GBC Falcon 60+ User manual

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GBC Falcon 60+(-1)
CE Laminator
Installation & Operation Manual

FALCON 60+(-1) CE
INSTALLATION &
OPERATION MANUAL
®
Document Number: 930-108 REV DATE: 06-9-04
©2004 GENERAL BINDING CORPORATION ALL RIGHTS RESERVED.
Do not duplicate without written permission.

Operations Manual
Page 3
FALCON 60+ (-1) CE
©2004 General Binding Corporation
Table of content
Cover ............................................................... 1
Table of Content ............................................... 3
Important Safety Instructions ........................ 5
Important Safeguards ..................................... 7
General .............................................................. 7
Electrical ............................................................ 7
Service ............................................................... 7
Warranty ........................................................... 9
Specifications .................................................11
Pre-Installation ............................................... 13
Installation ...................................................... 15
Features Guide ............................................... 17
Power Switch ....................................................17
Control Panel Indicators ....................................17
Control Panel Buttons .......................................17
E-Stop ............................................................. 18
Safety Shield Interlock Latch ........................... 18
Safety Shield .................................................... 19
Feed Table ....................................................... 19
Chill Idler .......................................................... 19
Film Shaft ......................................................... 19
Main Rollers ..................................................... 19
Idler Bar ........................................................... 19
Pull Rollers ....................................................... 19
Rewind Tube .................................................... 19
Film Shaft Brake .............................................. 20
Core Adapters .................................................. 20
Center Core Support ........................................ 20
Rewind Brake ................................................... 20
Main Roller Crank Handle ................................ 20
Pull Roller Crank Handle .................................. 20
Cooling Fans .................................................... 20
Clutch ............................................................. 20
Accelerator Footswitch ..................................... 21
Rear Table Latches .......................................... 21
Rear Table ........................................................ 21
Rear Run/ Stop Switch ..................................... 21
Film Web .......................................................... 21
Nip Point ........................................................... 21
Rear Slitter ....................................................... 21
Separator Bar ................................................... 21
Operating Instructions .................................. 23
Film Loading and Threading ............................ 23
Webbing Thermal Film ..................................... 24
Webbing PSA Film ........................................... 25
Start Laminating ............................................... 26
Tacking New Film ............................................. 27
Unweb the Laminator ....................................... 28
Clearing a Film Jam ......................................... 28
Applications ................................................... 29
Mounting Pre-Coated Boards .......................... 29
Single Sided Lamination .................................. 29
Accushield ........................................................ 31
Custom Application #1 ..................................... 31
Custom Application #2 ..................................... 31
The Art Of Lamination ................................... 33
Basic Rules ...................................................... 33
Film Tension ..................................................... 33
Heat ............................................................. 34
Output ............................................................. 34
Maintenance ................................................... 35
Caring for the Falcon 60+ (-1) .......................... 35
Troubleshooting Guide ................................. 37
Service Agreement ........................................ 37

