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© 1999 GBC Pro-Tech
Do not duplicate without written permission
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F-60+™
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GBC Pro-Tech
4151 Anderson Road
De Forest, Wisconsin 53532
Tel: 608-246-8844
Part Number 930-028
Fax: 608-246-8645
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F-60+ Operation and Maintenance Manual
Caution/Warning Label Locations ................................................................................... 1-3
Preinstallation Checklist ..................................................................................................2-1
Unpacking .......................................................................................................................2-4
Setup .............................................................................................................................. 2-6
Leveling ..........................................................................................................................2-7
Startup ............................................................................................................................ 2-7
Safety ..............................................................................................................................3-1
Operator Controls ...........................................................................................................3-2
Front Control Panel .....................................................................................................3-2
Footswitch Operation ..................................................................................................3-2
Rear Control ................................................................................................................ 3-3
Setup .............................................................................................................................. 3-3
Laminator Main Roll Pressure ..................................................................................... 3-3
Laminator Pull Roll Pressure ......................................................................................3-3
Web Up Options .......................................................................................................... 3-3
Loading the Film .............................................................................................................3-4
Recommended Materials ................................................................................................3-4
Films ........................................................................................................................... 3-4
Positioning the Film ........................................................................................................ 3-4
Heating ........................................................................................................................... 3-5
Pull Roll Clutch Adjustment ............................................................................................3-5
Paper Tips ....................................................................................................................... 3-5
Process Control Charts ...................................................................................................3-6
Mounting Only .................................................................................................................3-6
Setup ........................................................................................................................... 3-6
Procedure ...................................................................................................................3-7
Mounting/Laminating ...................................................................................................... 3-7
Setup ........................................................................................................................... 3-7
Procedure ...................................................................................................................3-7
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F-60+ Operation and Maintenance Manual
Encapsulation ................................................................................................................. 3-7
Setup .......................................................................................................................... 3-7
Procedure ................................................................................................................... 3-7
Two-Pass Mount and Laminate (Hot and Cold) .............................................................. 3-7
Setup .......................................................................................................................... 3-7
Procedure, Pass 1 ...................................................................................................... 3-7
Procedure, Pass 2 ...................................................................................................... 3-8
Cleaning ......................................................................................................................... 4-1
Adjusting the Nip ............................................................................................................ 4-3
Chain Tensioning ............................................................................................................ 4-4
Lubrication ...................................................................................................................... 4-5
Contacting Technical Support ......................................................................................... 4-5
Output Troubleshooting Guide ........................................................................................ 4-6
Limited Warranty ............................................................................................................. 5-1
Exclusions to the Warranty ......................................................................................... 5-1
iv
© GBC Pro-Tech 1999 April
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F-60+ Operation and Maintenance Manual
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.
DO NOT ATTEMPT TO OPERATE YOUR
F-60+ LAMINATOR UNTIL YOU HAVE READ
THIS SECTION CAREFULLY!
GBC Pro-Tech F-60+ Laminator is a powerful machine
that is designed to mount, laminate and encapsulate.
The forces required to accomplish these tasks can vary
from negligible to very large.
Your safety, as well as the safety of others, is important
to GBC Pro-Tech. This section contains important
safety information.
In addition, the laminating roll of the F-60+ can reach
temperatures of 270 °F (132 °C). At these temperatures
there is a danger of a severe burn if the roll is touched
during set-up, operation or servicing.
The following symbols are used throughout this man-
ual to indicate warnings and cautions.
Safety is an important feature of the F-60+ Laminator.
It has emergency stop buttons and a mechanical guard
system on the infeed. In addition, the pull rolls are con-
tained in an enclosure to prevent injury.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury.
The laminator is equipped with four emergency stop
buttons located on the top front and back of either side
of the laminator. Any of these, if engaged, stops the
laminator. To continue operation all emergency stop
buttons must be in the up position and you must press
the reset button above the fuse panel on the back of the
laminator (see Figure 1-2). The laminator is also
equipped with a power lockout (see Figure 1-3) which
stops power to the machine.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in death or
serious injury.
Push either
button to stop the
laminator
Twist pressed
button to resume
operation - the
button pops up
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.
Figure 1-1: Using the Emergency Stop Buttons
© GBC Pro-Tech 1999 April
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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.
POWER
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.
WARNING
Do not operate the laminator near water. You can
be severely shocked, electrocuted or cause a fire.
Figure 1-2: Resetting the Laminator
Insert
Lock
DANGER
Remove and lock out power from the laminator
before servicing. You can be severely shocked,
electrocuted or cause a fire.
P
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WARNING
Circuit
Breakers
Secured in
"Off" Position
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.
Figure 1-3: Power Lockout
Despite the safety features built into the F-60+ Lamina-
tor, extreme caution must be used when operating or
servicing the unit. READ THE FOLLOWING
WARNINGS AND CAUTIONS BEFORE
ATTEMPTING TO OPERATE OR SERVICE THE
F-60+ LAMINATOR.
WARNING
Exercise care when cleaning the rolls with 80%
isopropyl alcohol:
• Use only in a well ventilated area.
• Wear rubber gloves.
• Use only on cool rolls.
Cleaning heated rolls can ignite the fumes.
1-2
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F-60+ Operation and Maintenance Manual
CAUTION
WARNING
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 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-60+ Laminator is a large and heavy piece
of equipment. It is necessary to employ
LICENSED RIGGERS ONLY to move the
machine. GBC Pro-Tech’s warranty does not
cover malfunction of the equipment due to
mishandling.
CAUTION
Raise the upper main roll when the laminator is
not in operation. Prolonged contact can damage
the rolls.
GBC Pro-Tech bears no responsibility for
personal injury or damage due to moving the
laminator improperly.
CAUTION
Excess pressure can damage the laminating rolls.
Always select the minimum roll pressure
necessary to complete the task.
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.
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.
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.
WARNING
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.
Always use good safety practices when operating or
servicing the laminator and know how to react quickly
in an emergency.
Posted at various locations on your F-60+ Laminator
are important safety labels. PAY CAREFUL ATTEN-
TION TO THESE LABELS AT ALL TIMES! Figure
1-4 shows the location of each of these labels.
