GBC 930 028 User Manual

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© 1999 GBC Pro-Tech  
Do not duplicate without written permission  
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F-60+™  
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GBC Pro-Tech  
4151 Anderson Road  
De Forest, Wisconsin 53532  
Tel: 608-246-8844  
Part Number 930-028  
Fax: 608-246-8645  
F-60+ Operation and Maintenance Manual  
Caution/Warning Label Locations ................................................................................... 1-3  
Preinstallation Checklist ..................................................................................................2-1  
Unpacking .......................................................................................................................2-4  
Setup .............................................................................................................................. 2-6  
Leveling ..........................................................................................................................2-7  
Startup ............................................................................................................................ 2-7  
Safety ..............................................................................................................................3-1  
Operator Controls ...........................................................................................................3-2  
Front Control Panel .....................................................................................................3-2  
Footswitch Operation ..................................................................................................3-2  
Rear Control ................................................................................................................ 3-3  
Setup .............................................................................................................................. 3-3  
Laminator Main Roll Pressure ..................................................................................... 3-3  
Laminator Pull Roll Pressure ......................................................................................3-3  
Web Up Options .......................................................................................................... 3-3  
Loading the Film .............................................................................................................3-4  
Recommended Materials ................................................................................................3-4  
Films ........................................................................................................................... 3-4  
Positioning the Film ........................................................................................................ 3-4  
Heating ........................................................................................................................... 3-5  
Pull Roll Clutch Adjustment ............................................................................................3-5  
Paper Tips ....................................................................................................................... 3-5  
Process Control Charts ...................................................................................................3-6  
Mounting Only .................................................................................................................3-6  
Setup ........................................................................................................................... 3-6  
Procedure ...................................................................................................................3-7  
Mounting/Laminating ...................................................................................................... 3-7  
Setup ........................................................................................................................... 3-7  
Procedure ...................................................................................................................3-7  
© GBC Pro-Tech 1999 April  
iii  
F-60+ Operation and Maintenance Manual  
Encapsulation ................................................................................................................. 3-7  
Setup .......................................................................................................................... 3-7  
Procedure ................................................................................................................... 3-7  
Two-Pass Mount and Laminate (Hot and Cold) .............................................................. 3-7  
Setup .......................................................................................................................... 3-7  
Procedure, Pass 1 ...................................................................................................... 3-7  
Procedure, Pass 2 ...................................................................................................... 3-8  
Cleaning ......................................................................................................................... 4-1  
Adjusting the Nip ............................................................................................................ 4-3  
Chain Tensioning ............................................................................................................ 4-4  
Lubrication ...................................................................................................................... 4-5  
Contacting Technical Support ......................................................................................... 4-5  
Output Troubleshooting Guide ........................................................................................ 4-6  
Limited Warranty ............................................................................................................. 5-1  
Exclusions to the Warranty ......................................................................................... 5-1  
iv  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
The F-60+ Laminator has been designed with safety as  
a primary consideration. However, you must become  
thoroughly familiar with the controls, proper operation,  
proper service procedures, and safety features of the  
laminator before using or servicing the unit.  
DO NOT ATTEMPT TO OPERATE YOUR  
F-60+ LAMINATOR UNTIL YOU HAVE READ  
THIS SECTION CAREFULLY!  
GBC Pro-Tech F-60+ Laminator is a powerful machine  
that is designed to mount, laminate and encapsulate.  
The forces required to accomplish these tasks can vary  
from negligible to very large.  
Your safety, as well as the safety of others, is important  
to GBC Pro-Tech. This section contains important  
safety information.  
In addition, the laminating roll of the F-60+ can reach  
temperatures of 270 °F (132 °C). At these temperatures  
there is a danger of a severe burn if the roll is touched  
during set-up, operation or servicing.  
The following symbols are used throughout this man-  
ual to indicate warnings and cautions.  
Safety is an important feature of the F-60+ Laminator.  
It has emergency stop buttons and a mechanical guard  
system on the infeed. In addition, the pull rolls are con-  
tained in an enclosure to prevent injury.  
DANGER  
Indicates an imminently hazardous situation  
which, if not avoided, will result in death or  
serious injury.  
The laminator is equipped with four emergency stop  
buttons located on the top front and back of either side  
of the laminator. Any of these, if engaged, stops the  
laminator. To continue operation all emergency stop  
buttons must be in the up position and you must press  
the reset button above the fuse panel on the back of the  
laminator (see Figure 1-2). The laminator is also  
equipped with a power lockout (see Figure 1-3) which  
stops power to the machine.  
WARNING  
Indicates a potentially hazardous situation  
which, if not avoided, could result in death or  
serious injury.  
Push either  
button to stop the  
laminator  
Twist pressed  
button to resume  
operation - the  
button pops up  
CAUTION  
Indicates a potentially hazardous situation  
which, if not avoided, could result in minor or  
moderate injury, or alerts against unsafe  
practices, or alerts against actions which could  
damage the product.  
Figure 1-1: Using the Emergency Stop Buttons  
© GBC Pro-Tech 1999 April  
1-1  
Safety  
F-60+ Operation and Maintenance Manual  
Reset Button  
WARNING  
Never place fingers or arms between the rolls  
when they are turning or when the rolls are in the  
closed position. You can be crushed or burned.  
POWER  
WARNING  
Do not wear ties, loose fitting clothing or  
dangling jewelry while operating or servicing the  
laminator. These items can get caught in the nip  
and choke you or you can be crushed or burned.  
WARNING  
Do not operate the laminator near water. You can  
be severely shocked, electrocuted or cause a fire.  
Figure 1-2: Resetting the Laminator  
Insert  
Lock  
DANGER  
Remove and lock out power from the laminator  
before servicing. You can be severely shocked,  
electrocuted or cause a fire.  
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WARNING  
Circuit  
Breakers  
Secured in  
"Off" Position  
Do not use liquid or aerosol cleaners on the  
laminator. Do not spill liquid of any kind on the  
laminator. You can be severely shocked,  
electrocuted or cause a fire. Use only a damp  
cloth for cleaning.  
Figure 1-3: Power Lockout  
Despite the safety features built into the F-60+ Lamina-  
tor, extreme caution must be used when operating or  
servicing the unit. READ THE FOLLOWING  
WARNINGS AND CAUTIONS BEFORE  
ATTEMPTING TO OPERATE OR SERVICE THE  
F-60+ LAMINATOR.  
WARNING  
Exercise care when cleaning the rolls with 80%  
isopropyl alcohol:  
Use only in a well ventilated area.  
Wear rubber gloves.  
Use only on cool rolls.  
Cleaning heated rolls can ignite the fumes.  
1-2  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
CAUTION  
WARNING  
Use only 80% isopropyl alcohol or a rubber  
cement eraser to clean the laminating rolls.  
Harsh chemicals like toluene, acetone or MEK  
destroy the silicone covering of the rolls.  
Do not attempt to move the laminator across  
anything other than a flat, level surface without  
trained and qualified riggers. You can be crushed  
or seriously injured.  
The F-60+ Laminator is a large and heavy piece  
of equipment. It is necessary to employ  
LICENSED RIGGERS ONLY to move the  
machine. GBC Pro-Tech’s warranty does not  
cover malfunction of the equipment due to  
mishandling.  
CAUTION  
Raise the upper main roll when the laminator is  
not in operation. Prolonged contact can damage  
the rolls.  
GBC Pro-Tech bears no responsibility for  
personal injury or damage due to moving the  
laminator improperly.  
CAUTION  
Excess pressure can damage the laminating rolls.  
Always select the minimum roll pressure  
necessary to complete the task.  
WARNING  
Do not operate the laminator if the power cord is  
damaged or frayed. You can be severely shocked,  
electrocuted or cause a fire. Contact a qualified  
electrician to replace the cord.  
CAUTION  
If silicone adhesive contacts the upper or lower  
roll, remove it IMMEDIATELY using 80%  
isopropyl alcohol. It can harden within an hour  
and ruin the roll.  
WARNING  
Do not allow anything to rest on the power cord.  
Do not locate the cord where people can walk on  
it. You or others can be severely shocked,  
electrocuted or cause a fire.  
