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2013-06-04

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GBC F-60H
Roll Laminator

Instruction Manual

Provided By

http://www.MyBinding.com

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FALCON 60 H
OPERATION & MAINTENANCE
MANUAL
© APRIL 2001 GENERAL BINDING CORPORATION. ALL RIGHTS RESERVED.
Do not duplicate without written permission.

NG
RN
WA N
HTU
AC AR
N

F-6

O-T

Revision : A
Part number : 930 - 063

GBC Pro - Tech
4151 Anderson Road
DeForest, WI 53532
Ph: ( 608 ) 246 - 8844
Fx: ( 608 ) 246 - 8645

F 60 H Operation and Maintenance Manual

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The information in this publication is provided for reference and is believed to be accurate and complete. General Binding Corporation is not liable for errors in this publication or for
incidental or consequential damage in connection with the furnishing or use of the information
in this publication, including, but not limited to, any implied warranty of fitness or merchantability for any particular use.

General Binding Corporation reserves the right to make changes to this publication and
to the products described in it without notice. All specifications and information concerning
products are subject to change without notice.

Reference in this publication to information or products protected by copyright or patent
does not convey any license under the rights of General Binding Corporation or others. General
Binding Corporation assumes no liability arising from infringements of patents or any other
rights of third parties.

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
express written permission of the Genral Binding Corporation.

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please utilize the fax correspondence sheet following this read me file and fax it to the number
provided. Your comments and help will ensure up to date information. Thank you.
© April 2001 General Binding Corporation

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F 60 H Operation and Maintenance Manual

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F 60 H Operation and Maintenance Manual

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Fax number : ( 608 ) 246 - 8645

Date :

To : Technical Coordinator at GBC Protech
4151 Anderson Road
DeForest, WI 53532
From :
Company :
Address :
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Re : F 60 H Operations and Maintenance Manual ( 930063A )

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F 60 H Operation and Maintenance Manual

Table of Contents

Table of Contents
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

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

Page I

Table 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

F 60 H Operation and Maintenance Manual

Table of Contents

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

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

Page III

Table 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

F 60 H Operation and Maintenance Manual

Table of Contents

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

Page V

Table 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

F 60 H Operation and Maintenance Manual

1.0 Safety

Safety

1.1 Symbols
INFORMATION
C A U T IO N

D o not attem p t to operate you r
Falcon 60 H lam inator u ntil you
h ave read this section carefully!

Indicates helpful information that should be
considered before, during, or after an
action, step or procedure is given.

CAUTION

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

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

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.

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
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

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.

At these temperatures there is a danger of
severe burn if the rolls are touched during
setup, operation or servicing.

The word qualified is defined below;

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.

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.

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.

W AR N IN G

K eep hands and fingers clear of the
lam inator roller nip w hen adjusting nip.
Y ou can be C R U SH E D or B U R N E D !

• 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-Tech.

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

In addition, the main laminating rollers of the
Falcon 60 H can reach temperatures up to 200oF (100oC).

Page 1 - 2

F 60 H Operation and Maintenance Manual

1.3 Safety features

Safety
To continue operation, all E-STOPs must be in
the unlatched position. To reset, twist the E-STOP 1/4
turn counter clockwise.

1/4

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.

tu r n

E -S T O P

Press RESET located on the control side cabinet
at the rear of the machine just above the main power on/
off.
E -S T O P

Reset
PO
W
ER

To engage an E-STOP, press down on any of the
four. Any E-STOP, when engaged, removes power to
the laminator.

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.

INFORMATION

PHOTO-EYE
0H

The machine will only operate if all four
E-STOPS are in the unlatched position.

T
RO

Page 1 - 3

Safety

F 60 H Operation and Maintenance Manual

1.4 Installation

The following symbols are positioned at various
points in Section 4 Installation.

CAUTION

W A R N IN G

T he Falcon 60 H L am inator is a large and
heavy piece of equipm ent. It is necessary to
em ploy L IC E N SE D R IG G E R S O N L Y to
m ove the lam inator. T he lam inator is not
designed to be tipped up or sidew ays in any
w ay. Such action disturbs the exact
alignm ent of the rolling parts of the m achine
and requires extensive realignm ent. Y ou can
be crushed or seriously injured.

Failure to follow the pre-installation check
list can result in damage to the laminator.

INFORMATION

WARNING
The operating environment must be free of
dust, flammable liquids and vapors. You can
be injured by inhaling chemical vapors.

A L L S H I P M E N T S A R E E X - W O R K S . At our
dock, title passes to the buyer. Please review
your insurance coverage prior to shipment,
as you are responsible for all subsequent
freight charges and risks.

INFORMATION
WARNING
Vapor build up or stored flammable
liquids can cause a fire. Excessive
dust can damage the laminator.

C A U T IO N

D o not locate the Falcon 60 H w h ere air is
b low ing directly on th e m achine. T h e air
flow can cool the rolls un even ly and resu lt
in p oor outpu t q uality.

Page 1 - 4

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.

WARNING
The unpacking process requires at least two
people. You can be severely injured, crushed
or cause damage to the laminator.

F 60 H Operation and Maintenance Manual

Safety

INFORMATION
CAUTION
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.

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.

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.

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.

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 R M A T IO N

A b ou t recyclin g: T he crate com p on en ts can
b e reu sed for shipp ing th e lam in ator again
or can b e d isassem b led and th e w ood and
screw s recycled. T h e shrink w rap is n ot
recyclab le, so it m u st b e discarded.

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
C A U T IO N

D o not m ove the leveling nut w hen securin g
the inside nut to th e cabinet.

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 O R M AT IO N

WARNING
Y ou w ill need the control side cabinet cover
off to connect the electrical pow er.

If a safety feature is not working
properly, contact your local service
representative immediately.

ELECTRICAL
SHOCK
C AU T IO N

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.

Page 1 - 6

D o not use a hard substrate or a substrate
w ith sharp edges. Y ou m ay cause dam age to
the lam inating rollers!

F 60 H Operation and Maintenance Manual

Safety

1.5 Operations
W AR N IN G

The following symbols are positioned at various
points in Section 5 Operations.

W hen the lam inator rollers are in
m otion, keep hands and fingers
aw ay from the nip of the rollers.
Y ou m ay be C R U SH E D or B U R N E D !

W AR N IN G
W AR N IN G

D o not w ear ties, loose fit clothing or
dangling jew elry w hile operating or
servicing the lam inator. T hese item s can get
caught in the nip and choke you or you can
be crushed or burned.

IN F O R M AT IO N

T he m achine w ill only operate if all
four em ergency stops are unlatched and
R E SE T has been pressed.

W hen operating the lam inator using the
footsw itch, keep hands and fingers
aw ay from the nip of the rollers.
Y ou m ay be C R U SH E D or B U R N E D !

