ꢀꢁꢂꢃꢄꢅꢆꢇꢄꢇ ꢈꢉꢊꢋꢌꢍꢎꢄꢊꢎꢏꢄ
ꢐꢊꢌꢎꢋꢈꢎꢊꢎꢑꢈꢄꢐꢊꢎꢒꢊꢓ
© 1999 GBC Pro-Tech
Do not duplicate without written permission
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©1
GBC Pro-Tech
4151 Anderson Road
De Forest, Wisconsin 53532
Tel: 608-246-8844
Part Number 930-026
Fax: 608-246-8645
Download from Www.Somanuals.com. All Manuals Search And Download.
F-36 PRO Laminator Operation Manual
ꢔꢊꢕꢓꢈꢄꢍꢖꢄꢗꢍꢎꢋꢈꢎꢋꢘ
ꢙꢈꢑꢋꢌꢍꢎꢄꢚꢄꢛꢄꢙꢊꢖꢈꢋꢜ ꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢚꢁꢚ
Caution/Warning Label Locations.................................................................................... 1-4
ꢙꢈꢑꢋꢌꢍꢎꢄ ꢄꢛꢄ!ꢎꢘꢋꢊꢓꢓꢊꢋꢌꢍꢎ ꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝ ꢁꢚ
Preinstallation Checklist................................................................................................... 2-1
Unpacking........................................................................................................................ 2-3
Setup ............................................................................................................................... 2-6
Startup ............................................................................................................................. 2-8
ꢙꢈꢑꢋꢌꢍꢎꢄꢂꢄꢛꢄꢇ ꢈꢉꢊꢋꢌꢍꢎꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢂꢁꢚ
Safety............................................................................................................................... 3-1
Operator Controls ............................................................................................................ 3-2
Front Control Panel...................................................................................................... 3-2
Footswitch Operation....................................................................................................... 3-3
Setup ............................................................................................................................... 3-3
Laminator Roll Pressure .............................................................................................. 3-3
Loading the Film .............................................................................................................. 3-3
Recommended Materials................................................................................................. 3-4
Films (Excluding Vinyl Transfer and Overlamination) .................................................. 3-4
Positioning the Film .........................................................................................................3-4
Heating ............................................................................................................................ 3-4
Cooling............................................................................................................................. 3-5
Paper Tips........................................................................................................................ 3-5
Process Control Charts....................................................................................................3-5
Mounting and Laminating (One Pass) .............................................................................3-5
Setup and Procedure................................................................................................... 3-5
Mounting Only..................................................................................................................3-6
Setup and Procedure................................................................................................... 3-6
Two-Pass Mount and Laminate (Cold Overlaminate)...................................................... 3-6
Setup and Procedure, Pass 1......................................................................................3-6
Setup and Procedure, Pass 2......................................................................................3-7
Two-Pass Mount and Laminate (Hot Overlaminate)........................................................ 3-7
Setup and Procedure, Pass 1......................................................................................3-7
Setup and Procedure, Pass 2......................................................................................3-7
Encapsulation ..................................................................................................................3-8
Setup and Procedure................................................................................................... 3-8
© GBC Pro-Tech 1999 January
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F-36 PRO Laminator Operation Manual
Machine Shutdown.......................................................................................................... 3-8
Procedure .................................................................................................................... 3-8
ꢙꢈꢑꢋꢌꢍꢎꢄ"ꢄꢛꢄꢐꢊꢌꢎꢋꢈꢎꢊꢎꢑꢈꢄꢊꢎꢏꢄꢔꢉꢍꢒꢕꢓꢈꢘ#ꢍꢍꢋꢌꢎ$ꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝ"ꢁꢚ
Thermocouple Positioning and Cleaning......................................................................... 4-1
Adjusting the Nip ............................................................................................................. 4-5
Chain Tensioning............................................................................................................. 4-6
Lubrication....................................................................................................................... 4-7
Contacting Technical Support.......................................................................................... 4-7
Output Troubleshooting Guide......................................................................................... 4-8
ꢙꢈꢑꢋꢌꢍꢎꢄ%ꢄꢛꢄ&ꢊꢉꢉꢊꢎꢋꢜꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝ%ꢁꢚ
Limited Warranty.............................................................................................................. 5-1
Exclusions to the Warranty .......................................................................................... 5-1
ꢙꢈꢑꢋꢌꢍꢎꢄꢃꢄꢛꢄꢙ ꢈꢑꢌꢖꢌꢑꢊꢋꢌꢍꢎꢘ ꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢃꢁꢚ
ꢙꢈꢑꢋꢌꢍꢎꢄ'ꢛꢄ!ꢎꢏꢈ(ꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝ'ꢁꢚ
iv
© GBC Pro-Tech 1999 January
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F-36 PRO Laminator Operation Manual
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.
ꢙꢈꢑꢋꢌꢍꢎꢄꢚꢄꢛꢄꢙꢊꢖꢈꢋꢜ
DO NOT ATTEMPT TO OPERATE YOUR F-36
PRO LAMINATOR UNTIL YOU HAVE READ
THIS SECTION CAREFULLY!
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.
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 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.
The following symbols are used throughout this man-
ual to indicate warnings and cautions.
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.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury.
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.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in death or
serious injury.
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.
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 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.
The F-36 PRO 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 fea-
tures of the laminator before using or servicing the unit.
© GBC Pro-Tech 1999 January
1-1
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Safety
F-36 PRO Laminator Operation Manual
Push either
Twist and pull up
both buttons to
CAUTION
button to stop the
laminator
resume operation
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.
S
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Figure 1-1: Using the Emergency Stop Buttons
WARNING
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.
Always use care in lowering the top laminating
roll. You can be crushed or burned.
WARNING
Do not operate the laminator near water. You can
be severely shocked, electrocuted or cause a fire.
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.
DANGER
Unplug the laminator from the wall outlet and
lockout power switch before servicing. You can
be severely shocked, electrocuted or cause a fire.
WARNING
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.
Reset
Power Off
and
Lockout
Switch
GBC PRO-TECH ENGINEERING, INC.
Model No.
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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.
