GBC F - 160 User manual

F - 160 OPERATION AND
MAINTENANCE MANUAL
©November1999GBCPro-Tech
Do not duplicate without written permission.
Partnumber:930-031
GBC Pro - Tech
4151 Anderson Road
DeForest, WI 53532
Revision : B Ph: ( 608 ) 246 - 8844
Fx: ( 608 ) 246 - 8645
Plane4
Plane4
Plane4



F - 160 Operation and Maintenance Manual Read me file
© GBC Pro - Tech August 1999
Read Me File . . . . . . . . .
The information in this publication is provided for reference and is believed to be
accurate and complete. GBC Pro - Tech is not liable for errors in this publication or for
incidental or consequential damage in connection with the furnishing or use of the information
in this publication, including, but not limited to, any implied warranty of fitness or merchant-
ability for any particular use.
GBC Pro - Tech reserves the right to make changes to this publication and to the prod-
ucts described in it without notice. All specifications and information concerning products are
subject to change without notice.
Reference in this publication to information or products protected by copyright or
patent does not convey any license under the rights of GBC Pro - Tech or others. GBC Pro -
Tech assumes no liability arising from infringements of patents or any other rights of third
parties.
This publication is copyrighted © 1999 by GBC Pro - Tech. All rights reserved. The
information contained in this publication is proprietary and may not be reproduced, stored,
transmitted, or transferred, in whole or in part, in any form without the prior and express
written permission of GBC Pro - Tech.
In the electronic version of this publication, the hand will change to a pointer finger
identifying hyperlinked. When moving from page to page, use to return to the first
PAGE, use to advance to the last PAGE, use to go back one PAGE and use
to advance one PAGE. When moving from view to view, use to return to a previous
VIEW and use to advance to the next VIEW.
Should you find an error within this publication or would like to make a suggestion,
please utilize the fax correspondence sheet following this read me file and fax it to the number
provided. Your comments and help will ensure up to date information. Thank you.

F - 160 Operation and Maintenance ManualRead me file
© GBC Pro - Tech August 1999
This page intentionally left blank.

F - 160 Operation and Maintenance Manual Read me file
© GBC Pro - Tech August 1999
Fax Correspondence
Fax number : ( 608 ) 246 - 8645 Date :
To : Sean Flood @ GBC Pro - Tech
4151 Anderson Road
DeForest, WI 53532
From :
Company :
Address :
Phone number : ( ) Fax number : ( )
Re : Falcon 160 Operations and Maintenance Manual ( Rev. A )
What section ? What Page # ?
What needs correcting ?
Additional comments:

F - 160 Operation and Maintenance ManualRead me file
© GBC Pro - Tech August 1999
This page intentionally left blank.

F - 160 Operation and Maintenance Manual
© GBC Pro - Tech August 1999 Page I
Table ofContents
Table of Contents
Section 1: Safety
1.1 Symbols ......................................................................................................1 - 1
1.2 Safety features ...........................................................................................1 - 1
1.3 Installation .................................................................................................1 - 4
1.4 Operations..................................................................................................1 - 8
1.5 Applications ..............................................................................................1 - 12
1.6 Troubleshooting .......................................................................................1 - 16
1.7 Maintenance .............................................................................................1 - 16
1.8 Decal Explanation ....................................................................................1 - 19
Figure 1 - 6 Decal Location .......................................................1 - 20
Section 2: Warranty
2.1 Limited warranty information ...................................................................2 - 1
2.2 Exclusions to the warranty .......................................................................2 - 1

F - 160 Operation and Maintenance Manual
© GBC Pro - Tech August 1999Page II
Tableof Contents
Section 3: Specifications
3.1 General .......................................................................................................3 -1
3.2 Consumables..............................................................................................3 - 1
3.3 Function .....................................................................................................3 - 2
3.4 Electrical ...................................................................................................3 - 2
3.5 Dimensions ................................................................................................3 - 3
Figure 3.5.1 Dimensions ...............................................................3 - 3
Section 4: Installation
4.1 Preinstallation check list ...........................................................................4 - 1
Figure 4.1.1 Suggested floor layout .............................................4 - 3
Figure 4.1.2 Single phase ( U.S. ) ................................................4 - 4
Figure 4.1.3 Three phase ( Europe ) ...........................................4 - 4
4.2 Unpacking .................................................................................................4 - 5

