Falcon F-40 Operator's Manual

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© 1998 GBC Pro-Tech

Do not duplicate without written permission

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8.There is a potential hazard of entanglem
in this m
long hair, loose clothing and jew
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ake sure your clothing and hair fit
closely to your body and that all jew
rings and w

S, Inc. 800-748-0241

unw

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efore starting this m

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achine is free of paper scraps,

achine caused by item

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ever change or defeat the function of

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Training should include instruction
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and em

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by trained and authorized personnel.
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lockout procedures before

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SICHERHEITS­RICHTLINIEN

CONSIGNES DE
SÉCURITÉ

1.R
ead and understand the O

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anual and all safety labels before

operating this m

nly a trained person is to be
itted to operate this m

ergency situations.
achine is to be serviced only

achine for any

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SAFETY
INSTRUCTIONS

achine.

peration

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al conditions

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WARNING
ACHTUNG

MISE EN GARDE

Crush and burn
hazard. Stay clear

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of moving rollers.

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Stop machine and

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raise roll before

-0241

cleaning.

, Inc. 800-748
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1994
©

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

©1994 HCS, Inc. 800-748-0241 Reorder No.1033R-PT

WARNING
ACHTUNG

ISE EN GARDE
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Part Number 930-005

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

©1994 HCS, Inc. 800-748-0241 Reorder No.6001-PT

psi

100

kPa

90

700

80

630

70

560

60

490

50

420

40

350

30

280

20

210

10

140
70

8

6

10

4

12

2

48

0

16

18

WARNING
ACHTUNG

MISE EN GARDE

DANGER
GEFAHR

HAZARDOUS
VOLTAGE.

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: [phone]

Fax: [phone]

F-40 Laminator Operator Manual

ii

© GBC Pro-Tech 1998 February

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

© GBC Pro-Tech 1998 February

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

© GBC Pro-Tech 1998 February

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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

© GBC Pro-Tech 1998 February

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

© GBC Pro-Tech 1998 February

WARNING

WARNING

WARNING

CAUTION

WARNING

WARNING

DANGER

WARNING

Push either

button to stop the

laminator

A

U

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NOT

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OP

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Twist and pull up

both buttons to

resume operation

1

NOT

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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

A

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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

© GBC Pro-Tech 1998 February

1-3

WARNING

CAUTION

CAUTION

CAUTION

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

© GBC Pro-Tech 1998 February

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

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.

&DXWLRQ:DUQLQJ /DEHO /RFDWLRQV

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

© GBC Pro-Tech 1998 February

1-5

SAFETY

SAFETY

INSTRUCTIONS

INSTRUCTIONS

SICHERHEITS-

SICHERHEITS-

RICHTLINIEN

RICHTLINIEN

CONSIGNES DE

CONSIGNES DE

SÉCURITÉ

SÉCURITÉ

1. Read and understand the Operation

1. Read and understand the Operation

Manual and all safety labels before

Manual and all safety labels before

operating this machine.

operating this machine.

2. Only a trained person is to be

2. Only a trained person is to be

permitted to operate this machine.

permitted to operate this machine.

Training should include instruction

Training should include instruction

in operation under normal conditions

in operation under normal conditions

and emergency situations.

and emergency situations.

3. This machine is to be serviced only

3. This machine is to be serviced only

by trained and authorized personnel.

by trained and authorized personnel.

Follow lockout procedures before

Follow lockout procedures before

servicing.

servicing.

4. Never reach into the machine for any

4. Never reach into the machine for any

reason unless the machine is at a

reason unless the machine is at a

COMPLETE STOP.

COMPLETE STOP.

5. Never leave the machine stopped in

5. Never leave the machine stopped in

such a manner that another worker can

such a manner that another worker can

start the machine while you are working

start the machine while you are working

on or within the machine.

on or within the machine.

6. Never change or defeat the function of

6. Never change or defeat the function of

electrical interlocks or other machine

electrical interlocks or other machine

“shutdown” switches.

“shutdown” switches.

7. Before starting this machine, check that:

7. Before starting this machine, check that:

- All persons are clear of the machine.

- All persons are clear of the machine.

- No maintenance work is being performed

- No maintenance work is being performed

on the machine.

on the machine.

- All guards are in place.

- All guards are in place.

- All parent rolls are well chucked in the

- All parent rolls are well chucked in the

unwind stands.

unwind stands.

- The machine is free of paper scraps,

- The machine is free of paper scraps,

wraps and jams.

wraps and jams.

8. There is a potential hazard of entanglement

8. There is a potential hazard of entanglement

in this machine caused by items such as

in this machine caused by items such as

long hair, loose clothing and jewelry.

long hair, loose clothing and jewelry.

Make sure your clothing and hair fit

Make sure your clothing and hair fit

closely to your body and that all jewelry,

closely to your body and that all jewelry,

rings and watches are removed.

rings and watches are removed.

©1994 HCS, Inc. 800-748-0241 Reorder No.7002-PT

©1994 HCS, Inc. 800-748-0241 Reorder No.7002-PT

WARNING

WARNING

ACHTUNG

ACHTUNG

MISE EN GARDE

MISE EN GARDE

Moving parts can

Moving parts can

crush and cut.

crush and cut.

Do not operate with

Do not operate with

door open.

door open.

©1994 HCS, Inc. 800-748-0241 Reorder No. 1012-PT

©1994 HCS, Inc. 800-748-0241 Reorder No. 1012-PT

SAFETY

SAFETY

INSTRUCTIONS

INSTRUCTIONS

SICHERHEITS-

SICHERHEITS-

RICHTLINIEN

RICHTLINIEN

CONSIGNES DE

CONSIGNES DE

SÉCURITÉ

SÉCURITÉ

1.Read and understand the Operation

1.Read and understand the Operation

Manual and all safety labels before

Manual and all safety labels before

operating this machine.

operating this machine.

2.Only a trained person is to be

2.Only a trained person is to be

permitted to operate this machine.

permitted to operate this machine.

Training should include instruction

Training should include instruction

in operation under normal conditions

in operation under normal conditions

and emergency situations.

and emergency situations.

3.This machine is to be serviced only

3.This machine is to be serviced only

by trained and authorized personnel.

by trained and authorized personnel.

Follow lockout procedures before

Follow lockout procedures before

servicing.

servicing.

4.Never reach into the machine for any

4.Never reach into the machine for any

reason unless the machine is at a

reason unless the machine is at a

COMPLETE STOP.

COMPLETE STOP.

5.Never leave the machine stopped in

5.Never leave the machine stopped in

such a manner that another worker can

such a manner that another worker can

start the machine while you are working

start the machine while you are working

on or within the machine.

on or within the machine.

