GBC F-60H Manual

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GBC F-60H
Roll Laminator
Instruction Manual

WARNNG
ACHTUN
MSNAR
PRO-TECH
F-60 H
GBCPro-Tech
4151AndersonRoad
DeForest, WI 53532
Revision : A Ph: ( 608 ) 246 - 8844
Fx: ( 608 ) 246 - 8645
FALCON 60 H
OPERATION & MAINTENANCE
MANUAL
©APRIL2001GENERALBINDINGCORPORATION.ALLRIGHTSRESERVED.
Do not duplicate without written permission.
Partnumber:930-063

Read me fileF 60 H Operation and Maintenance Manual
© April 2001 General Binding Corporation
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Page I
TableofContentsF 60 H Operation and Maintenance Manual
© April 2001 General Binding Corporation
Table of Contents
1.0 Safety
1.1 Symbols .......................................................................................................1 - 1
1.2 Safety precautions ......................................................................................1 - 2
1.3 Safety features ............................................................................................1 - 3
1.4 Installation ..................................................................................................1 - 4
1.5 Operations ..................................................................................................1 - 7
1.6 Applications ................................................................................................1 - 9
1.7 Troubleshooting .........................................................................................1 - 10
1.8 Maintenance ...............................................................................................1 - 10
1.9 Decal explanation .......................................................................................1 - 12
Figure 1.9.1 Safety label locations ............................................1 - 14
2.0 Warranty
2.1 Limited warranty information ....................................................................2 - 1
2.2 Exclusions to the warranty ........................................................................2 - 1

Page II
Table ofContents F 60 H Operation and Maintenance Manual
© April 2001 General Binding Corporation
3.0 Specifications
3.1 General .......................................................................................................3 -1
3.2 Consumables...............................................................................................3 - 2
3.3 Function ......................................................................................................3 - 3
3.4 Electrical ....................................................................................................3 - 4
3.5 Dimensions ................................................................................................3 - 5
Figure 3.5.1 Dimensions ...............................................................3 - 6
4.0 Installation
4.1 Pre-installation 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 III
TableofContentsF 60 H Operation and Maintenance Manual
© April 2001 General Binding Corporation
4.7 Installing levelers .......................................................................................4 - 9
4.8 Leveling ......................................................................................................4 - 9
4.9 Connecting power ......................................................................................4 - 11
4.10 Safety check ............................................................................................4 - 13
5.0 Operations
5.1 Power ON/ OFF .........................................................................................5 - 2
5.2 Control panel ..............................................................................................5 - 3
Figure 5.2.1 Front control panel ...................................................5 - 4
5.3 Set temperature ..........................................................................................5 - 5
5.4 Load/ unload film ........................................................................................5 - 6
5.5 Unwind brake tension .................................................................................5 - 9
5.6 Rewind brake tension .................................................................................5 - 9
5.7 Setting the nip ...........................................................................................5 - 10
5.8 Footswitch ..................................................................................................5 - 12

Page IV
Table ofContents F 60 H Operation and Maintenance Manual
© April 2001 General Binding Corporation
6.0 Applications
6.1 Helpful hints ...............................................................................................6 - 1
6.2 Temperature conversion chart ...................................................................6 - 3
6.3 Charts and diagrams ..................................................................................6 - 5
Blank chart .......................................................................................................6 - 6
Blank diagram ..................................................................................................6 - 7
Blank diagram w/ roll to roll option ................................................................6 - 9
Chart - Pre-coating substrates ........................................................................6 - 10
Diagram - Pre-coating substrates ...................................................................6 - 11
Chart - Mounting an image ............................................................................6 - 12
Diagram - Mounting an image .......................................................................6 - 13
Chart - PSA decaling ......................................................................................6 - 14
Diagram - PSA decaling .................................................................................6 - 15
Diagram - PSA decaling w/ roll to roll options ..............................................6 - 17
Chart - Lo-Melt decaling ................................................................................6 - 18