WARNING  
The operating environment must be free of dust,  
flammable liquids and vapors. You can be  
injured by inhaling chemical vapors. Vapor build  
up or stored flammable liquids can cause a fire.  
Excessive dust can damage the laminator.  
Always use good safety practices when operating or  
servicing the laminator and know how to react quickly  
in an emergency.  
Posted at various locations on your F-60+ Laminator  
are important safety labels. PAY CAREFUL ATTEN-  
TION TO THESE LABELS AT ALL TIMES! Figure  
1-4 shows the location of each of these labels.  
CAUTION  
Do not use a knife or other sharp instrument  
during installation or while servicing the  
laminator. You can cause irreparable damage to  
the rolls.  
© GBC Pro-Tech 1999 April  
1-3  
Safety  
F-60+ Operation and Maintenance Manual  
(Inside cabinet)  
WARNING  
ACHTUNG  
MISE EN GARDE  
WARNING  
ACHTUNG  
MISE EN GARDE  
WARNING  
ACHTUNG  
MISE EN GARDE  
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©1994 Hazard Communication Systems, Inc. 800-748-0241  
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Figure 1-4: Locations of Safety Labels  
1-4  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
The following are typical safety hazard decals used on GBC Pro-Tech machines, with a brief description (“Mean-  
ing” column) of each decal.  
Decal  
Meaning  
Decal  
Meaning  
WARNING!  
WARNING!  
WARNING  
ACHTUNG  
MISE EN GARDE  
SAFETY  
INSTRUCTIONS  
Moving parts can  
crush and cut.  
1. Read and understand the Operation Manual and  
all safety labels before operating this machine.  
2. Only a trained person is to be permitted to operate  
this machine. Training should include instruction  
in operation under normal conditions and  
emergency situations.  
3. This machine is to be serviced only by trained and  
authorized personnel. Follow lockout procedures  
before servicing.  
SICHERHEITS-  
RICHTLINIEN  
Do not operate with  
guard or door open.  
CONSIGNES DE  
SÉCURITÉ  
4. Never reach into the machine for any reason unless  
the machine is at a COMPLETE STOP.  
5. Never leave the machine stopped in such a manner  
that another worker can start the machine while  
you are working on or within the machine.  
6. Never change or defeat the function of electrical  
interlocks or other machine "shutdown" switches.  
7. Before starting this machine, check that:  
- All persons are clear of the machine.  
- No maintenance work is being performed on  
the machine.  
WARNING!  
WARNING  
WARNING  
ACHTUNG  
MISE EN GARDE  
Crush and burn  
ACHTUNG  
hazard. Stay clear of  
moving rollers. Stop  
machine and raise roll  
before cleaning.  
MISE EN GARDE  
or  
- All guards are in place.  
- All parent rolls are well chucked in the unwind  
stands.  
- The machine is free of paper scraps, wraps and  
jams.  
WARNING!  
WARNING  
ACHTUNG  
MISE EN GARDE  
Carefully read  
8. There is a potential hazard of entanglement in this  
machine caused by items such as long hair, loose  
clothing, and jewelry. Make sure your clothing and  
hair fit closely to your body and that all jewelry,  
rings and watches are removed.  
Operator's Manual  
before handling this  
machine. Observe  
instructions and safety  
rules when operating.  
CAUTION!  
Air pressure must be less than 100 PSI (700 kPa) to  
avoid damaging the machine.  
WARNING!  
100 PSI  
HAZARDOUS  
VOLTAGE.  
700 KPa  
©1997 HCS, Inc. 800-748-0241 No. 6101-52BVPK  
or  
To be serviced only by  
trained and authorized  
personnel.  
Reset.  
©1994 Hazard Communication Systems, Inc. 800-748-0241  
Lockout power before  
servicing.  
WARNING!  
S
CAUTION!  
Surface is hot.  
EMERGENCY STOP BUTTON  
Press this button to stop the machine cycle, remove  
electric power, and separate (open) rolls to eliminate a  
pinch point (on some machines).  
or  
E
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A burn hazard exists.  
Electric power disconnect and lock out location.  
CAUTION!  
Rolls are heavy.  
Use proper lifting  
techniques to prevent  
injury.  
© GBC Pro-Tech 1999 April  
1-5  
Safety  
F-60+ Operation and Maintenance Manual  
Blank page.  
1-6  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
Installation  
CAUTION  
GBC Pro-Tech is committed to a program of ongoing  
product improvement. As a result, we are providing  
these instructions so that you can insure that your new  
F-60+ Laminator is properly and securely unpacked,  
moved and installed.  
Do not locate the laminator where air is blowing  
directly on the machine. The air flow can cool the  
rolls unevenly and result in poor quality output.  
Is there an appropriate power outlet available or  
has a certified electrician been contacted to wire  
the laminator directly?  
Before a F-60+ Laminator can be installed, there are a  
few requirements that must be met. Make certain that  
each of the requirements listed in the following prein-  
stallation checklist are met before beginning installa-  
tion.  
The laminator requires 60A single phase, 220/230/  
240 VAC service or, in Europe, 3 Phase, 240 VAC  
with 30 Amps per phase. See Figure 2-2 for alter-  
native power hookup configurations.  
CAUTION  
WARNING  
Failure to follow the preinstallation checklist can  
result in damage to the laminator.  
Do not attempt to defeat the grounding feature of  
the ground plug on the laminator. You can be  
severely shocked, electrocuted or cause a fire.  
The three prong plug fits only into a grounding-  
type power outlet. If you are unable to insert the  
plug into the existing outlet, contact a qualified  
electrician to replace the obsolete outlet.  
Are doorways and hallways wide enough for the  
laminator to be moved to the installation site?  
Is there ample room for the laminator?  
A work area must be established that allows for  
operation in both the front and the rear of the  
machine and provides space for efficient material  
flow. Figure 2-1 shows a typical machine area lay-  
out.  
WARNING  
Do not use an extension cord on this laminator.  
You can be severely shocked, electrocuted or  
cause a fire. If you need a longer cable contact a  
qualified electrician.  
Is the environment appropriate for the laminator?  
The laminator requires a clean, dust and vapor free  
environment to operate properly, such as an air  
conditioned office area with forced 10% make up  
air. However, the laminator must not be located  
where there is air blowing directly on it. Major  
fluctuation in temperature and humidity are to be  
avoided.  
WARNING  
Do not operate the laminator if the power cord is  
damaged or frayed. You can be severely shocked,  
electrocuted or cause a fire. Contact a qualified  
electrician to replace the cord.  
WARNING  
The operating environment must be free of dust,  
flammable liquids and vapors. You can be  
injured by inhaling chemical vapors. Vapor build  
up or stored flammable liquids can cause a fire.  
Excessive dust can damage the laminator.  
WARNING  
Do not allow anything to rest on the power cord.  
Do not locate the cord where people can walk on  
it. You or others can be severely shocked,  
electrocuted or cause a fire.  
© GBC Pro-Tech 1999 April  
2-1  
Installation  
F-60+ Operation and Maintenance Manual  
Wall  
4' x 6' (~1.22 m x 2 m)  
Work Table  
on Wheels  
Table Height  
35-3/4"  
(~.94 - .95 m)  
8'2"  
(~2.5 m)  
Electrical  
Supply  
78" (~2 m)  
Rear  
3' (~1 m)  
20'  
38.5"  
(~.6 m) (~.97 m)  
Front  
4' x 6' (~1.22 m x 2 m)  
Work Table  
on Wheels  
Table Height  
35-3/4"  
(~.94 - .95 m)  
8'2"  
(~2.5 m)  
13' (~4 m)  
Figure 2-1: Laminator Space Requirements  
2-2  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
Installation  
Single Phase  
Power  
Configuration  
Jumper Bar  
NORMAL AND  
RECOMMENDED  
CONFIGURATION  
Blue Wire  
L6  
L4  
L2  
L5  
L3  
L1  
Blue Wire  
Blue Wire  
Red Wire  
Red Wire  
Red Wire  
Hot Lead  
220/240  
Volts  
120  
Volts  
Hot Lead  
Delta 3 Phase  
Power  
Configuration  
Ground  
120  
Volts  
Copper/Ground Wire  
Jumper Bar  
Jumper Bar  
Blue Wire  
L6  
L4  
L2  
L5  
L3  
L1  
Jumper Bar  
Blue Wire  
220/240  
Volts  
Blue Wire  
Red Wire  
Red Wire  
Red Wire  
Hot Lead “A”  
220/240  
Volts  
Hot Lead “B”  
Hot Lead “C”  
Ground  
220/240  
Volts  
Copper/Ground Wire  
Jumper Wire  
Wye 3 Phase For  
European Models  
Power Configuration  
Jumper Bar  
Removed  
Blue Wire  
L6  
L4  
L2  
L5  
L3  
L1  
Blue Wire  
Blue Wire  
Red Wire  
Red Wire  
Red Wire  
Hot Lead  
220/240  
Volts  
220/240  
Volts  
Hot Lead  
Hot Lead  
Neutral  
220/240  
Volts  
Ground  
Copper/Ground Wire  
Jumper Bar  
Figure 2-2: Alternative Power Configurations  
© GBC Pro-Tech 1999 April  
2-3  
Installation  
F-60+ Operation and Maintenance Manual  
2. There are two hold down bridges that are con-  
nected to sides 4 and 5. Remove the hold down  
bridges and then remove sides 4 and 5.  