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.
© GBC Pro-Tech 1999 April
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Safety
F-60+ Operation and Maintenance Manual
(Inside cabinet)
WARNING
ACHTUNG
MISE EN GARDE
WARNING
ACHTUNG
MISE EN GARDE
WARNING
ACHTUNG
MISE EN GARDE
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©1994 Hazard Communication Systems, Inc. 800-748-0241
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Figure 1-4: Locations of Safety Labels
1-4
© GBC Pro-Tech 1999 April
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F-60+ Operation and Maintenance Manual
The following are typical safety hazard decals used on GBC Pro-Tech machines, with a brief description (“Mean-
ing” column) of each decal.
Decal
Meaning
Decal
Meaning
WARNING!
WARNING!
WARNING
ACHTUNG
MISE EN GARDE
SAFETY
INSTRUCTIONS
Moving parts can
crush and cut.
1. Read and understand the Operation Manual and
all safety labels before operating this machine.
2. Only a trained person is to be permitted to operate
this machine. Training should include instruction
in operation under normal conditions and
emergency situations.
3. This machine is to be serviced only by trained and
authorized personnel. Follow lockout procedures
before servicing.
SICHERHEITS-
RICHTLINIEN
Do not operate with
guard or door open.
CONSIGNES DE
SÉCURITÉ
4. Never reach into the machine for any reason unless
the machine is at a COMPLETE STOP.
5. 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.
6. Never change or defeat the function of electrical
interlocks or other machine "shutdown" switches.
7. Before starting this machine, check that:
- All persons are clear of the machine.
- No maintenance work is being performed on
the machine.
WARNING!
WARNING
WARNING
ACHTUNG
MISE EN GARDE
Crush and burn
ACHTUNG
hazard. Stay clear of
moving rollers. Stop
machine and raise roll
before cleaning.
MISE EN GARDE
or
- 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.
WARNING!
WARNING
ACHTUNG
MISE EN GARDE
Carefully read
8. 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.
Operator's Manual
before handling this
machine. Observe
instructions and safety
rules when operating.
CAUTION!
Air pressure must be less than 100 PSI (700 kPa) to
avoid damaging the machine.
WARNING!
≤ 100 PSI
HAZARDOUS
VOLTAGE.
≥ 700 KPa
©1997 HCS, Inc. 800-748-0241 No. 6101-52BVPK
or
To be serviced only by
trained and authorized
personnel.
Reset.
©1994 Hazard Communication Systems, Inc. 800-748-0241
Lockout power before
servicing.
WARNING!
S
CAUTION!
Surface is hot.
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).
or
E
O
A burn hazard exists.
Electric power disconnect and lock out location.
CAUTION!
Rolls are heavy.
Use proper lifting
techniques to prevent
injury.
© GBC Pro-Tech 1999 April
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Safety
F-60+ Operation and Maintenance Manual
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F-60+ Operation and Maintenance Manual
Installation
CAUTION
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.
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.
❏ Is there an appropriate power outlet available or
has a certified electrician been contacted to wire
the laminator directly?
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 prein-
stallation checklist are met before beginning installa-
tion.
The laminator requires 60A single phase, 220/230/
240 VAC service or, in Europe, 3 Phase, 240 VAC
with 30 Amps per phase. See Figure 2-2 for alter-
native power hookup configurations.
CAUTION
WARNING
Failure to follow the preinstallation checklist can
result in damage to the laminator.
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.
❏ Are doorways and hallways wide enough for the
laminator to be moved to the installation site?
❏ 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.
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.
❏ 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
fluctuation in temperature and humidity are to be
avoided.
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.
WARNING
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.
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.
© GBC Pro-Tech 1999 April
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Installation
F-60+ Operation and Maintenance Manual
Wall
4' x 6' (~1.22 m x 2 m)
Work Table
on Wheels
Table Height
35-3/4"
(~.94 - .95 m)
8'2"
(~2.5 m)
Electrical
Supply
78" (~2 m)
Rear
3' (~1 m)
20'
38.5"
(~.6 m) (~.97 m)
Front
4' x 6' (~1.22 m x 2 m)
Work Table
on Wheels
Table Height
35-3/4"
(~.94 - .95 m)
8'2"
(~2.5 m)
13' (~4 m)
Figure 2-1: Laminator Space Requirements
2-2
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F-60+ Operation and Maintenance Manual
Installation
Single Phase
Power
Configuration
Jumper Bar
NORMAL AND
RECOMMENDED
CONFIGURATION
Blue Wire
L6
L4
L2
L5
L3
L1
Blue Wire
Blue Wire
Red Wire
Red Wire
Red Wire
Hot Lead
220/240
Volts
120
Volts
Hot Lead
Delta 3 Phase
Power
Configuration
Ground
120
Volts
Copper/Ground Wire
Jumper Bar
Jumper Bar
Blue Wire
L6
L4
L2
L5
L3
L1
Jumper Bar
Blue Wire
220/240
Volts
Blue Wire
Red Wire
Red Wire
Red Wire
Hot Lead “A”
220/240
Volts
Hot Lead “B”
Hot Lead “C”
Ground
220/240
Volts
Copper/Ground Wire
Jumper Wire
Wye 3 Phase For
European Models
Power Configuration
Jumper Bar
Removed
Blue Wire
L6
L4
L2
L5
L3
L1
Blue Wire
Blue Wire
Red Wire
Red Wire
Red Wire
Hot Lead
220/240
Volts
220/240
Volts
Hot Lead
Hot Lead
Neutral
220/240
Volts
Ground
Copper/Ground Wire
Jumper Bar
Figure 2-2: Alternative Power Configurations
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Installation
F-60+ Operation and Maintenance Manual
2. There are two hold down bridges that are con-
nected to sides 4 and 5. Remove the hold down
bridges and then remove sides 4 and 5.
☞ 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 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.
CAUTION
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 machine
into position.
The F-60+ Laminator is shipped in a wood crate on a
skid.
A second person must support the side
labeled (5) in Figure 2-3. It can fall and damage
the laminator.