6.Never change or defeat the function of

6.Never change or defeat the function of

electrical interlocks or other machine

electrical interlocks or other machine

“shutdown” switches.

“shutdown” switches.

7.Before starting this machine, check that:

7.Before starting this machine, check that:

- All persons are clear of the machine.

- All persons are clear of the machine.

- No maintenance work is being performed

- No maintenance work is being performed

on the machine.

on the machine.

- All guards are in place.

- All guards are in place.

- All parent rolls are well chucked in the

- All parent rolls are well chucked in the

unwind stands.

unwind stands.

- The machine is free of paper scraps,

- The machine is free of paper scraps,

wraps and jams.

wraps and jams.

8.There is a potential hazard of entanglement

8.There is a potential hazard of entanglement

in this machine caused by items such as

in this machine caused by items such as

long hair, loose clothing and jewelry.

long hair, loose clothing and jewelry.

Make sure your clothing and hair fit

Make sure your clothing and hair fit

closely to your body and that all jewelry,

closely to your body and that all jewelry,

rings and watches are removed.

rings and watches are removed.

©1994 HCS, Inc. 800-748-0241 Reorder No.7002-PT
©1994 HCS, Inc. 800-748-0241 Reorder No.7002-PT

Crush and burn

Crush and burn

hazard. Stay clear

hazard. Stay clear

of moving rollers.

of moving rollers.

Stop machine and

Stop machine and

raise roll before

raise roll before

cleaning.

cleaning.

4
9
9
1

©1994 HCS, Inc. 800-748-0241

©

WARNING

WARNING

ACHTUNG

ACHTUNG

MISE EN GARDE

MISE EN GARDE

WARNING

WARNING

ACHTUNG

Crush and burn

Crush and burn

hazard. Stay clear

hazard. Stay clear

of moving rollers.

of moving rollers.

Stop machine and

Stop machine and

raise roll before

raise roll before

cleaning.

cleaning.

©1994 HCS, Inc. 800-748-0241 Reorder No.1033R-PT

WARNING

WARNING

ACHTUNG

ACHTUNG

MISE EN GARDE

MISE EN GARDE

Crush and burn

Crush and burn

hazard. Stay clear

hazard. Stay clear

of moving rollers.

of moving rollers.

Stop machine and

Stop machine and

raise roll before

raise roll before

cleaning.

cleaning.

0
0

0
0

. 8

c

. 8
c

, In
S

, In

C

S

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0

2

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8

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4

8
4

-7

7

-

©1994 HCS, Inc. 800-748-0241 Reorder No.1033R-PT

A

R

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OP

E

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T

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N

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E

C

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M

E

M

E

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NOT

S

U

NOT

A

S

U

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WARNING

WARNING

ACHTUNG

ACHTUNG

MISE EN GARDE

MISE EN GARDE

T

-P
3
3
0
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o

r N
e
rd
o
e

Reorder No.1033-PT

R

1
4
2

-0
8
4

-7

0
0
. 8
c

, In
S
C
H

ACHTUNG

MISE EN GARDE

MISE EN GARDE

Crush and burn

Crush and burn

hazard. Stay clear

hazard. Stay clear

of moving rollers.

of moving rollers.

Stop machine and

Stop machine and

raise roll before

raise roll before

cleaning.

cleaning.

©1994 HCS, Inc. 800-748-0241 Reorder No.1033-PT

©1994 HCS, Inc. 800-748-0241 Reorder No.1033-PT

A

A

R

R

R

R

OP

OP

E

E

T

T

T

T

S

S

D

D

Y

Y

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E

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M

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NOT

NOT

S

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U

U

A

A

240 VOL TS

240 VOL TS

LEM PRODUCTIONS, INC. DOYLESTOWN PA LVM-240C

LEM PRODUCTIONS, INC. DOYLESTOWN PA LVM-240C

WARNING

WARNING

ACHTUNG

ACHTUNG

MISE EN GARDE

MISE EN GARDE

Carefully read Operator's

Carefully read Operator's

Manual before handling

Manual before handling

this machine. Observe

this machine. Observe

instructions and safety

instructions and safety

rules when operating.

rules when operating.

©1994 HCS, Inc. 800-748-0241 Reorder No.6001-PT

©1994 HCS, Inc. 800-748-0241 Reorder No.6001-PT

REV

FANS

1

O

1

T

O

O

100

P

75

50

PROTECH

1

8

6

10

4

B

12

O

O

2

UT

O

150

T

48

175

125

0

T

100

16

O

75

18

M

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

50

PROTECH

275

°F

300

001-133

LO

WARNING

WARNING

ACHTUNG

ACHTUNG

MISE EN GARDE

MISE EN GARDE

Carefully read Operator's

Carefully read Operator's

Manual before handling

Manual before handling

this machine. Observe

this machine. Observe

instructions and safety

instructions and safety

rules when operating.

rules when operating.

©1994 HCS, Inc. 800-748-0241 Reorder No.6001-PT
©1994 HCS, Inc. 800-748-0241 Reorder No.6001-PT

A+A-

A+A-

CL

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

001-133

LO

200

HI

225

250

DANGER

DANGER

ic
n
u

m
m
o
C
d
r

a
z
a

H
4
9
9

©1994 Hazard Communication Systems, Inc. 800-748-0241 Reorder No. 5025-PT

1
©

©1994 Hazard Communication Systems, Inc. 800-748-0241 Reorder No. 5025-PT

©1994 Hazard Communication Systems, Inc. 800-748-0241 Reorder No. 5025-PT

L1L2

FUSE

FUSE

F-

F-

ARM

ARM

I1
I1

P2P1I1 F+

P2P1I1 F+

MIN IR
MIN IR

P3

P3

FUSE
FUSE

ACCEL

ACCEL
LINE
LINE

MAX
MAX

P/N 9884
P/N 9884

KBIC BARRIER TERMINAL BOARD

KBIC BARRIER TERMINAL BOARD

S
U
O

GEFAHR

D

GEFAHR

E.

T

R

-P
5
2

G

0
. 5
o

ZA

N
r
e

d
r

A

o

LTA

e
R

H

HAZARDOUS

O
V

VOLTAGE.

To be serviced only

To be serviced only

by trained and

by trained and

authorized personnel.

authorized personnel.

Lockout power before

Lockout power before

servicing.

servicing.

1
4
2

-0
8
4

-7
0
0

. 8
c
, In

s
m
te
s
y

S
n
tio
a

240 VOL TS

240 VOL TS

LEM PRODUCTIONS, INC. DOYLESTOWN PA LVM-240C

LEM PRODUCTIONS, INC. DOYLESTOWN PA LVM-240C

DANGER

DANGER

GEFAHR

GEFAHR

HAZARDOUS

HAZARDOUS

VOLTAGE.

