Bosch Power Tools Laminator 36 User's Manual

Bosch Power Tools Laminator 36 User's Manual
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© 1997 GBC Pro-Tech
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©1994
GBC Pro-Tech
4151 Anderson Road
De Forest, Wisconsin 53532
Tel: 608-246-8844
Part Number 930-400
Fax: 608-246-8645
Falcon 36 Operation Manual
The information in this publication is provided for reference and is believed to be
accurate and complete. GBC Pro-Tech is not liable for errors in this publication or for
incidental or consequential damage in connection with the furnishing or use of the
information in this publication, including, but not limited to, any implied warranty of
fitness or merchantability for any particular use.
GBC Pro-Tech reserves the right to make changes to this publication and to the products
described in it without notice. All specifications and information concerning products are
subject to change without notice.
Reference in this publication to information or products protected by copyright or patent
does not convey any license under the rights of GBC Pro-Tech or others. GBC Pro-Tech
assumes no liability arising from infringements of patents or any other rights of third
parties.
This Manual is Copyrighted © 1997 by GBC Pro-Tech. All rights reserved. The
information contained in this manual is proprietary and may not be reproduced, stored,
transmitted, or transferred, in whole or in part, in any form without the prior and express
written permission of GBC Pro-Tech.
ii
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
7DEOHRI&RQWHQWV
6HFWLRQ6DIHW\ Caution/Warning Label Locations........................................................................................1-4
6HFWLRQ,QVWDOODWLRQ Preinstallation Checklist.......................................................................................................2-1
Unpacking ............................................................................................................................2-4
Setup ...................................................................................................................................2-7
Startup .................................................................................................................................2-8
6HFWLRQ2SHUDWLRQ
Safety...................................................................................................................................3-1
Operator Controls ................................................................................................................3-2
Front Control Panel ..........................................................................................................3-2
Rear Panel Control ...........................................................................................................3-2
Setup ...................................................................................................................................3-3
Laminator Roll Pressure ...................................................................................................3-3
Loading the Film ..................................................................................................................3-3
Positioning the Film..............................................................................................................3-3
Heating.................................................................................................................................3-4
Cooling.................................................................................................................................3-4
Paper Tips ...........................................................................................................................3-4
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
Machine Shutdown ..............................................................................................................3-8
 GBC Pro-Tech 1997 October
iii
Falcon 36 Operation Manual
Procedure .........................................................................................................................3-8
PROCESS CONTROL CHART............................................................................................3-9
PROCESS CONTROL DIAGRAM .......................................................................................3-9
PROCESS CONTROL CHART 3-2 ...................................................................................3-10
PROCESS CONTROL DIAGRAM 3-2 ...............................................................................3-10
PROCESS CONTROL CHART 3-3 ...................................................................................3-11
PROCESS CONTROL DIAGRAM 3-3 ...............................................................................3-11
PROCESS CONTROL CHART 3-4a .................................................................................3-12
PROCESS CONTROL DIAGRAM 3-4a .............................................................................3-12
PROCESS CONTROL CHART 3-4b .................................................................................3-13
PROCESS CONTROL DIAGRAM 3-4b .............................................................................3-13
PROCESS CONTROL CHART 3-5a .................................................................................3-14
PROCESS CONTROL DIAGRAM 3-5a .............................................................................3-14
PROCESS CONTROL CHART 3-5b .................................................................................3-15
PROCESS CONTROL DIAGRAM 3-5b .............................................................................3-15
PROCESS CONTROL CHART 3-6 ...................................................................................3-16
PROCESS CONTROL DIAGRAM 3-6 ...............................................................................3-16
6HFWLRQ0DLQWHQDQFHDQG7URXEOHVKRRWLQJ Thermocouple Positioning and Cleaning .............................................................................4-1
Cleaning...............................................................................................................................4-4
Adjusting the Nip..................................................................................................................4-5
Chain Tensioning .................................................................................................................4-6
Lubrication ...........................................................................................................................4-7
Contacting Technical Support..............................................................................................4-7
Output Troubleshooting Guide.............................................................................................4-9
6HFWLRQ:DUUDQW\ Limited Warranty..................................................................................................................5-1
Exclusions to the Warranty...............................................................................................5-1
6HFWLRQ7HFKQLFDO,QIRUPDWLRQ
Specifications.......................................................................................................................6-1
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iv
 GBC Pro-Tech 1997 October
Falcon 36 Laminator Service Manual
6HFWLRQ 6DIHW\
DO NOT ATTEMPT TO OPERATE YOUR
FALCON 36 LAMINATOR UNTIL YOU
HAVE READ THIS SECTION
CAREFULLY!
Your safety, as well as the safety of others, is
important to GBC Pro-Tech. This section contains
important safety information.
The following symbols are used throughout this
manual to indicate warnings and cautions.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury.
Safety and Warranty Information
GBC Pro-Tech laminators are powerful machines
that are designed to mount, laminate and
encapsulate. The forces required to accomplish
these tasks can vary from negligible to very large.
The spring system used to provide downward
pressure on the top roll is capable of producing
forces greater than 1000 pounds (454kg). This force
is applied to any object presented in the opening
(called the nip) between the two rolls.
In addition, the laminating rolls of the Falcon 36 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
servicing.
An important feature of the laminator is the
photoelectric 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
Indicates a potentially hazardous situation
which, if not avoided, could result in death or
serious injury.
WARNING
Use extreme caution when operating the
laminator with the footswitch. The
photoelectric eye system is overridden and
your fingers can get caught in the nip. You
can be crushed or burned.
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 Falcon 36 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 qualified service technician should open
these cabinets.
The Falcon 36 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.
The laminator is equipped with two emergency stop
buttons located on the top of either side of the
laminator. Either of these, if engaged, stops the
laminator. To continue operation both emergency
stop buttons must be in the up position.
 GBC Pro-Tech 1997 October
1-1
Safety and Warranty Information
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Push either
button to stop the
laminator
Falcon 36 Laminator Service Manual
ARRET
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Figure 1-1: Using the Emergency Stop Buttons
Despite the safety features built into the Falcon 36
Laminator, extreme caution must be used when
operating or servicing the unit. READ THE
FOLLOWING WARNINGS AND CAUTIONS
BEFORE ATTEMPTING TO OPERATE OR
SERVICE THE FALCON 36 LAMINATOR.
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.