F - 160 Operation and Maintenance Manual
© GBC Pro - Tech August 1999 Page III
Table ofContents
4.3 Shrink wrapped ........................................................................................4 - 5
4.4 Crated ........................................................................................................4 - 6
4.5 Accessory pack content ............................................................................4 - 8
4.6 Leveling .....................................................................................................4 - 8
4.7 Safety check ............................................................................................4 - 11
4.7.1 Front and rear infeed tables ................................................................4 - 12
4.7.2 Front and rear safety shields ...............................................................4 - 14
4.7.3 Emergency stops ..................................................................................4 - 15
4.8 Function check ........................................................................................4 - 17
4.8.1 Control panel .......................................................................................4 - 18
Figure 4.8.1 Default settings ......................................................4 - 21
4.8.2 Variable speed footswitch ....................................................................4 - 22
4.8.3 Unwind shafts and unwind brakes .......................................................4 - 22

F - 160 Operation and Maintenance Manual
© GBC Pro - Tech August 1999Page IV
Tableof Contents
Section 5: Operations
5.1 Control panel .............................................................................................5 - 1
Figure 5.1.1 Front control panel ................................................5 - 9
5.2 Emergency ...............................................................................................5 - 10
5.3 Set up .......................................................................................................5 - 11
5.3.1 Power ....................................................................................................5 - 11
5.3.2 Film loading ..........................................................................................5 - 12
Figure 5.3.4 Measurement chart ................................................5 - 13
5.3.5 Heating .................................................................................................5 - 13
5.4 Job programming ...................................................................................5 - 15
Figure 5.4.1 Job save chart ......................................................5 - 17
5.5 Manual nip adjustment ...........................................................................5 - 17
5.5.1 Main roller manual nip adjustment .....................................................5 - 17
5.5.2 Pull roller manual nip adjustment ........................................................5 - 20

F - 160 Operation and Maintenance Manual
© GBC Pro - Tech August 1999 Page V
Table ofContents
5.6 Infeed tables ............................................................................................5 - 23
5.6.1 Removing the infeed tables ..................................................................5 - 23
5.6.2 Replacing the infeed tables ..................................................................5 - 23
Section 6: Applications
Group 1: No heat
6.1 Precoating substrates ...............................................................................6 - 1
6.2 Mounting only .........................................................................................6 - 10
6.3 Single sided lamination ( Sled method ) ..................................................6 - 17
6.4 Single sided lamination ( Craft paper method ) ......................................6 - 25
6.5 Decal and mount .....................................................................................6 - 34
Pass 1 Decal ........................................................................................6 - 34
Pass 2 Mount .......................................................................................6 - 43

F - 160 Operation and Maintenance Manual
© GBC Pro - Tech August 1999Page VI
Tableof Contents
Group 2: Top heat only
6.6 Precoating substrates ..............................................................................6 - 51
6.7 One pass mount and laminate .................................................................6 - 60
6.8 Thermal decal and mount .......................................................................6 - 69
Pass 1 Thermal decal ...........................................................................6 - 70
Pass 2 Mount ........................................................................................6 - 78
Group 3: Top and bottom heat
6.9 Encapsulation...........................................................................................6 - 85
6.10 Parameter charts and diagrams
Figure 6.10.1 Temperature conversion chart ...................6 - 95
Blank chart ....................................................................................................6 - 96
Blank diagram ...............................................................................................6 - 97
Chart 1 - Precoating substrates.....................................................................6 - 98