W AR N IN G

D o not operate the lam inator, except
during w eb set up, w ithout the front
and rear feed tables in position.

C AU T IO N
W AR N IN G

It is unsafe to sheet feed w ithout the
pressure plate properly placed on
the front feed table.

W A R N IN G

K eep h ands and fingers clear of the
lam inator roller n ip w hen changing G A P.
Y ou can be C R U S H E D or B U R N E D !

E nsure the roll of lam inate is loaded
properly on the unw ind shaft.
E xposed adhesive should be facing
aw ay from the rollers.
T his w ill prevent hours of roll cleaning!

IN F O R M AT IO N

T he Poly-in/ Poly-out diagram s refer to the
upper rolls of film only. T he m ount adhesive
and craft papers are for reference only.

Page 1 - 7

Safety

F 60 H Operation and Maintenance Manual

W AR N IN G

N ever leave the unw ind shaft out of the
unw ind support saddle unless loading
or unloading film .

C AU T IO N

W hen using tw o rolls on the m achine,
ensure the film w idths are identical.
E xposed adhesive can cause com plications.

C AU T IO N

N ever use an open blade near the lam inating
rollers. Y ou m ay cut the rollers or your self.

IN F O R M AT IO N

A lw ays use the m inim um am ount
of brake for the job.

IN F O R M AT IO N

If m ore brake is needed, add an O -ring
to the brake side of the rew ind.

Page 1 - 8

C AU T IO N

E xcess pressure can dam age the lam inating
rollers. A lw ays use the m inim um roll
pressure necessary to com plete the task.

C AU T IO N

O bjects other than m edia, film or approved
substrates, w ill cause irreparable dam age
to the rollers if caught in the nip.

C AU T IO N

Sharp edges on a substrate
should be filed sm ooth.
Sharp edges can C U T the rollers!

IN F O R M AT IO N

E xcessive pressure w ill cause the
substrate to bow or flatten.

IN F O R M AT IO N

D ensity of the substrate w ill determ ine the
am ount of pressure you m ay use.

F 60 H Operation and Maintenance Manual

Safety

1.6 Applications
IN F O R M AT IO N

The following symbols are positioned at various
points in Section 6 Applications.

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 O R M AT IO N

U se film brake tension to control the
separation point of the release liner.

IN F O R M AT IO N

Speeds and tem peratures w ill affect the
bond strength of L o-M elt adhesives.

E xcessive pressure w ill cause the
substrate to bow or flatten.

IN F O R M AT IO N

E xcessive brake tension m ay cause the
im age to curl. A lw ays use the m inim um
am ount of brake for the job.

C AU T IO N

E xcess pressure can dam age the lam inating
rollers. A lw ays use the m inim um roll
pressure necessary to com plete the task.

IN F O R M AT IO N

N ever stop the lam inator w hen an im age is
w ithin the nip of the rollers.

IN F O R M AT IO N
IN F O R M AT IO N

T he m ount adhesive m ust not exceed 1 in.
the w idth of the substrate. If it does, you
w ill experience com plications w ith this
application.

L am inates and papers should alw ays be
stored in a controlled envirom ent.

Page 1 - 9

Safety

F 60 H Operation and Maintenance Manual

1.7 Troubleshooting

1.8 Maintenance

The following symbols are positioned at various
points in Section 7 Troubleshooting.

The following symbols are positioned at various
points in Section 8 Maintenance.

WARNING
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.

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
INFORMATION

Improper maintenance, can
result in poor output quality.

For optimal temperature settings of
various laminates, contact your
supplier or sales representative.
ELECTRICAL
SHOCK
Remove power from the laminator before
servicing. You can be severely shocked,
electrocuted or cause a fire.

IN F O R M A T IO N

B elow is a recom m end ed m ain ten an ce
sch ed ule. B efore perform in g any of th e step s
listed , read th rou gh th e p rocedu res first.
Please follow the in structions pertaining to
the step you are perform ing.

Page 1 - 10

F 60 H Operation and Maintenance Manual

CAUTION
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!

Safety

ELECTRICAL
SHOCK
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.

W AR N IN G

R em ove A L L pow er to the lam inator before
rem oving any cabinet covers.
Y ou m ay be shocked or electrocuted!

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.

W AR N IN G

A lw ays practice lock out/ tag out procedures
w hen perform ing any type of service or
m aintenance w ork on the m achine.
W A R N IN G

W h en op erating th e lam inator u sin g the
footsw itch, keep hand s and fin gers
aw ay from th e n ip of the rollers.
Y ou m ay b e C R U S H E D or B U R N E D !

IN F O R M AT IO N

T he m otor controls the tension of the both
chains. If one chain is still too loose,
a half link m ay be rem oved.

Page 1 - 11

Safety

F 60 H Operation and Maintenance Manual

1.9 Label locations
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.

!
!

D AN G E R
G E FAHR

H AZA R D O U S
V O L T AG E

W A R N IN G

ACHT UNG

M IS E E N G A R D E

M o v in g p a rts c a n
c ru s h a n d c u t.

To be serviced on ly
by tr ain ed and
au tho riz ed perso nnel.
Lo ckout po w er b efo re
servicin g

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

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

W A R N IN G

ACHT UNG

M IS E E N G A R D E

C ru sh and b u rn
h az ard . S tay clear
o f m o v in g ro llers.
S to p m ach in e an d
raise ro ll b efo re
clean in g .

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

Page 1 - 12

W AR N IN G

AC H T U N G

M IS E E N G A R D E

C a re fu lly re a d O p e ra to r's
M a n u a l b e fo re h a n d lin g
th is m a c h in e . O b s e rv e
in s tru c tio n s a n d s a fe ty
ru le s w h e n o p e ra tin g .

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

F 60 H Operation and Maintenance Manual

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

Electrical Shock: Live voltage present. Exercise
extreme caution. You may be electrocuted!

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.

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

Moving parts can
cruch and cut.

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

(Inside cabinet)
!

NN
AR
U
H

DANGER
GEFAHR

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

WARNING
ACHTUNG
MISE EN GARDE

0H
F-6

O-T

Page 1 - 14

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

F 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.

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
Unauthorized customer alterations will
void this warranty.

Warranty

THE WARRANTY MADE HEREIN IS IN
LIEU OF ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING
ANY
WARRANTY
OR
MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE. GBC
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
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.

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 GBC Technician, GBC Specialist, and / or
GBC Films Group Technician that has been through the
GBC Pro-Tech service training course.

Page 2 - 2

F 60 H Operation and Maintenance Manual

Specifications

3.0 Specifications

Specifications provide all of the technical data for
the Falcon 60 H Laminator.

3.1 General

Description:

• 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.