WARNING
Always use care in lowering the top
laminating roll. You can be crushed or
burned.
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.
WARNING
Do not operate the laminator near water.
You can be severely shocked, electrocuted or
cause a fire.
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
Use extreme caution when operating the
laminator with the footswitch. The
photoelectric eye system is overridden and
your fingers can get caught in the nip. You
can be crushed or burned.
1-2
DANGER
Unplug the laminator from the wall outlet
before servicing. You can be severely
shocked, electrocuted or cause a fire.
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.
 GBC Pro-Tech 1997 October
Falcon 36 Laminator Service Manual
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.
Safety and Warranty Information
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.
Cleaning heated rolls can ignite the fumes.
CAUTION
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.
Do not use a knife or other sharp instrument
during installation or while servicing the
laminator. You can cause irreparable
damage to the rolls.
WARNING
CAUTION
Raise the upper main roll when the
laminator is not in operation. Prolonged
contact can damage the rolls.
CAUTION
Excess pressure can damage the laminating
rolls. Always select the minimum roll
pressure necessary to complete the task.
CAUTION
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 Falcon 36 Laminator is a large and
heavy piece of equipment. It is necessary to
employ LICENSED RIGGERS ONLY to
move the machine. The laminator is not
designed to be tipped up or sideways in any
way. Such action disturbs the exact
alignment of the rolling parts of the machine
and requires extensive realignment. GBC
Pro-Tech’s warranty does not cover
malfunction of the equipment due to
mishandling and/or tipping.
GBC Pro-Tech bears no responsibility for
personal injury or damage due to moving the
laminator improperly.
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.
 GBC Pro-Tech 1997 October
1-3
Safety and Warranty Information
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.
Falcon 36 Laminator Service Manual
WARNING
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
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.
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.
Never insert objects of any kind through any
of the slots on the laminator. You can touch
dangerous voltage points or short out parts.
You can be severely shocked, electrocuted or
cause a fire.
ALWAYS USE GOOD SAFETY PRACTICES
WHEN OPERATING OR SERVICING THE
LAMINATOR AND KNOW HOW TO REACT
QUICKLY IN AN EMERGENCY.
&DXWLRQ:DUQLQJ/DEHO/RFDWLRQV
Posted at various locations on your Falcon 36
Laminator are important safety labels. PAY
CAREFUL ATTENTION TO THESE LABELS AT
ALL TIMES! Figure 1-2 shows the location of each
of these labels.
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 1997 October
Falcon 36 Operation Manual
Safety
WARNING
WARNING
SAFETY
INSTRUCTIONS
SICHERHEITSRICHTLINIEN
ACHTUNG
ACHTUNG
MISE EN GARDE
MISE EN GARDE
CONSIGNES DE
SÉCURITÉ
WARNING
1. Read and understand the Operation
Manual and all safety labels before
operating this machine.
ACHTUNG
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.
Crush and burn
hazard. Stay clear
of moving rollers.
Stop machine and
raise roll before
cleaning.
Moving parts can
crush and cut.
Do not operate with
door open.
©1994 HCS, Inc. 800-748-0241
Reorder No. 1012-PT
©1994 HCS, Inc. 800-748-0241
ARRET
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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.
SE
MI
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.
- 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.
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.
©1994 HCS, Inc. 800-748-0241
Reorder No.7002-PT
Reorder No.1033R-PT
D'
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4. Never reach into the machine for any
reason unless the machine is at a
COMPLETE STOP.
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4 HCS,
Inc.
800-7
48-02
41
Reord
er
No.60
01-PT
240 VOLTS
LEM PRODUCTIONS, INC. DOYLESTOWN PA
LVM-240C
WARNING
ACHTUNG
MISE EN GARDE
DANGER
GEFAHR
HAZARDOUS
VOLTAGE.
Carefully read Operator's
Manual before handling
this machine. Observe
instructions and safety
rules when operating.
©1994 HCS, Inc. 800-748-0241
To be serviced only
by trained and
authorized personnel.
Lockout power before
servicing.
Reorder No.6001-PT
©1994 Hazard Communication Systems, Inc. 800-748-0241
Reorder No. 5025-PT
Figure 1-2: Locations of Safety Labels
 GBC Pro-Tech 1997 October
1-5
Safety
Falcon 36 Operation Manual
Blank page.
1-6
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
6HFWLRQ ,QVWDOODWLRQ
Before a Falcon 36 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.
CAUTION
Failure to follow the preinstallation checklist
can result in damage to the laminator.
Installation
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.
❒ Is there an appropriate power outlet available or
has a certified electrician been contacted to wire
the laminator directly?
The laminator requires 30A single phase service
and a power receptacle that accepts a 30A 250V
NEMA L6-30P plug.
3UHLQVWDOODWLRQ&KHFNOLVW
❒ 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 layout.
❒ Is the environment appropriate for the
laminator?
The laminator requires a clean, dust and vapor
free environment to operate properly. It must not
be located where there is air blowing directly on
the machine.
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.
 GBC Pro-Tech 1997 October
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.
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.
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.
2-1
Installation
Falcon 36 Operation Manual
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.
2-2
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
Installation
Recommended
clearance
73" (~1.8m)
Floor Trimmer
10'
(~3m)
4'6" (~1.1m)
3' x 6' (~1m x 2m)
Table
3' (~1m)
2'2"
(~.7m)
10'
(~3m)
Figure 2-1: Laminator Space Requirements
 GBC Pro-Tech 1997 October
2-3
Installation
Falcon 36 Operation Manual
8QSDFNLQJ
⇒ NOTE
ALL SHIPMENTS ARE EX- WORKS. At our dock
title passes to the buyer Please review your
insurance coverage prior to shipment, as you are
responsible for all subsequent freight charges and
risks. Before signing the Bill of Lading they should
be sure to inspect the crate and/or pallet for signs of
damage or missing items; if applicable, they should
make a note of this on the Bill of Lading.
The Falcon 36 Laminator is shipped one of two
ways. It is either encased in a plywood 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
/8" open end wrench or adjustable wrench
If the laminator is in a cardboard box:
1. Remove the securing screws around the bottom
of the box using the Phillips head screwdriver as
shown in Figure 2-2.
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.
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
2-4
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
Installation
CAUTION
Foot Bolt
Shipping
Pad
Figure 2-3: Removing the Packing Assemblies
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.
WARNING
Do not attempt to move the laminator across
anything other than a flat, level surface
without trained and qualified riggers. You
can be crushed or seriously injured.
