Falcon F-40 Operator's Manual

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SICHERHEITSRICHTLINIEN

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SAFETY INSTRUCTIONS

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WARNING ACHTUNG

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cleaning.

, Inc. 800-748 S C

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Crush and burn hazard. Stay clear of moving rollers. Stop machine and raise roll before cleaning.

WARNING ACHTUNG

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Part Number 930-005

Carefully read Operator's Manual before handling this machine. Observe instructions and safety rules when operating.

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To be serviced only by trained and authorized personnel. Lockout power before servicing.

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GBC Pro-Tech

4151 Anderson Road

De Forest, Wisconsin 53532

Tel: 608-246-8844

Fax: 608-246-8645

F-40 Laminator Operator Manual

ii

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, b ut not limited to, any implied warranty of fitness or merchantabi lity 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-Te ch assumes no liability arising from infringements of patents or any other rights of third parties.

This Manual is Copyrighted ©1998 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.

F-40 Laminator Operator Manual

iii

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Caution/Wa rning Label Locations................................ ......... .......... .................................1-4

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Preinstallation Checklist...................................................................................................2-1

Unpacking........................................................................................................................2-3

Setup ...............................................................................................................................2-6

Startup.............................................................................................................................2-7

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Safety...............................................................................................................................3-1

Operator Controls............................................................................................................3-2

Front Control Panel......................................................................................................3-2

Setup ...............................................................................................................................3-3

Laminator Roll Pressure..............................................................................................3-3

Loading the Film..............................................................................................................3-3

Positioning the Film .........................................................................................................3-3

Heating ............................................................................................................................3-4

Cooling.............................................................................................................................3-4

Paper Tips............ ......... .......... ......... ............................................... .................................3-4

Process Control Charts....................................................................................................3-5

Mounting and Laminating (One Pass).............................................................................3-5

Setup and Procedure...................................................................................................3-5

Mounting Only..................................................................................................................3-6

Setup and Procedure...................................................................................................3-6

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

Procedure ....................................................................................................................3-8

F-40 Laminator Operator Manual

iv

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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

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Limited Warranty.............................................................................................................. 4-1

Exclusions to the Warranty........................................ ......... .........................................4-1

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F-40 Laminator Operator Manual

Safety

1-1

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DANGER

WARNING

CAUTION

WARNING

DO NOT ATTEMPT TO OPERATE YOUR

F ALCON 40 LAMINA TO R 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 import ant safety information.

The following symbols are used throughout this manual to indicate warnings and cauti ons.

Indicates an imminently hazardous situation

which, if not avoided, will re sult in death or

serious injury.

GBC Pro-Tech laminators are powerful machines that are designed to mount, laminate and encapsulate. The forces require d to acc omplish these ta sks can va ry 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 40 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.

Indicates a potentially hazardo us situation

which, if not avoided, could resu lt in death or

serious injury.

Indicates a potentially hazardo us situation

which, if not avoided, could r esult in minor or

moderate injury, or alerts against unsafe

practices, or alerts against action s which could

damage the product.

The Falcon 40 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 serv icing the unit.

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 40 Laminator has a steel cabinet that is bolted closed to isolate the electrical and drive system components for the s afe ty 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 laminato r. To continue operation both emergency stop buttons must be in the up position.

Safety

F-40 Laminator Operator Manual

1-2

WARNING

CAUTION

WARNING

DANGER

WARNING

Push either

button to stop the

laminator

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Figur e 1-1: Us ing the Emergency Stop Buttons

ALWAYS CHECK THE INFRARED SENSORS

PRIOR TO OPERATION! The sensors must be

clean and have free view of the roll to maintain

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proper r oll oper ating temperatur es. T he r olls can overheat and cause a fir e or seriou sly damage the

laminator.

Despite the safety featur es built into the Falcon 40 Laminator, extreme caution must be used when operating or servicing the unit. READ THE FOLLOWING

WARNINGS AND CAUTIONS BEFORE YOU ATTEMPT TO OPERATE OR SERVICE THE FALCON 40 LAMINAT OR.

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.

Secure long hair so that it cannot get caught in

the machinery. 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 you can be choked,

crushed, or burned.

Always use care in lowering the top laminating

roll. Yo u ca n be cr us he d or burn ed .

Do not operate the laminator ne ar water. You can

be severely shocked, electrocuted or cause a fire.

Unplug the laminat or from the wall ou tlet before

servicing. You can be severely shocked,

electrocuted or cause a fire.

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,

electroc uted or cause a fire. Use only a damp

cloth for cleaning the cabinet.

Use extreme caution when operating the

laminator with the foots wit ch. The photoelectric

eye system is overridden and your fingers can get

caught in the nip. You can be crushed or burned.