NOTE  
ALL SHIPMENTS ARE EX- WORKS. At our dock title  
passes to the buyer. Please review your insurance cov-  
erage prior to shipment, as you are responsible for all  
subsequent freight charges and risks. Before signing  
the Bill of Lading you should be sure to inspect the  
crate and/or pallet for signs of damage or missing  
items; if applicable, make a note of this on the Bill of  
Lading.  
CAUTION  
Do not allow the top to fall into the crate. It can  
damage the laminator.  
Do not put packing screws on the floor. They can  
cause problems when trying to roll the machine  
into position.  
The F-60+ Laminator is shipped in a wood crate on a  
skid.  
A second person must support the side  
labeled (5) in Figure 2-3. It can fall and damage  
the laminator.  
WARNING  
3. The ramps are attached to the skid. Remove them  
and set them aside for later installation.  
The unpacking process requires at least two  
people. You can be severely injured or crushed.  
Tools required:  
Phillips head screwdriver  
Adjustable wrench  
Heaters  
2" x 4"  
Saddle  
2" x 4"  
Saddle  
To uncrate the laminator:  
Skid  
1. Remove the top of the crate and sides 2 and 3 as  
shown in Figure 2-3.  
Skid  
Lag Bolt  
2" x 4"  
Skid  
1
Lag Bolt  
5
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Install  
Screws  
I
Saddle  
Figure 2-4: Skid Configuration  
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CAUTION  
2
Do not use a knife or other sharp instrument  
during installation or while servicing the  
laminator. You can cause irreparable damage to  
the rolls.  
Figure 2-3: Removing the Crate  
2-4  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
Installation  
4. Carefully remove the accessory pack from the skid.  
The accessory pack should contain:  
10. The ramps included with the laminator can be  
secured to the edge of the crate bottom using the  
screws left over from the crate disassembly (see  
Figure 2-3).  
1 Slitting knife  
1 Manual  
11. Have the machine moved off the skid and placed  
on the floor by licensed riggers.  
1 Set, spare fuses  
1 Roll of masking tape  
1 100% cotton terry cloth  
4 Leveling pads  
Roll the machine off by securing included ramps to  
the edge of the crate bottom using the screws left  
over from the crate disassembly (See Figure 2-3).  
Lift the machine off by applying fork lift truck  
blades to the two bottom tie bars between the cabi-  
nets. The fork lift blades must be located at the lift  
label locations on the tie bars (see Figure 2-5).  
5. Locate the foot switch so as to prevent the foot  
switch wire from being damaged during removal of  
the machine from the skid.  
WARNING  
G
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Do not attempt to move the laminator across  
anything other than a flat, level surface without  
trained and qualified riggers. You can be crushed  
or seriously injured. Steps 6 through 11 should be  
completed by LICENSED RIGGERS ONLY.  
I
The F-60+ Laminator is a large and heavy piece  
of equipment. It is necessary to employ  
LICENSED RIGGERS ONLY to move the  
machine.  
100  
90  
80  
70  
60  
50  
40  
30  
20  
10  
CAL  
3200  
CAL  
3200  
4
5
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6
7
2
1
2
8
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F-60+™  
GBC Pro-Tech bears no responsibility for  
personal injury or damage due to moving the  
laminator improperly.  
Fork Lift Label  
Locations  
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6. The machine is supported above the skid by resting  
on a support saddle under each end of the machine.  
Remove the three long two by fours that attach to  
the support saddles.  
Figure 2-5: Fork Lift Blade Locations  
12. Remove any plastic strapping and packing paper  
taped to the rolls.  
7. On one side of the machine, remove the lag bolts  
holding the support saddle to the skid.  
8. Using two of the two by fours as levers, carefully  
lift the end of the machine enough to allow the sad-  
dle to be removed from the skid and the machine to  
rest on its wheels.  
CAUTION  
Do not use a knife or other sharp instrument  
during installation or while servicing the  
laminator. You can cause irreparable damage to  
the rolls.  
9. Repeat Steps 7 and 8 for the other end of the  
machine.  
13. Remove all packing materials to a safe distance  
from the laminator.  
© GBC Pro-Tech 1999 April  
2-5  
Installation  
F-60+ Operation and Maintenance Manual  
9. Using the 3/8" hex wrench, remove the bottom  
A NOTE ABOUT RECYCLING  
The crate components can be reused for shipping the  
machine again, or can be disassembled and the wood  
and screws recycled. The shrink wrap is not recyclable,  
however, so it must be discarded.  
screws holding the rear table under the pull rolls.  
Collect the screws and spacers for reuse. Pivot the  
table up into position behind the pull rolls and  
secure in place by installing the bolts into the top  
set of cabinet holes. Be sure the spacers are in posi-  
tion!  
14. Level the laminator using the procedure later in  
this section.  
Once the F-60+ Laminator has been unpacked and  
moved into final position check each of the following  
items.  
Tools required:  
Lower  
Hole in  
Cabinet  
1/8" hex wrench  
7/32" hex wrench  
3/8" hex wrench  
Adjustable wrench  
Figure 2-6: Installing the Rear Table  
Setup Procedure:  
1. Inspect the laminator for any obvious shipping  
damage.  
2. Using a 1/8" hex wrench, remove the screws secur-  
ing the cabinet panel to the control (electrical) side  
of the machine.  
3. Using a 7/32" hex wrench, remove the pull roll  
height adjust crank from the drive side of the  
machine.  
4. Using a 1/8" hex wrench, remove the screws secur-  
ing the cabinet panel to the drive side of the  
machine.  
5. Inspect all the bolts and tighten any that were loos-  
ened during shipping.  
6. Set the nip. (See Maintenance for the procedure.)  
7. Replace both cabinet covers.  
8. Replace the pull roll height adjust crank.  
2-6  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
Installation  
The first time the laminator is started and every time it  
is serviced you should use the following checklist to  
confirm that the unit is operating properly and that all  
safety mechanisms are functioning.  
Tools required:  
Adjustable wrench  
Carpenter's level  
Startup Checklist  
To level the laminator:  
Start the laminator and go through the following check-  
list.  
1. Raise each end, remove the castors and install a  
leveling pad and stud onto each of the foot brackets  
at the four bottom corners of the laminator. Thread  
third nut on stud below cabinet.  
Are the emergency stop buttons working?  
Push down on one of the emergency stop buttons.  
The laminator should stop. Rotate and pull up on  
the button and push the reset button on the lower  
back of the laminator. The laminator should  
resume operation. Always check all buttons.  
2. Thread stud into 4 leveling pads and lock down  
with nut. Thread second nut onto stud.  
3. Place a carpenter's level front to rear across the two  
lower tie bars at one end of the machine.  
4. Level this end of the machine front to rear, raising  
or lowering the leveling pads by adjusting the mid-  
dle nuts on the foot bolts.  
WARNING  
Never operate the laminator unless all of the  
emergency stop buttons are functioning properly.  
You can be crushed or burned.  
5. Move the level to the other end of the machine and  
level front to rear.  
