) 2SHUDWLRQ DQG 0DLQWHQDQFH 0DQXDO © 1998 GBC Pro-Tech Do not duplicate without written permission NING WAR UNG HT E AC GARD E EN MIS NING WAR UNG HT E AC GARD E EN MIS 100 90 80 70 60 50 40 30 20 CAL 3200 10 CAL 3200 4 5 6 3 7 2 1 2 8 9 10 0™ F-6 H EC O-T PR Part Number 930-016 GBC Pro-Tech 4151 Anderson Road De Forest, Wisconsin 53532 Tel: 608-246-8844 Fax: 608-246-8645
F-60 Operation and Maintenance Manual 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 merchantability for any particular use.
F-60 Operation and Maintenance Manual 7DEOH RI &RQWHQWV 6HFWLRQ 6DIHW\ Caution/Warning Label Locations ................................................................................... 1-3 6HFWLRQ ,QVWDOODWLRQ Preinstallation Checklist .................................................................................
F-60 Operation and Maintenance Manual Setup .......................................................................................................................... 3-6 Procedure, Pass 1 ...................................................................................................... 3-6 Procedure, Pass 2 ......................................................................................................
F-60 Operation and Maintenance Manual 6HFWLRQ 6DIHW\ DO NOT ATTEMPT TO OPERATE YOUR ORCA-IV VINYL TRANSFER MACHINE UNTIL YOU HAVE READ THIS SECTION CAREFULLY! Your safety, as well as the safety of others, is important to GBC Pro-Tech. This section contains important safety information. The following symbols are used throughout this manual to indicate warnings and cautions. DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Safety F-60 Operation and Maintenance Manual Reset Button WARNING Never place fingers or arms between the rolls when they are turning or when the rolls are in the closed position. You can be crushed or burned. PO W ER 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.
F-60 Operation and Maintenance Manual CAUTION Use only 80% isopropyl alcohol or a rubber cement eraser to clean the laminating rolls. Harsh chemicals like toluene, acetone or MEK destroy the silicone covering of the rolls. CAUTION Raise the upper main roll when the laminator is not in operation. Prolonged contact can damage the rolls. WARNING Do not attempt to move the laminator across anything other than a flat, level surface without trained and qualified riggers.
Safety F-60 Operation and Maintenance Manual (Inside cabinet) WARNING ACHTUNG MISE EN GARDE WARNING ACHTUNG MISE EN GARDE WARNING ACHTUNG MISE EN GARDE (Inside cabinet) ING RN WA UNG HT E AC GARD E EN MIS NING WAR UNG HT E AC GARD E EN MIS ©1994 Hazard Communication Systems, Inc.
F-60 Operation and Maintenance Manual The following are typical safety hazard decals used on GBC Pro-Tech machines, with a brief description (“Meaning” column) of each decal. Decal Meaning WARNING ACHTUNG WARNING! Moving parts can crush and cut. MISE EN GARDE Do not operate with guard or door open. Decal Meaning WARNING! SAFETY INSTRUCTIONS SICHERHEITSRICHTLINIEN 1. 2. CONSIGNES DE SÉCURITÉ 3. 4.
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F-60 Operation and Maintenance Manual 6HFWLRQ ,QVWDOODWLRQ GBC Pro-Tech is committed to a program of ongoing product improvement. As a result, we are providing these instructions so that you can insure that your new F-60 Laminator is properly and securely unpacked, moved and installed. Before a F-60 Laminator can be installed, there are a few requirements that must be met. Make certain that each of the requirements listed in the following preinstallation checklist are met before beginning installation.
Installation F-60 Operation and Maintenance Manual Wall 4' x 6' (~1.22 m x 2 m) Work Table on Wheels 8'6-1/2" (~2.6 m) Table Height 35-3/4" (~.94 - .95 m) Electrical Supply 78" (~2 m) Rear 3' (~1 m) 20' 30" (~.6 m) (~.76 m) Front 4' x 6' (~1.22 m x 2 m) Work Table on Wheels 8'6-1/2" (~2.6 m) Table Height 35-3/4" (~.94 - .
F-60 Operation and Maintenance Manual 8QSDFNLQJ ☞ NOTE 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. 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 a note of this on the Bill of Lading. The F-60 Laminator is shipped in a wood crate on a skid. Installation 2.
Installation F-60 Operation and Maintenance Manual 4. Carefully remove the accessory pack from the skid. The accessory pack should contain: 1 Set, hex wrenches 1 Slitting knife 10. The ramps included with the laminator can be secured to the edge of the crate bottom using the screws left over from the crate disassembly (see Figure 2-2). 11. Have the machine moved off the skid and placed on the floor by licensed riggers.