Figure 1-2: Rear of Control Cabinet Lock Out
Power Switch
1-2
© GBC Pro-Tech 1999 January
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F-36 PRO Laminator Operation Manual
Safety
WARNING
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.
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
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.
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.
CAUTION
Cleaning heated rolls can ignite the fumes.
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
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.
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.
CAUTION
Raise the upper main roll when the laminator is
not in operation. Prolonged contact can damage
the rolls.
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.
CAUTION
Excess pressure can damage the laminating rolls.
Always select the minimum roll pressure
necessary to complete the task.
GBC Pro-Tech bears no responsibility for
personal injury or damage due to moving the
laminator improperly.
© GBC Pro-Tech 1999 January
1-3
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Safety
F-36 PRO Laminator Operation Manual
WARNING
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.
Do not attempt to plug any device into the
vacuum table outlet that does not require 240V.
You can be severely shocked, electrocuted or
cause a fire.
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.
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.
ALWAYS USE GOOD SAFETY PRACTICES
WHEN OPERATING OR SERVICING THE LAMI-
NATOR AND KNOW HOW TO REACT QUICKLY
IN AN EMERGENCY.
ꢗꢊꢒꢋꢌꢍꢎ)&ꢊꢉꢎꢌꢎ$ꢄ*ꢊꢕꢈꢓꢄ*ꢍꢑꢊꢋꢌꢍꢎꢘ
WARNING
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.
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.
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
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.
1-4
© GBC Pro-Tech 1999 January
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F-36 PRO Laminator Operation Manual
Safety
WARNING
WARNING
ACHTUNG
ACHTUNG
MISE EN GARDE
MISE EN GARDE
WARNING
ACHTUNG
MISE EN GARDE
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240 VOLTS
LEM PRODUCTIONS, INC. DOYLESTOWN PA
LVM-240C
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©
240 VOLTS
LEM PRODUCTIONS, INC. DOYLESTOWN PA
LVM-240C
WARNING
ACHTUNG
MISE EN GARDE
©1994 Hazard Communication Systems, Inc. 800-748-0241
Figure 1-3: Locations of Safety Labels
© GBC Pro-Tech 1999 January
1-5
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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.
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.
1-6
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F-36 PRO Laminator Operation Manual
Installation
❏ Is there an appropriate power source available and
has a certified electrician been contacted to wire
the laminator directly?
ꢙꢈꢑꢋꢌꢍꢎꢄ ꢄꢛꢄ!ꢎꢘꢋꢊꢓꢓꢊꢋꢌꢍꢎ
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.
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.
CAUTION
CAUTION
Failure to follow the preinstallation checklist can
result in damage to the laminator.
Position the jumpers as shown in Figure 2-6 for
service choice.
ꢅꢉꢈꢌꢎꢘꢋꢊꢓꢓꢊꢋꢌꢍꢎꢄꢗ#ꢈꢑ+ꢓꢌꢘꢋ
❏ 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.
❏ 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.
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.
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
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Installation
F-36 PRO Laminator Operation Manual
Recommended
clearance
10'
(~3m)
4'6" (~1.1m)
2'2"
(~.7m)
3' (~1m)
10'
(~3m)
Figure 2-1: Laminator Space Requirements
2-2
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F-36 PRO Laminator Operation Manual
Installation
,ꢎ ꢊꢑ+ꢌꢎ$
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 in a
cardboard box on a skid.
WARNING
The unpacking process requires at least two
people. You can be severely injured or crushed.
Figure 2-2: Removing the Cardboard Box
2. Lift the cardboard box off the laminator.
3. Gently unwrap the shrink wrap from around the
laminator.
Tools required:
•
•
Phillips head screwdriver
7
/ " open end wrench or adjustable wrench
8
CAUTION
If the laminator is in a cardboard box:
Do not use a knife or other sharp instrument
during installation or while servicing the
laminator. You can cause irreparable damage to
the rolls.
1. Remove the securing screws around the bottom of
the box using the Phillips head screwdriver as
shown in Figure 2-2.
4. 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
© GBC Pro-Tech 1999 January
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Installation
F-36 PRO Laminator Operation Manual
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.
Foot Bolt
9. Remove all packing materials to a safe distance
from the laminator.
Shipping
Pad
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.
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.
☞ 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.
WARNING
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.
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
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.
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.
2-4
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F-36 PRO Laminator Operation Manual
Installation
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.
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.
CAUTION
Do not allow the top to fall into the crate. It can
damage the laminator.
3. Carefully remove any accessories packed with the
laminator. The accessory pack should contain:
1 Set, hex wrenches
1 Slitting knife
1 Manual
Do not put packing screws on the floor. They can
cause problems when trying to roll the machine
into position.
1 Set, spare fuses
1 Tape measure
1 Roll of masking tape
1 Rubber cement eraser
A second person must support the side labeled 5
in Figure 2-4. It can fall and damage the
laminator.
1
5
4
Foot Bolt
T
R
T
S
Y
U
R
C
N
E
G
G
E
N
C
R E
E
M
E
S
U
A
T
N
G
G
IN
N
R
A
W
N
U
T
H
C
A
M
I
S
E
EN
GARDE
D
E
S
Shipping
Pad
E
G
G
A
psi
100
kPa
90
80
70
60
50
40
30
20
10
700
630
560
490
420
350
280
210
140
70
OUT
Figure 2-5: The Foot Bolts
150
17
125
5
200
HI
0
225
75
PRO 50
TEC
H
°F
33 LO
0011
OUT
150
17
125
5
HI
100
5
75
0
PRO 50
TEC
H
°F
300
33 LO
001-1
2
6
8
10
12
4
2
48
6
0
18
3
4. Remove the screws holding the foot pads onto the
pallet using the Phillips head screwdriver.
W
A
R
N
A
IN
C
G
H
T
U
M
N
I
S
G
E
E
N
G
A
R
D
E
41
8-02
0-74
c
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Co
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d
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94
H
©19
5. 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.
Figure 2-4: Removing the Crate
2. Gently unwrap the shrink wrap from around the
laminator.
© GBC Pro-Tech 1999 January
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Installation
F-36 PRO Laminator Operation Manual
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.