Operations Manual
Page 4 ©2004 General Binding Corporation
FALCON 60+ (-1) CE

Operations Manual
Page 5
FALCON 60+ (-1) CE
©2004 General Binding Corporation
THIS SAFETY MESSAGE MEANS THAT YOU COULD
CUT YOURSELF IF YOU ARE NOT CAREFUL.
WARNING: THE SAFETY ALERT SYMBOL
PRECEDES EACH SAFETY MESSAGE IN
THIS INSTRUCTION MANUAL. THE SYMBOL
INDICATES A POTENTIAL PERSONAL SAFETY
HAZARD TO YOU OR OTHERS.
WARNING: DO NOT ATTEMPT
TO SERVICE OR REPAIR THE
FALCON 60+ (-1) LAMINATOR.
WARNING: DO NOT CONNECT THE LAMINATOR
TO AN ELECTRICAL SUPPLY OR ATTEMPT
TO OPERATE THE LAMINATOR UNTIL YOU
HAVE COMPLETELY READ THESE INSTRUC-
TIONS. MAINTAIN THESE INSTRUCTIONS IN
A CONVENIENT LOCATION FOR FUTURE
REFERENCE.
HOT SURFACE. USE CAUTION AS HOT SURFACE
COULD CAUSE BURNS.
Important Safety Instructions
YOUR SAFETY AS WELL AS THE SAFETY OF OTHERS
IS IMPORTANT TO GBC. IN THIS INSTRUCTION MANUAL
AND ON THE PRODUCT, YOU WILL FIND IMPORTANT
SAFET Y MESSAGES REGARDING THE PRODUCT. READ
THESE MESSAGES CAREFULLY. READ ALL OF THE
INSTRUCTIONS AND SAVE THESE INSTRUCTIONS
FOR LATER USE.
THE SAFETY ALERT SYMBOL PRECEDES
EACH SAFETY MESSAGE IN THIS INSTRUC-
TION MANUAL. THE SYMBOL INDICATES A
POTENTIAL PERSONAL SAFETY HAZARD TO
YOU OR OTHERS.
THE FOLLOWING WARNINGS ARE FOUND UPON
THIS PRODUCT.
THIS SAFETY MESSAGE MEANS THAT YOU COULD
BE SERIOUSLY HURT OR KILLED IF YOU OPEN THE
PRODUCT AND EXPOSE YOURSELF TO HAZARDOUS
VOLTAGE.
THIS SAFETY MESSAGE MEANS THAT YOU COULD
BE BURNED AND YOUR FINGERS AND HANDS COULD
BE TRAPPED AND CRUSHED IN THE HOT ROLLERS.
CLOTHING, JEWELRY AND LONG HAIR COULD BE
CAUGHT IN THE ROLLERS AND PULL YOU INTO
THEM.
ADVERTENCIA
!
Riesgo de choque
eléctrico
No abra
Adentro no hay
piezas reparables
por el usuario
Mantenimiento
solamente por
personal
ca ificado
ATTENTION
!
Risque de
secousse
électrique
Ne pas ouvrir
Pas de pièces
réparables par
l'ut lisateur
Entretien
seulement par
personnel qualifié
WARNING
!
Electrical shock
hazard
Do not open
No user
serviceable
parts inside
Refer servicing to
qualified service
personnel
ADVERTENCIA ATTENTION
!CAUTION
!
RODILLOS
CALIENTES.
PUNTO DE
PINCHAMIENTO.
Mantener manos y
ropa a distancia.
ROULEAUX
CHAUDS.
POINT DE
PINCEMENT.
Tenir mains et
vêtements à l'écart.
HOT ROLLS.
PINCH POINT.
Keep hands and
clothing away.
!
ADVERTENCIA
!ATTENTION
!CAUTION
!
NAVAJA FILOSA.
Mantener manos y
dedos a distancia.
LAME COUPANTE.
Tenir mains et
doigts à l'écart.
SHARP BLADE.
Keep hands and
clothing away.

Operations Manual
Page 6 ©2004 General Binding Corporation
FALCON 60+ (-1) CE

Operations Manual
Page 7
FALCON 60+ (-1) CE
©2004 General Binding Corporation
Do not operate the laminator with a damaged power supply
cord or attachment plug, upon occurrence of a malfunction,
or after the laminator has been damaged. Contact GBC’s
Technical Service Department or your dealer/distributor
for assistance.
Service
Perform only the routine maintenance procedures referred
to in these instructions.
WARNING: Do not attempt to service or repair the
laminator.
Disconnect the plug from the receptacle and contact GBC’s
Technical Department or your dealer/distributor when one
or more of the following has occurred.
- The power supply cord or attachment plug is
damaged.
- Liquid has been spilled into the laminator.
- The laminator is malfunctioning.
- The laminator does not operate as described in these
instructions.
Important Safeguards
WARNING: TO GUARD AGAINST INJURY, THE
FOLLOWING SAFETY PRECAUTIONS MUST BE
OBSERVED IN THE INSTALLATION AND USE
OF THE LAMINATOR.
General
Keep hands, long hair, loose clothing, and articles such as
necklaces or ties away from the front of the heat and pull
rollers to avoid entanglement and entrapment.
The heat rollers can reach temperatures over 300˚ F
(150° C).Avoid contact with the heat rollers during opera-
tion or shortly after power has been removed from the
laminator.
Keep hands and fingers away from the path of the sharp
film cutter blade located at the film exit.
Do not use the laminator for other than its intended
purpose.
Avoid moving the laminator on uneven floor surfaces.
Never tilt the laminator.
Do not defeat or remove electrical and mechanical safety
equipment such as interlocks, shields and guards.
Do not insert objects unsuitable for lamination or expose
the equipment to liquids.
Electrical
The laminator should be connected only to a source of
power as indicated in these instructions and on the serial
plate located on the rear of the laminator. Contact an
electrician should the attachment plug provided with the
laminator not match the receptacles at your location.
CAUTION: The receptacle must be located near
the equipment and easily accessible.