F-60 Operation and Maintenance Manual ☞ A NOTE ABOUT RECYCLING The crate components can be reused for shipping the machine again, or can be disassembled and the wood and screws recycled. The shrink wrap is not recyclable, however, so it must be discarded. 14. Level the laminator using the procedure later in this section. 6HWXS Once the F-60 Laminator has been unpacked and moved into final position check each of the following items.
Installation F-60 Operation and Maintenance Manual 6WDU WXS The first time the laminator is started and every time it is serviced you should use the following checklist to confirm that the unit is operating properly and that all safety mechanisms are functioning. WARNING Use extreme caution when operating the machine with the guard off. You can be crushed or burned. Startup Checklist Start the laminator and go through the following checklist.
F-60 Operation and Maintenance Manual Operation 6HFWLRQ 2SHUDWLRQ Reset Button 6DIHW\ The F-60 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. PO W ER GBC Pro-Tech F-60 Laminator is a powerful machine that is designed to mount, laminate and encapsulate.
Operation F-60 Operation and Maintenance Manual 2SHUDWRU &RQWUROV The operator controls for the F-60 Laminator are located on the front and rear of the unit, to the right of the operator position. The names and functions of these controls are as follows: )URQW &RQWURO 3DQHO 8. LOWER ROLL HEAT ON/OFF – Turns the heater controller for the lower main roll on or off. 9. COOLING FAN ON/OFF – Turns the cooling fan on or off. 10.
F-60 Operation and Maintenance Manual Operation away (on the outside) from the laminating roll. Otherwise it will immediately bond to the roll, creating a major clean-up project. 6HWXS Setup of the F-60 Laminator is quick and straightforward when instructions are followed exactly. To adjust the nip, please see Maintenance. Films have a shiny side and a dull side. The dull side is the one with the adhesive. The dull side should ALWAYS face outward from the laminating roll.
Operation F-60 Operation and Maintenance Manual 3RVLWLRQLQJ WKH )LOP 5DLVLQJ DQG /RZHULQJ WKH 3XOO 5ROOV The following procedure is applicable to both the top and bottom feed unwinds. The pull rolls on the F-60 Laminator are preset for optimum roll pressure and requires no nip adjustment. The pull rolls can be raised for a 3/8" gap that allows for easy webbing of the machine. 1. Open the top unwind by removing the pin and swinging the arm out. 2. Load the film. 3.
F-60 Operation and Maintenance Manual Operation 3URFHVV &RQWURO &KDUWV Process control charts allow you to record the way you thread film through the machine's rolls and idlers (called webbing) and the control settings for each product and process. Process control charts are an excellent tool for training new operators. They provide a "road map" for correct machine setup and operation.
Operation F-60 Operation and Maintenance Manual 0RXQWLQJ 2QO\ (QFDSVXODWLRQ 6HWXS 6HWXS 1. See process chart 3-1. 1. See process chart 3-3. 2. Shims: Set to the thickness of the material being used for mounting. 2. Laminating Roll Pressure: 30-40%. 3. Upper Laminator Roll Pressure: 10–30%. 4. Upper Laminator Roll Heat: 230°F (110 °C). 4. Speed: 3 fpm (1 m/min). 5. Lower Laminator Roll Heat: 32°F (0 °C). 5. Upper Laminator Roll Heat: 240°F (115 °C). 6. Cooling: Optional. 3URFHGXUH 1.
F-60 Operation and Maintenance Manual Operation 3URFHGXUH 3DVV 1. Prepare to put the print through a second time to mount the print to the substrate - anything from wood, to Masinote, to Gator foam. Start by setting the shims to the appropriate spacing for the material used. 2. Trim the board to the size of the print. 3. Align the work to the board and ensure an exact fit. Place weights on the center of the print to make sure that it does not move relative to the board during the next steps. 4.
Operation F-60 Operation and Maintenance Manual 352&(66 &21752/ &+$57 Product: _________________________ Process: ___________________________ Date: ________________ FRONT CONTROL SETTINGS Speed: Reverse/Forward: Roll Pressure: Top Heater: Cooling: Bottom Heater: 352&(66 &21752/ ',$*5$0 Identification Diagram (F) (RI) (U) (R) (UM) (LM) (UP) (LP) Fixed Idler Removable Idler Unwind Shaft Rewind Upper Main Roll Lower Main Roll Upper Pull Roll Lower Pull Roll U R F UM LM F RI UP LP U U 3-8
F-60 Operation and Maintenance Manual Operation 352&(66 &21752/ &+$57 Product:_________________________ Process: One Pass Mounting __________ Date:________________ FRONT CONTROL SETTINGS Speed: 2-3 fpm (60-90 cpm) Reverse/Forward: Forward Roll Pressure: Trial Top Heater: 240 ºF (115 ºC) Cooling: Off Bottom Heater: Off 352&(66 &21752/ ',$*5$0 One Pass Mounting ☞ NOTE Guard is removed for this operation. Use automatic slow roll speed (3 ft/min). Footswitch may be used.