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.
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.
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.
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.
ꢙꢈꢋꢒ
GBC Pro-Tech bears no responsibility for
personal injury or damage due to moving the
laminator improperly.
Once the F-36 PRO Laminator has been unpacked and
moved into final position check each of the following
items.
6. Once the laminator is in place set the locking
mechanism on all four wheels to ON.
Tools required:
1
•
•
/ " hex wrench
8
7. Remove any plastic strapping and packing paper
taped to the rolls.
Adjustable wrench
Setup Procedure
CAUTION
1. Inspect the laminator for any obvious shipping
damage.
Do not use a knife or other sharp instrument
during installation or while servicing the
laminator. You can cause irreparable damage to
the rolls.
2. Remove the drive and control side cabinet covers
1
with the / " hex wrench by removing the six
8
screws holding each cover in place.
3. Inspect all the bolts and tighten any that were loos-
ened during shipping.
8. Remove all packing materials to a safe distance
from the laminator.
4. Check the upper main roll assembly by using the
handwheel to raise and lower the roll. It should
move smoothly.
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.
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.
2-6
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F-36 PRO Laminator Operation Manual
Installation
WARNING
LINE 1
N
EUROPEAN
3–PHASE Y
A
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.
LINE 3
LINE 2
A
THE EUROPEAN
THREE-PHASE (STAR)
LINE–1
LINE–2
LINE–3
N
7. Plug the laminator into an approved socket or have
a certified electrician 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.
LINE 1
SINGLE PHASE (U.S.)
JUMPER
LINE 2
8. Replace both cabinet covers.
U.S. SINGLE PHASE
JUMPER
LINE 1
LINE 2
Figure 2-6: Power Cord Connection
© GBC Pro-Tech 1999 January
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Installation
F-36 PRO Laminator Operation Manual
❏ Is the footswitch operating?
ꢙꢋꢊꢉꢋꢒ
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.
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.
Once you have completed the startup checklist you can
safely run a test sample.
Startup Checklist
Start the laminator and go through the following check-
list.
❏ 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.
WARNING
Never operate the laminator unless both of the
emergency stop buttons are functioning properly.
You can be crushed or burned.
❏ Is the guard working?
With the laminator running, pull the guard towards
you. The rolls should stop. Replace the guard so
that the switch is engaged. The laminator should
resume operation.
WARNING
Never operate the laminator unless the guard
system is functioning properly. You can be
crushed or burned.
❏ 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.
❏ Are the heaters working?
Verify that the top heater controller heats the top
roll and the bottom heater controller heats the bot-
tom roll.
2-8
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F-36 PRO Laminator Operation Manual
Operation
ꢙꢈꢑꢋꢌꢍꢎꢄꢂꢄꢛꢄꢇ ꢈꢉꢊꢋꢌꢍꢎ
Push either
button to stop the
laminator
Twist and pull up
ꢙꢊꢖꢈꢋꢜ
both buttons to
resume operation
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.
S
S
M
M
E
C
E
C
R
R
N
N
G
G
E
E
E
E
N
G
G
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.
N
R U
'
R U
'
C
C
Y
Y
D
D
T
T
T
T
E
E
R
O
O
R
P
P
R
R
A
A
Figure 3-1: 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.
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 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.
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.
© GBC Pro-Tech 1999 January
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Operation
F-36 PRO Laminator Operation Manual
7. UPPER ROLL HEATER CONTROLLER –
Provides a readout of the temperature of the upper
roll and the set-point for the desired temperature.
ꢇ ꢈꢉꢊꢋꢍꢉꢄꢗꢍꢎꢋꢉꢍꢓꢘ
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:
8. LOWER ROLL HEATER CONTROLLER–
Provides a readout of the temperature of the lower
roll and the set-point for the desired temperature.
175
OUT
125
HI
150
200
Red: Set point has
not been reached
Solid: Temperature is
within 5° of set point
225
psi
100
90
80
70
60
50
40
30
20
10
kPa
700
630
560
490
420
350
280
210
140
70
6
Power
Indicator
Green: Temperature
is exactly at set point
Blinking: Temperature
is greater than 5° of set
point
1
100
75
250
275
Roll Pressure
Display
Off: Set point has been
reached or exceeded
50
PROTECH
300
001-133
Solid: Temperature is
within 5° of set point
175
OUT
125
HI
LO
150
200
°F
225
7
8
2
3
100
75
250
275
Blinking: Temperature is
lower than 5° of set point
Upper Roll Heater
Controller
Upper Roll Heat
ON/OFF
50
300
001-133
LO
PROTECH
°F
Off: Set point has been
reached or exceeded
175
OUT
150
HI
200
125
225
Lower Roll Heat
ON/OFF
Lower Roll Heater
Controller
100
75
250
275
50
PROTECH
300
001-133
LO
°F
Figure 3-3: Heater Controller
4
5
9
AUTO/STOP
Cooling Fan
ON/OFF
9. AUTO/STOP - Turns the drive system on or off.
10
8
12
6
4
48
16
10
10. MOTION CONTROL FORWARD/REVERSE -
Controls the direction of the drive system, forward,
reverse, or stop.
Speed Adjustment
Motion Control
FORWARD/REVERSE
2
0
18
Figure 3-2: Front Control Panel
1. ROLL PRESSURE DISPLAY – Displays the
WARNING
percentage of pressure pushing the main roll down.
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.
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.
3-2
© GBC Pro-Tech 1999 January
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F-36 PRO Laminator Operation Manual
Operation
A typical roll pressure for soft substrates such as Foam-
core or Orca Board is 1/4 revolution of the laminating
roll crank.
ꢀꢍꢍꢋꢘ-ꢌꢋꢑ#ꢄꢇ ꢈꢉꢊꢋꢌꢍꢎ
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 pressure you apply,
the faster the rolls turn. When you remove pressure
from the footswitch, the rolls stop.
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.
*ꢍꢊꢏꢌꢎ$ꢄꢋ#ꢈꢄꢀꢌꢓ.
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.
