GBC F-60H, FALCON 60 H Operation & Maintenance Manual

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GBC F-60H

Roll Laminator

Instruction Manual

FALCON 60 H

OPERATION & MAINTENANCE

MANUAL

© APRIL 2001 GENERAL BINDING CORPORA TION. ALL RIGHTS RESERVED.

Do not duplicate without written permission.

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F-60 H

PRO-TECH

GBC Pro - T ech

4151 Anderson Road

DeForest, WI 53532
Revision : A Ph: ( 608 ) 246 - 8844
Part number : 930 - 063

Fx: ( 608 ) 246 - 8645

Read me fileF 60 H Operation and Maintenance Manual

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incidental or consequential damage in connection with the furnishing or use of the information
in this publication, including, but not limited to, any implied warranty of fitness or merchantabil­ity for any particular use.

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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 General Binding Corporation or others. General
Binding Corporation assumes no liability arising from infringements of patents or any other
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This publication is copyrighted © 2001 by General Binding Corporation. All rights re­served. The information contained in this publication is proprietary and may not be repro­duced, stored, transmitted, or transferred, in whole or in part, in any form without the prior and
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4151 Anderson Road

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1.0 Safety

1.1 Symbols .......................................................................................................1 - 1

1.2 Safety precautions ......................................................................................1 - 2

1.3 Safety features ............................................................................................1 - 3

1.4 Installation ..................................................................................................1 - 4

T able of ContentsF 60 H Operation and Maintenance Manual

Table of Contents

1.5 Operations ..................................................................................................1 - 7

1.6 Applications ................................................................................................1 - 9

1.7 Troubleshooting .........................................................................................1 - 10

1.8 Maintenance ...............................................................................................1 - 10

1.9 Decal explanation .......................................................................................1 - 12

Figure 1.9.1 Safety label locations ............................................1 - 14

2.0 Warranty

2.1 Limited warranty information ....................................................................2 - 1

2.2 Exclusions to the warranty ........................................................................2 - 1

© April 2001 General Binding Corporation

Page I

T able of Contents F 60 H Operation and Maintenance Manual

3.0 Specifications

3.1 General .......................................................................................................3 -1

3.2 Consumables ...............................................................................................3 - 2

3.3 Function ......................................................................................................3 - 3

3.4 Electrical ....................................................................................................3 - 4

3.5 Dimensions ................................................................................................3 - 5

Figure 3.5.1 Dimensions ...............................................................3 - 6

4.0 Installation

4.1 Pre-installation check list ...........................................................................4 - 1

Figure 4.1.1 Suggested floor layout .............................................4 - 3

4.2 Know your machine ...................................................................................4 - 4

4.3 Unpacking ..................................................................................................4 - 5

4.4 Shrink wrapped .........................................................................................4 - 5

4.5 Crated .........................................................................................................4 - 6

4.6 Accessory pack content ............................................................................4 - 8

Page II

© April 2001 General Binding Corporation

4.7 Installing levelers .......................................................................................4 - 9

4.8 Leveling ......................................................................................................4 - 9

4.9 Connecting power ......................................................................................4 - 11

4.10 Safety check ............................................................................................4 - 13

5.0 Operations

5.1 Power ON/ OFF .........................................................................................5 - 2

T able of ContentsF 60 H Operation and Maintenance Manual

5.2 Control panel ..............................................................................................5 - 3

Figure 5.2.1 Front control panel ...................................................5 - 4

5.3 Set temperature ..........................................................................................5 - 5

5.4 Load/ unload film ........................................................................................5 - 6

5.5 Unwind brake tension .................................................................................5 - 9

5.6 Rewind brake tension .................................................................................5 - 9

5.7 Setting the nip ...........................................................................................5 - 10

5.8 Footswitch ..................................................................................................5 - 12

© April 2001 General Binding Corporation

Page III

T able of Contents F 60 H Operation and Maintenance Manual

6.0 Applications

6.1 Helpful hints ...............................................................................................6 - 1

6.2 Temperature conversion chart ...................................................................6 - 3

6.3 Charts and diagrams ..................................................................................6 - 5

Blank chart .......................................................................................................6 - 6

Blank diagram ..................................................................................................6 - 7

Blank diagram w/ roll to roll option ................................................................6 - 9

Chart - Pre-coating substrates ........................................................................6 - 10

Diagram - Pre-coating substrates ...................................................................6 - 11

Chart - Mounting an image ............................................................................6 - 12

Diagram - Mounting an image .......................................................................6 - 13

Chart - PSA decaling ......................................................................................6 - 14

Diagram - PSA decaling .................................................................................6 - 15

Diagram - PSA decaling w/ roll to roll options ..............................................6 - 17

Chart - Lo-Melt decaling ................................................................................6 - 18

Page IV

© April 2001 General Binding Corporation

T able of ContentsF 60 H Operation and Maintenance Manual

Diagram - Lo-Melt decaling ...........................................................................6 - 19

Diagram - Lo-Melt decaling w/ roll to roll options .........................................6 - 21

Chart - Mounting a decal ...............................................................................6 - 22

Diagram - Mounting a decal ..........................................................................6 - 23

Chart - PSA single sided lamination ( sled ) ...................................................6 - 24

Diagram - PSA single sided lamination ( sled ) ...............................................6 - 25

Chart - PSA single sided lamination ( craft paper ).........................................6 - 26

Diagram - PSA single sided lamination ( craft paper ) ...................................6 - 27

Diagram - PSA single sided lamination ( craft paper ) w/ roll to roll option ...6 - 29

Chart - PSA over-lamination of a mounted image .........................................6 - 30

Diagram - PSA over-lamination of a mounted image ....................................6 - 31

Chart - Lo-Melt over-lamination of a mounted image ...................................6 - 32

Diagram - Lo-Melt over-lamination of a mounted image ...............................6 - 33

© April 2001 General Binding Corporation

Page V

T able of Contents F 60 H Operation and Maintenance Manual

7.0 Troubleshooting

7.1 Wave problems ..........................................................................................7 - 1

7.2 Film problems .............................................................................................7 - 3

7.3 Machine problems ......................................................................................7 - 4

7.4 Glossary .....................................................................................................7 - 5

8.0 Maintenance

8.1 Maintenance schedule ................................................................................8 - 1

8.2 Cleaning the rollers ...................................................................................8 - 2

8.3 Clean cabinets and covers ..........................................................................8 - 4

8.4 Clean the control panel ..............................................................................8 - 4

8.5 Chain tensioning .........................................................................................8 - 5

Page VI

© April 2001 General Binding Corporation

F 60 H Operation and Maintenance Manual

Safety

1.0 Safety

CAUTIO N

Do n o t attempt to o p era te y ou r

Fa lco n 6 0 H lam in a tor u n til yo u

ha v e rea d th is s ectio n ca r efu lly !

Your safety, as well as the safety of others, is
important to GBC Films Group. This section contains
important safety information.

1.1 Symbols

INFORMATION

Indicates helpful information that should be

considered before, during, or after an

action, step or procedure is given.

CAUTION

Indicates a potentially hazardous situation

which, if not avoided, could result in minor

or moderate injury, or alerts against unsafe

practices or alerts against actions which

could damage the product.

The following symbols are used throughout this
manual to indicate Information, Caution, Warning,
Danger and Electrical Shock conditions.

WARNING

Indicates a potentially hazardous situation

which, if not avoided, could result in serious

injury.

DANGER

Indicates an imminently hazardous situation

which, if not avoided, could result in death

or serious injury.

ELECTRICAL

SHOCK

© April 2001 General Binding Corporation

Indicates an electrical shock situation which,

if not avoided, could result in serious

paralyzation of the body or death.

Page 1 - 1

Safety F 60 H Operation and Maintenance Manual

1.2 Safety precautions

DANGER

At these temperatures there is a danger of

severe burn if the rolls are touched during

The Falcon 60 H 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 servicing the unit.

The manual main roller lift mechanism used to
provide downward pressure on the upper main roller is
capable of producing forces greater than 400 pounds.
This force is applied to any object presented in the opening
( called the nip ) between the two rollers.

The word qualified is defined below;

Qualified;

setup, operation or servicing.

Use care in lowering the upper laminating roller
and know how to react quickly in an emergency. The
main laminator roll up / down control is located on the
right side of the machine within the front. Before turning
the crank handle to set the GAP down, ensure that nothing
is in the nip area.

WARNING

Keep h an d s an d fingers clear of the

laminator roller nip when adjusting nip.

You can be CRUSHED or BURNED!

• Any engineer that has experience with electrical
and mechanical design of lamination equipment. The
engineers should be fully aware of all aspects of safety
with regards to lamination equipment.

• Any commissioning or service engineer must be
of competent nature, trained and qualified to GBC Films
Group standards to fulfill that job. This person will have
completed and passed the full service training course from
GBC Pro-T ech.

• Any GBC T echnician, GBC Specialist, and / or
GBC Films Group T echnician that has been through the
GBC Pro-T ech service training course.

In addition, the main laminating rollers of the

Falcon 60 H can reach temperatures up to 200oF (100oC).

Page 1 - 2

© April 2001 General Binding Corporation

F 60 H Operation and Maintenance Manual

1

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n

POWER

Reset

ROT CH

F 60 H

PHOTO-EYE

Safety

1.3 Safety features

The laminator is equipped with four emergency

stops ( E-STOP ). Two are located at the front of the
cabinets and two are at the rear of the cabinets.

E-STOP

E-STOP

T o continue operation, all E-STOPs must be in

the unlatched position. T o reset, twist the E-STOP 1/4
turn counter clockwise.

Press RESET located on the control side cabinet

at the rear of the machine just above the main power on/
off.

T o engage an E-STOP, press down on any of the

four . Any E-STOP, when engaged, removes power to
the laminator .

INFORMATION

The machine will only operate if all four

E-STOPS are in the unlatched position.

© April 2001 General Binding Corporation

The nip area is protected by a electric photo-eye
which shoots a beam in front of the nip across the width
of the rollers. When this beam is broken, power to the
drive motor is removed. The objetc must be removed to
clear the photo-eye. The motor engage switch must be
pressed again to continue motor operation.

Page 1 - 3

Safety F 60 H Operation and Maintenance Manual

1.4 Installation

WARNING

The Fa lcon 60 H L am inator is a large and

The following symbols are positioned at various

points in Section 4 Installation.