VOLTAGE.

To be serviced only

To be serviced only

by trained and

by trained and

authorized personnel.

authorized personnel.

Lockout power before

Lockout power before

servicing.

servicing.

Figur e 1-2: Locations of Safety Labels

Safety

F-40 Laminator Operator Manual

1-6

© GBC Pro-Tech 1998 February

Blank page.

F-40 Laminator Operator Manual

Installation

© GBC Pro-Tech 1998 February

2-1

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CAUTION

WARNING

CAUTION

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

© GBC Pro-Tech 1998 February

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

© GBC Pro-Tech 1998 February

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

© GBC Pro-Tech 1998 February

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

© GBC Pro-Tech 1998 February

2-5

If the laminator is in a crate:

CAUTION

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

A
R

R

OP

E

T

T
S

D

Y

'

U

C

R

N

G

E

E

G

N

R

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E

E

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E

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S

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4

3

A

WARNING
ACHTUNG

MISE EN GARDE

rn

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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.

©
1
9
9
4
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C
S
, In
c

. 8
0
0

-
7
4
8

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E

E

G

N

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E

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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

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N

A

IN

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H
TU

MISE EN GARDE

N

G

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

DANGER

©
1
9
9
4
H
C
S
,
I
n
c
.

8
0
0

­7
4
8

­0
2
4
1

GEFAHR

R

e

o

r

d

e

r

N

o

.

6

0

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
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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.

Installation

F-40 Laminator Operator Manual

2-6

© GBC Pro-Tech 1998 February

WARNING

CAUTION

A NOTE ABOUT RECYCLING

NOTE

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.

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.

☞

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.

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.

6HWXS

Once the Falcon 40 Laminator has been unpacked and
moved into final position check each of the foll owing
items.

6. Once the lamin ator is in place set the locking
mechanism on all four wheels to ON.

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

Do not use a knife or other sharp instrument

during installation or while servicing the

laminator. You can cause irreparable damage to

8. Remove all packing materials to a safe distance
from the laminator.

☞

The crate components can be reused for shipping the
machine again, or can be disassembled and the wood
and scre ws recycled. The shrink wrap is not re cyc lable,
however, so it must be discarded.

roll

s.

the rolls.

T ools required:

1

•

/8" hex wrench

• Adjustable wrench

Setup Proce du re

1. Inspect the la minator for any obvious shipping
damage.

2. Remove the drive and control side cabinet covers

1

with the
screws holding each cover in place.

3. Inspect all the bolts and tighten any that were loos­ened during shipping.

4. Check the upp er ma in
handwheel to raise and lower the
move smoothly.

5. Set the nip. (See Section 4: Maintenance and Trou-
bleshooting for the procedur e.)

6. Verify that both inf rare d sensors are clean and have
an uninterrupted view of the rolls.

/8" hex wrench by removing the six

assembly by using the

roll

. It should

roll

F-40 Laminator Operator Manual

Installation

© GBC Pro-Tech 1998 February

2-7

WARNING

ALWAYS CHECK THE INFRARED SENSORS

L1-3

L2-3

N3

L3-3

L1-4

L2-4

N6N4N5

L3-4

L2-2

N7

N2

Blue

L1L2L3

N

Line-1

Line-2

Line-3

PE

GND

Cabinet

Stud

L1-3

L2-3
L3-3

The United States
3-Phase Delta

NU

N

L2

L1

L3

The European
3-Phase Y

L1-3

L2-3

N3

L3-3

L1-4

L2-4

N6N4N5

L3-4

L2-2

N7

N2

Blue

L1L2L3

N

Line-1

Line-2

Line-3

GND

Cabinet

Stud

Jumpers Relocate
As Shown For
Selected Service

L1-3

L2-3

N3

L3-3

L1-4

L2-4

N6N4N5

L3-4

L2-2

N7

N2

Blue

L1L2L3

N

Line-1

Line-2

GND

Cabinet

Stud

Single Phase (U.S.)

PRIOR TO OPERAT ION! The sensors must be

clean and ha ve free v ie w of the roll to maintain

proper r oll operatin g te mperatures. The rolls can

overheat and cause a fire or seriously damage

the laminator.

7. Plug the laminator into an approved socket or ha ve
a certifie d electrician wire the laminator directly to
a power source.
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.

8. Verify that the photoelectric eye is working prop­erly. (See the procedure below.)

9. Replace both cabinet covers.

Figure 2-6: Pow er Cord Connection

Installation

F-40 Laminator Operator Manual

2-8

© GBC Pro-Tech 1998 February

6WDUWXS

WARNING

WARNING

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.

Startup Checklist

Start the laminator and go through the foll owing check­list.

❏ 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 opera tion. Always
check both buttons.

Never operate the laminator unless both of the

emergency stop buttons are fun ction ing

properly. You can be crushed or burn ed.

operation. Verify that the footswitch overri des the
photoelectric eye by pressing the footswitch and
pushing an object as lar ge as your hand into the nip
area.

Once you have com pleted the startup checklist you can
safely run a test sample.

❏ Is the photoelectric eye system working?

With the laminator running, place an object
approximately the size of your hand just in front of
the nip to co nfirm that the photo elec tric e ye syste m
is functioning. The
object away from the nip. The laminator should
resume operation.

Never operate the laminator unless the

photoelectric eye system is functioning properly.

You can be crushed or burned.

❏ Is the motor functi oning?

Test the motor at various speeds ranging from
0-18. At 0 the
Run the motor in both forward and reverse.

❏ Are the heaters wor king?

Verify that the top heater controller heats the top
roll and the bottom heater controller heats the bot­tom roll.

roll

s should stop. Move the

roll

s should stop turning.

❏ Is the footswitch operating?

Test the footswitch for both forward and reverse

F-40 Laminator Operator Manual

Operation

© GBC Pro-Tech 1998 February

3-1

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WARNING

NOT

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NOT

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S

T

OP

A

R

R

E

T

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G

E

N

C

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Twist and pull up

both buttons to

resume operation

Push either

button to stop the

laminator

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GBC Pro-Tech laminators are powerful machines that
are designed to mount, laminate and encapsulate. The
forces required to accom plish these tasks can vary fr om
negligible to very lar ge.

The spring system used to provide downward pr ess ure
on the top roll is capable of producing f orce s 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 touch ed 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 objec t is
removed and the light beam reestablished, the rolls
resume turning. However, this system is overridden if
you use the footswitch.