Features:

• Two 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:

• Single sided lamination
• Mounting
• Decaling
• Low melt film

Page 3 - 1

Specifications

F 60 H Operation and Maintenance Manual

3.2 Consumable

Film types:

• Pressure sensitive laminates
• Pressure sensitive adhesives
• Low melt laminates

Film diameters:

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

Core size:

• 3 in. core standard ( 7.62 cm )
• 2-1/4 in. optional ( must have optional core adapters )
( 5.72 cm )

Film widths:

• 62 in. Pressure sensitive ( 162.6 cm )
• 60 in. Low Melt ( 157.8 cm )

Paper widths:

• 62 in. maximum paper width ( 157.8 cm )

Mounting thickness:

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

Safety:

• Designed to UL safety standards

Page 3 - 2

F 60 H Operation and Maintenance Manual

Specifications

3.3 Function

Speed:

• 0 - 16 ft / min ( 0 - 4.6 m / min )

Motor:

• 2-1/4 horse power drive motor
• Bi-directional D.C. motor

Heating capabilities:

• 68oF - 200oF ( 20oC - 93oC )

Controls:

• Front control panel
• Footswitch

Roll design:

• High release silicone rollers

Page 3 - 3

Specifications

F 60 H Operation and Maintenance Manual

3.4 Electrical
United Statesand Canada:

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

B.T.U. output:

• 18,520 B.T.U. / hour

Heater wattages:

• 5429 watts per heater @ 240 vac

Amperage draw:

• No heat, motor only : 1 - 3 amps
• Top heat and motor : 25 - 30 amps

D/C voltage used:

• 24 vdc

A/C voltage used:

• 230~ 240 vac ( minimum )

Page 3 - 4

F 60 H Operation and Maintenance Manual

Specifications

3.5 Dimensions

Weight:

Uncrated:

• 1350 lbs. ( 612 kg. )

Crated:

• 1625 lbs. ( 737 kg. )

Dimensions

Uncrated:

• 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

Crated

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

Nip Height:

• 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 )
G

IN
RN
WA NG
HTU
AC AR
N

57 in.
( 145 cm )

F-6

H
EC
O-T

38.5 in.
( 98 cm )

Page 3 - 6

F 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.

Installation
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

CAUTION

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.

WARNING

4.1 Pre-installation

Vapor build up or stored flammable
liquids can cause a fire. Excessive
dust can damage the laminator.

Are doorways and hallways wide enough for the
laminator to be moved to the installation site?

Is there ample room for the laminator?
C A U T IO N

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 4.1.1 illustrates a typical machine
area layout.

D o not locate the Falcon 60 H w h ere air is
b low ing directly on th e m achine. T h e air
flow can cool the rolls un even ly and resu lt
in p oor outpu t q uality.

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.

W A R N IN G

T he Falcon 60 H L am inator is a large and
heavy piece of equipm ent. It is necessary to
em ploy L IC EN SE D R IG G E R S O N L Y to
m ove the lam inator. T he lam inator is not
designed to be tipped up or sidew ays in any
w ay. Such action disturbs the exact
alignm ent of the rolling parts of the m achine
and requires extensive realignm ent. Y ou 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

F 60 H Operation and Maintenance Manual

Figure 4.1.1

Installation

Suggested Floor Layout

4 ft. x 6 ft. (1 .2 2 m x 2 m )
W o rk ta b le o n w h e e ls

8 .2 ft.
( 2 .5 7 m )

T a b le h e ig h t
3 7 -3 /4 in . (.9 5 - .9 6 m )

7 8 in .
(2 m )

E lectrical
supply

2 0 ft.
( 6 m )

3 8 .5 "
( .9 8 m )

3 ft. ( 1 m )

Front operating position

8 .2 ft.
( 2 .5 7 m )

4 ft. x 6 ft. (1 .2 2 m x 2 m )
W o rk ta b le o n w h e e ls

T a b le h e ig h t
3 7 -3 /4 in . (.9 5 - .9 6 m )

13' ( 4 m )

Page 4 - 3

Installation

F 60 H Operation and Maintenance Manual

4.2 Know your machine

Figure 4.2.3 Idlers and unwinds
Upper unwind
Web idler

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

Rear table idler
Tie bars

F-6

Figure 4.2.1 The laminator

Lower Unwind

Front table idler

e
sid
ive ft )
r
D Le
(
Re

Figure 4.2.4 Misc.
Run/ Stop
H
-60

Photo-eye

Fr
on

Main rollers

EC
OT

Rear table

e
sid
ol
ntr ht )
o
C Rig
(

F-6

Figure 4.2.2 Safety and controls

Unwind saddle

CH
-TE

Front table
Castors

Rewind drive
Main roller lift
Core grip
Upper unwind brake

Figure 4.2.5 Power

E-stop

Reset

F-6

Core support

H
EC
O-T
PR

Foot switch
Lower unwind brake
Control panel

Page 4 - 4

On/ Off

F 60 H Operation and Maintenance Manual

4.3 Unpacking

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

INFORMATION
A L L S H I P M E N T S A R E E X - W O R K S . At our
dock, title passes to the buyer. Please review
your insurance coverage prior to shipment,
as you are responsible for all subsequent
freight charges and risks.

4.4 Shrink Wrapped
a) Inspect the machine for any obvious shipping
damages upon receipt. Report any damage to
your carrier.

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.

b) Carefully unwrap the shrink wrap from around
the laminator.

CAUTION

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 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
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.

Page 4 - 5

Installation

F 60 H Operation and Maintenance Manual

4.5 Crated

To uncrate the laminator

W A R N IN G

T he Falcon 60 H L am inator is a large and
heavy piece of equipm ent. It is necessary to
em ploy L IC EN SE D R IG G E R S O N L Y to
m ove the lam inator. T he lam inator is not
designed to be tipped up or sidew ays in any
w ay. Such action disturbs the exact
alignm ent of the rolling parts of the m achine
and requires extensive realignm ent. Y ou can
be crushed or seriously injured.

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
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.

Tools required
CAUTION
• # 2 Phillips head screwdriver
• 7/8” open end wrench or adjustable wrench
• Crow bar
• A second person

Page 4 - 6

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.

F 60 H Operation and Maintenance Manual

Figure 4.5.1

Disassembling of the crate

1
A

Installation

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.

4
0H

F-6

E
R

WARNING

Removing the shrink wrap

a) Gently unwrap the shrink wrap from around the
laminator.

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.

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) Remove any plastic strapping and/or packing
paper taped to the rollers.
b) Move all packing materials to a safe distance.

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.

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.

Once the Falcon 60 H Laminator has been
unpacked and moved into final position, open the accessory
pack and verify the contents.

