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Falcon F-40 Operator's Manual

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Part Number 930-005
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© 1998 GBC Pro-Tech
Do not duplicate without written permission
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GBC Pro-Tech
4151 Anderson Road
Tel: 608-246-8844
Fax: 608-246-8645

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Summary of Contents for Falcon F-40

  • Page 1 )DOFRQ2SHUDWLRQ 0DQXDO © 1998 GBC Pro-Tech Do not duplicate without written permission IN G E EN M IS d bu cl ea rs . ta y ro lle C ru za rd in g hi ne m ov fo re ll be S to e ro...
  • Page 2 F-40 Laminator Operator 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 merchantabil- ity for any particular use.
  • Page 3 F-40 Laminator Operator Manual 7DEOH RI &RQWHQWV 6HFWLRQ   6DIHW\   Caution/Warning Label Locations ..................1-4 6HFWLRQ   ,QVWDOODWLRQ   Preinstallation Checklist....................2-1 Unpacking........................2-3 Setup ..........................2-6 Startup ..........................2-7 6HFWLRQ   2SHUDWLRQ   Safety..........................
  • Page 4 F-40 Laminator Operator Manual 6HFWLRQ   0DLQWHQDQFH DQG 7URXEOHVKRRWLQJ  Cleaning .......................... 4-1 Adjusting the Nip ......................4-5 Chain Tensioning ......................4-5 Lubrication ........................4-6 Contacting Technical Support ..................4-7 Output Troubleshooting Guide..................4-8 6HFWLRQ   :DUUDQW\  Limited Warranty......................
  • Page 5 GBC Pro-Tech. This section contains important safety information. In addition, the laminating rolls of the Falcon 40 can reach temperatures of over 200°F (100°C). At these The following symbols are used throughout this man- temperatures there is a danger of a severe burn if the ual to indicate warnings and cautions.
  • Page 6 Figure 1-1: Using the Emergency Stop Buttons WARNING Despite the safety features built into the Falcon 40 Always use care in lowering the top laminating Laminator, extreme caution must be used when operat- roll. You can be crushed or burned.
  • Page 7 Prolonged contact can damage the rolls. The Falcon 40 Laminator is a large and heavy piece of equipment. It is necessary to employ LICENSED RIGGERS ONLY to move the machine. The laminator is not designed to be CAUTION tipped up or sideways in any way.
  • Page 8 NATOR AND KNOW HOW TO REACT QUICKLY IN AN EMERGENCY. &DXWLRQ:DUQLQJ /DEHO /RFDWLRQV WARNING Posted at various locations on your Falcon 40 Lamina- Do not use an extension cord on this laminator. tor are important safety labels. PAY CAREFUL You can be severely shocked, electrocuted or ATTENTION TO THESE LABELS AT ALL TIMES! cause a fire.
  • Page 9 F-40 Laminator Operator Manual Safety WARNING WARNING WARNING WARNING SAFETY SAFETY ACHTUNG ACHTUNG INSTRUCTIONS INSTRUCTIONS ACHTUNG ACHTUNG SICHERHEITS- SICHERHEITS- MISE EN GARDE MISE EN GARDE MISE EN GARDE MISE EN GARDE RICHTLINIEN RICHTLINIEN CONSIGNES DE CONSIGNES DE SÉCURITÉ SÉCURITÉ WARNING WARNING 1.
  • Page 10 Safety F-40 Laminator Operator Manual Blank page. © GBC Pro-Tech 1998 February...
  • Page 11 6HFWLRQ   ,QVWDOODWLRQ Is there an appropriate power outlet available or has a certified electrician been contacted to wire Before a Falcon 40 Laminator can be installed there are the laminator directly? a few requirements that must be met. Make certain that...
  • Page 12 Installation F-40 Laminator Operator Manual Recommended clearance (~3m) 4'6" (~1.1m) 2'2" 3' (~1m) (~.7m) (~3m) Figure 2-1: Laminator Space Requirements © GBC Pro-Tech 1998 February...
  • Page 13 Bill of Lading. The Falcon 40 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 14 The Falcon 40 Laminator is a large and heavy Prior to start up of the machine, you must remove the piece of equipment. It is necessary to employ desiccite packs from each cabinet and discard.
  • Page 15 F-40 Laminator Operator Manual Installation If the laminator is in a crate: CAUTION 1. Remove the top of the crate and then the sides in the order shown in Figure 2-4. Do not use a knife or other sharp instrument during installation or while servicing the laminator.
  • Page 16 VCI protective film to provide total cor- rosion protection. This protective film is wrapped The Falcon 40 Laminator is a large and heavy around the machine and completely sealed. In addition, piece of equipment. It is necessary to employ...
