GBC Laminator F 36 User Manual

ꢀꢁ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  
iii  
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F-36 PRO Laminator Operation Manual  
Machine Shutdown.......................................................................................................... 3-8  
Procedure .................................................................................................................... 3-8  
ꢙꢈꢑꢋꢌꢍꢎꢄ"ꢄꢛꢄꢐꢊꢌꢎꢋꢈꢎꢊꢎꢑꢈꢄꢊꢎꢏꢄꢔꢉꢍꢒꢕꢓꢈꢘ#ꢍꢍꢋꢌꢎ$ꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝ"ꢁ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&ꢊꢉꢉꢊꢎꢋꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝ%ꢁꢚ  
Limited Warranty.............................................................................................................. 5-1  
Exclusions to the Warranty .......................................................................................... 5-1  
ꢙꢈꢑꢋꢌꢍꢎꢄꢃꢄꢛꢄꢙ ꢈꢑꢌꢖꢌꢑꢊꢋꢌꢍꢎꢘ ꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢃꢁꢚ  
ꢙꢈꢑꢋꢌꢍꢎꢄ'ꢛꢄ!ꢎꢏꢈ(ꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝꢝ'ꢁ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.  
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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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94  
19  
©
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  
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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.  
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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  
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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
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R
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G
G
E
N
C
R E  
E
M
E
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G
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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
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©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.  
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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  
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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.  
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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.  
 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  
Blinking: Temperature is  
lower than 5° of set point  
Off: Set point has been  
reached or exceeded  
175  
OUT  
125  
HI  
LO  
150  
200  
°F  
225  
7
8
2
3
100  
75  
250  
275  
Upper Roll Heater  
Controller  
Upper Roll Heat  
ON/OFF  
50  
300  
001-133  
LO  
PROTECH  
°F  
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  
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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
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D
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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
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N
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IN  
C
G
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T
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M
N
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I
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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
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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.  
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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$ꢄꢋ#ꢈꢄꢀꢌꢓ.  
Green: Temperature  
is exactly at set point  
Blinking: Temperature  
is greater than 5° of set  
point  
100  
75  
250  
275  
The following procedure is applicable to both the top  
and bottom feed unwinds.  
Off: Set point has been  
reached or exceeded  
50  
PROTECH  
300  
001-133  
Solid: Temperature is  
within 5° of set point  
Blinking: Temperature is  
lower than 5° of set point  
LO  
°F  
1. Secure the braking film mount arm so as to center  
the film between the side cabinets.  
Off: Set point has been  
reached or exceeded  
2. Loosen the core support film mount arm and slide  
it to the drive side of the machine.  
Figure 3-5: Heater Controller  
3. Install the laminating film onto the braking mount  
arm and slide the core support arm over to support  
the laminating film's end.  
5. It will take approximately 15 minutes for the lami-  
nating roll(s) to reach operating temperature. When  
the preset operating temperature has been reached,  
the machine is ready to use.  
4. Secure the support arm.  
3-4  
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F-36 PRO Laminator Operation Manual  
Operation  
The process control charts should be kept in this man-  
ual or in a book close to the laminator. Use the machine  
to encapsulate the popular charts so they can withstand  
food and coffee spills and so they are always available  
for ready reference.  
ꢗꢍꢍꢓꢌꢎ$  
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   
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.  
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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  
© GBC Pro-Tech 1999 January  
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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  
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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  
© GBC Pro-Tech 1999 January  
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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  
3-15  
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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.  
© GBC Pro-Tech 1999 January  
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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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Wire Routed  
Through to  
Control Side  
Thermocouple  
Lower Main Roll  
Underside of  
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  
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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  
© GBC Pro-Tech 1999 January  
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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  
W
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A
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TU  
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Grease  
Fittings  
E
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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  
6-1  
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Specifications  
F-36 PRO Laminator Operation Manual  
Blank page.  
6-2  
© GBC Pro-Tech 1999 January  
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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  
Chain  
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  
Film 3-4  
Outfeed slitters 6-1  
Outfeed table 6-1  
Loading 3-3  
Positioning 3-4  
Foot bolt 2-4, 2-5  
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  
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  
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  
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  
© GBC Pro-Tech 1999 January  
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