Accessory Pack contents
• One Fuse, 250 V, 20 amp ( 186 - 135 )
• Two Fuses, 2,5 amp ( 186 - 220 )
• One fuse, 0.5 amp ( 186-016 )
• One Operators Manual ( 930 - 063 )
• One Towel ( 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,
contact your local service technician or sales
representative.

Contacts:
GBC Parts ( 800 ) 790 - 7787
GBC Europe parts 33 - 45 - 535 - 7676

Page 4 - 8

F 60 H Operation and Maintenance Manual

4.7

Installing levelers

Installation

4.8 Leveling

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.

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” open end wrenches
• Four leveling pads
( from the accessory pack )

a) Verify that the laminator has sufficient room
around it to load film, walk around and to be
serviced if necessary.

• ( 2 ) 3/4 in. open end wrenches
• 1/8 in. allen wrench
• Level
• A second person

a) With a 1/8 in. allen wrench, remove the drive
side and control side cabinet covers by;
1) Loosen the three screws along the
bottom.

b) Place one leveling pad on each of the four
leveling bolts on the laminator.

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

Jam nuts

2
Leveling pads

F-6

O-T

c) Use a 3/4 in. open end wrench to secure the
jam nut against the leveling pad.
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.

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

Inside nuts

F-6

O-T

c) Position the level on the top of the control side
cabinet.
f) Level the drive side from front to back by
turning the leveling nut clockwise to raise or
counter clockwise to lower.

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

F-6

EC
OT

d) Level the control side from front to back by
turning the leveling nut clockwise to raise or
counter clockwise to lower.

F-6

Leveling nuts

Page 4 - 10

h) Level the laminator from drive side to control
side by turning the leveling nut clockwise to
raise or counter clockwise to lower.

F 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.

Installation

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.

Inside nuts

Tools required
• 1/8 in. allen wrench
• # 2 phillips head screw driver
• Multi meter
C AU T IO N

D o not m ove the leveling nut w hen securing
the inside nut to the cabinet.

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

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 Term inal B lock

IN F O R M AT IO N

Y ou w ill need the control side cabinet cover
off to connect the electrical pow er.

S train relief

P ower cable

Page 4 - 11

Installation

F 60 H Operation and Maintenance Manual

c) Connect the wires to the Line Terminal Block
(LTB) as illustrated below.

b lu e w ires

red w ires

f) Verify line voltage with regards to the type of
power being supplied to the laminator at the line
terminal block.

h o t le g
(A )

h o t le g
(B )

g ro u nd
(C )

• (A) - (B) = 230 ~ 240 VAC
h o t le g

h o t le g

g ro u n d

• (A) - (C) = 115 ~ 120 VAC
• (B) - (C) = 115 ~ 120 VAC

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.

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
PO

e) Turn the junction box power to the ON
position.

Page 4 - 12

On/ Off

F 60 H Operation and Maintenance Manual

Installation

4.10 Safety check
The safety check will ensure that all safety devices
and interlocks are functioning properly.

E-STOPs
a) Turn MAIN POWER to ON .

This procedure describes how to check one
E-STOP and the PHOTO-EYE. Repeat the steps for
the remaining three E-STOPS. ALL SAFETY
FEATURES MUST BE CHECKED!

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.

Off

b) Press RESET. The power indicator on the front
control panel will be illuminated.

Reset
PO

WARNING
If a safety feature is not working
properly, contact your local service
representative immediately.

c) Press the motor direction to FORWARD.

Contacts:

GBC National Service: ( 800 ) 790 - 7787
(reverse)

(forward)

My service rep:_____________________

Page 4 - 13

Installation

F 60 H Operation and Maintenance Manual

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

5
4
3
2

h) The bottom main roller stops turning, the power
indicator light goes out, the display on the
temperature controller unit goes out.

6
7
8
9

i) Turn the E-STOP 1/4 turn counter clockwise to
unlatch.

e) Press the motor engage/ disengage to ENGAGE.
1/4

tu r n

(disengage)

(engage)

j) Repeat steps b) through i) for the remaining
three E-STOPs.
f) Press the temperature on/off to ON.

PHOTO-EYE
(off)

(on)

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”.
g) Press one of the four E-STOPs.

C AU T IO N

D o not use a hard substrate or a substrate
w ith sharp edges. Y ou m ay cause dam ge to
the lam inating rollers.

Page 4 - 14

F 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.

Installation
f) Press the motor engage/ disengage to ENGAGE.

c) If the power indicator on the control panel is not
illuminated, press Reset.
(disengage)

(engage)

Reset
PO

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.

fin g e r b o a rd

(reverse)

(forward)

e) Lower the main roller to initial contact ( one bar
on the pressure display is illuminated ).

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.

(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 PHOTOEYEs.

o) Slide the “finger board” on the front feed table
towards the nip about ten in. ( 25 cm ) from the
control side.

k) Slide the “finger board” towards the roller nip
about center of the front feed table.

fin g e r b o a rd

p) The rollers should stop just before the finger
board can enter the roller nip.
fin g e r b o a rd

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.

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 PHOTOEYEs.

s) Raise the main roller.

(disengage)

(engage)

n) If the finger board comes in contact with the
rollers while they are turning, contact your
service representative to adjust the PHOTOEYEs.

Page 4 - 16

Operations

F 60 H Operation and Maintenance Manual

5.0 Operations
W AR N IN G

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.

W hen the lam inator rollers are in
m otion, keep hands and fingers
aw ay from the nip of the rollers.
Y ou m ay be C R U SH E D or B U R N E D !

The following general rules should always be
adhered while operating this machine.
W AR N IN G

W AR N IN G

K eep hands and fingers clear of the
lam inator roller nip w hen changing G A P.
Y ou can be C R U SH E D or B U R N E D !

D o not w ear ties, loose fit clothing or
dangling jew elry w hile operating or
servicing the lam inator. T hese item s can get
caught in the nip and choke you or you can
be crushed or burned.
W AR N IN G

IN F O R M AT IO N

W hen operating the lam inator using the
footsw itch, keep hands and fingers aw ay
from the nip of the rollers.
Y ou m ay be C R U SH E D or B U R N E D !

T he m achine w ill only operate if all
four em ergency stops are unlatched and
R E SE T has been pressed.

W AR N IN G
W AR N IN G

It is unsafe to sheet feed w ithout the
pressure plate properly placed on
the front feed table.

D o not operate the lam inator, except
during w eb set up, w ithout the front
and rear feed tables in position.

Page 5 - 1

Operations

F 60 H Operation and Maintenance Manual
d) Power indicator on the control panel should be
illuminated at this time.

5.1 Power On/ Off

Power on

a) Ensure the laminator is plugged in and that all ESTOPs are in the unlatched position.
4

Power indicator light
1/4
tu r n

Power off
a) Ensure the rollers are in the up position.
b) Turn the MAIN POWER to the up position.