Figure 3-1: Using the Emergency Stop Buttons

Despite the safety features built into the Falcon 40
Laminator , e xtreme caution must be used when operat­ing or servicing the unit.

Reset Button

Disconnect

laminator with the footswitch. The photoelectric

The Falcon 40 Laminator has a steel cabinet that is
bolted closed to isolat e the elec trical and drive system
components for the safety of the operator. Only a quali­fied service techni ci an should open these cabinets.

The laminator is equipped with two emergency stop
buttons located on the top of eith er side of the lamina­tor. Either of these, if engaged, stops the lamina tor. To
continue operation both e mergency stop buttons must
be in the up position and you must press the reset but­ton above the fuse panel on the back of the laminator.

Use extreme caution when operating the

eye system is overridden, and your fingers can

get caught in the nip. You can be crushed or

burned.

GBC PRO-TECH ENGINEERING, INC.

DE FOREST, W

Model No. Serial No.

ISCONSIN

VAC
Hz
Amps
Phase
Wires

M
AD

E IN

U.S.A.

Figure 3-2: Re s et Button

Operation

F-40 Laminator Operator Manual

3-2

© GBC Pro-Tech 1998 February

2SHUDWRU &RQWUROV

The operator controls fo r the Falc on 40 Laminator are
located on the front of the unit, to the right of the oper­ator position. The names and funct ions of these con­trols are as follows:

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Figure 3-3: Front Control Panel

psi

kPa

100

700

90

630

80

Roll Pressure

Display

1

560

70

490

60

420

50

350

40

280

30

210

20

140

10

70

7. LOWER ROLL HEATER CONTROLLER–

Provides a readout of the temperature of the lower
roll and the set-point for the desired temperature.

8. FOOT SWITCH/CONTINUOUS RUN AUTO/
STOP - Chang es control of the machine drive from
a foot switch to continuous run.

9. MOTION CONTROL FORWARD/REVERSE -
Controls the dir ection of th e drive system, f orward,
reverse, or stop.

10. POWER LIGHT - Indicates when the main power
is being applied to the machine. It is located aroun d
the left corner of the cabinet from the front pan el.

Upper Roll Heat

ON/OFF

Lower Roll Heat

ON/OFF

Cooling Fan

ON/OFF

Speed Adjustment

Power Light

(Located around

the left corner of

the catinet from the

front panel.)

2

3

4

6

4

59

2

0

10

CAL 3200

CAL 3200

108

12

48

16

18

6

Upper Roll Heater
Controller

7

Lower Roll Heater
Controller

8

Footswitch/
Continuous Run
AUTO/STOP

Motion Control
FORWARD/REVERSE

1. ROLL PRESSURE DISPLAY – Displays the

percentage of pressur e pushing the main roll down.

2. UPPER ROLL HEAT ON/OFF – Turns the

heater controll er for the upper main roll on or off.

3. LOWER ROLL HEAT ON/OFF – Turns the

heater controll er for the lower main roll on or off.

4. COOLING FANS ON/OFF – Turns the cooling

fans on or of f and tur ns t he vacuum ta ble fa ns on or
off, when a vacuum table option is installed.

5. SPEED ADJUSTMENT – Adjusts the speed of

the machine from zero to the maximum as the con­trol is turned clockwise.

6. UPPER ROLL HEATER CONTROLLER –

Provides a readout of the temperature of the upper
roll and the set-point for the desired temperature.

F-40 Laminator Operator Manual

Operation

© GBC Pro-Tech 1998 February

3-3

6HWXS

CAUTION

CAUTION

CAUTION

Setup of the Falcon 40 Laminator is quic k an d straight­forward when instructions are followed exactly.

T o adjust the nip, please see Section 4: Maintenance
and Troubleshooting.

Always mount the film so that the adhesive side

faces outward from the laminating r oll. This

prevents hours of roll cleaning .

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Use only the minimum amount of roll pressure needed
to accomplish the tas k. While higher press ure 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.

Excess pres sure can damage the laminating rol ls.

Minimum laminator roll pr essure is consistent

with good results.

A typical roll pressure for soft substrates such as Foam­core or Orca Board is 1/4 revolution of the laminating
roll crank.

A typical roll pressur e for hard substrates is 1/2 revolu­tion of the laminating roll cran k.

A typical roll pressure for encapsulation is 1/2 revolu­tion of the laminating roll cran k.

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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 o the r assort ed trouble s wil l
occur .

Carefully align the two films being fed into the

nip. If not, you will obtain poor result s.

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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 of 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.

Film is loaded on the appropriate unwinds. Loading
and aligning t he film are discussed later in this se ction.
For applications such a s enc apsulation, 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 unwind s. There are two
important points to remember when loading film:

1. The adhesi ve side of the film must be oriented
away (on the outside) from the laminating roll.
Otherwise it will immediate ly 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
should ALWAYS face outward from the laminat-
ing roll.

4. Secure the suppor t arm.

Operation

F-40 Laminator Operator Manual

3-4

© GBC Pro-Tech 1998 February

+HDWLQJ

NOTE

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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 heat er switc h to ON.

2. Adjust the temperature controller for the desired
operating temperat ure using the temperature con­troller dial adjustm en t.

3. When heati ng 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 to indic ate the status of the
heating system.

5. It will take approximately 15 minutes for the lami­nating roll(s) to reach operating temperature. When
the preset operating te mperature has been reached,
the machine is ready to use.

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The following procedure is the faste st way to cool the
machine. Natural cooling can al so be used.

1. Set the heat er switc hes to OFF.

1. Always cut the leading edge of a print strai ght 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 ºF and
increase the motor speed by one third.

2. Leave the cool ing system ON.

3. Lower the upper main roll until the laminating rolls
are touching.

4. Set the Forward/Reverse switch to FWD.

5. Set the speed control to 2.

6. Let the machi ne run until the laminating rolls
return to room temperature.

☞

In the cha ng e ove r 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.

F-40 Laminator Operator Manual

Operation

© GBC Pro-Tech 1998 February

3-5

3URFHVV &RQWURO &KDUWV

NOTE

WARNING

NOTE

Process control charts allow you to record the way you
thread film through the machi ne's rolls and idlers
(called webbing) and the control setting s for each prod­uct and process. Process control charts a re an excellent
tool for training new operat or s. The y provide a "road
map" for correct machine setup and operation.

This section contai ns a blank pr ocess control chart and
diagram for the Falcon 40 as well as completed charts
for the basic operation s of the lamina tor.

GBC Pro-Tech laminators respond in a very accurate
and repeatable m anner. 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 c lose t o the la minator. Use the machine
to encapsulat e the popular charts so t hey can withstand
food and coffee spills and so they are always available
for ready referen c e.