CAUTION

Failure to follow the pre-installation check

list can result in damage to the laminator.

heavy piece of equipment. It is necessary to

employ LICENSED RIGGERS ONLY to
move the lam inator. The lam inator is not

de sig n e d to b e tip p e d u p or sidew a y s in a n y

way. Such action disturbs the exact
alignment of the rolling parts of the machine
and requ ires extensive realignm en t. You can

be crushed or seriously injured.

INFORMATION

ALL SHIPMENTS ARE EX-WORKS.

dock, title passes to the buyer. Please review

WARNING

The operating environment must be free of

dust, flammable liquids and vapors. You can

be injured by inhaling chemical vapors.

WARNING

Vapor build up or stored flammable

liquids can cause a fire. Excessive

dust can damage the laminator.

At our

your insurance coverage prior to shipment,

as you are responsible for all subsequent

freight charges and risks.

INFORMATION

Before signing the Bill of Lading, you

should be sure to inspect the crate

and / or pallet for signs of damage or

missing items; if applicable, make

note of this on the Bill of Lading.

CAUTIO N

Do n ot locate the Falcon 60 H w h ere air is

blowing directly on the machine. Th e air

flow can co ol the rolls un ev en ly an d resu lt

in poor output quality.

Page 1 - 4

WARNING

The unpacking process requires at least two

people. You can be severely injured, crushed

or cause damage to the laminator.

© April 2001 General Binding Corporation

F 60 H Operation and Maintenance Manual

INFORMATION

Depending on the destination and customer

preference, your machine may be shipped in

various ways. The laminator may arrive

shrink wrapped or in a plywood crate on a

skid. Please follow the unpacking procedure

that pertains to your method of shipment.

Safety

CAUTION

Do not allow the top to fall into the crate. It

can damage the laminator.

INFORMATION

CAUTION

Do not use a knife or other sharp object to

remove the shrink wrap from around the

laminator. You can cause irreparable

damage to the rollers.

WARNING

Do not attempt to move the laminator across

anything other than a flat level surface

without trained and qualified riggers. You

can be crushed or seriously injured.

Do not put packing screws on the floor.

They can cause problems when trying to roll

the laminator into position or you can

become injured if stepped on.

CAUTION

A second person must support the side
labeled 5 in Figure 4.5.1 It can fall and

damage the laminator or cause harm to you

and others.

INFORMATION

GBC Film Group's warranty does not

cover malfunction of the equipment due to

mishandling and / or tipping. GBC Films

Group bears no responsibility for personal

injury or damage due to moving the

laminator improperly.

© April 2001 General Binding Corporation

WARNING

Do not attempt to use the ramps if they are

not secured to the pallet. Ensure the pallet is

on a flat even surface before attempting to

roll the machine off.

Page 1 - 5

Safety F 60 H Operation and Maintenance Manual

IN F O RM A T ION

Ab out recycling: The crate compon ents can

be reused for shipping the laminator again

or can be disassembled and the wood and

screws recycled. Th e sh rink wrap is not

recyclable, so it must be d iscarded.

CAUTION

Do n o t m ove th e leveling nu t when securin g

the inside nut to the cabinet.

WARNING

Follow the correct wiring diagram when

supplying power to the laminator. If

improperly connected, you can be seriously

injured or cause damage to the laminator.

WARNING

Do not wear ties, loose fit clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

IN F OR MAT ION

Yo u will ne ed the con tr o l sid e ca b in e t co v e r

off to conn ect the electrical power.

ELECTRICAL

SHOCK

Only a qualified electrician should connect

power to the laminator. You can be severely

shocked, electrocuted or cause a fire if

power is improperly applied.

WARNING

If a safety feature is not working

properly, contact your local service

representative immediately.

CAUTIO N

Do not use a hard substrate or a substrate

with sharp edges. You may cause damage to

the lam inating rollers!

Page 1 - 6

© April 2001 General Binding Corporation

F 60 H Operation and Maintenance Manual

1.5 Operations

The following symbols are positioned at various

points in Section 5 Operations.

WARNING

Do not w ear ties, loose fit clothing or

dangling jewelry while operating or

servicing the lam in ator. Th ese item s can g et

caught in the nip and choke you or you can

be crushed or burned.

Safety

WARNING

W h en the lam in ator ro llers are in

motion, keep hands and fingers

away from the nip of the rollers.

You may be CRUSHED or BURNED!

WARNING

When o p e ra tin g th e la minato r u sing the

footsw itch, keep h an d s an d fin gers

away from the nip of the rollers.

You may be CRUSHED or BURNED!

IN F OR MAT ION

The m ac h in e will only o p e ra te if a ll

four emergency stop s are u n latched an d

RESET has been pressed.

WARNING

It is u n sa fe to sh e et f eed with o u t the

pressu re plate pro p erly placed o n

the fron t feed tab le.

WARNING

Do n o t opera te the lam ina tor, except

during web set up, without the front

and rear feed tables in position.

CAUTIO N

En su re the roll of lam in ate is loaded

properly on the unwind shaft.

Exposed adhesive should be facing

away from the rollers.

Th is will pre v ent hou r s o f ro ll cle a n in g !

WARNING

Keep h an d s and fin gers clear of th e

lamina tor roller nip when ch an gin g G A P .

You can be CRUSHED or BURNED!

© April 2001 General Binding Corporation

IN F OR MAT ION

Th e P o ly -in / P o ly-o u t diagra ms refe r to th e

upper rolls of film only. The mount adhesive

and craft p ap ers are fo r referen ce on ly.

Page 1 - 7

Safety F 60 H Operation and Maintenance Manual

WARNING

Never leave the unw ind shaft out of the

unwind support saddle unless loading

or unloading film.

CAUTIO N

W h en u sing tw o rolls on th e m ach ine,

ensur e the film w idth s are id entical.

Exposed adhesive can cause complications.

CAUTIO N

CAUTIO N

Excess pressure can damage the laminating

rollers. Alway s u se the m in imu m roll

pressure n ecessa ry to co m p lete the task.

CAUTIO N

Objects other than m edia, film or approved

substrates, will cause irreparable damage

to the rollers if caugh t in the n ip.

CAUTIO N

Never use an open blade near the laminating

rollers. You may cut the rollers or yo ur self.

IN F OR MAT ION

Always use the minimum amount

of bra ke fo r the job .

IN F OR MAT ION

If mo re bra ke is need ed, ad d an O-ring

to the brake side of the rewind.

Sharp edges on a substrate

should be filed smooth.

Sha rp edg es can C U T th e rollers!

IN F OR MAT ION

Ex c es siv e pressu r e will cause the

substrate to bow or flatten.

IN F OR MAT ION

De n s ity o f the substrate w ill determine th e

amoun t of pressure you may use.

Page 1 - 8

© April 2001 General Binding Corporation

F 60 H Operation and Maintenance Manual

1.6 Applications

The following symbols are positioned at various

points in Section 6 Applications.

Safety

IN F OR MAT ION

Ex c es siv e pressu r e will cause the

substrate to bow or flatten.

WARNING

Do not wear ties, loose fit clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

IN F OR MAT ION

Use film brake tension to control the

separa tion po int of the r elease liner.

IN F OR MAT ION

Excessive brake tension may cause the

imag e to curl. A lw ays u se the minimum

amoun t of brake for the job.

CAUTIO N

Excess pressure can damage the laminating

rollers. Alway s u se the m in imu m roll

pressure n ecessa ry to co m p lete the task.

IN F OR MAT ION

Sp ee d s and tempera tu r es will affe ct th e

bond strength of Lo-Melt adhesives.

IN F OR MAT ION

Th e m o un t ad h esive m u st no t exceed 1 in.

the w idth of the substrate. If it does, you

w ill e xp e rie n ce c omplications with th is

application.

© April 2001 General Binding Corporation

IN F OR MAT ION

Never stop the lam inator when an im age is

within the n ip of th e rollers.

IN F OR MAT ION

Lam inates and papers should always be

stored in a co n trolled env irom en t.

Page 1 - 9

Safety F 60 H Operation and Maintenance Manual

1.7 Troubleshooting

The following symbols are positioned at various

points in Section 7 T roubleshooting.

WARNING

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 choke you or you can

be crushed or burned.

1.8 Maintenance

The following symbols are positioned at various

points in Section 8 Maintenance.

WARNING

Do not wear ties, loose fit clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

INFORMATION

For optimal temperature settings of

various laminates, contact your

supplier or sales representative.

INFORMATION

Improper maintenance, can

result in poor output quality.

ELECTRICAL

SHOCK

Remove power from the laminator before

servicing. You can be severely shocked,

electrocuted or cause a fire.

IN F O RM A T ION

Page 1 - 10

Below is a recommended maintenance

schedule. Before performing any of the steps

listed, read through the procedures first.

Please follow the instructions pertaining to

the step you are perform ing.

© April 2001 General Binding Corporation

F 60 H Operation and Maintenance Manual

CAUTION

Safety

ELECTRICAL

SHOCK

Excessive pressure can destroy the silicone

layer by pressing to hard or scrubbing

too long in one spot.

CAUTION

Exercise care when cleaning the laminating

rollers with 80% isopropyl alcohol:



Use only in a well ventilated area



Wear rubber gloves



Use only on cool rolls

CLEANING HEATED ROLLERS CAN

IGNITE THE FUMES!

Remove power from the laminator before

cleaning. You can be severely shocked,

electrocuted or cause a fire.

ELECTRICAL

SHOCK

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,

electrocuted or cause a fire. Use only a damp

cloth for cleaning unless other wise

specified.

WARNING

CAUTION

Do NOT pick or pull heat activated adhesive

off the rolls when they are cold. You can

cause irreparable damage to the

laminating rolls.

Always practice lock out/ tag out procedures

WARNING

W h en op erating the laminator using the

footswitch, keep hands and fingers

away from the nip of the rollers.

You may be CRUSHED or BURNED!

Rem o ve ALL p ow er to th e lam in ator b efo re

remo ving an y ca bin et covers.

You may be shocked or electrocuted!

WARNING

wh en p erforming any ty pe o f service or

main tena nce work on the machine.