F-40 Laminator Operator Manual

Safety

1-3

WARNING

CAUTION

WARNING

CAUTION

WARNING

Exercise care when cleaning the rolls with 80%

isopropyl alc ohol:

• Use only in a well ventilated area.

• Wear rubber gloves.

• Use only on cool rolls.

Cleaning hea te d rolls ca n ign i te the fum es.

Use only 80% isopropyl alcohol or a rubber

cement eraser to clean the laminating rolls.

Harsh chemicals like toluene, acetone or MEK

destroy the silic one covering of the rolls.

Raise the upper main roll when the laminator is not in operation. Prolonge d contact can damage

the rolls.

Excess pressure can damage the laminating rolls.

Always select the minimum roll pressure

necessary to complete the task.

If silicone adhesive contacts the upper or lower

roll, remove it IMMEDIATELY using 80%

isopropyl alc ohol. It can harden within an hour

and ruin the roll.

The operating environ ment 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.

Do not use a kni fe or ot her sharp instrum ent

during installation or while servic ing the

laminator. You can cause irrepara ble damage to

the rolls.

Do not attempt to move the laminator across

anything other than a f lat, level surface wit hout

trained and qualified riggers. You can be crushed

or seriously injured.

The Falcon 40 Laminator is a large and heavy

piece of equipment. It is necessary to employ

LICENSED RIGGERS ONL Y to move the

machine. The laminator is not designed to be

tipped up or sideways in any way . Suc h actio n

disturbs the exact alignment of the rolling parts

of the machine and requires extensive

realignment . G BC Pro-Tech’s war ranty 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 improp erly.

Safety

F-40 Laminator Operator Manual

1-4

WARNING

Connect the laminator only to the type of power

source indicat ed o n the label o n the back of the

laminato r. You can be severel y shocked,

electrocuted or cause a fire. If you are not sure of

the type of power available consult the dealer or

local power company.

Do not attempt to defeat the grounding feature of

the ground plug on the laminator. You can be severely shock ed , ele ctrocu ted or cause a fire.

The three prong plu g fits on ly into a grou nding-

type power outlet. If you are unable to insert the

plug into th e existi n g outlet, contac t a qua lified

electricia n to replace the obsolete o utlet.

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.

Never ins ert obj ect s of an y kin d thro ugh a ny of

the slots on the laminator. You can touch

dangerous volta g e poi nt s or sh o rt out pa rts . You

can be severely shocked, electrocuted or cause a

fire.

ALWAYS USE GOOD SAFETY PRACTICES WHEN OPERATING OR SERVICING THE LAMINATOR AND KNOW HOW TO REACT QUICKLY IN AN EMERGENCY.

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Do not use an extension cord on this laminator.

Yo u can be s ev erely shock ed , el ect rocu ted or

cause a fire. If you need a longer cable contact a

qualified electrician.

Do not operate t he laminator if the powe r cord is damaged or fr ayed. You can be severel y shocked,

electrocut ed o r caus e a fire. Contact a qualified

electrician to replace the cord.

Do not allow anything to rest on the power cord.

Do not locate the co rd where people can walk on

it. Yo u o r others can be severely sh ocked,

electrocuted or cause a fire.

Posted at various locations on your Falcon 40 Laminator are import ant sa fety label s. PAY CAREFUL ATTENTION TO THESE LABELS AT ALL TIMES! Figure 1-2 shows the location of each of these labels.

F-40 Laminator Operator Manual

Safety

1-5

SAFETY

INSTRUCTIONS

SICHERHEITS-

RICHTLINIEN

CONSIGNES DE

SÉCURITÉ

1. Read and understand the Operation

Manual and all safety labels before

operating this machine.

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. This machine is to be serviced only

by trained and authorized personnel.

Follow lockout procedures before

servicing.

4. Never reach into the machine for any

reason unless the machine is at a

COMPLETE STOP.

5. Never leave the machine stopped in

such a manner that another worker can

start the machine while you are working

on or within the machine.

6. Never change or defeat the function of

electrical interlocks or other machine

“shutdown” switches.

7. 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.

WARNING

ACHTUNG

MISE EN GARDE

Moving parts can

crush and cut.

Do not operate with

door open.

SAFETY

INSTRUCTIONS

SICHERHEITS-

RICHTLINIEN

CONSIGNES DE

SÉCURITÉ

1.Read and understand the Operation

Manual and all safety labels before

operating this machine.

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.This machine is to be serviced only

by trained and authorized personnel.

Follow lockout procedures before

servicing.

4.Never reach into the machine for any

reason unless the machine is at a

COMPLETE STOP.

5.Never leave the machine stopped in

such a manner that another worker can

start the machine while you are working

on or within the machine.