T
T
S
D
Y
R
C
N
E
G
G
E
N
C
R E
E
M
E
S
U
A
G
G
IN
N
R
A
W
N
U
T
H
E
ARD
C
A
G
E
IS
EN
M
G
G
IN
N
R
A
W
N
U
T
H
E
D
R
C
A
A
G
E
N
I
S
E
M
S
Y
U
R
C
N
E
G
G
E
N
C
R E
E
M
E
S
U
A
T
O
N
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:
psi
100
kPa
700
630
90
80
70
60
50
40
30
20
10
560
490
420
350
280
210
140
70
OUT
150
17
125
5
200
HI
225
75
5
PRO 50
TEC
H
275
°F
300
001-1
OUT
3
3
L
O
150
17
125
5
2
I
Feed
Material
Into Nip
100
75
PRO 50
TEC
H
°F
300
001-1
3
3
L
O
6
8
10
2
4
2
48
1
0
18
W
A
R
N
A
IN
C
G
H
T
U
M
N
G
I
S
E
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.
E
N
G
A
R
D
E
8-
0-74
0241
c
.
8
0
s, In
Sy
stem
n
atio
unic
Co
mm
d
azar
94
H
©19
Remove
Guard
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.
Press
Footswitch
(variable
speed)
Figure 3-4: Using the Footswitch
ꢙꢈꢋꢒ
CAUTION
Setup of the F-36 PRO Laminator is quick and straight-
forward when instructions are followed exactly.
Always mount the film so that the adhesive side
faces outward from the laminating roll. This
prevents hours of roll cleaning.
To adjust the nip, please see Section 4: Maintenance
and Troubleshooting.
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.
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.
CAUTION
Carefully align the two films being fed into the
nip. If not, you will obtain poor results.
CAUTION
Excess pressure can damage the laminating rolls.
Minimum laminator roll pressure is consistent
with good results.
© GBC Pro-Tech 1999 January
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Operation
F-36 PRO Laminator Operation Manual
ꢆꢈꢑꢍ..ꢈꢎꢏꢈꢏꢄꢐꢊꢋꢈꢉꢌꢊꢓꢘ
/ꢈꢊꢋꢌꢎ$
Use the following instructions when heating one or
both of the laminating rolls. The procedure is the same
for the top and bottom heaters.
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:
1. Set the heater switch to ON.
2. Adjust the temperature controller for the desired
operating temperature using the temperature con-
troller dial adjustment.
•
Laminate adhesives are compatible with image
materials.
3. When heating the rolls, keep the top roll down and
turning at a moderate speed to prevent uneven
heating.
•
The materials properly activate below the maxi-
mum roll temperature and within the speed and roll
nip pressure ranges available on the laminator.
4. 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.
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.
175
OUT
125
HI
150
200
Red: Set point has
not been reached
Solid: Temperature is
within 5° of set point
225
ꢅꢍꢘꢌꢋꢌꢍꢎꢌꢎ$ꢄꢋ#ꢈꢄꢀꢌꢓ.
Green: Temperature
is exactly at set point
Blinking: Temperature
is greater than 5° of set
point
100
75
250
275
The following procedure is applicable to both the top
and bottom feed unwinds.
Off: Set point has been
reached or exceeded
50
PROTECH
300
001-133
Solid: Temperature is
within 5° of set point
LO
°F
1. Secure the braking film mount arm so as to center
the film between the side cabinets.
Blinking: Temperature is
lower than 5° of set point
Off: Set point has been
reached or exceeded
2. Loosen the core support film mount arm and slide
it to the drive side of the machine.
Figure 3-5: Heater Controller
3. Install the laminating film onto the braking mount
arm and slide the core support arm over to support
the laminating film's end.
5. It will take approximately 15 minutes for the lami-
nating roll(s) to reach operating temperature. When
the preset operating temperature has been reached,
the machine is ready to use.
4. Secure the support arm.
3-4
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F-36 PRO Laminator Operation Manual
Operation
The process control charts should be kept in this man-
ual or in a book close to the laminator. Use the machine
to encapsulate the popular charts so they can withstand
food and coffee spills and so they are always available
for ready reference.
ꢗꢍꢍꢓꢌꢎ$
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.
☞ NOTE
3. Lower the upper main roll until the laminating rolls
are touching.
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.
4. Set the Forward/Reverse switch to FWD.
5. Set the speed control to 2.
The completed process control charts included in this
section are based on Falcon Film, Falcon Board, and
typical prints.
6. Let the machine run until the laminating rolls
return to room temperature.
☞ Note
ꢐꢍꢒꢎꢋꢌꢎ$ꢄꢊꢎꢏꢄ*ꢊ.ꢌꢎꢊꢋꢌꢎ$ꢄ0ꢇꢎꢈꢄꢅꢊꢘꢘ1
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 ºF), cold films
do not exhibit the phenomenon of silvering.
1. Adjust the machine settings as shown in process
chart 3-2.
ꢅꢊ ꢈꢉꢄꢔꢌ ꢘ
1. Always cut the leading edge of a print straight so it
can be fed perpendicular to the laminating rolls.
WARNING
2. Ink-Jet prints done on high gloss paper might not
bond or might experience bubbles (called pud-
dling). To solve this problem, raise the heat setting
of the laminator by approximately 20 ºF and
increase the motor speed by one third.
Do not operate the laminator without the infeed
table installed on the machine.
2. 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.
ꢅꢉꢍꢑꢈꢘꢘꢄꢗꢍꢎꢋꢉꢍꢓꢄꢗ#ꢊꢉꢋꢘ
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.
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.
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.
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 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.
© GBC Pro-Tech 1999 January
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Operation
F-36 PRO Laminator Operation Manual
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.
ꢔ-ꢍꢁꢅꢊꢘꢘꢄꢐꢍꢒꢎꢋꢄꢊꢎꢏꢄ*ꢊ.ꢌꢎꢊꢋꢈꢄ0ꢗꢍꢓꢏꢄ
ꢇ2ꢈꢉꢓꢊ.ꢌꢎꢊꢋꢈ1
For this process, the image is first encapsulated and
then mounted.
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 footswitch 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.
