
©April2000 GBCFilmsGroup
Do not duplicate without written permission.
Partnumber :930-065

Page I
TableofContentsF - 160 CE Operation and Maintenance Manual
© GBC Films Group April 2000
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

Page II
Table ofContents F - 160 CE Operation and Maintenance Manual
© GBC Films Group April 2000
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

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TableofContentsF - 160 CE Operation and Maintenance Manual
© GBC Films Group April 2000
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

Page IV
Table ofContents F - 160 CE Operation and Maintenance Manual
© GBC Films Group April 2000
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

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TableofContentsF - 160 CE Operation and Maintenance Manual
© GBC Films Group April 2000
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

Page VI
Table ofContents F - 160 CE Operation and Maintenance Manual
© GBC Films Group April 2000
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 VII
TableofContentsF - 160 CE Operation and Maintenance Manual
© GBC Films Group April 2000
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

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Table ofContents F - 160 CE Operation and Maintenance Manual
© GBC Films Group April 2000
This page intentionally left blank.

Safety
Page 1 - 1
F - 160 CE Operation and Maintenance Manual
© GBC Films Group April 2000
Section 1 Safety
CAUTION
Do not attempt to operate your Falcon 160
CE laminator until you have read this
section carefully!
Your safety, as well as the safety of others, is
important to GBC Films Group. This section contains
importantsafetyinformation.
Thefollowingsymbolsareusedthroughoutthis
manual to indicate Information,Caution, Warning,
Dangerand Electrical Shockconditions.
1.1 Symbols
INFORMATION
Indicates helpful information that should be
considered before, during, or after an
action, step or procedure is given.
CAUTION
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.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, could result in death
or serious injury.
ELECTRICAL
SHOCK
Indicates an electrical shock situation which,
if not avoided, could result in serious
paralyzation of the body or death.

Page 1 - 2
Safety F - 160CE Operation and Maintenance Manual
© GBC Films Group April 2000
1.2 Safety features
TheF-160CE laminator hasbeendesigned
withsafetyasaprimaryconsideration; however,you
must become thoroughly familiar with the controls,
properoperation, proper serviceproceduresand safety
featuresofthe laminatorbeforeusingorservicingthe
unit.
GBC Films Group laminators are powerful
machines that are designed to mount, laminate, and
encapsulate.Theforcesrequiredtoaccomplishthesetasks
canvaryfromnegligibletoverylarge.
Themotorizedmainrollerliftmechanismusedto
providedownward pressure onthe uppermain roller is
capable of producing forces greater than 400 pounds.
Thisforceisappliedtoanyobjectpresentedintheopening
(calledthe nip )betweenthetwo rollers.
Usecareinloweringtheupper laminating roller
and know how to react quickly in an emergency. The
main laminator roll up / down control is located on the
rightside of themachinewithin the frontcontrol panel.
The GAP up / down arrows control the motion of the
upperlaminatingroller.BeforepressingGAPdownarrow,
ensurethatnothingisinthenip area.
Inaddition,themainlaminatingrollersoftheF-
160CEcan reach temperaturesof over 200oF(100oC ).
DANGER
At these temperatures there is a danger of
severe burn if the rolls are touched during
setup, operation or servicing.
INFORMATION
Only a qualified service technician should
perform any procedure in Part B of this
manual.
Thewordqualifiedisdefinedbelow;
Qualified ;
•Any engineerthathasexperiencewithelectrical
and mechanical design of lamination equipment.The
engineersshould befully aware of all aspectsof safety
withregardstolaminationequipment.
•Anycommissioningorserviceengineermustbe
ofcompetentnature,trainedand qualified to GBCFilms
Groupstandardstofulfillthatjob.Thispersonwill have
completedandpassedthefullservicetrainingcoursefrom
GBCPro-Tech.