6.Never change or defeat the function of

electrical interlocks or other machine

“shutdown” switches.

7.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.

Crush and burn

hazard. Stay clear

of moving rollers.

Stop machine and

raise roll before

cleaning.

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WARNING

ACHTUNG

MISE EN GARDE

WARNING

ACHTUNG

Crush and burn

hazard. Stay clear

of moving rollers.

Stop machine and

raise roll before

cleaning.

WARNING

ACHTUNG

MISE EN GARDE

Crush and burn

hazard. Stay clear

of moving rollers.

Stop machine and

raise roll before

cleaning.

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ACHTUNG

MISE EN GARDE

Crush and burn

hazard. Stay clear

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Stop machine and

raise roll before

cleaning.

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240 VOL TS

LEM PRODUCTIONS, INC. DOYLESTOWN PA LVM-240C

WARNING

ACHTUNG

MISE EN GARDE

Carefully read Operator's

Manual before handling

this machine. Observe

instructions and safety

rules when operating.

REV

FANS

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PROTECH

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6

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150

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48

175

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PRO-TECH Engineering Madison,WI 608-246-8844

50

PROTECH

275

°F

300

001-133

LO

WARNING

ACHTUNG

MISE EN GARDE

Carefully read Operator's

Manual before handling

this machine. Observe

instructions and safety

rules when operating.

A+A-

CL

L1L2

psi

MOTOR

FWD

100

kPa

90

700

80

630

70

560

6

9

60

490

50

420

AUTO

40

12

350

3

30

280

20

210

10

140

15

0

70

SPEED

18

STOP

POWER

HEATERS

O UT

150

175

125

200

HI

225

250 275

°F

300

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200

HI

225

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To be serviced only

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Lockout power before

servicing.

1 4 2

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240 VOL TS

LEM PRODUCTIONS, INC. DOYLESTOWN PA LVM-240C

DANGER

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VOLTAGE.

To be serviced only

by trained and

authorized personnel.

Lockout power before

servicing.

Figur e 1-2: Locations of Safety Labels

Safety

F-40 Laminator Operator Manual

1-6

Blank page.

F-40 Laminator Operator Manual

Installation

2-1

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CAUTION

WARNING

CAUTION

Before a Falcon 40 Lamin ator can be i nstalled the re are a few requir ements that must be met. Make certain that each of the requirements listed in the following preinstallation checklist are met before beginning installation.

Failure t o follow the preinst allation checklist c an

result in damage to the laminator.

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❏ Are doorways and hall ways wide enough for the

laminator to be moved to the installation site?

❏ 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.

❏ 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 or, in Europe, 3 phase, 240/ 400 VAC with 20A per phase. See Figure 2-6 for power cord connection options.

Position the jumpers as shown in Figure 2-6 for

service cho ice.

❏ Is the environ ment appropriate for the laminator?

The laminator r equires a clean, dust and vapor free environment to operate properly. It must not be located where there is air blowing directly on the machine.

The operating environment must be free of dust,

flammable liquids and vapors. You can be

injured by inhali ng chemical vapors. Vapor build

up or stored flammable liqui ds can cause a fire .

Excessive dust can damage the laminator.

Do not locate the laminator where air is blowing

directly on the machine. The air flow can cool

the rolls unevenly and r esult in poor quality

output.

Installation

F-40 Laminator Operator Manual

2-2

Recommended clearance

73" (~1.8m)

Floor Trimmer

10'

(~3m)

4'6" (~1.1m)

3' (~1m)

Table

3' x 6' (~1m x 2m)

2'2" (~.7m)

10'

(~3m)

Figure 2-1: Laminator Space Requirements

F-40 Laminator Operator Manual

Installation

2-3

8QSDFNLQJ

NOTE

WARNING

CAUTION

☞

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, be sure to inspect the crate and/or pallet for signs of damage or missing items ; if applicable, make a note of this on the 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.

The unpacking process requires at least two

people. You can be severel y inj ured o r cru sh ed .

Tools required:

• Phillips head screwdrive r

7

•

/8" 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.

Figure 2-2: Re moving the Cardboard Box

2. Lift the cardb oard box off the laminator .

3. Gently unwrap the shr ink wrap from around the laminator.

Do not use a kni fe or ot her sharp instrum ent

during installation or while servic ing the

laminator. You can cause irrepara ble damage to

the rolls.