Page V
TableofContentsF 60 H Operation and Maintenance Manual
© April 2001 General Binding Corporation
Diagram - Lo-Melt decaling ...........................................................................6 - 19
Diagram - Lo-Melt decaling w/ roll to roll options .........................................6 - 21
Chart - Mounting a decal ...............................................................................6 - 22
Diagram - Mounting a decal ..........................................................................6 - 23
Chart - PSA single sided lamination ( sled ) ...................................................6 - 24
Diagram - PSA single sided lamination ( sled ) ...............................................6 - 25
Chart - PSA single sided lamination ( craft paper ).........................................6 - 26
Diagram - PSA single sided lamination ( craft paper ) ...................................6 - 27
Diagram - PSA single sided lamination ( craft paper ) w/ roll to roll option ...6 - 29
Chart - PSA over-lamination of a mounted image .........................................6 - 30
Diagram - PSA over-lamination of a mounted image ....................................6 - 31
Chart - Lo-Melt over-lamination of a mounted image ...................................6 - 32
Diagram - Lo-Melt over-lamination of a mounted image ...............................6 - 33

Page VI
Table ofContents F 60 H Operation and Maintenance Manual
© April 2001 General Binding Corporation
7.0 Troubleshooting
7.1 Wave problems ..........................................................................................7 - 1
7.2 Film problems .............................................................................................7 - 3
7.3 Machine problems ......................................................................................7 - 4
7.4 Glossary .....................................................................................................7 - 5
8.0 Maintenance
8.1 Maintenance schedule ................................................................................8 - 1
8.2 Cleaning the rollers ...................................................................................8 - 2
8.3 Clean cabinets and covers ..........................................................................8 - 4
8.4 Clean the control panel ..............................................................................8 - 4
8.5 Chain tensioning .........................................................................................8 - 5

Safety
Page 1 - 1
F 60 H Operation and Maintenance Manual
© April 2001 General Binding Corporation
1.0 Safety
CAUTION
Do not attempt to operate your
Falcon 60 H 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.
Thefollowingsymbols areusedthroughout this
manual to indicate Information,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.

Page 1 - 2
Safety F 60 H Operation and Maintenance Manual
© April 2001 General Binding Corporation
1.2 Safety precautions
The Falcon 60 H laminator has been designed
withsafetyasaprimaryconsideration;however,youmust
become thoroughly familiar with the controls, proper
operation,properservice proceduresandsafety features
ofthelaminatorbeforeusingorservicingtheunit.
Themanual main roller liftmechanism used to
providedownward pressure onthe upper main rolleris
capable of producing forces greater than 400 pounds.
Thisforceisappliedtoanyobjectpresentedintheopening
(called thenip )between thetwo rollers.
Usecareinlowering theupperlaminating roller
and know how to react quickly in an emergency. The
main laminator roll up / down control is located on the
rightsideofthemachine withinthefront.Beforeturning
thecrankhandletosettheGAPdown,ensurethatnothing
isinthe niparea.
WARNING
Keep hands and fingers clear of the
laminator roller nip when adjusting nip.
You can be CRUSHED or BURNED!
In addition, the main laminating rollers of the
Falcon60Hcanreachtemperaturesupto200oF(100oC).
DANGER
At these temperatures there is a danger of
severe burn if the rolls are touched during
setup, operation or servicing.
Thewordqualifiedis definedbelow;
Qualified;
•Any engineerthathasexperiencewithelectrical
and mechanical design of lamination equipment. The
engineersshould be fully aware ofall aspects of safety
withregardstolaminationequipment.
•Anycommissioningorserviceengineermustbe
ofcompetentnature,trainedand qualifiedtoGBCFilms
Groupstandardsto fulfillthatjob. Thispersonwill have
completedandpassedthefullservicetrainingcoursefrom
GBCPro-Tech.
•AnyGBCTechnician, GBCSpecialist,and/or
GBCFilmsGroup Technicianthat hasbeen throughthe
GBCPro-Tech service trainingcourse.