Operations Manual
Page 8 ©2004 General Binding Corporation
FALCON 60+ (-1) CE

Operations Manual
Page 9
FALCON 60+ (-1) CE
©2004 General Binding Corporation
Limited 90-Day Warranty
GBC warrants to the original purchaser for a period
of ninety days on labor and one year on parts after
installation that this laminator is free from defects
in workmanship and material under normal use and
service. GBC’s obligation under this limited warranty
is limited to replacement or repair, at GBC’s option,
of any part found defective by GBC without charge
for material or labor.
THIS LIMITED WARRANTY IS IN LIEU OF ALL
OTHER WARRANTIES EXPRESSED OR IMPLIED.
WARRANTIES OF MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE ARE EXPRESSLY
EXCLUDED. ANY REPRESENTATIONS OR
PROMISES INCONSISTENT WITH, OR IN ADDITION
TO, THIS LIMITED WARRANTY ARE UNAUTHORIZED
AND SHALL NOT BE BINDING UPON GBC. IN NO
EVENT SHALL GBC BE LIABLE FOR ANY SPECIAL,
INCIDENTAL, OR CONSEQUENTIAL DAMAGES,
WHETHER OR NOT FORESEEABLE.
This limited warranty shall be void if the laminator has
been misused; mishandled; damaged by negligence,
by accident, during shipment, or due to exposure to
extreme conditions; repaired, altered, moved, or installed
by anyone other than GBC or its authorized agents;
or if incompatible film was used. GBC’s obligation
under this limited warranty does not include routine
maintenance, cleaning, adjustment, normal cosmetic
or mechanical wear, or freight charges.
Without limiting the generality of the previous paragraph,
GBC’s obligation under this limited warranty does
not include:
1. Damage to the rollers caused by knives, razors, or
other sharp tools; by any foreign objects falling into
the working area of the laminator; or by cleaning the
laminator with solutions or materials that harm its
surfaces;
2. Damage caused by adhesives; nor
3. Damage caused by lifting, tilting or attempting to posi-
tion the laminator other than rolling it on its castors
across even surfaces.
FOR EUROPEAN UNION RESIDENTS ONLY: This guar-
antee does not affect the legal rights which consumers
have under applicable national legislation governing the
sale of consumer goods.

Operations Manual
Page 10 ©2004 General Binding Corporation
FALCON 60+ (-1) CE

Operations Manual
Page 11
FALCON 60+ (-1) CE
©2004 General Binding Corporation
79 in.
(201 cm)
57 in.
(145 cm)
33 in.
(84 cm)
Fig 1
Specifications
Operating Speed:
0 fpm to 18 fpm (5 mpm)
Maximum Film Width:
60 in. (152 cm)
Maximum Mounting Gap:
1 in. (2.54 cm)
Maximum Temperature:
300°F (150° C) Top + Bottom
Dimensions (W x L x H):
Unit alone: (Figure 1)
79 in. x 33 in. x 57 in.
(201 cm x 84 cm x 145 cm)
Shipping:
85 in. x 44.5 in. x 78 in.
(216 cm x 113 cm x 198 cm)
Weight:
Unit alone: 1498 lb. (679 kg.)
Shipping: 1900 lb. (862 kg.)
Noise Rating:
LpA: 66dB A (Sound Pressure Level) Fans OFF
LpA: 67dB A (Sound Pressure Level) Fan ON
Electrical Requirements:
Refer to the serial plate located on the rear of the laminator
for the specific electrical rating applicable to the unit.
Voltage: 400V~50 Hz
Current: 13A
Power: 7,500 W
Phase: 3
Interupting Capacity: 1500A
Ambient Air Temperature: 5-40 °C (41-104 °F)
Humidity Rating: 30-95% non-condensing
Altitude Rating: Up to 1000 Meters Min. (2540 Feet)