Operation F-60 Operation and Maintenance Manual 352&(66 &21752/ &+$57 Product: _________________________ Process: One Pass Mount & Laminate ___ Date: ________________ FRONT CONTROL SETTINGS Speed: 1-2 fpm (30-60 cpm) Reverse/Forward: Forward Roll Pressure: Trial Top Heater: 240 ºF (115 ºC) Cooling: Off Bottom Heater: Off 352&(66 &21752/ ',$*5$0 One Pass Mount and Laminate ☞ NOTE Guard is removed for this operation. Use automatic slow roll speed (3 ft/min). Footswitch may be used.
F-60 Operation and Maintenance Manual Operation 352&(66 &21752/ &+$57 Product: 3 Mil Gloss/3Mil Gloss _____ Process: Encapsulation ______________ Date:________________ FRONT CONTROL SETTINGS Speed: 0-6 fpm (0-180 cpm) Reverse/Forward: Forward Roll Pressure: 30-60% Top Heater: 230 ºF (110 ºC) Cooling: Optional Bottom Heater: 230 ºF (110 ºC) 352&(66 &21752/ ',$*5$0 Encapsulation Use Either Path © GBC Pro-Tech 1998 July 3-11
Operation F-60 Operation and Maintenance Manual 352&(66 &21752/ &+$57 Product: _________________________ Process: Cold Overlamination _________ Date: ________________ FRONT CONTROL SETTINGS Speed: 0-6 fpm (0-180 cpm) Reverse/Forward: Forward Roll Pressure: 30-60% Top Heater: 105 ºF (40 ºC) Cooling: Off Bottom Heater: 32 ºF (0 ºC) 352&(66 &21752/ ',$*5$0 Cold Overlamination Pro Gloss Release Paper Rewind Use Any Path Craft Paper 3-12 © GBC Pro-Tech 1998 July
F-60 Operation and Maintenance Manual Operation 352&(66 &21752/ &+$57 $ Product:______________________ Process: Cold Mount & Laminate (First Pass) Date:________________ FRONT CONTROL SETTINGS Speed: 0-6 fpm (180 cpm) Reverse/Forward: Forward Roll Pressure: 30-60% Top Heater: 105 ºF (40 ºC) Cooling: Off Bottom Heater: 32 ºF (0 ºC) 352&(66 &21752/ ',$*5$0 $ Cold Mount and Laminate (First Pass) Pro Gloss Release Paper Rewind Use Any Path Pro Mount © GBC Pro-Tech 1998 July 3-13
Operation F-60 Operation and Maintenance Manual 352&(66 &21752/ &+$57 % Product: ____________________ Process: Cold Mount & Laminate (Second Pass) Date: ________________ FRONT CONTROL SETTINGS Speed: 0-6 fpm (0-180 cpm) Reverse/Forward: Forward Roll Pressure: Trial Top Heater: 32-105 ºF (0-40 ºC) Cooling: Off Bottom Heater: 32 ºF (0 ºC) 352&(66 &21752/ ',$*5$0 % Cold Mount and Laminate (Second Pass) ☞ NOTE Guard is removed for this operation.
F-60 Operation and Maintenance Manual Operation 352&(66 &21752/ &+$57 $ Product:_________________ Process: Mount & Hot Overlaminate (First Pass) __ Date:________________ FRONT CONTROL SETTINGS Speed: 0-6 fpm (0-180 cpm) Reverse/Forward: Forward Roll Pressure: 30-60% Top Heater: 230 ºF (110 ºC) Cooling: Optional Bottom Heater: 32 ºF (0 ºC) 352&(66 &21752/ ',$*5$0 $ Mount and Hot Overlaminate (First Pass) 3 Mil Gloss Use Any Path Pro Mount © GBC Pro-Tech 1998 July 3-15
Operation F-60 Operation and Maintenance Manual 352&(66 &21752/ &+$57 % Product: __________________ Process: Mount & Hot Overlaminate (Second Pass) Date: ________________ FRONT CONTROL SETTINGS Speed : 0-6 fpm (0-180 cpm) Reverse/Forward: Forward Roll Pressure: Trial Top Heater: 32-105 ºF (0-40 ºC) Cooling: Off Bottom Heater: 32 ºF (0 ºC) 352&(66 &21752/ ',$*5$0 % Mount and Hot Overlaminate (Second Pass) ☞ NOTE Guard is removed for this operation.
