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Part Number 930-400
© 1997 GBC Pro-Tech
Do not duplicate without written permission
IN G
R N
W A
G
U N
H T
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33R-P
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No.10
ni ng
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48-02
41
800-7
4 HCS,
Inc.
©199
IN G
R N
W A
G
U N
H T
A C
R D
E
G A
E EN
M IS
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d bu
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an
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No.10
33-PT
ra is
ni ng
Reor
der
cl ea
48-02
41
Inc.
800-7
4 HCS,
©199
W A
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A C
IN
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G A
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C ar
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H R
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©199
4 HCS
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, Inc.
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800-
748-
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0241
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-748
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94
Haz
ard
©19
4151 Anderson Road
De Forest, Wisconsin 53532
GBC Pro-Tech
Tel: 608-246-8844
Fax: 608-246-8645
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Table of Contents
Related Manuals for GBC 930-400
Summary of Contents for GBC 930-400
- Page 1 C ru S to ra is cl ea ©199 Part Number 930-400 © 1997 GBC Pro-Tech Do not duplicate without written permission IN G E EN M IS d bu y cl rs . S ta ro lle C ru rd .
- Page 2 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.
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Page 3: Table Of Contents
Two-Pass Mount and Laminate (Cold Overlaminate) ...3-6 Setup and Procedure, Pass 1...3-6 Setup and Procedure, Pass 2...3-7 Two-Pass Mount and Laminate (Hot Overlaminate) ...3-7 Setup and Procedure, Pass 1...3-7 Setup and Procedure, Pass 2...3-7 Encapsulation ...3-8 Setup and Procedure...3-8 Machine Shutdown ...3-8 GBC Pro-Tech 1997 October... - Page 4 PROCESS CONTROL DIAGRAM 3-6 ...3-16 Thermocouple Positioning and Cleaning ...4-1 Cleaning...4-4 Adjusting the Nip...4-5 Chain Tensioning ...4-6 Lubrication ...4-7 Contacting Technical Support...4-7 Output Troubleshooting Guide...4-9 Limited Warranty...5-1 Exclusions to the Warranty...5-1 Specifications...6-1 Falcon 36 Operation Manual GBC Pro-Tech 1997 October...
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Page 5: Safety
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. -
Page 6: Cleaning
Unplug the laminator from the wall outlet 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... - Page 7 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.
- Page 8 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.
- Page 9 , Inc. ©19 rings and watches are removed. ©1994 HCS, Inc. 800-748-0241 Reorder No.7002-PT GBC Pro-Tech 1997 October WARNING ACHTUNG MISE EN GARDE Crush and burn hazard. Stay clear of moving rollers.
- Page 10 Safety Falcon 36 Operation Manual Blank page. GBC Pro-Tech 1997 October...
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Page 11: Preinstallation Checklist
Falcon 36 Operation Manual Before a Falcon 36 Laminator can be installed there are a few requirements that must be met. Make certain that each of the requirements listed in the following preinstallation checklist are met before beginning installation. CAUTION Failure to follow the preinstallation checklist can result in damage to the laminator. - Page 12 Falcon 36 Operation Manual WARNING Do not allow anything to rest on the power cord. Do not locate the cord where people can walk on it. You or others can be severely shocked, electrocuted or cause a fire. GBC Pro-Tech 1997 October...
- Page 13 Falcon 36 Operation Manual Recommended clearance GBC Pro-Tech 1997 October 4'6" (~1.1m) 3' (~1m) Figure 2-1: Laminator Space Requirements Installation (~3m) 2'2" (~.7m) (~3m)
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Page 14: Unpacking
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. - Page 15 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.
- Page 16 1 Rubber cement eraser 4. Remove the screws holding the foot pads onto the pallet using the Phillips head screwdriver. 5. Have the laminator lifted off the skid and placed on the floor by licensed riggers. The riggers r be...