Off

c) Press RESET located above the main power
on/off.

b) Turn the MAIN POWER to the down position.

Reset
PO

PO
W
ER

Off

Page 5 - 2

Operations

F 60 H Operation and Maintenance Manual

( 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.

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:

(reverse)

(forward)

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

5
4
3
2

( 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.

(off)
(disengage)

9
1

( 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.

(on)

(engage)

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. To set temperature refer to Section 5.3.

( 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.

CAL 3200

Figure 5.2.1 Front control panel

6
CAL 3200

3
5
4
3

7
8
9

Page 5 - 4

Operations

F 60 H Operation and Maintenance Manual

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
( 0 OC ) 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.

CAL 3200

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

b) Release the ✽ key and ▲ key once desired set
point has been obtained.

(72 is an example of room temperature )

Decrease set point
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.

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

CAL 3

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

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.

C AU T IO N

E nsure the roll of lam inate is loaded
properly on the unw ind shaft.
E xposed adhesive should be facing
aw ay from the rollers.
T his w ill prevent hours of roll cleaning!

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

IN F O R M AT IO N

T he Poly-in/ Poly-out diagram s refer to the
upper rolls of film only. T he m ount adhesive
and craft papers are for reference only.

Figure 5.4.2 PSA Poly-in/ Poly-out

PSA
film

L o -M e lt
film

L o -M e lt
P o ly - in

PSA
P o ly - in

C ra ft
paper

C raft
p ap er

L o -M e lt
film

PSA
film

L o -M e lt
P o ly - o u t

Mount
a d h e sive

Page 5 - 6

PSA
P o ly - o u t

Mount
a d h e sive

Operations

F 60 H Operation and Maintenance Manual

Load film
W AR N IN G

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.

N ever leave the unw ind shaft out of the
unw ind support saddle unless loading
or unloading film .

d) Swing the unwind shaft completely back into the
unwind support saddle and push the clevis pin
down.

R o ll o f film

C le v is p in
C o re c h u c k

C o re s u p p o rt

C o re c h u c k

U n w in d s u p p o rt s a d d le

b) Lift up on the clevis pin to the unwind shaft located
in the unwind support saddle.
C le v is p in

e) If using the lower unwind, center the upper roll of
film on the laminating rollers.

( A )

U n w in d s u p p o rt s a d d le
( C )

c) Swing the unwind shaft out far enough to slide the
roll of film completely on.

( B )

( C )

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

C AU T IO N

W hen using tw o rolls on the m achine,
ensure the film w idths are identical.
E xposed adhesive can cause com plications.

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.

b) Lift up on the clevis pin to the unwind shaft located
in the unwind support saddle.
C le v is p in

Alig n
C en te r

U n w in d s u p p o rt s a d d le

c) Swing the unwind shaft out far enough to slide the
roll of film completely off.

C AU T IO N

Unload film

W hen using tw o rolls on the m achine,
ensure the film w idths are identical.
E xposed adhesive can cause com plications.

a) Cut the roll of film from the web using an enclosed
blade.
d) Swing the unwind shaft completely back into the
unwind support saddle and push the clevis pin
down.
C AU T IO N
C le v is p in

N ever use an open blade near the lam inating
rollers. Y ou m ay cut the rollers or your self.

Page 5 - 8

U n w in d s u p p o rt s a d d le

Operations

F 60 H Operation and Maintenance Manual

5.5 Unwind brake tension

5.6 Rewind 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.

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.

IN F O R M AT IO N

A lw ays use the m inim um am ount
of brake for the job.

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.

IN F O R M AT IO N

If m ore brake is needed, add an O -ring
to the brake side of the rew ind.

In c re as e

d e crea se

Inc rea s e

b) Turn the upper black brake knob ( shown above)
or the lower gray brake disc ( not shown )
counter clockwise to decrease unwind brake
tension.

D e c re a se

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

a) Ensure all E-STOPs are unlatched, power is on
and RESET has been pressed.

Reset
1/4

tu r n

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.
b) Set the motor direction to REV.

W AR N IN G

K eep hands and fingers clear of the
lam inator roller nip w hen adjusting nip.
Y ou can be C R U SH E D or B U R N E D !
(reverse)

(forward)

C AU T IO N

E xcess pressure can dam age the lam inating
rollers. A lw ays use the m inim um roll
pressure necessary to com plete the task.

c) Set a comfortable speed for the application you
are performing.

5
4

C AU T IO N

3
2

O bjects other than m edia, film or approved
substrates, w ill cause irreparable dam age
to the rollers if caught in the nip.

Page 5 - 10

6
7
8
9

Operations

F 60 H Operation and Maintenance Manual

IN F O R M AT IO N

C AU T IO N

Sharp edges on a substrate
should be filed sm ooth.
Sharp edges can C U T the rollers!

E xcessive pressure w ill cause the
substrate to bow or flatten.

d) Position the substrate center of the feed table
between the two rollers.

S u ffic ie n t

E x c e s s iv e

IN F O R M AT IO N
0H

F-6

substrate

D ensity of the substrate w ill determ ine the
am ount of pressure you m ay use.

-TE

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

f) Press the motor engage/ disengage to engage or
step on the footswitch to back the board out
from the nip.

(disengage)

engage)

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
W AR N IN G

W AR N IN G

W hen operating the lam inator using the
footsw itch, keep hands and fingers
aw ay from the nip of the rollers.
Y ou m ay be C R U SH E D or B U R N E D !

T he variable speed footsw itch over-rides
the PH O T O -E Y E safety circuit !

c) When the footswitch is pressed, roller speed is
dependent on what you have selected on the
speed dial.

The footswitch operates differently based on the
motor direction setting.
d) You may adjust speed while the footswitch is
depressed.

Forward
a) Press the motor direction to FWD.

Reverse
a) Press the motor direction to REV.

(reverse)

(forward)

b) Set your speed dial to a comfortable operating
speed.

5
4
3
2

7
8
9

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..

F 60 H Operation and Maintenance Manual

Applications

6.0 Applications

6.1 Helpful hints

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

Pressure sensitive materials

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.

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 O R M AT IO N

U se film brake tension to control the
separation point of the release 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.

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 O R M AT IO N

Speeds and tem peratures w ill affect the
bond strength of L o-M elt adhesives.

Page 6 - 1

Applications

F 60 H Operation and Maintenance Manual

Mounting

Brake tension

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.

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 O R M AT IO N
IN F O R M AT IO N

T he m ount adhesive m ust not exceed 1 in.
the w idth of the substrate. If it does, you
w ill experience com plications w ith this
application.

General

Pressure
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.

Typically 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 O R M AT IO N

E xcessive pressure w ill cause the
substrate to bow or flatten.

