Bosch Power Tools Laminator 36 User's Manual
Contents
1. Figure 3 3 Heater Controller Rear Panel Control Foot Switch Continuous Run AUTO 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 A 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 GBC Pro Tech 1997 October Falcon 36 Operation Manual Setup Setup of the Falcon 36 Laminator is quick and straightforward when instructions are followed exactly To adjust the nip please see Maintenance Laminator Roll Pressure 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 A CAUTION Excess pressure can damage the laminating rolls Minimum laminator roll pressure is consistent with good results A typical roll pressure for soft substrates such as Foamcore or Orca Board is 1 4 a revolution of the laminating roll crank A typical roll pressure for hard substrates is 1 2 a revolution of the laminating roll crank A typical roll pressure for encapsulation is 1 2 a revolution of the laminating roll crank Loading the Film Film is loaded on th2. 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 A CAUTION Make sure that the adhesive side of the laminate is away from the roll to prevent an extensive clean up job 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 Falcon 36 Operation Manual Machine Shutdown 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 A CAUTION Failure to follow this procedure can result in damage to the rolls Procedure 1 Turn off the
3. to confirm that the unit is operating properly and that all safety mechanisms are functioning Startup Checklist Start the laminator and go through the following checklist O 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 A WARNING Never operate the laminator unless both of the emergency stop buttons are functioning properly You can be crushed or burned 2 8 Falcon 36 Operation Manual O Isthe 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 A WARNING Never operate the laminator unless the photoelectric eye system is functioning properly You can be crushed or burned A 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 O Is the footswitch operating Test the footswitch for both forward and reverse operation Verify that the footswitch overrides the photoe
4. This warranty specifically does not cover 1 Damage to the laminating rolls caused by knives razor blades other sharp objects or failure caused by adhesives 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 5 1 Warranty Falcon 36 Operation Manual Blank page 5 2 GBC Pro Tech 1997 October Falcon 36 Operation Manual Technical Information Section 6 Technical Information Specifications Table 6 1 Falcon 36 Laminator Specifications Characteristic Specifications Dimensions 56 x 31 x 56 Lx Dx H 1 42 x 79 x 1 42m Weight Uncrated 300 Ibs 136 kg Crated 500 Ibs 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 pressure sensitive 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 0 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
5. This process varies only slightly from the One Pass Mount and Laminate process Setup and Procedure 1 gt Adjust the machine settings as shown in process chart 3 3 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 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 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 Two Pass Mount and Laminate Cold Overlaminate For this process the image is first encapsulated and then mounted Setup and Procedure Pass 1 1 Adjust the machine settings as shown in process chart 3 4a and remove the infeed table 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 With a sin
6. 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 L 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 GBC Pro Tech 1997 October Maintenance and Troubleshooting Grease Fittings 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 Contacting Technical Support 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 4 7 Maintenance and Troubleshooting 4 8 Falcon 36 Operation Manual GBC Pro Tech 1997 October Falcon 36 Operation Manual Fo a ATA Problem D waves in the image not in the laminate Hints e Check paper tension e Check relative moisture content of the paper S Problem Waves on only one side of the output Hints e Check nip settings e Chec
7. ready to use Cooling 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 Set the speed control to 2 6 Let the machine run until the laminating rolls return to room temperature 3 4 Falcon 36 Operation Manual 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 F cold films do not exhibit the phenomenon of silvering Paper Tips 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 F and increase the motor speed by one third GBC Pro Tech 1997 October Falcon 36 Operation Manual Process Control Charts 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 c