Operations Manual
Page 12 ©2004 General Binding Corporation
FALCON 60+ (-1) CE

Operations Manual
Page 13
FALCON 60+ (-1) CE
©2004 General Binding Corporation
20 ft.
( 508 ) cm
13 ft
( 330 cm )
3 ft
( 91 cm )
8 ft 8 in
( 220 cm )
8 ft 8 in
( 220 cm )
Fig 2
Pre- Installation
Before a Falcon 60+ (-1) Laminator can be installed, ensure
the following requirements are met;
1. Are door ways and hallways wide enough for the
laminator to be moved to the installation site?
2. Is there ample room for the laminator?
– A work area must be established that allows for opera-
tion in both the front and rear of the laminator and
provides space for efficient material flow. (Figure 2)
3. Is the environment appropriate for the laminator?
– The laminator requires a clean, dust and vapor free
environment to operate properly.
– Avoid locating the laminator near sources of heat or
cold. Avoid locating the laminator in the direct path of
forced, heated or cooled air.
CAUTION: Air flow can cause uneven heating/ cooling of
the rollers and result in poor output quality
4. Have you contacted a certified electrician to wire the
receptacle and ensure that adequate power is being
supplied, having the appropriate capacity, over current
protection and safety lockouts available?
– 400V 50 Hz, 3 phase 5 wire service required.
Machine is supplied with:
Cord
– manufacturer: SCAME PARRE
– type: 211.3237
– rating: 346V-415V, 32A, 3P+N+E
Plug
– manufacturer: LAPP KABEL
– type: OLFLEX CLASSIC-110
– rating: 5 × 4.0 mm²
Electrical cord
drop
4 ft. x 6 ft.
(101.6 x 152 cm)
Work table on wheels
Back
Front
4 ft. x 6 ft.
(101.6 x 152 cm)
Work table on wheels

Operations Manual
Page 14 ©2004 General Binding Corporation
FALCON 60+ (-1) CE

Operations Manual
Page 15
FALCON 60+ (-1) CE
©2004 General Binding Corporation
Fig 3
Installation
1. Shipping damage should be brought to the imme-
diate attention of the delivering carrier.
2. With assistance, carefully roll the laminator into posi-
tion over flat and even surfaces.
3. The laminator should be positioned to allow exiting film
to flow freely to the floor (Figure 3) or a work table.
Accumulation of laminate immediately behind the lami-
nator as it exits the equipment may cause the film to
wrap around the pull rollers, resulting in a “jammed”
condition.
4. Avoid locating the laminator near sources of heat or
cold. Avoid locating the laminator in the direct path of
forced, heated or cooled air.
5. Leveling of the machine is a customer option. If you
choose not to level the laminator and encounter output
problems, please level the machine and try your
application again before calling for technical support.
Resting the laminator on the leveling pads prevent
the machine from rolling during set up, operation or
servicing. (Figure 4)
6. Connect the attachment plug provided with the
laminator to a suitably grounded outlet. AVOID
CONNECTING OTHER EQUIPMENT TO THE
SAME BRANCH CIRCUIT TO WHICH THE LAMI-
NATOR IS CONNECTED, AS THIS MAY RESULT
IN NUISANCE TRIPPING OF CIRCUIT BREAKERS
OR BLOWING FUSES.
x 4
Fig 4

Operations Manual
Page 16 ©2004 General Binding Corporation
FALCON 60+ (-1) CE

Operations Manual
Page 17
FALCON 60+ (-1) CE
©2004 General Binding Corporation
O
Fig 5
Fig 6
1
3
4
56
10
7
8
9
2
TOP TEMP
BOTTOM
TEMP
OC
OF
OC
OF
READY
READY
(1)
(2)
(3)
(4)
Fig 7
Features Guide
A. POWER ON/ OFF: (Figure 5) Located at the back left
of the machine applies power to the laminator. The control
panel will illuminate when the switch is rotated to the “l”
position. The off position, marked “O”, removes power
from the laminator.
B. CONTROL PANEL INDICATORS: (Figure 6)
1. POWER INDICATOR :Illuminates when the lami-
nator is plugged in and POWER ON/ OFF is in the
on, (I), position.
2. PRESSURE INDICATOR : Illuminates in increments
to correspond with the amount of pressure at the main
roller nip. Pressure is represented by percent from 0
(minimal) to 100 (maximum).
3. READY INDICATOR: “READY” Illuminates when the
actual temperature is equal to (+/- 5) set tempera-
ture.
4. °C INDICATOR: “°C” Illuminates indicating the
displayed value is in degrees Celsius.
5. °F INDICATOR: “°F” Illuminates indicating the displayed
value is in degrees Fahrenheit.
6. ON INDICATORS : Located near the heater and
cooling fan on buttons. Illuminates when the related
on button is pressed.
7. SELECTION INDICATORS : Located near the start/
stop and forward/ reverse buttons. Illuminates when
the selected button is pressed.
C. CONTROL PANEL BUTTONS: (Figure 7)
1. START : When pressed, indicator illuminates and
activates rollers for normal operation.
2. STOP : When pressed, indicator illuminates and
stops the movement of the rollers.
3. REVERSE : When pressed, indicator illuminates and
sets the motor direction for reverse roller movement
to clear film jams and wrap-ups.
4. FORWARD : When pressed, indicator illuminates and
sets the motor direction for forward roller movement
to run in normal operation mode.