The Falcon 36 Laminator is a large and
heavy piece of equipment. It is necessary to
employ LICENSED RIGGERS ONLY to
move the machine. The laminator is not
designed to be tipped up or sideways in any
way. Such action disturbs the exact
alignment of the rolling parts of the machine
and requires extensive realignment. GBC
Pro-Tech’s warranty does not cover
malfunction of the equipment due to
mishandling and/or tipping.
GBC Pro-Tech bears no responsibility for
personal injury or damage due to moving the
laminator improperly.
Do not use a knife or other sharp instrument
during installation or while servicing the
laminator. You can cause irreparable
damage to the rolls.
9. Remove all packing materials to a safe distance
from the laminator.
⇒ 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.
⇒ NOTE
A word about international shipments: As these are
heavy pieces of equipment, GBC Pro-Tech takes
every precaution to ensure that our laminators are
properly crated to the highest standards.
Before machines leave our loading dock, they are
pre-treated with a VCI protective film to provide
total corrosion protection. This protective film is
wrapped around the machine and completely sealed.
In addition, moisture absorbing silicone desiccite
packs are packed inside the crate and machine
cabinets.
Prior to start up of the machine, you must remove
the desiccite packs from each cabinet and discard.
DO NOT operate the machine with the desiccite
packs inside the cabinets.
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.
 GBC Pro-Tech 1997 October
2-5
Installation
Falcon 36 Operation Manual
If the laminator is in a crate:
CAUTION
1. Remove the top of the crate and then the sides in
the order shown in Figure 2-4.
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.
Do not put packing screws on the floor. They
can cause problems when trying to roll the
machine into position.
A second person must support the side
labeled 5 in Figure 2-4. It can fall and
damage the laminator.
1
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contain:
No.1033R-PT
Reorder
800-748-0241
Inc.
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©1994
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OP
ST
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D'
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N
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R GE
CY
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4. Remove the screws holding the foot pads onto
the pallet using the Phillips head screwdriver.
MO
TOR
FWD
6
9
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12
3
REV
15
0
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ED
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150
125
175
200 HI
100
225
75
250
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150
275
175
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225
250
50
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5025-PT
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tion
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©1994
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.
2-6
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
WARNING
Do not attempt to move the laminator across
anything other than a flat, level surface
without trained and qualified riggers. You
can be crushed or seriously injured.
The Falcon 36 Laminator is a large and
heavy piece of equipment. It is necessary to
employ LICENSED RIGGERS ONLY to
move the machine. The laminator is not
designed to be tipped up or sideways in any
way. Such action disturbs the exact
alignment of the rolling parts of the machine
and requires extensive realignment. GBC
Pro-Tech’s warranty does not cover
malfunction of the equipment due to
mishandling and/or tipping.
GBC Pro-Tech bears no responsibility for
personal injury or damage due to moving the
laminator improperly.
6. Once the laminator is in place set the locking
mechanism on all four wheels to ON.
7. Remove any plastic strapping and packing paper
taped to the rolls.
CAUTION
Do not use a knife or other sharp instrument
during installation or while servicing the
laminator. You can cause irreparable
damage to the rolls.
8. Remove all packing materials to a safe distance
from the laminator.
⇒ 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.
Installation
⇒ NOTE
A word about international shipments: As these are
heavy pieces of equipment, GBC Pro-Tech takes
every precaution to ensure that our laminators are
properly crated to the highest standards.
Before machines leave our loading dock, they are
pre-treated with a VCI protective film to provide
total corrosion protection. This protective film is
wrapped around the machine and completely sealed.
In addition, moisture absorbing silicone desiccite
packs are packed inside the crate and machine
cabinets.
Prior to start up of the machine, you must remove
the desiccite packs from each cabinet and discard.
DO NOT operate the machine with the desiccite
packs inside the cabinets.
6HWXS
Once the Falcon 36 Laminator has been unpacked
and moved into final position check each of the
following items.
Tools required:
•
1
•
Adjustable wrench
/8" hex wrench
Setup Procedure
1. Inspect the laminator for any obvious shipping
damage.
2. Remove the drive and control side cabinet
covers with the 1/8" hex wrench by removing the
six screws holding each cover in place.
3. Inspect all the bolts and tighten any that were
loosened during shipping.
4. Check the upper main roll assembly by using the
handwheel to raise and lower the roll. It should
move smoothly.
5. Set the nip. (See Section 4: Maintenance and
Troubleshooting for the procedure.)
6. Verify that both thermocouples make contact
with the rolls. (See Section 4: Maintenance and
Troubleshooting for the procedure.)
 GBC Pro-Tech 1997 October
2-7
Installation
Falcon 36 Operation Manual
WARNING
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.
7. Plug the laminator into an approved socket or
have a certified electrician wire the laminator
directly to a power source.
8. Verify that the photoelectric eye is working
properly. (See the procedure below.)
9. Replace both cabinet covers.
6WDUWXS
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.
❒ Is the photoelectric eye system working?
With the laminator running, place an object
approximately the size of your hand just in front
of the nip to confirm that the photoelectric eye
system is functioning. The rolls should stop.
Move the object away from the nip. The
laminator should resume operation.
WARNING
Never operate the laminator unless the
photoelectric eye 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 bottom roll.
Startup Checklist
❒ Is the footswitch operating?
Test the footswitch for both forward and reverse
operation. Verify that the footswitch overrides
the photoelectric eye by pressing the footswitch
and pushing an object as large as your hand into
the nip area.
Start the laminator and go through the following
checklist.
Once you have completed the startup checklist you
can safely run a test sample.
❒ Are the emergency stop buttons working?
Push down on one of the emergency stop
buttons. The laminator should stop. Pull up on
the button. 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.
2-8
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
RG E
U
RG E
P
STO
CY
N
U
1NO
/ 4 TtuAU
r nS EM
RG E
ARRET
D'
In addition, the laminating rolls of the Falcon 36 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
servicing.
Figure 3-1:
N
CE
E
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.
EM
D'
NOT AUS
RG E
N
CE
E
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.
Twist and pull up
both buttons to
resume operation
ARRET
6DIHW\
Push either
button to stop the
laminator
P
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6HFWLRQ 2SHUDWLRQ
Operation
Using the Emergency Stop Buttons
Despite the safety features built into the Falcon 36
Laminator, extreme caution must be used when
operating or servicing the unit.