IN F OR MAT ION

Th e m o tor con trols the tension of th e bo th

cha ins. If on e c h ain is still too lo o se ,

a half link may be removed.

© April 2001 General Binding Corporation

Page 1 - 11

Safety F 60 H Operation and Maintenance Manual

y

g

g

1.9 Label locations

WARNING

!

ACHT UNG

Posted at various locations on the Falcon 60 H

Laminator are important safety labels. Pay careful
attention to these labels at all times! Figure 1.12.1
illustrates the location of each of these labels.

!

DANGER

!

GEFAHR

HAZARDOUS
VOLTAGE

To be serviced only
by trained and
authorized personnel.

Lockout power b efore
servicing

Moving Parts: Keep hands and fingers away . Y ou
may be crushed and/ or cut.

!

M ISE EN GARDE

!

Moving parts can
crush and cut.

Hazardous V oltage: Do not open these cabinets. This
machine is to be serviced only by trained and authorized
personnel.

WARNING

!

ACHTUNG

!

MISE EN GARDE

!

Crush and burn
hazard. Sta
of movin
Stop m achine and
raise roll before
cleanin

clear

rollers.

.

WARNING

!

ACHTUNG

!

M ISE EN G ARDE

!

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

Roller Pinch Point: Keep hands and fingers away.
Y ou may be crushed and/ or burned.

Page 1 - 12

Read Manual: Read and understand the Operations
Manual before attempting to run this machine.

© April 2001 General Binding Corporation

F 60 H Operation and Maintenance Manual

Electrical Shock: Live voltage present. Exercise

extreme caution. Y ou may be electrocuted!

Safety

Refer to Figure 1.9.1 Label Placement illustrates
the location of each of these labels.

Lift Here: This point may be used as a lifting point. If

ignored, damage will occur to the laminator.

Reset: Machine reset. Press after initiating power to the
laminator or after an E-STOP or E-CABLE has been
engaged then reset.

© April 2001 General Binding Corporation

Page 1 - 13

Safety F 60 H Operation and Maintenance Manual

Figure 1.9.1 Safety label locations

(Inside cabinet)

WARNING
ACHTUNG

MISE EN GARDE

WARNING
ACHTUNG

MISE EN GARDE

Moving parts can
cruch and cut.

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

ARNN

A HU

N
S
M

(Inside cabinet)

!

DANGER

!

GEFAHR

HAZARDOUS
VOLTAGE

To be serviced only
by trained and
authorized personnel.

Lockout power before
servicing

F-60 H

PRO-TECH

WARNING
ACHTUNG

MISE EN GARDE

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

Page 1 - 14

© April 2001 General Binding Corporation

WarrantyF 60 H Operation and Maintenance Manual

2.0 Warranty

GBC Films Group warrants the equipment sold

is free from defects in material and workmanship for a
period of one ( 1 ) year parts ( excludes normal wear
items ) and 90 days labor from the date of installation.
This warranty is the only warranty made by GBC Films
Group and cannot be modified or amended.

GBC Films Group’s sole and exclusive
liability and the customer’s sole and exclusive
remedy under this warranty shall be, at GBC Films
Group’s option, to repair or replace any such
defective part or product. These remedies are only
available if GBC Films Group’s examination of the
product discloses to GBC Films Group’ s satisfaction
that such defects actually exist and were not caused
by misuse, neglect, attempt to repair , unauthorized
alteration or modification, incorrect line voltage, fire,
accident, flood, or other hazard.

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
FILMS GROUP 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.

2.2 Exclusions to the

2.1 Limited Warranty

This warranty specifically does not cover damage
to the laminating rollers caused by knives, razor blades,
other sharp objects, failure caused by adhesives or
improper use of the machine. Warranty repair or
replacement does not extend the warranty beyond the
initial one year period from the date of delivery .

CAUTION

Warranty

This warranty specifically does not
cover;

1. Damage to the laminating rollers 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 machine other than
rolling on the installed castors on even surfaces.

3. Improper use of the machine.

Unauthorized customer alterations will

void this warranty.

© April 2001 General Binding Corporation

4. Damage due from unqualified person(s) servicing the
machine.

Page 2 - 1

Warranty F 60 H Operation and Maintenance Manual

Qualified

• Any engineer that has experience with electrical
and mechanical design of lamination equipment. The
engineers should be fully aware of all aspects of safety
with regards to lamination equipment.

• Any commissioning or service engineer must be
of competent nature, trained and qualified to GBC Films
Group standards to fulfill that job. This person will have
completed and passed the full service training course from
GBC Pro-T ech.

• Any GBC T echnician, GBC Specialist, and / or
GBC Films Group T echnician that has been through the
GBC Pro-T ech service training course.

Page 2 - 2

© April 2001 General Binding Corporation

3.0 Specifications

Specifications provide all of the technical data for

the Falcon 60 H Laminator.

3.1 General

SpecificationsF 60 H Operation and Maintenance Manual

Description:

Features:

• Cost efficient, wide format color finisher for the sheet

fed ink jet market. The Falcon 60 H is a self standing,
bi-directional cold mounter and laminator with the abilty
to run Lo-Melt overlaminate.

• T wo unwinds ( 1 upper, 1 center/ front )

• One rewind ( upper front )

• Infeed and oufeed tables

• Footswitch

• Front and rear table idlers

• Bi-directional system

• Four E-STOPs

• Photo-eye nip protection

• Roll to roll capability ( option)

Applications:

© April 2001 General Binding Corporation

• Single sided lamination

• Mounting

• Decaling

• Low melt film

Page 3 - 1

Specifications F 60 H Operation and Maintenance Manual

3.2 Consumable

Film types:

Film diameters:

Core size:

• Pressure sensitive laminates

• Pressure sensitive adhesives

• Low melt laminates

• Up to a 8 in. roll diameter ( 20.3 cm )

• 3 in. core standard ( 7.62 cm )

• 2-1/4 in. optional ( must have optional core adapters )

( 5.72 cm )

Film widths:

Paper widths:

Mounting thickness:

Safety:

• 62 in. Pressure sensitive ( 162.6 cm )

• 60 in. Low Melt ( 157.8 cm )

• 62 in. maximum paper width ( 157.8 cm )

• Up to 1 in. thick ( 2.54 cm ) either direction

• Designed to UL safety standards

Page 3 - 2

© April 2001 General Binding Corporation

3.3 Function

SpecificationsF 60 H Operation and Maintenance Manual

Speed:

Motor:

Heating capabilities:

Controls:

• 0 - 16 ft / min ( 0 - 4.6 m / min )

• 2-1/4 horse power drive motor

• Bi-directional D.C. motor

o

• 68

F - 200oF ( 20oC - 93oC )

• Front control panel

• Footswitch

Roll design:

© April 2001 General Binding Corporation

• High release silicone rollers

Page 3 - 3

Specifications F 60 H Operation and Maintenance Manual

3.4 Electrical

United Statesand Canada:

B.T .U. output:

Heater wattages:

Amperage draw:

• 230 ~ 240 VAC, 50/60 Hz, single phase, 40 amps

• 18,520 B.T.U. / hour

• 5429 watts per heater @ 240 vac

• No heat, motor only : 1 - 3 amps

• T op heat and motor : 25 - 30 amps

D/C voltage used:

A/C voltage used:

Page 3 - 4

• 24 vdc

• 230~ 240 vac ( minimum )

© April 2001 General Binding Corporation

3.5 Dimensions

W eight:

SpecificationsF 60 H Operation and Maintenance Manual

Uncrated:

Crated:

Dimensions

Uncrated:

Crated

• 1350 lbs. ( 612 kg. )

• 1625 lbs. ( 737 kg. )

• 80 in. (L) x 38.5 in. (W) x 57 in. (H)

( 203 cm (H) x 98 cm (W) x 145 cm (L) )
Refer to Figure 3.5.1 Dimensions

• 90 in. (L) x 44 in. (W) x 68 in. (H)
( 229 cm (H) x 112 cm (W) x 173 cm (L) )

Nip Height:

© April 2001 General Binding Corporation

• 38 in. ( 96.5 cm )

Page 3 - 5

Specifications F 60 H Operation and Maintenance Manual

Figure 3.5.1 Dimensions

80 in.

( 203 cm )

ARNING

W

HTUNG

AC

MS N AR

57 in.

( 145 cm )

F-60 H

PRO-TECH

38.5 in.

( 98 cm )

Page 3 - 6

© April 2001 General Binding Corporation

InstallationF 60 H Operation and Maintenance Manual

4.0 Installation

GBC Films Group is committed to a program of
ongoing product improvement. As a result, we are
providing these instructions so you can insure that your
new Falcon 60 H Laminator is properly and securely
unpacked, moved, and installed. Installation should be
performed by a qualified technician.

Before a Falcon 60 H Laminator can be installed,
there are a few requirements that must be met. Make
certain that each of the requirements listed in the following
pre-installation checklist are met before beginning
installation.

CAUTION

Is the environment appropriate for the laminator?
The laminator requires a clean, dust and vapor
free environment to operate properly. Do not
locate it where there is air blowing directly on the
machine.

Have you contacted a certified electrician to both
wire the laminator and ensure that adequate power
is being supplied, having the appropriate capacity ,
over current protection and safety lockouts are
available?

WARNING

The operating environment must be free of

dust, flammable liquids and vapors. You can

be injured by inhaling chemical vapors.

Failure to follow the pre-installation check

list can result in damage to the laminator.

4.1 Pre-installation

Are doorways and hallways 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 rear of the

laminator and provides space for efficient material

flow. Figur e 4.1.1 illustrates a typical machine

area layout.

WARNING

Vapor build up or stored flammable

liquids can cause a fire. Excessive

dust can damage the laminator.

CAUTIO N

Do n ot locate the Falcon 60 H w h ere air is

blowing directly on the machine. Th e air

flow can co ol the rolls un ev en ly an d resu lt

in poor output quality.

© April 2001 General Binding Corporation

Page 4 - 1

Installation F 60 H Operation and Maintenance Manual

The Falcon 60 H requires single phase, 230 to
240 vac, 50/ 60 Hz, 40 amp service. No other
type of connection is permitted.

