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GBC F-36 User's Manual

1. Section 6 Specifications Table 6 1 F 36 PRO Laminator Specifications Part Description Recommended Number Quantity Characteristic Specifications 001 374 Assembly Force 1 Dimensions 56 x 31 x 56 Gauge PCB Lx Dx H 1 42 x 79 x 1 42m Weight Uncrated 300 Ibs 136 kg 001 504 Assembly Force 1 Crated 500 Ibs 225 kg penser Laminating Rolls 42 1 06m roll face with high 001 528 Relay Board 1 release surface upper and lower rolls internally heated 001 134 Temperature Control 1 Laminating 1 5 3 8 cm maximum opening 425 000 Motor 1 Opening controlled with infinitely vari able hand crank 690 001 Roll Main 1 Laminating Uses heat activated and pressure 690 002 Pull Roll Upper 1 Material sensitive materials 0 39 99 6 cm wide on a 3 7 6 cm 690 003 Pull Roll Lower 1 ID core 10 25 4 cm maximum 189 000 Heater Round 1 diameter Laminating 0 to 18 fmp o to 5 5 mpm with 240 120 Thermocouple J 1 Speeds variable speed reversible action type 72 start and stop controlled either 214 000 Microswitch Safety 1 through the instrument panel or al with the variable speed foot switch 220 160 Motor Controller 1 Encapsulating Pull rolls and cooling fans for Features uniform flat cooling 220 110 Barrier Board Motor Safety Features e Mechanical guard on infeed Senne e All electrical and moving 186 135 Fuse Ceramic 20A 1 mechanical parts are
2. MATERIALS Upper Media 3 mil gloss Image Media Bond Paper Lower Media N A Mounting Substrate Falcon Board LAMINATOR SETTINGS Top Heater Status ON 240 F 115 C Drive Mode Manual Footswitch Bottom Heater Status OFF Pull Roll Position UP Speed 1 2 ft min Output Cooling OFF Drive Direction FWD Main Roll Setting DOWN 1 4 turn PROCESS CONTROL DIAGRAM 3 2 Notes O ee Oar Ge E SA O 7 2 Board O 3 10 GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual Operation PROCESS CONTROL CHART 3 3 One Pass Mounting MATERIALS Upper Media N A Image Media Bond Paper Lower Media N A Mounting Substrate Falcon Board LAMINATOR SETTINGS Top Heater Status ON 240 F 115 C Drive Mode Manual Footswitch Bottom Heater Status OFF Pull Roll Position UP Speed 2 3 ft min Output Cooling OFF Drive Direction FWD Main Roll Setting DOWN 1 4 turn PROCESS CONTROL DIAGRAM 3 3 Notes Printed Image di FALCON Board GBC Pro Tech 1999 January Operation F 36 PRO Laminator Operation Manual PROCESS CONTROL CHART 3 4A Two Pass Mount and Cold Pressure Overlaminate First Pass MATERIALS Upper Media Pro Gloss Image Media Bond Paper Lower Media Pro Mount Mounting Subs
3. 4 1 AUS TIONING NID EE 4 5 AENA EE Ea aa an a EEEN AASEN 4 6 Eege EE 4 7 Contacting Rn e E d el EE 4 7 Output Troubleshooting RT EE 4 8 Section 5 Warranty EE EEEER ER saun unu KEE ES EE KEE ERR iaia ine ER ERR eee 5 1 Eire UY ANE ae a eae Ova Goo polo E 5 1 Exclusions to the Warranty ec A rali eroi i io 5 1 Section 6 Specifications EE ER EER KREE EE EER KREE a 6 1 Section 7 INC OX E 7 1 GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual Section 1 Safety DO NOT ATTEMPT TO OPERATE YOUR F 36 PRO LAMINATOR 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 man ual to indicate warnings and cautions A Indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury A 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 The F 36 PRO Laminator has been designed with safety as a primary consideration However you must become thoroughly familiar
4. EE Q E TE 10 3m Y Figure 2 1 Laminator Space Requirements 2 2 O GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual Unpacking c NOTE ALL SHIPMENTS ARE EX WORKS At our dock title passes to the buyer Please review your insurance cov erage prior to shipment as you are responsible for all subsequent freight charges and risks Before signing the Bill of Lading be sure to inspect the crate and or pallet for signs of damage or missing items if applica ble make a note of this on the Bill of Lading The F 36 PRO Laminator is shipped one of two ways It is either encased in a wood crate on a skid or ina cardboard box on a skid A WARNING The unpacking process requires at least two people You can be severely injured or crushed Tools required e Phillips head screwdriver VA open end wrench or adjustable wrench Ge Installation Figure 2 2 Removing the Cardboard Box Lift the cardboard box off the laminator Gently unwrap the shrink wrap from around the laminator caution If the laminator is in a cardboard box 1 Remove the securing screws around the bottom of the box using the Phillips head screwdriver as shown in Figure 2 2 Do not use a knife or other sharp instrument during installation or while servicing the laminator You can cause irreparable damage to the rolls Carefully remove any accessories packed with the laminator The ac
5. Web up the hot overlaminate by wrapping it around the upper film idler and draping it over the upper main roll Drape the film only about halfway down the upper main roll Pull the mount adhesive straight up from the lower unwind position being careful not to stick the film to the machine Tack it to the hot overlaminate 6 7 Operation Insert a starter board into the nip and lower the upper main roll onto it Press the footswitch Once the leader board is through the nip lower the upper main roll and then rotate the crank 1 2 a turn more Reinstall the infeed table Encapsulate the images Setup and Procedure Pass 2 1 Adjust the machine settings as shown in process chart 3 5b Trim the print to size and trim the board to the size of the print Insert the board into the nip area and lower the main roll until it contacts Turn the crank another 1 4 of a turn and remove the board using the foot switch Clean the board with a tack cloth or cleaning roller Place the image face down on a flat surface and peel back the release liner on the leading edge about two inches Lay the image on the board and align it carefully When aligned tack the exposed adhesive strip s center to the leading edge to the board Work towards the edges from the center being careful not to wrinkle the image Insert the already mounted portion of the piece into the pull roll nip Lower the upper pull roll onto the board and
6. This warranty specifically does not cover damage to the laminating rollers caused by knives razor blades other sharp objects failure caused by adhesives or improper use of the machine Warranty repair or replacement does not extend the warranty beyond the initial ninety day period from the date of delivery A CAUTION Unauthorized customer alterations will void this warranty THE WARRANTY MADE HEREIN IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PAR TICULAR PURPOSE GBC PRO TECH WILL NOT BE LIABLE FOR PROPERTY DAMAGE OR PER SONAL INJURY UNLESS PRIMARILY CAUSED BY ITS NEGLIGENCE LOSS OF PROFIT OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE THE EQUIPMENT Warranty Exclusions to the Warranty This warranty specifically does not cover 1 Damage to the laminating rolls caused by knives razor blades other sharp objects or failure caused by adhesives 2 Damage to the machine caused by lifting tilting and or any attempt to position the machine other than rolling on the installed casters on even sur faces 3 Improper use of the machine GBC Pro Tech 1999 January Warranty F 36 PRO Laminator Operation Manual Blank page 5 2 GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual Specifications Table 6 2 Replacement Parts
7. the machine All guards are in place All parent rolls are well chucked in the unwind stands The machine is free of paper scraps wraps and jams There is a potential hazard of entanglement in this machine caused by items such as long hair loose clothing and jewelry Make sure your clothing and hair fit closely to your body and that all jewelry rings and watches are removed CAUTION Air pressure must be less than 100 PSI 700 kPa to avoid damaging the machine WARNING EMERGENCY STOP BUTTON Press this button to stop the machine cycle remove electric power and separate open rolls to eliminate a pinch point on some machines Electric power disconnect and lock out location 1 6 GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual Section 2 Installation Before an F 36 PRO 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 A CAUTION Failure to follow the preinstallation checklist can result in damage to the laminator Installation Is there an appropriate power source available and has a certified electrician been contacted to wire the laminator directly The laminator requires 30A single phase service and a power receptacle that accepts a 30A 250V NEMA L6 30P plug or in Europe 3 phase 240 400 VAC with 20A pe