8. 1 2 shows the location of each of these labels 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 A WARNING A ACHTUNG A MISE EN GARDE SAFETY A WARNING INSTRUCTIONS A ACHTUNG SICHERHEITS RICHTLINIEN CONSIGNES DE d 4 SECURITE 1 Read and understand the Operation Manual and all safety labels before operating this machine PO Only a trained person is to be Crush and burn 2 ited tc ite this shine d Training should include instruction Moving parts can hazard Stay clear in operation under normal conditions crush and cut of moving rollers and emergency situations n o Do not operate with Stop machine and raise roll before cleaning 4 This machine is to be serviced only by trained and authorized personnel door open Follow lockout procedures before ne servicing l Never reach into the machine for any reason unless the machine is at a COMPLETE STOP NOM i Never leave the machine stopped in such a manner that another worker can start the machine while you are working gt Crush and burn on or within the machine hazard Stay clear Ne shat defeat the functic of d electrical interlocks or other machine A of moving rollers shutdown switches Stop machine and raise roll befor
9. 4035 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 A 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 A 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 A 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 Falcon 36 Laminator Service Manual A 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 A WARNING Always use care in lowering the top laminating roll You can be crushed or burned A WARNING Do not operate the laminator near water You can be severely shocked elec
10. Falcon 36 Laminator is a simple procedure that keeps the 6 system running smoothly and maximizes the efficiency of the motor Tools required e 1 hex wrench o va hex wrench e Screwdriver To adjust the chain tension 1 Unplug the laminator and make sure it won t be plugged back in while you are performing this procedure 2 Remove the drive side cabinet cover using the Lei hex wrench by removing the six screws holding the cover in place 4 6 Loosen Motor gt Falcon 36 Operation Manual Loosen all four motor mount bolts using the hie hex wrench as shown in Figure 4 6 The motor should just move freely within the slots WH A A WH A A LA V 1 4 to A WU A WI Ay 1 2 Play E Mount Bolts Downward _ Force Tightens Chain Figure 4 6 Adjusting the Chain Tension 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 W to 42 play in the chain Tighten the mounting bolts while maintaining the downward pressure on the motor Replace the cabinet cover and reconnect power to the laminator GBC Pro Tech 1997 October Falcon 36 Operation Manual Lubrication Tools required e Lien hex wrench e High temperature grease or lithium grease e Grease gun To lubricate the laminator A WARNING Do not lubricate the laminator when it is hot You can be burned A WARNING
11. You can be severely shocked electrocuted or Falcon 36 Laminator Service Manual A 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 A WARNING Never insert objects of any kind through any of the slots on the laminator You can touch dangerous voltage points or short out parts You can be severely shocked electrocuted or cause a fire 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 A 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 A 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 A WARNING Do not allow anything to rest on the power cord Do not locate the cord where people ALWAYS USE GOOD SAFETY PRACTICES WHEN OPERATING OR SERVICING THE LAMINATOR AND KNOW HOW TO REACT QUICKLY IN AN EMERGENCY Caution Warning Label Locations Posted at various locations on your Falcon 36 Laminator are important safety labels PAY CAREFUL ATTENTION TO THESE LABELS AT ALL TIMES Figure
12. 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 A WARNING The unpacking process requires at least two people You can be severely injured or crushed Tools required e Phillips head screwdriver o Zen 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 2 4 Falcon 36 Operation Manual Figure 2 2 Removing the Cardboard Box 2 Lift the cardboard box off the laminator Si Gently unwrap the shrink wrap from around the laminator A 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 GBC Pro Tech 1997 October Falcon 36 Operation Manual 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 lif
13. 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 6 FOOT SWITCH CONTINUOUS RUN AUTO STOP Changes control of the machine drive from a foot switch to continuous run 3 2 Falcon 36 Operation Manual 7 POWER LIGHT Indicates when the main power is being applied to the machine 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 Red Set point has Solid Temperature is not been reached Green Temperature is exactly at set point 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
