Falcon F-40 User manual

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© 1998 GBC Pro-Tech
Do not duplicate without written permission
GBC Pro-Tech
4151 Anderson Road
De Forest, Wisconsin 53532
Tel: [phone]
Part Number 930-005
Fax: [phone]
©1994HCS,Inc.800-748-0241 ReorderNo.1033R-PT
Crushand burn
hazard. Stay clear
ofmoving rollers.
Stopmachine and
raiseroll before
cleaning.
WARNING
ACHTUNG
MISEEN GARDE
©1994HCS,Inc.800-748-0241 Reorder No.1033-PT
Crushand burn
hazard. Stay clear
ofmoving rollers.
Stopmachine and
raiseroll before
cleaning.
WARNING
ACHTUNG
MISEEN GARDE
Tobe serviced only
bytrained and
authorized personnel.
Lockoutpower before
servicing.
HAZARDOUS
VOLTAG E.
DANGER
GEFAHR
©1994HazardCommunicationSystems,Inc.800-748-0241Reorder No. 5025-PT
©1994HCS,Inc.800-748-0241 ReorderNo.6001-PT
Carefullyread Operator's
Manualbefore handling
thismachine. Observe
instructionsand safety
ruleswhen operating.
WARNING
ACHTUNG
MISEEN GARDE
NOT
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CY
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©1994HCS,Inc. 800-748-0241 ReorderNo.7002-PT
SAFETY
INSTRUCTIONS
SICHERHEITS-
RICHTLINIEN
CONSIGNES DE
SÉCURITÉ
1. Readand understand the Operation
Manualand all safety labels before
operatingthis machine.
2. Onlya trained person is to be
permittedto operate this machine.
Trainingshould include instruction
inoperation under normal conditions
andemergency situations.
3. This machine is to be serviced only
bytrained and authorized personnel.
Followlockout procedures before
servicing.
4. Neverreach into the machine for any
reasonunless the machine is at a
COMPLETESTOP.
5. Neverleave the machine stopped in
sucha manner that another worker can
startthe machine while you are working
onor within the machine.
6. Neverchange or defeat the function of
electricalinterlocks or other machine
“shutdown”switches.
7. Beforestarting 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
unwindstands.
-The machine is free of paper scraps,
wrapsand jams.
8. Thereis a potential hazard of entanglement
inthis machine caused by items such as
longhair, loose clothing and jewelry.
Makesure your clothing and hair fit
closelyto your body and that all jewelry,
ringsand watches are removed.
NOT
AUS
E
M
E
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G
E
N
CY
ST
OP
ARR
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D'
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N
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F-40
18
16
48
12
10
8
6
4
2
0
psi
100
90
80
70
60
50
40
30
20
10
kPa
700
630
560
490
420
350
280
210
140
70

F-40 Laminator Operator Manual
ii
© GBC Pro-Tech 1998 February
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 merchantabil-
ity 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 par-
ties.
This Manual is Copyrighted ©1998 by GBC Pro-Tech. All rights reserved. The informa-
tion contained in this manual is proprietary and may not be reproduced, stored, transmit-
ted, or transferred, in whole or in part, in any form without the prior and express written
permission of GBC Pro-Tech.

F-40 Laminator Operator Manual
© GBC Pro-Tech 1998 February
iii
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Caution/Warning Label Locations....................................................................................1-4
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Preinstallation Checklist...................................................................................................2-1
Unpacking........................................................................................................................2-3
Setup ...............................................................................................................................2-6
Startup.............................................................................................................................2-7
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Safety...............................................................................................................................3-1
Operator Controls ............................................................................................................3-2
Front Control Panel......................................................................................................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
Procedure ....................................................................................................................3-8