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.
☞ 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.
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.
WARNING
ꢐꢍꢒꢎꢋꢌꢎ$ꢄꢇꢎꢓꢜ
Use extreme caution when using the single edge
razor not to damage the rolls or cut yourself.
This process varies only slightly from the One Pass
Mount and Laminate process.
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.
1. Adjust the machine settings as shown in process
chart 3-3.
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.
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.
6. Insert a starter board into the nip and lower the
upper main roll onto it.
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.
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.
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.
8. Reinstall the infeed table. You can operate with or
without the pull rolls at this point.
9. Encapsulate the images.
☞ 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.
3-6
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F-36 PRO Laminator Operation Manual
Operation
4. Insert a starter board into the nip and lower the
upper main roll onto it.
1. Adjust the machine settings as shown in process
chart 3-4b.
5. 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.
2. Trim the print to size and trim the board to the size
of the print.
6. Reinstall the infeed table.
7. Encapsulate the images.
3. 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.
1. Adjust the machine settings as shown in process
chart 3-5b.
4. Clean the board with a tack cloth or cleaning roller.
5. Place the image face down on a flat surface and
peel back the release liner on the leading edge
(about two inches).
2. Trim the print to size and trim the board to the size
of the print.
3. 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.
6. 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.
4. Clean the board with a tack cloth or cleaning roller.
7. 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.
5. Place the image face down on a flat surface and
peel back the release liner on the leading edge
(about two inches).
6. 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.
8. Trim the board and image to the finished size.
7. Insert the already mounted portion of the piece into
the pull roll nip. Lower the upper pull roll onto the
board and 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.
ꢔ-ꢍꢁꢅꢊꢘꢘꢄꢐꢍꢒꢎꢋꢄꢊꢎꢏꢄ*ꢊ.ꢌꢎꢊꢋꢈꢄ0/ꢍꢋꢄ
ꢇ2ꢈꢉꢓꢊ.ꢌꢎꢊꢋꢈ1
This process is very similar to the Two Pass Mount and
Laminate using cold overlaminate.
1. Adjust the machine settings as shown in process
chart 3-5a and remove the infeed table.
8. Trim the board and image to the finished size.
2. 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.
3. 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.
© GBC Pro-Tech 1999 January
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Operation
F-36 PRO Laminator Operation Manual
3ꢎꢑꢊ ꢘꢒꢓꢊꢋꢌꢍꢎ
ꢐꢊꢑ#ꢌꢎꢈꢄꢙ#ꢒꢋꢏꢍ-ꢎ
This is the most commonly performed process.
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.
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.
CAUTION
Failure to follow this procedure can result in
damage to the rolls.
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.
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.
CAUTION
CAUTION
Make sure that the adhesive side of the laminate
is away from the roll to prevent an extensive
clean up job.
The laminating and output rolls must always be
in the up position when the machine is not in use.
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-
switch. 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.
3-8
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F-36 PRO Laminator Operation Manual
Operation
ꢅꢆꢇꢗ3ꢙꢙꢄꢗꢇ4ꢔꢆꢇ*ꢄꢗ/5ꢆꢔ
MATERIALS
Image Media
Mounting Substrate
LAMINATOR SETTINGS
Upper Media
Lower Media
Top Heater Status
Bottom Heater Status
Speed
Drive Mode
Pull Roll Position
Output Cooling
Main Roll Setting
Drive Direction
ꢅꢆꢇꢗ3ꢙꢙꢄꢗꢇ4ꢔꢆꢇ*ꢄ6!57ꢆ5ꢐ
Identification Diagram
Notes
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
© GBC Pro-Tech 1999 January
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Operation
F-36 PRO Laminator Operation Manual
ꢅꢆꢇꢗ3ꢙꢙꢄꢗꢇ4ꢔꢆꢇ*ꢄꢗ/5ꢆꢔꢄꢂꢁ
One-Pass Mounting and Laminating
MATERIALS
Upper Media
Lower Media
3 mil gloss
Image Media
Bond Paper
N/A
Mounting Substrate
Falcon Board
LAMINATOR SETTINGS
Top Heater Status
Bottom Heater Status
Speed
ON @ 240 ºF (115 ºC)
Drive Mode
Manual (Footswitch)
OFF
Pull Roll Position
Output Cooling
Main Roll Setting
UP
1-2 ft/min
FWD
OFF
Drive Direction
DOWN - 1/4 turn
ꢅꢆꢇꢗ3ꢙꢙꢄꢗꢇ4ꢔꢆꢇ*ꢄ6!57ꢆ5ꢐꢄꢂꢁ
Leader
Board
Printed
Image
FALCON
Board