An important feature of the laminator is the
photoelectric 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
photoelectric eye system is overridden and
your fingers can get caught in the nip. You
can be crushed or burned.
The Falcon 36 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 qualified service technician should open
these cabinets.
The laminator is equipped with two emergency stop
buttons located on the top of either side of the
laminator. Either of these, if engaged, stops the
laminator. To continue operation both emergency
stop buttons must be in the up position.
 GBC Pro-Tech 1997 October
3-1
Operation
Falcon 36 Operation Manual
2SHUDWRU&RQWUROV
The operator controls for the Falcon 36 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:
)URQW &RQWURO 3DQHO
MOTOR
AUTO
9
12
6
1
Motion Control
FORWARD/
REVERSE
2
3
0
REV
15
6
18
SPEED
STOP
Foot Switch/
Continuous Run
AUTO/STOP
FANS
1
Cooling Fans
ON/Off
POWER
3
OUT
4
O
5
B
O
T
T
O
M
175
200
8
HI
250
275
75
OUT
150
175
200
HI
225
125
250
100
275
75
°F
300
001-133
LO
225
125
100
50
PROTECH
1
O
T
O
P
150
OUT
Red: Set point has
not been reached
Green: Temperature
is exactly at set point
50
PROTECH
HEATERS
1
Lower Roll Heat
ON/OFF
Power Light
7
O
.
Upper Roll Heat
ON/OFF
8. UPPER ROLL HEATER CONTROLLER –
Provides a readout of the temperature of the
upper roll and the set-point for the desired
temperature. (See Figure 3-3.)
9. LOWER ROLL HEATER CONTROLLER–
Provides a readout of the temperature of the
lower roll and the set-point for the desired
temperature. (See Figure 3-3.)
Speed Adjustment
FWD
7. POWER LIGHT – Indicates when the main
power is being applied to the machine.
150
°F
175
300
001-133
200
9
°F
250
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
HI
275
75
50
PROTECH
Top Roll Heater
Controller
225
125
100
LO
Solid: Temperature is
within 5° of set point
Blinking: Temperature
is greater than 5° of set
point
Off: Set point has been
reached or exceeded
LO
Lower Roll Heater
Controller
Figure 3-3: Heater Controller
5HDU 3DQHO &RQWURO
GBC Pro-Tech, De Forest, WI 608-246-8844
Figure 3-2: Front Control Panel
1. SPEED ADJUSTMENT – Adjusts the speed of
the machine from zero to the maximum as the
control is turned clockwise.
2. MOTION CONTROL
FORWARD/REVERSE - Controls the
direction of the drive system, forward, reverse,
or stop.
3. 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.
4. UPPER ROLL HEAT ON/OFF – Turns the
heater controller for the upper main roll on or
off.
5. LOWER ROLL HEAT ON/OFF – Turns the
heater controller for the lower main roll on or
off.
MOTOR
AUTO
Foot Switch/
Continuous Run
AUTO/STOP
STOP
Figure 3-4: Rear Panel Control
FOOT SWITCH/CONTINUOUS RUN
AUTO/STOP - Changes control of the machine
drive from a foot switch to continuous run.
WARNING
Use extreme caution when operating the
laminator with the footswitch. The
photoelectric eye system is overridden and
your fingers can get caught in the nip. You
can be crushed or burned.
6. FOOT SWITCH/CONTINUOUS RUN
AUTO/STOP - Changes control of the machine
drive from a foot switch to continuous run.
3-2
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
6HWXS
Setup of the Falcon 36 Laminator is quick and
straightforward when instructions are followed
exactly.
To adjust the nip, please see Maintenance.
/DPLQDWRU 5ROO 3UHVVXUH
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 generally cannot be cured by
applying more pressure.
Operation
should ALWAYS face outward from the
laminating roll.
CAUTION
Always mount the film so that the adhesive
side faces outward from the laminating roll.
This prevents hours of roll cleaning.
2. The film must be centered on the unwind for
best performance. This is vital when two films
are fed together. If the two films are not aligned,
feed problems, wrinkles and other assorted
troubles will occur.
CAUTION
Excess pressure can damage the laminating
rolls. Minimum laminator roll pressure is
consistent with good results.
CAUTION
Carefully align the two films being fed into
the nip. If not, you will obtain poor results.
A typical roll pressure for soft substrates such as
Foamcore or Orca Board is 1/4 a revolution of the
laminating roll crank.
3RVLWLRQLQJWKH)LOP
A typical roll pressure for hard substrates is 1/2 a
revolution of the laminating roll crank.
The following procedure is applicable to both the
top and bottom feed unwinds.
A typical roll pressure for encapsulation is 1/2 a
revolution of the laminating roll crank.
1. Secure the braking film mount arm so as to
center the film between the side cabinets.
/RDGLQJWKH)LOP
2. Loosen the core support film mount arm and
slide it to the drive side of the machine.
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.
3. Install the laminating film onto the braking
mount arm and slide the core support arm over
to support the laminating film's end.
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:
4. Secure the support arm.
1. The adhesive side of the film must be oriented
away (on the outside) from the laminating roll.
Otherwise it will immediately bond to the roll,
creating a major clean-up project.
Films have a shiny side and a dull side. The dull
side is the one with the adhesive. The dull side
 GBC Pro-Tech 1997 October
3-3
Operation
Falcon 36 Operation Manual
+HDWLQJ
Use the following instructions when heating one or
both of the laminating rolls. The procedure is the
same for the top and bottom heaters.
1. Set the heater switch to ON.
2. Adjust the temperature controller for the desired
operating temperature using the temperature
controller dial adjustment.
3. When heating the rolls, keep the top roll down
and turning at a moderate speed to prevent
uneven heating.
4. The temperature controllers have LED (light
emitting diode) readouts on the rotary dial to
indicate the status of the heating system. See
Figure 3-5 to learn about the readouts.
OUT
Red: Set point has
not been reached
Green: Temperature
is exactly at set point
150
175
200
250
100
275
75
50
PROTECH
°F
300
001-133
3DSHU7LSV
1. Always cut the leading edge of a print straight
so it can be fed perpendicular to the laminating
rolls.
2. Ink-Jet prints done on high gloss paper might
not bond or might experience bubbles (called
puddling). To solve this problem, raise the heat
setting of the laminator by approximately 20 ºF
and increase the motor speed by one third.
