GBC Falcon 60+ (-1), Falcon 60+ Operation & Maintenance Manual

Operations Manual

Orca 64

© 2003 General Binding Corporation

Page 2

Falcon 60+ (-1)

Falcon 60+ (-1)

Table of content

Cover 1
Table of Content 2
Important Safety Instructions 3
Important Safeguards 4

General 4
Electrical 4
Service 4

Warranty 5
Specifications 6
Pre-Installation 7
Installation 8
Features Guide 9

Power Switch 9
Control Panel Indicators 9
Control Panel Buttons 9
E-Stop 10
Safety Shield Interlock Latch 10
Safety Shield 11
Feed Table 11
Chill Idler 11
Film Shaft 11
Main Rollers 11
Idler Bar 11
Pull Rollers 11
Rewind Tube 11
Film Shaft Brake 12
Core Adapters 12
Center Core Support 12
Rewind Brake 12
Main Roller Crank Handle 12
Pull Roller Crank Handle 12
Cooling Fans 12
Clutch 12
Accelerator Footswitch 12
Rear Table Latches 13
Rear Table 13
Rear Run/ Stop Switch 13
Film Web 13
Nip Point 13
Rear Slitter 13
Separator Bar 13

Operating Instructions 14

Film Loading and Threading 14
Webbing Thermal Film 15

Webbing PSA Film 16
Start Laminating 17
Tacking New Film 18
Unweb the Laminator 19
Clearing a Film Jam 19

Applications 20

Mounting Pre-Coated Boards 20
Single Sided Lamination 20
Creating a Decal 21
Mounting a Decal 21
Thermal Encapsulation 21
Accushield 22
Custom Application #1 22
Custom Application #2 22

Speed / Temperature Guide 23

Chart °F 23
Chart °C 23

The Art Of Lamination 24

Basic Rules 24
Film Tension 24
Heat 25
Output 25

Maintenance 26

Caring for the Falcon 60+ (-1) 26

Troubleshooting Guide 27
Service Agreement 27

Operations Manual

© 2003 General Binding Corporation

Page 27

Falcon 60+ (-1)

Falcon 60+ (-1)

CORRECTIVE ACTION

Insert attachment plug into receptacle.

Remove safety shield and properly replace it.

Tilt feed table and properly replace it.
Pull out on the E-STOP push button.

Disengage the footswitch mode.

Enable rear controls.
Remove the rear slitter and install the safety shield.

Adjust tension per section FILM TENSION.
Adjust tension per section FILM TENSION.

Make sure bottom roll of film is around idler bar
and the it is in the normal operating position.

Release heat and pull roller pressure, align
the rolls of film.
Adhesive (matte) side of laminate film may be
against the heat rollers. Unweb and reload
the film properly.

Lower speed setting by pressing SLOW
button to slower speed
Wait for “READY” indicator to appear in the
control panel display.
Adhesive side of film must be facing away
from the heat rollers.
Bottom roll of film not threaded behind the
idle bar.
Clean heat rollers per procedure in section

CARING FOR THE GBC FALCON 60+(-1)
LAMINATOR.

Item may be dirty or may have nonporous
surface that is extremely difficult to laminate.

Under section titled THE ART OF LAMINATION.
Place a service call for calibration check.

SERVICE AGREEMENT

GBC’s Equipment Maintenance Agreement will insure the quality perfor mance and long life built into your laminator.
A service charge for travel time, labor and parts may be incurred for each out of warranty service call. GBC’s Equipment Maintenance Agreement

decreases these expenses and protects your valuable investment. GBC offers several types of agreements to suit your needs and budget. To contact
GBC write to:

GBC NATIONAL SERVICE IN CANADA: GBC NATIONAL SERVICE
ONE GBC PLAZA 49 RAILSIDE ROAD
NORTHBROOK, IL 60062 U.S.A. DON MILLS, ONTARIO

1.847.272.3700 M3A 1B3 Part Number 930-099 Revision -

Troubleshooting Guide

SYMPTOM

• The control panel display does not
illuminate when POWER ON/OFF is

in the ON, marked “I”, position.