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Page 17: Setup
GBC Pro-Tech 1997 October 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. -
Page 18: Startup
8. Verify that the photoelectric eye is working properly. (See the procedure below.) 9. Replace both cabinet covers. The first time the laminator is started and every time it is serviced you should use the following checklist to confirm that the unit is operating properly and that all safety mechanisms are functioning. - Page 19 Falcon 36 Operation Manual 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).
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Page 20: Operator Controls
001-133 Lower Roll Heat ON/OFF PROTECH 001-133 GBC Pro-Tech, De Forest, WI 608-246-8844 Figure 3-2: Front Control Panel 1. SPEED ADJUSTMENT – Adjusts the speed of the machine from zero to the maximum as the control is turned clockwise. 2. MOTION CONTROL... -
Page 21: Laminator Roll Pressure
Falcon 36 Operation Manual Setup of the Falcon 36 Laminator is quick and straightforward when instructions are followed exactly. To adjust the nip, please see Maintenance. /DPLQDWRU 5ROO 3UHVVXUH Use only the minimum amount of roll pressure needed to accomplish the task. While higher pressure can make the adhesive bond faster, excess pressure can damage the rolls. -
Page 22: Heating
Note In the change over from hot to pressure-sensitive materials, it is not necessary to return the laminator to full cold. With the rolls slightly heated (115 ºF), cold films do not exhibit the phenomenon of silvering. -
Page 23: Process Control Charts
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. - Page 24 1/2 a turn more. 8. Reinstall the infeed table. You can operate with or without the pull rolls at this point. 9. Encapsulate the images. GBC Pro-Tech 1997 October...
- Page 25 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.
- Page 26 Reinstall the infeed table. 7. Encapsulate the image. Falcon 36 Operation Manual 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. CAUTION Failure to follow this procedure can result in damage to the rolls.
- Page 27 Upper Media Lower Media Top Heater Status Bottom Heater Status Speed Drive Direction Notes ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ GBC Pro-Tech 1997 October MATERIALS Image Media Mounting Substrate LAMINATOR SETTINGS Drive Mode Pull Roll Position Output Cooling Main Roll Setting IDENTIFICATION DIAGRAM...
- Page 28 MATERIALS 3 mil gloss Image Media Mounting Substrate LAMINATOR SETTINGS Pull Roll Position 1-2 ft/min Output Cooling Main Roll Setting Falcon 36 Operation Manual Bond Paper Falcon Board Manual (Footswitch) DOWN - 1/4 turn Leader Board GBC Pro-Tech 1997 October...
- Page 29 Bottom Heater Status Speed Drive Direction Printed Image FALCON Board Notes ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ GBC Pro-Tech 1997 October One-Pass Mounting MATERIALS Image Media Mounting Substrate LAMINATOR SETTINGS Pull Roll Position 2-3 ft/min Output Cooling Main Roll Setting Operation Bond Paper...
- Page 30 Pro-Mount Mounting Substrate LAMINATOR SETTINGS Drive Mode Pull Roll Position 4-6 ft/min Output Cooling Main Roll Setting Release Liner Rewind Falcon 36 Operation Manual Bond Paper Manual or Auto UP or DOWN DOWN - 1/2 turn GBC Pro-Tech 1997 October...
- Page 31 Upper Media Lower Media Top Heater Status Bottom Heater Status Speed Drive Direction Notes ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ GBC Pro-Tech 1997 October MATERIALS Image Media Mounting Substrate LAMINATOR SETTINGS Drive Mode Pull Roll Position 2-6 ft/min Output Cooling Main Roll Setting...
- Page 32 3-14 MATERIALS 3 mil Gloss Image Media Pro-Mount Mounting Substrate LAMINATOR SETTINGS Pull Roll Position 3-4 ft/min Output Cooling Main Roll Setting Falcon 36 Operation Manual Bond Paper Manual or Auto DOWN DOWN - 1/2 turn GBC Pro-Tech 1997 October...
