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GBC F - 160 Section 4 Installation, 4.1 Pre-installation

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F - 160 Operation and Maintenance Manual	Installation

Section 4 Installation

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 Falcon 160 Laminator is properly and securely unpacked, moved, and installed.

Before a Falcon 160 Laminator can be installed, there are a few requirements that must be met. Make certain that each of the requirements listed in the following pre-installation checklist are met before beginning installation.

Is the environment appropriate for the laminator ? Th e laminato r require s a clean , dust an d vapo r fre e environmen t t o operate properly. It must not be located where there is ai r blowing directly on th e machine.

Have you contacted a certified electrician to bot h wir e th e laminato r an d ensur e that adequat e powe r i s bein g supplied , havin g the appropriate capacity, over current protection and safety lockouts are available.

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.

4.1 Pre-installation

Ar e doorway s an d hallway s wid e eneoug h for the laminator to be moved to the installation site?

I s ther e ampl e roo m fo r th e laminator?

A wor k are a mus t b e establishe d tha t allows for operation in both the front and rear of the laminator and provides space for efficient material flow. Figure 4.1.1 illustrates a typical machin e are a layout .

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.

© GBC Pro - Tech August 1999

Page 4 - 1

Contents

Page Read Me File first PAGE last PAGE go back one PAGE This page intentionally left blank Page Page Table of Contents Section 1: Safety Safety features Decal Explanation Figure 1 - 6 Decal Location Section 3: Specifications Consumables Function Section 4: Installation Page Section 5: Operations Section 6: Applications Group 1: No heat Precoating substrates Single sided lamination ( Sled method ) Single sided lamination ( Craft paper method ) 6.10 Parameter charts and diagrams Figure 6.10.1 Temperature conversion chart Blank chart Blank diagram Chart 1 - Precoating substrates Page Diagram 8 - One pass mount Chart 10 - Thermal decal and mount ( Mount ) Diagram 10 - Thermal decal and mount ( Mount ) Chart 11 - Encapsulation Section 7: Troubleshooting Wave problems Film problems 7.2.1 Thermal laminates 7.2.2 Pressure senstive Section 8: Maintenance Maintenance schedule Cleaning the rollers 8.2.1 Cabinets and covers 8.2.2 Touch screen control panel This page is intentionally left blank Section 1 Safety 1.1 Symbols 1.2 Safety features Figure 1.2.1 Cabinets and covers Emergency buttons stop 1.3 Installation that pertains to your method of shipment Do not allow the top to fall into the crate. It can damage the laminator 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 Improper leveling, will result in poor output quality Page 1.4 Operations Footswitch speed is not indicated in the SPEED DISPLAY on the control panel Twisting the roll of film while sliding makes loading the film onto the unwind shaft easier Page Page 1.5 Applications Ensure the roll of mount adhesive is loaded properly on the unwind shaft Page Page 1.6 Troubleshooting 1.7 Maintenance Below is a recommended maintenance schedule. Before performing any of the steps Excessive pressure can destroy the silicone layer by pressing to hard or scrubbing too long in one spot This will prevent anything from Page 1.8 Label locations Label locations Section 2 Warranty 2.1 Limited Warranty 2.2Exclusions to the Warranty Qualified Page 2 General Consumables Function Electrical Requirements Section 3.5 Dimensions Dimensions Page Section 4 Installation 4.1 Pre-installation Figure 4.1.2 illustrates proper wiring for single phase for the U.S Figure 4.1.3 illustrates proper wiring for Wye 3 phase for Europe Figure 4.1.1 Suggested Floor Layout Figure 4.1. 