F - 160 CE OPERATION AND MAINTENANCE MANUAL © April 2000 GBC Films Group Do not duplicate without written permission.
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 ................................
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 ..............................................
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.
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 ..............................................................................
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 ................................................................................
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 ) ..............................................................
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 ...................................................................
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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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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..
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.
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.
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.
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.
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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.
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.
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 - .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 ▼ .
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.
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.
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.
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.
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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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 ).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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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.
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.
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.
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.
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.
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.
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.
F - 160 CE Operation and Maintenance Manual Applications Web Diagram 3 - Single sided ( Sled ) P.S.A.
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.
F - 160 CE Operation and Maintenance Manual Applications Web Diagram 4 - Single sided ( Craft paper ) P .S .A.
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.
F - 160 CE Operation and Maintenance Manual Applications Web Diagram 5 - Decal and mount ( Decal ) P.S.A.
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.
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.
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.
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.
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.
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.
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
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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.
Troubleshooting Problem: Straight waves in the output Hints: • Check operational settings for materials being used.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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