WARNING

The Fa lcon 60 H L am inator is a large and

heavy piece of equipment. It is necessary to

employ LICENSED RIGGERS ONLY to
move the lam inator. The lam inator is not

de sig n e d to b e tip p e d u p or sidew a y s in a n y

way. Such action disturbs the exact
alignment of the rolling parts of the machine
and requ ires extensive realignm en t. You can

be crushed or seriously injured.

For instructions on how to connect power,

proceed to 4.9 Connecting power in this section.

Page 4 - 2

© April 2001 General Binding Corporation

Figure 4.1.1 Suggested Floor Layout

4 ft. x 6 ft. (1.22 m x 2 m )

Work table on wheels

InstallationF 60 H Operation and Maintenance Manual

20 ft.

( 6 m )

8.2 ft.

( 2.57 m )

38.5"

( .98 m )

Table height

37-3/4 in. (.95 - .96 m)

78 in.

( 2 m )

Electrical

supply

3 ft. ( 1 m )

Front operating position

8.2 ft.

( 2.57m )

© April 2001 General Binding Corporation

4 ft. x 6 ft. (1.22 m x 2 m )

Work table on wheels

Table height

37-3/4 in. (.95 - .96 m)

13' ( 4 m)

Page 4 - 3

Installation F 60 H Operation and Maintenance Manual

4.2 Know your machine

Before performing any procedure within this
manual, it is recommended that you take time to know
the parts of your new machine.

Figure 4.2.1 The laminator

Drive side

( Left )

Rear

Figure 4.2.3 Idlers and unwinds

Upper unwind

Web idler

Rear table idler

Tie bars

F-60 H

Lower Unwind

PRO TECH

Front table idler

Figure 4.2.4 Misc.

Front

F-60 H

Control side

PRO TECH

( Right )

Figure 4.2.2 Safety and controls

Rewind drive

Main roller lift

Core grip

E-stop

Upper unwind brake

Photo-eye

Unwind saddle

Front table

Figure 4.2.5 Power

Run/ Stop

Main rollers

Rear table

F-60 H

PR -TECH

Castors

Core support

F-60 H

Foot switch

Lower unwind brake

Control panel

Page 4 - 4

POWER

H

C

-TE

O

R

P

On/ Off

© April 2001 General Binding Corporation

Reset

InstallationF 60 H Operation and Maintenance Manual

4.3 Unpacking

INFORMATION

ALL SHIPMENTS ARE EX-WORKS.

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.

INFORMATION

Before signing the Bill of Lading, you

should be sure to inspect the crate

and / or pallet for signs of damage or

missing items; if applicable, make

note of this on the Bill of Lading.

At our

With regards to your shipping methods, use one
of the following procedure described to safely and
properly unwrap / uncrate your laminator .

4.4 Shrink Wrapped

a) Inspect the machine for any obvious shipping

damages upon receipt. Report any damage to

your carrier .

b) Carefully unwrap the shrink wrap from around

the laminator .

INFORMATION

Depending on the destination and customer

preference, your machine may be shipped in

various ways. The laminator may arrive

shrink wrapped or in a plywood crate on a

skid. Please follow the unpacking procedure

that pertains to your method of shipment.

WARNING

The unpacking process requires at least two

people. You can be severely injured, crushed

or cause damage to the laminator.

Do not attempt to move the laminator across

without trained and qualified riggers. You

CAUTION

Do not use a knife or other sharp object to

remove the shrink wrap from around the

laminator. You can cause irreparable

damage to the rollers.

c) Carefully wheel your Falcon 60 H Laminator

with a second person to the installation site.

WARNING

anything other than a flat level surface

can be crushed or seriously injured.

© April 2001 General Binding Corporation

Page 4 - 5

Installation F 60 H Operation and Maintenance Manual

4.5 Crated

WARNING

The Fa lcon 60 H L am inator is a large and

heavy piece of equipment. It is necessary to

employ LICENSED RIGGERS ONLY to
move the lam inator. The lam inator is not

de sig n e d to b e tip p e d u p or sidew a y s in a n y

way. Such action disturbs the exact
alignment of the rolling parts of the machine
and requ ires extensive realignm en t. You can

be crushed or seriously injured.

To uncrate the laminator

a) Remove the top of the crate and then the sides

in the order shown in Figure 4.5.1

CAUTION

Do not allow the top to fall into the crate. It

can damage the laminator.

INFORMATION

GBC Film Group's warranty does not

cover malfunction of the equipment due to

mishandling and / or tipping. GBC Films

Group bears no responsibility for personal

injury or damage due to moving the

laminator improperly.

Tools required

• # 2 Phillips head screwdriver

• 7/8” open end wrench or adjustable wrench

• Crow bar

• A second person

INFORMATION

Do not put packing screws on the floor.

They can cause problems when trying to roll

the laminator into position or you can

become injured if stepped on.

CAUTION

A second person must support the side
labeled 5 in Figure 4.5.1 It can fall and

damage the laminator or cause harm to you

and others.

Page 4 - 6

© April 2001 General Binding Corporation

InstallationF 60 H Operation and Maintenance Manual

Figure 4.5.1 Disassembling of the crate

3

A

U

A

1

5

4

F-60 H

R E

2

Removing the shrink wrap

Moving the laminator

a) Have the laminator rolled off the skid and placed
on the floor by licensed riggers. The ramps
included with the laminator can be secured utilizing
screws removed from the disassembled crate.
Figure 4.5.2 illustrates positioning of the ramps.

WARNING

Do not attempt to use the ramps if they are

not secured to the pallet. Ensure the pallet is

on a flat even surface before attempting to

roll the machine off.

a) Gently unwrap the shrink wrap from around the

laminator.

Figure 4.5.2 Positioning of the ramps

CAUTION

Do not use a knife or other sharp object to

remove the shrink wrap from around the

laminator. You can cause irreparable

damage to the rollers.

b) Move all packing materials to a safe distance.

b) Remove any plastic strapping and/or packing

paper taped to the rollers.

© April 2001 General Binding Corporation

Page 4 - 7

Installation F 60 H Operation and Maintenance Manual

4.6 Accessory pack

CAUTION

Do not use a knife or other sharp object to

remove the shrink wrap from around the

laminator. You can cause irreparable

damage to the rollers.

unpacked and moved into final position, open the accessory
pack and verify the contents.

Once the Falcon 60 H Laminator has been

c) Remove all packing materials to a safe distance

from the laminator and dispose of properly .

d) Use two people to carefully roll the laminator to

the desired location.

INFORMATION

About recycling: The crate components can

be reused for shipping the laminator again

or can be disassembled and the wood and

screws recycled. The shrink wrap is not

recyclable, so it must be discarded.

contact your local service technician or sales
representative.

Accessory Pack contents

• One Fuse, 250 V, 20 amp ( 186 - 135 )

• T wo Fuses, 2,5 amp ( 186 - 220 )

• One fuse, 0.5 amp ( 186-016 )

• One Operators Manual ( 930 - 063 )

• One T owel ( 475 - 950 )

• One Zippy knife ( 475 - 620 )

• One strain relief for main power ( 175-201 )

• One rubber cement pad ( 930320 )

• One crank handle ( 629-018 )

• One O-ring ( 480 - 005 )

• Four leveling pads ( 470 - 101 )

• One T-handle, 1/4 in. ( 475 - 210 )

• One roll of masking tape ( 475 - 000 )

• One crank handle ( ??? - ??? )

• One BHCS ( floor stock item )

If you are missing any of the items listed above,

Page 4 - 8

Contacts:

GBC Parts ( 800 ) 790 - 7787

GBC Europe parts 33 - 45 - 535 - 7676

© April 2001 General Binding Corporation

InstallationF 60 H Operation and Maintenance Manual

4.7 Installing levelers

Leveling of the machine is a customer option. If
you choose not to level the laminator and you encounter
output problems, please level the machine and try your
application again before calling for technical support.

Tools required

• ( 2 ) 3/4” open end wrenches

• Four leveling pads
( from the accessory pack )

4.8 Leveling

Leveling of the laminator is very important in the
way the machine performs. Leveling is crucial to the tram
( tracking ) of the materials through the machine.

Tools required

• ( 2 ) 3/4 in. open end wrenches

• 1/8 in. allen wrench

• Level

• A second person

a) V erify that the laminator has sufficient room

around it to load film, walk around and to be
serviced if necessary .

b) Place one leveling pad on each of the four

leveling bolts on the laminator.

Jam n uts

Leveling pads

a) W ith a 1/8 in. allen wrench, remove the drive

side and control side cabinet covers by;

1) Loosen the three screws along the
bottom.

2) Remove the seven screws along the
top and sides of the cover.

2

F-60 H

c) Use a 3/4 in. open end wrench to secure the

jam nut against the leveling pad.

© April 2001 General Binding Corporation

PRO-TECH

1

Page 4 - 9

Installation F 60 H Operation and Maintenance Manual

b) Loosen the nut on the inside of both cabinets

securing the leveling bolt with a 3/4 in. wrench.

Inside nuts

c) Position the level on the top of the control side

cabinet.

e) Position the level on the top of the drive side

cabinet.

A

F-60 H

PRO-TECH

f) Level the drive side from front to back by

turning the leveling nut clockwise to raise or
counter clockwise to lower .

F-60 H

PRO TECH

d) Level the control side from front to back by

turning the leveling nut clockwise to raise or
counter clockwise to lower.

9

Leveling nuts

g) Position the level center of the upper tie bar.

F-60 H

PRO TECH

h) Level the laminator from drive side to control

side by turning the leveling nut clockwise to
raise or counter clockwise to lower.

Page 4 - 10

© April 2001 General Binding Corporation

InstallationF 60 H Operation and Maintenance Manual

i) Verify that all three points are still leveled.

j) Hold the leveling nut in place with a 3/4 in. open

end wrench while you secure the inside nut to
the cabinet. Do this for both sides.

9

Inside nuts

4.9 Connecting power

ELECTRICAL

SHOCK

Only a qualified electrician should connect

power to the laminator. You can be severely

shocked, electrocuted or cause a fire if

power is improperly applied.

Tools required

CAUTIO N

Do n o t m ove th e leveling n ut when securin g

the inside nut to the cabinet.

k) Replace the drive side cabinet cover at this time.

IN F OR MAT ION

• 1/8 in. allen wrench

• # 2 phillips head screw driver

• Multi meter

a) Ensure the power at the junction box is in the
OFF position.

b) Feed the power cable through the main power

strain relief from the accessory pack, then

through the hole provided below the circuit

breaker on/ off.