6. Place the level directly on one of the tie bars and  
level the machine side to side.  
Are the guard table switches working?  
7. Recheck the front to rear level condition to insure  
that it has not changed. If it has, repeat the leveling  
procedure.  
With the laminator running, pull the front guard  
towards you. The rolls should stop. Move the guard  
back in. Press the RUN button on the front control  
panel. The laminator should resume operation.  
8. When all the measurements indicate that the  
machine is level, tighten down the top nuts on the  
foot brackets to lock the pads in their current posi-  
tion.  
WARNING  
Never operate the laminator unless the  
mechanical guard system is operating properly.  
You can be crushed or burned.  
Is the footswitch working?  
Press the footswitch. The laminator should start  
operation. Vary the speed using the footswitch (like  
an automobile accelerator) to ensure that the foot-  
switch is operating properly at various speeds.  
© GBC Pro-Tech 1999 April  
2-7  
Installation  
F-60+ Operation and Maintenance Manual  
WARNING  
Use extreme caution when operating the machine  
with the guard off. You can be crushed or  
burned.  
Is the motor functioning?  
Test the motor at various speeds ranging from  
0-15. At 0 the rolls should stop turning.  
Run the motor in both forward and reverse.  
Are the heaters working?  
Verify that the heater controller heats the top roll.  
NOTE  
The bottom roll heater controller must be turned on  
before the top roll heater controller will energize the  
top heater.  
Once you have completed the startup checklist you can  
safely run a test sample.  
2-8  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
Operation  
Reset Button  
The F-60+ Laminator has been designed with safety as  
a primary consideration. However, you must become  
thoroughly familiar with the controls, proper operation,  
proper service procedures, and safety features of the  
laminator before using or servicing the unit.  
POWER  
GBC Pro-Tech F-60+ Laminator is a powerful machine  
that is designed to mount, laminate and encapsulate.  
The forces required to accomplish these tasks can vary  
from negligible to very large.  
In addition, the laminating roll of the F-60+ can reach  
temperatures of 270 °F (132 °C). At these temperatures  
there is a danger of a severe burn if the roll is touched  
during set-up, operation or servicing.  
Safety is an important feature of the F-60+ Laminator.  
It has emergency stop buttons and a photoelectric eye  
system on the infeed.  
Figure 3-2: Resetting the Laminator  
The laminator is equipped with four emergency stop  
buttons located on the top front and back of either side  
of the laminator. Any of these, if engaged, stops the  
laminator. To continue operation all emergency stop  
buttons must be in the up position and you must press  
the reset button above the fuse panel on the back of the  
laminator (see Figure 3-2). The laminator is also  
equipped with a power lockout (see Figure 3-3) which  
stops power to the machine.  
Insert  
Lock  
P
O
W
E
R
Circuit  
Breakers  
Secured in  
"Off" Position  
Push either  
button to stop the  
laminator  
Twist pressed  
button to resume  
operation - the  
button pops up  
Figure 3-3: Power Lockout  
Figure 3-1: Using the Emergency Stop Buttons  
© GBC Pro-Tech 1999 April  
3-1  
Operation  
F-60+ Operation and Maintenance Manual  
6. UPPER ROLL HEAT ON/OFF – Turns the  
heater controller for the upper main roll on or off.  
The operator controls for the F-60+ Laminator are  
located on the front and rear of the unit, to the right of  
the operator position. The names and functions of these  
controls are as follows:  
7. LOWER ROLL HEATER CONTROLLER–  
Provides a readout of the temperature of the lower  
roll and the set-point for the desired temperature.  
8. LOWER ROLL HEAT ON/OFF – Turns the  
heater controller for the lower main roll on or off.  
9. COOLING FAN ON/OFF – Turns the cooling fan  
on or off.  
5
100  
Indicates  
10. POWER ON/OFF INDICATOR –  
Upper Roll Heater  
Controller  
90  
80  
70  
when the main power is being applied to the  
machine.  
CAL 3200  
60  
1
50  
6
7
Roll  
Pressure  
Display  
40  
30  
20  
10  
Upper Roll Heat  
ON/OFF  
Lower Roll Heater  
Controller  
CAL 3200  
The footswitch can be used for feeding materials  
through the main rolls (forward mode). Material speed  
is controlled by the Control Panel Speed Adjustment  
knob, resulting in constant speed operation when the  
footswitch is pressed. The footswitch can also be used  
for feeding materials through the pull rolls (reverse  
mode). Material speed is controlled by the footswitch,  
which operates much like the accelerator on an auto-  
mobile.  
8
Lower Roll Heat  
ON/OFF  
2
RUN/STOP/  
EYE RESET  
9
Cooling Fan ON/OFF  
3
4
Motion Control  
FORWARD/  
REVERSE  
5
6
7
4
3
8
10  
2
9
Speed  
Adjustment  
Power On/Off  
Indicator  
1
10  
Figure 3-4: Front Control Panel  
CAUTION  
1. ROLL PRESSURE DISPLAY - Displays the per-  
centage of force pushing the main laminating roll  
down.  
When the footswitch is used the photoelectric eye  
guarding the main rolls is turned off. Release the  
footswitch to stop the machine rolls.  
2. RUN/STOP/EYE RESET – Turns the drive sys-  
tem on or off and resets the photoelectric eyes  
when in automatic forward mode. The photoelec-  
tric eyes do not function in reverse mode.  
G
IN  
N
R
A
G
W
N
U
T
H
C
R
D
E
A
A
G
E
N
I
S
E
M
3. MOTION CONTROL FORWARD/REVERSE -  
Controls the direction of the drive system, forward,  
reverse, or stop.  
G
G
IN  
N
R
A
W
N
U
T
H
C
R
D
E
A
A
G
E
N
I
S
E
M
Feed  
Material  
Into Nip  
4. SPEED ADJUSTMENT – Adjusts the speed of  
the machine from zero to the maximum as the con-  
trol is turned clockwise. (Turtle is slow, rabbit is  
fast.)  
100  
90  
80  
70  
60  
50  
40  
30  
20  
C
A
L
3
1
0
2
0
0
CAL  
3
200  
4
5
3
6
2
1
7
2
8
9
10  
+
0
-6  
F
5. UPPER ROLL HEATER CONTROLLER –  
Provides a readout of the temperature of the upper  
roll and the set-point for the desired temperature.  
PRO-TECH  
Remove  
Guard  
Press Footswitch  
(variable speed)  
NOTE  
The bottom roll heater controller must be turned on  
before the top roll heater controller will energize the  
top heater.  
Figure 3-5: Using the Footswitch  
3-2  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
Operation  
The switch on the back of the drive cabinet starts and  
stops the main rolls when pressed while guards are in  
place.  
The F-60+ Laminator has an adjustable roll pressure  
for adjusting traction in the material across the width of  
the material using the pull roll height adjust crank. The  
same crank permits an infinite choice of gaps for board  
mount applications.  
Rear  
RUN/STOP  
Switch  
Figure 3-6: Rear RUN/STOP Switch  
Pull Roll  
Clutch  
Pull Roll  
Height  
Adjust  
Crank  
Setup of the F-60+ Laminator is quick and straightfor-  
ward when instructions are followed exactly.  
To adjust the nip, please see Maintenance.  
Figure 3-7: Pull Roll Clutch and Pull Roll  
Height Adjust Crank  
Use only the minimum amount of roll pressure needed  
to accomplish the task. While higher pressure can make  
the adhesive bond faster, excess pressure can damage  
the rolls. Wrinkles and bubbles have causes that gener-  
ally cannot be cured by applying more pressure.  
With the guard removed, move webs through the main  
roll nip by:  
1. Pressing the RUN button for a slow, constant main  
roll rotation.  
CAUTION  
or  
2. Pressing the STOP button, then pressing the foot-  
switch to set the required speed. Releasing the  
footswitch stops main roll rotation.  
Excess pressure can damage the laminating rolls.  
Minimum laminator roll pressure is consistent  
with good results.  
A typical roll pressure for soft substrates such as Foam-  
core is between 30 to 40%.  
The range of typical values for hard substrates is 30 to  
50%.  