14. 36 Operation Manual Operation PROCESS CONTROL CHART 3 5b Two Pass Mount and Hot Overlaminate Second Pass Top Heater Status Main Rol Setting PROCESS CONTROL DIAGRAM 3 5b CAUTION Do not allow foam board to drop below Fan Bridge Lip Encapsulated Image O Release Liner O O se mo Notes GBC Pro Tech 1997 October 3 15 Operation Falcon 36 Operation Manual PROCESS CONTROL CHART 3 6 Encapsulation Bond Paper NA Top Heater Status ON 230 F 110 C Manual or Auto ON 230 F 11050 PROCESS CONTROL DIAGRAM 3 6 O IC C Notes au GBC Pro Tech 1997 October Falcon 36 Operation Manual Maintenance and Troubleshooting Section 4 Maintenance and Tools required 1 Troubleshooting s s hex wrench Performing regular maintenance on the Falcon 36 e 80 isopropyl alcohol Laminator is critical to the proper operation of the e 100 cotton terry cloth machine A maintenance schedule and a section of procedures for disassembling and reassembling the serviceable areas of the laminator are included in A this section CAUTION Table 6 1 Maintenance Schedule ALWAYS CHECK THE POSITION AND CONDITION OF THE THERMOCOUPLES PRIOR TO OPERATION The thermal junction of the thermocouples MUST make Clean adjust the thermocouples Clean the rolls contact with the laminating rolls to maintain proper roll operating temperatures The ther
15. BC Pro Tech 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 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 A 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 Warranty Exclusions to the Warranty
16. Falcon 36 Operation Manual 1997 GBC Pro Tech Do not duplicate without written permission 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 GBC Pro Tech 1997 October Falcon 36 Oper
17. 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 AN DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury A 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 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 GBC Pro Tech 1997 October 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 app
18. OL CHART 3 3 asec Geen ie cae ea a aioe 3 11 a EIER RE EE 3 11 PROCESS CONTROL GHART 3 48 cseccasscaviveesesavcessavis ai 3 12 PROCESS CONTROL DIAGRAM 3 4a i 3 12 PROCESS GONTROL CHART Zb eeseteuEuEuSEESEuENERESEECEEESESEEEEENESESEEESENSSEEENEREAEERSEESNEAEeENT 3 13 PROCESS CONTROL DIAGRAM 3 4D san ode S BA S SVA O V REES 3 13 PROCESS CONTROL Tee 3 14 PROCESS CONTROL DIAGRAM 3 58 ees CECR 3 14 PROCESS CONTROL CHART ER deg tu Seechen mda s 3 15 PROCESS CONTROL DIAGRAM 3 5b rcalie ni is e EE ETE 3 15 PROCESS GONTROLGHART Ee 3 16 PROCESS CONTROL DIAGRAM 35633 sd i sa doo la o ad sa a eD Ee 3 16 Section 4 Maintenance and Troubleshooting enee RENE ER KKK EE EE KER ER iaia nana 4 1 Thermocouple Positioning and Cleaning 000000000 e nenene nenene 4 1 OSADU Eso diossine 4 4 Adj sting the e oa ao a ho doo ob bk o oo O ia 4 5 Chain WE Ee Ti Le WEE 4 6 KOBCANON niana aaa aa RARI aaa c ad doo o ha Eo doo 4 7 Contacting Technical Support i 4 7 Output Troubleshooting Guides 34335555 zu ela iaia 4 9 Section 5 Warranty e EEEEEEEEEEEREREREREEEEEEEEEEEEE KREE EEEEEEEEEEEREE KREE ER eee 5 1 lune RE dn EN 5 1 Excl sions tothe Waranty EE 5 1 Section 6 Technical Information ee EEEEEEEEEEEEEEEEREREREEEEEEEEEEEEE iaia iena 6 1 Specification EE 6 1 Section 7 Index ener EREREEEEEEEEEEEEEEEEEEEEEEE EE ER ER ER eee 7 1 iv GBC Pro Tech 1997 October Falcon 36 Laminator Service Manual Section 1 Safety DO
19. are in the nip area All electrical and moving mechanical parts are located in bolted cabinets Hand crank for laminating roll movement Options Unwind for rolled prints Rewind for rolled prints Vacuum table Outfeed Slitters e Outfeed Table Installation 220VAC 50 or 60 Hz single Requirement 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 Section 7 Index 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 Infeed table 4 4 Installation reguirements 2 1 6 1 Isopropyl alcohol 4 4 GBC Pro Tech 1997 October Index L Laminating material 6 1 Laminating opening 6 1 Laminating rolls 6 1 Laminating speeds 6 1 Lubrication 4 1 4 5 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 p
20. ass 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 reguirement 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 Index 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 Falcon 36 Operation Manual GBC Pro Tech 1997 October
21. ation Manual Table of Contents Section 1 E E 1 1 Caution Warning Label Been EE 1 4 Section 2 Installation e neneueuek ek EKEREREREE EE iaia iaia eee EE iaia iii 2 1 Preinstallation GHECKISE isa re edn EE Eh nda olin Dee eer 2 1 Mal o Tej Te EE 2 4 211100 V O O Cer err Sper O er er Seer O eege etary ert 2 7 EE EE 2 8 Section 3 Operation u iii ian 3 1 Sale las AA E A AA lea cor tatoo arr pria 3 1 Operator Controls farsene liane alii soc Cub mo ou 3 2 Front Control EE 3 2 Rear Panel Control 3 2 SEA ee a E A N 3 3 E tte RTE 3 3 koa ding the Gan EE 3 3 Positioning the FIM EE 3 3 FSA psec cece ssc gece toca ces GO u OGC A KH MO GE ela 3 4 Ciglia 3 4 Papel Ee 3 4 Process OOM OM EE EEN 3 5 Mounting and Laminating One Pass ea 3 5 Set p and ee EE 3 5 Mo nting Ke 3 6 Setup and lee 3 6 Two Pass Mount and Laminate Cold Overlaminate eee 3 6 Setup and Procedure Pass EEN 3 6 Selup and Procedure Eed a a a k 3 7 Two Pass Mount and Laminate Hot Overlaminate 3 7 Setup and Procedure Pass A 3 7 Setup and Procedure ees 3 7 Encapsulation prenistri ne a aE SO aE ora Ta oo oyun o ot 3 8 Setup EE DEE ege ee 3 8 Machine Shutdown WEE 3 8 GBC Pro Tech 1997 October Falcon 36 Operation Manual EROEM 3 8 PROGESS CONTROL CHART aiino diirai A aa aaa A A 3 9 PROCESS CONTROL DIAGRAM eege See eee 3 9 PROCESS CONTROL CHAR 3 2 aa 3 10 PROCESS CONTROL DIAGRAM 32 3 10 PROCESS CONTR