Line Terminal Block

Yo u will ne ed the con tr o l sid e ca b in e t co v e r

off to conn ect the electrical power.

© April 2001 General Binding Corporation

Stra in r elie f

Power cable

Page 4 - 11

Installation F 60 H Operation and Maintenance Manual

c) Connect the wires to the Line T erminal Block

(L TB) as illustrated below .

red wires blue wires

1

3

5

2

4

6

f) Verify line voltage with regards to the type of

power being supplied to the laminator at the line
terminal block.

1

3

5

2

4

6

hot leg

(A)

hot leg

(B)

ground

(C)

• (A) - (B) = 230 ~ 240 VAC

hot leg hot leg ground

WARNING

Follow the correct wiring diagram when

supplying power to the laminator. If

improperly connected, you can be seriously

injured or cause damage to the laminator.

d) Secure the main power strain relief to the

cabinet.

• (A) - (C) = 115 ~ 120 VAC

• (B) - (C) = 115 ~ 120 VAC

g) Replace the control side cabinet cover.

h) Turn the On/ Off to the “ON” position by

flipping the handle to the up position and press
reset.

Reset

POWER

e) Turn the junction box power to the ON

position.

Page 4 - 12

On/ Off

© April 2001 General Binding Corporation

InstallationF 60 H Operation and Maintenance Manual

4.10 Safety check

The safety check will ensure that all safety devices

and interlocks are functioning properly .

This procedure describes how to check one

E-STOP and the PHOTO-EYE. Repeat the steps for
the remaining three E-STOPS. ALL SAFETY

FEA TURES MUST BE CHECKED!

WARNING

E-STOPs

a) Turn MAIN POWER to ON .

POWER

On

Off

b) Press RESET. The power indicator on the front

control panel will be illuminated.

Do not wear ties, loose fit clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

WARNING

If a safety feature is not working

properly, contact your local service

representative immediately.

Reset

POWER

c) Press the motor direction to FORWARD.

Contacts:

GBC National Service: ( 800 ) 790 - 7787

My service rep:_____________________

© April 2001 General Binding Corporation

(reverse) (forward)

Page 4 - 13

Installation F 60 H Operation and Maintenance Manual

1

/

4

t

u

r

n

d) Rotate the speed dial to a setting greater than 1.

56

4

3

2

1

7

8

9

10

e) Press the motor engage/ disengage to ENGAGE.

(disengage) (engage)

h) The bottom main roller stops turning, the power

indicator light goes out, the display on the
temperature controller unit goes out.

i) T urn the E-STOP 1/4 turn counter clockwise to

unlatch.

f) Press the temperature on/off to ON.

(off) (on)

g) Press one of the four E-STOPs.

j) Repeat steps b) through i) for the remaining

three E-STOPs.

PHOTO-EYE

a) Cut a piece of 1/2 inch ( 1.3 cm ) thick foam

board to 4 inches x 6 inches. ( 10 cm x 15 cm )
This piece will be referred to as the “finger board”.

CAUTIO N

Page 4 - 14

Do not use a hard substrate or a substrate

with sharp edges. You may cause damge to

the lam inating ro llers.

© April 2001 General Binding Corporation

InstallationF 60 H Operation and Maintenance Manual

b) Ensure all E-STOPs are in the unlatched position

and remove the pressure plate from the front feed
table.

c) If the power indicator on the control panel is not

illuminated, press Reset.

Reset

POWER

f) Press the motor engage/ disengage to ENGAGE.

(disengage) (engage)

g) Slide the “finger board” on the front feed table

towards the nip about 10 in. ( 25 cm ) from the

control side.

d) Set the motor direction to FWD.

(reverse) (forward)

e) Lower the main roller to initial contact ( one bar

on the pressure display is illuminated ).

finger board

h) The rollers should stop just before the finger

board can enter the roller nip.

i) Slide the finger board back away from the rollers
nip. Press the motor engage/ disengage to

ENGAGE.

© April 2001 General Binding Corporation

(disengage) (engage)

Page 4 - 15

Installation F 60 H Operation and Maintenance Manual

j) If the finger board comes in contact with the

rollers while they are turning, contact your
service representative to adjust the PHOTO-

EYEs.

k) Slide the “finger board” towards the roller nip

about center of the front feed table.

finger board

o) Slide the “finger board” on the front feed table

towards the nip about ten in. ( 25 cm ) from the
control side.

finger board

p) The rollers should stop just before the finger

board can enter the roller nip.

l) The rollers should stop just before the finger

board can enter the roller nip.

m) Slide the finger board back away from the rollers

nip. Press the motor engage/ disengage to

ENGAGE.

(disengage) (engage)

q) Slide the finger board back away from the

rollers nip.

r) If the finger board comes in contact with the

rollers while they are turning, contact your
service representative to adjust the PHOTO-

EYEs.

s) Raise the main roller .

n) If the finger board comes in contact with the

rollers while they are turning, contact your
service representative to adjust the PHOTO-

EYEs.

Page 4 - 16

© April 2001 General Binding Corporation

F 60 H Operation and Maintenance Manual

5.0 Operations

In this section you will find information on how to
properly turn your Falcon 60 H Laminator on, learn
functions of the control panel, increase and decrease
temperature, properly load and unload film, use of the
unwind brake tensioning system, rewind brake tensioning,
how to manually set the nip for mounting, and foot switch
function.

The following general rules should always be
adhered while operating this machine.

Operations

WARNING

W h en the lam in ator ro llers are in

motion, keep hands and fingers

away from the nip of the rollers.

You may be CRUSHED or BURNED!

WARNING

WARNING

Do not w ear ties, loose fit clothing or

dangling jewelry while operating or

servicing the lam in ator. Th ese item s can g et

caught in the nip and choke you or you can

be crushed or burned.

IN F OR MAT ION

The m ac h in e will only o p e ra te if a ll

four emergency stop s are u n latched an d

RESET has been pressed.

Keep h an d s an d fin gers clear o f the

lamina tor roller nip when cha n ging G A P .

You can be CRUSHED or BURNED!

WARNING

When o p e ra tin g th e la minato r u sing the

footsw itch, keep h an d s an d fin gers a w a y

from th e n ip o f the rollers.

You may be CRUSHED or BURNED!

WARNING

It is u n sa fe to sh e et f eed with o u t the

pressu re plate pro p erly placed o n

the fron t feed tab le.

© April 2001 General Binding Corporation

WARNING

Do n o t opera te the lam ina tor, except

during web set up, without the front

and rear feed tables in position.

Page 5 - 1

Operations F 60 H Operation and Maintenance Manual

5.1 Power On/ Off

Power on

a) Ensure the laminator is plugged in and that all E-

STOPs are in the unlatched position.

1

/

4

t

u

r

n

d) Power indicator on the control panel should be

illuminated at this time.

00

4 7

2

9

Power indicator light

Power off

b) T urn the MAIN POWER to the up position.

POWER

On

Off

c) Press RESET located above the main power

on/off.

Reset

POWER

a) Ensure the rollers are in the up position.

b) T urn the MAIN POWER to the down position.

POWER

On

Page 5 - 2

Off

© April 2001 General Binding Corporation

F 60 H Operation and Maintenance Manual

Operations

5.2 Control panel

The operator control panel for the Falcon 60 H
Laminator is located to the right of the front operating
position. For an illustration of the complete front control
panel, please refer to Figure 5.2.1 Falcon 60 H. The
names and functions of these controls are as follows:

( 1 ) NIP PRESSURE DISPLAY: When pressure at
the nip of the rollers is applied, bars on the nip pressure
display are illuminated in increments of 5% up to 100%.

( 3 ) FWD / REV : When pressed to the right, the motor
turns in a forward direction as illustrated by the image
above the switch. When pressed to the left, the motor
turns in a reverse direction.

(reverse) (forward)

( 4 ) SPEED DIAL: When turned clockwise, increases
the speed of the motor. T urning it counter clockwise will
decrease motor speed.

( 2 ) MOTOR ENGAGE/ DISENGAGE: When
pressed to the right, power to the motor is supplied and
the rollers will begin to turn. When pressed to the left,
power to the motor is removed and the rollers stop turning.

56

4

3

2

1

7

8

9

10

( 5 ) TEMP ON/ OFF: When pressed to the right,
supplies power to the temperature controller unit located
just above it. When pressed to the left, removes power to
the temperature controller unit.

(disengage) (engage)

© April 2001 General Binding Corporation

(off) (on)

Page 5 - 3

Operations F 60 H Operation and Maintenance Manual

( 6 ) TEMPERATURE CONTROLLER UNIT :

Displays the current temperature of the upper roller . Allows
the operator to control the operating temperature of the
upper roller. T o set temperature refer to Section 5.3.

CAL 3200

Figure 5.2.1 Front control panel

( 7 ) POWER INDICATOR: When illuminated

represents power to the laminator is supplied. If not
illuminated, power to the laminator has been removed via
an E-STOP , no RESET , circuit breaker is the off position
or line voltage has been removed.

6

CAL 3200

1

5

2

3

56

4

3

4

2

1

7

8

9

10

7

Page 5 - 4

© April 2001 General Binding Corporation

F 60 H Operation and Maintenance Manual

Operations

5.3 Set Temperature

The Falcon 60 H has upper roller heating
capabilities which enables the machine to run Lo-Melt
film. You can set a desired temperature from 32 OF

O

( 0

C ) up to 200 OF ( 93 OC ).

When power to the temperature controller unit is
supplied, the display indicates the current temperature of
the upper roller.

Increase set point

a) Press and hold ✽ key while pressing ▲ key to
increase the set point temperature. Single presses
of the ▲ key increases the set point by increments
of one while holding the key down will increase
by increments of ones then tens.

CAL 3 0

CAL 3200

(72 is an example of room temperature )

To display the current set point value of the
temperature controller unit, press and hold the star key
located just to the left just below the temperature display .
When the star key is released, the temperature display
reverts to the current temperature of the upper roller .

b) Release the ✽ key and ▲ key once desired set

point has been obtained.

Decrease set point

a) Press and hold ✽ key while pressing ▼ key to
decrease the set point temperature. The same
increments apply.