WARNING
3. The ramps are attached to the skid. Remove them
and set them aside for later installation.
The unpacking process requires at least two
people. You can be severely injured or crushed.
Tools required:
•
•
Phillips head screwdriver
Adjustable wrench
Heaters
2" x 4"
Saddle
2" x 4"
Saddle
To uncrate the laminator:
Skid
1. Remove the top of the crate and sides 2 and 3 as
shown in Figure 2-3.
Skid
Lag Bolt
2" x 4"
Skid
1
Lag Bolt
5
3
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Install
Screws
I
Saddle
Figure 2-4: Skid Configuration
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CAUTION
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.
Figure 2-3: Removing the Crate
2-4
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F-60+ Operation and Maintenance Manual
Installation
4. Carefully remove the accessory pack from the skid.
The accessory pack should contain:
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 2-3).
1 Slitting knife
1 Manual
11. Have the machine moved off the skid and placed
on the floor by licensed riggers.
1 Set, spare fuses
1 Roll of masking tape
1 100% cotton terry cloth
4 Leveling pads
Roll the machine off by securing included ramps to
the edge of the crate bottom using the screws left
over from the crate disassembly (See Figure 2-3).
Lift the machine off by applying fork lift truck
blades to the two bottom tie bars between the cabi-
nets. The fork lift blades must be located at the lift
label locations on the tie bars (see Figure 2-5).
5. Locate the foot switch so as to prevent the foot
switch wire from being damaged during removal of
the machine from the skid.
WARNING
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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. Steps 6 through 11 should be
completed by LICENSED RIGGERS ONLY.
I
The F-60+ Laminator is a large and heavy piece
of equipment. It is necessary to employ
LICENSED RIGGERS ONLY to move the
machine.
100
90
80
70
60
50
40
30
20
10
CAL
3200
CAL
3200
4
5
3
6
7
2
1
2
8
9
10
F-60+™
GBC Pro-Tech bears no responsibility for
personal injury or damage due to moving the
laminator improperly.
Fork Lift Label
Locations
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6. The machine is supported above the skid by resting
on a support saddle under each end of the machine.
Remove the three long two by fours that attach to
the support saddles.
Figure 2-5: Fork Lift Blade Locations
12. Remove any plastic strapping and packing paper
taped to the rolls.
7. On one side of the machine, remove the lag bolts
holding the support saddle to the skid.
8. Using two of the two by fours as levers, carefully
lift the end of the machine enough to allow the sad-
dle to be removed from the skid and the machine to
rest on its wheels.
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. Repeat Steps 7 and 8 for the other end of the
machine.
13. Remove all packing materials to a safe distance
from the laminator.
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Installation
F-60+ Operation and Maintenance Manual
9. Using the 3/8" hex wrench, remove the bottom
☞ 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.
screws holding the rear table under the pull rolls.
Collect the screws and spacers for reuse. Pivot the
table up into position behind the pull rolls and
secure in place by installing the bolts into the top
set of cabinet holes. Be sure the spacers are in posi-
tion!
14. Level the laminator using the procedure later in
this section.
Once the F-60+ Laminator has been unpacked and
moved into final position check each of the following
items.
Tools required:
Lower
Hole in
Cabinet
•
•
1/8" hex wrench
7/32" hex wrench
•
•
3/8" hex wrench
Adjustable wrench
Figure 2-6: Installing the Rear Table
Setup Procedure:
1. Inspect the laminator for any obvious shipping
damage.
2. Using a 1/8" hex wrench, remove the screws secur-
ing the cabinet panel to the control (electrical) side
of the machine.
3. Using a 7/32" hex wrench, remove the pull roll
height adjust crank from the drive side of the
machine.
4. Using a 1/8" hex wrench, remove the screws secur-
ing the cabinet panel to the drive side of the
machine.
5. Inspect all the bolts and tighten any that were loos-
ened during shipping.
6. Set the nip. (See Maintenance for the procedure.)
7. Replace both cabinet covers.
8. Replace the pull roll height adjust crank.
2-6
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F-60+ Operation and Maintenance Manual
Installation
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.
Tools required:
•
•
Adjustable wrench
Carpenter's level
Startup Checklist
To level the laminator:
Start the laminator and go through the following check-
list.
1. Raise each end, remove the castors and install a
leveling pad and stud onto each of the foot brackets
at the four bottom corners of the laminator. Thread
third nut on stud below cabinet.
❏ 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 and push the reset button on the lower
back of the laminator. The laminator should
resume operation. Always check all buttons.
2. Thread stud into 4 leveling pads and lock down
with nut. Thread second nut onto stud.
3. Place a carpenter's level front to rear across the two
lower tie bars at one end of the machine.
4. Level this end of the machine front to rear, raising
or lowering the leveling pads by adjusting the mid-
dle nuts on the foot bolts.
WARNING
Never operate the laminator unless all of the
emergency stop buttons are functioning properly.
You can be crushed or burned.
5. Move the level to the other end of the machine and
level front to rear.
6. Place the level directly on one of the tie bars and
level the machine side to side.
❏ Are the guard table switches working?
7. Recheck the front to rear level condition to insure
that it has not changed. If it has, repeat the leveling
procedure.
With the laminator running, pull the front guard
towards you. The rolls should stop. Move the guard
back in. Press the RUN button on the front control
panel. The laminator should resume operation.
8. When all the measurements indicate that the
machine is level, tighten down the top nuts on the
foot brackets to lock the pads in their current posi-
tion.
WARNING
Never operate the laminator unless the
mechanical guard system is operating properly.
You can be crushed or burned.
❏ Is the footswitch working?
Press the footswitch. The laminator should start
operation. Vary the speed using the footswitch (like
an automobile accelerator) to ensure that the foot-
switch is operating properly at various speeds.
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Installation
F-60+ Operation and Maintenance Manual
WARNING
Use extreme caution when operating the machine
with the guard off. You can be crushed or
burned.
❏ Is the motor functioning?
Test the motor at various speeds ranging from
0-15. At 0 the rolls should stop turning.
Run the motor in both forward and reverse.