F-40 Laminator Operator Manual
iv
© GBC Pro-Tech 1998 February
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Cleaning .......................................................................................................................... 4-1
Adjusting the Nip .............................................................................................................4-5
Chain Tensioning............................................................................................................. 4-5
Lubrication....................................................................................................................... 4-6
Contacting Technical Support.......................................................................................... 4-7
Output Troubleshooting Guide......................................................................................... 4-8
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Limited Warranty.............................................................................................................. 4-1
Exclusions to the Warranty.......................................................................................... 4-1
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F-40 Laminator Operator Manual
Safety
© GBC Pro-Tech 1998 February
1-1
6HFWLRQ   6DIHW\
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 man-
ual to indicate warnings and cautions.
DANGER
WARNING
CAUTION
The Falcon 40 Laminator has been designed with
safety as a primary consideration. However, you must
become thoroughly familiar with the controls, proper
operation, proper service procedures, and safety fea-
tures of the laminator before using or servicing the unit.
GBC Pro-Tech 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 40 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 photoelec-
tric eye system that stops the machine when objects
move into the nip area. Once the blocking object is
removed and the light beam reestablished, the rolls
resume turning. However, this system is overridden if
you use the footswitch.
WARNING
The Falcon 40 Laminator has a steel cabinet that is
bolted closed to isolate the electrical and drive system
components for the safety of the operator. Only a quali-
fied service technician should open these cabinets.
The laminator is equipped with two emergency stop
buttons located on the top of either side of the lamina-
tor. Either of these, if engaged, stops the laminator. To
continue operation both emergency stop buttons must
be in the up position.
DO NOT ATTEMPT TO OPERATE YOUR
FALCON 40 LAMINATOR UNTIL YOU HAVE
READ THIS SECTION CAREFULLY!
Indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation
which, if not avoided, could result in death or
serious injury.
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.
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.

Safety
F-40 Laminator Operator Manual
1-2
© GBC Pro-Tech 1998 February
Figure 1-1: Using the Emergency Stop Buttons
Despite the safety features built into the Falcon 40
Laminator, extreme caution must be used when operat-
ing or servicing the unit. READ THE FOLLOWING
WARNINGS AND CAUTIONS BEFORE YOU
ATTEMPT TO OPERATE OR SERVICE THE
FALCON 40 LAMINATOR.
WARNING
WARNING
WARNING
CAUTION
WARNING
WARNING
DANGER
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.
Secure long hair so that it cannot get caught in
the machinery. Do not wear ties, loose fitting
clothing or dangling jewelry while operating or
servicing the laminator. These items can get
caught in the nip, and you can be choked,
crushed, or burned.
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.
NOT
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Twist and pull up
both buttons to
resume operation
Push either
button to stop the
laminator
1
/
4
tu
r
n
ALWAYS CHECK THE INFRARED SENSORS
PRIOR TO OPERATION! The sensors must be
clean and have free view of the roll to maintain
proper roll operating temperatures. The rolls can
overheat and cause a fire or seriously damage the
laminator.
Always use care in lowering the top laminating
roll. You can be crushed or burned.
Do not operate the laminator near water. You can
be severely shocked, electrocuted or cause a fire.
Unplug the laminator from the wall outlet before
servicing. You can be severely shocked,
electrocuted or cause a fire.
Do not use liquid or aerosol cleaners on the
laminator. Do not spill liquid of any kind on the
laminator. You can be severely shocked,
electrocuted or cause a fire. Use only a damp
cloth for cleaning the cabinet.

F-40 Laminator Operator Manual
Safety
© GBC Pro-Tech 1998 February
1-3
WARNING
CAUTION
CAUTION
CAUTION
CAUTION
WARNING
CAUTION
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.
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.
Raise the upper main roll when the laminator is
not in operation. Prolonged contact can damage
the rolls.
Excess pressure can damage the laminating rolls.
Always select the minimum roll pressure
necessary to complete the task.
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.
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.
Do not use a knife or other sharp instrument
during installation or while servicing the
laminator. You can cause irreparable damage to
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 Falcon 40 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.

Safety
F-40 Laminator Operator Manual
1-4
© GBC Pro-Tech 1998 February
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
ALWAYS USE GOOD SAFETY PRACTICES
WHEN OPERATING OR SERVICING THE LAMI-
NATOR AND KNOW HOW TO REACT QUICKLY
IN AN EMERGENCY.
&DXWLRQ:DUQLQJ /DEHO /RFDWLRQV
Posted at various locations on your Falcon 40 Lamina-
tor are important safety labels. PAY CAREFUL
ATTENTION TO THESE LABELS AT ALL TIMES!
Figure 1-2 shows the location of each of these
labels.
Connect the laminator only to the type of power
source indicated on the label on the back of the
laminator. You can be severely shocked,
electrocuted or cause a fire. If you are not sure of
the type of power available consult the dealer or
local power company.
Do not attempt to 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.
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.
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.
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.
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.
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.