4. Carefull y remove any accessories packed with the laminator. The accessory pack should contain:

1 Set, hex wrench e s 1 Slitting knife 1 Manual 1 Set, spare fuses 1 T ape measure 1 Roll of masking tape 1 Rubber ce ment eras e r

Installation

F-40 Laminator Operator Manual

2-4

WARNING

CAUTION

A NOTE ABOUT RECYCLING

NOTE

Foot Bolt

Shipping Pad

Figure 2-3: The Foot Bolts

5. Remove the screws holding the foot pads onto the pallet using the Phill ips head screwdriver.

6. Have the l aminator li f ted of f the ski d and pl aced on the floor by licensed riggers. The r iggers must also unscrew the foot bolts from the laminator frame since it requires lifting the laminator.

Do not attempt to move the laminator across

anything other th an a flat, level surface without

trained and qualified riggers. You can be crushed

or seriously injur ed.

Do not use a kni fe or ot her sharp instrum ent

during installation or while servic ing the

laminator. You can cause irrepara ble damage to

the rolls.

9. Remove all packing materials to a safe distance fro m the lamina to r.

☞

The pallet can be reused for shipping the machine again, or can be disassembled and the wood and screws recycled. The cardboard can be recycled. The shrink wrap is not recyclable, however, so it must be discarded.

☞

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 compl etely seale d. In addition , moisture absorbing silicone desiccite packs are packed inside the crate and machine cabinets.

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

tipped up or sideways in any way. Such action

disturbs the exact alignment of the rolling parts

of the machin e and requires extensive

realignment. GBC Pro-Tech’s warranty does not

cover malfun cti o n of the equipment du e 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 lamin ator is in place set the locking mechanism on all four wheels to ON.

8. Remove any plastic strapping and packing paper taped to the

roll

s.

Prior to start up of the machine, you must rem ove the desiccite packs from each cabinet and discard. DO NOT operate the machine with the desiccite packs inside the cabinets.

F-40 Laminator Operator Manual

Installation

2-5

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 kni fe or ot her sharp instrum ent

during installation or while servic ing the

laminator. You can cause irrepara ble damage to

the rolls.

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.

1

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MISE EN GARDE

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SAFETY

INSTRUCTIONS SICHERHEITSRICHTLINIEN

CONSIGNES DE SÉCURITÉ

1.Read and understand the Operation Manual and all safety labels before operating this machine.

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.This machine is to be serviced only by trained and authorized personnel.

Follow lockout procedures before servicing.

WARNING

4.Never reach into the machine for any

reason unless the machine is at a

ACHTUNG

COMPLETE STOP.

5.Never leave the machine stopped in

MISE EN GARDE

such a manner that another worker can start the machine while you are working on or within the machine.

6.Never change or defeat the function of electrical interlocks or other machine “shutdown” switches.

7.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

Crush and burn

unwind stands.

- The machine is free of paper scraps,

hazard. Stay clear

wraps and jams.

of moving rollers.

1 . o N r e d r o

8.There is a potential hazard of entanglement

e

Stop machine and

R

raise roll before

in this machine caused by items such as

1 4 2 0

- 8

long hair, loose clothing and jewelry.

4

cleaning.

7

- 0

0 8 . c n I ,

Make sure your clothing and hair fit

S C H 4 9 9 1

©

closely to your body and that all jewelry, rings and watches are removed.

. 8 0 0

- 7 4 8

- 0 2 4 1

R

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G

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G

N

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C

E

M

E

NOT S U

A

psi 100

kPa

90

700

80

630

70

560

60

490

50

420

40

350

30

280

20

210

10

140 70

8

6

1 0

4

1 2

2

4 8

0

1

6

1

8

W

A

R N

A

IN

C

G H TU

MISE EN GARDE

N

G

Carefully read Operator's Manual before handling this machine. Observe instructions and safety rules when operating.

DANGER

8 0 0

7 4 8

0 2 4 1

GEFAHR

R

e

o

r

d

e

r

N

o

.

6

0

1

P T

HAZARDOUS VOLTAGE.

T P

- 5 2 0 5

. o N r e

To be serviced only

d r o e

R

by trained and authorized personnel. Lockout power before servicing.

1 4 2 0

- 8 4 7

- 0 0 8 .

c n I , s m e t

s y S n o i t a c

i n u m m o C d r a

5

2

3. Carefull y remove any accessories packed with the laminator. The accessory pack should contain:

1 Set, hex wrench e s 1 Slitting knife 1 Manual 1 Set, spare fuses 1 T ape measure 1 Roll of masking tape 1 Rubber ce ment eras e r

Foot Bolt

Shipping Pad

Figure 2-5: The Foot Bolts

4. Remove the screws holding the foot pads onto the pallet using the Phillips head screwdriver.

5. Have the laminator lifte d off the skid and placed on the floor by lic ensed riggers. The riggers must also unscrew the foot bolts from the laminator frame since it requires lifting the laminator.

Figur e 2-4: R emov ing the Crate

2. Gently unwrap the shrink wrap from around the laminator.

Falcon F-40 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual