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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.
Falcon 36 Operation Manual 7DEOH RI &RQWHQWV 6HFWLRQ 6DIHW\ Caution/Warning Label Locations........................................................................................1-4 6HFWLRQ ,QVWDOODWLRQ Preinstallation Checklist...........................................................................................
Falcon 36 Operation Manual Procedure .........................................................................................................................3-8 PROCESS CONTROL CHART............................................................................................3-9 PROCESS CONTROL DIAGRAM .......................................................................................3-9 PROCESS CONTROL CHART 3-2 ...................................................................................
Falcon 36 Laminator Service Manual 6HFWLRQ 6DIHW\ DO 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. DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Safety and Warranty Information EM RG E U D' P STO CY N RG E RG E U 1NO / 4 TtuAU r nS EM E RG E N CE ARRET NOT AUS E N CE Twist and pull up both buttons to resume operation P STO CY N Push either button to stop the laminator Falcon 36 Laminator Service Manual ARRET D' 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.
Falcon 36 Laminator Service Manual WARNING Exercise care when cleaning the rolls with 80% isopropyl alcohol: • Use only in a well ventilated area. • Wear rubber gloves. • Use only on cool rolls. Safety and Warranty Information 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. Cleaning heated rolls can ignite the fumes.
Safety and Warranty Information 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. Falcon 36 Laminator Service Manual 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.
Falcon 36 Operation Manual Safety WARNING WARNING SAFETY INSTRUCTIONS SICHERHEITSRICHTLINIEN ACHTUNG ACHTUNG MISE EN GARDE MISE EN GARDE CONSIGNES DE SÉCURITÉ WARNING 1. Read and understand the Operation Manual and all safety labels before operating this machine. ACHTUNG 2. Only a trained person is to be permitted to operate this machine. Training should include instruction in operation under normal conditions and emergency situations. 3.
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Falcon 36 Operation Manual 6HFWLRQ ,QVWDOODWLRQ 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. Installation CAUTION Do not locate the laminator where air is blowing directly on the machine.
Installation 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.
Falcon 36 Operation Manual Installation Recommended clearance 73" (~1.8m) Floor Trimmer 10' (~3m) 4'6" (~1.1m) 3' x 6' (~1m x 2m) Table 3' (~1m) 2'2" (~.
Installation Falcon 36 Operation Manual 8QSDFNLQJ ⇒ 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 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.
Falcon 36 Operation Manual Installation CAUTION 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 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.
Installation Falcon 36 Operation Manual 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. You can cause irreparable damage to the rolls. 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.
Falcon 36 Operation Manual 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.
Installation Falcon 36 Operation Manual 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.
Falcon 36 Operation Manual RG E U RG E P STO CY N U 1NO / 4 TtuAU r nS EM RG E ARRET D' 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. Figure 3-1: N CE E The spring system used to provide downward pressure on the top roll is capable of producing forces greater than 1000 pounds (454kg).
Operation Falcon 36 Operation Manual 2SHUDWRU &RQWUROV 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.
Falcon 36 Operation Manual 6HWXS 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. Wrinkles and bubbles have causes that generally cannot be cured by applying more pressure.
Operation Falcon 36 Operation Manual +HDWLQJ 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.
Falcon 36 Operation Manual Operation 3URFHVV &RQWURO &KDUWV 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 after setting the nip. Reset the machine to forward operation.
Operation 0RXQWLQJ 2QO\ This process varies only slightly from the One Pass Mount and Laminate process. 6HWXS DQG 3URFHGXUH 1. Adjust the machine settings as shown in process chart 3-3. 2. 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. 3. Lay the image onto the adhesive side of the Falcon Board.
Falcon 36 Operation Manual 6HWXS DQG 3URFHGXUH 3DVV 1. Adjust the machine settings as shown in process chart 3-4b. 2. Trim the print to size and trim the board to the size of the print. 3. 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. 4. Clean the board with a tack cloth or cleaning roller. 5.
Operation Falcon 36 Operation Manual (QFDSVXODWLRQ 0DFKLQH 6KXWGRZQ This is the most commonly performed process. 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. 6HWXS DQG 3URFHGXUH 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.