HI
225
125
⇒ Note
In the change over from hot to pressure-sensitive
materials, 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.
LO
Solid: Temperature is
within 5° of set point
Blinking: Temperature
is greater than 5° of set
point
Off: Set point has been
reached or exceeded
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
Figure 3-5: Heater Controller
5. It will take approximately 15 minutes for the
laminating roll(s) to reach operating
temperature. When the preset operating
temperature has been reached, the machine is
ready to use.
&RROLQJ
The following procedure is the fastest way to cool
the machine. Natural cooling can also be used.
1. Set the heater switches to OFF.
2. Leave the cooling system ON.
3. Lower the upper main roll until the laminating
rolls are touching.
4. Set the Forward/Reverse switch to FWD.
5. Set the speed control to 2.
6. Let the machine run until the laminating rolls
return to room temperature.
3-4
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
Operation
3URFHVV&RQWURO&KDUWV
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 activating the motor. Do not adjust the
roll crank after setting the nip. Reset the
machine to forward operation.
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 product and process. Process control charts are
an excellent tool for training new operators. They
provide a "road map" for correct machine setup and
operation.
This section contains a blank process control chart
and diagram for the Falcon 36 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.
The process control charts should be kept in this
manual 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.
⇒ NOTE
When trying new products and processes, remember
that
GBC
Pro-Tech's
customer
service
representatives are only a phone call away. In North
America, call 1-800-236-8843.
The completed process control charts included in
this section are based on Falcon Film, Falcon Board,
and typical prints.
0RXQWLQJDQG/DPLQDWLQJ2QH
3DVV
6HWXS DQG 3URFHGXUH
1. Adjust the machine settings as shown in process
chart 3-2.
4. Web the film by wrapping it around the upper
film idler and draping it over the upper main
roll. Have about six inches laying on the infeed
table.
5. With a leader board of the same thickness as the
mounting board, (make sure the leader board is
also as wide as the film being used) press the
footswitch 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.
6. Lay the image onto the adhesive side of the
Falcon Board. Tacking the image down with a
tacking iron at this point is sometimes helpful.
7. Push the Falcon board and image up against the
leader board and press the footswitch. Be sure to
maintain paper tension throughout this
procedure.
8. Once the board is through the nip and it no
longer continues to feed, disengage the
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.
⇒ 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.
WARNING
Do not operate the laminator without the
infeed table installed on the machine.
2. Load the film onto the upper unwind assembly.
 GBC Pro-Tech 1997 October
3-5
Operation
0RXQWLQJ2QO\
This process varies only slightly from the One Pass
Mount and Laminate process.
6HWXS DQG 3URFHGXUH
1. Adjust the machine settings as shown in process
chart 3-3.
2. Insert Falcon Board, adhesive side down, into
the nip. Lower th upper main roll until it
contacts, and then turn it another 1/4 turn. Press
the footswitch to remove the board from the nip.
3. Lay the image onto the adhesive side of the
Falcon Board. Tacking the image down with a
tacking iron at this point is sometimes helpful.
4. Press the footswitch and carefully insert the
board and image into the nip. Be sure to keep it
perpendicular to the laminating rolls and
maintain paper tension throughout the process.
⇒ Note
Some images will release toner or ink to the upper
laminating 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 process.
Falcon 36 Operation Manual
7ZR3DVV0RXQWDQG/DPLQDWH
&ROG2YHUODPLQDWH
For this process, the image is first encapsulated and
then mounted.
6HWXS DQG 3URFHGXUH 3DVV 1. Adjust the machine settings as shown in process
chart 3-4a and remove the infeed table.
2. Web up the overlaminate by bringing it around
the upper film idler and up to the release paper
rewind. Tape the film to the rewind and give it
one full wrap around the rewind tube. Be sure to
check the process control chart to ensure correct
web up.
3. With a singe edge razor, cut across the film on
the rewind tube, being sure not to cut through
the release liner or the rolls.
WARNING
Use extreme caution when using the single
edge razor not to damage the rolls or cut
yourself.
4. Peel the film back and drape it over the upper
main roll. To get enough material to do this, it
may be necessary to turn the rewind tube by
hand.
5. Pull the mount film straight up from the lower
unwind position. Tack it to the laminate. Be
careful not to stick the film or mount adhesive to
the machine.
6. Insert a starter board into the nip and lower the
upper main roll onto it.
7. Press the footswitch. Once the leader board is
through the nip, lower the upper main roll and
then rotate the crank 1/2 a turn more.
8. Reinstall the infeed table. You can operate with
or without the pull rolls at this point.
9. Encapsulate the images.
3-6
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
6HWXS DQG 3URFHGXUH 3DVV 1. Adjust the machine settings as shown in process
chart 3-4b.
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 footswitch.
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).
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.
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
wrinkles in the nip area. Carefully peel off the
liner as the board progresses through the
laminator.
8. Trim the board and image to the finished size.
7ZR3DVV0RXQWDQG/DPLQDWH+RW
2YHUODPLQDWH
This process is very similar to the Two Pass Mount
and Laminate using cold overlaminate.
6HWXS DQG 3URFHGXUH 3DVV 1. Adjust the machine settings as shown in process
chart 3-5a and remove the infeed table.
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.
Operation
the film to the machine. Tack it to the hot
overlaminate.
4. Insert a starter board into the nip and lower the
upper main roll onto it.
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.
6. Reinstall the infeed table.
7. Encapsulate the images.
6HWXS DQG 3URFHGXUH 3DVV 1. Adjust the machine settings as shown in process
chart 3-5b.
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 footswitch.
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).
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.
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.
8. Trim the board and image to the finished size.
3. Pull the mount adhesive straight up from the
lower unwind position, being careful not to stick
 GBC Pro-Tech 1997 October
3-7
Operation
Falcon 36 Operation Manual
(QFDSVXODWLRQ
0DFKLQH6KXWGRZQ
This is the most commonly performed process.
It is very important that the Falcon 36 laminator is
shut down in proper manner. If not, the laminating
rolls can be damaged or destroyed.
6HWXS DQG 3URFHGXUH
1. Adjust the machine settings as shown in process
chart 3-6 and remove the infeed table. Be sure
that, while heating the machine, the rolls are
together and turning.
2. Install laminating film on the upper and lower
unwinds.
3. Web up the upper laminate by wrapping it
around the upper film idler and laying it over the
upper main roll. Do not drape too much film.