Notes
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
3-10
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F-36 PRO Laminator Operation Manual
Operation
ꢅꢆꢇꢗ3ꢙꢙꢄꢗꢇ4ꢔꢆꢇ*ꢄꢗ/5ꢆꢔꢄꢂꢁꢂ
One-Pass Mounting
MATERIALS
Image Media
Upper Media
Lower Media
N/A
N/A
Bond Paper
Mounting Substrate
LAMINATOR SETTINGS
Falcon Board
Top Heater Status
Bottom Heater Status
Speed
ON @ 240 ºF (115 ºC)
Drive Mode
Manual (Footswitch)
OFF
Pull Roll Position
Output Cooling
Main Roll Setting
UP
2-3 ft/min
FWD
OFF
Drive Direction
DOWN - 1/4 turn
ꢅꢆꢇꢗ3ꢙꢙꢄꢗꢇ4ꢔꢆꢇ*ꢄ6!57ꢆ5ꢐꢄꢂꢁꢂ
Printed
Image
FALCON
Board
Notes
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
© GBC Pro-Tech 1999 January
3-11
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Operation
F-36 PRO Laminator Operation Manual
ꢅꢆꢇꢗ3ꢙꢙꢄꢗꢇ4ꢔꢆꢇ*ꢄꢗ/5ꢆꢔꢄꢂꢁ"5
Two Pass Mount and Cold/Pressure Overlaminate, First Pass
MATERIALS
Upper Media
Lower Media
Pro-Gloss
Pro-Mount
Image Media
Bond Paper
N/A
Mounting Substrate
LAMINATOR SETTINGS
Top Heater Status
Bottom Heater Status
Speed
ON @ 110 ºF (43 ºC)
OFF
Drive Mode
Manual or Auto
UP or DOWN
OFF
Pull Roll Position
Output Cooling
Main Roll Setting
4-6 ft/min
FWD
Drive Direction
DOWN - 1/2 turn
ꢅꢆꢇꢗ3ꢙꢙꢄꢗꢇ4ꢔꢆꢇ*ꢄ6!57ꢆ5ꢐꢄꢂꢁ"5
Release
Liner Rewind
Release Liner
Notes
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
3-12
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F-36 PRO Laminator Operation Manual
Operation
ꢅꢆꢇꢗ3ꢙꢙꢄꢗꢇ4ꢔꢆꢇ*ꢄꢗ/5ꢆꢔꢄꢂꢁ"8
Two Pass Mount and Cold/Pressure Overlaminate, Second Pass
MATERIALS
Upper Media
Lower Media
N/A
N/A
Image Media
N/A
Mounting Substrate
Foam Core
LAMINATOR SETTINGS
Top Heater Status
Bottom Heater Status
Speed
OFF
Drive Mode
Manual (Footswitch)
OFF
Pull Roll Position
Output Cooling
Main Roll Setting
UP
2-6 ft/min
FWD
OFF
Drive Direction
DOWN - 1/4 turn
ꢅꢆꢇꢗ3ꢙꢙꢄꢗꢇ4ꢔꢆꢇ*ꢄ6!57ꢆ5ꢐꢄꢂꢁ"8
Hold Encapsulated
Image
Image
Face
Release
Liner
Notes
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
© GBC Pro-Tech 1999 January
3-13
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Operation
F-36 PRO Laminator Operation Manual
ꢅꢆꢇꢗ3ꢙꢙꢄꢗꢇ4ꢔꢆꢇ*ꢄꢗ/5ꢆꢔꢄꢂꢁ%5
Two Pass Mount and Hot Overlaminate, First Pass
MATERIALS
Upper Media
Lower Media
3 mil Gloss
Pro-Mount
Image Media
Bond Paper
N/A
Mounting Substrate
LAMINATOR SETTINGS
Top Heater Status
Bottom Heater Status
Speed
ON @ 230 ºF (110 ºC)
Drive Mode
Manual or Auto
DOWN
OFF
Pull Roll Position
Output Cooling
Main Roll Setting
3-4 ft/min
FWD
OFF
Drive Direction
DOWN - 1/2 turn
ꢅꢆꢇꢗ3ꢙꢙꢄꢗꢇ4ꢔꢆꢇ*ꢄ6!57ꢆ5ꢐꢄꢂꢁ%5
Notes
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
3-14
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F-36 PRO Laminator Operation Manual
Operation
ꢅꢆꢇꢗ3ꢙꢙꢄꢗꢇ4ꢔꢆꢇ*ꢄꢗ/5ꢆꢔꢄꢂꢁ%8
Two Pass Mount and Hot Overlaminate, Second Pass
MATERIALS
Upper Media
Lower Media
N/A
N/A
Image Media
N/A
Mounting Substrate
Foam Core
LAMINATOR SETTINGS
Top Heater Status
Bottom Heater Status
Speed
OFF
Drive Mode
Manual (Footswitch)
OFF
Pull Roll Position
Output Cooling
Main Roll Setting
DOWN
OFF
UP
2-3 ft/min
REV
Drive Direction
ꢅꢆꢇꢗ3ꢙꢙꢄꢗꢇ4ꢔꢆꢇ*ꢄ6!57ꢆ5ꢐꢄꢂꢁ%8
CAUTION: Do not
allow foam board to
drop below Fan
Bridge Lip
Encapsulated Image
Release Liner
Foam Core
Notes
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
© GBC Pro-Tech 1999 January
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Operation
F-36 PRO Laminator Operation Manual
ꢅꢆꢇꢗ3ꢙꢙꢄꢗꢇ4ꢔꢆꢇ*ꢄꢗ/5ꢆꢔꢄꢂꢁꢃ
Encapsulation
MATERIALS
Upper Media
Lower Media
3 mil Gloss
3 mil Gloss
Image Media
Bond Paper
N/A
Mounting Substrate
LAMINATOR SETTINGS
Top Heater Status
Bottom Heater Status
Speed
ON @ 230 ºF (110 ºC)
ON @ 230 ºF (110 ºC)
3-6 ft/min
Drive Mode
Manual or Auto
DOWN
Pull Roll Position
Output Cooling
Main Roll Setting
OFF
Drive Direction
FWD
DOWN - 1/4 turn
ꢅꢆꢇꢗ3ꢙꢙꢄꢗꢇ4ꢔꢆꢇ*ꢄ6!57ꢆ5ꢐꢄꢂꢁꢃ
Notes
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
3-16
© GBC Pro-Tech 1999 January
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F-36 PRO Laminator Operation Manual
Maintenance and Troubleshooting
Tools required:
ꢙꢈꢑꢋꢌꢍꢎꢄ"ꢄꢛꢄꢐꢊꢌꢎꢋꢈꢎꢊꢎꢑꢈꢄꢊꢎꢏꢄ
ꢔꢉꢍꢒꢕꢓꢈꢘ#ꢍꢍꢋꢌꢎ$
1
•
/ " hex wrench
8
•
•
80% isopropyl alcohol
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.
100% lint free paper or cotton terry cloth
CAUTION
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.
Table 4-1: Maintenance Schedule
Daily
•
•
•
Clean/adjust the thermocouples
Clean the rolls
Inspect the electrical cord for dam-
age
•
Inspect the footswitch cord for dam-
age
Monthly
•
•
•
Adjust the nip
Check the chain tension
WARNING
Inspect the area around the laminator
for possible hazards (dust buildup,
combustible items stored too close,
etc.)
Do not attempt to adjust the position of the
thermocouples if the rolls are hot. You can be
seriously burned.