F - 160 Operation and Maintenance Manual
© GBC Pro - Tech August 1999 Page VII
Table ofContents
Diagram 1 - Precoating subtrates .................................................................6 - 99
Chart 2 - Mounting only ...............................................................................6 - 100
Diagram 2 - Mounting only .........................................................................6 - 101
Chart 3 - Single sided ( Sled ) ......................................................................6 - 102
Diagram 3 - Single sided ( Sled ) .................................................................6 - 103
Chart 4 - Single sided ( Craft paper ) ..........................................................6 - 104
Diagram 4 - Single sided ( Craft paper ) .....................................................6 - 105
Chart 5 - Decal and mount ( Decal )...........................................................6 - 106
Diagram 5 - Decal and mount ( Decal ) ......................................................6 - 107
Chart 6 - Decal and mount ( Mount ) .........................................................6 - 108
Diagram 6 - Decal and mount ( Mount ) ....................................................6 - 109
Chart 7 - Precoating subtrates ....................................................................6 - 110
Diagram 7 - Precoating subtrates................................................................6 - 111
Chart 8 - One pass mount ............................................................................6 - 112

F - 160 Operation and Maintenance Manual
© GBC Pro - Tech August 1999Page VIII
Tableof Contents
Diagram 8 - One pass mount .......................................................................6 - 113
Chart 9 - Thermal decal and mount ( Decal ).............................................6 - 114
Diagram 9 - Thermal decal and mount ( Decal ) ........................................6 - 115
Chart 10 - Thermal decal and mount ( Mount ) ..........................................6 - 116
Diagram 10 - Thermal decal and mount ( Mount ) .....................................6 - 117
Chart 11 - Encapsulation .............................................................................6 - 118
Diagram 11 - Encapsulation ........................................................................6 - 119
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

F - 160 Operation and Maintenance Manual
© GBC Pro - Tech August 1999 Page IX
Table ofContents
7.4 Glossary ....................................................................................................7 - 5
Section 8: Maintenance
8.1 Maintenance schedule ...............................................................................8 - 1
8.2 Cleaning the rollers ..................................................................................8 - 2
8.2.1 Cabinets and covers ...............................................................................8 - 6
8.2.2 Touch screen control panel ....................................................................8 - 6

F - 160 Operation and Maintenance Manual
© GBC Pro - Tech August 1999Page X
Tableof Contents
This page is intentionally left blank

F - 160 Operation and Maintenance Manual
© GBC Pro - Tech August 1999 Page 1 - 1
Safety
Section 1 Safety
CAUTION
Do not attempt to operate your Falcon 160
laminator until you have read this section
carefully!
Yoursafety, as wellas thesafety of others,is
importantto GBC Pro- Tech.This sectioncontains
importantsafetyinformation.
Thefollowingsymbolsareusedthroughoutthis
manualtoindicateInformation,Caution,Warning,
Dangerand ElectricalShockconditions.
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.
1.2 Safety features
TheF-160laminator has beendesignedwith
safety as a primary consideration; however, you
must become thoroughly familiar with the controls,
properoperation, properservice procedures and safety
featuresofthelaminatorbeforeusingorservicingthe
unit.