• Heat rollers do not turn when I

press the RUN ( ) button.

• Heat rollers only turn if I use

the“footswitch.

• Rear controls do not operate.

• Laminated items exhibit curling.

• Adhesive deposited on heat rollers.

• Unsatisfactory adhesion of laminate.

• Waves in my output

POSSIBLE CAUSE

Laminator not connected to
electrical supply.

Safety shield is not properly
installed.
Feed table not properly installed.
E-STOP is engaged

Laminator is in footswitch mode.

Rear controls are not enabled.
Safety shield is not is not installed

in rear position.
Tension between the top and bottom

film roll is unequal.
Tension on top or bottom roll offilm is too
film is too loose.

Bottom film roll may be improperly
loaded.

Top and bottom film webs not aligned.
Laminate improperly loaded.

Speed setting too fast for type of material
being laminated.

Insufficient heat.

Laminate improperly loaded.

Heat rollers require cleaning.

Laminated item unsuitable for adhesion.

See sub section OUTPUT.
Nips may be out of calibration.

Falcon 60+ (-1)

Falcon 60+ (-1)

WARNING:THE SAFETY ALERT SYMBOL
PRECEDES EACH SAFETY MESSAGE IN

THIS INSTRUCTION MANUAL. THE
SYMBOL INDICATES A POTENTIAL PERSONAL
SAFETY HAZARD TO YOU OR OTHERS, AS
WELL AS PRODUCT OR PROPERTY DAMAGE.

WARNING: DO NOT ATTEMPT TO

SERVICE OR REPAIR THE FALCON 60+ (-

1) LAMINATOR.

WARNING: DO NOT CONNECT THE

LAMINATOR TO AN ELECTRICAL SUPPLY

OR ATTEMPT TO OPERATE THE
LAMINATOR UNTIL YOU HAVE COMPLETELY
READ THESE INSTRUCTIONS. MAINTAIN
THESE INSTRUCTIONS IN A CONVENIENT
LOCATION FOR FUTURE REFERENCE.

Operations Manual

© 2003 General Binding Corporation

Page 3

Important Safety Instructions

YOUR SAFETY AS WELL AS THE SAFETY OF
OTHERS IS IMPORTANT TO GBC. IN THIS
INSTRUCTION MANUAL AND ON THE
PRODUCT,YOU WILL FIND IMPORTANT SAFETY
MESSAGES REGARDING THE PRODUCT. READ
THESE MESSAGES CAREFULLY. READ ALL OF
THE INSTRUCTIONS AND SAVE THESE
INSTRUCTIONS FOR LATER USE.

THE SAFETY ALERT SYMBOL PRECEDES
EACH SAFETY MESSAGE IN THIS

INSTRUCTION MANUAL. THE SYMBOL
INDICATES A POTENTIAL PERSONAL SAFETY
HAZARD TO YOU OR OTHERS, AS WELL AS
PRODUCT OR PROPERTY DAMAGE.
THE FOLLOWING WARNINGS ARE FOUND
UPON THIS PRODUCT .

THIS SAFETY MESSAGE MEANS THAT YOU
COULD BE SERIOUSLY HURT OR KILLED IF
YOU OPEN THE PRODUCT AND EXPOSE
Y OURSELF TO HAZARDOUS VOL TA GE.

THIS SAFETY MESSAGE MEANS THAT YOU
COULD BE BURNED AND YOUR FINGERS AND
HANDS COULD BE TRAPPED AND CRUSHED IN
THE HOT ROLLERS.CLOTHING, JEWELRY AND
LONG HAIR COULD BE CAUGHT IN THE
ROLLERS AND PULL YOU INTO THEM.

THIS SAFETY MESSAGE MEANS THAT YOU
COULD CUT YOURSELF IF YOU ARE NOT
CAREFUL.

Falcon 60+ (-1)

Falcon 60+ (-1)

Operations Manual

© 2003 General Binding Corporation

Page 4

Service

Perform only the routine maintenance procedures
referred to in these instructions.