22. ation or while servicing the laminator You can cause irreparable damage to the rolls 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 Foot Bolt Shipping Pad Figure 2 5 Removing the Packing Assemblies Remove the screws holding the foot pads onto the pallet using the Phillips head screwdriver 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 GBC Pro Tech 1997 October Falcon 36 Operation Manual A 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 impro
23. ds 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 A 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 A 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 1 3 Safety and Warranty Information A 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 A WARNING Do not attempt to defeat the grounding feature of the ground plug on the laminator
24. e cleaning 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 240 VOLTS A DANGER A GEFAHR HAZARDOUS Carefully read Operator s VOLTAGE Manual before handling To be serviced only this machine Observe by trained and instructions and safety authorized personnel tules when operating Lockout power before servicing 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 Section 2 Installation 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 A CAUTION Failure to follow the preinstallation checklist can result in damage to the laminator Preins
25. e appropriate unwinds Loading and aligning the film are discussed later in this section For applications such as encapsulation film is fed from both the top and bottom feed unwinds The 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 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 Operation should ALWAYS face outward from the laminating roll A 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 A CAUTION Carefully align the two films being fed into the nip If not you will obtain poor results Positioning the Film The following procedure is applicable to both the top and bottom feed unwinds 1 Secure the braking film mount arm so as to center the film between the side cabinets 2 Loosen the core support film mount arm and slide it to the drive side o
26. er setting the nip Reset the machine to forward operation 4 Web the film by wrapping it around the upper film idler and draping it over the upper main roll Have about six inches laying on the infeed table 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 Operation Mounting Only
27. etween the laminating rolls as the media is drawn through the machine This procedure must be done regularly Tools required Ye hex wrench 2 34 open end wrenches To adjust the nip A 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 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 4 5 Maintenance and Troubleshooting 5 Adjust the nip by turning the adjusting bolt 3 using an 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 Properly Set Nip Distance Between Rolls is Equal l Figure 4 5 Properly Set Nip 6 Hold the adjustment bolt in place while tightening the jamnut on each side of the laminator 7 Replace both cabinet covers and reconnect 4 power to the laminator Chain Tensioning 5 Adjusting the chain tension on the
28. ews 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 Installation If the laminator is in a crate 1 Remove the top of the crate and then the sides in the order shown in Figure 2 4 A 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 Figure 2 4 Removing the Crate 2 Gently unwrap the shrink wrap from around the laminator 2 6 Falcon 36 Operation Manual A CAUTION Do not use a knife or other sharp instrument during install
29. f the machine 3 Install the laminating film onto the braking mount arm and slide the core support arm over to support the laminating film s end 4 Secure the support arm Operation Heating 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 175 Red Set point has Dim 200 not been reached gt K S lt Green Temperature is exactly at set point 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 50 301 PROTECH F om 133 L0 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