Safety F - 160 Operation and Maintenance Manual
© GBC Pro - Tech August 1999Page 1 - 2
GBCPro - Techlaminators arepowerful
machinesthataredesignedtomount,laminate,and
encapsulate.Theforcesrequired toaccomplishthese
taskscanvaryfromnegligibletoverylarge.
Themotorizedmainrollliftmechanismusedto
providedownward pressureon thetop rollis capable
ofproducingforces greaterthan 400 pounds.This force
isapplied to anyobject presentedin theopening (
calledthenip )between the tworolls.
Usecareinloweringthetoplaminatingrolland
knowhowtoreact quickly inanemergency.The main
laminatorrollup/ down controlislocatedonthe right
sideofthemachinewithinthefrontcontrolpanel.The
GAPup / down arrows controlsthe motion of thetop
mainlaminatingroll.BeforepressingtheGAPdown
arrow,ensure that nothingisinthe niparea.
Inaddition,themainlaminating rolls oftheF-
160can reach temperatures ofover 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 engineerthathas experience with
electricalandmechanicaldesignoflamination
equipment.Theengineersshouldbefullyawareofall
aspectsofsafetywithregardstolaminationequipment.
•Anycommissioningorserviceengineermust
beofcompetent nature,trainedand qualifiedtoGBC
Pro-Techstandardstofulfillthatjob.This person will
havecompletedandpassedthefullservicetraining
coursefrom GBCPro-Tech.
•AnyGBC Technician,GBC Specialist, and/
orGBCPro-Tech Technician that hasbeen through the
GBCPro-Techservicetraining course.
TheF-160laminator hassteelcabinets andleg
panelsthat are boltedclose toisolate the electricaland
drivesystemcomponents forthesafety oftheoperator.
Figure1.2.1illustratesplacement ofthecabinetsand
covers.
Figure 1.2.1 Cabinets and covers

Plane4 Plane4
C
a
bi
nets
Covers

F - 160 Operation and Maintenance Manual
© GBC Pro - Tech August 1999 Page 1 - 3
Safety
Animportantfeature of theF-160laminator are
thesafetyshields, when raised,theauto run isdisabled
anddrivecontrol is transferredtothe footswitch.
Figure1.2.2illustratesthesafety shields intheup
position.
Caution should always be exercised
when using the laminator with
the safety shields raised.
You can be seriously HURT or INJURED!
WARNING
Figure 1.2.2 Safety shields raised
Rear safety
shield Front safety
shield
Thelaminatorisequippedwithtwo
EMERGENCYSTOPSlocatedon the top of either
sideofthe laminator.Toengage the EMERGENCY
STOPfeature, pressdown on eitherone. Eitherof
these,whenengaged, stopsthelaminator.Referto
Figure1.2.3forillustration.
Figure 1.2.3 Emergency stops
Plane4
Plane4
Plane4

Emergency stop
buttons
To continueoperation, both EMERGENCY
STOPS( E-STOPS ) mustbe in the up position. To
resettheE-STOP,twist thebutton 1/4turnclockwise.
RefertoFigure1.2.4for illustration.
Figure 1.2.4 Reset E-Stop buttons

Unlatch

Safety F - 160 Operation and Maintenance Manual
© GBC Pro - Tech August 1999Page 1 - 4
PressRESET located on the leftleg at therear
ofthemachine.
Reset
Thefront andrear tablesmust bein proper
positionforthelaminatortooperate undernormal
condition.Figure1.2.5illustratesthetables andkeys.
Ifthese tablesare removed,you mayoperate
thelaminatorusingthevariablespeedfootswitch.The
speediscontrolledthrough a“acceleratorpedal”style
footswitch.Pleaseseefootswitch in section3ofthis
manual.
Figure 1.2.5 Tables and keys

1.3 Installation
Thefollowingsymbolsarepositioned at
variouspoints inSection4 Installation.
CAUTION
Failure to follow the pre-installation check
list can result in damage to the laminator.
WARNING
The operating environment must be free of
dust, flammable liquids and vapors. You can
be injured by inhaling chemical vapors.
WARNING
Vapor build up or stored flammable liquids
can cause a fire. Excessive dust can damage
the laminator.
CAUTION
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 quality output.

F - 160 Operation and Maintenance Manual
© GBC Pro - Tech August 1999 Page 1 - 5
Safety
WARNING
Be sure to follow the correct wiring diagram
when supplying power to the laminator. If
improperly connected, you can be seriously
injured or cause damage to the laminator.
INFORMATION
ALL SHIPMENTS ARE EX-WORKS. 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.
INFORMATION
Depending on the destination and customer
preference, the Falcon 160 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.
WARNING
The unpacking process requires at least two
people. You can be severely injured, crushed
or cause damage to the laminator.
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.
WARNING
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.
CAUTION
Do not allow the top to fall into the crate. It
can damage the laminator.