F-40 Laminator Operator Manual
Safety
© GBC Pro-Tech 1998 February
1-5
Figure 1-2: Locations of Safety Labels
©1994HCS,Inc.800-748-0241ReorderNo.1033R-PT
Crush and burn
hazard. Stay clear
of moving rollers.
Stop machine and
raise roll before
cleaning.
WARNING
ACHTUNG
MISE EN GARDE
©1994HCS,Inc. 800-748-0241 ReorderNo.1033-PT
Crush and burn
hazard. Stay clear
of moving rollers.
Stop machine and
raise roll before
cleaning.
WARNING
ACHTUNG
MISE EN GARDE
©1994HCS,Inc. 800-748-0241 ReorderNo.6001-PT
Carefullyread Operator's
Manualbefore handling
this machine. Observe
instructions and safety
rules when operating.
WARNING
ACHTUNG
MISE EN GARDE
©1994HCS, Inc. 800-748-0241 ReorderNo.7002-PT
SAFETY
INSTRUCTIONS
SICHERHEITS-
RICHTLINIEN
CONSIGNES DE
SÉCURITÉ
1. Read and understand the Operation
Manualand all safety labels before
operatingthis machine.
2. Only a trained person is to be
permittedto operate this machine.
Trainingshould include instruction
inoperation under normal conditions
andemergency situations.
3. This machine is to be serviced only
bytrained and authorized personnel.
Followlockout procedures before
servicing.
4. Never reach into the machine for any
reasonunless the machine is at a
COMPLETESTOP.
5. Never leave the machine stopped in
sucha manner that another worker can
startthe machine while you are working
onor within the machine.
6. Never change or defeat the function of
electricalinterlocks 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
inthis machine caused by items such as
longhair, loose clothing and jewelry.
Makesure your clothing and hair fit
closelyto your body and that all jewelry,
ringsand watches are removed.
NOT
AUS
E
M
E
R
G
E
N
CY
ST
OP
ARR
E
T
D'
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E
N
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T
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MOTOR
FWD
REV SPEED STOP
AUTO
FANS POWER
HEATERS
PRO-TECH Engineering Madison,WI 608-246-8844
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50
75
100
125
150 175 200
225
250
275
300
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75
100
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150 175 200
225
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Tobe serviced only
bytrained and
authorized personnel.
Lockoutpower before
servicing.
HAZARDOUS
VOLTAGE .
DANGER
GEFAHR
©1994HazardCommunicationSystems,Inc.800-748-0241ReorderNo.5025-PT
©1994 HCS, Inc. 800-748-0241 Reorder No. 1012-PT
Moving parts can
crush and cut.
Do not operate with
door open.
WARNING
ACHTUNG
MISE EN GARDE
To be serviced only
by trained and
authorized personnel.
Lockout power before
servicing.
HAZARDOUS
VOLTAGE.
DANGER
GEFAHR
©1994 Hazard Communication Systems, Inc. 800-748-0241 Reorder No. 5025-PT
©1994 HCS, Inc. 800-748-0241 Reorder No.6001-PT
Carefully read Operator's
Manual before handling
this machine. Observe
instructions and safety
rules when operating.
WARNING
ACHTUNG
MISE EN GARDE
©1994 HCS, Inc. 800-748-0241 Reorder No.7002-PT
SAFETY
INSTRUCTIONS
SICHERHEITS-
RICHTLINIEN
CONSIGNES DE
SÉCURITÉ
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.
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.
- 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.1033R-PT
Crush and burn
hazard. Stay clear
of moving rollers.
Stop machine and
raise roll before
cleaning.
WARNING
ACHTUNG
MISE EN GARDE
240VOLTS
LEM PRODUCTIONS, INC. DOYLESTOWN PA LVM-240C
©1994 HCS, Inc. 800-748-0241 ReorderNo.1033-PT
Crush and burn
hazard. Stay clear