Safety
Page 1 - 3
F - 160 CE Operation and Maintenance Manual
© GBC Films Group April 2000
•AnyGBCTechnician,GBCSpecialist,and/or
GBCFilmsGroupTechnician that hasbeenthroughthe
GBCPro-Tech servicetraining course.
TheF-160CElaminatorhas cabinets and
panelsthatare bolted close toisolatetheelectrical and
drivesystemcomponentsfor the safety of theoperator.
Figure1.2.1illustratesplacementofthecabinetsand
covers.
Figure 1.2.1 Cabinets and covers
Covers
Cabinets
1.3 Safety shield
AnimportantfeatureoftheF-160CE laminator
isthesafetyshields,when raised, theautorunisdisabled
anddrivecontrolis transferredtothefootswitch.Referto
Figure1.3.1Safety shield raised.
Caution should always be exercised
when using the laminator with
the safety shields raised.
You can be seriously HURT or INJURED!
WARNING
Figure 1.3.1 Safety shields raised

Page 1 - 4
Safety F - 160CE Operation and Maintenance Manual
© GBC Films Group April 2000
1.4 Emergency stop
Thelaminatorisequipped with four emergency
stops(E-STOP)located at the front ofthecabinetsand
therearofthecabinets.RefertoFigure1.4.1Emergency
stops.
Figure 1.4.1 Emergency stops
Front
Rear
Emergency stops
Emergency stops
ToengageanE-STOP,pressdownonanyofthe
four. Any E-STOP, when engaged, removes power to
thelaminator.RefertoFigure1.4.2EngageanE-STOP.
Figure 1.4.2 Engage an E-STOP
Push
INFORMATION
The machine will only operate if all four
E-STOPS are in the unlatched position.
Tocontinueoperation,all E-STOPs mustbein
theunlatched position.To reset,twist the E-STOP1/4
turn clockwise. Refer to Figure 1.4.3 Reset the E-
STOP.
Figure 1.4.3 Reset the E-STOP
Unlatch

Safety
Page 1 - 5
F - 160 CE Operation and Maintenance Manual
© GBC Films Group April 2000
PressRESETlocatedontherightlegatthefront
ofthe machine.Refer toFigure1.4.4 Machinereset.
Figure 1.4.4 Machine rest
Machine reset
1.5 Emergency cable
In the event an E-STOP is not reachable, use
yourfoot to activateanemergency cable (E-CABLE)
locatedat thebase ofthe stand fromthe frontor rearof
themachine. Refer toFigure1.5.1 Emergencycable.
INFORMATION
The machine will only operate if the
E-CABLE is in the unlatched position.
Figure 1.5.1 Emergency cable
Front
Rear
Emergency cable
Emergency cable
Tocontinueoperation,pressinonthecable reset
located on the right leg of the front operating position.
Refer to Figure 1.5.2 Reset the E-CABLE.
Figure 1.5.2 Reset the E-CABLE
Push in

Page 1 - 6
Safety F - 160CE Operation and Maintenance Manual
© GBC Films Group April 2000
PressRESETlocatedontherightlegatthefront
ofthe machine.Refer toFigure1.5.3 Machinereset.
Figure 1.5.3 Machine rest
Machine reset
1.6 Front feed table
The front feed table must be in proper position
forthelaminator to operateinautorun. Refer toFigure
1.6.1Front feed table.
Whenthekeyisremovedfromtheinterlock,the
laminatorwillstop.Withthetableremoved,thelaminator
willoperateusingthe variable speedfootswitch.
Figure 1.6.1 Front feed table
Tocontinueoperation,pressSTOP.
SPEED
SAFETY
FWD
REV
5.0
GO
STOP
Thenpress GO.
SPEED
SAFETY
FWD
REV
5.0
GO
STOP