Page 6 - 2

E xcessive brake tension m ay cause the
im age to curl. A lw ays use the m inim um
am ount of brake for the job.

C AU T IO N

E xcess pressure can dam age the lam inating
rollers. A lw ays use the m inim um roll
pressure necessary to com plete the task.

IN F O R M AT IO N

N ever stop the lam inator w hen an im age is
w ithin the nip of the rollers.

IN F O R M AT IO N

L am inates and papers should alw ays be
stored in a controlled envirom ent.

F 60 H Operation and Maintenance Manual

Applications

6.2 Temp conversion chart
A temperature conversion chart has been included for your convenience. Use the chart below for converting
temperatures from oF to oC and vice a versa.

Figure 6.2.1 Temperature conversion chart
o

F
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101

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

C
20
20.6
21.1
21.7
22.2
22.7
23.3
23.9
24.4
25
25.6
26.1
26.7
27.2
27.8
28.3
28.9
29.4
30
30.6
31.1
31.7
32.2
32.8
33.3
33.9
34.4
35
35.6
36.1
36.7
37.2
37.8
38.3

F
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135

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

C
38.9
39.4
40
40.6
41.1
41.7
42.2
42.8
43.3
43.9
44.4
45
45.6
46.1
46.7
47.2
47.8
48.3
48.9
49.4
50
50.6
51.1
51.7
52.2
52.8
53.3
53.9
54.4
55
55.6
56.1
56.7
57.2

F
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169

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

C
57.8
58.3
58.9
59.4
60
60.6
61.1
61.7
62.2
62.8
63.3
63.9
64.4
65
65.6
66.1
66.7
67.2
67.8
68.3
68.9
69.4
70
70.6
71.1
71.7
72.2
72.8
73.3
73.9
74.4
75
75.6
76.1

F
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200

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

C
76.7
77.2
77.8
78.3
78.9
79.4
80
80.6
81.1
81.7
82.2
82.8
83.3
83.9
84.4
85
85.6
86.1
86.7
87.2
87.8
88.3
88.9
89.4
90
90.6
91.1
91.7
92.2
92.8
93.3

Page 6 - 3

Applications

F 60 H Operation and Maintenance Manual

This page intentionally left blank.

Page 6 - 4

F 60 H Operation and Maintenance Manual

Applications

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.

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.

Page 6 - 5

Applications

F 60 H Operation and Maintenance Manual

PROCESS CONTROL CHART
Materials Top material :
Bottom material :
Other material (s) :
Motor Direction

Motor Speed

Heater

Upper Roller Temperature

9
1

10
CAL 3200

Roller Pressure
RANGE

RANGE

CAL 3200

Notes :

Page 6 - 6

F 60 H Operation and Maintenance Manual

Applications

Diagram - Blank

Page 6 - 7

Applications

F 60 H Operation and Maintenance Manual

This page intentionally left blank.

Page 6 - 8

F 60 H Operation and Maintenance Manual

Applications

Diagram - Blank w/ roll to roll options

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

Heater

Upper Roller Temperature

range
5
4

6
7

10
CAL 3200

Roller Pressure
RANGE

RANGE
CAL 3200

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

F 60 H Operation and Maintenance Manual

Applications

Diagram - Pre-coating substrates

R oll of
m ount
adhesive

S ubstrate
Leader board

Page 6 - 11

Applications

F 60 H Operation and Maintenance Manual

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

Motor Speed

Heater

Upper Roller Temperature

5
4
3
2
1

6
7
8
9
10
CAL 3200

Roller Pressure
RANGE

RANGE
CAL 3200

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

F 60 H Operation and Maintenance Manual

Applications

Diagram - Mounting an image

H old im age here
Im age

Liner

P re-coated
board

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

Heater

Upper Roller Temperature

range
5
4

6
7

9
1

10
CAL 3200

Roller Pressure
RANGE

RANGE
CAL 3200

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

F 60 H Operation and Maintenance Manual

Applications

Diagram - PSA decaling

R elease liner

R oll of
P S A film

Im age

D ecal

R oll of
m ount
adhesive

Page 6 - 15

Applications

F 60 H Operation and Maintenance Manual

This page intentionally left blank.

Page 6 - 16

F 60 H Operation and Maintenance Manual

Applications

Diagram - PSA decaling w/ roll to roll options

R elease liner

R oll of
P S A film

R oll of
m ount
adhesive

R ewind of decals
R oll of
prints

Page 6 - 17

Applications

F 60 H Operation and Maintenance Manual

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
Motor Direction

Motor Speed

ran

5
4
3

Heater

Upper Roller Temperature

6
7
8

9
1

10
CAL 3200

Roller Pressure
RANGE

RANGE
CAL 3200

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

F 60 H Operation and Maintenance Manual

Applications

Diagram - Lo-Melt decaling

R oll of
Lo-M elt
film

Im age

D ecal

R oll of
m ount
adhesive

Page 6 - 19

Applications

F 60 H Operation and Maintenance Manual

This page intentionally left blank.

Page 6 - 20

F 60 H Operation and Maintenance Manual

Applications

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

R oll of
Lo-M elt
film

R oll of
m ount
adhesive

R ewind of decals
R oll of
prints

Page 6 - 21

Applications

F 60 H Operation and Maintenance Manual

PROCESS CONTROL CHART
Materials - Mounting a decal
Top material : N/A
Bottom material : N/A
Other material (s) : Decal and substrate
Motor Direction

Motor Speed

Heater

Upper Roller Temperature

e
5

10
CAL 3200

Roller Pressure

RANGE

RANGE
CAL 3200

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

F 60 H Operation and Maintenance Manual

Applications

Diagram - Mounting a decal

H old dec al here
D ecal

Liner

S ubstrate

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

Heater

Upper Roller Temperature

range
5
4

6
7

9
1

10
CAL 3200

Roller Pressure
RANGE

RANGE
CAL 3200

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

F 60 H Operation and Maintenance Manual

Applications

Diagram - PSA single sided lamination
( sled method )

R elease liner

R oll of
P S A film

Im age

Leader board

P re-coated
board

Page 6 - 25

Applications

F 60 H Operation and Maintenance Manual

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
Motor Direction

Motor Speed

Heater

Upper Roller Temperature

range
5
4

6
7

9
1

10
CAL 3200

Roller Pressure
RANGE

RANGE
CAL 3200

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

F 60 H Operation and Maintenance Manual

Applications

Diagram - PSA single sided lamination
( craft paper method )

R elease liner

R oll of
P S A film

Im age

Finished
product

R oll of
craft
paper

Page 6 - 27

Applications

F 60 H Operation and Maintenance Manual

This page intentionally left blank.