  • Page 17 F-40 Laminator Operator Manual Installation WARNING The United States 3-Phase Delta ALWAYS CHECK THE INFRARED SENSORS PRIOR TO OPERATION! The sensors must be clean and have free view of the roll to maintain L1-3 B l u e proper roll operating temperatures. The rolls can...
  • Page 18 Installation F-40 Laminator Operator Manual 6WDUWXS operation. Verify that the footswitch overrides the photoelectric eye by pressing the footswitch and The first time the laminator is started and every time it pushing an object as large as your hand into the nip is serviced you should use the following checklist to area.
  • Page 19 Figure 3-1: Using the Emergency Stop Buttons between the two rolls. Despite the safety features built into the Falcon 40 In addition, the laminating rolls of the Falcon 40 can Laminator, extreme caution must be used when operat- reach temperatures of over 200°F (100°C). At these ing or servicing the unit.
  • Page 20 7. LOWER ROLL HEATER CONTROLLER– Provides a readout of the temperature of the lower The operator controls for the Falcon 40 Laminator are roll and the set-point for the desired temperature. located on the front of the unit, to the right of the oper- 8.
  • Page 21 F-40 Laminator Operator Manual Operation 6HWXS CAUTION Setup of the Falcon 40 Laminator is quick and straight- forward when instructions are followed exactly. Always mount the film so that the adhesive side To adjust the nip, please see Section 4: Maintenance faces outward from the laminating roll.
  • Page 22 Operation F-40 Laminator Operator Manual +HDWLQJ 3DSHU 7LSV Use the following instructions when heating one or 1. Always cut the leading edge of a print straight so it both of the laminating rolls. The procedure is the same can be fed perpendicular to the laminating rolls.
  • Page 23 6. Lay the image onto the adhesive side of the Falcon food and coffee spills and so they are always available Board.
  • Page 24 Tape the film to the rewind and give it one full wrap around the rewind tube. Be sure to check the 3. Lay the image onto the adhesive side of the Falcon process control chart to ensure correct web up.
  • Page 25 F-40 Laminator Operator Manual Operation 4. Insert a starter board into the nip and lower the 6HWXS DQG 3URFHGXUH 3DVV  upper main roll onto it. 1. Adjust the machine settings as shown in process 5. Press the footswitch. Once the leader board is chart 3-4b.
  • Page 26 F-40 Laminator Operator Manual (QFDSVXODWLRQ 0DFKLQH 6KXWGRZQ This is the most commonly performed process. It is very important that the Falcon 40 laminator is shut down in proper manner. If not, the laminating rolls can 6HWXS DQG 3URFHGXUH be damaged or destroyed.
  • Page 27 F-40 Laminator Operator Manual Operation 352&(66 &21752/ &+$57 MATERIALS Upper Media Image Media Lower Media Mounting Substrate LAMINATOR SETTINGS Top Heater Status Drive Mode Bottom Heater Status Pull Roll Position Speed Output Cooling Drive Direction Main Roll Setting 352&(66 &21752/ ',$*5$0...
  • Page 28 Operation F-40 Laminator Operator Manual 352&(66 &21752/ &+$57  One-Pass Mounting and Laminating MATERIALS Upper Media 3 mil gloss Image Media Bond Paper Lower Media Mounting Substrate Falcon Board LAMINATOR SETTINGS Top Heater Status ON @ 240 ºF (115 ºC)
  • Page 29 F-40 Laminator Operator Manual Operation 352&(66 &21752/ &+$57  One-Pass Mounting MATERIALS Upper Media Image Media Bond Paper Lower Media Mounting Substrate Falcon Board LAMINATOR SETTINGS Top Heater Status ON @ 240 ºF (115 ºC) Drive Mode Manual (Footswitch) Bottom Heater Status...
  • Page 30 Operation F-40 Laminator Operator Manual 352&(66 &21752/ &+$57 $ Two Pass Mount and Cold/Pressure Overlaminate, First Pass MATERIALS Upper Media Pro-Gloss Image Media Bond Paper Lower Media Pro-Mount Mounting Substrate LAMINATOR SETTINGS Top Heater Status ON @ 110 ºF (43 ºC)
  • Page 31 F-40 Laminator Operator Manual Operation 352&(66 &21752/ &+$57 % Two Pass Mount and Cold/Pressure Overlaminate, Second Pass MATERIALS Upper Media Image Media Lower Media Mounting Substrate Foam Core LAMINATOR SETTINGS Top Heater Status Drive Mode Manual (Footswitch) Bottom Heater Status...
  • Page 32 Operation F-40 Laminator Operator Manual 352&(66 &21752/ &+$57 $ Two Pass Mount and Hot Overlaminate, First Pass MATERIALS Upper Media 3 mil Gloss Image Media Bond Paper Lower Media Pro-Mount Mounting Substrate LAMINATOR SETTINGS Top Heater Status ON @ 230 ºF (110 ºC)