Safety
Page 1 - 3
F 60 H Operation and Maintenance Manual
© April 2001 General Binding Corporation
1.3 Safety features
Thelaminator isequippedwith fouremergency
stops ( E-STOP ). Two are located at the front of the
cabinetsand two are atthe rear ofthe cabinets.
E-STOP
E-STOP
ToengageanE-STOP,pressdownonanyofthe
four. Any E-STOP, when engaged, removes power to
thelaminator.
INFORMATION
The machine will only operate if all four
E-STOPS are in the unlatched position.
Tocontinueoperation, all E-STOPs mustbe in
theunlatched position. To reset,twist the E-STOP 1/4
turncounterclockwise.
1
/
4
tu
r
n
PressRESETlocatedonthecontrol sidecabinet
atthe rearofthe machinejust abovethe mainpoweron/
off.
POWER
Reset
Theniparea isprotected byaelectric photo-eye
whichshoots abeam infront ofthe nipacross thewidth
of the rollers. When this beam is broken, power to the
drivemotor isremoved. Theobjetc mustbe removedto
clear the photo-eye. The motor engage switch must be
pressedagainto continuemotor operation.
RO T CH
F 60 H
PHOTO-EYE

Page 1 - 4
Safety F 60 H Operation and Maintenance Manual
© April 2001 General Binding Corporation
WARNING
The Falcon 60 H 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.
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.
WARNING
The unpacking process requires at least two
people. You can be severely injured, crushed
or cause damage to the laminator.
1.4 Installation
Thefollowingsymbolsarepositioned atvarious
points in Section4 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 Falcon 60 H where air is
blowing directly on the machine. The air
flow can cool the rolls unevenly and result
in poor output quality.

Safety
Page 1 - 5
F 60 H Operation and Maintenance Manual
© April 2001 General Binding Corporation
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.
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.
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
CAUTION
Do not allow the top to fall into the crate. It
can damage the laminator.
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.
CAUTION
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.
WARNING
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.

Page 1 - 6
Safety F 60 H Operation and Maintenance Manual
© April 2001 General Binding Corporation
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.
INFORMATION
CAUTION
Do not move the leveling nut when securing
the inside nut to the cabinet.
You will need the control side cabinet cover
off to connect the electrical power.
INFORMATION
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.
WARNING
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.
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.
WARNING
If a safety feature is not working
properly, contact your local service
representative immediately.
CAUTION
Do not use a hard substrate or a substrate
with sharp edges. You may cause damage to
the laminating rollers!

Safety
Page 1 - 7
F 60 H Operation and Maintenance Manual
© April 2001 General Binding Corporation
1.5 Operations
Thefollowingsymbolsarepositioned atvarious
points in Section5 Operations.
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.
INFORMATION
The machine will only operate if all
four emergency stops are unlatched and
RESET has been pressed.
It is unsafe to sheet feed without the
pressure plate properly placed on
the front feed table.
WARNING
WARNING
Keep hands and fingers clear of the
laminator roller nip when changing GAP.
You can be CRUSHED or BURNED!
WARNING
When the laminator rollers are in
motion, keep hands and fingers
away from the nip of the rollers.
You may be CRUSHED or BURNED!
WARNING
When operating the laminator using the
footswitch, keep hands and fingers
away from the nip of the rollers.
You may be CRUSHED or BURNED!
WARNING
Do not operate the laminator, except
during web set up, without the front
and rear feed tables in position.
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!
CAUTION
INFORMATION
The Poly-in/ Poly-out diagrams refer to the
upper rolls of film only. The mount adhesive
and craft papers are for reference only.

Page 1 - 8
Safety F 60 H Operation and Maintenance Manual
© April 2001 General Binding Corporation
Never leave the unwind shaft out of the
unwind support saddle unless loading
or unloading film.
WARNING
When using two rolls on the machine,
ensure the film widths are identical.
Exposed adhesive can cause complications.
CAUTION
Never use an open blade near the laminating
rollers. You may cut the rollers or your self.
CAUTION
Always use the minimum amount
of brake for the job.
INFORMATION
If more brake is needed, add an O-ring
to the brake side of the rewind.
INFORMATION
CAUTION
Excess pressure can damage the laminating
rollers. Always use the minimum roll
pressure necessary to complete the task.
CAUTION
Objects other than media, film or approved
substrates, will cause irreparable damage
to the rollers if caught in the nip.
CAUTION
Sharp edges on a substrate
should be filed smooth.
Sharp edges can CUT the rollers!
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