☞

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 contr ol char ts included in this
section are based on Falcon Film, Falcon Board, and
typical prints.

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3. Insert Orca boa rd, 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.

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 sh ould
lay flat on the upper main roll. Stop feeding once
the back edge of the boa rd is one inch from the nip .

6. Lay the im age onto the adhesive side o f the Falcon
Board. Tacking the image down with a tacking ir on
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 throu ghout 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. W ith a knife, cut the laminate
on the infeed side. Pull the mounted image thr ough
the pull roll s. Do this quickly so a s to eliminate the
possibility of getting adhesive on the machine.

☞

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1. Adjust the machine settings as shown in process
chart 3-2.

Do not operate the laminator without the infeed

table installed on the machine.

2. Load the film onto the upper unwind assembly.

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

F-40 Laminator Operator Manual

3-6

© GBC Pro-Tech 1998 February

0RXQWLQJ 2QO\

Note

WARNING

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. Inser t Falcon Board, adhesive side down, into the
nip. Lower th upper main roll until it conta cts, and
then turn i t another 1/4 turn. Press the f ootswitc h to
remove the board from the nip.

3. Lay th e image onto t he adhesive s ide of the Fal con
Board. Tacking the image down with a ta cking ir on
at this point is sometimes helpful.

4. Press the footswitch and carefully insert the board
and image into the nip. Be sure to keep it perpen­dicular to the laminating r olls and maintain paper
tension throughout the process.

☞

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.

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For this process, the image is first encapsulated and
then mounted.

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1. Adjust the machine settings as shown in process
chart 3-4a and remove the infeed table.

2. Web up the overlaminate by bringing it around the
upper film idler and up to the re lease paper r ewind.
T ape the film to the rewind and give it one full
wrap around the rewind tube. Be sure to check the
process control chart to ensur e correct web up.

3. With a singe edge razor, cut acro ss the film on the
rewind tube, being sure not to cut through the
release liner or the rolls.

Use extreme caution when using the single edge

razor not to damage the rolls or cut yourself.

4. Peel the fil m back and drape it over the uppe r main
roll. To get enough material to do this, it may be
necessary to turn the rewind tube by hand.

5. 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.

6. Insert a starte r board into the nip and lower the
upper main roll onto it.

7. Press the foots witch. Once the leader board is
through the n ip, lower the upper m ain roll and then
rotate the crank 1/2 a turn more.

8. Reinstall the infeed table. You can operate with or
without the pull rolls at this point.

9. Encapsula te the images.

F-40 Laminator Operator Manual

Operation

© GBC Pro-Tech 1998 February

3-7

6HWXS DQG 3URFHGXUH 3DVV 

1. Adjust the machine settings as shown in process
chart 3-4b.

2. Trim the print to size and tri m the board to the size
of the print.

3. Insert the board into the nip area and lower the
main roll until it contac ts. Turn the crank another 1/
4 of a turn and remove the board using the foot­switch.

4. Clean t he board with a tack cloth or cleani ng roller.

5. Place the image face down on a flat surface and
peel back the release liner on the lead ing edge
(about two inches).

4. Insert a starte r board into the nip and lower the
upper main roll onto it.

5. Press the foots witch. Once the leader board is
through the ni p, lower the upper m ain roll and then
rotate the crank 1/2 a turn more.

6. Reinstall the infeed table.

7. Encapsula te the images.

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1. Adjust the machine settings as shown in process
chart 3-5b.

2. Tr im the print to size and trim the board to the size
of the print.

6. 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.

7. 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.

8. Trim the board and image to the finished size.

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This process is very simi lar to the Two Pass Mount and
Laminate using cold overla minate.

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1. Adjust the machine settings as shown in process
chart 3-5a and remove the infeed table.

2. Web up the hot overlaminate by wrapping it around
the upper film idler and draping it over the upper
main roll. Drape the film onl y about halfway down
the upper main ro ll.

3. Insert the boa rd into the nip area and lower the
main roll until it contacts . Tur n the crank anot her 1/
4 of a turn and remove the board using the foot­switch.

4. Clean the boa rd with a tack cloth or cleaning roller.

5. Place the image face down on a flat surface and
peel back the release liner on the leading edge
(about two inches).

6. 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.

7. Insert the alr eady mounte d port ion of t he pie ce 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.

8. Trim the board and image to the finished size.

3. Pull the mount adhesive straight up from the lower
unwind position, being careful not to stick the f ilm
to the machine. Tack it to the hot overlaminate.

Operation

F-40 Laminator Operator Manual

3-8

© GBC Pro-Tech 1998 February

(QFDSVXODWLRQ

CAUTION

CAUTION

CAUTION

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This is the most co mm o nly p erfo r me d pro ce ss.

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1. Adjust the machine settings as shown in process
chart 3-6 and remove the infeed ta ble. 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 aff ecting image quality.

Make sure that the adhesive side of the laminate

is away from the roll to prevent an extensive

clean up job.

It is very im portant that the Falcon 40 laminator is shut
down in proper manner. If not, the laminati ng rol ls can
be damaged or destroyed.

Failure to follow this procedure can result in

damage to the rolls.

3URFHGXUH

1. Tur n off the main power to the machine.

2. Raise the main lamina ting roll at least one inch.

3. Put the output roll into the upright position.

The laminating and output rolls must always be

in the up position when the machine is not in

use.

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. Inser t 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 ini tial
contact of the upper laminat ing ro ll 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 ta ble.

7. Encapsula te the image.

F-40 Laminator Operator Manual

Operation

© GBC Pro-Tech 1998 February

3-9

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

F-40 Laminator Operator Manual

3-10

© GBC Pro-Tech 1998 February

352&(66 &21752/ &+$57 

MATERIALS

Upper Media

3 mil gloss

Image Media

Bond Paper

Lower Media

N/A

Mounting Substrate

Falcon Board

LAMINATOR SETTINGS

Top Heater Status

ON @ 240 ºF (115 ºC)

Drive Mode

Manual (Footswitch)

Bottom Heater Status

OFF

Pull Roll Position

UP

Speed

1-2 ft/min

Output Cooling

OFF

Drive Direction

FWD

Main Roll Setting

DOWN - 1/4 turn

One-Pass Mounting and Laminating

352&(66 &21752/ ',$*5$0 

Leader
Board

Printed

Image

FALCON

Board

Notes

___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

F-40 Laminator Operator Manual

Operation

© GBC Pro-Tech 1998 February

3-11

352&(66 &21752/ &+$57 

MATERIALS

Upper Media

N/A

Image Media

Bond Paper

Lower Media

N/A

Mounting Substrate

Falcon Board

LAMINATOR SETTINGS

Top Heater Status

ON @ 240 ºF (115 ºC)