of moving rollers.
Stop machine and
raise roll before
cleaning.
WARNING
ACHTUNG
MISE EN GARDE
240VOLTS
LEM PRODUCTIONS, INC. DOYLESTOWN PA LVM-240C
©1994HCS,Inc.800-748-0241ReorderNo.1033R-PT
Crush and burn
hazard. Stay clear
of moving rollers.
Stop machine and
raise roll before
cleaning.
WARNING
ACHTUNG
MISE EN GARDE
©1994HCS,Inc.800-748-0241Reorder No.1033-PT
Crush and burn
hazard. Stay clear
of moving rollers.
Stop machine and
raise roll before
cleaning.
WARNING
ACHTUNG
MISE EN GARDE
©1994HCS,Inc. 800-748-0241 ReorderNo.6001-PT
Carefullyread Operator's
Manualbefore handling
this machine. Observe
instructions and safety
rules when operating.
WARNING
ACHTUNG
MISE EN GARDE
©1994HCS, Inc. 800-748-0241 ReorderNo.7002-PT
SAFETY
INSTRUCTIONS
SICHERHEITS-
RICHTLINIEN
CONSIGNES DE
SÉCURITÉ
1. Read and understand the Operation
Manualand all safety labels before
operatingthis machine.
2. Only a trained person is to be
permittedto operate this machine.
Trainingshould include instruction
inoperation under normal conditions
andemergency situations.
3. This machine is to be serviced only
bytrained and authorized personnel.
Followlockout procedures before
servicing.
4. Never reach into the machine for any
reasonunless the machine is at a
COMPLETESTOP.
5. Never leave the machine stopped in
sucha manner that another worker can
startthe machine while you are working
onor within the machine.
6. Never change or defeat the function of
electricalinterlocks 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
inthis machine caused by items such as
longhair, loose clothing and jewelry.
Makesure your clothing and hair fit
closelyto your body and that all jewelry,
ringsand watches are removed.
NOT
AUS
E
M
E
R
G
E
N
CY
ST
OP
ARR
E
T
D'
U
R
G
E
N
C
E
KBICBARRIER TERMINAL BOARD
LINE
FUSE
ACCEL
P/N9884
MAX MIN IR CL
ARM
FUSE
I1
P3 P2 P1 I1 F+ F- L1 L2 A+ A-
NOT
AUS
E
M
E
R
G
E
N
CY
ST
OP
ARR
E
T
D'
U
R
G
E
N
C
E
Tobe serviced only
bytrained and
authorized personnel.
Lockoutpower before
servicing.
HAZARDOUS
VOLTAGE.
DANGER
GEFAHR
©1994HazardCommunicationSystems, Inc. 800-748-0241 ReorderNo.5025-PT
©1994 HCS, Inc. 800-748-0241 Reorder No. 1012-PT
Moving parts can
crush and cut.
Do not operate with
door open.
WARNING
ACHTUNG
MISE EN GARDE
To be serviced only
by trained and
authorized personnel.
Lockout power before
servicing.
HAZARDOUS
VOLTAGE.
DANGER
GEFAHR
©1994 Hazard Communication Systems, Inc. 800-748-0241 Reorder No. 5025-PT
©1994 HCS, Inc. 800-748-0241 Reorder No.6001-PT
Carefully read Operator's
Manual before handling
this machine. Observe
instructions and safety
rules when operating.
WARNING
ACHTUNG
MISE EN GARDE
©1994 HCS, Inc. 800-748-0241 Reorder No.7002-PT
SAFETY
INSTRUCTIONS
SICHERHEITS-
RICHTLINIEN
CONSIGNES DE
SÉCURITÉ
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.
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.
- 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.1033R-PT
Crush and burn
hazard. Stay clear
of moving rollers.
Stop machine and
raise roll before
cleaning.
WARNING
ACHTUNG
MISE EN GARDE
240VOLTS
LEM PRODUCTIONS, INC. DOYLESTOWN PA LVM-240C
©1994 HCS, Inc. 800-748-0241 ReorderNo.1033-PT
Crush and burn
hazard. Stay clear
of moving rollers.
Stop machine and
raise roll before
cleaning.
WARNING
ACHTUNG
MISE EN GARDE
240VOLTS
LEM PRODUCTIONS, INC. DOYLESTOWN PA LVM-240C
18
16
48
12
10
8
6
4
2
0
psi
100
90
80
70
60
50
40
30
20
10
kPa
700
630
560
490
420
350
280
210
140
70

Safety
F-40 Laminator Operator Manual
1-6
© GBC Pro-Tech 1998 February
Blank page.