Too much can fold over and leave a line of glue
on the roll, thereby affecting image quality.
CAUTION
Failure to follow this procedure can result in
damage to the rolls.
3URFHGXUH
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
Make sure that the adhesive side of the
laminate is away from the roll to prevent an
extensive clean up job.
CAUTION
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
footswitch. 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
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
Operation
352&(66&21752/&+$57
MATERIALS
Upper Media
Image Media
Lower Media
Mounting Substrate
LAMINATOR SETTINGS
Top Heater Status
Drive Mode
Bottom Heater Status
Pull Roll Position
Speed
Output Cooling
Drive Direction
Main Roll Setting
352&(66&21752/',$*5$0
IDENTIFICATION DIAGRAM
Notes
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
 GBC Pro-Tech 1997 October
3-9
Operation
Falcon 36 Operation Manual
352&(66&21752/&+$57
One-Pass Mounting and Laminating
MATERIALS
Upper Media
3 mil gloss
Lower Media
N/A
Bond Paper
Image Media
Falcon Board
Mounting Substrate
LAMINATOR SETTINGS
Top Heater Status
ON @ 240 ºF (115 ºC) Drive Mode
OFF
Bottom Heater Status
1-2 ft/min
Speed
FWD
Drive Direction
Manual (Footswitch)
UP
Pull Roll Position
OFF
Output Cooling
DOWN - 1/4 turn
Main Roll Setting
352&(66&21752/',$*5$0
Leader
Board
Printed
Image
FALCON
Board
Notes
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
3-10
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
Operation
352&(66&21752/&+$57
One-Pass Mounting
MATERIALS
Upper Media
N/A
Image Media
Lower Media
N/A
Mounting Substrate
Bond Paper
Falcon Board
LAMINATOR SETTINGS
Top Heater Status
ON @ 240 ºF (115 ºC) Drive Mode
OFF
Bottom Heater Status
2-3 ft/min
Speed
FWD
Drive Direction
Pull Roll Position
Output Cooling
Main Roll Setting
Manual (Footswitch)
UP
OFF
DOWN - 1/4 turn
352&(66&21752/',$*5$0
Printed
Image
FALCON
Board
Notes
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
 GBC Pro-Tech 1997 October
3-11
Operation
Falcon 36 Operation Manual
352&(66&21752/&+$57D
Two Pass Mount and Cold/Pressure Overlaminate, First Pass
MATERIALS
Upper Media
Pro-Gloss
Image Media
Lower Media
Pro-Mount
Mounting Substrate
Bond Paper
N/A
LAMINATOR SETTINGS
Top Heater Status
Bottom Heater Status
ON @ 110 ºF (43 ºC)
OFF
4-6 ft/min
Speed
Drive Direction
FWD
Drive Mode
Pull Roll Position
Output Cooling
Main Roll Setting
Manual or Auto
UP or DOWN
OFF
DOWN - 1/2 turn
352&(66&21752/',$*5$0D
Release
Liner Rewind
Release Liner
Notes
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
3-12
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
Operation
352&(66&21752/&+$57E
Two Pass Mount and Cold/Pressure Overlaminate, Second Pass
MATERIALS
Upper Media
N/A
Image Media
Lower Media
N/A
Mounting Substrate
N/A
Foam Core
LAMINATOR SETTINGS
Top Heater Status
OFF
Drive Mode
Bottom Heater Status
OFF
Pull Roll Position
2-6 ft/min
Speed
Drive Direction
FWD
Output Cooling
Main Roll Setting
Manual (Footswitch)
UP
OFF
DOWN - 1/4 turn
352&(66&21752/',$*5$0E
Hold Encapsulated
Image
Image
Face
Release
Liner
Notes
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
 GBC Pro-Tech 1997 October
3-13
Operation
Falcon 36 Operation Manual
352&(66&21752/&+$57D
Two Pass Mount and Hot Overlaminate, First Pass
MATERIALS
Upper Media
3 mil Gloss
Image Media
Lower Media
Pro-Mount
Mounting Substrate
Bond Paper
N/A
LAMINATOR SETTINGS
Top Heater Status
Bottom Heater Status
ON @ 230 ºF (110 ºC) Drive Mode
OFF
3-4 ft/min
Speed
Drive Direction
FWD
Pull Roll Position
Output Cooling
Main Roll Setting
Manual or Auto
DOWN
OFF
DOWN - 1/2 turn
352&(66&21752/',$*5$0D
Notes
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
3-14
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
Operation
352&(66&21752/&+$57E
Two Pass Mount and Hot Overlaminate, Second Pass
MATERIALS
Upper Media
N/A
Image Media
N/A
Lower Media
N/A
Mounting Substrate
Foam Core
LAMINATOR SETTINGS
Top Heater Status
OFF
Drive Mode
Bottom Heater Status
OFF
Pull Roll Position
2-3 ft/min
Speed
Drive Direction
REV
Manual (Footswitch)
DOWN
OFF
Output Cooling
UP
Main Roll Setting
352&(66&21752/',$*5$0E
CAUTION: Do not
allow foam board to
drop below Fan
Bridge Lip
Encapsulated Image
Release Liner
Foam Core
Notes
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
 GBC Pro-Tech 1997 October
3-15
Operation
Falcon 36 Operation Manual
352&(66&21752/&+$57
Encapsulation
MATERIALS
Upper Media
3 mil Gloss
Image Media
Lower Media
3 mil Gloss
Mounting Substrate
Bond Paper
N/A
LAMINATOR SETTINGS
Top Heater Status
ON @ 230 ºF (110 ºC) Drive Mode
Bottom Heater Status
ON @ 230 ºF (110 ºC) Pull Roll Position
Speed
Drive Direction
3-6 ft/min
FWD
Output Cooling
Main Roll Setting
Manual or Auto
DOWN
OFF
DOWN - 1/4 turn
352&(66&21752/',$*5$0
Notes
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
3-16
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
6HFWLRQ 0DLQWHQDQFHDQG
7URXEOHVKRRWLQJ
Performing regular maintenance on the Falcon 36
Laminator is critical to the proper operation of the
machine. A maintenance schedule and a section of
procedures for disassembling and reassembling the
serviceable areas of the laminator are included in
this section.