  • Page 33 F-40 Laminator Operator Manual Operation 352&(66 &21752/ &+$57 % Two Pass Mount and Hot Overlaminate, Second Pass MATERIALS Upper Media Image Media Lower Media Mounting Substrate Foam Core LAMINATOR SETTINGS Top Heater Status Drive Mode Manual (Footswitch) Bottom Heater Status...
  • Page 34 Operation F-40 Laminator Operator Manual 352&(66 &21752/ &+$57  Encapsulation MATERIALS Upper Media 3 mil Gloss Image Media Bond Paper Lower Media 3 mil Gloss Mounting Substrate LAMINATOR SETTINGS Top Heater Status ON @ 230 ºF (110 ºC) Drive Mode...
  • Page 35 Maintenance and Troubleshooting &OHDQLQJ 6HFWLRQ   0DLQWHQDQFH DQG 7URXEOHVKRRWLQJ Tools required: Performing regular maintenance on the Falcon 40 • Adhesive coated board Laminator is critical to the proper operation of the machine. A maintenance schedule and a section of pro- •...
  • Page 36 Maintenance and Troubleshooting F-40 Laminator Operator Manual Upper Main Roll Infrared Sensor IN G M IS IN G u rn cl ea ta y rs . M IS C ru g ro ar d e an h az vi n...
  • Page 37 F-40 Laminator Operator Manual Maintenance and Troubleshooting To clean the laminator rolls: 1. Remove the infeed table and infeed pressure plate to gain access to the rolls. WARNING Exercise extreme caution while cleaning the laminator. You can be caught in the turning rolls and crushed or burned.
  • Page 38 Maintenance and Troubleshooting F-40 Laminator Operator Manual To clean beads of adhesive, dust and dirt from the To clean the cabinet and covers: rolls: 1. Unplug the laminator to clean the exterior. 1. Allow the laminator to cool slightly to no higher 2.
  • Page 39 &KDLQ 7HQVLRQLQJ 2. Remove the drive and control side cabinet covers Adjusting the chain tension on the Falcon 40 Lamina- with the " hex wrench by removing the six tor is a simple procedure that keeps the system running screws holding each cover in place.
  • Page 40 Maintenance and Troubleshooting F-40 Laminator Operator Manual WARNING Unplug the laminator and make sure it won't be plugged back in while you are performing this procedure. You could be severely shocked, electrocuted, or get your fingers caught in the 1/4" to drive mechanisms.
  • Page 41 F-40 Laminator Operator Manual Maintenance and Troubleshooting &RQWDFWLQJ 7HFKQLFDO 6XSSRUW For machine parts and technical service in North America, please call: 1-800-790-7787. Please provide serial number when calling for service. In Europe, please call: +44 (0) 1844 202 440 or fax: +44 (0) 1844 202 441.
  • Page 42 Maintenance and Troubleshooting F-40 Laminator Operator Manual 2XWSXW 7URXEOHVKRRWLQJ *XLGH Problem: Problem: Problem: D waves in the image, not in the D waves in the laminate. Straight waves in the output. laminate. Hints: Hints: Hints: • Increase clutch tension. • Decrease clutch tension.
  • Page 43 F-40 Laminator Operator Manual Warranty ([FOXVLRQV WR WKH :DUUDQW\ 6HFWLRQ   :DUUDQW\ /LPLWHG :DUUDQW\ This warranty specifically does not cover: 1. Damage to the laminating rolls caused by knives, GBC Pro-Tech Engineering Company, Inc. warrants razor blades, other sharp objects, or failure caused the equipment sold is free from defects in material and by adhesives.
  • Page 44 Warranty F-40 Laminator Operator Manual Blank page. © GBC Pro-Tech 1998 February...

  • Page 45: Specifications

    F-40 Laminator Operator Manual Specifications 6HFWLRQ   6SHFLILFDWLRQV Table 6-2: Falcon 40 Laminator Specifications Characteristic Specifications Dimensions 56" x 31" x 56" (L x D x H) (1.42 x .79 x 1.42m) Weight Uncrated: 300 lbs (136 kg) Crated : 500 lbs (225 kg) Laminating Rolls 42"...
  • Page 46 Specifications F-40 Laminator Operator Manual Blank page. © GBC Pro-Tech 1998 February...
  • Page 47 F-40 Laminator Operator Manual Index 6HFWLRQ  ,QGH[ Laminating material Laminating opening Accessory pack Laminating rolls Adjusting bolt Laminating speeds & Lubrication Chain Lubrication Main roll Tensioning Lower Cleaning Main rolls Clutch Maintenance schedule 2-7, 4-5, 4-6 Common problems Motor...
  • Page 48 Index F-40 Laminator Operator Manual Laminating material Laminating opening Laminating rolls Laminating speeds Weight Technical support Call 1-800-236-8843 3-6, 3-7 Two-pass mount and laminate Unpacking Cardboard box Crate 1-3, 2-6, 4-5 Upper main roll Upper main roll assembly Vacuum table...