Page 6 - 28

F 60 H Operation and Maintenance Manual

Applications

Diagram - PSA single sided lamination
( craft paper method w/ roll to roll option )

R elease liner

R oll of
P S A film

R oll of
craft
paper

R ewind of
finished product
R oll of
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

Heater

Upper Roller Temperature

rang e
5
4

6
7

9
1

10
CAL 3200

Roller Pressure
RANGE

RANGE
CAL 3200

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

F 60 H Operation and Maintenance Manual

Applications

Diagram - PSA over-lamination of a mounted image

R elease liner

R oll of
P S A film

M ounted im age
Leader board

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

ran

5
4

Heater

Upper Roller Temperature

6
7

9
1

10
CAL 3200

Roller Pressure
RANGE

RANGE
CAL 3200

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

F 60 H Operation and Maintenance Manual

Applications

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

R oll of
Lo-M elt
film

M ounted im age
Leader board

Page 6 - 33

Applications

F 60 H Operation and Maintenance Manual

This page intentionally left blank.

Page 6 - 34

F 60 H Operation and Maintenance Manual

7.0 Troubleshooting

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

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.
Hints: • Check paper tension
• Check relative moisture content of the paper

7.1 Wave problems

Problem: D Waves in the laminate

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.

Hints: • Check the roll pressure
• Check the main roll nip settings

Page 7 - 1

Troubleshooting

F 60 H Operation and Maintenance Manual

Problem: Straight waves in the output

Problem: Angled waves in the output on both sides

Hints: • Check operational settings for materials
being used.

Hints: • Check for insufficient main roller pressure
• Check the main roller nip settings

Problem: Waves on only one side of the output

Problem: Indent waves in output after the pull rollers

Hints: • Check the nip setting of main rolls
• Check for even paper tension

Hints: • Output travel was hindered
• Allow output to cool before handling
• Check operating temperatures of material

Page 7 - 2

F 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.

Troubleshooting

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

Pressure sensitive

Hints: • Decrease the speed
• Increase the operating temperature

Problem : Silvering in the laminate
Problem: Delamination
Hints : • Add 100 - 120oF ( 37 - 49oC ) to the
temperature
• Increase pressure to laminating rolls

Hints: • Check operating temperatures
• Check operating speed
• Laminate compatibility with ink
• Ink compatibility with paper

Problem : Tunneling

Hints : • Print should be wound image side out.
• Do not roll tightly
• Do not roll at all.

Mounting

Problem : Image creases when mounting
Problem: Delamination

Hints: • Check operating pressures
• Check operating speed
• Laminate compatibility with ink
• Ink compatibility with paper

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

Page 7 - 3

Troubleshooting

F 60 H Operation and Maintenance Manual

7.3 Machine problems

Problem : No illumination to the control panel

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.

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

You may do this by dialing 1 ( 800 ) 790 - 7787.
This will connect you with GBC National Service dispatch.
You 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 : 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 :
Problem : I press ENGAGE, the rollers will not turn.

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.

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.
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.

Page 7 - 4

Hints : • Check for excessive brake tension
• Confirm that the rolls of laminate are on
correctly.
• Check for proper chain tension.
• Place a service call.

F 60 H Operation and Maintenance Manual

7.4 Glossary
The glossary can help you in understanding some
of the terminology used when referring to the laminator,
applications, or troubleshooting aspects of the machine.

Troubleshooting
Craft paper
A strong brown paper commonly used for single
sided applications.

D waves
Blistering
A condition where the paper coating is bubbled
up from the image paper causing a “blister”. It is created
by using excessive heat during the lamination process.
Blistering is most commonly found with photographic and
ink jet media.

A term used to describe a wave pattern caused,
generally, by incorrect paper tension.

Delamination
Refers to either one of two conditions; 1) the
adhesive separating from the laminate substrate, or 2) the
laminate separating from the product being laminated.

Bond strength
Refers to one of three conditions; 1) the anchor
strength of adhesive to laminate substrate, 2) the anchor
strength of the laminating film to the product that has been
laminated, or 3) when two layers of film are laminated
together, the strength of the adhesive to adhesive bond.

Edgewrap
A mounting technique where the image wraps
around the edges of the mounting substrate so as to provide
a finished edge.

Center mount
Encapsulation
A mounting technique where an image is mounted
centrally on a substrate to provide a decorative border.

When an image is completely encased in laminating
film, it is encapsulated. A border of laminate on laminate
exists around the perimeter of the product.

Coiling
A term used to describe an image rolling up on
itself. This is caused by differences in the brake tension
used between the upper and lower laminates during and
application process.

Film
A two part material consisting an adhesive layer
and a substrate. The adhesive and the substrate may or
may not be clear. This is the material used for lamination.
Please refer to laminate.

Cold laminate
Film that does not require heat to activate the
adhesive. Please see P.S.A. for more information.

Page 7 - 5

Troubleshooting

F 60 H Operation and Maintenance Manual

Foamboard

Mount adhesive

A material commonly used as a mounting
substrate. It is made up of foam sandwiched between
two layers of paper, or paper like media.

A term used to describe a two sided pressure
sensitive adhesive used in mounting images to various
substrates. This material can come with one or two release
liners and may be optically clear for face mounting
applications.

Inkjet
A term used to describe a type of printing where
an ink is projected topically onto a paper or paper like
media. This is a non contact form of printing.

Nip
The interrelationship of any two rolls. The distance
between the closest points of the two rolls is referred to
as the nip of the rolls.

Laminate
A two part material consisting of an adhesive layer
and a substrate. The adhesive and the substrate may or
may not be clear. This is the material used for lamination.

Lo-Melt films
This is another type of thermal laminate. The name
Lo-Melt describes this product simply. Low heat to
activate ( melt ) the adhesive. Any temperature below
boiling point is typically considered to be low.

P.S.A.
Stands for Pressure Sensitive Adhesive. An
adhesive that requires no heat to activate, only pressure.
It is employed by removing a protective release liner and
then pressed onto the material to be laminated. This type
of film is commonly used on materials that are temperature
sensitive.

Release liner
A coated paper or other media used to protect
the adhesive side of a pressure sensitive material.

Main rollers
These are the rolls that perform the actual
lamination. They are rolls capable of being heated in
thermal roll laminators and are usually larger in diameter
than the pull rolls.

Rewind
A system that rolls up media. The rewind tube (s)
used on the Falcon 60 H laminator is a prime example.

Media
Roll to roll
Term used to describe the materials used to print
an image, i.e. the papers, inks, toners, etc.

Page 7 - 6

On a laminator, this means the roll of images, upper
roll of material and the lower roll of material can be fed by
the machine and wound on a rewind roll by the machine.

F 60 H Operation and Maintenance Manual

Troubleshooting

Scarring

Unwind

The visual effect of folding papers or laminates
and breaking the surface. When done to a printed material
it will be seen as a white crack in the image.