8. Output Cooling OFF Drive Direction FWD Main Roll Setting DOWN 1 4 turn PROCESS CONTROL DIAGRAM 3 6 Notes 3 16 GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual Section 4 Maintenance and Troubleshooting Performing regular maintenance on the F 36 PRO Laminator is critical to the proper operation of the machine A maintenance schedule and a section of pro cedures for disassembling and reassembling the ser viceable areas of the laminator are included in this section Table 4 1 Maintenance Schedule Daily e Clean adjust the thermocouples e Clean the rolls e Inspect the electrical cord for dam age e Inspect the footswitch cord for dam Maintenance and Troubleshooting Tools reguired b Ye hex wrench e 80 isopropyl alcohol e 100 lint free paper or cotton terry cloth A canon ALWAYS CHECK THE POSITION AND CONDITION OF THE THERMOCOUPLES PRIOR TO OPERATION The thermal junction of the thermocouples MUST make contact with the laminating rolls to maintain proper roll operating temperatures The thermocouples must also be free of adhesive and dirt The rolls can overheat and cause a fire or seriously damage the laminator e Check wire termination tightness Thermocouple Positioning and Cleaning One of the most crucial adjustments to the F 36 PRO Laminator is positioning the thermocouples and mak
9. PRO Laminator Operation Manual A CAUTION Do not use a knife or other sharp instrument during installation or while servicing the laminator You can cause irreparable damage to the rolls 9 Remove all packing materials to a safe distance from the laminator c A NOTE ABOUT RECYCLING The pallet can be reused for shipping the machine again or can be disassembled and the wood and screws recycled The cardboard can be recycled The shrink wrap is not recyclable however so it must be discarded ve NOTE A word about international shipments As these are heavy pieces of equipment GBC Pro Tech takes every precaution to ensure that our laminators are properly crated to the highest standards Before machines leave our loading dock they are pre treated with a VCI protective film to provide total cor rosion protection This protective film is wrapped around the machine and completely sealed In addition moisture absorbing silicone desiccite packs are packed inside the crate and machine cabinets Prior to start up of the machine you must remove the desiccite packs from each cabinet and discard DO NOT operate the machine with the desiccite packs inside the cabinets GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual If the laminator is in a crate 1 Remove the top of the crate and then the sides in the order shown in Figure 2 4 A CAUTION Installation Ako Do not allow the t
10. RIGGERS ONLY to move the machine 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 GBC Pro Tech s warranty does not cover malfunction of the equipment due to mishandling and or tipping GBC Pro Tech bears no responsibility for personal injury or damage due to moving the laminator improperly 6 Once the laminator is in place set the locking mechanism on all four wheels to ON 7 Remove any plastic strapping and packing paper taped to the rolls A CAUTION Do not use a knife or other sharp instrument during installation or while servicing the laminator You can cause irreparable damage to the rolls 8 Remove all packing materials to a safe distance from the laminator c 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 F 36 PRO Laminator Operation Manual c NOTE A word about international shipments As these are heavy pieces of equipment GBC Pro Tech takes every precaution to ensure that our laminators are properly crated to the highest standards Before machines leave our loading dock they are pre treated with a VCI protective film to provide total cor rosion protection This protective film is w
11. cedure 2 Remove the drive side cabinet cover using the Le hex wrench by removing the six screws holding the cover in place 3 Loosen all four motor mount bolts using the Yig hex wrench as shown in Figure 4 6 The motor should just move freely within the slots F 36 PRO Laminator Operation Manual WH VAN Wa Ar T A 1 4 to A Ah A WD WI 1 2 Play E Loosen Motor gt e gt Mount Bolts Downward Force Tightens Chain N Figure 4 6 Adjusting the Chain Tension 4 Using a screwdriver apply a small amount of downward pressure on the motor by prying against the inside of the side frame until there is 4 to 1 2 play in the chain 5 Tighten the mounting bolts while maintaining the downward pressure on the motor 6 Replace the cabinet cover and reconnect power to the laminator GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual Lubrication Tools required vey hex wrench e High temperature grease or lithium grease e Grease gun To lubricate the laminator A WARNING Do not lubricate the laminator when it is hot You can be burned A WARNING Unplug the laminator and lockout power while you are performing this procedure You could be severely shocked electrocuted or get your fingers caught in the drive mechanisms 1 Remove the drive and control side cabinet covers using the via hex wrench by removing the six screws holdin
12. image Very carefully wrap the print back and over the upper pull roll maintaining good print tension throughout the mounting process Be sure that there are no wrinkles in the nip area Carefully peel off the liner as the board progresses through the laminator Be careful not to hit the small lip on the fan bridge to avoid damaging the leading edge of the mounted image Trim the board and image to the finished size GBC Pro Tech 1999 January Operation Encapsulation This is the most commonly performed process Setup and Procedure 1 Adjust the machine settings as shown in process chart 3 6 and remove the infeed table Be sure that while heating the machine the rolls are together and turning 2 Install laminating film on the upper and lower unwinds 3 Web up the upper laminate by wrapping it around the upper film idler and laying it over the upper main roll Do not drape too much film Too much can fold over and leave a line of glue on the roll thereby affecting image quality A CAUTION Make sure that the adhesive side of the laminate is away from the roll to prevent an extensive clean up job 4 Web up the lower film by wrapping it around the lower film idler and bringing it up to the upper main roll Tack it to the upper laminating film 5 Insert a leader board into the nip and lower the upper main roll Press the footswitch Once the leader board is through the nip release the foot swit
13. located Motor Board in bolted cabinets e Redundant circuit protected safety shielding e Hand crank for laminating roll movement e Emergency stop buttons with a reset button circuit Options e Unwind for rolled prints e Rewind for rolled prints e Vacuum table e Outfeed Slitters e Outfeed Table Installation 220VAC 50 or 60 Hz single Requirement phase 30A or in Europe 3 phase 240 400 VAC with 20A per phase GBC Pro Tech 1999 January 6 1 Specifications F 36 PRO Laminator Operation Manual Blank page 6 2 GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual Index Index L A Laminate adhesives 3 4 Laminating material 6 1 Accessory pack 2 3 Laminating opening 6 1 Adjusting bolt 4 5 4 6 Laminating rolls 6 1 Laminating speeds 6 1 C Lubrication 4 7 Chain Lubrication 4 7 M Tensioning 4 6 Main roll Clutch Lower 4 5 Common problems 4 8 Main rolls 4 1 4 5 Controls Temperature 4 1 Front control panel 3 2 Maintenance schedule 4 1 Motor 2 8 4 6 E Mounting and laminating one pass 3 5 Emergency stop buttons 1 1 2 8 3 1 Mounting only 3 6 Encapsulating 6 1 N Encapsulation 3 8 Environment 2 1 Nip 1 1 1 2 2 6 2 8 3 1 4 1 4 4 4 5 4 6 F O Film 3 4 Outfeed slitters 6 1 Loading 3 3 Outfeed table 6 1 Positioning 3 4 Foot bolt 2 4 2 5 P Footswitch l 1 1 2 2 8 3 1 4 1 4 4 6 1 Paper 3 5 FWD REV switch 4 4 Photoelectric eye 2 7 2 8 3 1 G Power reguirement 2 1 Preinstallation checklist 2 1 Grease