- Page 33 Upper Media Lower Media Top Heater Status Bottom Heater Status Speed Drive Direction Notes ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ GBC Pro-Tech 1997 October MATERIALS Image Media Mounting Substrate LAMINATOR SETTINGS Drive Mode Pull Roll Position 2-3 ft/min Output Cooling Main Roll Setting...
- Page 34 3-16 Encapsulation MATERIALS 3 mil Gloss Image Media 3 mil Gloss Mounting Substrate LAMINATOR SETTINGS 3-6 ft/min Output Cooling Main Roll Setting Falcon 36 Operation Manual Bond Paper Manual or Auto DOWN DOWN - 1/4 turn GBC Pro-Tech 1997 October...
- Page 35 Falcon 36 Operation Manual Performing regular maintenance on the Falcon 36 Laminator is critical to the proper operation of the machine. A maintenance schedule and a section of procedures for disassembling and reassembling the serviceable areas of the laminator are included in this section.
- Page 36 5. Replace the thermocouple and tighten the screws. 6. Repeat the procedure for the other thermocouple. Use Your Other Hand to Gently Bend Roll Falcon 36 Operation Manual GBC Pro-Tech 1997 October...
- Page 37 748- 0241 , Inc. 800- 4 HCS ©199 M od N o. Wire Routed Through to Control Side GBC Pro-Tech 1997 October Thermocouple Wire IN G M IS u rn cl ea ta y rs . g ro C ru...
- Page 38 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 110ºF (43ºC). 2. Set the FWD/REV switch to the REV position and use the footswitch to move the rolls as you clean them.
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Page 39: Adjusting The Nip
CAUTION The main rolls must be at room temperature to achieve a proper nip setting. 1. Unplug the laminator and make sure it won’t be plugged back in while you are performing this procedure. 2. Remove the drive and control side cabinet covers with the "... - Page 40 " hex wrench " hex wrench 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 "...
- Page 41 High temperature grease or lithium grease Grease gun To lubricate the laminator: WARNING Do not lubricate the laminator when it is hot. You can be burned. WARNING Unplug the laminator and make sure it won't be plugged back in while you are performing this procedure.
- Page 42 Maintenance and Troubleshooting Falcon 36 Operation Manual GBC Pro-Tech 1997 October...
- Page 43 Problem: Waves on only one side of the output. Hints: • Check nip settings. • Check for even paper tension. GBC Pro-Tech 1997 October Maintenance and Troubleshooting Problem: Problem: D waves in the laminate. Straight waves in the output. Hints: Hints: •...
- Page 44 Maintenance and Troubleshooting Falcon 36 Operation Manual Blank page. 4-10 GBC Pro-Tech 1997 October...
- Page 45 (90) from the date of delivery to the customer. This warranty is the only warranty made by GBC Pro- Tech and cannot be modified or amended. GBC Pro-Tech’s sole and exclusive liability and the customer’s sole and exclusive remedy under...
- Page 46 Warranty Falcon 36 Operation Manual Blank page. GBC Pro-Tech 1997 October...
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Page 47: Specifications
Hand crank for laminating roll movement Options Unwind for rolled prints Rewind for rolled prints Vacuum table Outfeed Slitters Outfeed Table Installation 220VAC 50 or 60 Hz single Requirement phase, 30A GBC Pro-Tech 1997 October Technical Information... - Page 48 Technical Information Falcon 36 Operation Manual Blank page. GBC Pro-Tech 1997 October...
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Page 49: Mounting And Laminating (One Pass)
Heater, 2-8 Common problems, 4-8 Controller, 2-8 Heating, 3-4 Infeed table, 4-4 Installation requirements, 2-1, 6-1 Isopropyl alcohol, 4-4 GBC Pro-Tech 1997 October 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... - Page 50 Two-pass mount and laminate, 3-6, 3-7 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 Vacuum table, 6-1 Warnings and cautions. See Safety Information Warranty, 5-1 Falcon 36 Operation Manual GBC Pro-Tech 1997 October...