F-60 Operation and Maintenance Manual 6HFWLRQ 0DLQWHQDQFH DQG 7URXEOHVKRRWLQJ GBC Pro-Tech 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 and Troubleshooting To clean beads of adhesive, dust and dirt from the rolls: 1. Allow the laminator to cool slightly to no higher than 110ºF (43ºC). 2. Set the FWD/REV switch to the REV position. 3. Clean the rolls using a moderate amount of 80% isopropyl alcohol on a cotton terry cloth. CAUTION Use the minimum amount of pressure necessary to clean the rolls. You can destroy the silicone layer on the rolls by pressing to hard or scrubbing too long in one spot.
F-60 Operation and Maintenance Manual Maintenance and Troubleshooting $GMXVWLQJ WKH 1LS The gap between two rolls is called the nip. The purpose of adjusting the nip is to ensure continuous contact between the rolls as the media is drawn through the machine. This procedure must be done regularly for the main rolls. It is not necessary to set the nip on the pull rolls.
Maintenance and Troubleshooting F-60 Operation and Maintenance Manual &KDLQ 7HQVLRQLQJ Smaller chain tensioning adjustments on the F-60 Laminator are handled by a secondary chain tensioner, however, when installing a new chain or when the chain tension is more seriously out of adjustment, use the following procedure to adjust the chain tension.
F-60 Operation and Maintenance Manual /XEULFDWLRQ Maintenance and Troubleshooting &RQWDFWLQJ 7HFKQLFDO 6XSSRUW Tools required: • 1 • High temperature grease or lithium grease • Grease gun /8" hex wrench To lubricate the laminator: For machine parts and technical service in North America, please call: 1-800-790-7787. Please provide serial number when calling for service. In Europe, please call: +44 (0) 1844 202 440 or fax: +44 (0) 1844 202 441.
Maintenance and Troubleshooting F-60 Operation and Maintenance Manual 2XWSXW 7URXEOHVKRRWLQJ *XLGH Problem: Problem: D waves in the image, not in the D waves in the laminate. laminate. Hints: Hints: • Increase clutch tension. • Check paper tension. • Check roll pressures. • Check relative moisture content • Check nip settings. of the paper. Problem: Straight waves in the output. Hints: • Decrease clutch tension. • Check operational settings for materials being used.
F-60 Operation and Maintenance Manual 6HFWLRQ :DUUDQW\ /LPLWHG :DUUDQW\ GBC Pro-Tech Engineering Company, Inc. warrants the equipment sold is free from defects in material and workmanship for a period of ninety days (90) from the date of delivery to the customer. This warranty is the only warranty made by GBC Pro-Tech and cannot be modified or amended.
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F-60 Operation and Maintenance Manual Specifications Table 6-2: Replacement Parts 6HFWLRQ 6SHFLILFDWLRQV 3DUWV DQG 6FKHPDWLF Table 6-1: F-60 Laminator Specifications Characteristic Dimensions (L x D x H) Weight Laminating Rolls Laminating Material Laminating Speeds Heating Safety Features Part Number Description 001-374 Assembly, Force Gauge PCB 1 001-505 Assembly, Force Sensor 1 001-515 Assembly, Control PCB 1 186-200 Fuse, SB, 3AG, 3A 3 214-313 Switch, Palm, E-stop 1 230-007
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F-60 Operation and Maintenance Manual ,QGH[ $ Accessory pack 2-4 Adjusting nip 4-3 & Chain Lubrication 4-5 Tensioning 4-4 Cleaning 4-1 Controls front control panel 3-2 ( Emergency stop buttons 1-1, 2-6, 3-1 Encapsulation 3-6 Environment 2-1 Extension cord 2-1 ) Film loading 3-3 positioning 3-4 Footswitch 3-2, 4-1, 6-1 FWD/REV switch 4-2 * Grease fittings 4-5 Ground plug 2-1 Index Leveling 2-5 Lubrication 4-5 0 Main rolls 4-3 Maintenance schedule 4-1 Motor 2-6, 4-4 Mounting 3-6 Mounting/Laminating 3-6
Index F-60 Operation and Maintenance Manual 8 Unpacking 2-3 Crate 2-3 Upper main roll 1-3 : Warnings and cautions 1-1 Warranty 5-1 7-2 © GBC Pro-Tech 1998 July