Safety
Page 1 - 7
F - 160 CE Operation and Maintenance Manual
© GBC Films Group April 2000
WAARSCHUWING
!
ATTENZIONE
!
WARNUNG
!
Kans op
elektrische
schok.
Niet openen
Bevatgeen door
gebruik te
repareren
onderdelen.
Door bevoegd
service
personeel
laten repareren
Pericolo di
scarica
elettrica.
Nessuna parte
riparabile
dall' utente.
Chiamare un
servizio
di riparazioni
qualificato.
Spannun
g
sfUhrend
e
Teile.
Nicht offnen.
Enthalt keine vom
Enduerbraucher zu
wartende Teile.
Fur service bitte an
qualifiziertes
Service-Personal
wenden.
MUCHO
CUIDADO
!
Riesgo de
choque
electrico
No abra
Adentro, no hay
piezas
reparables
para el usuario.
Mantenimiento
solamente para
personal
calificado
MUCHO
CUIDADO
!
Risque de
secousse
electrique.
Ne pas ouvrir.
Pas de pieces
reparables par
l'utilisateur.
Entretien par
personnel
qualifie.
WARNING
!
Electrical shock
hazard.
Do not open.
No user
serviceable
parts inside.
Refer servicing to
qualified service
personnel.
DangerVoltage: Highvoltage wires behindthispanel.
Donotremovecover.Youmaybeshocked, electrocuted,
paralyzedordie!
DonotLift:This pointcannotbe used asalifting
point.Ifignored,damagewill occur tothelaminator.
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
andFigure1.7.2illustrates the location ofeachofthese
labels.
!
!
!
WARNING
ACHTUNG
MISE EN GARDE
RollerPinchPoint:Keep handsandfingersaway.
You may becrushedand/ or burned.
ElectricalShock:Livevoltage present. Exercise
extremecaution.Youmaybeelectrocuted!

Page 1 - 8
Safety F - 160CE Operation and Maintenance Manual
© GBC Films Group April 2000
Reset:Machine reset. Press after iniating power to the
laminator or after an E-STOP or E-CABLE has been
engagedthenresetted.

Safety
Page 1 - 9
F - 160 CE Operation and Maintenance Manual
© GBC Films Group April 2000
Figure 1.7.1 Label locations - Front
WAARSCHUWING
!
ATTENZIONE
!
WARNUNG
!
Kans op
elektrische
schok.
Niet openen
Bevat
g
een door
g
ebruik te
repareren
onderdelen.
Door bevoe
g
d
service
personeel
laten repareren
Pericolo di
scarica
elettrica.
Nessuna parte
riparabile
dall' utente.
Chiamare un
servizio
di riparazioni
q
ualificato.
Spannun
g
sfUhrend
e
Teile.
Nicht offnen.
Enthalt keine vom
Enduerbraucher zu
wartende Teile.
Fur service bitte an
q
ualifiziertes
Service-Personal
wenden.
MUCHO
CUIDADO
!
Ries
g
o de
cho
q
ue
electrico
No abra
Adentro, no ha
y
piezas
reparables
para el usuario.
Mantenimiento
solamente para
personal
calificado
MUCHO
CUIDADO
!
Ris
q
ue de
secousse
electri
q
ue.
Ne pas ouvrir.
Pas de pieces
reparables par
l'utilisateur.
Entretien par
personnel
q
ualifie.
WARNING
!
Electrical shock
hazard.
Do not open.
No user
serviceable
parts inside.
Refer servicin
g
to
q
ualified service
personnel.
!
!
!
WARNING
ACHTUNG
MISE EN GARDE
!
!
!
WARNING
ACHTUNG
MISE EN GARDE
WAARSCHUWING
!
ATTENZIONE
!
WARNUNG
!
Kans op
elektrische
schok.
Niet openen
Bevat
g
een door
g
ebruik te
repareren
onderdelen.
Door bevoe
g
d
service
personeel
laten repareren
Pericolo di
scarica
elettrica.
Nessuna parte
riparabile
dall' utente.
Chiamare un
servizio
di riparazioni
q
ualificato.
Spannun
g
sfUhrend
e
Teile.
Nicht offnen.
Enthalt keine vom
Enduerbraucher zu
wartende Teile.
Fur service bitte an
q
ualifiziertes
Service-Personal
wenden.
MUCHO
CUIDADO
!
Ries
g
o de
cho
q
ue
electrico
No abra
Adentro, no ha
y
piezas
reparables
para el usuario.
Mantenimiento
solamente para
personal
calificado
MUCHO
CUIDADO
!
Ris
q
ue de
secousse
electri
q
ue.
Ne pas ouvrir.
Pas de pieces
reparables par
l'utilisateur.
Entretien par
personnel
q
ualifie.
WARNING
!
Electrical shock
hazard.
Do not open.
No user
serviceable
parts inside.
Refer servicin
g
to
q
ualified service
personnel.