Falcon 36 Operation 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 IDENTIFICATION DIAGRAM Notes ___________________________________________________________________________________________ _____________________________________________________________________________________
Operation Falcon 36 Operation Manual 352&(66 &21752/ &+$57 One-Pass Mounting and Laminating MATERIALS Upper Media 3 mil gloss Lower Media N/A Bond Paper Image Media Falcon Board Mounting Substrate LAMINATOR SETTINGS Top Heater Status ON @ 240 ºF (115 ºC) Drive Mode OFF Bottom Heater Status 1-2 ft/min Speed FWD Drive Direction Manual (Footswitch) UP Pull Roll Position OFF Output Cooling DOWN - 1/4 turn Main Roll Setting 352&(66 &21752/ ',$*5$0 Leader Board Printed Image FALC
Falcon 36 Operation Manual Operation 352&(66 &21752/ &+$57 One-Pass Mounting MATERIALS Upper Media N/A Image Media Lower Media N/A Mounting Substrate Bond Paper Falcon Board LAMINATOR SETTINGS Top Heater Status ON @ 240 ºF (115 ºC) Drive Mode OFF Bottom Heater Status 2-3 ft/min Speed FWD Drive Direction Pull Roll Position Output Cooling Main Roll Setting Manual (Footswitch) UP OFF DOWN - 1/4 turn 352&(66 &21752/ ',$*5$0 Printed Image FALCON Board Notes __________________________
Operation Falcon 36 Operation Manual 352&(66 &21752/ &+$57 D Two Pass Mount and Cold/Pressure Overlaminate, First Pass MATERIALS Upper Media Pro-Gloss Image Media Lower Media Pro-Mount Mounting Substrate Bond Paper N/A LAMINATOR SETTINGS Top Heater Status Bottom Heater Status ON @ 110 ºF (43 ºC) OFF 4-6 ft/min Speed Drive Direction FWD Drive Mode Pull Roll Position Output Cooling Main Roll Setting Manual or Auto UP or DOWN OFF DOWN - 1/2 turn 352&(66 &21752/ ',$*5$0 D Release Liner Rew
Falcon 36 Operation Manual Operation 352&(66 &21752/ &+$57 E Two Pass Mount and Cold/Pressure Overlaminate, Second Pass MATERIALS Upper Media N/A Image Media Lower Media N/A Mounting Substrate N/A Foam Core LAMINATOR SETTINGS Top Heater Status OFF Drive Mode Bottom Heater Status OFF Pull Roll Position 2-6 ft/min Speed Drive Direction FWD Output Cooling Main Roll Setting Manual (Footswitch) UP OFF DOWN - 1/4 turn 352&(66 &21752/ ',$*5$0 E Hold Encapsulated Image Image Face Release
Operation Falcon 36 Operation Manual 352&(66 &21752/ &+$57 D Two Pass Mount and Hot Overlaminate, First Pass MATERIALS Upper Media 3 mil Gloss Image Media Lower Media Pro-Mount Mounting Substrate Bond Paper N/A LAMINATOR SETTINGS Top Heater Status Bottom Heater Status ON @ 230 ºF (110 ºC) Drive Mode OFF 3-4 ft/min Speed Drive Direction FWD Pull Roll Position Output Cooling Main Roll Setting Manual or Auto DOWN OFF DOWN - 1/2 turn 352&(66 &21752/ ',$*5$0 D Notes ________________________
Falcon 36 Operation Manual Operation 352&(66 &21752/ &+$57 E Two Pass Mount and Hot Overlaminate, Second Pass MATERIALS Upper Media N/A Image Media N/A Lower Media N/A Mounting Substrate Foam Core LAMINATOR SETTINGS Top Heater Status OFF Drive Mode Bottom Heater Status OFF Pull Roll Position 2-3 ft/min Speed Drive Direction REV Manual (Footswitch) DOWN OFF Output Cooling UP Main Roll Setting 352&(66 &21752/ ',$*5$0 E CAUTION: Do not allow foam board to drop below Fan Bridge Lip
Operation Falcon 36 Operation Manual 352&(66 &21752/ &+$57 Encapsulation MATERIALS Upper Media 3 mil Gloss Image Media Lower Media 3 mil Gloss Mounting Substrate Bond Paper N/A LAMINATOR SETTINGS Top Heater Status ON @ 230 ºF (110 ºC) Drive Mode Bottom Heater Status ON @ 230 ºF (110 ºC) Pull Roll Position Speed Drive Direction 3-6 ft/min FWD Output Cooling Main Roll Setting Manual or Auto DOWN OFF DOWN - 1/4 turn 352&(66 &21752/ ',$*5$0 Notes _______________________________________
Falcon 36 Operation Manual 6HFWLRQ 0DLQWHQDQFH DQG 7URXEOHVKRRWLQJ 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.