14. raise the heat setting of the laminator by approximately 20 F and increase the motor speed by one third Process Control Charts 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 prod uct and process Process control charts are an excellent tool for training new operators They provide a road map for correct machine setup and operation This section contains a blank process control chart and diagram for the F 36 PRO Laminator as well as com pleted charts for the basic operations of the laminator GBC Pro Tech laminators respond in a very accurate and repeatable manner The charts provide a way to set up each time every time for repeatable performance by assuring that all controls are set to optimum Operation The process control charts should be kept in this man ual or in a book close to the laminator Use the machine to encapsulate the popular charts so they can withstand food and coffee spills and so they are always available for ready reference i NOTE When trying new products and processes remember that GBC Pro Tech s customer service representatives are only a phone call away In North America call 1 800 236 8843 The completed process control charts included in this section are based on Falcon Film Falcon Board and typical prints Mounting and Laminating One Pass Setup and Procedure 1 Adjust t
15. you are performing this pro cedure 2 Remove the drive and control side cabinet covers with the e hex wrench by removing the six screws holding each cover in place 3 Using the handwheel lower the upper main roll until there is a small gap of light between the upper and lower main rolls 4 Loosen the jamnut on the nip adjusting bolt on each side of the laminator as shown in Figure 4 4 amp Adjusting Bolt Jamnut Figure 4 4 Adjusting the Nip GBC Pro Tech 1999 January Maintenance and Troubleshooting 5 Adjust the nip by turning the adjusting bolt using an 34 open end wrench clockwise to lower the roll end and counter clockwise to raise the roll end Adjust the ends of the upper main roll until there is an even gap between the rolls as shown in Figure 4 5 Properly Set Nip Distance Between Rolls is Equal i Figure 4 5 Properly Set Nip 6 Hold the adjustment bolt in place while tightening the jamnut on each side of the laminator 7 Replace both cabinet covers and reconnect power to the laminator Chain Tensioning Adjusting the chain tension on the F 36 PRO Lamina tor is a simple procedure that keeps the system running smoothly and maximizes the efficiency of the motor Tools required EN hex wrench e 3 16 hex wrench e Screwdriver To adjust the chain tension 1 Unplug the laminator and make sure it won t be plugged back in while you are performing this pro
16. 230 F 110 C Drive Mode Manual or Auto Bottom Heater Status OFF Pull Roll Position DOWN Speed 3 4 ft min Output Cooling OFF Drive Direction FWD Main Roll Setting DOWN 1 2 turn PROCESS CONTROL DIAGRAM 3 5A O C rm Notes 3 14 GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual Operation PROCESS CONTROL CHART 3 5B Two Pass Mount and Hot Overlaminate Second Pass MATERIALS Upper Media N A Image Media N A Lower Media N A Mounting Substrate Foam Core LAMINATOR SETTINGS Top Heater Status OFF Drive Mode Manual Footswitch Bottom Heater Status OFF Pull Roll Position DOWN Speed 2 3 ft min Output Cooling OFF Drive Direction REV Main Roll Setting UP PROCESS CONTROL DIAGRAM 3 5B CAUTION Do not allow foam board to drop below Fan Bridge Lip Encapsulated Image O Release Liner O O _ ep AE Notes GBC Pro Tech 1999 January 3 15 Operation F 36 PRO Laminator Operation Manual PROCESS CONTROL CHART 3 6 Encapsulation MATERIALS Upper Media 3 mil Gloss Image Media Bond Paper Lower Media 3 mil Gloss Mounting Substrate N A LAMINATOR SETTINGS Top Heater Status ON 230 F 110 C Drive Mode Manual or Auto Bottom Heater Status ON 230 F 110 C Pull Roll Position DOWN Speed 3 6 ft min
17. F 36 PRO Operation and Maintenance Manual 1999 GBC Pro Tech Do not duplicate without written permission GBC Pro Tech 4151 Anderson Road De Forest Wisconsin 53532 Tel 608 246 8844 Part Number 930 026 Fax 608 246 8645 F 36 PRO Laminator Operation 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 merchantabil ity for any particular use GBC Pro Tech reserves the right to make changes to this publication and to the products described in it without notice All specifications and information concerning products are subject to change without notice Reference in this publication to information or products protected by copyright or patent does not convey any license under the rights of GBC Pro Tech or others GBC Pro Tech assumes no liability arising from infringements of patents or any other rights of third par ties This manual is copyrighted 1999 by GBC Pro Tech All rights reserved The information contained in this manual is proprietary and may not be reproduced stored transmitted or transferred in whole or in part in any form without the prior and express written permis sion of GBC Pro Tech GBC Pro Tec
18. OLL HEATER CONTROLLER Provides a readout of the temperature of the upper roll and the set point for the desired temperature LOWER ROLL HEATER CONTROLLER Provides a readout of the temperature of the lower roll and the set point for the desired temperature Red Set point has s not been reached Green Temperature is exactly at set point Solid Temperature is within 5 of set point Blinking Temperature is greater than 5 of set point Off Set point has been reached or exceeded 150 me 200 VII p pe Ny Solid Temperature is within 5 of set point Blinking Temperature is lower than 5 of set point Off Set point has been reached or exceeded 50 a PROTECH F 001133 LO Figure 3 3 Heater Controller 9 AUTO STOP Turns the drive system on or off 10 MOTION CONTROL FORWARD REVERSE Controls the direction of the drive system forward reverse or stop A WARNING Use extreme caution when operating the laminator with the footswitch The guard system is overridden and your fingers can get caught in the nip You can be crushed or burned GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual Footswitch Operation The footswitch on the F 36 PRO Laminator operates much like the accelerator on an automobile When the mechanical guard is removed use the footswitch to feed material into the laminator at the rate you select by pressing the footswitch The more pres
19. You can be injured by inhaling chemical vapors Vapor build up or stored flammable liquids can cause a fire Excessive dust can damage the laminator Akon 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 Do not use a knife or other sharp instrument during installation or while servicing the laminator You can cause irreparable damage to the rolls CAUTION A WARNING Raise the upper main roll when the laminator is not in operation Prolonged contact can damage the rolls A CAUTION Excess pressure can damage the laminating rolls Always select the minimum roll pressure necessary to complete the task 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 The F 36 PRO Laminator is a large and heavy piece of equipment It is necessary to employ LICENSED RIGGERS ONLY to move the machine 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 GBC Pro Tech s warranty does not cover malfunction of the equipment due to mishandling and or tipping GBC Pro Tech bears no responsibility for per