2 Single phase, U.S Incoming line voltage Figure 4.1.3 Wye 3 phase, Europe only L 3 Correct Configuration 4.2 Unpacking 4.3Shrink Wrapped 4.4 Crated Moving the laminator Figure 4.4.2 Positioning of the ramps b)Remove any plastic strapping and/or packing paper taped to the rolls 4.5 Accessory pack 4.6 Leveling Figure 4.6.1 Foot bolts Figure 4.6.2 Front to back Leveling Reset 4.7 Safety check 4.7.1Front and rear infeed tables Page 4.7.2Front and rear safety shields 4.7.3 EMERGENCY STOPS ( E-STOP) E-STOP 4.8 Function check 4.8.1Control panel Page q) Press SPEED t once. SPEED DISPLAY REV Figure 4.8.1 Default settings 4.8.3Unwind shafts and unwind brakes Upper unwind brake adjustment knob Page Section 5 Operations 5.1 Control Panel Page 1/4 ( 15 ) JOB ( 18 ) SAVE : Section 5.4 Job Programming ( 16 ) JOB ( 19 ) SHUTDOWN : ( 21 ) SPEED ( 24 ) STOP : ( 22 ) SPEED ( 25 ) FORWARD FORWARD Panel to Footswitch Footswitch to Panel •Press and hold the variable speed footswitch down •Release the variable speed footswitch •Release GO. GO should be solid To raise the safety shield • Raise the safety shield Footswitch speed is not indicated in the SPEED DISPLAY on the control panel To lower the safety shield When the safety shield is lowered, speed reverts to the panel speed setting SEL SAV REV SAFETY 5.2 Emergency Set up 5.3.1 Power 5.3.2 Film loading 5.3.5 Heating Page 5.4 Job programming Page 5.5.1Main roller manual nip adjustment 5.5 Manual nip adjustment Page Figure 5.5.1 Main roller pressure Proper pressure Excessive g)Press REV tfor a reverse motor direction 5.5.2Pull roller manual nip adjustment Refer to Figure 5.5.2 for proper roller Figure 5.5.2 Pull roller pressure h)The pull roller nip has now been manually set i)Press STOP j)Press REV tfor a reverse motor direction g)Step on the variable speed footswitch to back the leader board out 5.6 Infeed tables 5.6.1 Removing the table 5.6.2Replacing the infeed table If the tables are not properly seated, the laminator will not operate in "Panel" mode Figure 5.6.3 Safety roller switch Safety Section 6 Applications 6.1 Precoating substrates Group 1 : No heat b)Place these two pieces by the laminator for future use Figure 6.1.1 MAIN POWER / RESET g)Lift the clevis pin located in the saddle of the upper unwind shaft c)Turn MAIN POWER to “ ON”. Refer to d)Press RESET. Refer to Figure Figure 6.1.2 Unwind shaft i)Once loaded, swing the upper unwind shaft back into the saddle j)Push the clevis pin back down to secure the unwind shaft in its saddle k)Raise the front safety shield l)Press SEL. SEL will stop flashing n)Press FWD s If the board is loose, press Process Figure 6.1.3 Leader board c)Press STOP d)Press FWD s Excessive tension will cause the substrate to bow g)Have the second person stand at the rear of the laminator Steps " h " and " i" will be performed Figure 6.1.4 ( 1/2 in. ) Gap Figure 6.1.5 Trailer board Finishing Do not use an open blade to cut the web near the rollers. You can put cuts into the rollers This will prevent any exposed adhesive from contacting the rollers Section 8.2 Cleaning the rollers 6.2 Mounting only e)Press SEL. SEL will stop flashing g)Press FWD s Figure 6.2.2 Align edges Figure 6.2.4 Trim the image Figure 6.2.3 Trim the release liner Figure 6.2.5 Peel back release liner f)Press STOP Figure 6.2.6 Tack leading edge h)Push the leading edge of the precoated board up to the nip of the main rolls Figure 6.2.7 Draping the image 1)Press STOP 2)Press REV t 4)Press STOP 5)Press FWD s Figure 6.2.9 Non conformed print Steps " l" and " m " will be performed Yo u ma y b e CRUSHE D o r BURNED o)The mounted image can now be removed from the rear of the laminator 6.3Single sided lamination ( Sled method ) Figure 6.3.1 MAIN POWER / RESET Figure 6.3.2 Unwind shaft g)Once loaded, swing the upper unwind shaft back into the saddle h)Push the clevis pin back down to secure the unwind shaft in its saddle i)Raise the front safety shield k)Press SEL l)Press FWD s Y o u c a n C R U S H E D o r B U R N E D Figure 6.3.3 Laminate to rewind c)Wrap one full turn of laminate onto the upper rewind tube Figure 6.3.4 Laminate separation Steps " i" and " j" will be performed Figure 6.3.5 Separation point Page 6.4Single sided lamination ( Craft paper method ) Figure 6.4.1 MAIN POWER / RESET Page Figure 6.4.3 Laminate to rewind Figure 6.4.4 Laminate separation Figure 6.4.5 Craft paper k)Press GAP tto enter a 0 in. gap setting l)Press FWD s Keep hands and fingers clear of Steps " m " and " n " will be performed the laminator roller nip when adjustin g PRESSURE If you choose to use the lower rewind tube make note of the direction of travel Figure 6.4.6 Finish product rewind clockwise after you feel the initial contact. Refer to Figure Do not use an open blade to cut the web near the rollers Page Page 6.5 Decal and mount Saddle Clevis pin Figure 6.5.2 Unwind shaft Figure 6.5.3 Laminate to rewind Figure 6.5.4 Laminate separation Figure 6.5.5 Mount adhesive Page Page Figure 6.5.6 Finish product rewind Page Pass two : Mount •Prints ( Decals ) •Substrates •Leader board ( substrate width x 6” ) a)Replace the front infeed table h)Press REV t to reverse the direction of the motor Figure 6.5.8 Setting the