CAL 3

CAL 3

© April 2001 General Binding Corporation

b) Release the ✽ key and ▼ key once desired set

point has been obtained.

Page 5 - 5

Operations F 60 H Operation and Maintenance Manual

5.4 Load/ Unload film

CAUTIO N

En su re the roll of lam in ate is loaded

properly on the unwind shaft.

Exposed adhesive should be facing

away from the rollers.

Th is will pre v ent hou r s o f ro ll cle a n in g !

Figure 5.4.1 Lo-Melt Poly-in/ Poly-out

The film supply shafts, commonly known as unwind
shafts, pivot out for ease of loading and unloading of film.
Always pay particular attention to which side is the
adhesive side and which side is the carrier side. The
adhesive side will always face away from the rollers. Refer
to Figure 5.4.1 and Figure 5.4.2.

IN F OR MAT ION

Th e P o ly -in / P o ly-o u t diagra ms refe r to th e

upper rolls of film only. The mount adhesive

and craft p ap ers are fo r referen ce on ly.

Figure 5.4.2 PSA Poly-in/ Poly-out

Craft

paper

Lo-Melt

Po ly - in

Lo-Melt

film

Lo-Melt

Lo-Melt

Po ly - o u t

film

Craft

paper

PSA

Po ly - in

PSA
film

PSA

Po ly - o u t

PSA

film

Mount

adhesive

Page 5 - 6

Mount

adhesive

© April 2001 General Binding Corporation

F 60 H Operation and Maintenance Manual

Load film

a) Adjust the core grips so they are close to the edge

of the roll of film being used but remain inside the
core when the roll of film is positioned on the
unwind shaft.

Operations

WARNING

Never leave the unw ind shaft out of the

unwind support saddle unless loading

or unloading film.

Ro ll of film

Core chuck Core chuckCore support

b) Lift up on the clevis pin to the unwind shaft located
in the unwind support saddle.

Clevis pin

Unwind support saddle

d) Swing the unwind shaft completely back into the

unwind support saddle and push the clevis pin
down.

Clevis pin

Unwind support saddle

e) If using the lower unwind, center the upper roll of

film on the laminating rollers.

( A )

( C )

( B )

( C )

c) Swing the unwind shaft out far enough to slide the

roll of film completely on.

© April 2001 General Binding Corporation

( A ) - ( B ) / 2 = ( C )

CAUTIO N

W h en u sing tw o rolls on th e m ach ine,

ensur e the film w idth s are id entical.

Exposed adhesive can cause complications.

f) Repeat steps a) through c) to load film on the

lower unwind shaft.

Page 5 - 7

Operations F 60 H Operation and Maintenance Manual

g) Measure the distance from the side frame to the

edge of the upper roll of film. Use this
measurement to evenly align the roll of mount
adhesive or craft paper.

Align

Center

b) Lift up on the clevis pin to the unwind shaft located
in the unwind support saddle.

Clevis pin

Unwind support saddle

c) Swing the unwind shaft out far enough to slide the

roll of film completely off.

Unload film

a) Cut the roll of film from the web using an enclosed

blade.

CAUTIO N

Never use an open blade near the laminating

rollers. You may cut the rollers or yo ur self.

Page 5 - 8

CAUTIO N

W h en u sing tw o rolls on th e m ach ine,

ensur e the film w idth s are id entical.

Exposed adhesive can cause complications.

d) Swing the unwind shaft completely back into the

unwind support saddle and push the clevis pin

down.

Clevis pin

Unwind support saddle

© April 2001 General Binding Corporation

F 60 H Operation and Maintenance Manual

Operations

5.5 Unwind brake tension

The unwind brakes are uniquely designed to allow
you to change rolls of film without changing your current
brake setting. Brake tension may vary from roll to roll so
some adjustments may be required for optimal output.

IN F OR MAT ION

Always use the minimum amount

of bra ke fo r the job .

5.6 Rewind brake tension

The rewind brake controls the tension of the
rewind tubes. Rewind brakes along with the unwind brakes
allow for precise control of the release liner in PSA films.
If your Falcon 60 H is equipped with the roll to roll option,
the rewind brakes are helpful as the finished product
rewind becomes heavier by adding more friction to the
rewind tube.

a) Turn the brake dial counter clockwise to

increase rewind brake tension.

a) Turn the upper black brake knob ( shown below)

or the lower gray brake disc ( not shown )
clockwise to increase unwind brake tension.

Increase decrease

IN F OR MAT ION

If mo re bra ke is need ed, ad d an O-ring

to the brake side of the rewind.

Increase Decrease

b) Turn the upper black brake knob ( shown above)

or the lower gray brake disc ( not shown )
counter clockwise to decrease unwind brake
tension.

© April 2001 General Binding Corporation

b) Turn the brake dial clockwise to decrease

rewind brake tension.

Page 5 - 9

Operations F 60 H Operation and Maintenance Manual

5.7 Setting the nip

Setting the nip is made easy when it comes to
performing a mounting application. Pressure will vary with
regards to the types of substrate being used. An incorrect
nip setting can cause complications with output quality .

For safe nip setting, always adhere to the following
rules listed below .

WARNING

a) Ensure all E-STOPs are unlatched, power is on

and RESET has been pressed.

Reset

1

/

4

t

u

r

n

POWER

On

b) Set the motor direction to REV.

Keep h an d s an d fingers clear of the

laminator roller nip when adjusting nip.

You can be CRUSHED or BURNED!

CAUTIO N

Excess pressure can damage the laminating

rollers. Alway s u se the m in imu m roll

pressure n ecessa ry to co m p lete the task.

CAUTIO N

Objects other than m edia, film or approved

substrates, will cause irreparable damage

to the rollers if caugh t in the n ip.

(reverse) (forward)

c) Set a comfortable speed for the application you

are performing.

56

4

3

2

1

7

8

9

10

Page 5 - 10

© April 2001 General Binding Corporation

F 60 H Operation and Maintenance Manual

(disengage) engage)

Operations

CAUTIO N

Sharp edges on a substrate

should be filed smooth.

Sha rp edg es can C U T th e rollers!

d) Position the substrate center of the feed table

between the two rollers.

IN F OR MAT ION

Ex c es siv e pressu r e will cause the

substrate to bow or flatten.

Sufficient Excessive

IN F OR MAT ION

F-60 H

substrate

PR -TECH

e) Lower the upper main roller until it makes
contact with the substrate. Lower enough to
apply sufficient pressure without crushing the
substrate.

De n s ity o f the substrate w ill determine th e

amoun t of pressure you may use.

f) Press the motor engage/ disengage to engage or

step on the footswitch to back the board out
from the nip.

© April 2001 General Binding Corporation

f) The nip is now set for the substrate being used.
Remember to set the motor direction to FWD.

Page 5 - 11

Operations F 60 H Operation and Maintenance Manual

5.8 Footswitch

WARNING

Th e va riable sp eed fo otswitch over-rides

WARNING

W h en op erating the lam in ator u sing th e

footswitch, keep hands and fingers

away from the nip of the rollers.

You may be CRUSHED or BURNED!

The footswitch operates differently based on the
motor direction setting.

the PH OTO -E YE safety circuit !

c) When the footswitch is pressed, roller speed is

dependent on what you have selected on the
speed dial.

d) You may adjust speed while the footswitch is

depressed.

Forward

a) Press the motor direction to FWD.

(reverse) (forward)

b) Set your speed dial to a comfortable operating

speed.

Reverse

a) Press the motor direction to REV.

56

4

3

2

1

7

8

9

10

Page 5 - 12

b) Press on the footswitch. The footswitch speed is

limited to 1 foot per minute ( 30 cm/ minute )
regardless of motor speed dial setting..

© April 2001 General Binding Corporation

ApplicationsF 60 H Operation and Maintenance Manual

6.0 Applications

The Falcon 60 H can accommodate Poly-in or
Poly-out films. Poly-out means the adhesive is on the
outside of the roll.

The shiny side of clear film must contact the main
rollers with the dull sides ( adhesive side ) facing out. Use
caution when loading matte or de-luster film since both
sides appear dull.

The top and bottom rolls of laminating film must
be of the same width and be present simultaneously . If
performing a single sided lamination process, a craft paper
carrier or a substrate of the same width must be used in
place of the bottom laminate.

6.1 Helpful hints

Pressure sensitive materials

In most cases, a little heat ( 120 oF / 49 oC ) helps
the adhesive in pressure sensitive films flow smoothly to
prevent what we call “silvering” in the laminate.

The release liner on pressure sensitive films should
separate just above the main roller.

IN F OR MAT ION

Use film brake tension to control the

separa tion po int of the r elease liner.

WARNING

Do not wear ties, loose fit clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

The process control charts and web diagrams
illustrated in this section are reference points only .
Parameters will vary with regards to laminate
thickness, laminate widths, laminate types, print
types, ink or toner types, paper types, environment
conditions and operator experience.

© April 2001 General Binding Corporation

Lo-Melt film materials

Most Lo-Melt adhesives activate around 180OF
~ 200OF ( 82OC ~ 93OC ) which is below the boiling
point for water based inks. For thicker Lo-Melt films,
adjust the speed to allow for a longer dwell time in the
nip.

IN F OR MAT ION

Sp ee d s and tempera tu r es will affe ct th e

bond strength of Lo-Melt adhesives.

Page 6 - 1

Applications

F 60 H Operation and Maintenance Manual

Mounting

Mounting on the Falcon 60 H is achieved from
the front operating position. Heat can also assist with
mounting, it follows the same hints as pressure sensitive
materials.

IN F OR MAT ION

Th e m o un t ad h esive m u st no t exceed 1 in.

the w idth of the substrate. If it does, you

w ill e xp e rie n ce c omplications with th is

application.

Pressure

Brake tension

Brake tension should always be minimal. Brake
tension should always be even from the top roll of film
to the lower roll of film. Never use excessive amount of
brake tension.

IN F OR MAT ION

Excessive brake tension may cause the

imag e to curl. A lw ays u se the minimum

amoun t of brake for the job.

General

Most lamination is performed at 50 ~ 70% of
pressure on the rollers. Once again, there are variables
that may require some adjustments of the above mentioned
pressures.