© GBC Pro-Tech 1999 April  
3-3  
Operation  
F-60+ Operation and Maintenance Manual  
Film is loaded on the appropriate unwinds. Loading  
and aligning the film are discussed later in this section.  
For applications such as encapsulation, film is fed from  
both the top and bottom feed unwinds.  
The F-60+ Laminator is capable of processing a wide  
range of pressure sensitive and thermal laminates onto  
an equally wide range of image materials. The primary  
considerations are:  
The process of loading and aligning film is the same  
for both the top and the bottom unwinds. There are two  
important points to remember when loading film:  
Laminate adhesives are compatible with image  
materials.  
1. The adhesive side of the film must be oriented  
away (on the outside) from the laminating roll.  
Otherwise it will immediately bond to the roll, cre-  
ating a major clean-up project.  
The materials properly activate below the maxi-  
mum roll temperature and within the speed and roll  
nip pressure ranges available on the laminator.  
It is the operator’s responsibility to ensure the compati-  
bility and operational settings for any laminates/image  
material combination. GBC Pro-Tech Technical Sup-  
port is available at the number provided in the Mainte-  
nance chapter for advice on some material  
combinations.  
Films have a shiny side and a dull side. The dull  
side is the one with the adhesive. The dull side  
should ALWAYS face outward from the laminat-  
ing roll.  
CAUTION  
CAUTION  
Always mount the film so that the adhesive side  
faces outward from the laminating roll. This  
prevents hours of roll cleaning.  
Substituting materials can cause severe damage  
to your machine and is not recommended or  
covered under our warranty.  
2. The film must be centered on the unwind for best  
performance. This is vital when two films are fed  
together. If the two films are not aligned, feed  
problems, wrinkles and other assorted troubles will  
occur.  
The following procedure is applicable to both the top  
and bottom feed unwinds.  
1. Open the top unwind by removing the pin and  
swinging the arm out.  
CAUTION  
2. Load the film.  
3. Return the arm to its locked position and reinsert  
the locking pin.  
Carefully align the two films being fed into the  
nip. If not, you will obtain poor results.  
4. Center the film on the unwind arm by measuring  
the distance from the ends of the film to the sides  
of the machine using a tape measure.  
3-4  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
Operation  
Use the following instructions when heating one or  
both of the laminating rolls. The procedure is the same  
for the top and bottom heaters.  
CAUTION  
When the machine is not in use, the pull rolls  
must be raised to prevent damaging the rolls.  
1. Set the heater switch to ON.  
2. Adjust the temperature controller for the desired  
operating temperature using the temperature con-  
troller push buttons.  
Always feed prints perpendicular to the laminating  
rolls.  
3. When heating the rolls, keep the top roll down and  
turning at a moderate speed to prevent uneven  
heating.  
1. Lock core support to middle of the shaft. Lock two  
core chucks on shaft ends, located to support mate-  
rial a few inches from ends of the roll.  
4. It will take approximately 30 minutes for the lami-  
nating roll(s) to reach operating temperature. When  
the preset operating temperature has been reached,  
the machine is ready to use.  
Note  
Paper unwind may require two evenly spaced core sup-  
ports if wide rolls of prints (paper) are used.  
2. Place the roll on the unwind shaft.  
3. Carefully close the unwind shaft, holding the roll  
away from the hinge.  
The F-60+ Laminator has an adjustable clutch for the  
pull rolls on the machine, allowing you to adjust the  
amount that the film is tensioned as it leaves the main  
rolls and is cooled. The clutch adjustment is made by  
using the knob on the drive side of the machine.  
4. When the shaft is in the saddle, push in the locking  
pin.  
5. Center the roll of material.  
6. Web and tension film per process control chart and  
diagram.  
Pull roll clutch tension adjustment:  
Turning the knob clockwise increases tension.  
Turning the knob counterclockwise decreases tension.  
© GBC Pro-Tech 1999 April  
3-5  
Operation  
F-60+ Operation and Maintenance Manual  
Process control charts allow you to record the way you  
thread film through the machine's rolls and idlers  
(called webbing) and the control settings for each prod-  
uct and process. Process control charts are an excellent  
tool for training new operators. They provide a "road  
map" for correct machine setup and operation.  
Brake  
Adjustment  
Knob  
This section contains a blank process control chart and  
diagram for the F-60+ as well as completed charts for  
the basic operations of the laminator.  
GBC Pro-Tech laminators respond in a very accurate  
and repeatable manner. The charts provide a way to set  
up each time, every time for repeatable performance by  
assuring that all controls are set to optimum.  
Core  
Support  
The process control charts should be kept in this man-  
ual or in a book close to the laminator. Use the machine  
to encapsulate the popular charts so they can withstand  
food and coffee spills and so they are always available  
for ready reference.  
Core  
Chuck  
NOTE  
When trying new products and processes, remember  
that GBC Pro-Tech's customer service representatives  
are only a phone call away.  
The completed process control charts included in this  
section are based on Orca-Film and typical prints.  
LOWER UNWINDS  
Figure 3-8: Brake Configuration  
1. See process chart 3-1.  
2. Set the nip to the thickness of the material being  
used for mounting.  
3. Upper Laminator Roll Pressure: 10–30%.  
4. Speed: 3 fpm (1 m/min).  
5. Upper Laminator Roll Heat: 240 °F (115 °C).  
3-6  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
Operation  
1. Lay the print on the board. Using a tack iron, tack  
the leading edge of the print down onto the board  
so it is held in place.  
1. See process chart 3-3.  
2. Put a piece of contact/release paper over the print  
and board. Otherwise, adhesive will be applied to  
the laminating roll, which can cause damage and  
the ink from electrostatic prints will be deposited  
on the roll.  
2. Laminating Roll Pressure: 30-40%.  
3. Speed: 0-6 fpm (0-180 cpm).  
4. Upper Laminator Roll Heat: 230 °F (110 °C).  
5. Lower Laminator Roll Heat: 32 °F (0 °C).  
6. Cooling: Optional.  
3. Feed the print/board package through the nip.  
7. Use of the rear wind-up roll for the finished mate-  
rial is optional. It is a good procedure for long runs.  
The following procedure is for one-step mounting and  
heat-activated laminating using mounting board with  
one adhesive side.  
Feed the work into the nip with the leading edge tight  
and entering the nip evenly from side to side. For thin  
paper from electrostatic printers in roll form it is best to  
fold over the leading edge approximately 6 inches to  
create a square leading edge.  
1. See process chart 3-2.  
2. Mount the film and web as shown in diagram  
3-2.  
3. Set the nip for the substrate thickness by raising or  
lowering the upper main roll using the hand crank.  
There are several approaches to the mount/laminate  
task. It can be accomplished with either hot or cold  
laminate film on the top. Also, the second pass for  
mounting can be done by feeding from either the front  
or back of the laminator.  
4. Laminator Roll Pressure: 10–30%.  
5. Speed: 3 fpm (1 m/min).  
6. Upper Laminator Roll Heat: 240 °F (115 °C).  
1. Lay the print on the board. Using a tack iron, tack  
the leading edge of the print down onto the board  
so it is held in place.  
See process charts 3-4, 3-5A & B, and 3-6A & B for  
film mounting instructions and machine adjustments.  
2. Feed the print/board package through the nip.  
1. Run the print through to apply adhesive and lami-  
nate.  
2. Trim to slightly larger than the desired finished  
size.  
© GBC Pro-Tech 1999 April  
3-7  
Operation  
F-60+ Operation and Maintenance Manual  
1. Prepare to put the print through a second time to  
mount the print to the substrate - anything from  
wood, to Masinote, to Gator foam. Start by setting  
the shims to the appropriate spacing for the mate-  
rial used.  
2. Trim the board to the size of the print.  
3. Align the work to the board and ensure an exact fit.  
Place weights on the center of the print to make  
sure that it does not move relative to the board dur-  
ing the next steps.  
4. Raise one end of the print and peel back approxi-  
mately two inches of the liner to expose the adhe-  
sive that was applied to the print in the first pass.  
Fold it under.  
5. Lay the print back down evenly and extremely flat.  
From the center outward, tack the exposed adhe-  
sive to the substrate.  