Table 6-1: Maintenance Schedule
Daily
Monthly
Every
Six
Months
•
Clean/adjust the thermocouples
•
Clean the rolls
•
Inspect the electrical cord for
damage
•
Inspect the footswitch cord for
damage
•
Adjust the nip
•
Check the chain tension
•
Inspect the area around the
laminator for possible hazards (dust
buildup, combustible items stored
too close, etc.)
•
Lubricate the grease fittings and
chain
•
Check wire termination tightness
Maintenance and Troubleshooting
Tools required:
•
1
•
80% isopropyl alcohol
•
100% cotton terry cloth
/8" hex wrench
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.
WARNING
Do not attempt to adjust the position of the
thermocouples if the rolls are hot. You can be
seriously burned.
To adjust a thermocouple:
1. Locate the thermocouple to be adjusted using
the illustration in Figure 4-3.
7KHUPRFRXSOH3RVLWLRQLQJDQG
&OHDQLQJ
2. Remove the two screws securing the
thermocouple to the laminator using the 1/8" hex
wrench and take the thermocouple out.
One of the most crucial adjustments to the Falcon 36
Laminator is positioning the thermocouples and
making sure they are clean. There are two
thermocouples that control the temperature of the
main rolls. If a thermocouples loses contact with its
roll, the roll can overheat and be seriously damaged
or can even start a fire. Therefore, it is absolutely
critical that both thermocouples 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.
 GBC Pro-Tech 1997 October
4-1
Maintenance and Troubleshooting
Falcon 36 Operation Manual
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.
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
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
Maintenance and Troubleshooting
Upper Main
Roll
Thermocouple
Tube to Frame
Thermocouple
Wire
STOP
ARRET
D'
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Thermocouple
Lower Main Roll
Underside of
Laminator
Figure 4-3: Locations of the Thermocouples
 GBC Pro-Tech 1997 October
4-3
Maintenance and Troubleshooting
Falcon 36 Operation Manual
&OHDQLQJ
To clean beads of adhesive, dust and dirt from
the rolls:
Tools required:
1. Allow the laminator to cool slightly to no higher
than 110ºF (43ºC).
•
Adhesive coated board
•
80% isopropyl alcohol (or dishwashing
detergent)
•
Rubber cement eraser
•
Several 100% cotton terry cloths
•
Protective rubber gloves
To clean the laminator rolls:
1. Remove the infeed table and infeed pressure
plate to gain access to the rolls.
2. Set the FWD/REV switch to the REV position
and use the footswitch to move the rolls as you
clean them. Set the Speed Control to 1.5 ft/min.
3. Clean the rolls using a moderate amount of 80%
isopropyl alcohol on a cotton terry cloth.
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
Exercise extreme caution while cleaning the
laminator. You can be caught in the turning
rolls and crushed or burned.
2. While the laminator is at normal operating
temperature, put on the rubber gloves and, using
a rubber cement eraser, remove any heat
activated adhesive from the rolls.
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
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.
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 laminator. Be sure to set the
nip for the thickness of the board used.
5. Allow the laminator to cool.
4-4
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
Maintenance and Troubleshooting
To clean the cabinet and covers:
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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
continuous 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
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.
Tools required:
1
/8" hex wrench
(2) ¾" open end wrenches
To adjust the nip:
CAUTION
The main rolls must be at room temperature
to achieve a proper nip setting.
1. Unplug the laminator and make sure it won’t be
plugged back in while you are performing this
procedure.
2. Remove the drive and control side cabinet
covers with the 1/8" hex wrench by removing the
six screws holding each cover in place.
3. Using the handwheel, lower the upper main roll
until there is a small gap of light between the
upper and lower main rolls.
4. Loosen the jamnut on the nip adjusting bolt on
each side of the laminator as shown in
Figure 4-4.
Adjusting
Bolt
Jamnut
Figure 4-4: Adjusting the Nip
 GBC Pro-Tech 1997 October
4-5
Maintenance and Troubleshooting
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.
Falcon 36 Operation Manual
3. Loosen all four motor mount bolts using the 3/16"
hex wrench as shown in Figure 4-6. The motor
should just move freely within the slots.
1/4" to
1/2" Play
Properly Set Nip
(Distance Between
Rolls is Equal)
Figure 4-5: Properly Set Nip
6. Hold the adjustment bolt in place while
tightening the jamnut on each side of the
laminator.
Loosen Motor
Mount Bolts
Downward
Force Tightens
Chain
Figure 4-6: Adjusting the Chain Tension
7. Replace both cabinet covers and reconnect
power to the laminator.
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.
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5. Tighten the mounting bolts while maintaining
the downward pressure on the motor.
Adjusting the chain tension on the Falcon 36
Laminator 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
•
3
•
Screwdriver
/8" hex wrench
/16" hex wrench
To adjust the chain tension:
1. Unplug the laminator and make sure it won’t be
plugged back in while you are performing this
procedure.
2. Remove the drive side cabinet cover using the
1
/8" hex wrench by removing the six screws
holding the cover in place.
4-6
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
Maintenance and Troubleshooting
/XEULFDWLRQ
Tools required:
•
1
•
High temperature grease or lithium grease
•
Grease gun
/8" hex wrench
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To lubricate the laminator:
WARNING
Do not lubricate the laminator when it is hot.
You can be burned.
WARNING
Unplug the laminator and make sure it won't
be plugged back in 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 six 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 temperature grease.
Figure 4-7: Grease Fittings
3. Lubricate the chain using a soft cloth and
automotive oil.
4. Replace the cabinet covers and reconnect power
to the laminator.
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For machine parts and technical service:
North America: 1-800-790-7787.
Europe: +44 (0) 1844 202 440
or fax: +44 (0) 1844 202 441.
Please provide serial number when calling for
service.
For film and application questions:
North America: 1-800-236-8843.
Europe: +44 (0) 1844 202 440
or fax: +44 (0) 1844 202 441.
 GBC Pro-Tech 1997 October
4-7
Maintenance and Troubleshooting
4-8
Falcon 36 Operation Manual
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
Maintenance and Troubleshooting
2XWSXW7URXEOHVKRRWLQJ*XLGH
Problem:
Problem:
D waves in the image, not in the D waves in the laminate.
laminate.
Hints:
Hints:
• Increase clutch tension.
• Check paper tension.
• Check roll pressures.
• Check relative moisture content • Check nip settings.
of the paper.
Problem:
Straight waves in the output.
Hints:
• Decrease clutch tension.
• Check operational settings for
materials being used.