20. able outlet that does not require 240V You can be severely shocked electrocuted or cause a fire A WARNING Never insert objects of any kind through any of the slots on the laminator You can touch dangerous voltage points or short out parts You can be severely shocked electrocuted or cause a fire ALWAYS USE GOOD SAFETY PRACTICES WHEN OPERATING OR SERVICING THE LAMI NATOR AND KNOW HOW TO REACT QUICKLY IN AN EMERGENCY Caution Warning Label Locations Posted at various locations on your F 36 PRO Lamina tor are important safety labels PAY CAREFUL ATTENTION TO THESE LABELS AT ALL TIMES Figure 1 2 shows the location of each of these labels GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual Safety AWARNING 240 VOLTS 240 VOLTS A WARNING A WARNING MISE EN GARDE Figure 1 3 Locations of Safety Labels GBC Pro Tech 1999 January 1 5 Safety F 36 PRO Laminator Operation Manual The following are typical safety hazard decals used on GBC Pro Tech machines with a brief description Mean ing column of each decal AWARNING A ACHTUNG A MISE EN GARDE WARNING MISE EN GARDE WARNING SAFETY INSTRUCTIONS SICHERHEITS RICHTLINIEN CONSIGNES DE S CURIT Moving parts ca
21. aintenance and Troubleshooting Use Your Other Hand to Provide Gently Bend Support At Rivets Figure 4 1 Adjusting the Thermocouple Once installed the critical point of the thermocouple MUST make direct contact with the roll as shown in Figure 4 2 Thermal Junction Figure 4 2 Correct Thermocouple Contact A CAUTION Firmly hold the thermocouple where the guitar pick sensor is riveted to the aluminum base while bending You can break the sensor off the base if you do not provide this added support 5 Replace the thermocouple and tighten the screws 6 Repeat the procedure for the other thermocouple F 36 PRO Laminator Operation Manual GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual Maintenance and Troubleshooting Tube to Frame Thermocouple Wire gt Upper Main A Roll 11 Thermocouple Wire Routed Through to Control Side Thermocouple Lower Main Roll Underside fA Laminator Figure 4 3 Locations of the Thermocouples GBC Pro Tech 1999 January 4 3 Maintenance and Troubleshooting To clean the laminator rolls 1 Remove the infeed table and infeed pressure plate to gain access to the rolls A warno Exercise extreme caution while cleaning the laminator You can be caught in the turning rolls and crushed or burned 2 While the laminator is at normal operating temper ature put on the rubber glov
22. al Two Pass Mount and Laminate Cold Overlaminate For this process the image is first encapsulated and then mounted Setup and Procedure Pass 1 1 Adjust the machine settings as shown in process chart 3 4a and remove the infeed table 2 Web up the overlaminate by bringing it around the upper film idler and up to the release paper rewind Tape the film to the rewind and give it one full wrap around the rewind tube Be sure to check the process control chart to ensure correct web up 3 With a singe edge razor cut across the film on the rewind tube being sure not to cut through the release liner or the rolls A WARNING Use extreme caution when using the single edge razor not to damage the rolls or cut yourself 4 Peel the film back and drape it over the upper main roll To get enough material to do this it may be necessary to turn the rewind tube by hand 5 Pull the mount film straight up from the lower unwind position Tack it to the laminate Be careful not to stick the film or mount adhesive to the machine 6 Insert a starter board into the nip and lower the upper main roll onto it 7 Press the footswitch Once the leader board is through the nip lower the upper main roll and then rotate the crank 1 2 a turn more 8 Reinstall the infeed table You can operate with or without the pull rolls at this point 9 Encapsulate the images GBC Pro Tech 1999 January F 36 PRO Laminator Ope
23. ards you The rolls should stop Replace the guard so that the switch is engaged The laminator should resume operation A WARNING Never operate the laminator unless the guard system is functioning properly You can be crushed or burned LI Is the motor functioning Test the motor at various speeds ranging from 0 18 At 0 the rolls should stop turning Run the motor in both forward and reverse Li Are the heaters working Verify that the top heater controller heats the top roll and the bottom heater controller heats the bot tom roll F 36 PRO Laminator Operation Manual A Is the footswitch operating Test the footswitch for both forward and reverse operation Verify that the footswitch overrides the photoelectric eye by pressing the footswitch and pushing an object as large as your hand into the nip area Once you have completed the startup checklist you can safely run a test sample GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual Section 3 Operation Safety GBC Pro Tech laminators are powerful machines that are designed to mount laminate and encapsulate The forces required to accomplish these tasks can vary from negligible to very large The spring system used to provide downward pressure on the top roll is capable of producing forces greater than 1000 pounds 454kg This force is applied to any object presented in the opening called the nip between the two rolls In add
24. ature is greater than 5 of set point Off Set point has been reached or exceeded Solid Temperature is within 5 of set point Blinking Temperature is lower than 5 of set point Off Set point has been reached or exceeded 300 01 133 LO 5 PROTECH Figure 3 5 Heater Controller 5 It will take approximately 15 minutes for the lami nating roll s to reach operating temperature When the preset operating temperature has been reached the machine is ready to use 3 4 GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual Cooling The following procedure is the fastest way to cool the machine Natural cooling can also be used 1 Set the heater switches to OFF 2 Leave the cooling system ON 3 Lower the upper main roll until the laminating rolls are touching 4 Set the Forward Reverse switch to FWD Set the speed control to 2 Let the machine run until the laminating rolls return to room temperature t Note In the change over from hot to pressure sensitive mate rials it is not necessary to return the laminator to full cold With the rolls slightly heated 115 F cold films do not exhibit the phenomenon of silvering Paper Tips 1 Always cut the leading edge of a print straight so it can be fed perpendicular to the laminating rolls 2 Ink Jet prints done on high gloss paper might not bond or might experience bubbles called pud dling To solve this problem
25. be severely shocked electrocuted or cause a fire Secure long hair so that it cannot get caught in the machinery 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 you can be choked crushed or burned A WARNING Use extreme caution when operating the laminator with the footswitch The guard is overridden and your fingers can get caught in the nip You can be crushed or burned a Reset _9 Power Off and Lockout Switch Figure 1 2 Rear of Control Cabinet Lock Out Power Switch GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual A WARNING Safety A CAUTION Do not use liquid or aerosol cleaners on the laminator Do not spill liquid of any kind on the laminator You can be severely shocked electrocuted or cause a fire Use only a damp cloth for cleaning the cabinet A WARNING Exercise care when cleaning the rolls with 80 isopropyl alcohol e Use only in a well ventilated area e Wear rubber gloves e Use only on cool rolls Cleaning heated rolls can ignite the fumes A CAUTION If silicone adhesive contacts the upper or lower roll remove it IMMEDIATELY using 80 isopropyl alcohol It can harden within an hour and ruin the roll A WARNING The operating environment must be free of dust flammable liquids and vapors
26. cessory pack should contain 1 Set hex wrenches 1 Slitting knife 1 Manual 1 Set spare fuses 1 Tape measure 1 Roll of masking tape 1 Rubber cement eraser GBC Pro Tech 1999 January Installation Foot Bolt Shipping Pad Figure 2 3 The Foot Bolts 5 Remove the screws holding the foot pads onto the pallet using the Phillips head screwdriver 6 Have the laminator lifted off the skid and placed on the floor by licensed riggers The riggers must also unscrew the foot bolts from the laminator frame since it requires lifting the laminator A 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 The F 36 PRO Laminator is a large and heavy piece of equipment It is necessary to employ LICENSED RIGGERS ONLY to move the machine 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 GBC Pro Tech s warranty does not cover malfunction of the equipment due to mishandling and or tipping GBC Pro Tech bears no responsibility for personal injury or damage due to moving the laminator improperly 7 Once the laminator is in place set the locking mechanism on all four wheels to ON 8 Remove any plastic strapping and packing paper taped to the rolls F 36