6. Position the piece so that the end with the liner  
peeled back is facing the nip. Insert the first one  
inch of the board into the nip. Very carefully wrap  
the print back and over the top laminating roll. Be  
sure there are no wrinkles in the nip area. Carefully  
peel off the liner as the board progresses through  
the laminator.  
7. Trim the piece to the finished size.  
3-8  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
Operation  
352&(66ꢄ&21752/ꢄ&+$57  
Product:_________________________ Process: __________________________ Date:________________  
FRONT CONTROL SETTINGS  
Speed:  
Reverse/Forward:  
Top Heater:  
Roll Pressure:  
Cooling:  
Bottom Heater:  
352&(66ꢄ&21752/ꢄ',$*5$0  
Identification Diagram  
(F)  
Fixed Idler  
U
R
(RI) Removable Idler  
(U) Unwind Shaft  
(R) Rewind  
(UM) Upper Main Roll  
(LM) Lower Main Roll  
(UP) Upper Pull Roll  
(LP) Lower Pull Roll  
F
UM  
LM  
UP  
LP  
RI  
F
F
U
U
R
© GBC Pro-Tech 1999 April  
3-9  
Operation  
F-60+ Operation and Maintenance Manual  
352&(66ꢄ&21752/ꢄ&+$57ꢄꢇꢀꢈ  
Product: _________________________ Process: One Pass Mounting___________ Date: ________________  
FRONT CONTROL SETTINGS  
Speed: 2-3 fpm (60-90 cpm)  
Roll Pressure: Trial  
Cooling: Off  
Reverse/Forward: Forward  
Top Heater: 240 °F (115 °C)  
Bottom Heater: 32 °F (0 °C)  
352&(66ꢄ&21752/ꢄ',$*5$0ꢄꢇꢀꢈ  
One Pass Mounting  
NOTE  
Footswitch may be used.  
Printed  
Image  
Leader  
Board  
Falcon  
Board  
3-10  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
Operation  
352&(66ꢄ&21752/ꢄ&+$57ꢄꢇꢀꢉ  
Product:_________________________ Process: One Pass Mount & Laminate __ Date:________________  
FRONT CONTROL SETTINGS  
Speed: 1-2 fpm (30-60 cpm)  
Roll Pressure: Trial  
Cooling: Off  
Reverse/Forward: Forward  
Top Heater: 240 °F (115 °C)  
Bottom Heater: 32 °F (0 °C)  
352&(66ꢄ&21752/ꢄ',$*5$0ꢄꢇꢀꢉ  
One Pass Mount and Laminate  
NOTE  
Footswitch may be used.  
Printed  
Image  
Leader  
Board  
Falcon  
Board  
© GBC Pro-Tech 1999 April  
3-11  
Operation  
F-60+ Operation and Maintenance Manual  
352&(66ꢄ&21752/ꢄ&+$57ꢄꢇꢀꢇ  
Product: 3 Mil Gloss/3Mil Gloss______ Process: Encapsulation _______________ Date: ________________  
FRONT CONTROL SETTINGS  
Speed: 0-6 fpm (0-180 cpm)  
Roll Pressure: 30-60%  
Cooling: Optional  
Reverse/Forward: Forward  
Top Heater: 230 °F (110 °C)  
Bottom Heater: 230 °F (110 °C)  
352&(66ꢄ&21752/ꢄ',$*5$0ꢄꢇꢀꢇ  
Encapsulation  
3-12  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
Operation  
352&(66ꢄ&21752/ꢄ&+$57ꢄꢇꢀꢊ  
Product:_________________________ Process: Cold Overlamination _________ Date:________________  
FRONT CONTROL SETTINGS  
Speed: 0-6 fpm (0-180 cpm)  
Roll Pressure: 30-60%  
Cooling: Off  
Reverse/Forward: Forward  
Top Heater: 105 °F (40 °C)  
Bottom Heater: 32 °F (0 °C)  
352&(66ꢄ&21752/ꢄ',$*5$0ꢄꢇꢀꢊ  
Cold Overlamination  
Pro  
Gloss  
Release  
Paper  
Rewind  
Optional  
Craft  
Paper  
© GBC Pro-Tech 1999 April  
3-13  
Operation  
F-60+ Operation and Maintenance Manual  
352&(66ꢄ&21752/ꢄ&+$57ꢄꢇꢀꢋ$  
Product: ______________________ Process: Cold Mount & Laminate (First Pass) Date: ________________  
FRONT CONTROL SETTINGS  
Speed: 0-6 fpm (180 cpm)  
Roll Pressure: 30-60%  
Cooling: Off  
Reverse/Forward: Forward  
Top Heater: 105 °F (40 °C)  
Bottom Heater: 32 °F (0 °C)  
352&(66ꢄ&21752/ꢄ',$*5$0ꢄꢇꢀꢋ$  
Cold Mount and Laminate (First Pass)  
Pro  
Gloss  
Release  
Paper  
Rewind  
Optional  
Pro  
Mount  
3-14  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
Operation  
352&(66ꢄ&21752/ꢄ&+$57ꢄꢇꢀꢋ%  
Product:____________________ Process: Cold Mount & Laminate (Second Pass) Date:________________  
FRONT CONTROL SETTINGS  
Speed: 0-6 fpm (0-180 cpm)  
Roll Pressure: Trial  
Cooling: Off  
Reverse/Forward: Forward  
Top Heater: 32-105 °F (0-40 °C)  
Bottom Heater: 32 °F (0 °C)  
352&(66ꢄ&21752/ꢄ',$*5$0ꢄꢇꢀꢋ%  
Cold Mount and Laminate (Second Pass)  
NOTE  
Use footswitch to load, then accelerate materials through rolls.  
Hold  
Encapsulated  
Image  
Release Liner  
(Peel prior to nip)  
OPTIONAL  
Foam  
Core  
Board can be fed  
through the pull  
rolls using reverse  
mode.  
© GBC Pro-Tech 1999 April  
3-15  
Operation  
F-60+ Operation and Maintenance Manual  
352&(66ꢄ&21752/ꢄ&+$57ꢄꢇꢀꢁ$  
Product: _________________ Process: Mount & Hot Overlaminate (First Pass)___ Date: ________________  
FRONT CONTROL SETTINGS  
Speed: 0-6 fpm (0-180 cpm)  
Roll Pressure: 30-60%  
Cooling: Optional  
Reverse/Forward: Forward  
Top Heater: 230 °F (110 °C)  
Bottom Heater: 32 °F (0 °C)  
352&(66ꢄ&21752/ꢄ',$*5$0ꢄꢇꢀꢁ$  
Mount and Hot Overlaminate (First Pass)  
3 Mil  
Gloss  
Optional  
Pro  
Mount  
3-16  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
Operation  
352&(66ꢄ&21752/ꢄ&+$57ꢄꢇꢀꢁ%  
Product:___________________ Process: Mount & Hot Overlaminate (Second Pass) Date:________________  
FRONT CONTROL SETTINGS  
Speed : 0-6 fpm (0-180 cpm)  
Roll Pressure: Trial  
Cooling: Off  
Reverse/Forward: Forward  
Top Heater: 32-105 °F (0-40 °C)  
Bottom Heater: 32 °F (0 °C)  
352&(66ꢄ&21752/ꢄ',$*5$0ꢄꢇꢀꢁ%  
Mount and Hot Overlaminate (Second Pass)  
NOTE  
Use footswitch to load, then accelerate materials through rolls.  
Hold  
Encapsulated  
Image  
Release Liner  
(Peel prior to nip)  
OPTIONAL  
Board can be fed  
through the pull  
rolls using reverse  
mode.  
Foam  
Core  
© GBC Pro-Tech 1999 April  
3-17  
Operation  
F-60+ Operation and Maintenance Manual  
Blank page.  
3-18  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
Maintenance and Troubleshooting  
Tools required:  
GBC Pro-Tech laminators require minimal mainte-  
nance. However, regular maintenance is essential to  
keep any piece of precision machinery at peak perfor-  
mance. A maintenance schedule and a section of proce-  
dures are included in this section.  