T ypically the thicker the paper, the more pressure
required and for thinner paper ( tissue paper/ light bond
paper ) you can use less pressure ( as little as 50 % ) on
the roller.

When it comes to mounting, the one general “rule”
is to not crush the substrate. Most substrates only require
about 20-50 % of pressure, but variables can effect how
much pressure is actually needed. ( width, thickness,
density , etc. )

IN F OR MAT ION

CAUTIO N

Excess pressure can damage the laminating

rollers. Alway s u se the m in imu m roll

pressure n ecessa ry to co m p lete the task.

IN F OR MAT ION

Never stop the lam inator when an im age is

within the n ip of th e rollers.

IN F OR MAT ION

Ex c es siv e pressu r e will cause the

substrate to bow or flatten.

Page 6 - 2 © April 2001 General Binding Corporation

Lam inates and papers should always be

stored in a co n trolled env irom en t.

6.2 Temp conversion chart

A temperature conversion chart has been included for your convenience. Use the chart below for converting

o

temperatures from

Figure 6.2.1 Temperature conversion chart

F to oC and vice a versa.

ApplicationsF 60 H Operation and Maintenance Manual

o

F
68 20
69 20.6
70 21.1
71 21.7
72 22.2
73 22.7
74 23.3
75 23.9
76 24.4
77 25
78 25.6
79 26.1
80 26.7
81 27.2
82 27.8
83 28.3
84 28.9
85 29.4
86 30
87 30.6
88 31.1
89 31.7
90 32.2
91 32.8
92 33.3
93 33.9
94 34.4
95 35
96 35.6
97 36.1
98 36.7
99 37.2

100 37.8
101 38.3

o

C

=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=

o

F
102 38.9
103 39.4
104 40
105 40.6
106 41.1
107 41.7
108 42.2
109 42.8
110 43.3
111 43.9
112 44.4
113 45
114 45.6
115 46.1
116 46.7
117 47.2
118 47.8
119 48.3
120 48.9
121 49.4
122 50
123 50.6
124 51.1
125 51.7
126 52.2
127 52.8
128 53.3
129 53.9
130 54.4
131 55
132 55.6
133 56.1
134 56.7
135 57.2

o

C

=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=

o

F
136 57.8
137 58.3
138 58.9
139 59.4
140 60
141 60.6
142 61.1
143 61.7
144 62.2
145 62.8
146 63.3
147 63.9
148 64.4
149 65
150 65.6
151 66.1
152 66.7
153 67.2
154 67.8
155 68.3
156 68.9
157 69.4
158 70
159 70.6
160 71.1
161 71.7
162 72.2
163 72.8
164 73.3
165 73.9
166 74.4
167 75
168 75.6
169 76.1

o

C

=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=

o

F
170 76.7
171 77.2
172 77.8
173 78.3
174 78.9
175 79.4
176 80
177 80.6
178 81.1
179 81.7
180 82.2
181 82.8
182 83.3
183 83.9
184 84.4
185 85
186 85.6
187 86.1
188 86.7
189 87.2
190 87.8
191 88.3
192 88.9
193 89.4
194 90
195 90.6
196 91.1
197 91.7
198 92.2
199 92.8
200 93.3

o

C

=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=

© April 2001 General Binding Corporation

Page 6 - 3

Applications

This page intentionally left blank.

F 60 H Operation and Maintenance Manual

Page 6 - 4 © April 2001 General Binding Corporation

6.3 Charts and diagrams

Process control charts allow you to record the
way you thread film through the machine’ s rollers and idlers
(called webbing) and the control settings for each prod­uct and process. Process control charts are an excellent
tool for training new operators. They provide a “road
map” for correct machine setup and operation.

This section contains a blank process control chart
and diagram for the Falcon 60 H as well as completed
charts for the basic operations of the laminator. The pro­cess control charts should be kept in this manual or in a
book close to the laminator .

ApplicationsF 60 H Operation and Maintenance Manual

The Falcon 60 H laminator responds in a very
accurate and repeatable manner. 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 completed process control charts included
in this section are based on GBC films, GBC boards and
typical prints. Charts and diagrams start on page 6-6. If
your machine is equipped with the roll to roll option, web­bing diagrams for related applications are aslo incleded.

© April 2001 General Binding Corporation

Page 6 - 5

Applications

Top material :
Bottom material :

Other material (s) :

F 60 H Operation and Maintenance Manual

PROCESS CONTROL CHART

Materials -

Motor Direction

Motor Speed

56

4

3

2

1

7

8

9

10

Heater

Upper Roller Temperature

CAL 3200

Roller Pressure

RANGE

Notes :

Page 6 - 6 © April 2001 General Binding Corporation

RANGE

CAL 3200

Diagram - Blank

ApplicationsF 60 H Operation and Maintenance Manual

© April 2001 General Binding Corporation

Page 6 - 7

Applications

This page intentionally left blank.

F 60 H Operation and Maintenance Manual

Page 6 - 8 © April 2001 General Binding Corporation

Diagram - Blank w/ roll to roll options

ApplicationsF 60 H Operation and Maintenance Manual

© April 2001 General Binding Corporation

Page 6 - 9

Applications

F 60 H Operation and Maintenance Manual

PROCESS CONTROL CHART

Materials - Pre-coating substrates

Top material : Roll of pressure sensitive mount adhesive
Bottom material : N/A

Other material (s) : Substrates, leader board and trailer board

Motor Direction

Motor Speed

range

56

4

3

2

1

7

8

9

10

Heater

Upper Roller Temperature

CAL 3200

Roller Pressure

RANGE

Notes : The roll of mount adhesive should not exceed the substrate by more than 1 in.
(2.5 cm). Speed will be determined by what is comfortable with the operator. Pressure
is dependent on the substrate. Do not crush the substrate. Use a leader board to start
the run and stop the run when the trailer board is in the nip of the rollers. Stopping on
a subtsrate will leave an impression on the board. Refer to helpful hints for pressure
sensitive materials and mounting.

Page 6 - 10 © April 2001 General Binding Corporation

RANGE

CAL 3200

Diagram - Pre-coating substrates

Ro ll o f
mount

adhesive

Substrate

Leader board

ApplicationsF 60 H Operation and Maintenance Manual

© April 2001 General Binding Corporation

Page 6 - 11

Applications

PROCESS CONTROL CHART

Materials - Mounting an image
Top material : N/A
Bottom material : N/A
Other material (s) : Image and a Pre-coated board

F 60 H Operation and Maintenance Manual

Motor Direction

Motor Speed

range

56

4

3

2

1

7

8

9

10

Heater

Upper Roller Temperature

CAL 3200

Roller Pressure

RANGE

Notes: The image shoud not exceed the pre-coated board by more than 1 in. ( 2.5 cm ). If
the image is smaller than the precoated board, trim the board or pre-trim the release liner
around the image. Speed for mounting should be comfortable for the operator. Use the
footswitch for this application. Pressure will be dependent on the type of subtrate. No
heat is required for this application. Do not crush the substrate. Do not stop in the middle
of the run. Refer to helpful hints for mounting.

Page 6 - 12 © April 2001 General Binding Corporation

RANGE

CAL 3200

Diagram - Mounting an image

ApplicationsF 60 H Operation and Maintenance Manual

Hold image here

Liner

Pre-coated

board

Image

© April 2001 General Binding Corporation

Page 6 - 13

Applications

F 60 H Operation and Maintenance Manual

PROCESS CONTROL CHART

Materials - PSA Decaling
Top material : Roll of pressure sensitive laminate
Bottom material : Roll of pressure sensitive mount adhesive
Other material (s) : prints

Motor Direction

Motor Speed

range

56

4

3

2

1

7

8

9

10

Heater

Upper Roller Temperature

CAL 3200

Roller Pressure

RANGE

Notes: Speed should be comfortable for the operator. Pressure will vary depending on the
weight and width of the image and laminate. Heat is optional. Some will assist the flow of
the adhesive in pressure sensitive films. Refer to helpful hints for pressure sensitive films.

Page 6 - 14 © April 2001 General Binding Corporation

RANGE

CAL 3200

Diagram - PSA decaling

ApplicationsF 60 H Operation and Maintenance Manual

Image

Ro ll o f
mount

adhesive

Release liner

Ro ll o f

PSA film

Decal

© April 2001 General Binding Corporation

Page 6 - 15

Applications

This page intentionally left blank.

F 60 H Operation and Maintenance Manual

Page 6 - 16 © April 2001 General Binding Corporation

ApplicationsF 60 H Operation and Maintenance Manual

Diagram - PSA decaling w/ roll to roll options

Ro ll o f
mount

adhesive

Release liner

Ro ll o f

PSA film

© April 2001 General Binding Corporation

Rewind of decals

Ro ll o f

prints

Page 6 - 17

Applications

PROCESS CONTROL CHART

Materials - Lo-Melt Decaling
Top material : Roll of Lo-Melt film
Bottom material : Roll of pressure sensitive adhesive
Other material (s) : prints

F 60 H Operation and Maintenance Manual

Motor Direction

Motor Speed

56

range

4

3

2

1

7

Heater

Upper Roller Temperature

8

9

10

CAL 3200

Roller Pressure

RANGE

Notes : Speed will be dependent on the activation of the Lo-Melt adhesive. If the output
appears cloudy or milky, reduce the speed. Pressure will vary depending on the weight
and width of the image and laminate. For thinner laminates, use the 180 oF ( 82 oC ) and
for thicker films, use the 200 oF ( 93 oC ).

Page 6 - 18 © April 2001 General Binding Corporation

RANGE

CAL 3200

Image

ApplicationsF 60 H Operation and Maintenance Manual

Diagram - Lo-Melt decaling

Ro ll o f

Lo-Melt

film

Ro ll o f
mount

adhesive

Decal

© April 2001 General Binding Corporation

Page 6 - 19

Applications

This page intentionally left blank.