W

ARNING: Do not attempt to service or

repair the laminator.

Disconnect the plug from the receptacle and contact
GBC’s Technical Department or your
dealer/distributor when one or more of the following
has occurred.

- The power supply cord or attachment plug is
damaged.

- Liquid has been spilled into the laminator.

- The laminator is malfunctioning after being
mishandled.

- The laminator does not operate as described in

these instructions.

Important Safeguards

WARNING: TO GUARD AGAINST INJURY,
THE FOLLOWING SAFETY PRECAUTIONS
MUST BE OBSERVED IN THE

INSTALLATION AND USE OF THE LAMINATOR.

General

Keep hands, long hair, loose clothing, and articles
such as necklaces or ties away from the front of the
heat and pull rollers to avoid entanglement and
entrapment.
The heat rollers can reach temperatures over 300˚
F. Avoid contact with the heat rollers during
operation or shortly after power has been removed
from the laminator.
Keep hands and fingers away from the path of the
sharp film cutter blade located at the film exit.
Do not use the laminator for other than its intended
purpose.
Avoid moving the laminator on uneven floor
surfaces.Never tilt the laminator.
Do not defeat or remove electr ical and mechanical
safety equipment such as interlocks, shields and
guards.
Do not insert objects unsuitable for lamination or
expose the equipment to liquids.

Electrical

The laminator should be connected only to a source
of power as indicated in these instructions and on
the serial plate located on the rear of the laminator.
Contact an electrician should the attachment plug
provided with the laminator not match the
receptacles at your location.

CA

UTION:

The receptacle must be located

near the equipment and easily accessible.

Do not operate the laminator with a damaged power
supply cord or attachment plug, upon occurrence of
a malfunction, or after the laminator has been
damaged. Contact GBC’s Technical Service
Department or your dealer/distributor for assistance.

Falcon 60+ (-1)

Falcon 60+ (-1)

Operations Manual

© 2003 General Binding Corporation

Page 5

Limited 90-Day Warranty

GBC warrants to the original purchaser for a period
of one year parts and ninety days labor, after
installation that this laminator is free from defects in
workmanship and material under normal use and
service. GBC’s obligation under this limited
warranty is limited to replacement or repair, at
GBC’s option, of any par t found defective by GBC
without charge for material or labor.

THIS LIMITED WARRANTY IS IN LIEU OF ALL
OTHER WARRANTIES EXPRESSED OR
IMPLIED. WARRANTIES OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE
ARE EXPRESSLY EXCLUDED. ANY
REPRESENTATIONS OR PROMISES
INCONSISTENT WITH, OR IN ADDITION TO,THIS
LIMITED WARRANTY ARE UNAUTHORIZED AND
SHALL NOT BE BINDING UPON GBC. IN NO
EVENT SHALL GBC BE LIABLE FOR ANY
SPECIAL, INCIDENTAL, OR CONSEQUENTIAL
DAMAGES, WHETHER OR NOT FORESEEABLE.

This limited warranty shall be void if the laminator
has been misused; mishandled; damaged by
negligence, by accident, during shipment, or due to
exposure to extreme conditions; repaired, altered,
moved, or installed by anyone other than GBC or its
authorized agents; or if incompatible film was used.
GBC’s obligation under this limited warranty does
not include routine maintenance, cleaning,
adjustment, normal cosmetic or mechanical wear,

nor freight charges.

Without limiting the generality of the previous
paragraph, GBC’s obligation under this limited
warranty does not include:

1. Damage to the rollers caused by knives, razors,
or other sharp tools; by any foreign objects falling
into the working area of the laminator; or by cleaning
the laminator with solutions or materials that harm
its surfaces;

2. Damage caused by adhesives; nor

3. Damage caused by lifting, tilting or attempting to

position the laminator other than rolling it on its
castors across even surfaces.

FOR EUROPEAN UNION RESIDENTS ONLY:This
guarantee does not affect the legal rights which
consumers have under applicable national
legislation governing the sale of consumer goods.