30. ge edge razor cut across the film on the rewind tube being sure not to cut through the release liner or the rolls A WARNING Use extreme caution when using the single edge razor not to damage the rolls or cut yourself 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 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 Insert a starter board into the nip and lower the upper main roll onto it 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 Reinstall the infeed table You can operate with or without the pull rolls at this point Encapsulate the images GBC Pro Tech 1997 October 3 6 Falcon 36 Operation Manual Setup and Procedure Pass 2 1 8 Adjust the machine settings as shown in process chart 3 4b Trim the print to size and trim the board to the size of the print 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 Clean the board with a tack cloth or cleaning roller Place the image face down on a flat surface and peel back the release liner on the leading edge about two inches Lay the image on t
31. he 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 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 Trim the board and image to the finished size Two Pass Mount and Laminate Hot Overlaminate This process is very similar to the Two Pass Mount and Laminate using cold overlaminate Setup and Procedure Pass 1 1 Adjust the machine settings as shown in process chart 3 5a and remove the infeed table 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 Pull the mount adhesive straight up from the lower unwind position being careful not to stick GBC Pro Tech 1997 October 6 7 Operation the film to the machine Tack it to the hot overlaminate Insert a starter board into the nip and lower the upper main roll onto it Press the footswitch Once the leader board is through the nip lower the upper main ro
32. k for even paper tension Output Troubleshooting Guide Sea a M Problem D waves in the laminate Hints e Increase clutch tension e Check roll pressures e Check nip settings Problem Angled waves on the output Hints e Check for insufficient clutch tension e Check for insufficient main roll pressure Maintenance and Troubleshooting Problem Straight waves in the output Hints e Decrease clutch tension e Check operational settings for materials being used Feed Direction Other Common Problems Problem Blistering in the image Hints Increase speed or lower the operating temperature Problem Coiling of encapsulated images Hints e 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 e Increase chain tension decrease unwind brake tension GBC Pro Tech 1997 October Maintenance and Troubleshooting Falcon 36 Operation Manual Blank page 4 10 GBC Pro Tech 1997 October Falcon 36 Operation Manual Section 5 Warranty Limited Warranty 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 G
33. lectric eye by pressing the footswitch and pushing an object as large as your hand into the nip area Once you have completed the startup checklist you can safely run a test sample GBC Pro Tech 1997 October Falcon 36 Operation Manual Section 3 Operation Safety GBC Pro Tech laminators are powerful machines that are designed to mount laminate and encapsulate The forces required to accomplish these tasks can vary from negligible to very large 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 A 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 tha
34. lied 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 A 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 1 1 Safety and Warranty Information Push either Twist and pull up button to stop the both buttons to laminator resume operation 1 Ki S dTM 5 o gt gt Q 5 Q a J une dos P J une
35. ll and then rotate the crank 1 2 a turn more Reinstall the infeed table Encapsulate the images Setup and Procedure Pass 2 1 Adjust the machine settings as shown in process chart 3 5b Trim the print to size and trim the board to the size of the print 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 Clean the board with a tack cloth or cleaning roller Place the image face down on a flat surface and peel back the release liner on the leading edge about two inches 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 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 Trim the board and image to the finished size Operation Encapsulation This is the most commonly performed process Setup and Procedure
36. main power to the machine 2 Raise the main laminating roll at least one inch 3 Put the output roll into the upright position A CAUTION The laminating and output rolls must always be in the up position when the machine is not in use GBC Pro Tech 1997 October 3 8 Falcon 36 Operation Manual Operation PROCESS CONTROL CHART MATERIALS Upper Medio Lmeiege Lower media Mounting substrate LAMINATOR SETTINGS Top Heater status Drivemode Bottom Heater status Pun rolt Position Spee lopatce O O Drive Direction mainronsetins PROCESS CONTROL DIAGRAM IDENTIFICATION DIAGRAM Notes GBC Pro Tech 1997 October 3 9 Operation Falcon 36 Operation Manual PROCESS CONTROL CHART 3 2 One Pass Mounting and Laminating Bottom Heater Status Pull Roll Position UP 1 2 timin output Cooling OFF PROCESS CONTROL DIAGRAM 3 2 Top Heater Status ON 240 F 115 C Manual Footswitch F O Leader Board Printed Image C 7 FALCON Board Notes 30 5 GBC Pro Tech 1997 October Falcon 36 Operation Manual Operation PROCESS CONTROL CHART 3 3 One Pass Mounting MATERIALS Upper Media Image Media Bond Paper LAMINATOR SETTINGS Bottom Heater Status Pull Roll Position UP 2 3 fimn Output Cooling OFF PROCESS CONTROL DIAGRAM 3 3 Top Heater Status ON 240 F 115 C Ma