Every Six
Months
•
•
Lubricate the grease fittings and
chain
To adjust a thermocouple:
1. Locate the thermocouple to be adjusted using the
illustration in Figure 4-3.
Check wire termination tightness
ꢔ#ꢈꢉ.ꢍꢑꢍꢒ ꢓꢈꢄꢅꢍꢘꢌꢋꢌꢍꢎꢌꢎ$ꢄꢊꢎꢏꢄ
ꢗꢓꢈꢊꢎꢌꢎ$
2. Remove the two screws securing the thermocouple
1
to the laminator using the / " hex wrench and take
8
the thermocouple out.
One of the most crucial adjustments to the F-36 PRO
Laminator is positioning the thermocouples and mak-
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.
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.
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Maintenance and Troubleshooting
F-36 PRO Laminator Operation Manual
Use Your
Other Hand to
Gently Bend
Provide
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.
Bend
Rivets
Thermal
Junction
Roll
Figure 4-2: Correct Thermocouple Contact
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.
4-2
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F-36 PRO Laminator Operation Manual
Maintenance and Troubleshooting
Upper Main
Roll
Tube to Frame
Thermocouple
Thermocouple
Wire
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Laminator
Figure 4-3: Locations of the Thermocouples
© GBC Pro-Tech 1999 January
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Maintenance and Troubleshooting
F-36 PRO Laminator Operation Manual
To clean the laminator rolls:
To clean beads of adhesive, dust and dirt from the
rolls:
1. Remove the infeed table and infeed pressure plate
to gain access to the rolls.
1. Allow the laminator to cool slightly to no higher
than 110ºF (43ºC).
2. Set the FWD/REV switch to the REV position and
use the footswitch to move the rolls as you clean
them. Set the Speed Control to 1.5 ft/min.
WARNING
Exercise extreme caution while cleaning the
laminator. You can be caught in the turning rolls
and crushed or burned.
3. Clean the rolls using a moderate amount of 80%
isopropyl alcohol on a cotton terry cloth.
2. While the laminator is at normal operating temper-
ature, put on the rubber gloves and, using a rubber
cement eraser, remove any heat activated adhesive
from the rolls.
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.
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.
WARNING
Exercise care when cleaning the rolls with 80%
isopropyl alcohol:
• Use only in a well ventilated area.
• Wear rubber gloves.
CAUTION
• Use only on cool rolls.
Do NOT pick or pull heat activated adhesive off
the rolls when they are cold. You can cause
irreparable damage to the laminating 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 110º 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.
4-4
© GBC Pro-Tech 1999 January
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F-36 PRO Laminator Operation Manual
Maintenance and Troubleshooting
To clean the cabinet and covers:
5ꢏ9ꢒꢘꢋꢌꢎ$ꢄꢋ#ꢈꢄ4ꢌ
1. Unplug the laminator to clean the exterior.
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.
2. Using a damp cotton terry cloth (water only), clean
the exterior of the laminator.
WARNING
Tools required:
1
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.
•
•
/ " hex wrench
8
(2) ¾" open end wrenches
To adjust the nip:
CAUTION
WARNING
The main rolls must be at room temperature to
achieve a proper nip setting.
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.
1. Unplug the laminator and make sure it won’t be
plugged back in while you are performing this pro-
cedure.
2. Remove the drive and control side cabinet covers
1
with the / " hex wrench by removing the six
8
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.
Adjusting
Bolt
Jamnut
Figure 4-4: Adjusting the Nip
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Maintenance and Troubleshooting
F-36 PRO Laminator Operation Manual
5. Adjust the nip by turning the adjusting bolt using
an ¾" 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.
1/4" to
1/2" Play
Properly Set Nip
(Distance Between
Rolls is Equal)
Loosen Motor
Mount Bolts
Downward
Force Tightens
Chain
Figure 4-5: Properly Set Nip
6. Hold the adjustment bolt in place while tightening
the jamnut on each side of the laminator.
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 ¼" to ½"
play in the chain.
7. Replace both cabinet covers and reconnect power
to the laminator.
ꢗ#ꢊꢌꢎꢄꢔꢈꢎꢘꢌꢍꢎꢌꢎ$
5. Tighten the mounting bolts while maintaining the
downward pressure on the motor.
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.
6. Replace the cabinet cover and reconnect power to
the laminator.
Tools required:
1
•
/ " hex wrench
8
3
•
•
/ " hex wrench
16
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-
cedure.
1
2. Remove the drive side cabinet cover using the / "
8
hex wrench by removing the six screws holding the
cover in place.
3
3. Loosen all four motor mount bolts using the / "
16
hex wrench as shown in Figure 4-6. The motor
should just move freely within the slots.
4-6
© GBC Pro-Tech 1999 January
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F-36 PRO Laminator Operation Manual
Maintenance and Troubleshooting
*ꢒꢕꢉꢌꢑꢊꢋꢌꢍꢎ
Tools required:
1
•
/ " hex wrench
8
•
•
High temperature grease or lithium grease
Grease gun
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Fittings
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To lubricate the laminator:
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WARNING
Do not lubricate the laminator when it is hot. You
can be burned.
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.
Figure 4-7: Grease Fittings
3. Lubricate the chain using a soft cloth and automo-
tive oil.
1. Remove the drive and control side cabinet covers
1
using the / " hex wrench by removing the six
8
4. Replace the cabinet covers and reconnect power to
the laminator.
screws holding 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.
ꢗꢍꢎꢋꢊꢑꢋꢌꢎ$ꢄꢔꢈꢑ#ꢎꢌꢑꢊꢓꢄꢙꢒ ꢍꢉꢋ
For machine parts and technical service in North
America, please call: 1-800-790-7787. Please provide
serial number when calling for service. In Europe,
please call: +44 (0) 1844 202 440 or fax: +44 (0) 1844
202 441.
For film and application questions in North America,
please call 1-800-236-8843. In Europe, please call: +44
(0) 1844 202 440 or fax: +44 (0) 1844 202 441.