Drive Mode

Manual (Footswitch)

Bottom Heater Status

OFF

Pull Roll Position

UP

Speed

2-3 ft/min

Output Cooling

OFF

Drive Direction

FWD

Main Roll Setting

DOWN - 1/4 turn

One-Pass Mounting

352&(66 &21752/ ',$*5$0 

Printed

Image

FALCON

Board

Notes

__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________

Operation

F-40 Laminator Operator Manual

3-12

© GBC Pro-Tech 1998 February

352&(66 &21752/ &+$57 $

MATERIALS

Upper Media

Pro-Gloss

Image Media

Bond Paper

Lower Media

Pro-Mount

Mounting Substrate

N/A

LAMINATOR SETTINGS

Top Heater Status

ON @ 110 ºF (43 ºC)

Drive Mode

Manual or Auto

Bottom Heater Status

OFF

Pull Roll Position

UP or DOWN

Speed

4-6 ft/min

Output Cooling

OFF

Drive Direction

FWD

Main Roll Setting

DOWN - 1/2 turn

Two Pass Mount and Cold/Pressure Overlaminate, First Pass

352&(66 &21752/ ',$*5$0 $

Release

Liner Rewind

Release Liner

Notes

___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

F-40 Laminator Operator Manual

Operation

© GBC Pro-Tech 1998 February

3-13

352&(66 &21752/ &+$57 %

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

Manual (Footswitch)

Bottom Heater Status

OFF

Pull Roll Position

UP

Speed

2-6 ft/min

Output Cooling

OFF

Drive Direction

FWD

Main Roll Setting

DOWN - 1/4 turn

Two Pass Mount and Cold/P ressure Overlaminate, Second Pass

352&(66 &21752/ ',$*5$0 %

Hold Encapsulated

Release

Notes

__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________

Liner

Image

Image
Face

Operation

F-40 Laminator Operator Manual

3-14

© GBC Pro-Tech 1998 February

352&(66 &21752/ &+$57 $

MATERIALS

Upper Media

3 mil Gloss

Image Media

Bond Paper

Lower Media

Pro-Mount

Mounting Substrate

N/A

LAMINATOR SETTINGS

Top Heater Status

ON @ 230 ºF (110 ºC)

Drive Mode

Manual or Auto

Bottom Heater Status

OFF

Pull Roll Position

DOWN

Speed

3-4 ft/min

Output Cooling

OFF

Drive Direction

FWD

Main Roll Setting

DOWN - 1/2 turn

Two Pass Mount and Hot Overlaminate, First Pass

352&(66 &21752/ ',$*5$0 $

Notes

___________________________________________________________ ________________________________
___________________________________________________________ ________________________________
___________________________________________________________ ________________________________

F-40 Laminator Operator Manual

Operation

© GBC Pro-Tech 1998 February

3-15

352&(66 &21752/ &+$57 %

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

Manual (Footswitch)

Bottom Heater Status

OFF

Pull Roll Position

DOWN

Speed

2-3 ft/min

Output Cooling

OFF

Drive Direction

REV

Main Roll Setting

UP

T wo Pass Mount and Hot Overlaminate, Second Pass

352&(66 &21752/ ',$*5$0 %

CAUTION: Do not
allow foam board to
drop below Fan
Bridge Lip

Encapsulated Image

Release Liner

Foam Core

Notes

__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________

Operation

F-40 Laminator Operator Manual

3-16

© GBC Pro-Tech 1998 February

352&(66 &21752/ &+$57 

MATERIALS

Upper Media

3 mil Gloss

Image Media

Bond Paper

Lower Media

3 mil Gloss

Mounting Substrate

N/A

LAMINATOR SETTINGS

Top Heater Status

ON @ 230 ºF (110 ºC)

Drive Mode

Manual or Auto

Bottom Heater Status

ON @ 230 ºF (110 ºC)

Pull Roll Position

DOWN

Speed

3-6 ft/min

Output Cooling

OFF

Drive Direction

FWD

Main Roll Setting

DOWN - 1/4 turn

Encapsulation

352&(66 &21752/ ',$*5$0 

Notes

___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

F-40 Laminator Operator Manual

Maintenance and Troubleshooting

© GBC Pro-Tech 1998 February

4-1

6HFWLRQ   0DLQWHQDQFH DQG

CAUTION

Daily

Monthly

Every Six

Months

7URXEOHVKRRWLQJ

Performing regular maintenance on the Falcon 40
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.

&OHDQLQJ

T ools required:

• Adhesive coated board

• 80% isopropyl alcohol (or dishwash ing det ergent)

• Rubb er cem en t eras er

• Several 100% cotton terry cloths

Table 4-1: Maintenanc e Sc hedule

• Clean the infrared sensors

• Clean the rolls

• Inspect the el ec tric al cord fo r dam­age

• Inspect the footswitc h cord for dam­age

• Adjust the nip

• Check the chain tension

• Inspect the area around the laminator
for possible hazards (d ust buildup,
combustible items stor ed too close ,
etc.)

• Lubricate the grease fittings and
chain

• Check wire termination tightness

• Protective rubber gloves

T o clean the infrared sensors:

ALWAYS CHECK THE INFRARED SENSORS

PRIOR TO OPERATION! The sensors must be

clean and have free view of the roll to maintain

proper r oll oper ating temperatur es. T he r olls can

overheat and cause a fire or seriously damage

the laminator.

Using a clean, damp cloth, gently wipe both infrared
sensors. See Figure 4-1 for sensor loca tion.

Maintenance and Troubleshooting

F-40 Laminator Operator Manual

4-2

© GBC Pro-Tech 1998 February

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

©1994 HCS, Inc. 800-748-0241

Upper Main
Roll

Infrared Sensor

A

R

R

OP

E

T

T
S

D

Y

'

U

C

R

N

G

E

E

G

N

R

C

E

E

M

E

NOT

S

U

A

WARNING
ACHTUNG

WARNING
ACHTUNG

MISE EN GARDE

Reorder No.1033-PT

MISE EN GARDE

Crush and burn
hazard. Stay clear

T

-P

of moving rollers.

033R
o.1
er N
rd

Stop machine and

eo

R

raise roll before

41

cleaning.

, Inc. 800-748-02
S

C
1994 H
©

Fan Bridge

GBC PRO-TECH ENGINEERING, INC.

DE FOREST, WISCONSIN

Model No. Serial No.