❏ Are the heaters working?
Verify that the heater controller heats the top roll.
☞ NOTE
The bottom roll heater controller must be turned on
before the top roll heater controller will energize the
top heater.
Once you have completed the startup checklist you can
safely run a test sample.
2-8
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F-60+ Operation and Maintenance Manual
Operation
Reset Button
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.
POWER
GBC Pro-Tech F-60+ Laminator is a powerful machine
that is designed to mount, laminate and encapsulate.
The forces required to accomplish these tasks can vary
from negligible to very large.
In addition, the laminating roll of the F-60+ can reach
temperatures of 270 °F (132 °C). At these temperatures
there is a danger of a severe burn if the roll is touched
during set-up, operation or servicing.
Safety is an important feature of the F-60+ Laminator.
It has emergency stop buttons and a photoelectric eye
system on the infeed.
Figure 3-2: Resetting the Laminator
The laminator is equipped with four emergency stop
buttons located on the top front and back of either side
of the laminator. Any of these, if engaged, stops the
laminator. To continue operation all emergency stop
buttons must be in the up position and you must press
the reset button above the fuse panel on the back of the
laminator (see Figure 3-2). The laminator is also
equipped with a power lockout (see Figure 3-3) which
stops power to the machine.
Insert
Lock
P
O
W
E
R
Circuit
Breakers
Secured in
"Off" Position
Push either
button to stop the
laminator
Twist pressed
button to resume
operation - the
button pops up
Figure 3-3: Power Lockout
Figure 3-1: Using the Emergency Stop Buttons
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Operation
F-60+ Operation and Maintenance Manual
6. UPPER ROLL HEAT ON/OFF – Turns the
heater controller for the upper main roll on or off.
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:
7. LOWER ROLL HEATER CONTROLLER–
Provides a readout of the temperature of the lower
roll and the set-point for the desired temperature.
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.
5
100
Indicates
10. POWER ON/OFF INDICATOR –
Upper Roll Heater
Controller
90
80
70
when the main power is being applied to the
machine.
CAL 3200
60
1
50
6
7
Roll
Pressure
Display
40
30
20
10
Upper Roll Heat
ON/OFF
Lower Roll Heater
Controller
CAL 3200
The footswitch can be used for feeding materials
through the main rolls (forward mode). Material speed
is controlled by the Control Panel Speed Adjustment
knob, resulting in constant speed operation when the
footswitch is pressed. The footswitch can also be used
for feeding materials through the pull rolls (reverse
mode). Material speed is controlled by the footswitch,
which operates much like the accelerator on an auto-
mobile.
8
Lower Roll Heat
ON/OFF
2
RUN/STOP/
EYE RESET
9
Cooling Fan ON/OFF
3
4
Motion Control
FORWARD/
REVERSE
5
6
7
4
3
8
10
2
9
Speed
Adjustment
Power On/Off
Indicator
1
10
Figure 3-4: Front Control Panel
CAUTION
1. ROLL PRESSURE DISPLAY - Displays the per-
centage of force pushing the main laminating roll
down.
When the footswitch is used the photoelectric eye
guarding the main rolls is turned off. Release the
footswitch to stop the machine rolls.
2. RUN/STOP/EYE RESET – Turns the drive sys-
tem on or off and resets the photoelectric eyes
when in automatic forward mode. The photoelec-
tric eyes do not function in reverse mode.
G
IN
N
R
A
G
W
N
U
T
H
C
R
D
E
A
A
G
E
N
I
S
E
M
3. MOTION CONTROL FORWARD/REVERSE -
Controls the direction of the drive system, forward,
reverse, or stop.
G
G
IN
N
R
A
W
N
U
T
H
C
R
D
E
A
A
G
E
N
I
S
E
M
Feed
Material
Into Nip
4. 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.)
100
90
80
70
60
50
40
30
20
C
A
L
3
1
0
2
0
0
CAL
3
200
4
5
3
6
2
1
7
2
8
9
10
™
+
0
-6
F
5. UPPER ROLL HEATER CONTROLLER –
Provides a readout of the temperature of the upper
roll and the set-point for the desired temperature.
PRO-TECH
Remove
Guard
Press Footswitch
(variable speed)
☞ NOTE
The bottom roll heater controller must be turned on
before the top roll heater controller will energize the
top heater.
Figure 3-5: Using the Footswitch
3-2
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F-60+ Operation and Maintenance Manual
Operation
The switch on the back of the drive cabinet starts and
stops the main rolls when pressed while guards are in
place.
The F-60+ Laminator has an adjustable roll pressure
for adjusting traction in the material across the width of
the material using the pull roll height adjust crank. The
same crank permits an infinite choice of gaps for board
mount applications.
Rear
RUN/STOP
Switch
Figure 3-6: Rear RUN/STOP Switch
Pull Roll
Clutch
Pull Roll
Height
Adjust
Crank
Setup of the F-60+ Laminator is quick and straightfor-
ward when instructions are followed exactly.
To adjust the nip, please see Maintenance.
Figure 3-7: Pull Roll Clutch and Pull Roll
Height Adjust Crank
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.
With the guard removed, move webs through the main
roll nip by:
1. Pressing the RUN button for a slow, constant main
roll rotation.
CAUTION
or
2. Pressing the STOP button, then pressing the foot-
switch to set the required speed. Releasing the
footswitch stops main roll rotation.
Excess pressure can damage the laminating rolls.
Minimum laminator roll pressure is consistent
with good results.
A typical roll pressure for soft substrates such as Foam-
core is between 30 to 40%.
The range of typical values for hard substrates is 30 to
50%.
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Operation
F-60+ Operation and Maintenance Manual
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 F-60+ Laminator is capable of processing a wide
range of pressure sensitive and thermal laminates onto
an equally wide range of image materials. The primary
considerations are:
The process of loading and aligning film is the same
for both the top and the bottom unwinds. There are two
important points to remember when loading film:
•
Laminate adhesives are compatible with image
materials.
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, cre-
ating a major clean-up project.
•
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 operational 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.
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.
CAUTION
CAUTION
Always mount the film so that the adhesive side
faces outward from the laminating roll. This
prevents hours of roll cleaning.