Adhesive coated board  
80% isopropyl alcohol (or dishwashing detergent)  
Rubber cement eraser  
Several 100% lint free paper or cotton terry cloths  
Protective rubber gloves  
Table 4-1: Maintenance Schedule  
Clean the rolls  
To remove heat activated adhesive from laminator  
rolls:  
Inspect the electrical cord for dam-  
age  
Daily  
Inspect the footswitch cord for dam-  
age  
WARNING  
Adjust the nip  
Exercise extreme caution while cleaning the  
laminator. You can be caught in the turning rolls  
and crushed or burned.  
Check the chain tension  
Inspect the area around the laminator  
for possible hazards (dust buildup,  
combustible items stored too close,  
etc.)  
Monthly  
While the laminator is still at normal operating temper-  
ature (200-250 ºF), put on the rubber gloves and, using  
a rubber cement eraser, remove any heat activated  
adhesive from the rolls. Use “footswitch mode” and  
slow speed to rotate the rolls in reverse.  
Lubricate the grease fittings and  
chain  
Every Six  
Months  
Check wire termination tightness  
CAUTION  
If silicone adhesive contacts the upper or lower  
roll, remove it IMMEDIATELY using a rubber  
cement eraser. It can harden within an hour and  
ruin the roll.  
CAUTION  
Do NOT pick or pull heat activated adhesive off  
the rolls when they are cold. You can cause  
irreparable damage to the laminating rolls.  
WARNING  
Do not use compressed air to clean the machine.  
Blowing debris can be forced into places where it  
will later ignite or short electric circuits.  
© GBC Pro-Tech 1999 April  
4-1  
Maintenance and Troubleshooting  
F-60+ Operation and Maintenance Manual  
To clean beads of adhesive, dust and dirt from the  
rolls:  
To clean the cabinet and covers:  
1. Allow the laminator to cool slightly to no higher  
than 110ºF (43ºC).  
WARNING  
2. Set the FWD/REV switch to the REV position.  
Remove and lockout power from the laminator  
while you are performing this procedure. You  
could be severely shocked, electrocuted, or get  
your fingers caught in the drive mechanisms.  
3. Clean the rolls using a moderate amount of 80%  
isopropyl alcohol on a cotton terry cloth.  
1. Using a damp cotton terry cloth (water only), clean  
the exterior of the laminator.  
CAUTION  
Use the minimum amount of pressure necessary  
to clean the rolls. You can destroy the silicone  
layer on the rolls by pressing to hard or  
scrubbing too long in one spot.  
WARNING  
Do not use liquid or aerosol cleaners on the  
laminator. Do not spill liquid of any kind on the  
laminator. You can be severely shocked,  
electrocuted or cause a fire. Use only a damp  
cloth for cleaning.  
WARNING  
Exercise care when cleaning the rolls with 80%  
isopropyl alcohol:  
Use only in a well ventilated area.  
Wear rubber gloves.  
Use only on cool rolls.  
Cleaning heated rolls can ignite the fumes.  
CAUTION  
Use only 80% isopropyl alcohol or a rubber  
cement eraser to clean the laminating rolls.  
Harsh chemicals like toluene, acetone or MEK  
destroy the silicone covering of the rolls.  
4. With the laminator rolls no hotter than 110ºF,  
remove dust and dirt from the silicone laminating  
rolls by running an adhesive-coated board through  
the laminator. Be sure to set the nip for the thick-  
ness of the board used.  
5. Allow the laminator to cool.  
4-2  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
Maintenance and Troubleshooting  
The gap between two rolls is called the nip.  
The purpose of adjusting the nip is to ensure continu-  
ous contact between the rolls as the media is drawn  
through the machine. This procedure must be done reg-  
ularly for the main rolls. It is not necessary to set the  
nip on the pull rolls.  
Lift  
Assembly  
Bolt  
Jam  
Nut  
Properly Set Nip  
(Distance Between  
Rolls is Equal)  
Figure 4-2: Nip Setting Assembly  
Figure 4-1: Properly Set Nip  
4. Adjust the nip so that there is an even line of light  
across the width of the rolls.  
Tools required:  
5. Secure the jam nut on the lift assembly bolt.  
6. Replace the cabinet cover.  
1/8" hex wrench  
¾" hex wrench  
To adjust the main roll nip:  
CAUTION  
The main roll must be at room temperature to  
achieve a proper nip setting.  
1. Remove the left side cabinet cover with the 1/8"  
hex wrench by removing the seven screws holding  
the cover in place. Gently rotate the cover around  
the clutch knob to allow access to the roll lift sys-  
tem.  
2. Lower the upper main roll so that there is a small  
visible gap between it and the lower main roll.  
3. Loosen the ¾" jam nut securing the lift assembly  
bolt. Adjust the nip by rotating the lift assembly  
bolt clockwise to raise the end being adjusted and  
counterclockwise to lower it.  
© GBC Pro-Tech 1999 April  
4-3  
Maintenance and Troubleshooting  
F-60+ Operation and Maintenance Manual  
Smaller chain tensioning adjustments on the F-60+  
Laminator are handled by a secondary chain tensioner,  
however, when installing a new chain or when the  
chain tension is more seriously out of adjustment, use  
the following procedure to adjust the chain tension.  
1/4" to  
1/2" Play  
Tools required:  
1/8" hex wrench  
7/32" hex wrench  
1/4" to  
3/16" hex wrench  
1/2" Play  
l
Screwdriver  
Downward  
To adjust the chain tension:  
Force Tightens  
i
Loosen  
Motor  
Mount  
Bolts  
Chain  
i
WARNING  
Remove and lockout power from the laminator  
while you are performing this procedure. You  
could be severely shocked, electrocuted, or get  
your fingers caught in the drive mechanisms.  
Figure 4-3: Adjusting the Chain Tension  
5. Using a screwdriver, apply a small amount of  
downward pressure on the motor by prying against  
the inside of the side frame until there is ¼" to ½"  
play in the chain.  
1. Remove the drive side cabinet cover using the 1/8"  
hex wrench by removing the seven screws holding  
the cover in place.  
6. Tighten the mounting bolts while maintaining the  
downward pressure on the motor.  
2. Using a 7/32" hex wrench, remove the pull roll  
7. Engage the top rewind chain tensioner and apply  
pressure until its chain exhibits similar tension to  
the primary chain tension.  
height adjust crank from the drive side of the  
machine.  
3. Loosen the top rewind chain tensioner.  
8. Engage the bottom rewind chain tensioner and  
apply pressure until its chain exhibits similar ten-  
sion to the primary chain tension.  
4. Loosen all four motor mount bolts using the 3/16"  
hex wrench as shown in the figure below. The  
motor should just move freely within the slots.  
9. Replace the cabinet cover.  
10. Replace the pull roll height adjust crank.  
11. Reapply power to the laminator.  
4-4  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
Maintenance and Troubleshooting  
For machine parts and technical service in North  
America, please call: 1-800-790-7787. Please provide  
serial number when calling for service. In Europe,  
please call: +44 (0) 1844 202 440 or fax: +44 (0) 1844  
202 441.  
Tools required:  
1/8" hex wrench  
High temperature grease or lithium grease  
Grease gun  
For film and application questions in North America,  
please call 1-800-236-8843. In Europe, please call: +44  
(0) 1844 202 440 or fax: +44 (0) 1844 202 441.  
To lubricate the laminator:  
WARNING  
Do not lubricate the laminator when it is hot. You  
can be burned.  
WARNING  
Remove and lockout power from the laminator  
while you are performing this procedure. You  
could be severely shocked, electrocuted, or get  
your fingers caught in the drive mechanisms.  
1. Remove the drive and control side cabinet covers  
using the 1/8" hex wrench by removing the seven  
screws holding each cover in place. Gently rotate  
the cover around the clutch knob to allow access to  
the lubrication points.  
2. Using the grease gun, lubricate each grease fitting  
with one squirt of high temperature grease.  
3. Lubricate the chain using a soft cloth and automo-  
tive oil.  
4. Replace the cabinet covers, close the safety shields  
and reapply power to the laminator.  
© GBC Pro-Tech 1999 April  
4-5  
Maintenance and Troubleshooting  
F-60+ Operation and Maintenance Manual  
Problem:  
Problem:  
Problem:  
D waves in the image, not in the D waves in the laminate.  
Straight waves in the output.  
laminate.  
Hints:  
Hints:  
Hints:  
• Check paper tension.  