© GBC Pro-Tech 1999 January
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Maintenance and Troubleshooting
F-36 PRO Laminator Operation Manual
ꢇꢒꢋ ꢒꢋꢄꢔꢉꢍꢒꢕꢓꢈꢘ#ꢍꢍꢋꢌꢎ$ꢄ7ꢒꢌꢏꢈ
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:
• Increase clutch tension.
• Check roll pressures.
• Check nip settings.
• Decrease clutch tension.
• Check operational settings for
materials being used.
• Check paper tension.
• Check relative moisture
content of the paper.
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
output.
Longitudinal waves or stuttering, jerking, or
excessive noise from the drive side of the
laminator.
Hints:
Hints:
• Check nip settings.
• Check for even paper tension.
• Increase chain tension, decrease unwind
brake tension.
4-8
© GBC Pro-Tech 1999 January
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F-36 PRO Laminator Operation Manual
Warranty
ꢙꢈꢑꢋꢌꢍꢎꢄ%ꢄꢛꢄ&ꢊꢉꢉꢊꢎꢋꢜ
This warranty specifically does not cover:
*ꢌ.ꢌꢋꢈꢏꢄ&ꢊꢉꢉꢊꢎꢋꢜ
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,
attempt to repair, unauthorized alteration or modi-
fication, incorrect line voltage, contaminated air
supply, or by fire, accident, flood, or other hazard.
3. Improper use of the machine.
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.
© GBC Pro-Tech 1999 January
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Warranty
F-36 PRO Laminator Operation Manual
Blank page.
5-2
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F-36 PRO Laminator Operation Manual
Specifications
Table 6-2: Replacement Parts
ꢙꢈꢑꢋꢌꢍꢎꢄꢃꢄꢛꢄꢙ ꢈꢑꢌꢖꢌꢑꢊꢋꢌꢍꢎꢘ
Table 6-1: F-36 PRO Laminator Specifications
Part
Number
Description
Recommended
Quantity
Characteristic
Specifications
001-374 Assembly, Force
Gauge PCB
1
Dimensions
(L x D x H)
56" x 31" x 56"
(1.42 x .79 x 1.42m)
001-504 Assembly, Force
Sensor
1
Weight
Uncrated: 300 lbs (136 kg)
Crated : 500 lbs (225 kg)
Laminating Rolls 42" (1.06m) roll face with high
release surface, upper and lower
rolls internally heated
001-528 Relay Board
001-134 Temperature Control
425-000 Motor
1
1
1
1
1
1
1
1
Laminating
Opening
1.5" (3.8 cm) maximum opening
controlled with infinitely vari-
able hand crank
690-001 Roll, Main
Laminating
Material
Uses heat activated and pressure-
sensitive materials 0 - 39"
(99.6 cm) wide on a 3" (7.6 cm)
ID core, 10" (25.4 cm) maximum
diameter
690-002 Pull Roll, Upper
690-003 Pull Roll, Lower
189-000 Heater, Round
240-120 Thermocouple, J-
type, 72"
Laminating
Speeds
0 to 18 fmp (o to 5.5 mpm) with
variable speed, reversible action,
start and stop controlled either
through the instrument panel or
with the variable speed foot-
switch
214-000 Microswitch, Safety,
Interlock
1
220-160 Motor Controller
1
1
Encapsulating
Features
Pull rolls and cooling fans for
uniform flat cooling
220-110 Barrier Board, Motor
Control
Safety Features
•
•
Mechanical guard on infeed
186-135 Fuse, Ceramic 20A
(Motor Board)
1
All electrical and moving
mechanical parts are located
in bolted cabinets
•
•
•
Redundant circuit protected
safety shielding
Hand crank for laminating
roll movement
Emergency stop buttons with
a reset button circuit
Options
•
•
•
•
•
Unwind for rolled prints
Rewind for rolled prints
Vacuum table
Outfeed Slitters
Outfeed Table
Installation
Requirement
220VAC 50 or 60 Hz single
phase, 30A or, in Europe, 3
phase, 240/400 VAC with 20A
per phase
© GBC Pro-Tech 1999 January
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Specifications
F-36 PRO Laminator Operation Manual
Blank page.
6-2
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F-36 PRO Laminator Operation Manual
Index
*
!ꢎꢏꢈ(ꢄ
Laminate adhesives 3-4
Laminating material 6-1
Laminating opening 6-1
Laminating rolls 6-1
Laminating speeds 6-1
Lubrication 4-7
5
Accessory pack 2-3
Adjusting bolt 4-5, 4-6
ꢗ
Chain
ꢐ
Lubrication 4-7
Tensioning 4-6
Clutch
Main roll
Lower 4-5
Common problems 4-8
Controls
Main rolls 4-1, 4-5
Temperature 4-1
Front control panel 3-2
Maintenance schedule 4-1
Motor 2-8, 4-6
3
Mounting and laminating (one pass) 3-5
Mounting only 3-6
Emergency stop buttons 1-1, 2-8, 3-1
Encapsulating 6-1
Encapsulation 3-8
4
Environment 2-1
Nip 1-1, 1-2, 2-6, 2-8, 3-1, 4-1, 4-4, 4-5, 4-6
ꢀ
ꢇ
Film 3-4
Outfeed slitters 6-1
Outfeed table 6-1
Loading 3-3
Positioning 3-4
Foot bolt 2-4, 2-5
ꢅ
Footswitch 1-1, 1-2, 2-8, 3-1, 4-1, 4-4, 6-1
FWD/REV switch 4-4
Paper 3-5
Photoelectric eye 2-7, 2-8, 3-1
Power requirement 2-1
Preinstallation checklist 2-1
Pressure
7
Grease fittings 4-7
Laminator roll 3-3
Process control charts 3-5
/
Handwheel 2-6, 4-5
Heater 2-8
Controller 2-8
Heating 3-4
ꢆ
Riggers 1-3, 2-4, 2-5, 2-6
!
Infeed table 4-4
Installation requirements 2-1, 6-1
© GBC Pro-Tech 1999 January
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Index
F-36 PRO Laminator Operation Manual
ꢙ
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
ꢔ
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
,
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
:
Vacuum table 6-1
&
Warnings and cautions 1-1
Warranty 5-1
7-2
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|