Substituting materials can cause severe damage
to your machine and is not recommended or
covered under our warranty.
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.
The following procedure is applicable to both the top
and bottom feed unwinds.
1. Open the top unwind by removing the pin and
swinging the arm out.
CAUTION
2. Load the film.
3. Return the arm to its locked position and reinsert
the locking pin.
Carefully align the two films being fed into the
nip. If not, you will obtain poor results.
4. Center the film on the unwind arm by measuring
the distance from the ends of the film to the sides
of the machine using a tape measure.
3-4
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F-60+ Operation and Maintenance Manual
Operation
Use the following instructions when heating one or
both of the laminating rolls. The procedure is the same
for the top and bottom heaters.
CAUTION
When the machine is not in use, the pull rolls
must be raised to prevent damaging the rolls.
1. Set the heater switch to ON.
2. Adjust the temperature controller for the desired
operating temperature using the temperature con-
troller push buttons.
Always feed prints perpendicular to the laminating
rolls.
3. When heating the rolls, keep the top roll down and
turning at a moderate speed to prevent uneven
heating.
1. Lock core support to middle of the shaft. Lock two
core chucks on shaft ends, located to support mate-
rial a few inches from ends of the roll.
4. It will take approximately 30 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.
☞ Note
Paper unwind may require two evenly spaced core sup-
ports if wide rolls of prints (paper) are used.
2. Place the roll on the unwind shaft.
3. Carefully close the unwind shaft, holding the roll
away from the hinge.
The F-60+ Laminator has an adjustable clutch for the
pull rolls on the machine, allowing you to adjust the
amount that the film is tensioned as it leaves the main
rolls and is cooled. The clutch adjustment is made by
using the knob on the drive side of the machine.
4. When the shaft is in the saddle, push in the locking
pin.
5. Center the roll of material.
6. Web and tension film per process control chart and
diagram.
Pull roll clutch tension adjustment:
Turning the knob clockwise increases tension.
Turning the knob counterclockwise decreases tension.
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Operation
F-60+ Operation and Maintenance Manual
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.
Brake
Adjustment
Knob
This section contains a blank process control chart and
diagram for the F-60+ as well as completed 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.
Core
Support
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.
Core
Chuck
☞ NOTE
When trying new products and processes, remember
that GBC Pro-Tech's customer service representatives
are only a phone call away.
The completed process control charts included in this
section are based on Orca-Film and typical prints.
LOWER UNWINDS
Figure 3-8: Brake Configuration
1. See process chart 3-1.
2. Set the nip to the thickness of the material being
used for mounting.
3. Upper Laminator Roll Pressure: 10–30%.
4. Speed: 3 fpm (1 m/min).
5. Upper Laminator Roll Heat: 240 °F (115 °C).
3-6
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F-60+ Operation and Maintenance Manual
Operation
1. Lay the print on the board. Using a tack iron, tack
the leading edge of the print down onto the board
so it is held in place.
1. See process chart 3-3.
2. Put a piece of contact/release paper over the print
and board. Otherwise, adhesive will be applied to
the laminating roll, which can cause damage and
the ink from electrostatic prints will be deposited
on the roll.
2. Laminating Roll Pressure: 30-40%.
3. Speed: 0-6 fpm (0-180 cpm).
4. Upper Laminator Roll Heat: 230 °F (110 °C).
5. Lower Laminator Roll Heat: 32 °F (0 °C).
6. Cooling: Optional.
3. Feed the print/board package through the nip.
7. Use of the rear wind-up roll for the finished mate-
rial is optional. It is a good procedure for long runs.
The following procedure is for one-step mounting and
heat-activated laminating using mounting board with
one adhesive side.
Feed the work into the nip with the leading edge tight
and entering the nip evenly from side to side. For thin
paper from electrostatic printers in roll form it is best to
fold over the leading edge approximately 6 inches to
create a square leading edge.
1. See process chart 3-2.
2. Mount the film and web as shown in diagram
3-2.
3. Set the nip for the substrate thickness by raising or
lowering the upper main roll using the hand crank.
There are several approaches to the mount/laminate
task. It can be accomplished with either hot or cold
laminate film on the top. Also, the second pass for
mounting can be done by feeding from either the front
or back of the laminator.
4. Laminator Roll Pressure: 10–30%.
5. Speed: 3 fpm (1 m/min).
6. Upper Laminator Roll Heat: 240 °F (115 °C).
1. Lay the print on the board. Using a tack iron, tack
the leading edge of the print down onto the board
so it is held in place.
See process charts 3-4, 3-5A & B, and 3-6A & B for
film mounting instructions and machine adjustments.
2. Feed the print/board package through the nip.
1. Run the print through to apply adhesive and lami-
nate.
2. Trim to slightly larger than the desired finished
size.
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Operation
F-60+ Operation and Maintenance Manual
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 mate-
rial 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 dur-
ing the next steps.
4. Raise one end of the print and peel back approxi-
mately two inches of the liner to expose the adhe-
sive that was applied to the print in the first pass.
Fold it under.
5. Lay the print back down evenly and extremely flat.
From the center outward, tack the exposed adhe-
sive to the substrate.
6. 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. Be
sure there are no wrinkles in the nip area. Carefully
peel off the liner as the board progresses through
the laminator.
7. Trim the piece to the finished size.
3-8
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F-60+ Operation and Maintenance Manual
Operation
352&(66ꢄ&21752/ꢄ&+$57
Product:_________________________ Process: __________________________ Date:________________
FRONT CONTROL SETTINGS
Speed:
Reverse/Forward:
Top Heater:
Roll Pressure:
Cooling:
Bottom Heater:
352&(66ꢄ&21752/ꢄ',$*5$0
Identification Diagram
(F)
Fixed Idler
U
R
(RI) Removable Idler
(U) Unwind Shaft
(R) Rewind
(UM) Upper Main Roll
(LM) Lower Main Roll
(UP) Upper Pull Roll
(LP) Lower Pull Roll
F
UM
LM
UP
LP
RI
F
F
U
U
R
© GBC Pro-Tech 1999 April
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Operation
F-60+ Operation and Maintenance Manual
352&(66ꢄ&21752/ꢄ&+$57ꢄꢇꢀꢈ
Product: _________________________ Process: One Pass Mounting___________ Date: ________________
FRONT CONTROL SETTINGS
Speed: 2-3 fpm (60-90 cpm)
Roll Pressure: Trial
Cooling: Off
Reverse/Forward: Forward
Top Heater: 240 °F (115 °C)
Bottom Heater: 32 °F (0 °C)
352&(66ꢄ&21752/ꢄ',$*5$0ꢄꢇꢀꢈ
One Pass Mounting
☞ NOTE
Footswitch may be used.