37. mocouples must also be free of adhesive and dirt The rolls can overheat and cause a fire or seriously damage the laminator Inspect the electrical cord for damage Inspect the footswitch cord for damage Monthly Adjust the nip Check the chain tension A WARNING Inspect the area around the laminator for possible hazards dust buildup combustible items stored too close etc Do not attempt to adjust the position of the thermocouples if the rolls are hot You can be seriously burned Every Lubricate the grease fittings and Six hai Months pa To adjust a thermocouple Check wire termination tightness 1 Locate the thermocouple to be adjusted using the illustration in Figure 4 3 2 Remove the two screws securing the Thermocouple Positioning and thermocouple to the laminator using the ii hex Cleaning wrench and take the thermocouple out One of the most crucial adjustments to the Falcon 36 3 Inspect the thermocouple If there is any Laminator is positioning the thermocouples and adhesive or dirt on the thermocouple gently making sure they are clean There are two clean it off with 80 isopropyl alcohol and a thermocouples that control the temperature of the cotton terry cloth 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
38. nual Footswitch F Printed Image C 7 FALCON Board Notes GBC Pro Tech 1997 October 3 11 Operation Falcon 36 Operation Manual PROCESS CONTROL CHART 3 4a Two Pass Mount and Cold Pressure Overlaminate First Pass Bond Paper NA Puli Roll Position UP or DOWN 46 fmin Output Cooling Main Roll Setting DOWN 1 2 tum PROCESS CONTROL DIAGRAM 3 4a Top Heater Status ON 110 F 43 C Manual or Auto Release Liner Rewind Release Liner OC Notes au GBC Pro Tech 1997 October Falcon 36 Operation Manual Operation PROCESS CONTROL CHART 3 4b Two Pass Mount and Cold Pressure Overlaminate Second Pass MATERIALS Upper Media Image Medi Mounting Substrate LAMINATOR SETTINGS Top Heater Status Manual Footswitch ue Main Roll Setting DOWN 1 4 turn PROCESS CONTROL DIAGRAM 3 4b Hold Encapsulated Image Image O Face Release Liner O O Notes GBC Pro Tech 1997 October 3 13 Operation Falcon 36 Operation Manual PROCESS CONTROL CHART 3 5a Two Pass Mount and Hot Overlaminate First Pass Bond Paper Pro Mount NA Bottom Heater Status Pull Roll Position DOWN PROCESS CONTROL DIAGRAM 3 5a Top Heater Status ON 230 F 110 C Manual or Auto F ae Notes 4000 GBC Pro Tech 1997 October Falcon
39. ober 4 3 Maintenance and Troubleshooting Cleaning Tools required e Adhesive coated board e 80 isopropyl alcohol or dishwashing detergent Rubber cement eraser Several 100 cotton terry cloths e Protective rubber gloves To clean the laminator rolls 1 Remove the infeed table and infeed pressure plate to gain access to the rolls A 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 A 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 A 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 4 4 Falcon 36 Operation Manual To clean beads of adhesive dust and dirt from the rolls 1 Allow the laminator to cool slightly to no higher than 110 F 43 C 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 A CAUTION Use the minimum amount of pressure necessa
40. ontains 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 Mounting and Laminating One Pass Setup and Procedure 1 Adjust the machine settings as shown in process chart 3 2 A 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 Operation 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 aft
41. operating the laminator and it should become second nature to check their condition prior to applying power to the laminator GBC Pro Tech 1997 October 4 1 Maintenance and Troubleshooting 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 Provide Gently Bend 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 Thermal Junction Figure 4 2 Correct Thermocouple Contact A 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 Falcon 36 Operation Manual GBC Pro Tech 1997 October Falcon 36 Operation Manual Maintenance and Troubleshooting Upper Main Tube to Frame Roll Thermocouple Wire Thermocouple Wire to Control Side Wire Routed Through to Control Side Thermocouple Lower Main Roll Underside oi Laminator Figure 4 3 Locations of the Thermocouples GBC Pro Tech 1997 Oct