Page 1 - 10
Safety F - 160CE Operation and Maintenance Manual
© GBC Films Group April 2000
Figure 1.7.2 Label locations - Rear
WAARSCHUWING
!
ATTENZIONE
!
WARNUNG
!
Kans op
elektrische
schok.
Niet openen
Bevatgeen door
gebruik te
repareren
onderdelen.
Door bevoegd
service
personeel
laten repareren
Pericolo di
scarica
elettrica.
Nessuna parte
riparabile
dall' utente.
Chiamare un
servizio
di riparazioni
qualificato.
SpannungsfUhrend
e
Teile.
Nicht offnen.
Enthalt keine vom
Enduerbraucher zu
wartende Teile.
Fur service bitte an
qualifiziertes
Service-Personal
wenden.
MUCHO
CUIDADO
!
Riesgo de
choque
electrico
No abra
Adentro, no hay
piezas
reparables
para el usuario.
Mantenimiento
solamente para
personal
calificado
MUCHO
CUIDADO
!
Risque de
secousse
electrique.
Ne pas ouvrir.
Pas de pieces
reparables par
l'utilisateur.
Entretien par
personnel
qualifie.
WARNING
!
Electrical shock
hazard.
Do not open.
No user
serviceable
parts inside.
Refer servicing to
qualified service
personnel.
!
!
!
WARNING
ACHTUNG
MISE EN GARDE
!
!
!
WARNING
ACHTUNG
MISE EN GARDE

Page 2 - 1
WarrantyF - 160 CE Operation and Maintenance Manual
© GBC Films Group April 2000
Section 2 Warranty
GBCFilmsGroup warrants theequipmentsold
is free from defects in material and workmanship for a
period of one( 1) yearparts and90 dayslabor from
thedateofinstallation.Thiswarrantyistheonlywarranty
madeby GBCFilms Groupand connot bemodified or
amended.
GBC Films Group’s sole and exclusive
liability and the customer’s sole and exclusive
remedyunderthis warrantyshallbe, atGBCFilms
Group’s option, to repair or replace any such
defectivepart or product.These remediesare only
availableif GBCFilms Group’sexamination ofthe
productdisclosestoGBCFilmsGroup’ssatisfaction
thatsuchdefectsactuallyexist andwerenot caused
bymisuse, neglect,attempt torepair, unauthorized
alterationormodification,incorrectlinevoltage,fire,
accident,flood,orother hazard.
2.1 Limited Warranty
Thiswarrantyspecificallydoesnotcoverdamage
tothelaminating rollers caused byknives,razorblades,
other sharp objects, failure caused by adhesives or
improper use of the machine. Warranty repair or
replacement does not extend the warranty beyond the
initialoneyearperiodfromthedate of delivery.
CAUTION
Unauthorized customer alterations will
void this 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. Damagetothelaminatingrollerscausedby knives,
razor blades, other sharp objects or failure caused
by adhesives.
2. Damagetothemachinecausedby lifting, tilting and/
oranyattempt to positionthe machine otherthan
rolling ontheinstalled castors onevensurfaces.
3. Improperuse of the machine.
4. Damageduefromunqualified person(s)servicingthe
machine.