A system that unwinds media. Unwinds are used
on all laminators to dispense laminate for lamination.

Web
Second surface
A term to denote the back side of a substrate.
Commonly referenced when discussing front mounted
images to a clear substrate with an optically clear mount
adhesive.

The path that rolled media unwinding from a supply
roll takes through a machine or array of rollers.

Silvering
A term used to describe one of two occurrences;
1) air bubbles trapped between the product and a thermal
laminate, generally caused by insufficient heat being applied
to the laminator or 2) the adhesive not fully activated in a
pressure sensitive film, which will disappear once the
adhesive is fully activated. This activation process can be
sped up if a small amount of heat is applied during the
application.

Substrate
The material to which an adhesive is to be bonded.
In film, the substrate is the polyester and in mounting, the
substrate is the material being mounted to.

Tunneling
When a laminated image is rolled up for any period
of time and the laminate separates from the image.
Generally in a pattern that follows the direction the
laminated image was rolled up in. This is very common
with pressure sensitive laminates and finished products
that have been wound tightly.

Page 7 - 7

Troubleshooting

F 60 H Operation and Maintenance Manual

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Page 7 - 8

F 60 H Operation and Maintenance Manual

8.0 Maintenance

GBC Films Group laminators require minimal
maintenance. However, regular maintenance is essential
to keep any piece of precision machinery at peak
performance. A maintenance schedule and a section of
procedures are included in this section.

Maintenance

8.1 Maintenance Schedule

INFORMATION
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 performing.

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.

Daily
• Clean the rollers
( See cleaning in this section )
• Inspect the electrical cord for damage.
( If damaged, you should replace or repair it
immediately )
• Inspect the footswitch cord for damage.
( If damaged, you should replace or repair it
immediately )

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.

Monthly
• Adjust the nip if needed.
( performed by service technician )
• Check the chain tension.
( performed by service technician )
• Inspect the area around the laminator for
possible hazards
( dust buildup, combustible items stored too
close, etc. )

Page 8 - 1

Maintenance

F 60 H Operation and Maintenance Manual

Semi-Annual
• Lubricate the grease fittings, chain, and gears.
( performed by service technician )
• Check wire termination tightness.
( performed by service technician )

ELECTRICAL
SHOCK
Remove power from the laminator before
servicing. You can be severely shocked,
electrocuted or cause a fire.

8.2 Cleaning the rollers

Tools required
• Protective rubber gloves
( This will protect your hands from the isopropyl
alcohol )
• 80% isopropyl alcohol
( a mild dishwashing detergent and water may
be used instead )
• Rubber cement eraser
( a belt sander dressing block may be used
instead )
• Several 100% cotton terry cloths
( best for lint free cleaning )

a) Turn the main power to the ON position.

Off

b) Press machine RESET.

Reset
PO
W
ER

Page 8 - 2

F 60 H Operation and Maintenance Manual

Maintenance

c) Set motor direction to REV.

CAUTION
Exercise care when cleaning the laminating
rollers with 80% isopropyl alcohol:
(reverse)

(forward)

Use only in a well ventilated area
Wear rubber gloves
Use only on cool rolls

CLEANING HEATED ROLLERS CAN
IGNITE THE FUMES!
d) For pressure sensitive adhesives: put the rubber
gloves on and use isopropyl alcohol and a
terry cloth towel to rub the adhesive off.

CAUTION
CAUTION
Excessive pressure can destroy the silicone
layer by pressing to hard or scrubbing
too long in one spot.

Do NOT pick or pull heat activated adhesive
off the rolls when they are cold. You can
cause irreparable damage to the
laminating rolls.

W A R N IN G

e) For thermal adhesives: while the laminator is at
normal operating temperature, put on the rubber
gloves and use the rubber cement eraser. This
allows the eraser to bead up the adhesive.

W h en op erating th e lam inator u sin g the
footsw itch, keep hand s and fin gers
aw ay from th e n ip of the rollers.
Y ou m ay b e C R U S H E D or B U R N E D !

f) Wipe away the beads with isopropyl alcohol
and a cotton terry cloth.
d) Use the footswitch to rotate the rollers when
finished cleaning that area.

Page 8 - 3

Maintenance

F 60 H Operation and Maintenance Manual

8.3 Clean cabinets and covers 8.4 Clean the control panel

ELECTRICAL
SHOCK

Remove power from the laminator before
cleaning. You can be severely shocked,
electrocuted or cause a fire.

a) Use a damp cotton terry cloth ( water only ),
clean the exterior of the laminator.

a) Use only a slightly damp ( water only ) non
abrasive cloth.

b) If water is not strong enough, you may use a
mild dishwashing detergent with water and a
cotton terry cloth.

b) The same type of cloth used to clean eye
glasses may be used instead.

Page 8 - 4

F 60 H Operation and Maintenance Manual

Maintenance

8.5 Chain tensioning

Tools required
• 1/8 inch allen wrench
• 7/16 inch wrench or socket

A properly tensioned chain should have a 1/2 in
( 1.3 cm ) of total play at the longest stretch of the chain.
Read and understand the precautions below before
attempting any service work.
a) Ensure all power to the laminator has been
removed.

b) Use proper lock out/ tag out procedure.
W AR N IN G

D o not w ear ties, loose fit clothing or
dangling jew elry w hile operating or
servicing the lam inator. T hese item s can get
caught in the nip and choke you or you can
be crushed or burned.

c) With a 1/8 in. allen wrench, remove the drive
side cabinet cover by;

1) Loosen the three screws along the
bottom.

2) Remove the seven screws along the
top and sides of the cover.
W AR N IN G

R em ove A L L pow er to the lam inator before
rem oving any cabinet covers.
Y ou m ay be shocked or electrocuted!

2
F6

W AR N IN G
PR

A lw ays practice lock out/ tag out procedures
w hen perform ing any type of service or
m aintenance w ork on the m achine.

O-T

Page 8 - 5

Maintenance

F 60 H Operation and Maintenance Manual

d) Check the primary chain ( outer ) and the
secondary chain ( inner ) for proper chain
tension.

f) Press firmly down on the motor housing and
tighten the motor mount bolts.

S e c o n d a ry c h a in

P re s s
firm ly
h e re

y
ar

e) If the chains require tensioning, loosen the four
motor mount bolts with a 7/16 in. wrench.

g) Check the primary chain ( outer ) and the
secondary chain ( inner ) again for proper chain
tension.

h) Replace the drive side cabinet cover and restore
power to the machine.

F o u r b o lts

IN F O R M AT IO N

T he m otor controls the tension of the both
chains. If one is chain is still too loose,
a half link m ay be rem oved.

Page 8 - 6

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