Other Common
Problems:
Feed
Direction Problem:
Blistering in the image.
Hints:
• Increase speed or lower
the operating
temperature.
Problem:
Coiling of encapsulated
images.
Problem:
Waves on only one side of the
output.
Hints:
• Check nip settings.
• Check for even paper tension.
Problem:
Angled waves on the output.
Hints:
• Check for insufficient clutch
tension.
• Check for insufficient main roll
pressure
Hints:
• Balance the upper and
lower unwind brake
tension. Make sure
main roll temperatures
are the same. Adjust
cooling fans.
Problem:
Longitudinal waves or
stuttering, jerking, or
excessive noise from the
drive side of the laminator.
Hints:
• Increase chain tension,
decrease unwind brake
tension.
 GBC Pro-Tech 1997 October
4-9
Maintenance and Troubleshooting
Falcon 36 Operation Manual
Blank page.
4-10
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
6HFWLRQ :DUUDQW\
/LPLWHG:DUUDQW\
Warranty
([FOXVLRQV WR WKH :DUUDQW\
This warranty specifically does not cover:
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 ProTech and cannot be modified or amended.
GBC Pro-Tech’s sole and exclusive liability and
the customer’s sole and exclusive remedy under
this warranty shall be, at GBC Pro-Tech’s
option, to repair or replace any such defective
part or product. 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 modification,
incorrect line voltage, contaminated air supply,
or by fire, accident, flood, or other hazard.
1. Damage to the laminating rolls caused by
knives, razor blades, other sharp objects, or
failure caused by adhesives.
2. Damage to the machine caused by lifting, tilting,
and/or any attempt to position the machine other
than rolling on the installed casters on even
surfaces.
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
PARTICULAR PURPOSE. GBC PRO-TECH
WILL NOT BE LIABLE FOR PROPERTY
DAMAGE OR PERSONAL 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 1997 October
5-1
Warranty
Falcon 36 Operation Manual
Blank page.
5-2
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
Technical Information
6HFWLRQ7HFKQLFDO,QIRUPDWLRQ
6SHFLILFDWLRQV
Table 6-1.
Falcon 36 Laminator
Specifications
Characteristic
Specifications
Dimensions
(L x D x H)
56" x 31" x 56"
(1.42 x .79 x 1.42m)
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
Laminating Opening
1.5" (3.8 cm) maximum opening
controlled with infinitely
variable hand crank
Laminating Material
Uses heat activated and pressuresensitive materials 0 - 39"
(99.6 cm) wide on a 3" (7.6 cm)
ID core, 10" (25.4 cm)
maximum diameter
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 footswitch
Encapsulating Features
Pull rolls and cooling fans for
uniform flat cooling
Safety Features
•
Photoelectric eye system
prevents laminating roll
movement when hands are
in the nip area
•
All electrical and moving
mechanical parts are located
in bolted cabinets
•
Hand crank for laminating
roll movement
•
Unwind for rolled prints
•
Rewind for rolled prints
•
Vacuum table
•
Outfeed Slitters
•
Outfeed Table
Options
Installation
Requirement
220VAC 50 or 60 Hz single
phase, 30A
 GBC Pro-Tech 1997 October
6-1
Technical Information
Falcon 36 Operation Manual
Blank page.
6-2
 GBC Pro-Tech 1997 October
Falcon 36 Operation Manual
Index
6HFWLRQ ,QGH[
A
Accessory pack, 2-4
Adjusting bolt, 4-5, 4-6
C
Chain
Lubrication, 4-7
Tensioning, 4-6
Cleaning, 4-4
Clutch
Common problems, 4-8
Controls
front control panel, 3-2
E
Emergency stop buttons, 1-1, 2-8, 3-1
Encapsulating, 6-1
Encapsulation, 3-8
Environment, 2-1
Extension cord, 2-1
F
Film
loading, 3-3
positioning, 3-3
Foot bolt, 2-5, 2-6
Footswitch, 1-1, 1-2, 2-8, 3-1, 4-1, 4-4, 6-1
FWD/REV switch, 4-4
G
Grease fittings, 4-7
Ground plug, 2-1
H
Handwheel, 2-7, 4-5
Heater, 2-8
Common problems, 4-8
Controller, 2-8
Heating, 3-4
I
Infeed table, 4-4
Installation requirements, 2-1, 6-1
Isopropyl alcohol, 4-4
 GBC Pro-Tech 1997 October
L
Laminating material, 6-1
Laminating opening, 6-1
Laminating rolls, 6-1
Laminating speeds, 6-1
Lubrication, 4-1–4-5
M
Main roll
Lower, 4-5
Main rolls, 4-1, 4-5
Temperature, 4-1
Maintenance schedule, 4-1
Motor, 2-8, 4-6
Mounting and laminating (one pass), 3-5
Mounting only, 3-6
N
Nip, 1-1, 1-2, 2-7, 2-8, 3-1, 4-1, 4-4, 4-5, 4-6, 6-1
O
Outfeed slitters, 6-1
Outfeed table, 6-1
P
Paper, 3-4
Photoelectric eye, 1-1, 1-2, 2-8, 3-1
Power cord, 2-2
Power requirement, 2-1
Preinstallation checklist, 2-1
Pressure
laminator roll, 3-3
Process control charts, 3-16, 3-5
R
Riggers, 1-3, 2-5, 2-6, 2-7
Rubber cement eraser, 4-4
S
Safety features, 6-1
Safety information, 1-1
Safety labels. See Safety information
Setup, 3-3
Setup procedure, 2-7–2-8
Shutdown, 3-8
Specifications
Dimensions, 6-1
7-1
Index
Falcon 36 Operation Manual
Encapsulating, 6-1
Laminating material, 6-1
Laminating opening, 6-1
Laminating rolls, 6-1
Laminating speeds, 6-1
Weight, 6-1
T
Technical support
Call 1-800-236-8843, 4-7
thermocouple, 4-1
Thermocouple, 1-2, 2-7, 2-8, 4-1, 4-2, 4-3
Locations, 4-3
Two-pass mount and laminate, 3-6, 3-7
U
Unpacking, 2-4
Cardboard box, 2-4
Crate, 2-6
Upper main roll, 1-3, 2-7, 4-5, 4-6
Upper main roll assembly, 2-7
V
Vacuum table, 6-1
W
Warnings and cautions. See Safety Information
Warranty, 5-1
7-2
 GBC Pro-Tech 1997 October
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