decal Figure 6.5.7 Align edges Figure 6.5.9 Trim the decal Figure 6.5.10 Peel back release liner Figure 6.5.11 Tack leading edge Steps " j" and " k " will be performed Figure 6.512 Draping the decal Figure 6.5.14 Non conformed decal Figure 6.5.13 Conformed print Steps " n " and " o " will be performed Page Group 2 : Top heat only 6.6 Precoating substrates Figure 6.6.1 MAIN POWER / RESET d) Press RESET. Refer to Figure Figure 6.6.2 Unwind shaft o)Press SPEED s to set a motor speed of 2 ft. / min. ( .6 m / min. ) s)Press STOP p)Press GAP t to enter a 0 in. gap setting q)Press GO r)Continue with step s) when the TOP TEMP DISPLAY stops flashing Page Figure 6.6.3 Leader board Page Figure 6.6.4 ( 1/2” ) Gap Figure 6.6.5 Trailer board 6.7One pass mount and laminate •Leader and trailer board •Roll of thermal laminate •Glue stick ( print that are not heat sensitive ) Figure Page u) Press on the variable speed footswitch while guiding the leader board into the nip to confirm Page Figure 6.7.4 Leader board The thin line of glue will assist with holding the layers to the board h) Press FWD s j) Apply the minimum amount of brake tension on the roll of thermal laminate to prevent it from free spinning Figure 6.7.5 Trailer board 6.8Thermal decal and mount Figure 6.8.1 MAIN POWER / RESET Figure 6.8.2 Unwind shaft Page Page Laminate Figure 6.8.4 Mount adhesive The mount adhesive will adhere to the activated adhesive from the laminate Page Figure 6.8.5 Finish product rewind Page Page Page d) Press FWD s g) Press REV t to reverse the direction of the motor e)Press on the variable speed footswitch to back the leader board out Figure 6.8.6 Align edges Figure 6.8.9 Peel back release liner Figure 6.8.7 Setting the decal Figure 6.8.8 Trim the decal Figure 6.8.10 Tack leading edge f)Set the substrate and decal in the center of the rear infeed table Steps " g " and " h " will be performed “ i” i)Drape the loose part of the decal over the upper main roller. Refer to Figure Figure 6.8.11 Draping the decal j)Make sure the image is conformed to the upper main roller. Refer to Figure Figure 6.8.13 Non conformed decal Figure 6.8.12 Conformed print motion, keep hands and fingers away from the nip of the rollers Group 3 : Top / bottom heat 6.9 Encapsulation Figure 6.9.1 MAIN POWER / RESET Figure 6.9.2 Unwind shaft Page Page Figure 6.9.3 Laminate Figure 6.9.4 Lower laminate Page Figure 6.9.5 Finish product rewind Page 6.10 Charts and Diagrams Figure 6.10.1 Temperature conversion chart Parameter Chart - Blank GAP & PRESSURE MOTOR DIRECTION & SPEED Web Diagram - Blank ApplicationsF - 160 Operation and Maintenance Manual Parameter Chart 1 - Precoating substrates UPPE R UNWIN D : Pro Mount SUBSTRAT E : 1/4" Foam Core LOWE R UNWIN D : N / A Web Diagram 1 - Precoating substrate Parameter Chart 2 - Mounting only Web Diagram 2 - Mounting only Parameter Chart 3 - Single sided ( Sled ) Web Diagram 3 - Single sided ( Sled ) Parameter Chart 4 - Single sided ( Craft paper ) SUBSTRAT E : N / A LOWE R UNWIN D : Craft Paper Web Diagram 4 - Single sided ( Craft paper ) Parameter Chart 5 - Decal and mount ( Decal ) LOWE R UNWIN D : Pro Mount Web Diagram 5 - Decal and mount ( Decal ) Parameter Chart 6 - Decal and mount ( Mount ) PRINTS : Decals Web Diagram 6 - Decal and mount ( Mount ) Parameter Chart 7 - Precoating substrates ( Thermal ) Web Diagram 7 - Precoating substrate ( Thermal ) Parameter Chart 8 - One pass mount and laminate UPPE R UNWIN D : 3 mil Octiva Gloss PRINTS : Electrostatic images Web Diagram 8 - One pass mount and laminate Parameter Chart 9 - Thermal decal and Mount ( Decal ) PRINTS : Any type Web Diagram 9 - Thermal decal and mount ( Decal ) Parameter Chart 10 - Thermal decal and Mount ( Mount ) Web Diagram 10 - Thermal decal and mount ( Mount ) Parameter Chart 11 - Encapsulation LOWE R UNWIN D : 3 mil Octiva Gloss Web Diagram 11 - Encapsulation Page Section 7 Troubleshooting 7.1 Wave problems Page 7.2 Film problems 7.2.2 Pressure sensitive 7.2.1 Thermal laminates 7.3Machine problems 7.4 Glossary Clutch tension Encapsulation Coiling Cold laminate Film Main rollers Pull rollers Media Mount adhesive Mount tissue Silvering Substrate Tunneling Unwind Web Section 8 Maintenance 8.1 Maintenance Schedule 8.2 Cleaning the rollers Removing adhesive build up c)Wipe away the beads with isopropyl alcohol and a cotton terry cloth Cleaning the beads of adhesives, dust and dirt from the rolls Method a)Allow the laminator to cool slightly to no higher than 110oF ( 43oC ) Page 8.2.1 Clean the cabinets and 8.2.2 Cleaning the touch covers screen