27. ch Lower the roll 1 2 a turn past the initial contact of the upper laminating roll with the lower 6 Press the footswitch until the leader board is through the pull rolls and lower the upper pull roll Reinstall the infeed table 7 Encapsulate the image F 36 PRO Laminator Operation Manual Machine Shutdown It is very important that the F 36 PRO Laminator is shut down in proper manner If not the laminating rolls can be damaged or destroyed A CAUTION Failure to follow this procedure can result in damage to the rolls Procedure 1 Turn off the main power to the machine 2 Raise the main laminating roll at least one inch 3 Put the output roll into the upright position A CAUTION The laminating and output rolls must always be in the up position when the machine is not in use GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual Operation PROCESS CONTROL CHART MATERIALS Upper Media Image Media Lower Media Mounting Substrate LAMINATOR SETTINGS Top Heater Status Drive Mode Bottom Heater Status Pull Roll Position Speed Output Cooling Drive Direction Main Roll Setting PROCESS CONTROL DIAGRAM Identification Diagram Notes GBC Pro Tech 1999 January 3 9 Operation F 36 PRO Laminator Operation Manual PROCESS CONTROL CHART 3 2 One Pass Mounting and Laminating
28. eing used Other Common Problems Feed Problem Blistering in the image Hints Increase speed or lower the operating temperature Problem Coiling of encapsulated images Hints e Balance the upper and lower unwind brake tension Make sure main roll temperatures are the same Adjust cooling fans Problem Longitudinal waves or stuttering jerking or excessive noise from the drive side of the laminator Hints e Increase chain tension decrease unwind brake tension 4 8 GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual Section 5 Warranty Limited Warranty 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 GBC Pro Tech s sole and exclusive liability and the customer s sole and exclusive remedy under this warranty shall be at GBC Pro Tech s option to repair or replace any such defective part or prod uct These remedies are only available if GBC Pro Tech s examination of the product discloses to GBC Pro Tech s satisfaction that such defects actually exist and were not caused by misuse neglect attempt to repair unauthorized alteration or modi fication incorrect line voltage contaminated air supply or by fire accident flood or other hazard
29. es and using a rubber cement eraser remove any heat activated adhesive from the rolls A CAUTION F 36 PRO Laminator Operation Manual To clean beads of adhesive dust and dirt from the rolls 1 Allow the laminator to cool slightly to no higher than 110 F 43 C 2 Set the FWD REV switch to the REV position and use the footswitch to move the rolls as you clean them Set the Speed Control to 1 5 ft min 3 Clean the rolls using a moderate amount of 80 isopropyl alcohol on a cotton terry cloth A 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 If silicone adhesive contacts the upper or lower roll remove it IMMEDIATELY using a rubber cement eraser It can harden within an hour and ruin the roll A WARNING A CAUTION Do NOT pick or pull heat activated adhesive off the rolls when they are cold You can cause irreparable damage to the laminating rolls Exercise care when cleaning the rolls with 80 isopropyl alcohol e Use only in a well ventilated area e Wear rubber gloves e Use only on cool rolls Cleaning heated rolls can ignite the fumes A 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 roll
30. f the lamina tor Either of these if engaged stops the laminator To continue operation both emergency stop buttons must be in the up position GBC Pro Tech 1999 January Safety Push either Twist and pull up button to stop the both buttons to laminator resume operation w q 5 O Q a uyy 4015 Figure 1 1 Using the Emergency Stop Buttons Despite the safety features built into the F 36 PRO Laminator extreme caution must be used when operat ing or servicing the unit READ THE FOLLOWING WARNINGS AND CAUTIONS BEFORE YOU ATTEMPT TO OPERATE OR SERVICE THE F 36 PRO LAMINATOR A WARNING F 36 PRO Laminator Operation Manual A CAUTION ALWAYS CHECK THE TEMPERATURE SENSORS PRIOR TO OPERATION The sensors must be clean and have free view of the roll to maintain proper roll operating temperatures The rolls can overheat and cause a fire or seriously damage the laminator A WARNING Always use care in lowering the top laminating roll You can be crushed or burned A WARNING Do not operate the laminator near water You can be severely shocked electrocuted or cause a fire 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 A DANGER WARNING Unplug the laminator from the wall outlet and lockout power switch before servicing You can
31. fittings 4 7 Pressure Laminator roll 3 3 H Process control charts 3 5 Handwheel 2 6 4 5 R Heater 2 8 Controller 2 8 Riggers 1 3 2 4 2 5 2 6 Heating 3 4 I Infeed table 4 4 Installation requirements 2 1 6 1 GBC Pro Tech 1999 January 7 1 Index S Safety features 6 1 Safety information 1 1 Safety labels 1 4 Setup 3 3 Setup procedure 2 6 Shutdown 3 8 Specifications Dimensions 6 1 Encapsulating 6 1 Laminating material 6 1 Laminating opening 6 1 Laminating rolls 6 1 Laminating speeds 6 1 Weight 6 1 T Technical support Call 1 800 236 8843 4 7 Thermocouple 4 1 4 2 4 3 Locations 4 3 thermocouple 4 1 Two pass mount and laminate 3 6 3 7 U Unpacking 2 3 Cardboard box 2 3 Crate 2 5 Upper main roll 1 3 2 6 4 5 4 6 Upper main roll assembly 2 6 V Vacuum table 6 1 W Warnings and cautions 1 1 Warranty 5 1 F 36 PRO Laminator Operation Manual 7 2 GBC Pro Tech 1999 January
32. g each cover in place 2 Using the grease gun lubricate each grease fitting shown in Figure 4 7 with one squirt of high tem perature grease Maintenance and Troubleshooting Grease Fittings Figure 4 7 Grease Fittings 3 Lubricate the chain using a soft cloth and automo tive oil 4 Replace the cabinet covers and reconnect power to the laminator Contacting Technical Support 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 For film and application questions in North America please call 1 800 236 8843 In Europe please call 44 0 1844 202 440 or fax 44 0 1844 202 441 GBC Pro Tech 1999 January Maintenance and Troubleshooting F 36 PRO Laminator Operation Manual Output Troubleshooting Guide Se Problem D waves in the image not in the laminate Hints e Check paper tension e Check relative moisture content of the paper S Problem Waves on only one side of the output Hints e Check nip settings e Check for even paper tension Direction o ee p Problem Straight waves in the output Problem D waves in the laminate Hints Increase clutch tension e Check roll pressures e Check nip settings Hints e Decrease clutch tension e Check operational settings for materials b
33. h 1999 January F 36 PRO Laminator Operation Manual Table of Contents Section 1 Safety common 1 1 Caution Watning Label Locations EE 1 4 Section 2 Installation ene EEERERKEREEEREEERERKEEEEEREERER ER KEE ER EEREE ER EE RER ER EEEER EE KREE 2 1 Preinstallation ee E 2 1 Unpacking EE 2 3 CUD EE 2 6 AU A A A 2 8 Section 3 Operation EE KEE eens EE ia iaia ie eee 3 1 e 3 1 Operator COMMONS E 3 2 Front Control Panelis uzasne delete medion 3 2 ut te Ee 3 3 TE 3 3 Laminator Roll Pressure eenegen 3 3 Loading the nn DEE 3 3 Recommended Materials E 3 4 Films Excluding Vinyl Transfer and Overlamination i 3 4 Positioning the un EE 3 4 Heating lecitina I R EK 3 4 COUN bo se sete ate ested lia eee EP edt anon 3 5 ee 3 5 Process ege RE 3 5 Mounting and Laminating One Pass 3 5 Setup and Procede asa 3 5 MOLI OA o da 3 6 SOUP and Gei 3 6 Two Pass Mount and Laminate Cold Overlaminate i 3 6 Setup and Procedure Pass druida A nee 3 6 Setup and Procedure Pass d s sa EE ee aoe 3 7 Two Pass Mount and Laminate Hot Cverlammaiel 3 7 Sel and Procedure Passa AAA aaa 3 7 Sel and Procedure Passiria 3 7 Encapsulation PE ee nd 3 8 Selup and Procedilre sillaba 3 8 GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual Een ET ele Un EE 3 8 PROC Eeer 3 8 Section 4 Maintenance and Troubleshooting mmmmmmmmmmemmmenmennnennnn 4 1 Thermocouple Positioning and Cleaning
34. he machine settings as shown in process chart 3 2 A WARNING Do not operate the laminator without the infeed table installed on the machine D Load the film onto the upper unwind assembly 3 Insert Orca board adhesive side down in between the rolls Lower them until they contact with the board Turn the crank another 1 4 of a turn Set the machine to reverse and remove the board by acti vating the motor Do not adjust the roll crank after setting the nip Reset the machine to forward oper ation 4 Web the film by wrapping it around the upper film idler and draping it over the upper main roll Have about six inches laying on the infeed table 5 With a leader board of the same thickness as the mounting board make sure the leader board is also as wide as the film being used press the foot switch and insert the leader board into the nip square to the rolls Thin input from the film should lay flat on the upper main roll Stop feeding once the back edge of the board is one inch from the nip GBC Pro Tech 1999 January Operation 6 Lay the image onto the adhesive side of the Falcon Board Tacking the image down with a tacking iron at this point is sometimes helpful 7 Push the Falcon board and image up against the leader board and press the footswitch Be sure to maintain paper tension throughout this procedure 8 Once the board is through the nip and it no longer continues to feed disengage the f
35. ing sure they are clean There are two thermocouples that control the temperature of the main rolls If a ther mocouples loses contact with its roll the roll can over heat and be seriously damaged or can even start a fire Therefore it is absolutely critical that both thermocou ples be clean and positioned properly before operating the laminator and it should become second nature to check their condition prior to applying power to the laminator age Monthly Adjust the nip e Check the chain tension A WARNING e Inspect the area around the laminator for possible hazards dust buildup Do not attempt to adjust the position of the combustible items stored too close thermocouples if the rolls are hot You can be etc seriously burned Every Six Lubricate the grease fittings and Months chain To adjust a thermocouple 1 Locate the thermocouple to be adjusted using the illustration in Figure 4 3 2 Remove the two screws securing the thermocouple to the laminator using the we hex wrench and take the thermocouple out 3 Inspect the thermocouple If there is any adhesive or dirt on the thermocouple gently clean it off with 80 isopropyl alcohol and a cotton terry cloth 4 Grasp the aluminum base of the thermocouple on either side of the rivets to provide support as shown in Figure 4 1 Using your fingers gently bend the thermocouple where the guitar pick sensor meets the aluminum base GBC Pro Tech 1999 January M
36. ition the laminating rolls of the F 36 PRO Lami nator can reach temperatures of over 200 F 100 C At these temperatures there is a danger of a severe burn if the rolls are touched during set up operation or ser vicing An important feature of the laminator is the photoelec tric eye system that stops the machine when objects move into the nip area Once the blocking object is removed and the light beam reestablished the rolls resume turning However this system is overridden if you use the footswitch A WARNING Use extreme caution when operating the laminator with the footswitch The guard system is overridden and your fingers can get caught in the nip You can be crushed or burned The F 36 PRO Laminator has a steel cabinet that is bolted closed to isolate the electrical and drive system components for the safety of the operator Only a quali fied service technician should open these cabinets The laminator is equipped with two emergency stop buttons located on the top of either side of the lamina tor Either of these if engaged stops the laminator To continue operation both emergency stop buttons must be in the up position Operation Push either Twist and pull up button to stop the both buttons to laminator resume operation Ze S o o V gt de 5 Gei 43uyy goss P 43yyy 40 Figure 3 1 Using the Emergency Stop Buttons Despite the safety features built into the F 36 PRO Laminato
37. l settings for any laminates image material combination GBC Pro Tech Technical Sup port is available at the number provided in the Mainte nance chapter for advice on some material combinations Positioning the Film The following procedure is applicable to both the top and bottom feed unwinds 1 Secure the braking film mount arm so as to center the film between the side cabinets 2 Loosen the core support film mount arm and slide it to the drive side of the machine 3 Install the laminating film onto the braking mount arm and slide the core support arm over to support the laminating film s end 4 Secure the support arm F 36 PRO Laminator Operation Manual Heating Use the following instructions when heating one or both of the laminating rolls The procedure is the same for the top and bottom heaters Set the heater switch to ON Adjust the temperature controller for the desired operating temperature using the temperature con troller dial adjustment 3 When heating the rolls keep the top roll down and turning at a moderate speed to prevent uneven heating The temperature controllers have LED light emit ting diode readouts on the rotary dial to indicate the status of the heating system See Figure 3 5 to learn about the readouts 1 Red Set point has js lu II ie not been reached 125 K x Green Temperature is exactly at set point Solid Temperature is within 5 of set point Blinking Temper
38. lectrician wire the laminator directly to a power source The laminator requires 30A single phase service and a power receptacle that accepts a 30A 250V NEMA L6 30P plug or in Europe 3 phase 240 400 VAC with 20A per phase See Figure 2 6 for power cord connection options 8 Replace both cabinet covers Installation EUROPEAN LINE 1 3 PHASE Y z LINE 3 AN THE EUROPEAN THREE PHASE STAR LINE 1 LINE 2 LINE 3 N LINE 1 SINGLE PHASE U S A JUMPER LINE 2 U S SINGLE PHASE JUMPER LINE 1 LINE 2 Figure 2 6 Power Cord Connection GBC Pro Tech 1999 January Installation Startup 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 Startup Checklist Start the laminator and go through the following check list Q Are the emergency stop buttons working Push down on one of the emergency stop buttons The laminator should stop Rotate and pull up on the button Press the Reset button then press RUN on the control panel The laminator should resume operation Always check both buttons A WARNING Never operate the laminator unless both of the emergency stop buttons are functioning properly You can be crushed or burned LI Is the guard working With the laminator running pull the guard tow
39. n crush and cut Do not operate with guard or door open WARNING Crush and burn hazard Stay clear of moving rollers Stop machine and raise roll before cleaning WARNING Carefully read Operator s Manual before handling this machine Observe instructions and safety rules when operating WARNING HAZARDOUS VOLTAGE lt 100 PSI 2700 KPa To be serviced only by trained and authorized personnel Lockout power before servicing CAUTION Surface is hot A burn hazard exists CAUTION Rolls are heavy Use proper lifting techniques to prevent injury Meaning WARNING Read and understand the Operation Manual and all safety labels before operating this machine Only a trained person is to be permitted to operate this machine Training should include instruction in operation under normal conditions and emergency situations This machine is to be serviced only by trained and authorized personnel Follow lockout procedures before servicing Never reach into the machine for any reason unless the machine is ata COMPLETE STOP Never leave the machine stopped in such a manner that another worker can start the machine while you are working on or within the machine Never change or defeat the function of electrical interlocks or other machine shutdown switches Before starting this machine check that All persons are clear of the machine No maintenance work is being performed on
40. ootswitch and raise the main roll With a knife cut the laminate on the infeed side Pull the mounted image through the pull rolls Do this quickly so as to eliminate the possibility of getting adhesive on the machine ce NOTE You can run more than one image and board during a run of this process Feed one board after another until complete Make sure that the edge of the board being fed into the nip is pushed up against the rear edge of the board already in the nip area Mounting Only This process varies only slightly from the One Pass Mount and Laminate process Setup and Procedure 1 Adjust the machine settings as shown in process chart 3 3 2 Insert Falcon Board adhesive side down into the nip Lower the upper main roll until it contacts and then turn it another 1 4 turn Press the footswitch to remove the board from the nip 3 Lay the image onto the adhesive side of the Falcon Board Tacking the image down with a tacking iron at this point is sometimes helpful 4 Press the footswitch and carefully insert the board and image into the nip Be sure to keep it perpen dicular to the laminating rolls and maintain paper tension throughout the process t Note Some images will release toner or ink to the upper lam inating rolls If this happens clean immediately with alcohol To prevent this problem a sheet of paper can be used to cover the image during the mounting pro cess F 36 PRO Laminator Operation Manu
41. op 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 machine into position A second person must support the side labeled 5 in Figure 2 4 It can fall and damage the laminator Do not use a knife or other sharp instrument during installation or while servicing the laminator You can cause irreparable damage to the rolls Figure 2 4 Removing the Crate 2 Gently unwrap the shrink wrap from around the laminator Carefully remove any accessories packed with the laminator The accessory pack should contain 1 Set hex wrenches 1 Slitting knife 1 Manual 1 Set spare fuses 1 Tape measure 1 Roll of masking tape 1 Rubber cement eraser Foot Bolt Shipping Pad Figure 2 5 The Foot Bolts Remove the screws holding the foot pads onto the pallet using the Phillips head screwdriver Have the laminator lifted off the skid and placed on the floor by licensed riggers The riggers must also unscrew the foot bolts from the laminator frame since it requires lifting the laminator GBC Pro Tech 1999 January Installation A 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 The F 36 PRO Laminator is a large and heavy piece of equipment It is necessary to employ LICENSED
42. r extreme caution must be used when operat ing or servicing the unit GBC Pro Tech 1999 January Operation Operator Controls The operator controls for the F 36 PRO Laminator are located on the front of the unit to the right of the oper ator position The names and functions of these con trols are as follows Front Control Panel o Power Indicator Roll Pressure Display 2 7 Upper Roll Heat 4 of Upper Roll Heater ON OFF SR Controller 3 o ES Lower Roll Heat En or Lower Roll Heater ON OFF E Controller Cooling Fan 9__ AUTO STOP 8 10 gt See Speed Adjustment PR P 10 Motion Control Le FORWARD REVERSE Figure 3 2 Front Control Panel 1 ROLL PRESSURE DISPLAY Displays the percentage of pressure pushing the main roll down 2 UPPER ROLL HEAT ON OFF Turns the heater controller for the upper main roll on or off 3 LOWER ROLL HEAT ON OFF Turns the heater controller for the lower main roll on or off 4 COOLING FANS ON OFF Turns the cooling fans on or off and turns the vacuum table fans on or off when a vacuum table option is installed 5 SPEED ADJUSTMENT Adjusts the speed of the machine from zero to the maximum as the con trol is turned clockwise Turtle is slow rabbit is fast 6 POWER INDICATOR Indicates when the main power is being applied to the machine F 36 PRO Laminator Operation Manual 7 UPPER R
43. r phase See Figure 2 6 for power cord connection options A CAUTION Preinstallation Checklist LI Are doorways and hallways wide enough for the laminator to be moved to the installation site LI Is there ample room for the laminator A work area must be established that allows for operation in both the front and the rear of the machine and provides space for efficient material flow Figure 2 1 shows a typical machine area lay out A Is the environment appropriate for the laminator The laminator requires a clean dust and vapor free environment to operate properly such as an air conditioned office area with forced 10 make up air However the laminator must not be located where there is air blowing directly on it Major fluctuations in temperature and humidity are to be avoided A WARNING Position the jumpers as shown in Figure 2 6 for service choice The operating environment must be free of dust flammable liquids and vapors You can be injured by inhaling chemical vapors Vapor build up or stored flammable liquids can cause a fire Excessive dust can damage the laminator A 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 1999 January Installation F 36 PRO Laminator Operation Manual A Recommended clearance
44. rapped around the machine and completely sealed In addition moisture absorbing silicone desiccite packs are packed inside the crate and machine cabinets Prior to start up of the machine you must remove the desiccite packs from each cabinet and discard DO NOT operate the machine with the desiccite packs inside the cabinets Setup Once the F 36 PRO Laminator has been unpacked and moved into final position check each of the following items Tools required PA hex wrench e Adjustable wrench Setup Procedure 1 Inspect the laminator for any obvious shipping damage 2 Remove the drive and control side cabinet covers with the Bry hex wrench by removing the six screws holding each cover in place 3 Inspect all the bolts and tighten any that were loos ened during shipping 4 Check the upper main roll assembly by using the handwheel to raise and lower the roll It should move smoothly 5 Set the nip See Section 4 Maintenance and Trou bleshooting for the procedure 6 Verify that both sensors are clean and properly con tact the rolls GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual A WARNING ALWAYS CHECK THE SENSORS PRIOR TO OPERATION The sensors must be clean and contact the roll to maintain proper roll operating temperatures The rolls can overheat and cause a fire or seriously damage the laminator 7 Plug the laminator into an approved socket or have a certified e
45. ration Manual Setup and Procedure Pass 2 1 8 Adjust the machine settings as shown in process chart 3 4b Trim the print to size and trim the board to the size of the print Insert the board into the nip area and lower the main roll until it contacts Turn the crank another 1 4 of a turn and remove the board using the foot switch Clean the board with a tack cloth or cleaning roller Place the image face down on a flat surface and peel back the release liner on the leading edge about two inches Lay the image on the board and align it carefully When aligned tack the exposed adhesive strip s center to the leading edge to the board Work towards the edges from the center being careful not to wrinkle the image Position the piece so that the end with the liner peeled back is facing the nip Insert the first one inch of the board into the nip Very carefully wrap the print back and over the top laminating roll maintaining good print tension throughout the mounting process Be sure that there are no wrin kles in the nip area Carefully peel off the liner as the board progresses through the laminator Trim the board and image to the finished size Two Pass Mount and Laminate Hot Overlaminate This process is very similar to the Two Pass Mount and Laminate using cold overlaminate Setup and Procedure Pass 1 1 Adjust the machine settings as shown in process chart 3 5a and remove the infeed table