Printed
Image
Leader
Board
Falcon
Board
3-10
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F-60+ Operation and Maintenance Manual
Operation
352&(66ꢄ&21752/ꢄ&+$57ꢄꢇꢀꢉ
Product:_________________________ Process: One Pass Mount & Laminate __ Date:________________
FRONT CONTROL SETTINGS
Speed: 1-2 fpm (30-60 cpm)
Roll Pressure: Trial
Cooling: Off
Reverse/Forward: Forward
Top Heater: 240 °F (115 °C)
Bottom Heater: 32 °F (0 °C)
352&(66ꢄ&21752/ꢄ',$*5$0ꢄꢇꢀꢉ
One Pass Mount and Laminate
☞ NOTE
Footswitch may be used.
Printed
Image
Leader
Board
Falcon
Board
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Operation
F-60+ Operation and Maintenance Manual
352&(66ꢄ&21752/ꢄ&+$57ꢄꢇꢀꢇ
Product: 3 Mil Gloss/3Mil Gloss______ Process: Encapsulation _______________ Date: ________________
FRONT CONTROL SETTINGS
Speed: 0-6 fpm (0-180 cpm)
Roll Pressure: 30-60%
Cooling: Optional
Reverse/Forward: Forward
Top Heater: 230 °F (110 °C)
Bottom Heater: 230 °F (110 °C)
352&(66ꢄ&21752/ꢄ',$*5$0ꢄꢇꢀꢇ
Encapsulation
3-12
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F-60+ Operation and Maintenance Manual
Operation
352&(66ꢄ&21752/ꢄ&+$57ꢄꢇꢀꢊ
Product:_________________________ Process: Cold Overlamination _________ Date:________________
FRONT CONTROL SETTINGS
Speed: 0-6 fpm (0-180 cpm)
Roll Pressure: 30-60%
Cooling: Off
Reverse/Forward: Forward
Top Heater: 105 °F (40 °C)
Bottom Heater: 32 °F (0 °C)
352&(66ꢄ&21752/ꢄ',$*5$0ꢄꢇꢀꢊ
Cold Overlamination
Pro
Gloss
Release
Paper
Rewind
Optional
Craft
Paper
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Operation
F-60+ Operation and Maintenance Manual
352&(66ꢄ&21752/ꢄ&+$57ꢄꢇꢀꢋ$
Product: ______________________ Process: Cold Mount & Laminate (First Pass) Date: ________________
FRONT CONTROL SETTINGS
Speed: 0-6 fpm (180 cpm)
Roll Pressure: 30-60%
Cooling: Off
Reverse/Forward: Forward
Top Heater: 105 °F (40 °C)
Bottom Heater: 32 °F (0 °C)
352&(66ꢄ&21752/ꢄ',$*5$0ꢄꢇꢀꢋ$
Cold Mount and Laminate (First Pass)
Pro
Gloss
Release
Paper
Rewind
Optional
Pro
Mount
3-14
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F-60+ Operation and Maintenance Manual
Operation
352&(66ꢄ&21752/ꢄ&+$57ꢄꢇꢀꢋ%
Product:____________________ Process: Cold Mount & Laminate (Second Pass) Date:________________
FRONT CONTROL SETTINGS
Speed: 0-6 fpm (0-180 cpm)
Roll Pressure: Trial
Cooling: Off
Reverse/Forward: Forward
Top Heater: 32-105 °F (0-40 °C)
Bottom Heater: 32 °F (0 °C)
352&(66ꢄ&21752/ꢄ',$*5$0ꢄꢇꢀꢋ%
Cold Mount and Laminate (Second Pass)
☞ NOTE
Use footswitch to load, then accelerate materials through rolls.
Hold
Encapsulated
Image
Release Liner
(Peel prior to nip)
☞ OPTIONAL
Foam
Core
Board can be fed
through the pull
rolls using reverse
mode.
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Operation
F-60+ Operation and Maintenance Manual
352&(66ꢄ&21752/ꢄ&+$57ꢄꢇꢀꢁ$
Product: _________________ Process: Mount & Hot Overlaminate (First Pass)___ Date: ________________
FRONT CONTROL SETTINGS
Speed: 0-6 fpm (0-180 cpm)
Roll Pressure: 30-60%
Cooling: Optional
Reverse/Forward: Forward
Top Heater: 230 °F (110 °C)
Bottom Heater: 32 °F (0 °C)
352&(66ꢄ&21752/ꢄ',$*5$0ꢄꢇꢀꢁ$
Mount and Hot Overlaminate (First Pass)
3 Mil
Gloss
Optional
Pro
Mount
3-16
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F-60+ Operation and Maintenance Manual
Operation
352&(66ꢄ&21752/ꢄ&+$57ꢄꢇꢀꢁ%
Product:___________________ Process: Mount & Hot Overlaminate (Second Pass) Date:________________
FRONT CONTROL SETTINGS
Speed : 0-6 fpm (0-180 cpm)
Roll Pressure: Trial
Cooling: Off
Reverse/Forward: Forward
Top Heater: 32-105 °F (0-40 °C)
Bottom Heater: 32 °F (0 °C)
352&(66ꢄ&21752/ꢄ',$*5$0ꢄꢇꢀꢁ%
Mount and Hot Overlaminate (Second Pass)
☞ NOTE
Use footswitch to load, then accelerate materials through rolls.