F 60 H Operation and Maintenance Manual

Page 6 - 20 © April 2001 General Binding Corporation

ApplicationsF 60 H Operation and Maintenance Manual

Diagram - Lo-Melt decaling w/ roll to roll options

Ro ll o f

Lo-Melt

film

Ro ll o f
mount

adhesive

Ro ll o f

prints

Rewind of decals

© April 2001 General Binding Corporation

Page 6 - 21

Applications

PROCESS CONTROL CHART

Materials - Mounting a decal
Top material : N/A
Bottom material : N/A
Other material (s) : Decal and substrate

F 60 H Operation and Maintenance Manual

Motor Direction

Motor Speed

range

56

4

3

2

1

7

8

9

10

Heater

Upper Roller Temperature

CAL 3200

Roller Pressure

RANGE

Notes: Speed for mounting should be comfortable for the operator. Use the footswitch
for this application. Pressure will be dependent on the type of subtrate. No heat is
required for this application. Do not crush the substrate. Do not stop in the middle of
the run. Refer to helpful hints for mounting.

Page 6 - 22 © April 2001 General Binding Corporation

RANGE

CAL 3200

Diagram - Mounting a decal

ApplicationsF 60 H Operation and Maintenance Manual

Hold decal here

Liner

Substrate

Decal

© April 2001 General Binding Corporation

Page 6 - 23

Applications

F 60 H Operation and Maintenance Manual

PROCESS CONTROL CHART

Materials - PSA Single sided lamination ( sled method)
Top material : Roll of pressure sensitive laminate
Bottom material : N/A
Other material (s) : Images, leader board, trailer board and a pre-coated board

Motor Direction

Motor Speed

range

56

4

3

2

1

7

8

9

10

Heater

Upper Roller Temperature

CAL 3200

Roller Pressure

RANGE

Notes : The leader board and trailer board should be the same width as the pre-coated
board. The laminate should not exceed the pre-coated board by more than 1 in. ( 2.54 cm ).
Do not use excessive brake tension for this application. Pre-coated board is reusable
since the laminate does not bond with the release liner from the pressure sensitive
adhesive. Speed should be comfortable for the operator. Pressure will vary depending on
the type of substrate. Heat is optional. Some heat will assist the flow of adhesive. Refer to
helpful hints for pressure sensitive films.

Page 6 - 24 © April 2001 General Binding Corporation

RANGE

CAL 3200

Diagram - PSA single sided lamination

( sled method )

ApplicationsF 60 H Operation and Maintenance Manual

Image

Pre-coated

board

Release liner

Leader board

Ro ll o f

PSA film

© April 2001 General Binding Corporation

Page 6 - 25

Applications

PROCESS CONTROL CHART

Materials - PSA Single sided lamination ( craft paper method)
Top material : Roll of pressure sensitive laminate
Bottom material : Roll of craft paper
Other material (s) : Prints

F 60 H Operation and Maintenance Manual

Motor Direction

Motor Speed

range

56

4

3

2

1

7

8

9

10

Heater

Upper Roller Temperature

CAL 3200

Roller Pressure

RANGE

Notes: Top and bottom material should be of the same width. Do not use excessive brake
tension for this application. Speed should be comfortable for the operator. Pressure will
vary depending on the width and weight of the image and laminate. Heat is optional.
Some heat will assist the flow of adhesive. Refer to helpful hints for pressure sensitive
films.

Page 6 - 26 © April 2001 General Binding Corporation

RANGE

CAL 3200

Diagram - PSA single sided lamination

( craft paper method )

ApplicationsF 60 H Operation and Maintenance Manual

Image

Ro ll o f

craft

paper

Release liner

Ro ll o f

PSA film

Finished
product

© April 2001 General Binding Corporation

Page 6 - 27

Applications

This page intentionally left blank.

F 60 H Operation and Maintenance Manual

Page 6 - 28 © April 2001 General Binding Corporation

Diagram - PSA single sided lamination

( craft paper method w/ roll to roll option )

ApplicationsF 60 H Operation and Maintenance Manual

Ro ll o f

craft

paper

Release liner

Ro ll o f

PSA film

© April 2001 General Binding Corporation

Rewind of

finished product

Ro ll o f

prints

Page 6 - 29

Applications

F 60 H Operation and Maintenance Manual

PROCESS CONTROL CHART

Materials - PSA over-lamination of a mounted image
Top material : Roll of pressure sensitive laminate
Bottom material : N/A
Other material (s) : A pre-mounted image to a board, leader board and trailer board

Motor Direction

Motor Speed

range

56

4

3

2

1

7

8

9

10

Heater

Upper Roller Temperature

CAL 3200

Roller Pressure

RANGE

Notes : The laminate should not exceed the pre-mounted image by more than 3 in. (7.6 cm).
Speed will be determined by what is comfortable with the operator. Pressure is dependent
on the substrate. Do not crush the substrate. Use a leader board to start the process and
finish with a trailer board. Stopping on the image will aleave an impression on the board
or image. Heat is optional. Refer to helpful hints for pressure sensitive materials and
mountng.

Page 6 - 30 © April 2001 General Binding Corporation

RANGE

CAL 3200

ApplicationsF 60 H Operation and Maintenance Manual

Diagram - PSA over-lamination of a mounted image

Mounted image

Release liner

Leader board

Ro ll o f

PSA film

© April 2001 General Binding Corporation

Page 6 - 31

Applications

F 60 H Operation and Maintenance Manual

PROCESS CONTROL CHART

Materials - Lo-Melt over-lamination of a mounted image
Top material : Roll of Lo-Melt film
Bottom material : N/A
Other material (s) : A pre-mounted image to a board, leader board and trailer board

Motor Direction

Motor Speed

56

range

4

3

2

1

Heater

Upper Roller Temperature

7

8

9

10

CAL 3200

Roller Pressure

RANGE

Notes : The laminate should not exceed the pre-mounted image by more than 3 in. (7.6 cm).
Speed will be determined by what is comfortable with the operator. Pressure is dependent
on the substrate. Do not crush the substrate. Use a leader board to start the process and
finish with a trailer board. Stopping on the image will aleave an impression on the board
or image. Heat is dependent on the thickness of the film. Refer to helpful hints for Lo-Melt
films and mountng.

Page 6 - 32 © April 2001 General Binding Corporation

RANGE

CAL 3200

ApplicationsF 60 H Operation and Maintenance Manual

Diagram - Lo-Melt over-lamination of a mounted image

Ro ll o f

Lo-Melt

film

Mounted image

Leader board

© April 2001 General Binding Corporation

Page 6 - 33

Applications

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F 60 H Operation and Maintenance Manual

Page 6 - 34 © April 2001 General Binding Corporation

TroubleshootingF 60 H Operation and Maintenance Manual

7.0 Troubleshooting

WARNING

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 choke you or you can

be crushed or burned.

As an operator, you can perform some simple
troubleshooting in attempt to correct your typical output
type problems. Use the easy to follow guide for assistance.

Problem: D waves in the image but not in the laminate

Hints: • Check paper tension

• Check relative moisture content of the paper

7.1 Wave problems

The following is a list of common output wave
problems you may encounter .

The arrow along the length of the output
represents the direction of feed ( travel ).

INFORMATION

For optimal temperature settings of

various laminates, contact your

supplier or sales representative.

Problem: D W aves in the laminate

Hints: • Check the roll pressure

• Check the main roll nip settings

© April 2001 General Binding Corporation

Page 7 - 1

T roubleshooting F 60 H Operation and Maintenance Manual

Problem: Straight waves in the output

Hints: • Check operational settings for materials

being used.

Problem: Angled waves in the output on both sides

Hints: • Check for insufficient main roller pressure

• Check the main roller nip settings

Problem: W aves on only one side of the output

Hints: • Check the nip setting of main rolls

• Check for even paper tension

Problem: Indent waves in output after the pull rollers

Hints: • Output travel was hindered

• Allow output to cool before handling

• Check operating temperatures of material

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© April 2001 General Binding Corporation

TroubleshootingF 60 H Operation and Maintenance Manual

7.2 Film problems

The following is a list of common film problems
you may encounter.

For definitions of terminologies, please refer to

7.4 Glossary of terminology.

Pressure sensitive

Problem : Silvering in the laminate

Lo-Melt laminates

Problem: Blistering within the image

Hints: • Increase the speed

• Decrease the operating temperature

• Allow a longer drying time for the image

Problem: Silvering in the laminate

Hints: • Decrease the speed

• Increase the operating temperature

Hints : • Add 100 - 120oF ( 37 - 49oC ) to the

temperature

• Increase pressure to laminating rolls

Problem : Tunneling

Hints : • Print should be wound image side out.

• Do not roll tightly

• Do not roll at all.

Problem: Delamination

Hints: • Check operating pressures

• Check operating speed

• Laminate compatibility with ink

• Ink compatibility with paper

Problem: Delamination

Hints: • Check operating temperatures

• Check operating speed

• Laminate compatibility with ink

• Ink compatibility with paper

Mounting

Problem : Image creases when mounting

Hints : • Press down on leading edge from center

outwards.

• Be sure image is conformed to the roll

• Use a speed you are comfortable with

• Be sure even tension is supplied to the image

© April 2001 General Binding Corporation

Page 7 - 3

T roubleshooting F 60 H Operation and Maintenance Manual

7.3 Machine problems

Once the Hints are all checked, and your problem

still exists, a service call must be placed for a qualified
service personnel to fix the problem.

Y ou may do this by dialing 1 ( 800 ) 790 - 7787.
This will connect you with GBC National Service dispatch.
Y ou will be required to give the serial number of your
machine when placing a service call.

A space below has been provided to keep this
number readily available if and when needed.

Problem : No illumination to the control panel

Hints : • Ensure an E-STOP has not been pushed

down

• Press RESET.

• Confirm that the MAIN POWER is to the

on position.

• Be sure power is supplied to the laminator

Problem : I can only operate using the footswitch.

Hints : • Ensure the PHOTO-EYE is not blocked.

• Place a service call to calibrate sensors.

My Falcon 60 H Laminator serial # is :

At no time does GBC Films Group suggest or
recommend that you attempt to fix the machine by
removing the cabinets or leg covers yourself.

WARNING

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 choke you or you can

be crushed or burned.

Problem : I press ENGAGE, the rollers will not turn.

Hints : • Be sure a speed has been set.

• Make sure a motor direction has been

selected.

• Ensure the PHOTO-EYE is not blocked.

Problem : Jerking, stuttering, or excessive noise from

the laminator.

Hints : • Check for excessive brake tension

• Confirm that the rolls of laminate are on

correctly .

• Check for proper chain tension.

• Place a service call.

Page 7 - 4

© April 2001 General Binding Corporation