VAC
Hz
Amps
Phase
Wires

M
A

D
E
IN

U

.S

A

A

R
R

R

R
OP
OP

E
E

T

T

T

T

S
S

D
D

Y
Y

'

'

U
U

C

C

R

R

N
N

G

G

E

E

E

E

G

G

N
N

R

R

C
C

E
E

E
E

M

M

E
E

NOT

NOT

S
S
U
U

A

.A
.

A

F-40

Infrared Sensor

Underside of

Laminator

Figure 4-1: Infrared Sensor Locations

F-40 Laminator Operator Manual

Maintenance and Troubleshooting

© GBC Pro-Tech 1998 February

4-3

To clean the laminator rolls:

WARNING

CAUTION

CAUTION

1. Remove the infe ed table and infeed pressure plate
to gain access to the rolls.

Exercise ext rem e cauti o n whi le cl ea ning the

laminator. Y ou c an be caught in the turning r olls

and crushed or burned.

2. While the lamina tor is at normal operating temper­ature, put on the rubber gloves and, using a rubbe r
cement eraser, remove any heat activated adhesive
from the rolls.

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.

Do NOT pick or pull heat activated adhesive off

the rolls when they are cold. You can cause
irreparable damage to the laminating rolls.

Maintenance and Troubleshooting

F-40 Laminator Operator Manual

4-4

© GBC Pro-Tech 1998 February

To clean bead s of adhe sive, dus t a nd dirt from the

CAUTION

WARNING

CAUTION

WARNING

rolls:

1. Allow the lami nator to cool slightly to no higher
than 110º F (43ºC).

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.

T o clean the cabinet and covers:

1. Unplug the laminator to clean the exterior.

2. Using a damp cotton te rry clot h (water only), cle an
the exterior of the laminator.

3. Clean the rol ls using a moderate amount of 80%
isopropyl alcohol on a cotton te rry c loth.

Use the minimum amount of pressure necessary

to clean the rolls. You can destroy the silicone

layer on the rolls by pressin g to hard or

scrubbing too long in one spot.

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.

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.

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.

4. W ith the laminator ro lls no hotter than 1 10º remove
dust and dirt from the silicone laminating rolls by
running an adhesive-coa te d board through the lam­inator . Be sure t o set the nip for the th ickness of the
board used.

5. Allow the lami nator to cool.

F-40 Laminator Operator Manual

Maintenance and Troubleshooting

© GBC Pro-Tech 1998 February

4-5

$GMXVWLQJ WKH 1LS

CAUTION

The gap between the two main rolls is called the nip.
The purpose of adjusting the nip is to ensur e continu­ous contact between the lamina ting rolls as the media is
drawn through the machine. This procedure must be
done regularly.

Tools required:

1

•

/8" hex wrench

• (2) ¾" open end wrenches

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 r oll until there is
an even gap between the rolls as shown in Figure
4-3.

To adjust the nip:

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 contr ol side cabinet covers

1

with the

/8" 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 ligh t bet ween the upper
and lower main rolls.

4. Loosen the ja mnut on the nip adjusting bolt on
each side of the laminator as shown in
Figure 4-2.

Properly Set Nip

(Distance Between

Rolls is Equal)

Figure 4-3: Properly Set Nip

6. Hold the adjustment bolt in place while tightening
the jamnut on each side of the laminator.

7. Replace both cabi net covers and reconnect power
to the laminator.

&KDLQ 7HQVLRQLQJ

Adjusting the chain tension on the Falc on 40 Lamina­tor is a simple procedure that keeps the system running
smoothly and maximizes the efficiency of the motor.

T ools required:

1

•

/8" hex wrench

3

•

/16" hex wrench

• Screwdriver

Figure 4-2: Adjusting the Nip

Adjusting
Bolt

Jamnut

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 cabine t cover using the

1

hex wrench by removing the si x scr ews hol ding the
cover in place.

3. Loosen all four motor mount bolts using the

3

/16"

hex wrench as shown in Figure 4-4. The motor
should just move freely wi thin the slots.

/8"

Maintenance and Troubleshooting

F-40 Laminator Operator Manual

4-6

© GBC Pro-Tech 1998 February

WARNING

WARNING

1/4" to

1/2" Play

Loosen Motor

Mount Bolts

Downward

Force Tightens

Chain

Figure 4-4: Adjusting the Chain Tension

4. Using a screwdr iver, apply a small amount of
downward pressure on the motor by prying against
the inside of the side frame until there is ¼" to ½"
play in the chain.

5. Tighten the mounting bolts while maintaining the
downward pressure on the motor.

6. Replace the cabinet cover and reconnect power to
the laminator.

Unplug the laminator and make sure it won't be

plugged back in while you are performing this

procedure. You could be severely shocked,

electrocute d, or get you r fi ngers caught in the

drive mechanisms.

1. Remove the drive and control side cabinet covers

1

using the

/8" hex wrench by removing the six

screws holding each cover in place.

2. Using the grease gun, lubr icate each grease fitting
(shown in Figure 4-5) with one squirt of high tem­perature g rea se .

WARNING
ACHTUNG

Grease
Fittings

MISE EN GARDE

Moving parts can
crush and cut.
Do not operate with
door open.

©

1
9
9
4
H
C

S
, In
c

. 8
0
0

-
7
4
8

-0

2
4
1

R
e
o
r
d
e

r
N
o

. 1
0
1

2

-P
T

/XEULFDWLRQ

Tools required:

1

•

/8" hex wrench

• High temperature grease or lithium grease

• Grease gun

To lubricate the laminator:

Do not lubricate the laminat or when i t is hot. You

can be burned.

Figure 4-5: Grease Fittings

3. Lubricate the chain using a soft cloth and automo­tive oil.

4. Replace th e cabinet covers and reconnect power to
the laminator.

F-40 Laminator Operator Manual

Maintenance and Troubleshooting

© GBC Pro-Tech 1998 February

4-7

&RQWDFWLQJ 7HFKQLFDO 6XSSRUW

For machine parts and technical service in North
America, please call: 1-8 00-790-7787. Please provide
serial number when calling for service. In Europe,
please call: [phone] or fax: [phone]
202 441.

For film and application questions in North America,
please call 1-800- 236-8843. In Eu rope, pl ease call: +44
(0) 1844 202 440 or fax: [phone].

Maintenance and Troubleshooting

F-40 Laminator Operator Manual

4-8

© GBC Pro-Tech 1998 February

2XWSXW 7URXEOHVKRRWLQJ *XLGH

Problem:

D waves in the image, not in the
laminate.

Hints:

• Check paper tension.

• Check relative moisture
content of the paper.

Problem:

Waves on only one side of the
output.

Problem:

D waves in the laminate.