Hold
Encapsulated
Image
Release Liner
(Peel prior to nip)
☞ OPTIONAL
Board can be fed
through the pull
rolls using reverse
mode.
Foam
Core
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Operation
F-60+ Operation and Maintenance Manual
Blank page.
3-18
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F-60+ Operation and Maintenance Manual
Maintenance and Troubleshooting
Tools required:
GBC Pro-Tech laminators require minimal mainte-
nance. However, regular maintenance is essential to
keep any piece of precision machinery at peak perfor-
mance. A maintenance schedule and a section of proce-
dures are included in this section.
•
•
•
•
•
Adhesive coated board
80% isopropyl alcohol (or dishwashing detergent)
Rubber cement eraser
Several 100% lint free paper or cotton terry cloths
Protective rubber gloves
Table 4-1: Maintenance Schedule
•
•
Clean the rolls
To remove heat activated adhesive from laminator
rolls:
Inspect the electrical cord for dam-
age
Daily
•
Inspect the footswitch cord for dam-
age
WARNING
•
•
•
Adjust the nip
Exercise extreme caution while cleaning the
laminator. You can be caught in the turning rolls
and crushed or burned.
Check the chain tension
Inspect the area around the laminator
for possible hazards (dust buildup,
combustible items stored too close,
etc.)
Monthly
While the laminator is still at normal operating temper-
ature (200-250 ºF), put on the rubber gloves and, using
a rubber cement eraser, remove any heat activated
adhesive from the rolls. Use “footswitch mode” and
slow speed to rotate the rolls in reverse.
•
•
Lubricate the grease fittings and
chain
EverySix
Months
Check wire termination tightness
CAUTION
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.
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.
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.
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Maintenance and Troubleshooting
F-60+ Operation and Maintenance Manual
To clean beads of adhesive, dust and dirt from the
rolls:
To clean the cabinet and covers:
1. Allow the laminator to cool slightly to no higher
than 110ºF (43ºC).
WARNING
2. Set the FWD/REV switch to the REV position.
Remove and lockout power from the laminator
while you are performing this procedure. You
could be severely shocked, electrocuted, or get
your fingers caught in the drive mechanisms.
3. Clean the rolls using a moderate amount of 80%
isopropyl alcohol on a cotton terry cloth.
1. Using a damp cotton terry cloth (water only), clean
the exterior of the laminator.
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.
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.
WARNING
Exercise care when cleaning the rolls with 80%
isopropyl alcohol:
• Use only in a well ventilated area.
• Wear rubber gloves.
• Use only on cool rolls.
Cleaning heated rolls can ignite the fumes.
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.
4. With the laminator rolls no hotter than 110ºF,
remove dust and dirt from the silicone laminating
rolls by running an adhesive-coated board through
the laminator. Be sure to set the nip for the thick-
ness of the board used.
5. Allow the laminator to cool.
4-2
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F-60+ Operation and Maintenance Manual
Maintenance and Troubleshooting
The gap between two rolls is called the nip.
The purpose of adjusting the nip is to ensure continu-
ous contact between the rolls as the media is drawn
through the machine. This procedure must be done reg-
ularly for the main rolls. It is not necessary to set the
nip on the pull rolls.
Lift
Assembly
Bolt
Jam
Nut
Properly Set Nip
(Distance Between
Rolls is Equal)
Figure 4-2: Nip Setting Assembly
Figure 4-1: Properly Set Nip
4. Adjust the nip so that there is an even line of light
across the width of the rolls.
Tools required:
5. Secure the jam nut on the lift assembly bolt.
6. Replace the cabinet cover.
•
•
1/8" hex wrench
¾" hex wrench
To adjust the main roll nip:
CAUTION
The main roll must be at room temperature to
achieve a proper nip setting.
1. Remove the left side cabinet cover with the 1/8"
hex wrench by removing the seven screws holding
the cover in place. Gently rotate the cover around
the clutch knob to allow access to the roll lift sys-
tem.
2. Lower the upper main roll so that there is a small
visible gap between it and the lower main roll.
3. Loosen the ¾" jam nut securing the lift assembly
bolt. Adjust the nip by rotating the lift assembly
bolt clockwise to raise the end being adjusted and
counterclockwise to lower it.
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Maintenance and Troubleshooting
F-60+ Operation and Maintenance Manual
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.
1/4" to
1/2" Play
Tools required:
•
•
1/8" hex wrench
7/32" hex wrench
1/4" to
•
•
3/16" hex wrench
1/2" Play
l
Screwdriver
Downward
To adjust the chain tension:
Force Tightens
i
Loosen
Motor
Mount
Bolts
Chain
i
WARNING
Remove and lockout power from the laminator
while you are performing this procedure. You
could be severely shocked, electrocuted, or get
your fingers caught in the drive mechanisms.
Figure 4-3: Adjusting the Chain Tension
5. 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 ¼" to ½"
play in the chain.
1. Remove the drive side cabinet cover using the 1/8"
hex wrench by removing the seven screws holding
the cover in place.
6. Tighten the mounting bolts while maintaining the
downward pressure on the motor.
2. Using a 7/32" hex wrench, remove the pull roll
7. Engage the top rewind chain tensioner and apply
pressure until its chain exhibits similar tension to
the primary chain tension.
height adjust crank from the drive side of the
machine.
3. Loosen the top rewind chain tensioner.
8. Engage the bottom rewind chain tensioner and
apply pressure until its chain exhibits similar ten-
sion to the primary chain tension.
4. Loosen all four motor mount bolts using the 3/16"
hex wrench as shown in the figure below. The
motor should just move freely within the slots.
9. Replace the cabinet cover.
10. Replace the pull roll height adjust crank.
11. Reapply power to the laminator.
4-4
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F-60+ Operation and Maintenance Manual
Maintenance and Troubleshooting
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.
Tools required:
•
1/8" hex wrench
•
•
High temperature grease or lithium grease
Grease gun
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.
To lubricate the laminator:
WARNING
Do not lubricate the laminator when it is hot. You
can be burned.
WARNING
Remove and lockout power from the laminator
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 1/8" hex wrench by removing the seven
screws holding each cover in place. Gently rotate
the cover around the clutch knob to allow access to
the lubrication points.