42. perly 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 A 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 ANOTE 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 GBC Pro Tech 1997 October 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 Setup Once the Falcon 36 Laminator has been unpacked and moved into final position check each of
43. ry to clean the rolls You can destroy the silicone layer on the rolls by pressing to hard or scrubbing too long in one spot A WARNING Exercise care when cleaning the rolls with 80 isopropyl alcohol e Use only in a well ventilated area e Wear rubber gloves e Use only on cool rolls Cleaning heated rolls can ignite the fumes A 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 110 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 GBC Pro Tech 1997 October Falcon 36 Operation Manual To clean the cabinet and covers 1 Unplug the laminator to clean the exterior 2 Using a damp cotton terry cloth water only clean the exterior of the laminator A 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 Maintenance and Troubleshooting Adjusting the Nip The gap between the two main rolls is called the nip The purpose of adjusting the nip is to ensure continuous contact b
44. t 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 Operation Push either Twist and pull up button to stop the both buttons to laminator resume operation Figure 3 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 Operation Operator Controls 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 Front Control Panel Speed Adjustment Motion Control 3 FORWARD AUTO Foot Switch Continuous Run REVERSE me oan Sop AUTO STOP FANS 1 POWER Cooling Fans ON Off d 17 Power Light HEATERS Top Roll Heater Controller 1 Upper Roll Heat ON OFF d d Lower Roll Heat ON OFF d BC Pro Tech De Lower Roll Heater Controller sSO10m Forest WI 608 246 8884 Figure 3 2 Front Control Panel 1 SPEED ADJUSTMENT Adjusts the speed of
45. tallation Checklist O Are doorways and hallways wide enough for the laminator to be moved to the installation site O 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 O 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 A 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 Installation A 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 O 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 A 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 fi
46. ted 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 A 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 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 Installation A CAUTION Do not use a knife or other sharp instrument during installation or while servicing the laminator You can cause irreparable damage to the rolls 9 Remove all packing materials to a safe distance from the laminator ANOTE ABOUT RECYCLING The pallet can be reused for shipping the machine again or can be disassembled and the wood and scr
47. the following items Tools required o KE hex wrench e Adjustable wrench Setup Procedure 1 Inspect the laminator for any obvious shipping damage 2 Remove the drive and control side cabinet covers with the 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 Installation A 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 Startup The first time the laminator is started and every time it is serviced you should use the following checklist
48. trocuted or cause a fire AY DANGER Unplug the laminator from the wall outlet before servicing You can be severely shocked electrocuted or cause a fire A 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 1 2 GBC Pro Tech 1997 October Falcon 36 Laminator Service Manual A WARNING Exercise care when cleaning the rolls with 80 isopropyl alcohol e Use only in a well ventilated area e Wear rubber gloves e Use only on cool rolls Cleaning heated rolls can ignite the fumes A 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 A CAUTION Raise the upper main roll when the laminator is not in operation Prolonged contact can damage the rolls A CAUTION Excess pressure can damage the laminating rolls Always select the minimum roll pressure necessary to complete the task A CAUTION If silicone adhesive contacts the upper or lower roll remove it IMMEDIATELY using 80 isopropyl alcohol It can harden within an hour and ruin the roll GBC Pro Tech 1997 October Safety and Warranty Information A WARNING The operating environment must be free of dust flammable liqui
49. ts 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 A 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 A 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 Installation A 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 Falcon 36 Operation Manual GBC Pro Tech 1997 October Falcon 36 Operation Manual E m o N Floor Trimmer lt 3 1m FS 46 1 1m A Recommended clearance 10 3m 10 3m y Figure 2 1 Laminator Space Requirements GBC Pro Tech 1997 October Installation 2 3 Installation Unpacking 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
Download Pdf Manuals
Related Search