Operations Manual
Page 18 ©2004 General Binding Corporation
FALCON 60+ (-1) CE
Fig 8
Fig 9
(1) (2)
(E)
Fig 10
For items 5 -13, refer to Figure 8.
5. SPEED : This means machine roller speed. Turn
clockwise to increase speed or counterclockwise to
decrease speed. Speed range is 1 - 10.
6. TEMPERATURE CONTROLS: The upper and lower
heaters have identical controls, on, off, increase,
decrease and measure. The top set of controls relate
to the upper heater ( ) and the lower set of controls
relate to the lower heater ( ).
7. TEMPERATURE CONTROL ON : When pressed,
indicator illuminates and turns power on to the tempera-
ture controller unit.
8. TEMPERATURE CONTROL OFF : When pressed,
turns power off to the temperature controller unit.
9. TEMPERATURE INCREASE : When pressed,
increases the temperature set point value.
10. TEMPERATURE DECREASE : When pressed,
decreases the temperature set point value.
11. TEMPERATURE MEASURE: When pressed, flashes
the actual temperature of the roller.
12. COOLING O N : When pressed, indicator illumi-
nates and turns on the cooling fans.
13. COOLING O F F : When pressed, turns off
the cooling fans.
D. E-STOP: Four emergency stop buttons exist on the
laminator. Two located on the left and right front and two
on the left and right rear of the laminator. (Figure 9)
To engage, push (1) any emergency stop push button.
Power to the motor is removed. To disengage, turn (2) the
push button 1/4 turn counterclockwise.
E. SAFETY SHIELD INTERLOCK LATCH: (Figure 10)
Used to lock the safety shield into position and activate an
interlock switch. The interlock latch is located on the left
side of the safety shield. When pushed to the full left (1),
the safety shield is locked. When pushed to the full right
(2), the safety shield is unlocked.

Operations Manual
Page 19
FALCON 60+ (-1) CE
©2004 General Binding Corporation
F. SAFETY SHIELD: (Figure 11) Prevents entanglement,
entrapment and inadvertent contact with the heat rollers.
The laminator will operate normally only when the
Safet y Shield is located in the fully locked and closed
position. When shield is open, the laminator will only
run at 1 mpm (approximately 3.25 ft/m).
To remove the safety shield, unlock the safety shield inter-
lock latch and lift the safety shield (1) up and away from
the safety shield mounting pins (2).
G. FEED TABLE: (Figure 12) The Feed Table is used to
position items for lamination. To pivot the feed table, remove
the safety shield, lift up on the feed table, pull back, then
carefully lower. The laminator will operate only when the
Feed Table is properly installed.
NOTE: You can not raise or lower the main roller with
the table pivoted.
H. CHILL IDLER: (Figure 12) Assist in the cooling process
of the web material as it exits the heat rollers.
To remove the chill idler, lift the chill idler straight up and
out from the chill idler brackets.
I. FILM SHAFT: (Figure 12) The film shaft holds the film
supply on the machine.
J. MAIN ROLLERS: (Figure 12) Silicone rubber coated
steel tubes heat the laminating film and compress the
heated film to the items being laminated. Heat is provided
by an internal heating element. The heat rollers are motor
driven for ease of loading new film.
K. IDLER BAR: (Figure 13) The idler bars, located near
each heat roller, are used to direct the film to the heat roller
nip. The bottom Idler Bar is movable to ease film loading.
L. PULL ROLLERS: (Figure 13) The pull rollers, located at
the back of the laminator, are motor driven. They simultane-
ously pull the film and improve the quality of the laminated
item.
M. REWIND TUBE: (Figure 13) The front rewind tube is
used to rewind release liner while the rear bottom rewind
tube is used to rewind finished product. To remove the
rewind tube, push the tube against the rewind brake and
remove the tube from the rewind support side.
(1)
(2)
(F)
Fig 11
(G)
(J)
(H)
(I)
(I)
Fig 12
(K) (L)
(M)
(M)
Fig 13