2. Using the grease gun, lubricate each grease fitting
with one squirt of high temperature grease.
3. Lubricate the chain using a soft cloth and automo-
tive oil.
4. Replace the cabinet covers, close the safety shields
and reapply power to the laminator.
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Maintenance and Troubleshooting
F-60+ Operation and Maintenance Manual
Problem:
Problem:
Problem:
D waves in the image, not in the D waves in the laminate.
Straight waves in the output.
laminate.
Hints:
Hints:
Hints:
• Check paper tension.
• Check relative moisture content • Check nip settings.
of the paper.
• Increase clutch tension.
• Decrease clutch tension.
• Check operational settings for
materials being used.
• Check roll pressures.
Other Common
Problems:
Feed
Direction
Problem:
Blistering in the image.
Hints:
• Increase speed or lower
the operating
temperature.
Problem:
Coiling of encapsulated
images.
Hints:
• Balance the upper and
lower unwind brake
tension. Make sure
main roll temperatures
are the same. Adjust
cooling fans.
Problem:
Problem:
Waves on only one side of the Angled waves on the output.
output.
Hints:
Hints:
• Check nip settings.
• Check for even paper tension. • Check for insufficient main roll
pressure
• Check for insufficient clutch
tension.
Problem:
Longitudinal waves or
stuttering, jerking, or
excessive noise from the
drive side of the laminator.
Hints:
• Increase chain tension,
decrease unwind brake
tension.
4-6
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F-60+ Operation and Maintenance Manual
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.
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.
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.
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,
3. Improper use of the machine.
attempt to repair, unauthorized alteration or modi-
fication, incorrect line voltage, contaminated air
supply, or by fire, accident, flood, or other hazard.
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.
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.
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Warranty
F-60+ Operation and Maintenance Manual
Blank page.
5-2
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F-60+ Operation and Maintenance Manual
Specifications
Table 6-2: Replacement Parts
Part
Number
Description
Recommended
Quantity
Table 6-1: F-60+ Laminator Specifications
001-374 Assembly, Force
Gauge PCB
1
1
1
Characteristic
Specifications
Dimensions
(L x D x H)
Uncrated: 80" x 38.5" x 57"
(202 x 84 x 145 cm)
001-505 Assembly, Force
Sensor
Crated: 90" x 44" x 68"
(202 x 84 x 145 cm)
001-515 Assembly, Control
PCB
Weight
Uncrated: 1200 lbs (544 kg)
Crated :1700 lbs (771 kg)
186-200 Fuse, SB, 3AG, 3A
214-313 Switch, Palm, E-stop
230-007 Temperature Control
425-003 Motor
3
1
1
1
1
1
1
1
1
Laminating Rolls
64" (163 cm) roll face with a
high release surface, upper and
lower rolls internally heated.
Laminating Material Uses pressure sensitive materi-
als up to 62 inches (158 cm)
wide and hot/heat activated
materials up to 61 inches (155
cm) wide on a 3-inch (7.6 cm)
inside diameter core, maxi-
mum roll diameter of 10 inches
(25.4 cm).
690-059 Roll, Rubber
189-032 Heater, Round
230-006 IR Sensor
860-014 Tube, Rewind Brake
Laminating Speeds
0 to 15 fmp (0 to 4.57 mpm)
with variable speed, reversible
action at slow speed (less than 3
ft/min (1 m/min)), start and
stop controlled either through
the instrument panel or with the
variable speed footswitch.
186-135 Fuse, 250V, 20A,
Ceramic
690-052 Roll, Pull, Upper
690-053 Roll, Pull, Lower
1
1
Heating
Capable of operating tempera-
tures of up to 270 ºF (132 ºC).
Safety Features
•
•
•
Redundant circuit pro-
tected safety shielding
Mechanical guards protect
main roll and pull roll nips
Four emergency stop but-
tons
Installation
Requirement
60A single phase, 220/230/240
VAC or, in Europe, 3 Phase,
240 VAC with 30 Amps per
phase.
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Specifications
F-60+ Operation and Maintenance Manual
Blank page.
6-2
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F-60+ Operation and Maintenance Manual
Index
Laminate adhesives 3-4
Laminating material 6-1
Laminating rolls 6-1
Laminating speeds 6-1
Leveling 2-7
Accessory pack 2-5
Adjusting
nip 4-3
Lubrication 4-5
Chain
Lubrication 4-5
Tensioning 4-4
Cleaning 4-1
Controls
Main rolls 4-3
Maintenance schedule 4-1
Motor 2-8, 4-4
Mounting 3-6
front control panel 3-2
Mounting/Laminating 3-7
Emergency stop buttons 1-1, 2-7, 3-1
Encapsulation 3-7
Nip 1-2, 2-6, 4-1, 4-2, 4-3
Environment 2-1
Extension cord 2-1
Paper 3-5
Power cord 2-1
Power requirement 2-1
Preinstallation checklist 2-1
Pressure
Film 3-4
loading 3-4
positioning 3-4
Footswitch 3-2, 4-1, 6-1
FWD/REV switch 4-2
laminator roll 3-3
Process control charts 3-6
Pull roll
clutch adjustment 3-5
Grease fittings 4-5
Ground plug 2-1
Resetting the laminator 1-1, 3-1
Riggers 1-3, 2-5
Rubber cement eraser 4-1
Heater 2-8
Controller 2-8
Heaters
Installing 2-6
Heating 3-5
Safety features 6-1
Safety information 1-1
Safety labels 1-3
Setup 3-3
Setup procedure 2-6
Specifications
Installation requirements 2-1, 6-1
Isopropyl alcohol 4-1
Dimensions 6-1
Laminating material 6-1
Laminating rolls 6-1
Laminating speeds 6-1
Weight 6-1
Startup checklist 2-7
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Index
F-60+ Operation and Maintenance Manual
Technical support
Call 1-800-236-8843 4-5
Two-pass mount and laminate 3-7
Unpacking 2-4
Crate 2-4
Upper main roll 1-3
Warnings and cautions 1-1
Warranty 5-1
7-2
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