• Check relative moisture content • Check nip settings.  
of the paper.  
• Increase clutch tension.  
• Decrease clutch tension.  
• Check operational settings for  
materials being used.  
• Check roll pressures.  
Other Common  
Problems:  
Feed  
Direction  
Problem:  
Blistering in the image.  
Hints:  
• Increase speed or lower  
the operating  
temperature.  
Problem:  
Coiling of encapsulated  
images.  
Hints:  
• Balance the upper and  
lower unwind brake  
tension. Make sure  
main roll temperatures  
are the same. Adjust  
cooling fans.  
Problem:  
Problem:  
Waves on only one side of the Angled waves on the output.  
output.  
Hints:  
Hints:  
• Check nip settings.  
• Check for even paper tension. • Check for insufficient main roll  
pressure  
• Check for insufficient clutch  
tension.  
Problem:  
Longitudinal waves or  
stuttering, jerking, or  
excessive noise from the  
drive side of the laminator.  
Hints:  
• Increase chain tension,  
decrease unwind brake  
tension.  
4-6  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
Warranty  
This warranty specifically does not cover:  
1. Damage to the laminating rolls caused by knives,  
razor blades, other sharp objects, or failure caused  
by adhesives.  
GBC Pro-Tech Engineering Company, Inc. warrants  
the equipment sold is free from defects in material and  
workmanship for a period of ninety days (90) from the  
date of delivery to the customer. This warranty is the  
only warranty made by GBC Pro-Tech and cannot be  
modified or amended.  
2. Damage to the machine caused by lifting, tilting,  
and/or any attempt to position the machine other  
than rolling on the installed casters on even sur-  
faces.  
GBC Pro-Tech’s sole and exclusive liability and the  
customer’s sole and exclusive remedy under this  
warranty shall be, at GBC Pro-Tech’s option, to  
repair or replace any such defective part or prod-  
uct. These remedies are only available if GBC Pro-  
Tech’s examination of the product discloses to GBC  
Pro-Tech’s satisfaction that such defects actually  
exist and were not caused by misuse, neglect,  
3. Improper use of the machine.  
attempt to repair, unauthorized alteration or modi-  
fication, incorrect line voltage, contaminated air  
supply, or by fire, accident, flood, or other hazard.  
This warranty specifically does not cover damage to  
the laminating rollers caused by knives, razor blades,  
other sharp objects, failure caused by adhesives or  
improper use of the machine. Warranty repair or  
replacement does not extend the warranty beyond the  
initial ninety day period from the date of delivery.  
CAUTION  
Unauthorized customer alterations will void this  
warranty.  
THE WARRANTY MADE HEREIN IS IN LIEU OF  
ALL OTHER WARRANTIES, EXPRESS OR  
IMPLIED, INCLUDING ANY WARRANTY OR  
MERCHANTABILITY OR FITNESS FOR A PAR-  
TICULAR PURPOSE. GBC PRO-TECH WILL NOT  
BE LIABLE FOR PROPERTY DAMAGE OR PER-  
SONAL INJURY (UNLESS PRIMARILY CAUSED  
BY ITS NEGLIGENCE), LOSS OF PROFIT OR  
OTHER INCIDENTAL OR CONSEQUENTIAL  
DAMAGES ARISING OUT OF THE USE OR  
INABILITY TO USE THE EQUIPMENT.  
© GBC Pro-Tech 1999 April  
5-1  
Warranty  
F-60+ Operation and Maintenance Manual  
Blank page.  
5-2  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
Specifications  
Table 6-2: Replacement Parts  
Part  
Number  
Description  
Recommended  
Quantity  
Table 6-1: F-60+ Laminator Specifications  
001-374 Assembly, Force  
Gauge PCB  
1
1
1
Characteristic  
Specifications  
Dimensions  
(L x D x H)  
Uncrated: 80" x 38.5" x 57"  
(202 x 84 x 145 cm)  
001-505 Assembly, Force  
Sensor  
Crated: 90" x 44" x 68"  
(202 x 84 x 145 cm)  
001-515 Assembly, Control  
PCB  
Weight  
Uncrated: 1200 lbs (544 kg)  
Crated :1700 lbs (771 kg)  
186-200 Fuse, SB, 3AG, 3A  
214-313 Switch, Palm, E-stop  
230-007 Temperature Control  
425-003 Motor  
3
1
1
1
1
1
1
1
1
Laminating Rolls  
64" (163 cm) roll face with a  
high release surface, upper and  
lower rolls internally heated.  
Laminating Material Uses pressure sensitive materi-  
als up to 62 inches (158 cm)  
wide and hot/heat activated  
materials up to 61 inches (155  
cm) wide on a 3-inch (7.6 cm)  
inside diameter core, maxi-  
mum roll diameter of 10 inches  
(25.4 cm).  
690-059 Roll, Rubber  
189-032 Heater, Round  
230-006 IR Sensor  
860-014 Tube, Rewind Brake  
Laminating Speeds  
0 to 15 fmp (0 to 4.57 mpm)  
with variable speed, reversible  
action at slow speed (less than 3  
ft/min (1 m/min)), start and  
stop controlled either through  
the instrument panel or with the  
variable speed footswitch.  
186-135 Fuse, 250V, 20A,  
Ceramic  
690-052 Roll, Pull, Upper  
690-053 Roll, Pull, Lower  
1
1
Heating  
Capable of operating tempera-  
tures of up to 270 ºF (132 ºC).  
Safety Features  
Redundant circuit pro-  
tected safety shielding  
Mechanical guards protect  
main roll and pull roll nips  
Four emergency stop but-  
tons  
Installation  
Requirement  
60A single phase, 220/230/240  
VAC or, in Europe, 3 Phase,  
240 VAC with 30 Amps per  
phase.  
© GBC Pro-Tech 1999 April  
6-1  
Specifications  
F-60+ Operation and Maintenance Manual  
Blank page.  
6-2  
© GBC Pro-Tech 1999 April  
F-60+ Operation and Maintenance Manual  
Index  
Laminate adhesives 3-4  
Laminating material 6-1  
Laminating rolls 6-1  
Laminating speeds 6-1  
Leveling 2-7  
Accessory pack 2-5  
Adjusting  
nip 4-3  
Lubrication 4-5  
Chain  
Lubrication 4-5  
Tensioning 4-4  
Cleaning 4-1  
Controls  
Main rolls 4-3  
Maintenance schedule 4-1  
Motor 2-8, 4-4  
Mounting 3-6  
front control panel 3-2  
Mounting/Laminating 3-7  
Emergency stop buttons 1-1, 2-7, 3-1  
Encapsulation 3-7  
Nip 1-2, 2-6, 4-1, 4-2, 4-3  
Environment 2-1  
Extension cord 2-1  
Paper 3-5  
Power cord 2-1  
Power requirement 2-1  
Preinstallation checklist 2-1  
Pressure  
Film 3-4  
loading 3-4  
positioning 3-4  
Footswitch 3-2, 4-1, 6-1  
FWD/REV switch 4-2  
laminator roll 3-3  
Process control charts 3-6  
Pull roll  
clutch adjustment 3-5  
Grease fittings 4-5  
Ground plug 2-1  
Resetting the laminator 1-1, 3-1  
Riggers 1-3, 2-5  
Rubber cement eraser 4-1  
Heater 2-8  
Controller 2-8  
Heaters  
Installing 2-6  
Heating 3-5  
Safety features 6-1  
Safety information 1-1  
Safety labels 1-3  
Setup 3-3  
Setup procedure 2-6  
Specifications  
Installation requirements 2-1, 6-1  
Isopropyl alcohol 4-1  
Dimensions 6-1  
Laminating material 6-1  
Laminating rolls 6-1  
Laminating speeds 6-1  
Weight 6-1  
Startup checklist 2-7  
© GBC Pro-Tech 1999 April  
7-1  
Index  
F-60+ Operation and Maintenance Manual  
Technical support  
Call 1-800-236-8843 4-5  
Two-pass mount and laminate 3-7  
Unpacking 2-4  
Crate 2-4  
Upper main roll 1-3  
Warnings and cautions 1-1  
Warranty 5-1  
7-2  
© GBC Pro-Tech 1999 April  

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