Falcon 60+ (-1)

Falcon 60+ (-1)

Operations Manual

© 2003 General Binding Corporation

Page 6

Fig 1

Specifications

Operating Speed:

0 fpm to 18 fpm (5 mpm)

Maximum Film Width:

60 in. (152 cm)

Maximum Mounting Gap:

3/4 in. (1.91 cm)

Maximum T emperature:

270 OF (132 OC)

Dimensions (W x L x H):

Unit alone: (Figure 1)
79 in. x 33 in. x 57 in.
(201 cm x 84 cm x 145 cm)

Shipping:

85 in. x 44.5 in. x 78 in.
(216 cm x 113 cm x 198 cm)

Weight:

Unit alone: 1498 lb. (679 kg.)

Shipping: 1900 lb. (862 kg.)

Electrical Requirements:

Refer to the serial plate located on the rear of the
laminator for the specific electrical rating applicable
to the unit.

Voltage: 220V~60 Hz
Current: 24.5A
Power: 5500 W
Phase: Single

FCC NOTE: This equipment has been tested and

found to comply with the limits for a Class A digital
device, pursuant to part 15 of the FCC Rules.These
limits are designed to provide reasonable protection
against harmful interference when the equipment is
operated in a commercial environment. This
equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in
accordance with the instruction manual, may cause
harmful interference to radio communications.
Operation of this equipment in a residential area is
likely to cause harmful interference in which case
the user will be required to correct the interference
at his/ her own expense.

Changes or modifications not expressly approv ed by
General Binding Corporation could void the users
authority to operate the equipment.

This Class A digital apparatus complies with
Canadian ICES-003.

(Cet appareil numérique de las Classe A est
conforme a la norme NMB-003 du Canada)

Falcon 60+ (-1)

Falcon 60+ (-1)

Operations Manual

© 2003 General Binding Corporation

Page 7

Pre- Installation

Before a Falcon 60+ (-1) Laminator can be installed,
ensure the following requirements are met;

1. Are door ways and hallways wide enough for the
laminator to be moved to the installation site?

2. Is there ample room for the laminator?
– A work area must be established that allows for
operation in both the front and rear of the laminator
and provides space for efficient material flow.
(Figure 2)

3. Is the environment appropriate for the laminator?
– The laminator requires a clean, dust and vapor
free environment to operate properly.

– Avoid locating the laminator near sources of heat
or cold. Avoid locating the laminator in the direct
path of forced, heated or cooled air.

CA

UTION: Air flow can cause uneven

heating/ cooling of the rollers and result in
poor output quality

4.Have you contacted a cer tified electrician to wire
the receptacle and ensure that adequate power is
being supplied, having the appropriate capacity,
over current protection and safety lockouts
available?
– 220V at 60hz with 25 amp service. Use the
receptacle supplied with your machine (Nema 6­30R).

Fig 2

Falcon 60+ (-1)

Falcon 60+ (-1)

Fig 3

Installation

1. Shipping damage should be brought to the
immediate attention of the delivering carrier.

2. With assistance, carefully roll the laminator into

position over flat and even surfaces.

3. The laminator should be positioned to allow
exiting film to flow freely to the floor (Figure 3) or a
work table. Accumulation of laminate immediately
behind the laminator as it exits the equipment may
cause the film to wrap around the pull rollers,
resulting in a “jammed” condition.

4. Avoid locating the laminator near sources of heat
or cold. Avoid locating the laminator in the direct
path of forced, heated or cooled air.

5. Leveling of the machine is a customer option. If
you choose not to level the laminator and encounter
output problems, please level the machine and try
your application again before calling for technical
support. Resting the laminator on the leveling pads
prevent the machine from rolling during set up,
operation or servicing. (Figure 4)

6. Connect the attachment plug provided with the
laminator to a suitably grounded outlet. Avoid
connecting other equipment to the same branch
circuit to which the laminator is connected, as this
may result in nuisance tripping of circuit breakers or
blowing fuses.

Operations Manual

© 2003 General Binding Corporation

Page 8

Fig 4