46. s 4 With the laminator rolls no hotter than 110 remove dust and dirt from the silicone laminating rolls by running an adhesive coated board through the lam inator Be sure to set the nip for the thickness of the board used 5 Allow the laminator to cool GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual To clean the cabinet and covers 1 Unplug the laminator to clean the exterior 2 Using adamp cotton terry cloth water only clean the exterior of the laminator A WARNING Do not use liquid or aerosol cleaners on the laminator Do not spill liquid of any kind on the laminator You can be severely shocked electrocuted or cause a fire Use only a damp cloth for cleaning A WARNING Do not use compressed air to clean the machine Blowing debris can be forced into places where it will later ignite or short electric circuits Maintenance and Troubleshooting Adjusting the Nip The gap between the two main rolls is called the nip The purpose of adjusting the nip is to ensure continu ous contact between the laminating rolls as the media is drawn through the machine This procedure must be done regularly Tools required b VC hex wrench e 2 4 open end wrenches To adjust the nip A CAUTION The main rolls must be at room temperature to achieve a proper nip setting 1 Unplug the laminator and make sure it won t be plugged back in while
47. sonal injury or damage due to moving the laminator improperly GBC Pro Tech 1999 January Safety A WARNING F 36 PRO Laminator Operation Manual A WARNING Connect the laminator only to the type of power source indicated on the label on the back of the laminator You can be severely shocked electrocuted or cause a fire If you are not sure of the type of power available consult the dealer or local power company A WARNING Do not attempt to defeat the grounding feature of the ground plug on the laminator You can be severely shocked electrocuted or cause a fire The three prong plug fits only into a grounding type power outlet If you are unable to insert the plug into the existing outlet contact a qualified electrician to replace the obsolete outlet A WARNING Do not use an extension cord on this laminator You can be severely shocked electrocuted or cause a fire If you need a longer cable contact a qualified electrician A WARNING Do not operate the laminator if the power cord is damaged or frayed You can be severely shocked electrocuted or cause a fire Contact a qualified electrician to replace the cord A WARNING Do not allow anything to rest on the power cord Do not locate the cord where people can walk on it You or others can be severely shocked electrocuted or cause a fire Do not attempt to plug any device into the vacuum t
48. sure you apply the faster the rolls turn When you remove pressure from the footswitch the rolls stop Material e Remove Guard Press Footswitch variable speed Figure 3 4 Using the Footswitch Setup Setup of the F 36 PRO Laminator is quick and straight forward when instructions are followed exactly To adjust the nip please see Section 4 Maintenance and Troubleshooting Laminator Roll Pressure Use only the minimum amount of roll pressure needed to accomplish the task While higher pressure can make the adhesive bond faster excess pressure can damage the rolls Wrinkles and bubbles have causes that gener ally cannot be cured by applying more pressure A CAUTION Excess pressure can damage the laminating rolls Minimum laminator roll pressure is consistent with good results Operation A typical roll pressure for soft substrates such as Foam core or Orca Board is 1 4 revolution of the laminating roll crank A typical roll pressure for hard substrates is 1 2 revolu tion of the laminating roll crank A typical roll pressure for encapsulation is 1 2 revolu tion of the laminating roll crank Loading the Film Film is loaded on the appropriate unwinds Loading and aligning the film are discussed later in this section For applications such as encapsulation film is fed from both the top and bottom feed unwinds The process of loading and aligning film is the same for both the top and
49. the bottom unwinds There are two important points to remember when loading film 1 The adhesive side of the film must be oriented away on the outside from the laminating roll Otherwise it will immediately bond to the roll creating a major clean up project 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 laminat ing roll A CAUTION Always mount the film so that the adhesive side faces outward from the laminating roll This prevents hours of roll cleaning 2 The film must be centered on the unwind for best performance This is vital when two films are fed together If the two films are not aligned feed problems wrinkles and other assorted troubles will occur A CAUTION Carefully align the two films being fed into the nip If not you will obtain poor results GBC Pro Tech 1999 January Operation Recommended Materials Films The F 36 PRO Laminator is capable of processing a wide range of pressure sensitive and thermal laminates onto an equally wide range of image materials The pri mary considerations are e Laminate adhesives are compatible with image materials e The materials properly activate below the maxi mum roll temperature and within the speed and roll nip pressure ranges available on the laminator It is the operator s responsibility to ensure the compati bility and operationa
50. trate N A LAMINATOR SETTINGS Top Heater Status ON 110 F 43 C Drive Mode Manual or Auto Bottom Heater Status OFF Pull Roll Position UP or DOWN Speed 4 6 ft min Output Cooling OFF Drive Direction FWD Main Roll Setting DOWN 1 2 turn PROCESS CONTROL DIAGRAM 3 4A Notes _ Release Liner Rewind Release Liner O ome 3 12 GBC Pro Tech 1999 January F 36 PRO Laminator Operation Manual Operation PROCESS CONTROL CHART 3 4B Two Pass Mount and Cold Pressure Overlaminate Second Pass MATERIALS Upper Media N A Image Media N A Lower Media N A Mounting Substrate Foam Core LAMINATOR SETTINGS Top Heater Status OFF Drive Mode Manual Footswitch Bottom Heater Status OFF Pull Roll Position UP Speed 2 6 ft min Output Cooling OFF Drive Direction FWD Main Roll Setting DOWN 1 4 turn PROCESS CONTROL DIAGRAM 3 4B Notes Hold Encapsulated Image Release Liner Image O Face an O ES Vo GBC Pro Tech 1999 January Operation F 36 PRO Laminator Operation Manual PROCESS CONTROL CHART 3 5A Two Pass Mount and Hot Overlaminate First Pass MATERIALS Upper Media 3 mil Gloss Image Media Bond Paper Lower Media Pro Mount Mounting Substrate N A LAMINATOR SETTINGS Top Heater Status ON
51. with the controls proper operation proper service procedures and safety fea tures of the laminator before using or servicing the unit Safety GBC Pro Tech laminators are powerful machines that are designed to mount laminate and encapsulate The forces required to accomplish these tasks can vary from negligible to very large The spring system used to provide downward pressure on the top roll is capable of producing forces greater than 1000 pounds 454kg This force is applied to any object presented in the opening called the nip between the two rolls In addition the laminating rolls of the F 36 PRO Lami nator can reach temperatures of over 200 F 100 C At these temperatures there is a danger of a severe burn if the rolls are touched during set up operation or ser vicing An important feature of the laminator is the guard that stops the machine when opened However this system is overridden if you use the footswitch A WARNING Use extreme caution when operating the laminator with the footswitch The guard is overridden and your fingers can get caught in the nip You can be crushed or burned The F 36 PRO Laminator has a steel cabinet that is bolted closed to isolate the electrical and drive system components for the safety of the operator Only a quali fied service technician should open these cabinets The laminator is equipped with two emergency stop buttons located on the top of either side o

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