Hints:

• Increase clutch tension.

• Check roll pressures.

• Check nip settings.

Feed

Direction

Problem:

Straight waves in the output.

Hints:

• Decrease clutch tension.

• Check operational settings for
materials being used.

Other Common Problems:
Problem:

Blistering in the image.

Hints:

• Increase speed or lower the operating
temperature.

Problem:

Coiling of encapsulated images.

Hints:

• 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:

• Check nip settings.

• Check for even paper tension.

Hints:

• Increase chain tension, decrease unwind
brake tension.

F-40 Laminator Operator Manual

Warranty

© GBC Pro-Tech 1998 February

5-1

6HFWLRQ   :DUUDQW\

CAUTION

([FOXVLRQV WR WKH :DUUDQW\

/LPLWHG :DUUDQW\

GBC Pro-Tech Engineering Company, Inc. warrants
the equipment sold is free from defects in ma te rial and
workmanship for a period of nine ty days (90) from the
date of delivery to the customer. This warranty is the
only warran ty ma d e by GBC Pro-Tech and cannot be
modified or amended.

GBC Pro-Tech’s sole and exclusive liabilit y 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 Pro­Tech’s examination of the product discloses to GBC
Pro-Tech’s satisfaction that such defects actually
exist and were not caused by misuse, negle ct,
attempt to repair, unauthorize d alt era tio n or m od i­fication, incorrect line voltage, contaminated air
supply, or by fire, accident, flood, or other hazard.

This warran ty spe ci fica lly does not cover damage to
the laminating rolle rs caused by knives, razor blades,
other sharp objects, failure caused by adhesives or
improper use of the machine. Warranty repair or
replacement does not exte nd the warra nty beyond the
initial ninety day period from the date of delivery .

This warranty specifically does not cover:

1. Damage to the laminating r olls 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 machi ne other
than rolling on the installed casters on even sur­faces.

3. Improper use of the machine.

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 .

Warranty

F-40 Laminator Operator Manual

5-2

© GBC Pro-Tech 1998 February

Blank page.

F-40 Laminator Operator Manual

Specifications

© GBC Pro-Tech 1998 February

6-1

6HFWLRQ   6SHFLILFDWLRQV

Characteristic

Specifications

Table 6-2: Falcon 40 Laminator Specifications

Dimensions
(L x D x H)

Weight Uncrated: 300 lbs (136 kg)

Laminating Rolls 42" (1.06m) roll face with high

Laminating
Opening

Laminating
Material

Laminating
Speeds

Encapsulating
Features

Safety Features • Photoelectric eye system

56" x 31" x 56"
(1.42 x .79 x 1.42m)

Crated : 500 lbs (225 kg)

release surface , uppe r and lower
rolls internally heated

1.5" (3.8 cm) maximum opening
controlled with infinitely vari­able hand crank

Uses heat activated and pressure­sensitive materi als 0 - 39"
(99.6 cm) wide on a 3" (7.6 cm)
ID core, 10" (25.4 cm) maximum
diam et er

0 to 18 fmp (o to 5.5 mpm) with
variable spee d, r eversible action,
start and stop controlle d ei ther
through the instrument pan el or
with the footswitch

Pull rolls and cooling fans for
uniform flat cooling

prevents laminati ng roll
movement when hands ar e in
the nip area

• All electrical and moving
mechanical parts are locate d
in bolted cabinets

• Hand crank for laminating
roll movement

• Emergency stop buttons with
a reset button circuit

Options • Unwind for rolled prints

• Rewind for rolled prints

• Vacuum table

• Outfeed Slitters

• Outfeed Table

Installation
Requirement

220VAC 50 or 60 Hz single
phase, 30A

Specifications

F-40 Laminator Operator Manual

6-2

© GBC Pro-Tech 1998 February

Blank page.

F-40 Laminator Operator Manual

Index

© GBC Pro-Tech 1998 February

7-3

6HFWLRQ  ,QGH[

/

$

Accessory pack
Adjusting bolt

2-3

4-5

&

Chain

Lubrication

Tensioning
Cleaning
Clutch

Common problems
Controls

Front control panel

4-6

4-5

4-1

(

Emergency stop buttons
Encapsulating
Encapsulation
Environment
Extension cord

6-1
3-8

2-1

2-1

4-8
3-2

1-1, 2-7, 3-1

Laminating material
Laminating opening
Laminating rolls
Laminating speeds
Lubrication

4-6

6-1

6-1

6-1

6-1

0

Main roll

4-5

Lower
Main rolls
Maintenance schedule
Motor
Mounting and laminating (one pass)
Mounting only

4-5

4-1

2-7, 4-5, 4-6

3-5

3-6

1

1-1, 1-2, 2-6, 2-7, 3-1, 4-1, 4-4, 4-5, 6-1

Nip

2

Outfeed slitters
Outfeed table

6-1

6-1

)

Film

Loading

Positioning
Foot bolt
Footswitch
FWD/REV switch

3-3

3-3

2-4, 2-5

1-1, 1-2, 2-7, 3-1, 4-1, 4-4, 6-1

4-4

*

Grease fittings
Ground plug

4-6

2-1

+

Handwheel
Heater

Controller
Heating

2-6, 4-5

2-7

2-7

3-4

,

Infeed table
Infrared sensor locations
Infrared sen sor s
Installation r equirements
Isopropyl alcohol

4-3

2-6, 2-7, 4-1

4-1

4-2

2-1, 6-1

3

3-4

Paper
Photoelectric eye
Power cord
Power requ irement
Preinstallation ch ecklist
Pressure

Laminator roll

Process control charts

1-1, 1-2, 2-7, 3-1

2-1

2-1

3-3

3-5

5

Riggers
Rubber cem en t eraser

1-3, 2-4, 2-5, 2-6

4-1

6

Safety fea ture s
Safety information
Safety la b e l s

3-3

Setup
Setup procedure
Shutdown
Specifications

Dimensions
Encapsulating

6-1

1-1

1-4

2-6

3-8

6-1

6-1

2-1

Index

F-40 Laminator Operator Manual

7-4

© GBC Pro-Tech 1998 February

Laminating material
Laminating opening
Laminating rolls
Laminating speeds
Weight

6-1

6-1

6-1

6-1

6-1

7

Technical support

Call 1-800-236-8843

Two-pass mount and laminate

4-7

8

3-6, 3-7

Unpacking

Upper main ro ll
Upper main ro ll ass em bly

2-3

Cardboard box

2-5

Crate

1-3, 2-6, 4-5

2-3

9

Vacuum table

6-1

:

Warnings and cautions
Warranty

4-1

1-1

2-6