Maintenance and Troubleshooting Falcon 36 Operation Manual 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 Gently Bend Provide 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.
Falcon 36 Operation Manual Maintenance and Troubleshooting Upper Main Roll Thermocouple Tube to Frame Thermocouple Wire STOP ARRET D' U E CE N RG E RGE CY N NOT AUS EM G IN RN WA NG HTU E AC GARD Wire to Control Side SE MI ING RN WA NG HTU E AC GARD MO TO R AU SE MI TO EN rn ar d bucle h an ay s. us St ler d Crzard. g rol an e hamovinchine for of mal be rol Stop se . rai aning cle EN R-PT r No.1033 Reorde -0241 800-748 Inc. HCS, ©1994 ST OP rn ar d bucle h an ay s.
Maintenance and Troubleshooting Falcon 36 Operation Manual &OHDQLQJ To clean beads of adhesive, dust and dirt from the rolls: Tools required: 1. Allow the laminator to cool slightly to no higher than 110ºF (43ºC). • Adhesive coated board • 80% isopropyl alcohol (or dishwashing detergent) • Rubber cement eraser • Several 100% cotton terry cloths • Protective rubber gloves To clean the laminator rolls: 1. Remove the infeed table and infeed pressure plate to gain access to the rolls. 2.
Falcon 36 Operation Manual Maintenance and Troubleshooting To clean the cabinet and covers: $GMXVWLQJ WKH 1LS 1. Unplug the laminator to clean the exterior. The gap between the two main rolls is called the nip. The purpose of adjusting the nip is to ensure continuous contact between the laminating rolls as the media is drawn through the machine. This procedure must be done regularly. 2. Using a damp cotton terry cloth (water only), clean the exterior of the laminator.
Maintenance and Troubleshooting 5. Adjust the nip by turning the adjusting bolt using an ¾" 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. Falcon 36 Operation Manual 3. Loosen all four motor mount bolts using the 3/16" hex wrench as shown in Figure 4-6. The motor should just move freely within the slots.
Falcon 36 Operation Manual Maintenance and Troubleshooting /XEULFDWLRQ Tools required: • 1 • High temperature grease or lithium grease • Grease gun /8" hex wrench WA R AC NING HT UN MIS G E EN Grease Fittings GA RD E Mov crusing pa Do h and rts do not cut.can or op op erat en e . with ©199 4 HCS, Inc. 800-7 48-02 41 Reor der No. 1012PT To lubricate the laminator: WARNING Do not lubricate the laminator when it is hot. You can be burned.
Maintenance and Troubleshooting 4-8 Falcon 36 Operation Manual GBC Pro-Tech 1997 October
Falcon 36 Operation Manual Maintenance and Troubleshooting 2XWSXW 7URXEOHVKRRWLQJ *XLGH Problem: Problem: D waves in the image, not in the D waves in the laminate. laminate. Hints: Hints: • Increase clutch tension. • Check paper tension. • Check roll pressures. • Check relative moisture content • Check nip settings. of the paper. Problem: Straight waves in the output. Hints: • Decrease clutch tension. • Check operational settings for materials being used.
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Falcon 36 Operation Manual 6HFWLRQ :DUUDQW\ /LPLWHG :DUUDQW\ Warranty ([FOXVLRQV WR WKH :DUUDQW\ This warranty specifically does not cover: 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 GBC ProTech and cannot be modified or amended.
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Falcon 36 Operation Manual Technical Information 6HFWLRQ 7HFKQLFDO ,QIRUPDWLRQ 6SHFLILFDWLRQV Table 6-1. Falcon 36 Laminator Specifications Characteristic Specifications Dimensions (L x D x H) 56" x 31" x 56" (1.42 x .79 x 1.42m) Weight Uncrated: 300 lbs (136 kg) Crated : 500 lbs (225 kg) Laminating Rolls 42" (1.06m) roll face with high release surface, upper and lower rolls internally heated Laminating Opening 1.5" (3.
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Falcon 36 Operation Manual Index 6HFWLRQ ,QGH[ 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 Handwhee
Index Falcon 36 Operation Manual 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.